cronus 2010 service information
Service Information Cronus 2010 The Gary Fisher Cronus is the lightest, strongest frameset we have ever made. To accomplish this, we have used shaped and very thin-walled carbon tubes. Because of its unique features, the Gary Fisher Cronus requires different or additional assembly techniques, provided here: + Carbon fiber care + Headset bearing installation + Front hub and fork integration + Bottom bracket bearing installation for a variety of bottom bracket types Check www.fisherbikes.
Table of Contents Working with Carbon Fiber Parts.....................................................................................................................1 Cutting a carbon fiber steerer......................................................................................................................... 2 To cut the steerer................................................................................................................................................... 3 Headset Installation..
Working with Carbon Fiber Parts Carbon fiber parts are different from metal parts, so they require different treatment. Keep carbon away from sharp edges or excessive pressure Carbon fiber composite can be damaged by sharp edges or clamping mechanisms which cause a point load, or a high pressure area. The clamps on some parts are not compatible with carbon; some stems, seat post clamps, etc. have sharp edges and/or clamps that create pressure points.
Cutting a carbon fiber steerer These instructions explain the best practices for cutting a carbon fiber steerer tube. Warning! A steerer that is damaged by incorrect cutting, installation or maintenance is unsafe and could break, causing loss of control and injury. Follow the instructions carefully. About cutting carbon fiber High quality carbon fiber composite behaves like a solid; if the layers of carbon are correctly bonded together, there will be no layers or loose fibers apparent.
To cut the steerer 1. Clamp the saw guide securely in the bench vise. 2. Clamp the steerer in the saw guide. + Be careful not to crush the steerer; do not overtighten. 3. Using only light pressure on the saw blade, cut about halfway through the steerer (Figure 1). + Be careful not to create loose fibers—on the inside or the outside the steerer. 4. While keeping the cut aligned with the cutting guide, rotate the fork 180 degrees in Figure 1. Use light pressure when cutting. the guide (Figure 2). 5.
Headset Installation Headset spacers Bearing cover The headset of the Cronus uses a 1.5” lower bearing and 11/8” upper bearing (Figure 5). The bearings are slip-fit into the frame. There are many benefits to this design, and one is Shims Centering washer Upper bearing that the Cronus headset is a tool-less installation. The bearings are slip fit, so a headset press or fork race setting tool are not needed.
To install the bearings 1. Apply a light coat of grease to the inner race of the lower bearing. 2. Install the bearing on the steerer (Figure 6). + The bearing is symmetrical, so either side is “right-side up.” 3. Apply a liberal coat of grease to the bearing seats of the head tube, both top and bottom (Figure 7). 4. Slide the steerer (with the bearing installed) through the head tube (Figure 8). 5. Slide the upper bearing down the steerer and into the frame. 6.
To install the shims, bearing cover, and spacers Fisher installs three 1mm shims between the centering washer and the bearing cover to ensure an adequate space between the bearing cover and the top of the head tube. There should be at least 0.5 millimeter space to prevent contact or interference. 1. Slide the three shims onto the steerer. 2. Slide the bearing cover onto the steerer (Figure 10). 3. Measure the gap between the head tube and the bearing cover.
Fender Installation This section explains how to install front and rear fenders on a Cronus using the accessory dropout adapters and custom brake attachment nuts. Each dropout adapter, or “eyelet,” is a special screw with an eyelet. The brake attachment nut includes a bolt that threads into the nut. Description Part number Custom dropout eyelet w/locknut, set of four Eyelet (2) 295468 Locknut (2) 300381 Figure 12.
Finishing the installation 1. Attach the foot of the rear fender. If the fender has a clip instead of a hole, remove the clip fastener with a drill. If necessary, use the drill to enlarge the empty hole. 2. Place a screw through the hole in the foot of the fender and thread it into the frame (Figure 16). Tighten to 40-60 Lb•in (4.5-6.8 Nm). 3. Put the wheels back onto the bike. 4. Attach the fender struts to the fenders and eyelets (Figure 17). 5.
FCC Steering System The Cronus uses the FCC (Fisher Control Column) with a special front hub that is mated to the front fork. This mating creates a unified structure that is extra strong and extra stiff, which makes the bicycle corner and handle better. The result is a hub/fork interface that is 25% stiffer. And with a weight penalty or a few grams at most. Wider hub flanges One way to increase handling precision is to use a front wheel that is stiffer laterally.
Crankset Installation SRAM GXP These instructions explain how to install a SRAM/TruVativ/Bontrager GXP crankset Part description SRAM Kit 404700 Ceramic kit 411814 Drive side parts Bearing 281824 instructions, available at: http://www.sram.com/_media/techdocs/2005_gxp-05-r5-e.pdf Ceramic Bearing 293617 Tools and materials required Seal 281820 Wave washer 282866 (Figure 20) in a new Cronus.
To install the bearings 1. Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side of the bottom bracket shell (Figure 21). 2. Slide a bearing onto the installation tool. + E ither side of the drive-side bearing is the “right side.” The non-drive bearing on GXP systems has a lip (Figure 22). Install the bearing so that the lip faces in. 3. Press one bearing into the drive side of the bottom bracket shell (Figure 23).
3. Install the wave washer and with the grease facing up, slide the bearing seal onto the axle (Figure 25). 4. Apply a light coat of grease to the bearing contact area of the axle (Figure 26). + T he grease areas should be about 1 inch (25 mm) wide. On the drive side, start at the bearing seal. On the non-drive side, start at the splines and apply toward the drive side of the axle. 5. Insert the axle through the drive-side bearing in the bottom bracket (Figure 27).
Shimano HollowTech These instructions explain how to install a Shimano HollowTech (Figure 29) in a new Cronus. To complete the installation, you will also need the Shimano instructions, available at: http://techdocs.shimano.com/media/techdocs/content/cycle/SI/Dura-Ace/FC-7800- Part description Shimano Kit 404699 Ceramic kit 411813 Drive side parts 7803/SI_1F30H_En_v1_m56577569830605111.pdf.
To install the bearings 1. Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side of the bottom bracket shell (Figure 30). 2. Slide a bearing onto the installation tool. + Either side of the bearing is the “right side.” 3. Press one bearing into the drive side of the bottom bracket shell (Figure 31). + To remove the installation tool, press the release tab. 4. Repeat steps 1-3 for the other bearing on the non-drive side. Figure 30.
To install the drive-side crankarm When handling the seals, avoid bending them. A bent seal will rub on the bearing, creating drag. 1. Apply a light coat of grease to the bearings on the face and the axle contact surface. 2. Apply a light coat of grease to the metal inside of one bearing seal (Figure 32). 3. With the grease facing up, slide the bearing seal onto the axle (Figure 33). 4. Apply a light coat of grease to the bearing contact area of the axle (Figure 34).
To install the non-drive side crankarm 1. Apply a light coat of grease to the inside of the other bearing seal. 2. With the grease side toward the bearing, slide the bearing seal onto the axle (Figure 36). 3. Align the non-drive crank arm with the groove on the axle and slide the crank onto the axle. + The non-drive crank arm should point 180 degrees opposite of the drive-side crank arm. 4. With the plastic installation tool, press the crank onto the axle (Figure 37) as far as it will go. 5.
Campagnolo UltraTorque The Cronus uses a special bearing system that has no parts that thread into the frame. Part description Campagnolo Kit 407383 Drive side parts Instead, the bearings are a slip-fit into the frame. However, the Campagnolo UltraTorque system requires you to attach bearing supports (seal seats) to the bottom bracket shell of the Cronus (Figure 38). This section explains how to do that. The seal seats might fit into the frame tightly.
To install the seal seats 1. Clean all surfaces to be bonded (bottom bracket shell, seal seats) with alcohol wipes or similar (Figure 39). 2. Apply a thin film of LocTite Primer to the outer step of the bearings cups and the outer shoulder of the bottom bracket shell (Figure 40). Allow the primer to evaporate completely. 3. Apply LocTite 638 to the faced of the seal seat that contacts the bottom bracket shell. 4. Press the seal seat into the frame (Figure 41).
3. Insert the Wave washer into the non-drive side seal seat (Figure 44). 4. Slide the non-drive side axle through the seal seat and bottom bracket shell (Figure 45). To install the drive side bearings The drive-side bearings are attached to the crankarm. 1. Insert a washer into the drive side seal seat. 2. Apply a liberal coat of grease to the contact surfaces of the bearing (Figure 42) and the drive side seal seat (Figure 43). 3.
FSA MegaExo AL These instructions and parts are for the aluminum FSA cranks only. The current “B” kit will not work for FSA carbon cranks. The Cronus uses a special bearing system that has no parts that thread into the frame. Instead, the bearings are a slip-fit into the frame (Figure 47). This section explains how to install the bearings and crankset.
To install the bearings 1. Apply a liberal coat of grease to the contact surfaces of one bearing and the drive side of the bottom bracket shell (Figure 48). 2. With the plastic bearing shield facing out, press one bearing into the drive side of the bottom bracket shell (Figure 49). 3. Repeat Steps 1-2 for the other bearing on the non-drive side. To install the drive-side crankarm 1. Apply a light coat of grease to the axle surface where the bearings will be in contact Figure 48.
To install the non-drive side crankarm 1. Align the non-drive crank arm with the groove on the axle and slide the crank onto the axle. + The non-drive crank arm should point 180 degrees opposite of the drive-side crank arm. 2. Install the FSA crank bolt and tighten to their torque specifications (Figure 52). 3. Follow the FSA instructions to complete the installation. 4. Follow the steps in “Inspecting the bottom bracket.
Cronus Crankset Troubleshooting This section describes problems that occasionally occur, and possible solutions. If these solutions do not solve a problem, contact Customer Service. Bearing play in a GXP crank or bottom bracket assembly The crank feels loose when grasped at the pedal end and rocked side-to-side. Cause Solution Wave washer not compressed fully First, verify that the crank has been tightened to 420-480 Lb•In (50-57 Nm).
Crank is rubbing or there is excessive drag If you notice that the crank arms rotate poorly, there are several possible issues. Cause Solution Out of spec or bent non-drive metal seal Install a new metal seal (same Part Number: 282865). We have revised the metal seal by adding a ring of material, 0.3mm thick, to the seal around the inner diameter. This will move the outer edge of the seal away from the bearing. + T he inside chamfer of the metal seal (Figure 54) rubs on the outer race of the bearing.
