BikePack Issue 4.1 - Mekon Aerospace and Defenceaerospace-defence.com/wp-content/uploads/.../07/BikePack-Issue-4-… · S1000D speechification. There are some preferences which can

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MM-A-00-00-00-00A-000A-AIssue number: 001.01 Front CoverResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A Mountain BicycleIssue 4.1 XML Bike Pack

TypePedalled Transport Method

General Description & Maintenance

Issue 1

Published by: Mekon Limited, Sutton Surrey, UK using the Eclipse BookBuild application

Tel: +44(0)20 8722 8400

Fax: +44(0)1895 832587

e-mail: [email protected]

COPYRIGHT V 2014 MEKON LIMITED.

Sample Statement - All rights reserved. No part of this publication can be reproduced or transmitted in any formor by any means, electronic or mechanical, including photocopying, recording or by any data storage orretrieval system, without the written approval of the Mekon Limited.

The content of this publication is taken from the S1000D Bike Pack version 4.1 as supplied by ASD and thecontent copyright resides with them.

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MEKON-A-00-00-00-00A-000A-AIssue number: 001.01

Preface – About this BookResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

1 IntroductionThis publication has been created by Mekon staff using the S1000D Example files which constitute the Issue 4.1 Bike Pack.

This Data Module was incorporated into two books, one comprising the 2.3 SGML Data Modules and the other created from the Issue 2.3 XML files and has now been modified and accommodated in an Issue 4,1 Descriptive Data Module for use within the Issue 4.1 Book.

The tool which has been used to create this publication is an application called Eclipse BookBuild which runs under Adobe FrameMaker in conjunction with Eclipse S1000D for FrameMaker.

2 Eclipse BookBuild

2.1 FunctionalityThe Eclipse BookBuild application can produce a range of different format publications from source S1000D data modules which comply with Issue 1 Change 6 to Issue 4.1 SGML and/or XML as appropriate. Within some limitations it is possible to mix Issue/Change Data Modules in the same publication.

The publications conform with the S1000D specification in terms of layout and other formatting instructions and suggestions.

The structure of the publication is determined by creating a BookBuild. Using BookBuild it is possible to divide the publication into various options e.g.

– Chapters comprising single Data Modules

– Chapters comprising several Data Modules (MultiDM chapters)

– Volumes (or Sections) which contain single or MultiDM chapters

– Decimalized chapters (i.e. 1, 1.1, 1.1.1 etc.) where each chapter can contain one or more data modules

This range of options makes BookBuild into a very versatile tool for both hard copy and PDF publication delivery (more on the latter later)

2.1.1 Data Modules and Chapters

The ASD S1000D Specification has all the chapters authored as single Data Modules.

When considering the requirements of the specification, however, it is clear that the concept is to have relatively small Data Modules containing unique information. This concept normally results in a relatively large number of small Data Modules. These do not sit well in single Data Module Chapters and so Mekon have provided the means to combine these small chunks of data into a single chapter to make a more complete story for the readers of Hard Copy publications.

2.1.2 Structure Outline

A stylized representation of possible methods of structuring a Book is shown in Fig 1.

The figure shows three simplified methods of structuring a book. Clearly there are other possibilities including:

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– Having decimalized chapters within each Section or Volume

– Having deeper nesting of decimalized chapters

– Skipping Section/Volume/Chapter numbers - each of these elements is provided with a Start Number attribute which is particularly useful when your publications have predefined structures but not all books have all items.

As in most projects, it is important to have an idea of the desired Book structure prior to creation of the book. If a publication module is available then this can be used to provide the structure although at present it is not possible to import it into the BookBuild file. Fig 1 Some possible Book Structures

The means of populating the BookBuild file is provided within the application. However, where the number of files is great, there are strategies which can be employed to greatly reduce the amount of time required to populate the BookBuild file with data module file references.

These strategies may require a person with some knowledge of SGML and XML file structures without formatting and the ability to manipulate these files in a text editor. Mekon can advise on these strategies which have been employed in its BookBuild Bureau service or, if required, even create the BookBuild file in the first instance so that a project can be even more quickly up and running and producing output.

Fig 1 Some possible Book Structures

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2.1.3 Publishing Options

Mention was made in Para 2.1.1 of the need to consider and determine the structure of the book prior to starting to create the BookBuild file. It is also important to determine the various Publishing Options that are available both globally and locally throughout the Book.

Carefully considering these, particularly the local options, and getting them right first time will save a considerable amount of time if a change is required in each chapter. In large publications there can be a large number of chapters and if a particular option requires changing each one then this has the potential of being a time consuming period.

As in most cases with an application of this sort, it is often a good starting position to create and build a small book (perhaps an abbreviated version of a `real' book) so that the options can be explored and approval obtained for the selection made.

2.1.4 Size of Publication

Originally the size of publication which could be produced using BookBuild was limited by FrameMaker functionality and capability to around 900 data modules.

Mekon is continually seeking to improve BookBuild and has now modified the operation to enable publications in excess of 3000 Data Module to be produced.

Some speeding up of BookBuild has been possible but a considerable amount of processing is required during a build and the time taken to produce a book vary considerably depending on the machine which is being used at the time.

2.2 Auto generated MaterialEclipse BookBuild provides a range of auto generated material some of which is optional. This material is as follows:

– Tables of Contents

• These are required at various places throughout a publication

• An empty Descriptive DM is all that is required

• Insertion of the Table Of Contents DM results in it being populated with the relevant information i.e. complete publication, volume (or section) or chapter as appropriate

– Omnibus Tools, Test Equipment, Materials chapters

• These are optional items

• An empty Descriptive DM is all that is required

• These chapters can be placed in several places throughout the publication

• They contain the information obtained from the appropriate tables in procedural data modules

• The content can be global (e.g. when the DM is placed at the front of the publication) or local (e.g. when placed inside a Volume/Section container

– List of effective pages (this can be configured as List of Effective Pages, List of Effective Chapters, or omitted. The List of Effective Pages is configured as the List of Effective Chapters in this example.

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– Technical Standard Record - as required by S1000D specification (optional). This is included but is empty because the Bikepack does not have this feature populated.

– Highlights (Obtained from Reason for Update or Reason for Change (or both) which should be populated during the Data Module update procedure. This is included in this publication.

This publication which uses the S1000D Issue 4.1 Bike Pack data modules contains some of the above features for you to view and/or consider.

Note

Issue 4.1 provides, for the first time, structures which may be sued for preliminary materialsuch as Title Page, Table of Contents, List of Effective Pages etc. This particular publicationdoes not use these items but will, at some time in the future, provide the option to includethem.

The List of Abbreviations and Index may be pre-defined by using new structures but thispublication uses the automatically generated pages. By choosing this option the content ofthe lists will reflect the material in the Bike Pack as supplied.

2.3 User Provided MaterialQuite often there is a need to reproduce material in a document which can be regarded as Standard Information. Examples of this type of material could be:

– Preface (similar to this Data Module)

– Change Record for users to complete as updates are provided

– Abbreviations

These data modules are most likely to be descriptive.

3 BookBuild OutputsBookBuild can provide three outputs as given below in no particular order:

1 Output direct to a printer

2 A single PDF file

3 Multiple PDF files, one for each Chapter, Table of Contents etc.

One of the features is that BookBuild is able to detect fold out pages automatically provided the user has incorporated the Figures and/or Tables within the S1000D Foldout element.

4 Output FormattingThe formatting of the pages produced by BookBuild follows the guidelines provided by the S1000D speechification.

There are some preferences which can be set in the Eclipse S1000D for Framemaker application which enable legacy data (data modules which comply with earlier Issues of S1000D) to be produced reflecting the fact that material produced with Issue 1.6 through to Issue 4.1 can be accommodated.

It is possible to modify the output to closer match a great number of specifications if required. However, modification should only be carried out by persons being very familiar with Adobe

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FrameMaker methods of text display. Mekon Ltd. can provide help to modify the output on a consultancy basis. Please enquire regarding this service.

5 Brief Outline of OperationOperation of BookBuild is straightforward as indicated in Para 2. First time users have found it relatively easy to obtain a simple output. Once the basics have been mastered moving on to more complex structures is assured.Fig 2 Simplified BookBuild Workflow

The process is briefly as follows:

1 Data modules obtained from the CSDB (if one is used) or other source are placed in a folder with the graphics located in a folder which will satisfy the relative path indicated in the Data Module (standard SGML/XML processes).

2 Author creates BookBuild file - the Eclipse BookBuild equivalent of the S1000D Publication Module

2.1 By manually creating the this file and manipulating it to the structure that is required. See Para 2.1.2 for more information when using this option.

2.2 Import the information from a Publication Module. If this method is chosen the author will need to select the various options which are not available in the Publication Module. BookBuild provides a much richer set of option than is available in the Publication Module.

3 Initialize the BookBuild file

Fig 2 Simplified BookBuild Workflow

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4 Build the Book

5 Print the book (or produce a PDF file). If the PDF file option is chosen the following should be noted:

5.1 The PDF file has all the cross referencing enabled as hypertext links. This includes the conversion of references to data modules which are displayed as the relevant Volume/Chapter and, if the additional function in S1000D is used, Figures, Tables and Paragraphs in the target Data Module.

5.2 Where there are Foldout Illustrations or Tables in the BookBuild material two PDF files will be created, one for viewing and the other for printing purposes. The one for printing purposes has, for technical reasons, the folded pages flipped vertically to ensure that the printed output is correct.

6 Prior to working on the next issue of the book, carry out an Issue process (automatically handled once initiated).

It really is as easy as that!

6 RequirementsThe minimum requirements for using BookBuild are:

– Adobe FrameMaker version 7.0 through to 10 (7.2 or later must be used if XML books are to be created)

– Eclipse S1000D for FrameMaker

– Eclipse BookBuild

The versions of Eclipse must be compatible. Because they are so closely integrated it is essential that this compatibility is maintained to ensure correct operation.

7 Further InformationFurther information about this application, pricing and availability can be obtained from Mekon Ltd. using the telephone numbers or E-mail address on the front page.

Under some circumstances Mekon Ltd. is able to provide a bureaux service for producing books using S1000D compliant data modules. Please enquire about this service.

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List of Acronyms

MM-A-00-00-00-00A-000A-AIssue number: 001.01

List of AcronymsResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

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Bicycle - Title pageU8025Bicycle - Title pageU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-001A-A_001-00en-US01S1000DBIKE-AAA-D00-00-00-00AA-001A-AIssue number: 001.00

To be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY S1000D Sample PublicationMountain bicycleMountain storm Mk1Brook trekker Mk9

Mountain bicycle manualBIKE

S1000DBIKE-C3002-EPWG1-00Issue No. 001 Issue Date: 2010-06-08To be made available to all S1000D users.

Export of this publication to all countries that are the residence of organizations that are users of S1000D is permitted.Users may destroy this publication in accordance with any local procedures.There are no dissemination limitations that apply to this publication.Responsible partner company:CORENA N4701

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Bicycle - List of effective data modulesU8025Bicycle - List of effective data modulesU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-002A-A_001-00en-US01S1000DBIKE-AAA-D00-00-00-00AA-002A-AIssue number: 001.00

List of effective data modulesTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY

Document title Data module code Issue dateIssue No.

No. of pages

Applicable to

Bicycle – Description of how it is made S1000DBIKE-AAA-D00-00-00-00AA-041A-A

N 2008-08-01001

Bicycle – Description of function S1000DBIKE-AAA-D00-00-00-00AA-042A-A

N 2008-08-01001

Bicycle – Description attributed to crew S1000DBIKE-AAA-D00-00-00-00AA-043A-A

N 2008-08-01001

Mountain bicycle – Applicability cross-reference table catalog

S1000DBIKE-AAA-D00-00-00-00AA-0A3A-D

N 2010-02-18001

Bicycle – Pre-operation procedures (crew) S1000DBIKE-AAA-D00-00-00-00AA-121A-A

N 2008-08-01001

Bicycle – Riding a bicycle S1000DBIKE-AAA-D00-00-00-00AA-130A-A

N 2007-01-01001

Bicycle – Normal operation procedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-131A-A

N 2008-08-01001

Bicycle – Post-operation procedures (crew)

S1000DBIKE-AAA-D00-00-00-00AA-151A-A

N 2008-08-01001

Bicycle – Servicing: Attention S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T10B

N 2009-10-19001

Bicycle – Servicing: Prerequisite concept review

S1000DBIKE-AAA-D00-00-00-00AA-200A-T-T36D

N 2009-10-19001

Bicycle – Other procedures to clean S1000DBIKE-AAA-D00-00-00-00AA-258A-A

N 2008-08-01001

Bicycle – Place on test stand S1000DBIKE-AAA-D00-00-00-00AA-330A-A

N 2008-08-01001

Bicycle – Standard repair procedures S1000DBIKE-AAA-D00-00-00-00AA-663A-A

N 2008-08-01001

Bicycle – Performance support S1000DBIKE-AAA-D00-00-00-00AA-952A-T-H31A

N 2009-07-22001


N 2009-07-22001

Bicycle – Illustrated Parts Data - IPD S1000DBIKE-AAA-D00-00-00-00AA-941A-D

N 2008-08-01001

Bicycle – Time limits S1000DBIKE-AAA-D05-10-00-00AA-000A-A

N 2008-08-01001

Bicycle – Scheduled maintenance lists S1000DBIKE-AAA-D05-20-00-00AA-000A-A

N 2008-08-01001

Bicycle – Scheduled maintenance checks S1000DBIKE-AAA-D05-40-00-00AA-000A-A

N 2008-08-01001

Wheel – Description of how it is made S1000DBIKE-AAA-DA0-00-00-00AA-041A-A

N 2008-08-01001

Continued

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Wheels – Description of how it is made: Knowledge Check

S1000DBIKE-AAA-DA0-00-00-00AA-041A-T-T61E

N 2009-10-02001

Inner tube – Remove and install a new item

S1000DBIKE-AAA-DA0-10-10-00AA-921A-A

N 2008-08-01001

Tire – Fill with air S1000DBIKE-AAA-DA0-10-20-00AA-215A-A

N 2008-08-01001

Tire – Check pressure S1000DBIKE-AAA-DA0-10-20-00AA-362B-A

N 2008-08-01001

Front wheel – Fault reports and isolation procedures


N 2008-08-01001

Front wheel – Remove procedures: Interactive content - Procedure

S1000DBIKE-AAA-DA0-10-20-00AA-520A-T-T4JC

N 2009-10-02001

Tire – Remove and install a new item S1000DBIKE-AAA-DA0-10-20-00AA-921A-A

N 2008-08-01001

Rear wheel – Detected fault S1000DBIKE-AAA-DA0-20-00-00AA-412A-A

N 2008-08-01001

Rear wheel – Remove procedures S1000DBIKE-AAA-DA0-20-00-00AA-520A-A

N 2008-08-01001

Brake system – Description of how it is made


N 2008-08-01001

Brake system – Manual test S1000DBIKE-AAA-DA1-00-00-00AA-341A-A

N 2008-08-01001

Brake pads – Clean with rubbing alcohol S1000DBIKE-AAA-DA1-10-00-00AA-251A-A

N 2008-08-01001

Steering – Description of how it is made S1000DBIKE-AAA-DA2-00-00-00AA-041A-A

N 2008-08-01001

Steering – Description of how it is made: Knowledge Check


N 2009-07-30001

Stem – Remove procedures S1000DBIKE-AAA-DA2-10-00-00AA-520A-A

N 2008-08-01001

Stem – Install procedures S1000DBIKE-AAA-DA2-10-00-00AA-720A-A

N 2008-08-01001

Handlebar – Remove procedures S1000DBIKE-AAA-DA2-20-00-00AA-520A-A

N 2008-08-01001

Handlebar – Install procedures S1000DBIKE-AAA-DA2-20-00-00AA-720A-A

N 2008-08-01001

Headset – Description of how it is made S1000DBIKE-AAA-DA2-30-00-00AA-041A-A

N 2008-08-01001

Headset – Remove procedures S1000DBIKE-AAA-DA2-30-00-00AA-520A-A

N 2008-08-01001

Headset – Install procedures S1000DBIKE-AAA-DA2-30-00-00AA-720A-A

N 2008-08-01001


No. of pages

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Continued

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Frame – Description of how it is made S1000DBIKE-AAA-DA3-00-00-00AA-041A-A

N 2008-08-01001

Horn – Isolated fault S1000DBIKE-AAA-DA3-10-00-00AA-411A-A

N 2008-08-01001

Horn – Remove and install a new item S1000DBIKE-AAA-DA3-10-00-00AA-921A-A

N 2008-08-01001

Drivetrain – Description of how it is made S1000DBIKE-AAA-DA4-00-00-00AA-041A-A

N 2008-08-01001

Chain – Oil S1000DBIKE-AAA-DA4-10-00-00AA-241A-A

N 2008-08-01001

Chain – Clean with chain cleaning fluid S1000DBIKE-AAA-DA4-10-00-00AA-251B-A

N 2008-08-01001

Drive train – Correlated fault S1000DBIKE-AAA-DA4-10-00-00AA-414A-A

N 2008-08-01001

Gears – Description of how it is made S1000DBIKE-AAA-DA5-00-00-00AA-041A-A

N 2008-08-01001

Mechs – Description of how it is made S1000DBIKE-AAA-DA5-10-00-00AA-041A-A

N 2008-08-01001

Hubs – Clean with degreasing agent S1000DBIKE-AAA-DA5-20-00-00AA-251C-A

N 2008-08-01001

Shifters – Description of how it is made S1000DBIKE-AAA-DA5-30-00-00AA-041A-A

N 2008-08-01001


No. of pages

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Bicycle - Table of contentsU8025Bicycle - Table of contentsU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-009A-A_001-00en-US01S1000DBIKE-AAA-D00-00-00-00AA-009A-AIssue number: 001.00

Table of contentsTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYAllMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and Mountain storm Mk1Mountain bicycle and Brook trekker Mk9


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Bicycle – Description of how it is made

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Bicycle – Description of function S1000DBIKE-AAA-D00-00-00-00AA-042A-A

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Bicycle – Description attributed to crew

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Mountain bicycle – Applicability cross-reference table catalog

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Bicycle – Pre-operation procedures (crew)

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Bicycle – Riding a bicycle S1000DBIKE-AAA-D00-00-00-00AA-130A-A

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Bicycle – Normal operation procedures (crew)

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Bicycle – Post-operation procedures (crew)

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Bicycle – Servicing: Prerequisite concept review

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Bicycle – Standard repair procedures

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Bicycle – Scheduled maintenance checks

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Wheel – Description of how it is made


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Inner tube – Remove and install a new item


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Tire – Fill with air S1000DBIKE-AAA-DA0-10-20-00AA-215A-A

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Tire – Check pressure S1000DBIKE-AAA-DA0-10-20-00AA-362B-A

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Front wheel – Fault reports and isolation procedures


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Tire – Remove and install a new item


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Rear wheel – Detected fault S1000DBIKE-AAA-DA0-20-00-00AA-412A-A

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Brake system – Manual test S1000DBIKE-AAA-DA1-00-00-00AA-341A-A

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Brake pads – Clean with rubbing alcohol


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Steering – Description of how it is made


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Steering – Description of how it is made: Knowledge Check


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Stem – Remove procedures S1000DBIKE-AAA-DA2-10-00-00AA-520A-A

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Stem – Install procedures S1000DBIKE-AAA-DA2-10-00-00AA-720A-A

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Handlebar – Remove procedures S1000DBIKE-AAA-DA2-20-00-00AA-520A-A

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Headset – Description of how it is made


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Frame – Description of how it is made


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Horn – Isolated fault S1000DBIKE-AAA-DA3-10-00-00AA-411A-A

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Horn – Remove and install a new item


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Drivetrain – Description of how it is made


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Chain – Oil S1000DBIKE-AAA-DA4-10-00-00AA-241A-A

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Chain – Clean with chain cleaning fluid

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Drive train – Correlated fault S1000DBIKE-AAA-DA4-10-00-00AA-414A-A

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Gears – Description of how it is made


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Mechs – Description of how it is made


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Hubs – Clean with degreasing agent

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Shifters – Description of how it is made


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MM-A-00-00-00-00A-000A-A

Issue number: 001.01 Table of ContentsResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Preliminary Pages

Table of Contents

Title Page Range

Front Cover i - ii

Preface – About this Book iii - viii

List of Acronyms ix - x

xi - xii

List of effective data modules xiii - xvi

Table of contents xvii - xxiv

Chapter Title

1 General Description

1.1 General

1.1.1 Bicycle

1.1.2 Headset

1.1.3 Frame

1.1.4 Steering

1.1.5 Wheel – Description of how it is made

1.1.6 Electrical system

1.2 Description of Gears and Drive Train

1.2.1 Shifters

1.2.2 Gears

1.2.3 Drivetrain

1.2.4 Mechs

2 Bicycle Operating Instructions

2.1 Description attributed to crew

2.2 Bicycle – Pre-operation procedures (crew)

2.3 Normal operation procedures (crew)

2.4 Bicycle – Post-operation procedures (crew)

2.5 Place on test stand

3 Maintenance

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3.1 Brakes

3.2 Bicycle

3.3 Forks

3.4 Bicycle axis – Modification procedures

3.5 Wheels

3.6 Tyres

3.6.1 Remove and install a new item

3.6.2 Tyres

3.7 Front Brake Removal and Replacement

3.8 Stem Removal and Replacement

3.9 Handlebar and Headset

3.9.1 Handlebar

3.9.2 Headset

3.9.3 Spacer – Install procedures

3.9.4 Horn – Remove and install a new item

3.10 Chain

3.10.1 Chain – Oil

3.10.2 Chain – Clean with chain cleaning fluid

3.11 Hubs – Clean with degreasing agent

3.12 Lighting

3.12.1 Lights – Manual test

3.12.2 Lighting – Assemble, install and connect procedures

3.12.3 Lighting – Remove and install a new item

4 Fault Finding

4.1 Front wheel – Fault reports and isolation procedures

4.2 Rear wheel – Detected fault

4.3 Horn – Isolated fault

4.4 Drive train – Correlated fault

4.5 Lights – Observed fault

5 Parts List

5.1 Bicycle – Illustrated Parts Data - IPD

5.2 Light system – Illustrated Parts Data - IPD

Index Index

Chapter Title

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Chapter 1


General DescriptionResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

1 General Description

1.1 General

1.1.1 Bicycle

1.1.2 Headset

1.1.3 Frame

1.1.4 Steering




1.2.1 Shifters

1.2.2 Gears

1.2.3 Drivetrain

1.2.4 Mechs

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Chapter 1.1


GeneralResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

1.1 General

1.1.1 Bicycle

1.1.2 Headset

1.1.3 Frame

1.1.4 Steering



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Chapter 1.1.1

S1000DBIKE-------Issue number: 002.

BicycleResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)schema cleanupelement/attribute renamingschema cleanupelement/attribute renaming

Table of contents PageDescription of how it is made. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Physical description of a bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Functional description of a bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

List of tables Page1 Bicycle parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of figures Page1 Complete bicycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Description of how it is made

1 Physical description of a bicycleA bicycle (refer to Fig 1) is a frame and a number of movable components with mechanical parts that are completely open. There are no covers or sheet metal panels that prevent access to the mechanical parts. Thus, you can disassemble the different components of a bicycle (refer to HOTSPOT DYNAMIC) to do:

– an inspection

– a maintenance task

– a repair task

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Fig 1 Complete bicycle

The parts that you can immediately identify on a bicycle are given in Table 1. Table 1 Bicycle parts

Table 1 Bicycle parts

Item Refer to Definition

Frame HOTSPOT DYNAMIC

A bicycle frame is made of metal tubes that are welded together.

Wheels The wheels include these parts:

– Hub

– Spokes

– Metal rim

– Rubber tire

– Rear wheel HOTSPOT DYNAMIC

– Front wheel HOTSPOT DYNAMIC

2

111

1

109

12 8

7 6 2 5 4 3

0

2

Fig 1 Complete bicycle

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Description of function

2 Functional description of a bicycleBelow is a list of the different bicycle components and a functional description of them.

Seat and seat post HOTSPOT DYNAMIC

These install into the seat tube with a mechanism you can use to change the height.

Handle bars HOTSPOT DYNAMIC

A horizontal bar that attaches to the stem with grips at the ends that attach to the brake levers and the shifters.

Handle bar stem HOTSPOT DYNAMIC

This attaches the handle bar to the steering tube (head set).

Cranks HOTSPOT DYNAMIC

A lever that extends from the bottom of the bracket to the pedal.

Pedals HOTSPOT DYNAMIC

The two platforms for the feet that attach to the crank.

Chain HOTSPOT DYNAMIC

A circular set of links that connect the chain ring to the cogs on the freewheel.

Gears HOTSPOT DYNAMIC

The gears include:

– Front chain ring

– Rear freewheel

– Front and the rear derailleur

– Shift lever on the handle bars

– Cables

Brakes HOTSPOT DYNAMIC

The brakes include:

– Actuators on the handlebars

– Brake cable

– Brake callipers

– Brake pads

Frame The frame is the skeleton of the bicycle. Refer to Chapter 1.1.3 for a functional description of the frame system.

Wheel The wheel is the point of contact between the bicycle and the road for the bicycle to have movement. Refer to Chapter 1.1.5 for a functional description of the wheel.

Table 1 Bicycle parts (Continued)

Item Refer to Definition

Continued

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Spokes The spokes are thick wires with tension applied that connect the hub to the rim. You can adjust the tension with the nipple on the rim side.

Hub The hub attaches to the center of the wheel where the axle and the bearings are.

Metal rim The metal rim is a metal ring that has a U-shaped cross section to hold the spokes on the inner side and the tire on the outer side.

Seat The Seat, which is also known as the 'saddle', is used as the support platform for the person to sit on the bicycle.

Seat post The Seat post is used as a support post for the seat and to change the height of the seat for the rider.

Handle bar The handle bar is a horizontal bar with handles on each end. The handle bar is a steering mechanism that the rider uses to change the direction of the bicycle. The brake levers are also on the handle bar. Refer to Chapter 3.9.1 - Step 4 for information on how to install the handle bar. Refer to Chapter 3.9.1 - Step 1 for information on removing the handlebar.

Handle bar stem The handle bar stem (the stem) attaches the handle bar to the steering tube. Refer to Chapter 3.8 - Step 3 for information on how to install a stem. Refer to Chapter 3.8 - Step 1 for information on how to remove the stem.

Brake levers When you operate the brake lever, the brake pads move against the wheel to decrease the speed. The brake lever on the left side operates the front brake. The brake lever on the right side operates the rear brake.

Brakes When you operate the brakes, the brake pad moves against the wheel to decrease the speed of the bicycle. Refer to Chapter 3.1 - Para 1 for a description of the braking system.

Shifters The shifters are the mechanisms that you use to change the gears on the bicycle. There are 7 different types of shifters that have been developed over the years, but they all have the same functionality. When you operate the shifters, they pull the control cable to move the derailleur towards a larger diameter chain ring. The shifters can also loosen the cable to let the derailleur move towards a smaller diameter chain ring. Refer to Chapter 1.2.1 for a functional description of the shifters.

Crank The crank moves the power to the chain rings when the pedals operate.

Pedals The pedals move the force of movement from the feet to the cranks.

Chain The chain moves the power from the chain rings to the cogs on the freewheel. Refer to Chapter 3.10.2 for the procedure on how to clean the chain.

Continued

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Gears The gears have different mechanisms that function together to change the speed of the bicycle. These mechanisms include:

the sprockets

the chain

the derailleur

Refer to Chapter 1.2.2 for a functional description of the gear system.

Chain rings The chain rings (also known as the 'chain wheel') pull on the chain when the cranks turn.

Derailleur A derailleur moves the chain from one sprocket to another to change the gears. There are two different types of derailleur, the front and the rear. The highest ratio (highest gear) is when the chain is on the largest sprocket on the front and the smallest at the rear. To get the lowest gear, the smallest sprocket is at the front and the largest at the rear. Refer to Chapter 1.2.4 for a functional description of the derailleur system.

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Chapter 1.1.2

Headset - Description of how it is madeU8025Headset - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA2-30-00-00AA-041A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA2-30-00-00AA-041A-AIssue number: 007.00

HeadsetTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY143schema cleanupelement/attribute renaming

Table of contents Page1 Headset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of figures Page1 Headset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 HeadsetThe headset (refer to Fig 1) is a pair of bearings on the two ends of the head tube of the frame. These bearings permit the fork to turn rearward and forward (for example, to let the rider turn the handlebars for the steering).

The headset (refer to Fig 1) includes the parts that follow:

The bearing races that push into the head tube

a bearing race that pushes on the fork steerer tube

an adjustable upper race

two sets of ball bearings

A headset has cups that are pushed into the head tube and a ring on the fork. All three must be fully parallel. It is usually necessary to remove rough paint to get all three fully parallel.

The upper race installs onto the steerer tube with a thread. A locknut is used to safety the upper race.

A clamp bolt holds the stem to the steerer tube.

The fourth remaining bearing race is part of a nut that installs on the threaded top end of the fork. This is done after you install it in the head tube. It is sometimes necessary for some headsets to have more thread at the top of the head tube. If the fork is too long, the spacer rings can be installed. If it is too short, there is a limit to the number of headsets you can use.

For an illustration of the parts of the headset (refer to Fig 1).

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Fig 1 Headset

A

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Fig 1 Headset

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Chapter 1.1.3

Frame - Description of how it is madeU8025Frame - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA3-00-00-00AA-041A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA3-00-00-00AA-041A-AIssue number: 007.00

FrameTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY15schema cleanupelement/attribute renaming

Table of contents Page1 The bicycle frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of figures Page1 Welded frame joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 The bicycle frameThe frame is the skeleton, the primary part of your bicycle. Its structure makes the bicycle resistant to large forces.

The initial frames (refer to Fig 1) were tubes of aluminum or steel welded together.

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Fig 1 Welded frame joints

Subsequent frames (refer to Fig 2) can be made out of a wide variety of materials, including aluminium, titanium, or chrome moly.

A

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Fig 1 Welded frame joints

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Fig 2 Frame

are different and can also be of different materials (for example, titanium or chrome moly). Some bicycle frames are of carbon fiber. To get this material, it is necessary to put sheets of carbon fiber cloth on foam forms and epoxy them in position. This procedure gives a very light, strong structure that can have different shapes.

The frame includes the parts that follow:

– the top tube (the higher bar of the bicycle frame)

– the down tube (the section of the frame that extends from the stem to the bottom bracket)

– the head tube (the part of the frame that the fork steerer tube goes through)

– the seat tube (the vertical part of the frame that is the rear of the front triangle and that is between the bottom bracket and the top tube)

– the seat stay (the tube that includes the distance between the seat tube and the rear dropouts)

– the chain stay (the tube that is the bottom part of the rear triangle)

SEAT STAYS

TOP TUBEHEAD TUBE

SEAT TUBE

DOWN TUBE

BOTTOM BRACKET SHELLDERAILLEUR HANGER

CHAIN STAYS

Fig 2 Frame

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Chapter 1.1.4

Steering - Description of how it is madeU8025Steering - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA2-00-00-00AA-041A-A_008-00en-US01_cc51_cv51S1000DBIKE-AAA-DA2-00-00-00AA-041A-AIssue number: 008.00

SteeringTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY142schema cleanupelement/attribute renaming

Table of contents Page1 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Headset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 SteeringThe steering on the bike is what enables the bike to manoeuvre in a given direction during travel. The steering system on the bike is made of three parts, they are:

Para 1.1 The handlebar

Para 1.2 The headset

Para 1.3 The stem

1.1 HandlebarThis consists of a horizontal bar attached to the stem with handgrips at the end. Brake levers and shifters are also attached to this bar although they do not have any part in the steering mechanism. The handlebars manoeuvrability is a sideways swivelling action. The handlebars themselves do not provide this swivelling, the headset (also known as the steering tube) is the mechanism that enables the handlebars to swivel.

1.2 HeadsetThis mechanism is situated in front of the frame and connects the front fork to the stem and handlebars. The headset allows the handlebars to swivel left and right for steering purposes.

For a full description of the headset, refer to Chapter 1.1.2 .

1.3 StemThe stem is a piece that attaches the handlebar to the steering tube. Basically the stem is just a threaded stem bolt situated inside the steerer tube and is what attaches the handlebars to the headset.

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Chapter 1.1.5

Wheel - Description of how it is madeU8025Wheel - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA0-00-00-00AA-041A-A_008-00en-US01_cc51_cv51S1000DBIKE-AAA-DA0-00-00-00AA-041A-AIssue number: 008.00

Wheel – Description of how it is madeTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYPage Layout Measurement Unit ConsistencyCPF 2009-060US

Table of contents Page1 The bicycle wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Spokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 Wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 Tube and tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

List of figures Page1 Parts of the wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 The tire and rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 The bicycle wheelThe wheel (refer to Fig 1) of a bicycle is a complex structure. The wheel assembly has these parts:

the tire

the tube

the spokes

the spoke nipples

the valve

the hub

On their own, the individual components are not very strong. But, when they are installed together, the components make the complete wheel (refer to Fig 1). The complete wheel is resistant to almost any type of heavy loads and operation.

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Fig 1 Parts of the wheel

1.1 SpokesThe spokes go out from the hub and go across and below each other. The spoke nipples attach the spokes to the rim with the threads on the end of the spokes. You can use the spoke nipples to adjust the tension of the spokes. The tension on each of the spokes must be equal.

1

4

3

2

A

A

5

Fig 1 Parts of the wheel

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1.2 Wheel rimThe rim (refer to Fig 2) of the wheel has a lining of rim tape. This tape protects the tube from damage that the rough edges on the spoke nipples can cause.Fig 2 The tire and rim

1

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Fig 2 The tire and rim

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1.3 Tube and tireThe tube and the tire install on the rim. The sidewalls of the tire have markings on them. These which are used to indicate the correct direction of rotation. The markings also make sure the tire installs on the rim and that the directional arrows points in the correct direction. You install the tube into the tire before you inflate it. The tube has a valve (refer to Fig 3) which you put through the hole in the rim. This valve (refer to Fig 3) is used to inflate the tube and the tire to the correct pressure. A dust cap installs on the valve (refer to Fig 3) to prevent damage that dust and debris can cause.

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Fig 3 Valve

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Fig 3 Valve

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S1000DLIGHTING-AAA-D00-00-00-00AA-040A-A

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Chapter 1.1.6

Electrical system - Description of how it is made and its functionU8025Electrical system - Description of how it is made and its functionU8025U80252011-01-31texttext/xmlS1000DLIGHTING-AAA-D00-00-00-00AA-040A-A_007-00en-US01_cc51_cv51S1000DLIGHTING-AAA-D00-00-00-00AA-040A-AIssue number: 007.00

Electrical systemTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-D20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DLTApplicability ExternalizationCPF 2009-144S1

Table of contents Page1 Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of figures Page1 Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Lighting systemThe illustration that follows (see Fig 1) shows the lighting system of the bicycle.Fig 1 Lighting system

L1 L2

S1Rel

Gen

Bat

G

Fig 1 Lighting system

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Chapter 1.2


Description of Gears and Drive TrainResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title


1.2.1 Shifters

1.2.2 Gears

1.2.3 Drivetrain

1.2.4 Mechs

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Chapter 1.2.1

Shifters - Description of how it is madeU8025Shifters - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA5-30-00-00AA-041A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA5-30-00-00AA-041A-AIssue number: 007.00

ShiftersTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY173schema cleanupelement/attribute renaming

Table of contents Page1 Shifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 How a thumb shifter is made up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of figures Page1 Thumb shifter index type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Unscrew wingnut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Loosen the nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Loosen the shifter clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 ShiftersThe thumb shifter is a usual type in modern bicycles. It is possible to adjust this type of shifter for operation in the index position or in the friction position. The differences between the two are:

– The index shifters change the gears with a click of a lever.

– The friction shifters hold the derailleur in its position by friction.

The thumb shifters (refer to Fig 1) are held on the bicycle with a screw. The paragraph that follows gives a description of a thumb shifter.

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Fig 1 Thumb shifter index type

2 How a thumb shifter is made upA wing nut (refer to Fig 2) from the top of the lever holds the thumb shifter. The lever is on top of the mount and the mount is on the handle bar with a nut. To remove the mount, it is necessary to loosen the nut of two turns (refer to Fig 3), then the mount can move from the handle bar from the

A

A

Fig 1 Thumb shifter index type

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top of the lever. The lever sits on top of the mount and the mount is fixed into pace on the handle bar by a nut.Fig 2 Unscrew wingnut

A

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Fig 2 Unscrew wingnut

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Fig 3 Loosen the nut

On modern models of this shifter, there is a clamp bolt that holds the shifter in its position (refer to Fig 4). The user can loosen the clamp bolt with an applicable tool. This lets the shifter release the handlebar.

A

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Fig 3 Loosen the nut

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Fig 4 Loosen the shifter clamp bolt

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Fig 4 Loosen the shifter clamp bolt

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Chapter 1.2.2

Gears - Description of how it is madeU8025Gears - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA5-00-00-00AA-041A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA5-00-00-00AA-041A-AIssue number: 007.00

GearsTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY17schema cleanupelement/attribute renaming

Table of contents Page1 Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 GearsThe gears include the mechanism, the hubs and the shifters.

The description of the mechanisms is given in Chapter 1.2.4

The description of the shifters is given in Chapter 1.2.1

The bicycles of these days can have 27 gears or more. The mountain bikes use a set that includes:

– Three socket sprockets of different dimension on the front

– Nine socket sprockets of different dimensions at the rear

This set gives the gear ratios.

The shifters installed on the handlebars change the gears and operate the mechanisms (also known as derailleurs). These derailleurs are cable-actuated mechanisms. They move the chain from the different sprockets.

The hub is the center of the wheel and contains the axle and bearings.

The gears let the rider crank at the pedals at a constant movement on slopes of different angles.

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Chapter 1.2.3

Drivetrain - Description of how it is madeU8025Drivetrain - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA4-00-00-00AA-041A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA4-00-00-00AA-041A-AIssue number: 007.00

DrivetrainTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY16schema cleanupelement/attribute renaming

Table of contents Page1 Drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Drive trainThe drive train is the group of components that are necessary for the operation of the bicycle. The drive train is the primary system for the movement of the bicycle. A typical drive train has the chain wheels, the chain, the pedals and the saddle.

Since the drive train has many components, it is necessary to do a regular maintenance. The drive train maintenance is easy and the users can disassemble and assemble each part of the drive train. Because of this, when one part is defective, it is possible to remove and replace it with a new one.

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Chapter 1.2.4

Mechs - Description of how it is madeU8025Mechs - Description of how it is madeU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA5-10-00-00AA-041A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA5-10-00-00AA-041A-AIssue number: 007.00

MechsTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY171schema cleanupelement/attribute renaming

Table of contents Page1 Derailleur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Front derailleur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Rear derailleur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

List of figures Page1 Front derailleur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Rear derailleur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 DerailleurThere are two different types of derailleur, the front and the rear.

1.1 Front derailleurThe front derailleur (refer to Fig 1) contains two types of screws to keep the movement of the derailleur to a minimum. These screws are:

the stop screw low-gear

the stop screw high-gear

The function of these screws is to prevent the rider from over shifting . If this occurs, the chain will go out of the chain wheel.

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Fig 1 Front derailleur

The derailleur is installed on the bicycle seat tube with a clamp and is parallel to the three front sprockets.

A

2

3

4

1

A

5

6

7

Fig 1 Front derailleur

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The shift cable is connected between the shifters on the handle bars and the cable clamp bolt on the front derailleur. This operates the derailleur. On the sprockets there is an inner and outer cage. The clamp attaches the cage.

1.2 Rear derailleurThe rear derailleur (refer to Fig 2) section contains the sprockets for the different gear changes. When the cable clamp bolt is tight, it holds the shift cable in its position. A screwed bolt holds the tension wheel.

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Fig 2 Rear derailleur

The derailleur mounting bolt connects the derailleur to the frame. When the user attaches this bolt, this makes sure that the cage plates are parallel with the chain rings.

A

2

34

5

6

7

A

1

Fig 2 Rear derailleur

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The guide wheel has the function to move the chain with the derailleur. It moves the chain from one sprocket to the other. The guide wheel must not move on its axis. If this occurs, there will be wear on the wheel. The position of the guide wheel is below the largest sprocket.

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Chapter 2


Bicycle Operating InstructionsResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

2 Bicycle Operating Instructions

2.1 Description attributed to crew

2.2 Bicycle – Pre-operation procedures (crew)

2.3 Normal operation procedures (crew)

2.4 Bicycle – Post-operation procedures (crew)

2.5 Place on test stand

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Chapter 2.1

Bicycle - Description attr ibuted to crewU8025Bicycle - Description attr ibuted to crewU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-043A-A_008-00en-US01_cc51S1000DBIKE-AAA-D00-00-00-00AA-043A-AIssue number: 008.00

Description attributed to crewTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYschema cleanupelement/attribute renaming

Table of contents Page1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 Shifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of tables Page1 shifter correlation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 brake lever correlation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 IntroductionData about the bicycle and its control system is given in this document. This data will help you operate the bicycle.

2

2.1 ControlsData about the controls that follow is given in this document:

– Para 2.2Steering

– Para 2.3Shifters

– Para 2.4Brakes

– Para 2.5Pedals

2.2 SteeringThe handlebars are used to steer the bike. They are at the front of the bicycle. You hold one of the handlebar grips with each hand and move the handle bar to change the direction of the bike.

2.3 ShiftersThe gears control the ratio of pedal rotation to wheel rotation. You can change this with the shifters Chapter 1.2.1 . The shifters are on the handlebar.

A description of the two Table 1shifters follows.

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Table 1 shifter correlation

2.4 Brakes

WARNINGIf you operate the front brake without the rear brake you can cause a crash.

You can decrease the speed of the bike with the brakes. You operate the brakes with the brake levers on the handlebar.

A description of the Table 2brake levers follows. Table 2 brake lever correlation

2.5 PedalsThe Control Indicator Ref: ci-0004 are at the bottom of the seat tube. You operate the Control Indicator Ref: ci-0004 to move the bicycle forward.

Table 1 shifter correlation

Shifter Location Affected Gears

Left The buttons on the left shifter changes the gears on the front derailleur.

Right The buttons on the right shifter changes the gears on the rear derailleur.

Table 2 brake lever correlation

Brake Lever Location Affected Brake

Left This lever operates the front brake.

Right This lever operates the rear brake.

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Chapter 2.2

Bicycle - Pre-operation procedures (crew)U8025Bicycle - Pre-operation procedures (crew)U8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-121A-A_008-00en-US01_cc51S1000DBIKE-AAA-D00-00-00-00AA-121A-AIssue number: 008.00

Bicycle – Pre-operation procedures (crew)To be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYschema cleanupelement/attribute renaming

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of figures Page1 Hydraulic brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Brake pad seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preliminary requirements

Required personnel

Support equipment

Consumables, materials and expendables

1 Examine the condition of the brakes.

1.1 Open the brake quick release.

1.2 Examine the condition and the thickness of the brake pads.

Table 1 Required personnel

Person Category/Trade Skill Level Trade Code Estimated Time

Man A Basic user Operator 0,3h

Table 2 Support equipment

Nomenclature Identification No. Qty Remarks

Tire pressure gauge NSCM: KZ666Pt. No.: BSK-TLST-001-01

1 EA

Specialist toolset NSCM: KZ666Pt. No.: BSK-TLST-001

1 EA

Table 3 Supplies


General lubricant NSCM: KZ222Pt. No.: LL-001

As required

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1.2.1 Make sure that there is a large quantity of rubber left.

1.2.2 Make sure that the pad is not too hard.

1.3 Clean all the unwanted material.

2 Do an inspection of the installation of the brakes.

2.1 Check the hydraulic brake system function.Fig 1 Hydraulic brake function

2.2 Make sure that there is sufficient clearance between the pad and the inner diameter of the brake surface.

2.3

CAUTIONIf the position of the pads is too low on the rim, as shown in Fig 2 , the pads can move. Thiscould cause the separation of the spokes from their mountings., they could slip off causingthe spokes to be torn out of their mountings.

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Fig 2 Brake pad seating

Make sure that the pads are correctly installed in the center of the inner diameter of the brake surface.

3 Do a check of the tire pressure.

A

A

Fig 2 Brake pad seating

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3.1 Do a check of the tire pressure with the Tire pressure gauge .

3.2 Compare the value you read with the recommended pressure that is shown into the sidewall of the tire.

3.3 Add the necessary air.

4 Examine the condition of the wheels.

4.1 Examine the rims for bulges and dents.

4.2 Examine for splits at the seam where an extruded rim is bonded.

5 Do a check of the headset bearings.

5.1 Straddle the bicycle.

Apply the front brakes and push the handle bars forward.

5.2 Make sure that the headset bearings are tight.

6 Do the checks on the chain.

6.1 Visually examine the chain.

If the chain is too dirty, clean it as specified in the clean chain task (refer to Chapter 3.10.2 ).

6.1.1 Visually examine the chain for links that are frozen or that do not move easily.

6.1.2 Apply the necessary General lubricant .

6.2 Do a check of the chain to make sure that it is tight.

6.2.1 Make sure that the play of the chain is not too much.

6.2.1.1 Move the chain on the largest chain ring.

6.2.1.2 Try to pull the chain away from the front of the chain ring.

Make sure that the chain is not loose. Tighten the chain if, when you pull it away from the chain ring, you can see a full tooth.

6.2.2 Tighten the chain with the Allen wrench from the Specialist toolset.

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Chapter 2.3

Bicycle - Normal operation procedures (crew)U8025Bicycle - Normal operation procedures (crew)U8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-131A-A_008-00en-US01_cc51S1000DBIKE-AAA-D00-00-00-00AA-131A-AIssue number: 008.00

Normal operation procedures (crew)To be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYschema cleanupelement/attribute renamingCaption color "blue" is not in the list of S1000D interpreted values. Has been set to "co51".

List of tables Page1 Correlation of tire pressure and terrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mountain storm Mk1Brook trekker Mk9 Pre-ride inspection

Brakes

Pads

1. Pads . . . . . . . . . . . . . . . . . . . . . . . . . Free of unwanted material

2. Pads . . . . . . . . . . . . . . . . . . . . . . . . . Acceptable pad width

3. Pads . . . . . . . . . . . . . . . . . . . . . . . . . Acceptable pad clearance

Callipers

1. Link Wire . . . . . . . . . . . . . . . . . . . . . . . Firmly attached

Levers

1. Levers . . . . . . . . . . . . . . . . . . . . . . . . Approximately 1 inch of travel before engagement

2. Levers . . . . . . . . . . . . . . . . . . . . . . . . Space between lever and handlebar when fully pulled

Cables

1. Cables . . . . . . . . . . . . . . . . . . . . . . . . No cuts or fraying

Tires1. Pressure . . . . . . . . . . . . . . . . . . . . . . . Table 1 Correlation of tire pressure and terrain

2. Tires . . . . . . . . . . . . . . . . . . . . . . . . . No cracks or splits

Wheels1. Wheels . . . . . . . . . . . . . . . . . . . . . . . . No loose bearings

Table 1 Correlation of tire pressure and terrain

Tire Pressures Min Max

Off Road 35lbs 40lbs

On Road 55lbs 60lbs

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2. Wheels. . . . . . . . . . . . . . . . . . . . . . . . True

3. Spokes. . . . . . . . . . . . . . . . . . . . . . . . Not broken

Spokes not broken

4. Spokes . . . . . . . . . . . . . . . . . . . . . Tight

5. Axel Nuts . . . . . . . . . . . . . . . . . . . . . . Tight

Headset1. Headset bearings . . . . . . . . . . . . . . . . . . Tight

Chain1. Links . . . . . . . . . . . . . . . . . . . . . . . . . Easy movement of links

Handlebar

WARNINGDo not ride with a cracked stem

Stem cracked

1. Replace stem

Stem is loose

1. Tighten stem

Handlebars twist in stem

2. Tighten clamp bolt

Computer1. Computer Display. . . . . . . . . . . . . . . . . .

ALTITUDE 0 miles

SPEED 0 mph

DISTANCE 0 miles

SPEED 0 mph

DISTANCE 0 miles

ALTITUDE 0 miles

SPEED 0 mph

DISTANCE 0 miles

SPEED 0 mph

DISTANCE 0 miles

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Chapter 2.4

Bicycle - Post-operation procedures (crew)U8025Bicycle - Post-operation procedures (crew)U8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-151A-A_008-00en-US01_cc51S1000DBIKE-AAA-D00-00-00-00AA-151A-AIssue number: 008.00

Bicycle – Post-operation procedures (crew)To be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYschema cleanupelement/attribute renaming

List of tables Page1 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Support equipment


1 Clean the bicycle.

1.1 Clean the bicycle with water.

1.2 Use the brush from the Specialist toolset to clean the brakes, the shift levers, the sprockets and the tires.

1.3 Let the bicycle dry.

2 Lubricate the bicycle

2.1 Spray the General lubricant, to these moving parts:

the brake pivots

the derailleur pivots

the derailleur tension guides

the brake lever pivots

the control cables

the gear sprockets




1 EA

Table 2 Supplies



As required

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the chain

2.2 Remove the lubricant which is more than the necessary.

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Chapter 2.5

Bicycle - Place on test standU8025Bicycle - Place on test standU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-00AA-330A-A_008-00en-US01_cc51S1000DBIKE-AAA-D00-00-00-00AA-330A-AIssue number: 008.00

Place on test standTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with thier own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY112schema cleanupelement/attribute renaming

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Required personnel

Support equipment

1 Ensure Test stand is level.

2 Place bicycle on the test stand.

3 Tight clamps until bicycle is securely attach to the test stand.






Test stand NSCM: KZ666Pt. No.: BSK-TLST-999-01

1 EA

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Intentionally Blank

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Chapter 3


MaintenanceResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

3 Maintenance

3.1 Brakes

3.2 Bicycle

3.3 Forks

3.4 Bicycle axis – Modification procedures

3.5 Wheels

3.6 Tyres


3.6.2 Tyres

3.7 Front Brake Removal and Replacement

3.8 Stem Removal and Replacement


3.9.1 Handlebar

3.9.2 Headset



3.10 Chain



3.11 Hubs – Clean with degreasing agent

3.12 Lighting




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Chapter 3.1


BrakesResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)ModelIdentCode changed to BRAKECPF 2008-020S1ModelIdentCode changed to BRAKECPF 2008-020S1ModelIdentCode changed to BRAKECPF 2008-020S1

Table of contents PageBrake system – Description of how it is made. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Cantilever brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 Brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Brake system – Manual test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Brake pads – Clean with rubbing alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Brake pads – Clean with rubbing alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

List of figures Page1 Cantilever brake with straddle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Exploded diagram of a brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Typical components of a mountain bicycle lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


1 Brake systemThe most important part of the bicycle is the brake system. Only a minimum maintenance of the brake system is necessary. But, when a problem does occur, make sure you to do the necessary maintenance as quickly as possible. If you do not do this the bicycle will be dangerous to use.

There are nine different types of brake systems. The one found on most bicycles is the cantilever brake (refer to Para 1.1).

1.1 Cantilever brakeThe brake system (refer to Fig 1) has these primary components:

the brake lever (refer to Para 1.3)

the brake cable

the brake arm

the brake clamp (also known as callipers)

the brake pads (refer to Para 1.2)


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Fig 1 Cantilever brake with straddle cable

A cable that goes from the brake levers on the handlebars pulls the two levers on the brakes together. This presses the brake pads against the outer rim of the wheel, which decreases the speed of the bicycle.

A

6

7

8

23

4

A

5

1

Fig 1 Cantilever brake with straddle cable


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1.2 Brake padsThere are four brake pads (refer to Fig 2) on the bicycle. Two are found on the front wheel and two on the rear wheel. The brake pads are made out of hard wearing rubber. The pads press against the rim of the wheel to cause friction when the you operate the brake levers.Fig 2 Exploded diagram of a brake

A

A

Fig 2 Exploded diagram of a brake


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1.3 Brake leverThe brake levers (refer to Fig 3) are easily damaged. The lever is installed in the mount. A clamp bolt holds the mount. This bolt is not visible because it is found in the mount. The lever turns on a lever pivot bolt. The adjuster lock nut holds the brake cable. This lock nut adjusts the tension of the cable.Fig 3 Typical components of a mountain bicycle lever

The left brake lever holds the brake pads on the front wheel and the right brake pads hold the brakes on the rear wheel.

A

A

345

6

2

1

Fig 3 Typical components of a mountain bicycle lever


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Brake system – Manual test

Preliminary requirementsRequired personnel

1 Put the bicycle in a vertical position.

2 Hold the handle bars and push the bicycle forwards.

3 Apply the brakes.

4 Make sure that the wheels lock and the bicycle stops.



5 Do a visual inspection of the brakes as given in the pre-ride checks (refer to Chapter 2.2).

6 Clean the brake pads.

6.1 Find each of the brake pads.

6.2 Apply a thin layer of the Rubbing alcohol on each of the brake pads.

6.3 Rub the surface until you have applied the Rubbing alcohol to the complete surface of the pad.

6.4 Remove the unwanted alcohol.



7 Do a visual inspection of the brakes as given in the pre-ride checks (refer to Chapter 2.2).

8 Clean the brake pads.










S1000DBIKE-AAA-DA1-00-00-00AA-341A-A, S1000DBIKE-AAA-DA1-10-00-00AA-251A-A, BRAKE-AAA-DA1-10-00-00AA-251A-A

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8.1 Find each of the brake pads.

8.2 Apply a thin layer of the Rubbing alcohol on each of the brake pads.

8.3 Rub the surface until you have applied the Rubbing alcohol to the complete surface of the pad.

8.4 Remove the unwanted alcohol.

BRAKE-AAA-DA1-10-00-00AA-251A-A

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Chapter 3.2


BicycleResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)totally revisedSchema cleanup element/attribute renamingschema cleanupelement/attribute renaming

Table of contents PageOther procedures to clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Standard repair procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

List of figures Page1 Cleaning the bike. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Degreasing the freehub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Unseating the tire with a tire lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Circle leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Sanding the application area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Apply glue to application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Apply pressure to tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Required conditions

Safety conditions

WARNINGS• Do not get Detergent A into your eyes. If it gets into your eyes, wash them immediately

in clean warm water.

• Do not get Detergent B into your eyes. If it gets into your eyes, wash them immediatelyin clean warm water.

CAUTIONS• Do not use a Water hose that has high pressure. A water hose that has high pressure

can cause some parts to become loose or full of water.

Table 1 Required conditions

Action/Condition Data Module/Technical Publication

The bicycle is outdoors Not Applicable

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• Do not point the hose directly at the hub or at the bottom bracket bearings. This cancause damage to the parts.

• Apply Detergent B in accordance with the instruction on the container. The substancemay cause damage to the Bike paint if it is not applied correctly.

• When you remove the rear wheel to repair a puncture, disconnect the brake arm fromthe chain stay.

Inline Applicability:Applicability: ID: apMK9 Config:

Mountain bicycle Brook trekker Mk9Evaluate: (Operator: and, applicDisplayClass: )

Assert:applicPropertyIdent: typePropertyType: prodattrPropertyValues: Mountain bicycleDisplayClass:

and Assert:PropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass:

and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass:

Applicability: ID: apMK1 Config:

Mountain bicycle Mountain storm Mk1Evaluate: (Operator: and, applicDisplayClass: )


and Assert:PropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass:


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Other procedures to clean


Required personnel

1 Clean the bicycle with water to remove all dirt. Refer to Fig 1.



Man A Chemical technician

Intermediate Bike cleaner 1,0h



Man B Operator Intermediate Bike rider 1,0h

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Fig 1 Cleaning the bike

2 Use a Stiff bristle brush to get access to areas that are not easy to clean. These are the shift levers, the knobbly tires, and the brakes.

3 Clean the caked grime from the chain and the sprockets with a screwdriver that has a small blade.

4 Remove the grease from the freewheel assembly with the Degreasing agent as shown in Fig 2 . Use a brush to remove the grease from these parts:

– sprockets

– guide and tension wheels of the derailleur

– chain ring teeth

Fig 1 Cleaning the bike

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Fig 2 Degreasing the freehub

5 Flush the sprockets, the derailleurs, the chain rings and the chain with water.

Note

If necessary, do the flush procedure again.

A

A

Fig 2 Degreasing the freehub

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6 Wash the Bike6.1 Soak the Sponge into Detergent A and water.

6.2 Clean the bicycle with the soaked sponge.

6.3 Flush the bicycle and make sure that all Detergent A is removed.

6.4 Move the bicycle up and down on its tires to remove all water.

7 Wash the Bike7.1 Soak the Sponge into Detergent B and water.

7.2 Clean the bicycle with the soaked sponge.

7.3 Soak the Sponge into Detergent A and water.

7.4 Fully clean the bicycle with the soaked sponge.

7.5 Flush the bicycle to make sure that all detergents are removed.

7.6 Move the bicycle up and down on its tires to remove all water.

8 Lubricate the bicycle (refer to Chapter 3.10.1).

Requirements after job completion

Required conditions

Standard repair procedures


9 Remove the rear wheel. (Refer to Chapter 3.5 - Step 1)

10 Make sure that there is no air in the tube.

10.1 Loosen the cap on the valve stem.

10.2 Push the valve stem core down to bleed all the air.

11 Use a Tire lever to move the tire bead out of its seat. Lift the tire bead above the lip of the rim.



Make sure the bicycle is dry Not Applicable



Man A Operator Basic Bike rider 0,5h


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Fig 3 Unseating the tire with a tire lever

12 Remove the tube.

13 Inflate (not fully) the tube with the Foot pump. Examine the tube for leaks.

14 If you find a leak, identify it with a circle made with a Marker pen.

A

A

Fig 3 Unseating the tire with a tire lever

S1000DBIKE-AAA-D00-00-00-00AA-663A-A

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Fig 4 Circle leak

15 Release most of the air.

16 Use a piece of sandpaper from the Tube patch kit and make the area on and around the hole rough. This will help the patch bond correctly.

A

A

Fig 4 Circle leak

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Fig 5 Sanding the application area

17 Apply a thin layer of glue from the patch kit on and around the hole. Make sure that the area with the glue is larger than the patch.

A

A

Fig 5 Sanding the application area

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Fig 6 Apply glue to application area

18 Let the glue dry for five minutes until it becomes tacky and dim.

19 Remove the rear foil from the patch (that is a part of the patch kit) and push the patch in its position.

20 Push with your thumbs from the center of the patch to the outer part of the applied area.

A

A

Fig 6 Apply glue to application area

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Fig 7 Apply pressure to tube

21 Remove the thin cover from the patch.

22 Put a very thin layer of talcum powder on and around the patch.

23 Inflate (not fully) the repaired tube with the foot pump.

24 Start at the valve stem and install the tube again between the tire and the rim.

A

A

Fig 7 Apply pressure to tube

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25 Push the valve stem through the hole in the rim.

26 Make sure that the valve stem is straight.

27 Install the remaining of the tire.

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Chapter 3.3


ForksResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and Mountain storm Mk1Mountain bicycle and Brook trekker Mk9Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)

Table of contents PageManual test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Remove procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Install procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Install procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required Techincal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Required Techincal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Required Techincal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Required Techincal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Required personnel

Manual test

1 Climb on the bicycle.

2 Turn right and left several times.

3 Ride forward the bicycle.

4 Make sure that the wheels are stable.

5 Push in the fork.

6 Make sure that no oil or air is leaking out the fork.



– Manual testMan A Basic user Operator 0,1h – Remove proceduresAs required – Install proceduresAs required – Install proceduresAs required

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Remove procedures

Preliminary requirementsRequired technical information

7 Remove the stem, refer to: Chapter 3.8 - Step 1

8 Remove the headset, refer to: Chapter 3.9.2 - Step 1

9 Push the fork downwards to remove it from the frame

10 Put the frame on the floor

Install procedures


11 Apply grease (General grease) on theS1000DBIKE-AAA-D00-00-00-0000-121A-A headset

12 Install the headset, refer to: Chapter 3.9.2 - Step 4

13 To install the spacers, refer to: Chapter 3.9.3

14 Install the stem, refer to: Chapter 3.8 - Step 3

15 Install the fork (Fork)

Table 2 Required Techincal Information

Data Module/Technical Publication Title

Chapter 3.8 - Step 1

Chapter 3.9.2 - Step 1





Chapter 3.9.3


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Install procedures


16 Apply grease (General grease) on the headset

17 Install the headset, refer to: Chapter 3.9.2 - Step 4

18 Install the stem, refer to: Chapter 3.8 - Step 3

19 Install the fork (Fork)

Inline Applicability:Applicability: ID: XX19054 Config:

Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Evaluate: (Operator: and, applicDisplayClass: )


and Evaluate: (Operator: or, applicDisplayClass: )Evaluate: (Operator: and, applicDisplayClass: )

Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass:


or Evaluate: (Operator: and, applicDisplayClass: )Assert:

applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass:





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Applicability: ID: app-0002 Config:

Mountain bicycle and Mountain storm Mk1Evaluate: (Operator: and, applicDisplayClass: )


and Evaluate: (Operator: and, applicDisplayClass: )Assert:

applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass:


Applicability: ID: app-0003 Config:

Mountain bicycle and Brook trekker Mk9Evaluate: (Operator: and, applicDisplayClass: )


and Evaluate: (Operator: and, applicDisplayClass: )Assert:

applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass:


S1000DBIKE-AAA-D00-00-01-00AB-720A-A

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Replacement procedure

Preliminary requirementsProduction management data

Maintenance Action Duration:Preliminary requirements ................ 0 hProcedure ........................................ 1,5 hRequirements after job completion . 0 h

Production management data

Maintenance Action Duration:Preliminary requirements ................ 0 hProcedure ........................................ 1 hRequirements after job completion . 0 h

Required technical information

20 PREPARATION20.1 Remove the front wheel, refer to: Chapter 3.5 - Step 5

20.2 Remove the front brakes, refer to: Chapter 3.7 - Step 1

21 PROCEDURE21.1 Remove the fork, refer to: Chapter 3.3 - Step 7

21.2 Change the bike axis, refer to: Chapter 3.4





Chapter 3.3 - Step 7 – Remove procedures

Chapter 3.4

Chapter 3.3 - Step 11 – Install procedures

Chapter 3.3 - Step 16 – Install procedures



Chapter 3.3 - Step 1 – Manual test

BRAKE-AAA-DA1-00-00-00AA-341A-A

S1000DBIKE-AAA-D00-00-01-00AA-933A-A

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21.3 Install the new fork, refer to: Chapter 3.3 - Step 11

21.4 Install the new fork, refer to: Chapter 3.3 - Step 16

21.5 Install the front brakes, refer to: Chapter 3.7 - Step 4

21.6 Install the front wheel, refer to: Chapter 3.5 - Step 9

22 TEST22.1 Test that the fork is properly installed, refer to: Chapter 3.3 - Step 1

22.2 Front brakes test, refer to: BRAKE-AAA-DA1-00-00-00AA-341A-A

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Chapter 3.4

Bicycle axis - Modification proceduresU8025Bicycle axis - Modification proceduresU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-01-00AA-93AA-A_001-00en-US01_cc51_cv51S1000DBIKE-AAA-D00-00-01-00AA-93AA-AIssue number: 001.00

Bicycle axis – Modification proceduresTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY

List of tables Page1 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Support equipment

Spares

1 Use the (Saw tool) to saw the (Wheel axis)

Use the (Threading tool) when the saw is unbended

2 Put the frame on the floor



Saw tool set S1000DBIKE-AAA-D00-00-01-00AA-930A-A Issue 001.00

1 EA

Saw tool NSCM: KZ666Pt. No.: BSK-TW-100

1 EA

Threading tool NSCM: KZ666Pt. No.: BSK-THR-3001

1 EA

Table 2 Spares


Wheel axis NSCM: KZ666Pt. No.: BSK-AXS-2001

1 EA

Wheel axis NSCM: KZ666Pt. No.: BSK-AXS-2000

1 EA

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Chapter 3.5


WheelsResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)schema cleanupelement/attribute renaming

Table of contents PageRear wheel – Remove procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Front wheel – Remove procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Front wheel – Install procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Required personnel

Rear wheel – Remove procedures

1 Hold the rear of the bicycle.

2 Push the wheel forwards and down to disengage the chain from the sprocket.

3 Turn the wheel to the side and lift it away from the frame.

4 Put the frame on the floor.

Front wheel – Remove procedures

5 Hold the front of the bicycle.

6 Use the (Specialist toolset) to disengage the fork from the chainring by pushing the wheel forwards and down.

7 Lift the wheel away from the frame.


Front wheel – Install procedures

9



Rear wheel – Remove proceduresAs required Front wheel – Remove proceduresAs required Front wheel – Install proceduresAs required

S1000DBIKE-AAA-DA0-20-00-00AA-520A-A, S1000DBIKE-AAA-DA0-30-00-00AA-520A-A, S1000DBIKE-AAA-DA0-30-00-00AA-720A-A

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Note

It is necessary to install the fork and the brakes before installing the wheel


11 Install the wheel with (Specialist toolset) and be careful to not damage the chainring.

12 Put the bike on the floor.


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MM-A-00-00-00-00A-000A-A

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Chapter 3.6


TyresResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

3.6 Tyres


3.6.2 Tyres

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Chapter 3.6.1

Inner tube - Remove and install a new itemU8025Inner tube - Remove and install a new itemU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA0-10-10-00AA-921A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA0-10-10-00AA-921A-AIssue number: 007.00

Remove and install a new itemTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY111schema cleanupelement/attribute renaming

List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

List of figures Page1 Removing the inner tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Required conditions

Required personnel

Spares

Safety conditions

CAUTIONBe careful with sharp or hard tools. They can cause damage to the inner tube.

1 Remove the old inner-tube.



The tire is removed. S1000DBIKE-AAA-DA0-10-20-00AA-215A-A




Table 3 Spares


Inner tube NSCM: KT222Pt. No.: IT-001

1 EA

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Fig 1 Removing the inner tube

2 Install the new Inner tube.

A

A

Fig 1 Removing the inner tube

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Required conditions Table 4 Required conditions


Replace the tire. Not ApplicableInflate the tire with air. S1000DBIKE-AAA-DA0-10-20-00AA-215A-A

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Chapter 3.6.2


TyresResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)schema cleanupelement/attribute renamingschema cleanupelement/attribute renamingschema cleanupelement/attribute renaming

Table of contents PageFill with air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Check pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Remove and install a new item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Required personnel

Fill with air

1 Ensure bicycle is on the repair stand.

2 Locate the deflated tire.

3 Attach the outlet valve of the Foot pump, from the Specialist toolset, to the valve of the deflated tire.

4 Inflate the tire.

4.1 Operate the foot pump to pump air into the tire.

4.2 Check tire pressure. Refer to Chapter 3.6.2 - Step 5

Check pressure

5 Locate the valve stem of tire.

6 Use the tire pressure gauge (Tire pressure gauge) to check the tire pressure.

7 Tire pressure should between 2000 hPa to 2700 hPa.

7.1 If tire pressure is less than 2000 hPa inflate tire. Refer to Chapter 3.6.2 - Step 1



– Fill with airMan A Basic user Operator – Check pressureMan A Basic user Operator 0,3h – Remove and install a new itemMan A Basic user Operator 0,3h

S1000DBIKE-AAA-DA0-10-20-00AA-215A-A, S1000DBIKE-AAA-DA0-10-20-00AA-362B-A

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7.2 If the tire cannot maintain pressure or the tire pressure is greater than 2700 hPa replace the inner tube. Refer to Chapter 3.6.1

Remove and install a new item

8 Lift and turn the bicycle and make sure the bicycle is held safely in this position.

9 Use a standard wrench from the Specialist toolset and loosen the brake caliper.

10 Remove the axle bolt.

11 Remove the wheel.

12 Deflate the tire.

13 Use the Tire lever from the Specialist toolset and remove the old tire from the wheel.

14 Use the Tire lever from the Specialist toolset and attach the new Tire to the wheel. Refer to Chapter 1.1.5

15 Inflate the tire (refer to Chapter 3.6.2 - Step 1).

16 Install the wheel.

17 Tighten the axle bolt.

18 Tighten the brake caliper.




Lift and turn the bicycle to the correct position. Not ApplicableDo a test of the brakes as given in the brake test procedure. S1000DBIKE-AAA-DA1-00-00-00AA-341A-A

S1000DBIKE-AAA-DA0-10-20-00AA-362B-A, S1000DBIKE-AAA-DA0-10-20-00AA-921A-A

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Chapter 3.7


Front Brake Removal and ReplacementResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)

Table of contents PageRemove procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Install procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Remove procedures



2 Remove the front brake forwards.


Install procedures


4

Note

It is necessary to install the fork before installing the brakes


6 Install the front brakes on the fork.



As required



As required

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Chapter 3.8


Stem Removal and ReplacementResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)schema cleanupelement/attribute renamingschema cleanupelement/attribute renaming


List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

List of figures Page1 Remove the bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Lubricate the thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Tighten the bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Required conditions

Safety conditions

CAUTIONS• Do not tighten the stem bolt too much. You can cause damage to the headset bearings

if you tighten the stem too much.

• The stem bolt does not safety the stem.

Note 1

It is not necessary to remove the handlebar when you remove the stem to get access to theheadset.

Note 2

The stem must point forward in alignment with the wheel.



Safety the bicycle in a bicycle stand and hold the front wheel off the ground

Not Applicable

Make sure the bicycle is held safely on a work stand with the front wheel free of the ground

Not Applicable

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Remove procedures


1 Remove the handlebar Chapter 3.9.1 - Step 1

2 Remove the stem.

2.1 Remove the bolt in the center of the stem cap.



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Fig 1 Remove the bolt

2.2 Loosen the stem clam bolt with a Set of Allen wrenches.

2.3 Remove the stem from the steerer tube.

2.4 Note: It is not necessary to remove the handlebar if you remove the stem to get access to the headset.

A

A

Fig 1 Remove the bolt


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Install procedures


3 Remove all the rust and the corrosion with a Clean dry cloth and Rubbing alcohol.

4 Install the stem.

4.1 Use a General lubricant and lubricate:

– the threads of the Stem and Stem bolt

– the sides

– the top of the wedge



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Fig 2 Lubricate the thread

4.2 Install the Stem in the steerer tube.

A

A

Fig 2 Lubricate the thread


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Fig 3 Tighten the bolt

4.3 Adjust to align the Stem with the wheel and tighten the Stem bolt firmly.

5 Install the handlebars (refer to Chapter 3.9.1 - Step 4).

A

A

Fig 3 Tighten the bolt


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Chapter 3.9


Handlebar and HeadsetResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title


3.9.1 Handlebar

3.9.2 Headset



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Chapter 3.9.1


HandlebarResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)schema cleanupelement/attribute renamingschema cleanupelement/attribute renaming


List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of figures Page1 Loosen the clamp screw with the Allen wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Loosen the clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Required conditions

Required personnel

Safety conditions

WARNINGS• Do not ride a bicycle with no grips on the handlebar. This can cause the hands of the

rider to slip.

• Do not ride the bicycle until the grips have become dry and are firmly held in position.If the grips are wet, your hands can move off the grips when you ride the bicycle.

• Do not ride a bicycle with no grips on the handlebar.



The bicycle is held safely on a work stand. Not ApplicableThe bicycle is held safely on work stand. Refer to (Work stand)

Not Applicable



– Remove proceduresMan A Bike rider Intermediate Operator 1,5h – Install proceduresMan A Bike rider Intermediate Operator 1,5h

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CAUTIONMake sure the handlebar is correctly aligned in the center of the stem.

Remove procedures

1 Remove the grips1.1 Put a long thin screwdriver below the grip and apply water between the grip and the handle bar.

1.2 Turn the grip forwards and rearwards to loosen it and then pull it off the end of the handlebar.

2 Remove the brake and the shift levers from the handlebars2.1 Loosen the clamp screw (refer to Fig 1 ) which is behind or below the brake lever (as shown).


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Fig 1 Loosen the clamp screw with the Allen wrench

2.2 Remove the lever and the mount from the handlebar.

2.3 Loosen the clamp bolt and remove the shifter from the handlebar.

3 Remove the handlebarUse a Set of Allen wrenches and loosen the clamp bolt (refer to Fig 2 ). To remove, move the handlebar out of the stem.

A

A

Fig 1 Loosen the clamp screw with the Allen wrench


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Fig 2 Loosen the clamp bolt

Install procedures

4 Put the Handlebar in the stem and tighten the clamp bolt with a Set of Allen wrenches. Make sure the handlebar is correctly aligned in the center of the stem. Tighten the clamp bolt.

A

A

Fig 2 Loosen the clamp bolt

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5 Put the Brake lever and Shifter lever on the handlebar.

5.1 Move the Shifter lever on the Handlebar again and make sure you do not catch the cables.

5.2 Tighten the clamp bolt.

5.3 Move the Brake lever mount and the brake lever on the Handlebar again.

5.4 Tighten the clamp screw.

6 Replace the Handlebar grips.

6.1 Apply with the Extra firm hold hairspray to the Handlebar grips area of the Brake lever mount.

6.2 Before the Extra firm hold hairspray becomes dry, move the Handlebar grips into the correct position. Make sure the grip protects the end of the Handlebar or install a Handlebar plug.


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Chapter 3.9.2


HeadsetResponsible partner company: Originat or:Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)Mountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9)schema cleanupelement/attribute renamingschema cleanupelement/attribute renaming


List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of figures Page1 Lift the upper bearing cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Required conditions

Required personnel

Safety conditionsNote

It is not necessary to remove the handlebar for this procedure.

Remove procedures

1 Remove the stem (refer to Chapter 3.8 - Step 1).

2 Remove:

the spacers



The bicycle is safely held on a work stand Not ApplicableThe bicycle is safely held on a work stand Not Applicable



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the brake cable hangar

the dust seals

the conical expansion washer(s) from the steerer tube

3 Lift the upper bearing cup off (refer to Fig 1) and then remove the fork from the frame.Fig 1 Lift the upper bearing cup

A

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Fig 1 Lift the upper bearing cup


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Install procedures

4 Install the Frame fork on the frame.

5 Install the Upper bearing cup.

6 Install the components that follow on the steering tube:

the Brake cable hangar

the Dust seal

the Conical expansion washer

7 Install the stem (refer to Chapter 3.8 - Step 3).


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Chapter 3.9.3

Spacer - Install proceduresU8025Spacer - Install proceduresU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA2-40-00-00AA-720A-A_001-00en-US01_cc51_cv51S1000DBIKE-AAA-DA2-40-00-00AA-720A-AIssue number: 001.00

Spacer – Install proceduresTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and Mountain storm Mk1 Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY142

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Required personnel

Spares

1

Note

It is necessary to install the headset before installing any spacer

2 Install the spacer (Spacer)



As required

Table 2 Spares


Fork set NSCM: KZ666Pt. No.: SPA-1000-1S1000DBIKE-AAA-D00-00-01-00AA-930A-A Issue 001.00

1 EA

Spacer NSCM: KZ666Pt. No.: SPC-200-12

1 EA

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Chapter 3.9.4

Horn - Remove and install a new itemU8025Horn - Remove and install a new itemU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA3-10-00-00AA-921A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA3-10-00-00AA-921A-AIssue number: 007.00

Horn – Remove and install a new itemTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY151schema cleanupelement/attribute renaming

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Required personnel

Support equipment

Spares

1 Safely hold the bicycle.

2 Remove the horn.

2.1 Use the 8mm Allen wrench from the Specialist toolset and remove the two Allen screws.

2.2 Remove the horn.

3 Install the new Horn.



As required




1 EA

8mm Allen wrench NSCM: KZ666Pt. No.: BSK-TLST-001-08

1 EA

Table 3 Spares


Horn NSCM: KZ444Pt. No.: Horn-001

1 EA

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3.1 Install the new Horn on the handlebars.

3.2 Use the 8mm Allen wrench from the Specialist toolset and tighten the two Allen screws.




Safely discard the horn that you removed Local Disposal Procedures

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Chapter 3.10


ChainResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

3.10 Chain



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Chapter 3.10.1

Chain - OilU8025Chain - OilU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA4-10-00-00AA-241A-A_008-00en-US01_cc51_cv51S1000DBIKE-AAA-DA4-10-00-00AA-241A-AIssue number: 008.00

Chain – OilTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY161schema cleanupelement/attribute renaming

List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of figures Page1 Derailleur pivots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Derailleur tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Brake lever pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Lubricate the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


Required conditions

Required personnel

Support equipment



The bicycle chain is clean and dry Not Applicable



Man A Operator Intermediate Bike rider 0,5h



Clean dry cloth NSCM: KZ666Pt. No.: BSK-TLST-001-12

1 EA

Floor covering NSCM: KK999Pt. No.: PPP-001

1 pack

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Safety conditions

WARNINGS• Dry Lube is a very dangerous substance. Do not get it onto your skin. Use it in a well

ventilated area. If you swallow it seek immediate medical advice. If it gets into youreyes wash your eyes in clean water and seek medical advice.

• Wet Lube is a very dangerous substance. Do not get it onto your skin. Use it in a wellventilated area. If you swallow it seek immediate medical advice. If it gets into youreyes wash your eyes in clean water and seek medical advice.

1 Apply the penetrating lubricant into all the parts of the bike that move. This includes:

– derailleur pivots (refer to Fig 1)

– derailleur tension (refer to Fig 2)

– brake lever pivots (refer to Fig 3)

These brake lever pivots include:

– derailleur pivots

– derailleur tension

– guide wheels

– brake lever pivots

– control cables and where they go into their casings

Table 4 Supplies


Wet lube NSCM: KZ222Pt. No.: LL-007

1 dl

Dry lube NSCM: KZ222Pt. No.: LL-006

1 dl

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Fig 1 Derailleur pivots

A

A

Fig 1 Derailleur pivots

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Fig 2 Derailleur tension

A

A

Fig 2 Derailleur tension

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Fig 3 Brake lever pivots

2 Lubricate the chain.

2.1 Make sure the chain is clean and dry.

2.2 Put the Floor covering on the floor below the chain.

A

A

Fig 3 Brake lever pivots

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2.3 Use a Dry lube for dry conditions.

2.4 Use a Wet lube for wet conditions

2.5 Apply the lubricant to each roller of the chain (refer to Fig 4) but only apply a small quantity.Fig 4 Lubricate the chain

A

AFig 4 Lubricate the chain

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2.6 Hold the nozzle of the container above the front of the chain ring and slowly turn the cranks rearwards.

2.7

CAUTIONDo not get lubrication oil into the brake system. Oil in the break system can affect theefficiency of the bake system. Do not get oil onto the floor where it can easily gettransferred onto the brake system.

Let the lubricant soak into chain before you clean the unwanted lubricant from the chain.

3 Do a check of the rear wheel rim and clean the unwanted lubricant if necessary.

4 Do a check of the chain to make sure that each link is lubricated. If there are links that do not move easily or have become frozen, lubricate the chain again (refer to Step 2).

5 Do a check of the remaining lubricated parts and clean the unwanted lubricant with a Clean dry cloth.

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Chapter 3.10.2

Chain - Clean with chain cleaning fluidU8025Chain - Clean with chain cleaning fluidU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA4-10-00-00AA-251B-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA4-10-00-00AA-251B-AIssue number: 007.00

Chain – Clean with chain cleaning fluidTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY161schema cleanupelement/attribute renaming

List of tables Page1 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Support equipment


1 Inspect the chain.

Do the inspection of the chain as given in the pre-ride checks (refer to Chapter 2.2).

2 Prepare the cleaning area.

2.1 Put the Floor covering on a satisfactory floor area.

2.2 Put the bicycle on the floor covering.

3 Clean debris from the chain.

3.1 Use the Stiff bristle brush and loosen as much unwanted material as possible.

3.2 Make sure that you remove all the unwanted material from the chain.



Stiff bristle brush NSCM: KZ666Pt. No.: BSK-TLST-001-02

1 EA

Chain cleaning fluid NSCM: KZ222Pt. No.: LL-003

As required

Chain cleaning tool NSCM: KZ666Pt. No.: BSK-TLST-001-03

1 EA

Table 2 Supplies


Floor covering NSCM: KK999Pt. No.: PPP-001

1 pack


As required

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4 Clean the chain.

4.1 Open the Chain cleaning tool and fill with the Chain cleaning fluid.

4.2 Move the chain to the middle chainring and the middle sprocket at the rear.

4.3 Put the chain in the chain guides of the chain cleaning tool and lock the tool on the chain.

4.4 Hold the tool with the left hand and slowly turn the rearwards with the right hand.

4.5 Press the button on the cleaning tool to make sure that cleaning fluid flows until the tool is empty.

4.6 If necessary, remove the unwanted chain cleaning fluid.

5 Lubricate the chain.

5.1 Use the General lubricant and lubricate the chain.

5.2 Unlock and remove the cleaning tool.

5.3 If necessary, remove the unwanted lubricant.




Move the bicycle to its storage area and remove the floor covering.

Not Applicable

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Chapter 3.11

Hubs - Clean with degreasing agentU8025Hubs - Clean with degreasing agentU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA5-20-00-00AA-251C-A_008-00en-US01_cc51_cv51S1000DBIKE-AAA-DA5-20-00-00AA-251C-AIssue number: 008.00

Hubs – Clean with degreasing agentTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY172schema cleanupelement/attribute renaming

List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

List of figures Page1 Removing the axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


Required conditions

Required personnel

Support equipment



Rear wheel removed S1000DBIKE-AAA-DA0-20-00-00AA-520A-A



Man B Supervisor Advanced Bicycle mechanic 0,8hMan A Basic user Operator 0,3h




1 EA

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1 Remove the axle.

1.1 Use the cone-wrench from the Specialist toolset and remove the locknut from one side of the axle.

1.2 Remove the washer and the cone from the axle.

1.3

CAUTIONMake sure you do not lose the bearings from the hub. Be prepared to catch the bearings ifthey fall out. Missing bearings can cause damage to the hub.

Pull the axle out from the other side as shown in Fig 1 .

Table 4 Supplies


Degreasing agent NSCM: KZ222Pt. No.: LL-004

As required

General grease NSCM: KZ222Pt. No.: LL-005

As required

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Fig 1 Removing the axle

2 Remove the bearings.

2.1 Use a small screwdriver from the Specialist toolset and remove the bearings from their races.

2.2 Make sure that each side of the hub has the same number of bearings.

A

A

Fig 1 Removing the axle

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2.3 Use the Degreasing agent and clean all the parts of the hub.

2.4 Do a check of the axle to make sure that it is straight.

2.5 Examine the bearing contact area on the cones and the races in the hub for pitting and other signs of damage.

2.6 Do a check of the ball bearings for signs of damage.

2.7 Apply a large quantity of General grease on each hub race.

3 Assemble the hub.

3.1 Install the ball bearings into the races and push them into the grease.

3.2 Apply more grease on the tops of the bearings.

3.3 Install the axle through the hub.

3.4 Install the cone, the washer and the locknut on the other side of the axle.

3.5 Use the cone-wrench from the specialist toolset and carefully tighten the locknut.

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Chapter 3.12


LightingResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

3.12 Lighting




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Chapter 3.12.1

Lights - Manual testU8025Lights - Manual testU8025U80252011-01-31texttext/xmlS1000DLIGHTING-AAA-D00-00-00-00AA-341A-A_007-00en-US01_cc51_cv51S1000DLIGHTING-AAA-D00-00-00-00AA-341A-AIssue number: 007.00

Lights – Manual testTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-D20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DLTApplicability ExternalizationCPF 2009-144S1

List of tables Page1 Required personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Required personnel

1 Set the lights to on.

2 Make sure that all the lights operate correctly.




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Chapter 3.12.2

Lighting - Assemble, install and connect proceduresU8025Lighting - Assemble, install and connect proceduresU8025U80252011-01-31texttext/xmlS1000DLIGHTING-AAA-D00-00-00-00AA-700A-A_007-00en-US01_cc51_cv51S1000DLIGHTING-AAA-D00-00-00-00AA-700A-AIssue number: 007.00

Lighting – Assemble, install and connect proceduresTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-D20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DLTApplicability ExternalizationCPF 2009-144S1Functional Item Identifier2009-063AAZone and Tool references2009-0xxAA

List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1



200

300

Required conditions

Support equipment

1 Impacted zones:200 and 300

2 Functional Item Number: S1 exact

3 Functional Item Number: ELO-Box exact

4 Remove the lighting system from the packaging.

5 Make sure that the components in the package are the same as those on the S1000DLIGHTING-AAA-D00-00-00-00AA-941A-D

6 Install the light bulb to the front and rear lights (refer to Chapter 3.12.3).

7 Attach the front light fitting on the top of the handlebar.

7.1 Apply the protective strip around the handlebar.

7.2 Pull the clamp open and put it around the protective strip with the light connector at the top.



Bike is stationary Not Applicable



Specialist toolset DescrSpecialist toolset

1 EA

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7.3 Install the washer on the screw.

7.4 Use the correct screwdriver from the Specialist toolset Descr and tighten the screw into the hole at the bottom of the clamp. This safeties the clamp to the handlebar.

8 Attach the rear light fitting to the rear triangle of the bike frame.

8.1 Apply the protective strip around one of the two rear triangle up-tubes.

8.2 Pull the clamp open and put it around the protective strip. Make sure the light connector points rearwards.

8.3 Install the washer on the screw.

8.4 Use the correct screwdriver from the Specialist toolset Descr and tighten the screw into the hole at the bottom of the clamp. This safeties the clamp to the tube.

9 Attach the light with the white glass to the front connector.

10 Attach the light with the red glass to the rear connector.

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Chapter 3.12.3

Lighting - Remove and install a new itemU8025Lighting - Remove and install a new itemU8025U80252011-01-31texttext/xmlS1000DLIGHTING-AAA-D00-00-00-00AA-921A-A_007-00en-US01_cc51_cv51S1000DLIGHTING-AAA-D00-00-00-00AA-921A-AIssue number: 007.00

Lighting – Remove and install a new itemTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-D20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DLTRelated CPF No.2006-054AAUpdated to illustrate Warning and Caution ExternalizationRelated CPF No. 2009-125GBCSN - break into attributesRelated CPF No. 2009-158S1Add the concept of removed parts to procedural data modulesRelated CPF No. 2009-162S1Additional technical information in ProceduresApplicability ExternalizationCPF 2009-144S1

List of tables Page1 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Required conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WARNINGMake sure that the bulb is cool before you replace it.

CAUTIONS• Do not touch the glass of the bulb.

• Make sure that the glass is clean before installing it on the light.



F11 Half front

Work area on the handlebars

R11 Half rear

Work area under the saddle



Light set to off Not ApplicableLight removed from bicycle Not Applicable

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Support equipment

Spares

footnote 1



Special Toolset 1 EAScrewdriver Tool reference: No: BSK-SCRDV-

001 manufacturerCode: specific: no toolAlt:

1 EA

Table 3 Spares


Bulb CSN: DMC-S1000DLIGHTING-AAA-D00-00-00-01A-941A-D#D00000001A010 -00ANSCM: KZ777Pt. No.: LIRUS-L1-11

2 EA

Kit 1 EABulb CSN: DMC-S1000DLIGHTING-

AAA-D00-00-00-01A-941A-D#D00000001A020 -00ANSCM: KZ777Pt. No.: LIRUS-B1-12F

1 EA 1.

Bulb CSN: DMC-S1000DLIGHTING-AAA-D00-00-00-01A-941A-D#D00000001A021 -00ANSCM: KZ777Pt. No.: LIRUS-B1-12R

1 EA 1.

Glass CSN: DMC-S1000DLIGHTING-AAA-D00-00-00-01A-941A-D#D00000001A022 -00ANSCM: KZ777Pt. No.: LIRUS-G1-10

1 EA

Glass CSN: DMC-S1000DLIGHTING-AAA-D00-00-00-01A-941A-D#D00000001A023 -00ANSCM: KZ777Pt. No.: LIRUS-G1-10H

1 EA

Glass CSN: DMC-S1000DLIGHTING-AAA-D00-00-00-01A-941A-D#D00000001A022 -00ANSCM: KZ777Pt. No.: LIRUS-G1-10

1 EA

1. Make sure that the new bulb is not cracked.

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Safety conditions

WARNINGMake sure that the bulb is cool before you replace it.

CAUTIONS• Do not touch the glass of the bulb.

• Make sure that the glass is clean before installing it on the light.

1 From location , remove the glass Glass.

2 Remove the used front yellow bulb Bulb.

3 Discard the used bulb Bulb.

4 Remove the new white bulb Bulb from the kit Kit.

5 Install the new white bulb Bulb.

6 Install the glass Glass on the light.

7 Attach the light fitting on the handlebar.

8 Apply the protective strip around the handlebar.

9 Install the washer on the screw.

10 Use the special screwdriver Screwdriver from the toolset Special Toolset and tighten the screw into the hole at the bottom of the clamp. This safeties the clamp to the handlebar.

11 From location Remove the glass Glass.

12 Remove the used yellow rear bulb Bulb.

13 Discard the used bulb Bulb.

14 Remove the new white bulb Bulb from the kit Kit.

15 Install the new white Bulb.

16 Drill a 4mm hole in the middle of the glass Glass in order to allow venting and heat evacuation when the light is switched on.

The glass with the hole may be ordered independently with the reference Glass.

17 Install the glass with the hole Glass on the light.




Switch the lights on if necessary. Not Applicable

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Chapter 4


Fault FindingResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

4 Fault Finding

4.1 Front wheel – Fault reports and isolation procedures

4.2 Rear wheel – Detected fault

4.3 Horn – Isolated fault

4.4 Drive train – Correlated fault

4.5 Lights – Observed fault

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Chapter 4.1

Front wheel - Fault reports and isolation proceduresU8025Front wheel - Fault reports and isolation proceduresU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA0-10-20-00AA-400A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA0-10-20-00AA-400A-AIssue number: 007.00

Front wheel – Fault reports and isolation proceduresTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY112schema cleanupelement/attribute renaming

List of tables PageFault code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Support equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Support equipment

Procedure

1 Use the tire pressure gauge (Tire pressure gauge) to do a check of the pressure

2 What is the tire pressure reading?

2.1 More than 2700 hPa: Go to Step 3

2.2 Between 100 hPa and 2700 hPa: Go to Step 4

2.3 Less than 100 hPa: Go to Step 5

3 Deflate the tire until the pressure is 2700 hPa

Go to Requirements after job completion.

4 Inflate the tire as given in Chapter 3.6.2 - Step 1


5 To do a check of the tire for damage

Fault codeFault code Fault description

NYCJD04 Tire does not function correctly



Tire pressure gauge NSCM: KZ666Pt. No.: BSK-TLST-001-01

1 EA


1 EA

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6 Is there damage to the tire?

6.1 Yes: Go to Step 7

6.2 No: Go to Step 8

7 Replace the tire (refer to Chapter 3.6.2 - Step 8 )


8 Replace the inner-tube (refer to Chapter 3.6.1)


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Chapter 4.2

Rear wheel - Detected faultU8025Rear wheel - Detected faultU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA0-20-00-00AA-412A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA0-20-00-00AA-412A-AIssue number: 007.00

Rear wheel – Detected faultTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY12schema cleanupelement/attribute renaming

List of tables Page1 Detected Line Replaceable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Detected Line Replaceable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fault Code

NYCJD00

Fault Description

The rear wheel does not operate correctly

Fault Detection

Fault Location

Remarks:

Prepare the rear wheel for the removal of the tire

Table 1 Detected Line Replaceable Unit

Nomenclature Identification No.

Tire KT666TIRES-010101



Rear wheel KZ333WH-001

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Chapter 4.3

Horn - Isolated faultU8025Horn - Isolated faultU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-DA3-10-00-00AA-411A-A_007-00en-US01_cc51_cv51S1000DBIKE-AAA-DA3-10-00-00AA-411A-AIssue number: 007.00

Horn – Isolated faultTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY151schema cleanupelement/attribute renaming

List of tables Page1 Detected Line Replaceable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fault Code

NYCJD03

Fault Description

Horn failed

LRI Identification

Repair Procedure

References



Horn KZ444Horn-001

Table 2 References


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Chapter 4.4

Drive train - Correlated faultSF815Drive train - Correlated faultSF815SF8152011-01-31texttext/xmlS1000DBIKE-AAA-DA4-10-00-00AA-414A-A_005-00en-US01_cc51_cv51S1000DBIKE-AAA-DA4-10-00-00AA-414A-AIssue number: 005.00

Drive train – Correlated faultTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:SIOM SF815Originat or:SIOMSF815S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBY151schema cleanupelement/attribute renaming

List of tables Page1 Detected Line Replaceable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Correlated Fault

Bit MessageFault Code: 100FC01

Fault Description

The pedal mechanism is jammed

Bit MessageFault Code: 200FC01

Fault Description

The derailleur is jammed

Fault Location

Prepare the derailleur to put transmission chain back on pedal mechanism.



Bicycle chain KZ120Tchain-120

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Chapter 4.5

Lights - Observed faultU8025Lights - Observed faultU8025U80252011-01-31texttext/xmlS1000DLIGHTING-AAA-D00-00-00-00AA-413A-A_007-00en-US01_cc51_cv51S1000DLIGHTING-AAA-D00-00-00-00AA-413A-AIssue number: 007.00

Lights – Observed faultTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-D20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DLTRelated CPF No.2006-054AAUpdated to illustrate Warning and Caution ExternalizationApplicability ExternalizationCPF 2009-144S1

List of tables Page1 Detected Line Replaceable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

WARNINGS• Make sure that the bulb is cool before you replace it.

• Make sure the light glass is not broken before handling it

CAUTIONDo not touch the glass of the bulb.


Safety conditions

WARNINGS• Make sure that the bulb is cool before you replace it.

• Make sure the light glass is not broken before handling it

CAUTIONDo not touch the glass of the bulb.

Fault Code

NYCJD02

Fault Description

The lights are set to the dim position.

Fault ContextDuring use or maintenance

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Test Procedure

Test DescriptionTest the bulbs

Test parameters : From: 1 Days, To: 1 Days

Test Procedure Chapter 3.12.1

Repair Procedure

References

Remarks:

This is the data module you would visit when you notice that the lights do not operate correctly.



Bulb KZ111LiRUs-L1-11

Table 2 References


Chapter 3.12.3

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Chapter 5


Parts ListResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

Table of contents

Chapter Title

5 Parts List

5.1 Bicycle – Illustrated Parts Data - IPD

5.2 Light system – Illustrated Parts Data - IPD

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Chapter 5.1

Bicycle - Illustrated Parts Data - IPDU8025Bicycle - Illustrated Parts Data - IPDU8025U80252011-01-31texttext/xmlS1000DBIKE-AAA-D00-00-00-01AA-941A-D_007-00en-US01_cc51_cv51S1000DBIKE-AAA-D00-00-00-01AA-941A-DIssue number: 007.00

Bicycle – Illustrated Parts Data - IPDTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-DMountain bicycle and (Mountain storm Mk1 or Brook trekker Mk9) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: typeProper tyType: prodattrProper tyValues: Mountain bicycleDisplayClass: and Evaluate: (Operator: or, applicDisplayClass: ) Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Mountain stormDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk1DisplayClass: or Evaluate: (Operator: and, applicDisplayClass: ) Assert:applicPropertyIdent: modelPropertyType: prodattrPropertyValues: Brook trekkerDisplayClass: and Assert:PropertyIdent: versionPropertyType: prodattrPropertyValues: Mk9DisplayClass: 20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DBYRelated CPF No. 2009-148S1part data in IPDRelated CPF No. 2009-125GBCSN - break into attributesThis DM was originally named DMC-S1000DBIKE-AAA-D00-00-00-00AA-941A-A

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Fig 1 Bicycle

005

005

003001

005

004 002

007 008

000

004

004

004

Fig 1AA Bicycle

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Fig Item

Units perassembly/Unit ofissue NCAGE

Part No.NATO stock No. Nomenclature

* Usable oncode assy• MV/Effect

ICY

1AA

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000 REF KZ999 BICYCLE-001 Bicycle • MB001 1 EA KZ999 BICYCLE-001/1 • Frame assembly • MB002 1 EA KZ999 BICYCLE-001/2A • • Seat, assembly • MB002 1 EA KZ999 BICYCLE-001/2B • • Cruiser Seat, assembly • MB003 1 EA KZ999 BICYCLE-001/3 • • Steering system • MB004 1 EA KZ999 BICYCLE-001/4 • • Drive train system • MB005 1 EA KZ999 BICYCLE-001/5 • • Brake sub-system • MB006 1 EA KZ777 LRU1001 • • Light system • MB007 1 EA KZ888 WH-001 • • Wheel, assembly rear • MB008 1 EA KZ888 WH-002 • • Wheel, assembly front • MB009 1 EA KZ888 CP-001 • • Computer • MB

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Chapter 5.2

Light system - Illustrated Parts Data - IPDU8025Light system - Illustrated Parts Data - IPDU8025U80252011-01-31texttext/xmlS1000DLIGHTING-AAA-D00-00-00-01AA-941A-D_007-00en-US01_cc51_cv51S1000DLIGHTING-AAA-D00-00-00-01AA-941A-DIssue number: 007.00

Light system – Illustrated Parts Data - IPDTo be made available to all S1000D users.Expor t of this data module to all countries that are the residence of organizations that are users of S1000D is permitted. Storage of this data module is to be at the discretion of the organization.There are no specific handling instructions for this data module.Users may destroy this data module in accordance with their own local procedures.There are no dissemination limitations that apply to this data module.Copyright ( C) 2013 by each of the following organizations:– AeroSpace and Defence Industries Associations of Europe - ASD.– Ministries of Defence of the member countries of ASD.Limitations of Liability:– This material is provided "As Is" and neither ASD nor any person who has contributed to the creation, revision or maintenance of the material makes any representations or warranties, express or implied, including but not limited to, warranties of merchantability or fitness for any particular purpose.– Neither ASD nor any person who has contributed to the creation, revision or maintenance of this material shall be liable for any direct, indirect, special or consequential damages or any other liability arising from any use of this material.– Revisions to this document may occur after its issuance. The user is responsible for determining if revisions to the material contained in this document have occurred and are applicable.TPSMG TOR 001There are no known conditions that would change the data restrictions for, or security classification of, this data module.Responsible partner company:UK MoD U8025Originat or:UK MoDU8025S1000DBIKE-AAA-D00-00-00-00AA-00WA-D20010131Bike bookS1000DBIKE-AAA-D00-00-00-00AA-022A-DLTRelated CPF No. 2009-125GBCSN - break into attributesRelated CPF No. 2009-148S1Partdata in IPDRelated CPF No. 2009-158S1Add the concept of removed parts to procedural data modulesApplicability ExternalizationCPF 2009-144S1This DM was originally named DMC-S1000DBIKE-AAA-D00-00-00-00AA-941A-A

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Fig 1 Light system

7

89 10 2

11

5

4

3

000

12

6

14

15

13

16

18

19

1 17

Fig 1AA Light system

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Fig Item

Units perassembly/Unit ofissue NCAGE

Part No.NATO stock No. Nomenclature

* Usable oncode assy• MV/Effect

ICY

1AA

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000 REF KZ777 LRU1001001 1 KZ777 LRU1010 • (FRONT)002 1 KZ777 LRU1011 • •003 1 KZ777 LRU1012 • • •004 1 KZ777 LRU1013 • • • •005 2 KZ777 LIRUS-L1-10 • • •006 1 KZ777 LRU1018 • •007 1 KZ777 LRU1019 • • •008 1 KZ777 LRU1022 • • • •009 1 KZ777 LRU1020 • • •010 2 KZ777 LIRUS-L1-11 • • • •011 1 KZ777 LRU1026 • •012 1 KZ777 LRU-B001 •013 1 KZ777 LRU-B003 • •014 1 KZ777 LRU-B124 (

015 1 KZ777 LRU-B556 (

016 1 KZ777 LRU-B789 • • •017 1 KZ777 LRU2010 •018 1 KZ777 LRU1011 • • (REAR)019 1 KZ777 LRU2018 • •020 1 KZ777 LIRUS-B1-12F • • •021 1 KZ777 LIRUS-B1-12R • • •022 2 KZ777 LIRUS-G1-10 • • •023 1 KZ777 LIRUS-G1-10H • • •

01-03-2013


Effectivity:† All

UNCLASSIFIED

MM-A-00-00-00-00A-000A-A

Page Index -† 1

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Index


IndexResponsible partner company: Originat or:MM-A-00-00-00-00A-000A-A

01-03-2013


Effectivity:† All

UNCLASSIFIED

MM-A-00-00-00-00A-000A-A

Page Index -† 2

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01-03-2013

Intentionally Blank

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