Bicycle Repair and Overhaul (BRO)

BICYCLE REPAIR & OVERHAUL IN A NUTSHELL

This course is the definitive program for shop mechanics. It covers all the basic material that is in the Bicycle Assembly & Maintenance program, and adds to it virtually every nuance that is part of the job of being a shop mechanic. Home enthusiasts enjoy this program when only the best will satisfy! There are no prerequisites for this program, but taking Bicycle Assembly & Maintenance first is strongly encouraged (depending on your level of experience).

WHO TAKES BICYCLE REPAIR & OVERHAUL?

This course is designed to suit individuals who demand a complete understanding of bicycle mechanics, including:
1. Existing shop owners and managers who realize the need to stay abreast of technological changes and advance their shop's utilization of professional standards.
2. Existing bicycle mechanics in need of solid training to eliminate guesswork and to establish themselves as true professionals.
3. Cycling enthusiasts who must know the most advanced techniques just to satisfy their passion for the sport.
4. Accomplished mechanics who need to convert their strong mechanical skills into teaching skills for the purpose of in-store training of new and less experienced mechanics.
5. Owners, managers, and mechanics who want to distinguish their shop from other competitors.
6. Aspiring professionals who would like an exciting "insider's view" of the industry they are considering joining.

WHAT KIND OF BIKES WILL I LEARN TO WORK ON?

The knowledge gained will be applicable to all types of bikes, inexpensive and exotic, road and off-road, adult and juvenile.

HOW LONG IS THE COURSE?

Bicycle Repair & Overhaul takes 12 days to complete. There are ten class days of approximately eight hours each for a total of 80 classroom hours. Additionally, the students are expected to complete approximately 15 hours of independent study. Days six and seven are off days.

HOW MUCH HANDS-ON WILL I GET?

Approximately fifty-five percent of the class time is hands-on lab work, and forty-five percent is divided between demonstration and lecture.

WILL I GET A CERTIFICATE?

Based on your performance and attendance, you will earn a certificate of completion. For details see the attendance official policies. In addition, if you meet the experience requirement, you may take the BSE Level 2 Certification exam that is offered immediately after the completion of this program in order to receive a certificate that indicates your skill level achieved.

HOW MUCH DOES IT COST AND WHEN IS IT OFFERED?

See the Schedule & Prices page for price and schedule information.

WHAT SUBJECTS ARE COVERED?
NOTE: The topics below in bold type are only covered in the Bicycle Repair & Overhaul program.
The topics below in normal type are covered both in the Bicycle Repair & Overhaul program
and in the Bicycle Assembly & Maintenance program.

MECHANICAL SKILLS
• Thread identification and preparation
• Press fit preparations
• Use of lubricants
• Use of cleansers and solvents
• Use of Loctite compounds

FRAMES AND FORKS
• Dropout alignment
• Aligning rear triangles
• Fork blade alignment
• Identifying unrepairable frames
• Identifying unrepairable forks
• Sizing replacement forks

BOTTOM BRACKET BEARINGS
• Adjustable-cup bottom bracket adjustment
• Cartridge bottom bracket installation
• Thread identification of bottom brackets
• Spindle interchangeability
• Troubleshooting bottom brackets
• Adjustable-cup bottom bracket installation

HEADSET BEARINGS
• Headset overhaul
• Threaded headset adjustment
• Threadless headset adjustment
• Installation and removal of pressed pieces
• Troubleshooting headsets
• Headset fit and interchangeability

HUB BEARINGS
• Hub and freehub bearing overhaul
• Hub and freehub bearing adjustment
• Freehub body replacement
• Thread identification of axles
• Hub cone interchangeability
• Troubleshooting hub bearings
• Overhaul of cartridge-bearing hubs

WHEELS AND TIRES
• Truing wheel lateral (side-to-side)
• Truing wheel radial (round)
• Adjusting wheel dish (rim centering)
• Adjusting wheel tension
• Stressing and stabilizing wheel true
• Tire installation
• Wheel installation
• Flat tire repair
• Calculation of spoke length
• Lacing wheels
• Repair of damaged rims
• Understanding tire and rim sizes
• Identification of tire wear and damage

SEATS AND SEAT POSTS
• Seat installation
• Fit of seat posts to frame

HANDLEBARS AND STEMS
• Stem alignment and installation
• Handlebar installation
• Drop-bar handlebar alignment
• MTB handlebar alignment
• Fits of stems to forks
• Fits of bars to stems
• Fits of control levers to bars

DRIVE TRAIN
• Square-taper crank arm removal and installation
• Spline-fit crank arm removal and installation
• Pedal installation
• Cassette replacement
• Cassette wear
• Chain removal, sizing, and installation
• Chain wear
• Identification and adjustment of chainline errors
• Installation and interchangeability of chainrings
• Identification of chainring wear
• Fit of cotterless crank arms to spindles
• Freewheel removal and installation
• Freewheel mounting-thread identification and compatibility
• Freewheel/freehub cog installation and removal
• Adjusting freewheel bearings
• Troubleshooting freewheels
• Chain damage
• Chain/freewheel compatibility

DERAILLEUR SYSTEMS
• Gear hanger alignment
• Shift lever installation
• Cable routing and installation
• Rear derailleur installation
• Rear derailleur limit-screw adjustment
• Rear derailleur indexing adjustment
• Front derailleur installation
• Front derailleur limit-screw adjustment
• Front derailleur indexing adjustment
• Overhauling rear derailleurs
• Derailleur capacities
• Troubleshooting derailleurs

BRAKE SYSTEMS
• Brake lever installation and alignment
• Cable routing and installation
• Dual-pivot brake installation and adjustment
• Cantilever brake installation and adjustment
• V-brake installation and adjustment
• Fit of brake levers
• Troubleshooting brake levers
• Brake cable routing and sizing
• Compatibility of levers and cables
• Overhauling sidepull calipers
• Mounting of sidepull calipers
• Pad adjustments for sidepulls
• Sidepull clearance and centering adjustments
• Disc-brake rotor installation
• Hydraulic disc brake setup and bleeding
• Mechanical disc-brake installation and adjustment
• Mechanical disc-brake caliper overhaul

MACHINE PROCESSES
• Cutting steerer tubes
• Re-threading forks
• Tapping and facing bottom brackets
• Reaming and facing head tubes
• Milling fork crowns