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:
- Existing shop owners and managers who realize the need to stay abreast of technological changes and advance their shop's utilization of professional standards.
- Existing bicycle mechanics in need of solid training to eliminate guesswork and to establish themselves as true professionals.
- Cycling enthusiasts who must know the most advanced techniques just to satisfy their passion for the sport.
- 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.
- Owners, managers, and mechanics who want to distinguish their shop from other competitors.
- 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.
DO I NEED TO PURCHASE A TEXTBOOK?
Yes, Barnett's Manual DX is required for the Bicycle Repair & Overhaul class. We will provide loaner laptop computers for use in class to anyone who needs one. However, if you have a laptop computer we strongly encourage you to bring it with you.
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 successful completion. For details see the attendance official policies.
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
- Mechanical disc-brake installation and adjustment
- Fit of brake levers
- Troubleshooting brake levers
- Brake cable routing and sizing
- Compatibility of levers and cables
- Mounting of sidepull calipers
- Pad adjustments for sidepulls
- Sidepull clearance and centering adjustments
- Disc-brake rotor installation
- Hydraulic disc brake setup and bleeding
- Hydraulic 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