Technical Information-
AW Three Speed Hub
1.1 Scope of this leaflet
This leaflet refers to the Sturmey-Archer AW
Three Speed Hub Gear, and associated
controls, cables and fittings.
The hub model can be identified from the
markings on the hub shell.
Part 1 GENERAL INFORMATION
Part 2 ROUTINE MAINTENANCE
Part 3 ASSEMBLY/DISASSEMBLY
INSTRUCTIONS
1.5 Sprockets
The overall drive ratio can be altered by
changing the size of the sprocket. A range of
sprockets from 14 to 22 teeth is available,
suitable for 1/2"x1/8"chain.
When service problems arise they usually
occur outside the hub, and thefollowing checks
must be made beforeremovingthe wheelfrom
the bicycle:
1.4 Gear Ratios
The AW hub has three gears:
1st gear
_
Decrease of 25%
2nd gear
_
Direct drive
3rd gear
_
Increase of 331/3%
1.2 Lubrication
No routine lubrication is required. However,
during assembly/disassembly the hub
greases should be replenished (See Section
3). Grease types meeting the following
Sturmey-Archer Technical Standards should
be used:
For Bearings - SA103B
For all other internal parts - SA103A
Please contact Sturmey-Archer for
information on the availability of these
greases.
2.1 Gear Adjustment
1. Check that the fulcrum clip is secured
tightly to the frame tube, and that the
indicator rod is screwed correctly into the
axle.
2. Select 3rd gear position on the gear
control. Screw the cable adjuster (1) onto
the indicator coupling.
3. Change down to 2nd gear and turn the
cable adjuster until the end of the
indicator rod is exactly level with the end
Gear
Adjustment
of the axle. This can be seen through the
round window in the right hand axle nut
(3).
4. Tighten the locknut (2) against the
adjuster. Check that all 3 gears are
selected correctly. If correct adjustment
cannot be achieved, the fulcrum clip
must be moved in the appropriate
direction along the frame tube. Re-
tighten the clip and adjust as described
above.
WARNING: The hub must not be ridden out
of adjustment as this may damage the
internal parts and cause the hub to
malfunction.
2.2 Hub Bearing Adjustment
If for any reason the bearing adjustment is
altered, the cones must be reset correctly
before using the hub. The right-hand cone is
pre-set at the factory and should only be
disturbed at major service intervals. The left-
hand cone is used to adjust the bearings in
the hub.
Left Hand Cone:
1. Loosen the cone locknut.
2. Adjust the left hand cone until very slight
side play can be felt at the wheel rim, and
none at the hub.
3. Tighten the cone locknut.
Right Hand Cone:
1. Loosen the left hand cone locknut and
cone.
2. Loosen the right hand cone locknut.
Disengage the cone lockwasher.
3. Screw down the right hand cone figure
tight.
4. Unscrew the right hand cone by half a
turn.
5. Fit the cone lockwasher. If the washer will
not engage with the cone, unscrew the
cone slightly.
NB Under no circumstances must the
right hand cone be unscrewed more than
5/8of a turn.
6. Tighten the right hand cone locknut.
7. Tighten the left hand cone locknut and
adjust as above.
When service problems occur which cannot
be corrected by attention to external
maintenance, a close inspection of the
working parts inside the hub will be
necessary.
Fig. 2
1. Loosen the right hand ball ring with a C-
spanner or hammer and punch, and
unscrew the ball ring to release the
internal assembly from the hub shell.
2. Remove the left hand low gear pawls,
pins and springs.
Fig. 3
1. Clamp the left hand end of the axle in a
vice.
2. Remove the right hand cone locknut,
spacers, lockwasher, cone, spring, cap
and clutch spring.
Fig. 4
1. Lift off the driver, ball cage, ball ring and
gear ring.
2. Remove the gear ring pawls, pawl pins
and springs.
Fig. 5
Lift off the thrust ring, axle key, clutch and
clutch sleeve.
Fig. 6
1. Remove the planet pinion pins and
pinions.
2. Lift the planet cage off the axle.
1.3 Gear Changing
Gear changing is simple and smooth with the
proven Sturmey-Archer indexed control
system. Continue pedalling, but ease
pressure on the pedals, and select the gear
required. If stationary, simply select gear
required.
3.1 Disassembly
Fig. 1
1. Remove the indicator rod, axle nuts and
spacing washers from both ends of the
axle.
2. Use a screwdriver to release the sprocket
circlip from the driver, then remove the
spacing washers, sprocket and outer
dustcap ( note the order of these parts).
3. Unscrew the left hand cone locknut and
cone.
Fig. 1
Fig. 2
Fig. 3
