I’ve had Wahoo turbo trainers for the previous few years. The primary being the Kickr Snap which labored properly however its resistance would fluctuate fairly a bit relying on tyre stress and air temperature.
I made a decision in January 2019 to get a wheel off Kickr 18 as I actually like driving on Zwift and the wheel off meant that I may virtually match and overlook.
Inside a few weeks the unit started to show the clunking and clicking that many models had suffered. The flywheel was additionally working with a little bit of a wobble. A substitute arrived a number of days after elevating a help ticket and submitting a brief video of the problem.
I’ve been utilizing that substitute ever since and have lined virtually 2000km on it for nearly the final 12 months and a half.
Final week it began to make a number of slight noises that I didn’t just like the sound of and a vibration could possibly be detected by means of the pedals. The noise was a slight click on and a rubbing/squeal from the belt drive. The squeal was noticeable when the flywheel was coming to a cease.
Because it seems is appears that the noises it had been making had been creating for a while however because it was gradual I didn’t actually discover immediately till it was fairly dangerous. I didn’t realise this till it was mounted.
Given the present world huge lockdown state of affairs all makes of turbo trainers are in excessive demand and I didn’t wish to be in a state of affairs of being and not using a coach. And even worse obtain an equally damaged substitute as a number of customers on social media have reported. Wahoo are additionally now not sending out the DIY restore package (K118).
Now to avoid wasting you studying on I’ve recognized and glued the problem with components which can be available and utilizing instruments that I had.
There are many nice movies on-line that present the Kickr taken aside so I haven’t bothered to indicate that.
Kickr have acknowledged there is a matter with some models. It appears to be like like my substitute unit additionally fell throughout the window of the dodgy batch.
Taking aside YOUR coach is at YOUR threat. I take no duty for any injury or damage which will happen should you do what I did. Please presume that any DIY work could void your guarantee.
To take away the quilt and get entry to the pulley you will have a 2.5mm hex key, and two in another way sized Philips head screw drivers to take away three cowl retaining screws.
Hex keys had been wanted to take away the unique M6 and M5 two bolts. 10mm and 8mm sockets had been wanted to lock in my new bolts. I additionally used a punch to assist match the brand new key.
A torque wrench was additionally used to make sure the brand new bolts had been comfortable however not too tight.
As soon as of you will have entry to the pulley wheel and belt tensioner. The pulley is held on with a M6 12mm bolt and the tensioner is held in place with a M5 12mm bolt. The tensioner is moved up and down with an extended bolt. I used a marked to determine the place the centre of the bolt was situated. The tensioners M5 bolt was again off and the tensioning bolt was unwound with a 2.5mm hex key to take away the stress on the belt drive. The belt was then faraway from the pulley.
Each the M6 and M5 bolt have washers which can be deformed throughout becoming. With a view to keep away from this the substitute bolts had been ordered, M6 x 12mm and M5 x 16mm with flanged heads and a bigger M6 18mm diameter washer.
Within the Wahoo restore package K118 the bolt equipped for the pull wheel is a excessive tensile 10.9 flange metal hex which is able to take 16Nm. I initially used a black stainless bolt as pictured and torqued as much as 10Nm however have since sourced the ten.9 spec bolts and have changed with a 16Nm torque setting.
When the pulley was eliminated the important thing merely fell out. I discovered it was undersized once I measured it so was by no means going to suit. 5 x 5 x 12mm substitute parallel keys had been ordered from Amazon. You possibly can get bins that include a number of sizes however you’ll solely want the 5 x 5 x 12mm ones.
That is perpetrator when you have the banging or clicking sound.
The flywheel rotates on two doubled seal 6003 bearings from NSK. Each popped out simply sufficient when the flywheel and axel had been eliminated. The flywheel facet match is way tighter. I’ve learn some stories that this bearing wants a little bit of coaxing to come back out. It’s definitely a tighter match than the opposite however I didn’t must resort to hammering it out.
Each of the bearing seemed OK and span freely however as they had been out I made a decision to switch them as they did have indicators of corrosion.
The 2 SKF 6003 replacements price £5.66 every. I may have gotten them cheaper if I searched round a bit however I needed them quick.
Once they arrived I positioned one (nonetheless in its plastic bag) within the freezer for a few hours. This was to shrink it very barely in dimension so I may refit into the flywheel facet recess with ease. The flywheel facet had a tighter match.
The bearings within the pulley tensioner are 6001 ZZ bearings. They’ve a metallic defend that may’t be eliminated to be able to examine/regrease. Mine appeared wonderful however I think about that the 2 that sit within the tensioner can be each troublesome to get out and again in with out the proper instruments.
Placing it again collectively:
Bearings changed with the frozen one dropped straight into the flywheel sided with out concern.
Flywheel axel greased and refitted. I used Phil’s Waterproof Grease.
Key hammered into the keyway with a bit of Loctite 243. I used a hammer and punch to ship this house ensuring it was tight and way back to it will go.
Pulley was refitted and bolted in place. The M6 flanged bolt was given some Loctite 243 and the washer refitted earlier than doing it as much as 16Nm as beneficial within the Wahoo DIY restore directions.
The pulley pressure bolt was changed with the M5 flanged bolt. I made a decision to make use of one other M6 washer to assist unfold the load additional, though a large M5 washer would have been higher. Once more this was given some Loctite 243 earlier than bolting it up. This bolt simply must be tight sufficient to stop slippage.
The belt was then fitted and the stress returned to its authentic place making certain the stress was good. Each trainers I’ve had aside have the stress set at about midway as seen within the picture above.
I then tried spinning the flywheel by hand to make sure nothing was binding. Sadly the rubbing/squealing was nonetheless current. Altering the stress didn’t make a distinction. Some research led to a fan belt video on youtube. Because the video recommended you can diagnose a belt concern with water. I stuffed a water bottle with some faucet water, protected the digital components of the coach and poured the water onto the within of the belt as I rotated the flywheel. As soon as moist the noise disappeared indicating it was a belt concern.
The water additionally flushed out a load of wonderful black grains of rubber that should have been from the belt. A little bit of Aerospace 303, that I take advantage of for dry prime latex seals, was sprayed on the internal facet of the belt and extra wiped off.
Did it work. Sure, no banging clunking, squealing. The one noise is from my bikes drive practice. I’ve accomplished quite a few rides on Zwift with out concern together with a jaunt up Alpe du Zwift right this moment.
No points in any respect.
For the components required I spent underneath £30 however have sufficient bolts, washers and keys to do one other 9 models. Excluding the bearings it’s round £3.00 per Kickr.
I’ve since repaired one other Kickr 18 with the components I’ve sourced.
thirtieth November 2020. Six months on and the Kickr is working because it ought to. It stays quiet and bearings appear to be OK. I’ve had the quilt off a number of instances over the previous few months to test on the Woodruff key and it hasn’t budged in any respect.
third January 2021. The coach has been used an increasing number of over the past month as outside biking as a result of Covid and the climate has ceased. I accomplished the Rapha Festive 500 biking over 500km on the Kickr throughout between Christmas Eve and New Yr’s Eve. The coach stays quiet.
1st January 2022. As per above. Not a single concern to this point with no additional adjustment or tweaking required.
I do have sufficient spares to do the bolts and keys for a handful of trainers. If you’re within the UK and are occupied with getting maintain of some please drop me a line within the feedback part beneath.