Here is a techie tale of real world, long term product testing and what an enormous influence bike maintenance can have on your cycling pleasure. You may recall that I use my own bike to test components and accessories, usually for a couple years unless something just sucks. Then I just remove it as quickly as possible. If I really like something I just call it “mine” and leave it in place until I have a reason to do otherwise.
About a year ago during a several week cold spell I decided that my own Fr8 was deadly, painfully slow compared to others. But I hate repairing my own bikes so I just kept on riding it through the winter, spring, summer, fall and some more winter until a couple days ago. Nothing was really broken nor made even an annoying peep; I just had the feeling I was pedaling pretty hard while grandmas with flowers in their hands and moms on bakfietsen loaded with four kids glided on past. Was I just a little tired… for an entire year? Cycling on this bike just wasn’t as much fun as our others but usually I wouldn’t notice it and if I did notice I’d forget about it shortly after locking up (or not!) and walking inside.
This is exactly why we exhort you to regularly service your bike, unlike yours truly. A well maintained bike is just nice to ride and a crappy running bike is less so, even if you don’t actually notice it. Why sweat more than you need to? Why feel that click, clack or sloppy drivetrain when you can daily enjoy the pleasure of pedaling along silently and effortlessly. This must be one of the world’s cheapest pleasures.
I assumed the abundant friction in my bike had something to do with the NuVinci N360 infinitely variable hub since that’s its most unusual feature. With the bike in the lift the rear wheel required a good tug to turn and it didn’t spin at all. I was totally wrong about the hub but will get to that later. We’ve discussed the Nuvinci friction thing ad infinitum on the @Workcycles Facebook group. Unfortunately a Facebook group can’t be searched so finding those discussions again would mean hours of scrolling. No doubt Mr. Zuckerberg is snickering this very moment while he employs his own powerful FB search engine to scan the Groups for info about Nuvinci hubs and Workcycles Fr8’s.
I spoke to the folks at Fallbrook/Nuvinci. They assured us that that the cold should have little influence on the hub’s efficiency so there must be something wrong with my hub. A replacement hub was quickly dispatched. It then waited patiently for a half year, for the day that I have both the time and willpower to pull my Fr8 apart, build a new wheel and put it back together. The other day the temperature dropped well below freezing and my rear brake and shifter cables froze. After spinning madly to school and work for a few days in the tiny ratio it was stuck in I declared my bike officially “broken”. The operation could commence. I gathered several other new parts to try and stripped my bike.
With the wheel out of the bike and the rollerbrake removed I clamped the axle in the vise and spun. It spun rather well I must say. I mean this ain’t my track bike whose unsealed, oiled bearing wheels will spin for several minutes before gradually stopping, but the Nuvinci wheel did spin almost as well as most other multigear hubs do. Further, spinning axles with my fingers, I couldn’t detect any difference between the 18 month old, ridden daily and stored outdoors Nuvinci and the brand new one. As far as I can tell this hub is as good as new.
What then is dragging my ass down? Could it be the Hebie Chainglider, which “glides” along the chain instead of being attached to the frame? It and the chain running through it were both filled with a gritty, slimy paste of oil and dirt. It was vaguely audible while riding and sounds take energy to create. I decided: Away with Chainglider! I only put it on this bike because I was too lazy to cut up a real Hesling chaincase to fit around the Nuvinci’s shifter interface and the Monark “Mother of All Centerstands”. Actually I’m still kinda lazy; I removed the Monark centerstand and installed another Ursus Jumbo. I’d previously tested and broken one of these but it’s apparently been improved since then. Time to try it again, and very convenient that it just barely fits together with the chaincase.
Still, I couldn’t believe that either the Chainglider or the filthy (but almost new) chain were really causing so much friction. Spinning the crank backwards the friction was negligible, despite the scraping noises. So the Chainglider wasn’t helping the bike’s efficiency but it also couldn’t have been the root of the problem. Nonetheless a real Dutch chaincase is always better if it fits. After half an hour of Dremel grinding and careful adjustments to the brackets the chain ran through the Hesling case silently and with no friction whatsoever.
Next stop: Rollerbrakes. The Shimano IM80 rollerbrakes on this bike have performed admirably since I installed them. They stop the bike with authority and have good lever feel too. The braking power was confidence inspiring even while cycling in the steep hills of Brussels with two kids and baggage aboard.
Little did I realize, however, that my powerful rollerbrakes were braking ALL the time. Once the rear brake was in my hands it was obvious who the real culprit was; A fine paste of Shimano’s sacred, expensive rollerbrake grease and road dirt filled the brake unit requiring serious hand force to rotate it. The front brake was better but not much. Did I screw them up myself by putting too much grease in them? I don’t remember.
With copious quantities of brake cleaning fluid and compressed air I removed every trace of everything from the brake units. Wonder of wonders they spun almost freely now, rather like the name “Rollerbrake” would imply. No way I’m going to sludge these babies up with that stupid grease again! What else could I put in there to keep them from rusting and lubricate the innards? After a quick inventory of the dozens of little bottles and cans on the Workcycles shelves we decided that a thick, clingy OIL ought to work, even if it violates all instructions, death-warnings and warranties. After all these brakes are fairly well enclosed and don’t see any substantial heat here in cool, mostly flat Amsterdam. The most likely problem I anticipate is that they’ll have to be oiled periodically but whether that means monthly or half yearly remains to be seen. Even generously lubed with oil the rollerbrakes spun quite freely. Back in the bike the rear wheel and brake now spun totally normally.
While I was at it I adjusted the front (dynamo) hub cones: They were waaaay too tight, as delivered from the factory. Now my front wheel spins and spins as if it weren’t filled with magnets and coils. Take that, hub dynamo haters!
Of course I also had to fix the problem that pushed me to tear the bike down in the first place: All four cables were removed and given the super special Workcycles anti-freezing treatment. That was when I discovered that the Nuvinci shifter’s adjustment barrels had rusted solid. I just replaced the whole shifter, noting that the new one came with smoother, drawn cables. This is then the only problem the Nuvinci hub has had thus far, an excellent record for a first generation product.
The last update for the day was swapping the older 44T steel crank for the new Sugino 38T forged aluminium crank we’ve begun using. The 44/20 gearing had always seemed a little on the tall side so I figured 38/20 should be about right. Like the Shimano Nexus 8sp hub we fit thousands of, the Nuvinci’s 1:1 ratio is in the upper middle of the range. That is, these hubs have somewhat more undergearing than overgearing, generally quite handy for heavy duty bikes with full sized wheels.
Everything back in place, grips securely glued to the handlebars… and let’s see how it rides. I rolled out the door, pedaled along and Lijnbaansgracht and immediately found myself spinning out in the highest ratio? Huh? I did lower the gearing but not by so much and it was too high to begin with. It was dinner time so I just continued my spinning session for the kilometer home to deal with the gearing later.
The following morning I hung the bike up again and pulled the wheel to check that the shifter was installed correctly and reaching the full range of ratios. It was. Then I swapped the 20T cog for an 18T making the gearing almost the same as the old (too tall) 44/20. That was a considerable improvement but bizarrely the gearing is still much too low. Once up to speed on any flat road I just twist it into the highest ratio. Even the steepest bridges require shifting down to only about halfway through the range. So I’ll try 17T and 16T when I find them.
The upshot is that I’ve basically been dragging a plow around behind my bike for at least a year. Fixing the brakes, chaincase and front hub wasn’t just a “marginal gain”. It has improved the bike’s efficiency by so much that it can be ridden much faster with the same effort. I can’t be bothered to do the math but it really must be at least a 25-30% speed difference. That’s huge. Faster is funner and easier is nicer… so maintain your bikes folks! It really matters.