replacing a spoke without rebuilding

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

Hi

How does one go about replacing a spoke on the wheel without dismantling the other spokes or the whole wheel?

I have found that I can only feed the spoke in a straight line and turn up when I get to the elbow of the spoke - but once this far the other spokes are in the way to where the hole is in the rim......

any suggestions?

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

Is it becouse another two are crossed over at the rim end? I dont think you can without undoing a few more. You should still be able to get your wheel true undoing a couple. Just take your time and check after each time to turn the tightners.

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

looks like an expensive wheel rebuild. Yes the other spokes are in the way ie they cross over but getting them out is PITA as they have rusted solid to the nipples pretty much Sad

Honda want £3 per spoke?!

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

I did it once when i burst three on a DT leaving the chain on when i took off. Embarassed

Let the air out the tyre to save bursting the tube. You can always buy a few more spokes and the nipples and cut out the bad ones but obviously you need the tyre off. I managed to get mine about 2mm out what was not bad for a first time and just spinning it on the bike.

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

looks like i'm going to have the whole wheel rebuilt. The other spokes are refusing to budge.

Is there anywhere where I can get a cheap set of spokes?

Saw some on ebay for about £10 a set but for a C90, who ride these things?! They are virtually non existence Laughing

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

No, i just got mine from Yamaha. This was the 80's when things were cheap. When you find a price find a price for another wheel before you start.

trisers · Scooby Slapper Joined: 29 Jul 2009 Karma :

I managed to replace a spoke on my H100 by threading it through the hub right up to the elbow then flexing it enough to thread it past other spokes and into the rim...it felt like it might form a permanent bend but i guess it's hard enough steel not too.

Of course the spokes on it are pretty small diameter so maybe if it's a much larger bike you couldn't flex a spoke that far?

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

trisers · Scooby Slapper Joined: 29 Jul 2009 Karma :

Yeah i got mine from central wheel components. I did manage to pick a rim up on ebay which was in good nick and rebuild one wheel with it and the new spokes.

Why on earth powder coat the hubs though...half an hour with wire brush, wire wool then autosol brought them up like new!

And as for the rebuilding, I'd never done anything like it before but gave it a go..there's one or two youtube vids to follow and although it took a little time because of the repetitive nature of it i found it was quite straightforward and not very difficult at all!

So that's reduced the cost by over a half even with new rims Wink

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

Hmmm I really don't mind giving the wheel building a shot.

Did you have any problems lacing the wheel up, having to bend spokes etc?

trisers · Scooby Slapper Joined: 29 Jul 2009 Karma :

No problem whatsoever doing a whole set...i found it helped having the other wheel lying alongside while i did it as a useful reference to the way the spokes are arranged...you just need a little patience to get them all in and in the correct place.

Once all the new spokes were through the rim then just screw the nipples on a few turns on each one to stop the spokes going anywhere then go around doing each one up another half turn until they start to tighten across the rim. I didn't use any special tool just a screwdriver on the back of each nipple.

Having got them all just nipped up (no real tension) i clamped the axle in a vice and put the wheel on it so i could gently spin it. Destroy a wire coat hanger and duct tape a length to the bench or vice and bend it so that the tip just touches the rim...as you spin the wheel you'll soon see any deviation caused by uneven tension in the spokes.

You'll have to work out which ones to tighten further to deviate the rim to get it to run true so when you spin it the tip of the bit of coat hanger remains just touching the rim without the rim 'wobbling' away from it (side to side or back and forwards)

It took me a while and as i said you need a little patience just because you need to keep going round tightening nipples by an eighth of a turn or so each time to get it true but once i'd done that the wheel was totally rigid and each spoke had a satisfying 'ping' to it when tapped.

First time i'd done it and totally satisfying Wink

example :- https://www.youtube.com/watch?v=-CUuugCn4eY

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

Just dont do one at a time. Put them all in the hub first and tape one side up. Screw the other in place, just screw dont do them up and start with the other. If you give one two turns you are best to go to the oposet side and give that two turns then go on to the next and do the same. Might be worth a wee bit tape on your first spoke to remember where you start. Also good chance one side spokes are longer than the other. Check before you start. Enjoy.

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

thanks guys, i'll do a picture progress at some point, rims ordered, waiting to hear back from CWC about the spokes.

Going to be interesting to say the least!

trisers · Scooby Slapper Joined: 29 Jul 2009 Karma :

trisers · Scooby Slapper Joined: 29 Jul 2009 Karma :

And btw...the new spokes on my rear wheel transformed the appearance of the whole bike too :-

https://i2.photobucket.com/albums/y27/clivejameson/2011-07-02171932.jpg

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

ooooh!

Any chance of close up pictures on the hub/spokes?

I too have notice that the head angle is different between the inner and outer spokes

map · Mr Calendar Joined: 14 Jun 2004 Karma :

Am I missing something but would a complete new (as in used) wheel not be cheaper then rebuilding a wheel with spokes?
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Vincent · Banned Joined: 16 Oct 2006 Karma :

Just replace one spoke at a time. If the old ones are seized, snip them off.
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truslack · World Chat Champion Joined: 08 Apr 2007 Karma :

A brand new pattern rear wheel for an H100 is £60.

The rear spokes are the same as the longer spokes from a C90 spoke set.
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Current: Suzuki RG 125 Gamma, Honda H100, Triumph Tiger 800XC, Suzuki SV650 (minitwin)

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

truslack · World Chat Champion Joined: 08 Apr 2007 Karma :

cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

where's the pattern rear wheel you mention? I can't find one

truslack · World Chat Champion Joined: 08 Apr 2007 Karma :

...in Hi-levels catalogue.

Without a proper look, this appears to be the one https://www.hilevel1.co.uk/cpg14/displayimage.php?album=475&pos=15

No prices on their website though.
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Current: Suzuki RG 125 Gamma, Honda H100, Triumph Tiger 800XC, Suzuki SV650 (minitwin)

trisers · Scooby Slapper Joined: 29 Jul 2009 Karma :

truslack · World Chat Champion Joined: 08 Apr 2007 Karma :

H100 SG and SJ wheels are identical to older cg125 wheels, they can also be used in SD models and get away with the separate sprocket carrier casting. I know this as I used a CG wheel in mine with the H100 brake plate and spacers.
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Current: Suzuki RG 125 Gamma, Honda H100, Triumph Tiger 800XC, Suzuki SV650 (minitwin)