Replacing Rohloff Hub Oil Seals…

9 05 2013
Leaky Rohloff...

Leaky Rohloff…

The Rohloff IGH in my Surly Big Dummy has been leaking oil for a while. This doesn’t really matter a whole lot as the Rohloff continued to work just fine, but I knew it was something I should sort out. So I collected the parts I needed and specialized Rohloff tools last year and finally got around to making it happen last week.

Most of what I needed...

Most of what I needed…

Here is what you need:

  • Hub oil seals x 2 = #8244
  • Tools for mounting hub seals = #8503
  • Paper gaskets = #8710
  • Loctite = #8347
  • Oil change kit = #8410
  • Sprocket removal tool = #8510
  • Rohloff instruction manual
  • Torx 20 driver
  • 3mm, 5mm & 8mm allen keys
  • large adjustable wrench
  • chain whip
  • paper towel
  • q-tips
  • rubbing alcohol
  • beer x 6
  • music

Before getting started wash your hub/rim/tire and let dry. You don’t want to have chunks of dirt fall into the open hub and it will be nicer to work with a clean wheel.

Axle side oil seal removed...

Axle side oil seal removed…

Like all Rohloff projects I’ve embarked on it was much easier than I had feared, but complicated enough that I ran into a couple glitches. Here are some instructions on how to replace the hub oil seals.

You will also need to read up on:

  • removing/installing the disc brake [assuming you have one]
  • removing/installing the shifting mechanism
  • removing/installing the drive sprocket
  • how to do an oil change

It’s worth reading all the way through so you can be sure you have all the parts and tools you need.

Staying organized...

Staying organized…

I started on the axle side where the shift box attaches. Pulling off the disc brake rotor and the shifting mechanism was easy. The hub oil seal was in pretty tight so it took me a few tries to get it out. It helps that you can destroy it in the process since it’s headed for the bin anyways.

New hub seal...

New hub seal…

With the Rohloff tool installing the new hub seal is dead easy. Just make sure you clean out the old seal mating surface before installing and don’t get crazy with the Loctite around the new seal. You don’t want to contaminate the hub.

Seal installed...

Seal installed…

Once the hub seal is installed just reassemble the axle side of the hub. It’s a bit fiddly so read the instructions first and then tackle it.

Paper gaskets...

Paper gaskets…

It was about this point that I realized I was missing 2 small paper gaskets I needed to reinstall my shift mechanism. I was a bit bummed because I didn’t think I’d be able to source them locally and figured I might be waiting 2 weeks for mail order parts to arrive. Happily I went down to the Fairfield Bicycle Shop and they had exactly what I needed in stock. Awesome! ūüôā

It’s really nice to have a LBS who services Rohloffs in town. If I ever have questions I can talk to them and they carry the parts I need for any projects.

The video above shows how to remove the sprocket from a Rohloff hub. These sprockets are threaded onto the hub and continuously tightened by your pedalling action. So they are a bitch to get off.

I tried....

I tried….

I tried to loosen the sprocket at home, but failed. So I carried the hub down to the kind folks at Cycles West my neighbourhood LBS. They used their bench vice to hold the hub and spin off the sprocket with a chain whip. Thanks guys – you rock! ūüôā

The video above shows how to replace the hub oil seal on the drive side of the hub.

SLX brake parts...

SLX brake parts…

I cleaned the brake rotor with rubbing alcohol to remove any traces of hub oil that may have gotten on to it. I sanded down the pads and then set them ablaze for a while in a pool of rubbing alcohol to clean them up as well. I probably need new pads, but I’m a bit lazy so I’ll use these for now until I get some freshies.

My Big Dummy repair stand... ;)

My Big Dummy repair stand… ūüėČ

With the hub back together I pumped some cleaning solution into it as the first part of an oil change.

The video above explains how to do an oil change.

Time to haul...

Time to haul…

I needed to work the cleaning solution all through the hub so I figured I might as well go get some groceries.

Checking everything out...

Checking everything out…

The ride let me check that the hub was working correctly in case I had goofed something during reassembly. As it turns out the IGH was purring like a kitten! ūüôā

My buddy Steve...

My buddy Steve…

I ran into my buddy Steve so we talked cargo bikes and he checked out the passenger deck.

Fresh oil...

Fresh oil…

Once home I let the dirty oil drain out and then I injected 25ml of the clean stuff and buttoned up the Rohloff.

See you in 5000kms...

See you in 5000kms…

Since my Big Dummy doesn’t see big mileage these days and lives inside I won’t be messing with this Rohloff for a few years.

Ready for summer...

Ready for summer…

Now that I have been through it all once I could replace a set of Rohloff hub seals in 1hr – assuming I had the parts and a bench vice at home. Sadly I’ll probably forget everything I just did by the time I need to do it again! ūüėČ

Gravel Pimp – Dead End Recon…

23 06 2012

Enjoying a ride along the coast…

If you haven’t read the Extreme Recon chapter of the Gravel Pimp Saga than click here and read it so you know what’s shaking.

Our last attempt to pioneer a dirt route between Lake Cowichan and Victoria BC failed when we were diverted by a security zone around the Victoria Water Supply Area [aka The DMZ]. Not to be deterred we retreated back to Gravel Pimp HQ and reviewed our maps then plotted a new route.

Pink is the new route – click for larger…

The map above shows our planned route in pink. The green route is what we had hoped to ride last time when we were stopped. As you can see the new route is a significant detour, but better a few extra KMs of dirt than riding pavement home. Where the pink and green tracks meet at the bottom of the map is Leectown and the top of the Galloping Goose MUP.

Our bikes ready to roll…

Trying to schedule a ride between everyone’s work obligations and weather was a challenge, but finally we found a window that worked. A-Man couldn’t make this edition of Gravel Pimping, but he has a sweet Moots 29er ready for next time!


We had a¬† few beers to adequately prepare for the rigors of the ride….;)

Scott enjoying some sunshine…

Rolling down the Goose MUP was pleasant as always.

My trusty steed got a new frame bag that actually fits!…=)

Our first night’s goal was modest since we didn’t want to try any of the hard route finding until the AM. So in true Gravel Pimp style we detoured to a pub and enjoyed some additional beers as well as some burgers.

Home sweet home…

We took advantage of the Barnes Station Shelter, but threw up the mesh tents as bug nets. You can tell spring is here when you can snack just by riding with your mouth open!

Is it morning already?

Scott was super keen to get rolling so he kicked me out of my sleeping bag at 5am. Breakfast was a variety of cold snacks I had stuffed into my front pouch [aka the Feed Bag].

You can’t bitch about the scenery – Sooke River…

Our first goal was finding Leechtown – an old mining settlement that would mark the start of the hard route finding.

Scott finds Leechtown…

Finding Leechtown was just an easy few km spin up the Goose MUP to its end. Although we realized we were on the wrong side of the Sooke River so we needed to do some ‘schwacking!

It’s all gone green…

We followed some forest tracks to the river.

There was a bit of walking…

A little hike-a-bike never hurt anyone.

Even Scott had to walk…

The nice thing about finding your way next to a river is that you can’t get lost!

Crossing the river part 1…

Although the Sooke River is pretty intense further downstream it was broken up into a few manageable creeks where we were trying to cross.

The might Sooke River has been tamed!

The ‘schwacking continued after the water crossing.

Need any spare parts…

We started to see derelict machinery, but we never did see any old buildings.

Denied by the DMZ again!

As we scouted out route options we encountered the first dead end at the Evil Red DMZ Gate. These gates are all around the water supply area. Happily the guards didn’t notice us and Scott wasn’t beaten half to death this time.

Checking out some equipment we may need later!

Denied by the DMZ we tried some of the logging roads that ran west along the Leech River.

Scott is thinking about a kickstand for the Hunter…

But, before we did anything hasty it was time for a snack break.

I like snack breaks!

I streamlined my food supply – leaving three elements at home – fruit, sandwiches and M&Ms. Mistake! Next time I will have all three with me. Recon work is tough and I got hungrier than I thought I would. I didn’t run out of food, but what I was putting in my mouth just didn’t seem to satisfy me as well as it should.

Steep loose gravel…

After the DMZ gate our first attempt was a rough double track that was clearly made with a bulldozer and never improved for frequent vehicle traffic. The big chunky rocks were hard to ride up and scary to ride down. It was fairly “climby”, but it had a nice remote feel that would have made for a great bikepacking route.

It was good – until it ended!

Sadly the road just ended. We don’t mind a hike-a-bike, but not 30kms of it over a mountain range!

Guess what?

As we backtracked we tried a side trail that had some potential, but it ended as well.

Clear cut…

We ended up back at Leechtown and headed west on a well used logging road on the south side of the Leech River. This was shown on our map as connecting up with the other logging roads we needed to get to further north.

Yup…it’s true….denied again!

But as we found out that was a lie. The road just stopped at a scree slope that was hard to walk across let alone carry a bike across.

Overgrown double track…

Although it didn’t go anywhere this section of the ride had some super fun overgrown double track to pedal. Life could be worse than riding your bike in the forest looking for promising bikepacking routes….;)

Hmmm….why is Scott walking back?

There was a turn off from the main road that went higher and we hoped got around the rock slide. So we cranked uphill and found that it did go a bit further, but it also dead ended despite being shown on our map as continuing onwards.

Scott immersion testing his Rohloff!

So defeated yet again we rode back to Leechtown to regroup. Our time and energy levels were running low as we still had a few hours of riding back home to Victoria. The most promising option was straight up a mountain north of Leechtown and neither of us could handle the thought of 15kms of grinding uphill only to be denied. So we decided it was time to roll for home.

Nearly road kill…

Scott bunny hopped over a snake on the Galloping Goose so we stopped and herded him off the trail so he could live to slither another day!

Another snack stop…

The roll home was pleasant, but to be honest we’re over the Goose MUP. It’s a convenient way to get out of town on dirt, but after you’ve ridden it 12 times in a year you want to load a movie on the iPhone just to stay awake! Don’t get me wrong it’s far better than hoovering exhaust fumes on the side of Hwy 14 while dodging trucks. I’m just a spoiled whiner!

Pink was the theoretical route – dark red the actual GPS track…

All told the ride was ~145kms long with ~1200m elevation gain. Progress was slower and harder than those stats would indicate with a lot of walking & talking to workout what to do next. While it wasn’t successful in finding a route north to Lake Cowichan we did expand our knowledge of the area and confirm that the maps we have are “optimistic” when it comes to the logging roads. You can click on either map to enlarge them.

Our full route – click for larger…

So what’s next?

  • Craig Main is a logging road up a mountain north of Leechtown that connects through based on our maps. It would provide the most direct route so it’s the next priority for recon effort.
  • Butler Main is a logging road that heads west, but offers the potential of then branching north where we want to go. It’s not very direct, but if Craig Main doesn’t go it’s next.
  • After those two options are explored if we aren’t successful I think our next move is to go back to the north side of the route and explore south as far as we can. Eventually we’ll have GPS tracks for everything reasonably close we can ride and we can figure out if an extreme bushwack is possible to connect the route.

Of course my hope is that there is a nice logging road through to Lake Cowichan, but so far such a beast has been elusive. Time will tell!

Surly Troll Rohloff Build…

5 05 2012

Pushing Pedals Blog…

The Surly Troll is a popular 26″ bikepacking rig and some smart folks are building them up with Rohloff hubs. If you click on the images in this post you’ll be launched to other sites where you can enjoy some IGH bikepacking goodness,,,,=-)

Cass Gilbert’s Rohloff Troll…

BTW – Pushing Pedals Blog has a shout out to Porcelain Rocket that’s worth a look.

Gravel Pimping…

16 02 2012

The Gravel Pimps at Oak Bay Bikes Westshore...

Scott and I have been talking about getting out and doing some bikepacking on the south end of Vancouver Island, but life has been getting in the way. So we decided to make a break for it when we saw a window of good weather Monday. With both of us busy with work our departure got pushed back until 4pm. In December that would have meant a 100% night ride our first day, but just a few weeks later we still had nearly 2hrs of daylight to enjoy from the saddle. We stopped in at the Westshore location of Oak Bay Bikes just to say hi and check out what they had on the floor.

What else would I rock for bags?

It got dark soon after we left OBB on the Galloping Goose Trail. We both had about 900 lumens of LED firepower at our disposal which we didn’t use at¬†full-power¬†given the easy terrain and our sedate cruising speed. ¬†We wanted to hit up the 17 Mile House Pub on Hwy 14 for beers and burgers so I stopped a few times to check my iPhone. I don’t like riding with a GPS on my bars unless absolutely necessary so I had to stop and¬†retrieve¬†my phone each time.

Scott warming his hands...

During one of these stops I found myself at the top of a set of stairs [click here for a photo from the next day’s return trip]. Scott wisely backtracked and went down the trail. I of course had to do a stupid human trick and decided to ride down the stairs. Now normally this would be no problem, but at night with a new bike loaded for the first time with gear and backpack, my weight distribution and inability to get back off the saddle because of the seatbag resulted in an over the bars endo/vault. Thankfully not very fast, but nevertheless I ended up with two sore palms and a bashed up¬†elbow/knee on the left side of my body.


It’s been years since I’ve been even moderately hurt on a MTB so I don’t feel hard done by, but what a dumb way to get banged up. No heroic story of a 6′ drop off a skinny wood bridge while being chased by a cougar…just operator error!

Got gravel?

Luckily I was able to find a hand position on my bar ends that wasn’t terribly painful and we cranked along the rest of the way to the pub. Several pints of beer and many dead chicken wings later I was feeling better. I climbed back on my bike gingerly and we cruised the rest of the way to our destination for the night.

A room with a view and no doors!

I had spotted this shelter last time I was up this way biking with Aaron. Since only crazy people go camping in early February on Vancouver Island we had the place to ourselves and simply ignored the no camping signs. Yeah we are bad asses!

Low rent, hardwood floors and indoors bike parking - score!

The shelter was spacious and clean with great protection from wind and the inevitable rain that was to fall that night. Bikepacking bags only let you carry the bare essentials so we didn’t get up to much upon arrival beyond setting up our sleeping bags and munching on a few snacks. When it’s dark and cold I find myself very quickly jumping into a down¬†cocoon! I told Scott he could yell and kick me if I was snoring too loud and with that I passed out.

Black and white On One Scandal 29er...

I woke up in the middle of the night and did a quick inventory of my aches and pains. Everything was feeling pretty good except for my left hand which was very tender and swollen. Not great, but at least I knew I could bike home with 4 out of 5 contact points on the bike feeling decent. Back to sleep I went.

Rohloff'd Hunter 29er...

I wish I had a watch in my sleeping bag as I got up at 6am [according to Scott] to pee and went back to bed because it was still dark. Had I known it was 6am I would have probably made a move to get rolling. After a certain point sleeping on a hard surface with a thin thermarest doesn’t provide much additional benefit.

It's alive!

It started to just get light at 8am so I got rolling. I fired up the stove and made a random dehydrated meal I found at home and some green tea. It was less than gourmet, but it hit the spot.

Minimal, but effective...

Water is plentiful in the rainforest so dehydrated meals are very handy if not the most delicious thing you can eat…=-)

Clean well stocked toilets...

Although we didn’t make much use of the campsite infrastructure there were lots of tables, water and clean toilets close at hand. Nice to see tax payer $$ going towards something I cared about instead of fighter jets!

Sooke Potholes Regional Park...

There was an old mining town a few KMs north from us and I had hoped to spin up there and check it out, but my hand was really sore and I decided it was best to make tracks for home, painkillers, ice and beer!

Scott loading my bike bags...

With one bum hand I was having issues loading my gear back into my bike bags. Scott was kind enough to help me out. Lucky for him I hurt my left hand otherwise I would have needed some assistance in the toilet as well….hahaha! =)

One last look back at our hut...

The scenery up this far along the Galloping Goose Trail is stunning something you can’t appreciate riding it at night.

Pointing our bikes down the map back towards home...

I was sad to miss the mining town, but it will be there next trip. This run up the Goose is our entry pass into a vast network of forest service roads. So unless we drive our bikes to a different starting point all our bikepacking rides will pass this way.

One of the many wooden bridges on the Goose...

My left hand wasn’t terribly happy, but as long as I lifted it off the bars before any major bump was encountered I was able to tolerate light pressure as I gripped the bar end.

Scott keeps it in first gear...

We rode down the Goose slowly in a light rain. Scott kept his back brake on the whole time just to get a better workout…=-)

Yo - check the Pimp rig...

Happily the wide 29er tires rolled well over the gravel/dirt trail surface making it an easy task to spin back towards Victoria.

Another killer view...

The spectacular views helped me keep my mind off my aches and pains!

My bike not looking so clean...

I was happy to roll into my yard and pop a couple Tylenol as I took a swig from an ice cold Corona! Despite my stupidity it was still great to be out on the bike on the South Shore of Vancouver Island. This ride let me figure out some things about my bike and how to best pack it for future adventures.

Nothing a quick hose down can't fix...

The Alfine 11 IGH and the 29er hardtail bike is proving to be a fun versatile machine that’s ideal for lots of different adventures. I’m going to take a few days off the bike to let my left hand rest and then I’ll be back hard at work wearing out parts…=-)

BTW – in case you are wondering about the title of this post we decided that “Gravel Grinding” sounded too boring for a couple wild and crazy guys like us – hence we coined the new term “Gravel Pimping”. You have our permission to use it as you wish!

Surly Black Ops 1×1 Mountain Bike…

24 11 2011

It's rigid and black and beautiful...=-)

Riding with Scott and Aaron on their hardtail MTBs has shown me that my XL sized Santa Cruz Nomad isn’t the best weapon for tight twisty singletrack where the speed never climbs to warp levels. I love my Nomad and won’t be getting rid of her until she dies of natural causes, but I wanted to try something more nimble that better suits the realities of mountain biking in the Forests of Endor.

Shimano XT + Mavic XC717 front wheel...

Thing is I didn’t have any desire to buy a new MTB so I looked around the garage and decided I’d try franken-building something. I stole the front wheel from my Surly Big Dummy as I had a dynohub wheel I had planned to install anyways.

160mm disc up front...

Avid 160mm disc rotor from the Big Dummy. Shimano SLX hydraulic brake that I bought for my CETMA cargo bike, but never installed. I was going to use it on my Pugsley, but stuck with the tried and true Avid BB7s on the fatty. So that freed them up for this build.

Jonny Tomac pro-model rubber!

Kenda 2.35″ Nevegal with stick-E rubber compound to get some traction in the slick forest.

Lots of room in there...

If this experiment proves successful I’ll be looking for wider rubber to add some float to this rigid frame…something between 2.5″-3.0″

38T x 16T...

The Shimano Deore BB/crank from the fixie build lives on with a Thorn 38T chainring. I may go lower in terms of my gearing, but I had the 38T ring so we’ll start there and stay legal!…=-)

IGH bling...

Of course having a spare disc ready Rohloff IGH built up into a nice Velocity Aeroheat wheel from the CETMA was the critical element in the whole plan. I had a spare Rohloff disc rotor so I was golden. Note the Surly Tugnut to keep the wheel from sliding in the horizontal dropouts due to my massively powerful chicken legs. No need for a chain tensioner on the 1×1.

Slick Rohloff setup...

I used a Monkey Bone disc adapter & Rohloff OEM2 axle plate to keep the IGH from¬†spinning. 160mm Rohloff rotor and external gear mechanism is normal fare for a mountain bike. I used a Nashbar allen bolt semi-QR skewer so I could¬†tighten¬†the wheel up better than a QR. We’ll see how this works.

Where did I go?

I see some night winter MTBing in my future so I left one light on the 1×1.

Right hand control setup...

I had a previously¬†hacked set of Ergon Grips I threw on the bike with some rubber bar ends and the SLX levers. I managed to cable the Rohloff backwards so gear #1 is the hardest and gear #14 is the easiest. Since it works fine I’ll just use it like that.

Time to break you in!

I kept the very very very hard narrow Brooks B17 saddle from the fixed 1×1 build. I figure I’ll break it in MTBing or die trying…=-)

Black is back...

You’ll notice in the top photo I’ve added a rear clip on fender to the downtube mounted splash guard. This should keep the Brooks from self-destructing and keep my back from sporting the brown MTB strip of shame.

My plan going forward is:

  • ride the 1×1 rigid and see what I think
  • consider a short travel suspension fork if I can find one that’s reasonably priced [EBay?]
  • try some wider rubber
  • try some lower gearing

Is that all the rubber you got?

If I’m happy I’ll keep tweaking and riding her. If it’s not a fun setup I’ll probably strip her down and return the parts to the spares bin.

You might be thinking what about the Pugsley as a rigid MTB? I’ll be testing out the fatty this winter as well. I’ll end up using whichever one makes me smile the most.

This was what the 1x1 looked like when started the MTB build...

The right Rohloff for your Big Dummy?

7 05 2011

A Big Dummy love a Rohloff!

This is is a repost from an old blog. I figured it would be useful to have here in case someone was searching for Surly Big Dummy Rohloff information.

One problem with buying a Rohloff hub is that there are a TON of options to navigate if you want to get the right hub. In this post I’ll run through the options to let you know what works and what I chose.


  • available in¬†red, black and silver
  • the anodized cases [black and red] should withstand salt and other elements a bit better than the polished aluminum case
  • cases are now laser engraved. If you see one with a sticker on the hub it is older stock.
  • I chose black for the stealth Big Dummy look
Internal or External Gear Mechanism:
  • the external gear mechanism is a box that attaches to your hub and your cables terminate there
  • this means you can easily detach it for removing the rear wheel
  • cables are run fully covered to the external gear mechanism so they are immune to the elements
  • it is easier to field service the external gear mechanism
  • the trade off is the shifting is slightly less smooth
  • you cannot use disc brakes with the internal gear mechanism
  • I went with the external gear mechanism for the ease of maintenance and so I could use disc brakes.
Disc Brakes:
  • you will need to use the external gear mechanism
  • you will need to specify disc brake use when ordering your hub
  • you will need a¬†Rohloff specific disc rotor
  • you can use a Rohloff disc hub on a rim brake bike as long as you use a rim with a braking surface
  • I went this route as I wanted to use Avid BB7 disc brakes on my Big Dummy
Torque Support:
  • without any torque support the hub will want to spin and will not drive the bike forward
  • you can get a Rohloff with the following torque support options:
  • you need to be sure you get the OEM2 axle plate
Accessories you’ll need:
  • chain tensioner¬†– you’ll need this as the Big Dummy has vertical drop outs. Keep in mind there is a standard and DH version. You want the standard version.
  • Tandem length cables – due to the length of the Big Dummy you’ll need the longer tandem length cables.
  • Rohloff specific disc rotor – you cannot use the rotor supplied with your brakes as it will have the wrong bolt pattern.
Accessories you may want:
  • chain guide¬†– keeps your chain on the front ring
  • oil change kit¬†– you’ll need one of these every 5,000kms so it migt be easiest to buy one or two when you get your hub.
  • Sprockets¬†-all hubs come with a 16T sprocket. You can also get 13T, 15T & 17T sprockets.
Non-Rohloff specific parts you’ll need:
  • 38T or larger front chain ring that will fit on the outside of your cranks – same position as big chain ring on a MTB triple. You want a ~54mmm chain line. This chain ring does not need to be pinned and ramped. You’ll be able to flip it around and use the other side when it wears out.
  • 2 chains – you’ll only use 1 and a bit, but you can save the extra portion and use it dnotw h road. You’ll also be able to flip your chain and rear cog around when things start to wear out and get more miles out of your drive train. I bought two 8 speed SRAM chains as they were cheap.
Rohloff Part Numbers

To make your life easier here are the part numbers you can use to ensure you are getting exactly what you need when you order your Rohloff hub:

  • Silver disc brake CC External Gear Mech OEM hub [specify OEM2] – #8025
  • Red disc brake CC External Gear Mech OEM hub [specify OEM2] – #8026
  • Black disc brake CC External Gear Mech OEM hub [specify OEM2] – #8027
  • Axle plate OEM2 [if you forgot to ask for it like I did and got an OEM hub] – #8227
  • Tandem Length cables – #8267
  • Chain Guide – #8290
  • Avid/Shimano 160mm disc rotor – #8281S
  • Hayes 160mm disc rotor – #8281H
  • Magura 160mm disc rotor – #8280
  • Oil Change Kit – #8410
  • 13T Sprocket – #8219
  • 15T Sprocket – #8220
  • 16T Sprocket – #8221
  • 17T Sprocket – #8222

Drivetrain Efficiency…

11 12 2010


This interesting article was posted over at BROL.  It discusses some measurements of various drivetrain efficiencies.   Click on the image to read the PDF Рarticle starts at pg 3.

One question I have is that they note that efficiencies are worst at lower input power. ¬†Since cyclists have a short peak of power twice per crank revolution followed by 2 lows and the majority of the power stroke is between the low and high values I wonder what the measured efficiencies would be with a variable power input that simulated how a cyclist’s legs worked?