Step-by-Step: Bearing Replacement in EXC 1200 SPLINE Wheels

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The EXC 1200 SPLINE [paid link] wheels from DT Swiss are renowned for their performance and durability. Over time, however, the bearings within the wheels may wear out or become damaged, affecting the smoothness and overall performance of the wheelset. Replacing the bearings is a crucial maintenance task that ensures your wheels continue to deliver optimal performance.

This guide will provide a detailed, step-by-step process for replacing the bearings in your EXC 1200 SPLINE [paid link] wheels, ensuring that you maintain the longevity and efficiency of your wheels.

Tools Required

  • Bearing press [paid link] or a suitable tool for removing and installing bearings
  • Allen wrenches [paid link] (5mm, 6mm)
  • 10mm or 12mm adjustable wrench (depending on axle type)
  • Grease (specifically for bearings)
  • A clean rag
  • Flathead screwdriver
  • Bearing puller (optional)
  • Torque wrench [paid link]
  • Plastic mallet (optional)

Disassembling the EXC 1200 SPLINE Wheel

Before replacing the bearings, it is important to carefully disassemble the wheel. Follow these steps:

1. Remove the Wheel from the Bike

  • Begin by detaching the wheel from the bike. If the wheel uses a quick release, remove it by opening the lever and pulling the wheel out. If it uses through-axles, loosen the axle with the appropriate tool (usually a 10mm or 12mm wrench).

2. Remove the Hub End Caps

  • The EXC 1200 SPLINE wheels feature end caps that must be removed before accessing the bearings. Use your hands or a flathead screwdriver to carefully pry off the end caps, taking care not to damage the wheel.

3. Loosen the Locknuts

  • Use an appropriate size wrench to loosen and remove the locknuts that hold the hub together. These may be located at both sides of the wheel hub.

4. Take Off the Hub Shell

  • Once the locknuts are removed, you can carefully slide off the hub shell from the axle. Be cautious of any washers or spacers that may be present and keep them in order for reassembly.

Removing the Old Bearings

With the wheel hub now disassembled, the bearings can be accessed. Follow these steps to remove the old bearings:

1. Identify the Bearings

  • There are typically two bearings: one on the non-drive side and one on the drive side of the hub. The non-drive side may have an additional spacer or seal that needs to be removed before the bearing can be accessed.

2. Use a Bearing Puller

  • If the bearings are pressed in tightly, you may need to use a bearing puller to remove them from their seat. Position the puller around the outer race of the bearing and slowly pull the bearing out. Alternatively, if you don’t have a bearing puller, a plastic mallet and careful tapping on the axle can help push the bearing out from the opposite side. Take care to avoid damaging the bearing seat.

3. Clean the Bearing Seats

  • Once the old bearings are removed, clean the bearing seats in the hub shell using a clean rag to remove any debris, grease, or dirt. This step is important to ensure proper installation of the new bearings.

Installing the New Bearings

Now that the old bearings have been removed, you can begin installing the new ones. Follow these instructions:

1. Apply Grease

  • Apply a small amount of grease to the bearing seats inside the hub. This helps ensure smooth rotation and protects the bearings from moisture and contaminants.

2. Press the New Bearings Into Place

  • Carefully press the new bearings into their respective seats. If you have a bearing press [paid link], use it to ensure the bearings are seated evenly and securely. If you do not have a bearing press, you can carefully tap the bearings into place with a plastic mallet. Be sure not to hit the bearing directly—use a soft, flat tool to distribute the force evenly.

3. Ensure Proper Orientation

  • When installing the bearings, ensure that they are oriented correctly. Typically, the non-drive side bearing may have a different setup due to the presence of a spacer or seal. Always refer to the manufacturer’s instructions if you’re unsure about the bearing orientation.

Reassembling the Hub

Once the bearings are securely installed, you can reassemble the hub. Follow these steps:

1. Place the Hub Shell Back onto the Axle

  • Slide the hub shell back onto the axle, ensuring that the bearings are properly aligned and seated. Ensure that any washers, spacers, or seals are also in place as per the original configuration.

2. Tighten the Locknuts

  • Use the appropriate tool to tighten the locknuts back onto the axle. Be sure to torque the locknuts to the recommended specifications, typically around 10-15Nm for most DT Swiss hubs.

3. Reinstall the End Caps

  • Carefully reinstall the end caps onto the hub. Ensure they are seated firmly, but be cautious not to overtighten them, as this can lead to damaging the end caps or bearing seats.

Testing the Wheel

After the wheel is reassembled, it’s essential to test it to ensure everything is functioning correctly.

1. Spin the Wheel

  • Before reinstalling the wheel onto the bike, spin it by hand to ensure that the bearings are rotating smoothly. The wheel should spin freely without any grinding or resistance. If you feel any roughness or hesitation, the bearings may not be properly installed, or there could be an issue with the bearing seats.

2. Check for Play

  • Gently rock the hub back and forth to check for any play in the bearings. If there is any noticeable movement, recheck the bearing installation and ensure the locknuts are properly tightened.

3. Reinstall the Wheel on the Bike

  • Once the wheel has passed the test, reinstall it on the bike. Tighten the quick release or through axle, and make sure the wheel is centered in the frame.

Conclusion

Replacing the bearings in your DT Swiss EXC 1200 SPLINE wheels is a straightforward process that requires patience and attention to detail. By following the steps outlined in this guide, you can ensure that your wheelset continues to perform at its best. Regular maintenance of the bearings will not only extend the life of your wheels but will also keep your ride smooth and efficient.