Step-by-Step: Bearing Replacement in Crossmax XL S Wheels

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The Mavic Crossmax XL S [paid link] wheels are designed for aggressive mountain biking, offering robust performance, durability, and a smooth ride. However, like all high-performance wheels, the bearings in the hub may eventually wear out due to regular use. Replacing the bearings in your Crossmax XL S [paid link] wheels is an essential maintenance task that ensures your wheels continue to perform optimally. This guide will walk you through the process of bearing replacement, helping you keep your wheels in top condition.

Tools Required

  • 5mm Allen wrench [paid link]
  • 10mm socket wrench
  • Bearing puller tool
  • New bearings (specific to Crossmax XL S model)
  • Grease
  • Hub tool [paid link] for Mavic hubs
  • Rags for cleaning
  • Torque wrench [paid link]
  • Flathead screwdriver (for removal)
  • Small hammer (optional)

Disassembly of the Hub

Before you begin replacing the bearings, it’s important to disassemble the hub to gain access to the bearings. Follow these steps carefully to avoid damaging any parts.

  1. Remove the Wheel: Start by removing the wheel from the bike. Release the quick release or through-axle, depending on your bike setup.
  2. Remove the End Caps: Using the 5mm Allen wrench [paid link], carefully remove the end caps on both sides of the wheel hub. This will expose the axle and allow access to the internals of the hub.
  3. Take Out the Axle: Depending on the specific version of your Crossmax XL S, you may need to remove the axle using a 10mm socket wrench. Keep track of any washers or spacers as you remove the axle so they can be reassembled in the correct order later.
  4. Remove the Freehub Body: Use the appropriate tool to remove the freehub body. On Mavic hubs, this typically requires a hub tool [paid link] or a freehub tool specific to the Mavic system. Carefully slide off the freehub body, ensuring no other internal components are disturbed.
  5. Inspect the Hub Internals: Before proceeding with the bearing replacement, inspect the internal parts of the hub for any signs of wear or damage, such as broken pawls or loose springs. Replace any damaged parts during this process.

Bearing Removal

With the hub disassembled, you can now proceed with removing the old bearings.

  1. Locate the Bearings: The Crossmax XL S typically has two main bearings located on either side of the hub. These bearings are typically sealed and may require some force to remove.
  2. Use the Bearing Puller Tool: Place the bearing puller tool around the bearing and carefully extract it. You may need to use a small hammer to gently tap the bearing puller tool if the bearing is stuck.
  3. Clean the Hub: Once the bearings are removed, clean the hub thoroughly using a rag. Remove any old grease, dirt, and debris from the hub shell, freehub body, and axle. A clean hub ensures that the new bearings will seat properly.
  4. Check for Residual Bearing Fragments: Ensure no bearing fragments or debris remain in the bearing cups, as this can cause issues with the installation of new bearings.

Installing the New Bearings

Now that the old bearings are removed and the hub is clean, it’s time to install the new bearings. Follow these steps carefully to ensure proper installation.

  1. Select the Correct Bearings: Mavic Crossmax XL S wheels require specific bearings. Ensure the new bearings match the exact specifications needed for your hub model. Refer to your Mavic manual or consult an authorized Mavic dealer if you are unsure about the correct bearing size.
  2. Grease the Bearings: Apply a light coat of high-quality grease to the new bearings. This helps them slide into place more easily and also provides lubrication to reduce wear over time.
  3. Press the Bearings into Place: Using the bearing press [paid link] tool or a socket of appropriate size, press the new bearings into the bearing cups of the hub shell. Be sure that the bearings are seated firmly and evenly in the cup, ensuring no misalignment.
  4. Check Bearing Alignment: Once the bearings are installed, double-check that they are properly aligned and seated in the bearing cups. If the bearings are not seated properly, they may not function as intended and could wear out prematurely.

Reassembly of the Hub

After the bearings are installed, it’s time to reassemble the hub. Follow these steps to complete the process.

  1. Reinstall the Freehub Body: Slide the freehub body back onto the hub, making sure it fits securely. Depending on the type of freehub, you may need to lubricate the pawls and springs before reinstalling the freehub body.
  2. Insert the Axle: Carefully insert the axle back through the hub. If necessary, apply a small amount of grease to the axle to prevent future corrosion.
  3. Reattach the End Caps: Once the axle is properly inserted, reattach the end caps on both sides of the wheel. Ensure they are properly aligned and secure.
  4. Tighten Everything: Use a torque wrench [paid link] to tighten the axle and end caps to the manufacturer’s recommended torque settings. This ensures that the hub is properly tensioned and free of play.

Testing and Adjusting the Hub

After reassembling the hub, it’s important to test the wheel to ensure everything is functioning properly.

  1. Spin the Wheel: Spin the wheel by hand to check for smoothness. The wheel should spin freely without any grinding or resistance. If you feel any rough spots, the bearings may not be installed properly, or there may be dirt or debris in the hub.
  2. Check for Play: With the wheel installed on the bike, check for any lateral or radial play in the hub. If there is any play, it could indicate an improperly installed bearing or loose axle.
  3. Recheck the Freehub: Ensure that the freehub engages properly when the wheel is spun. It should click smoothly when the pedals are turned, indicating that the pawls inside the freehub are functioning correctly.
  4. Lubricate the Hub: Apply some grease to the freehub body and pawls as needed. This will ensure smooth engagement and prevent future issues with the hub.

Troubleshooting Common Issues

If you encounter issues during the bearing replacement process, consider these common troubleshooting tips:

  • Rough Spinning: If the wheel doesn’t spin smoothly after bearing replacement, check for misaligned bearings or dirt within the hub. Ensure that the new bearings are seated correctly and that no foreign material has entered the hub during reassembly.
  • Excessive Play: If you experience play in the hub, double-check that the axle and end caps are properly tightened and that the bearings are seated correctly.
  • Freehub Issues: If the freehub is not engaging properly after reassembly, check the freehub pawls and ensure they are lubricated and positioned correctly. If needed, replace any worn pawls or springs inside the freehub.

Conclusion

Replacing the bearings in your Mavic Crossmax XL S wheels is an essential maintenance task that helps to prolong the lifespan of your wheels and maintain optimal performance. By following the steps outlined in this guide, you can ensure that your bearings are replaced properly and your hub remains in top condition. Regular maintenance like bearing replacement can also improve the smoothness of your ride, reduce friction, and prevent more costly repairs down the line.