KICKR CORE Clicking Noise Repair Process         

Required Tools:

  • 8 inch Socket Driver/Wrench (or Torque Wrench) with 14mm & 10mm Sockets
  • Phillips Screwdriver (size 1)
  • Allen keys (sizes 5mm, 4mm, 2.5mm and 2mm)
  • Silver Permanent Marker and Paper (pencil or nail polish also works)

Required Parts:

  • None (no additional parts needed for repairs)

Process Outline:

  1. Remove plastic cover
  2. Measure and mark belt tension, loosen and remove belt
  3. Check key alignment, tighten axle bolt and set screw
  4. Tension belt back to original setting
  5. Replace plastic cover

             Repair Process

Note: Before beginning, extend, lock and level KICKR CORE legs to ensure a secure repair foundation.

1. Remove plastic cover:
Loosen and remove the screws in the image below to remove cover, then set them inside the cover to avoid misplacement.


             Image below shows KICKR CORE with cover removed and tension screw marked:

2. Measure and mark belt tension, loosen and remove belt

Warning: Wahoo strongly advises against setting belt tension outside of factory settings!  Please take every precaution to ensure belt tension is set to original/factory setting before use. 

  1. Insert paper between belt and cover backing. Use silver permanent marker, pencil, or nail polish to mark original/factory tension screw position on both the paper and front of the screw as shown in image below. Ensure 2.5mm tension screw is marked both above and below the metal tensioner assembly it intersects. Marking paper and 2.5mm tension screw ensures alignment of both vertical height and screw rotation.
  2. Once position is marked both on paper and top/bottom of screw, loosen the 10mm tensioner assembly mounting bolt (marked 1 in image below) by ⅛  turn to relieve tension just enough to allow the whole tensioner assembly to slide.  

  1. Loosen the 2.5mm tensioner screw (marked 2 in above image) by ½ turn to relieve tension - the whole tensioner assembly should slide down towards the base of the KICKR. If the assembly does not slide, loosen the 10mm tensioner assembly mounting bolt (1 above) another ⅛ turn. Once the assembly slides, continue to loosen the 2.5mm tension screw until tension is fully relieved, then remove the belt.

                     Loosen (but do not remove) 2.5mm tensioner screw to remove belt. 

  1. Remove the 10mm tensioner assembly mounting bolt and entire tensioner assembly, then unscrew the 2mm bolts near the large pulley as shown below to detach the back cover. 


  1. Once back cover is removed, hold the flywheel to remove the 14mm axle bolt + washer.

Use the belt to help steady the flywheel, if needed.
Any leftover rubber marks may be easily removed with rubbing alcohol.
 

3. Check key alignment, tighten axle bolt and set screw

  1. Once the 14mm axle bolt and washer are removed, remove the 2mm set screw by first rotating the pulley to align the set screw with the gap in the frame as shown below.
  2. With the set screw removed, check the “key” between the axle and the pulley which surrounds it. The key should be recessed, as shown below. If the key is not properly recessed, use a punch or flathead screwdriver to drive the key deeper back into the keyway (shown below) while holding the flywheel (or ask another to help to stabilize, if available) by hammering with a rubberised mallet.

  1. Push flywheel completely back if moved, as shown below:

                                                    Flywheel gap size: 2mm
                           

  1. With the key now properly recessed and the flywheel sitting against the frame, ensure no gap exists between the pulley and frame on the opposing side of the flywheel, as shown below:

The gap can be typically be closed by pushing the pulley (by hand) into the axle while holding the flywheel. If the gap cannot be closed by hand, use a rubberised mallet (or hammer) to gently tap the pulley towards the flywheel while holding it. When finished, both flywheel and pulley should be snug against the sides of the frame.

  1. Apply Loctite Threadlocker 242 (if available) to the 14mm axle bolt then reinsert (with washer) into flywheel axle. Tighten with socket driver. Complete tightening by holding the flywheel with your left hand (and belt as previously shown), then tapping the end of the socket driver with a rubberised mallet (or hammer) attached to the bolt. Tighten bolt with significant force to secure (20 Nm with a torque wrench, if available).
  2. Apply Loctite Threadlocker 242 (if available) to the 2mm set screw, then reinsert into the pulley, tightening just until secure. Very little force (2 Nm) is necessary - do NOT overtighten as this may strip the set screw. Contact support for a new set screw, if stripped.


4. Tension belt back to original setting

  1. Reattach the rear cover with the 2 (size 2mm) screws removed in 2.d, then reattach (but do not yet tighten) the tensioner assembly with the 10mm tensioner assembly mounting bolt (marked 1 below). Attach the belt in the correct path and orientation.
  2. Gently tighten the 10mm tensioner assembly mounting bolt (marked 1 below) in ⅛ turn increments until just tight enough to still slide. Avoid over-loosening or over-tightening the 10mm tensioner assembly mounting bolt (1) as this may cause the tension screw (2) to bend - the tensioner assembly should still slide freely as the tension screw (2) is tightened, while remaining snug and square with the unit.  Use paper and screw markings to tighten tension screw (marked 2 below) back to original position to ensure proper belt tension. Use paper to tighten tension screw back to original vertical height and orientation, ensuring markings face forward.
  3. Once correct height and rotation is achieved, re-tighten the 10mm tensioner assembly mounting bolt (1 above) until secure (to 15 Nm with a torque wrench).

5. Replace plastic cover

Reattach plastic cover with previously removed screws. Screws should fit easily with proper alignment. 

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