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My SA XL RD-5w Shifting FLAW finally Solved. Yippie !!!!

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My SA XL RD-5w Shifting FLAW finally Solved. Yippie !!!!

Old 07-16-20, 05:45 PM
  #1  
GamblerGORD53
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My SA XL RD-5w Shifting FLAW finally Solved. Yippie !!!!

In 2012 I bought this RD5w hub from SJS, my first IGH. My spokes were slow coming, so I played with the shift chain several times. I kept wondering why it kept sticking going back in. I used it a year and liked it very much but, it didn't get any better. So the next annual take apart, I sanded the corners on the 2 key nubs. It was a little better, but still troublesome. The last time I tried it gears 2, 3, 4 wouldn't work at all, so I let it sit 3 years.

This week it was raining so I got it out again. I stripped it down to the axle and pinion planets assembly, HSA675. I put it in the vice horizontally and spent an hour yanking on the key chain till I figured it out. There are 6 rows of 4 nubs in the assembly, so there are 5 slots the key goes in/ out.
ONE of them was OK, the other 4 were NOT. This may be why so many of these hubs failed.
=====The SOLUTION turned out to be very EASY. I got out my diamond bit engraver to mark the bad slots. Then I got the bright idea to use it to lightly grind off the last 6 mm at the mouth end of the slots and round off the lip more. The grinder works very fast, so it just takes 30 seconds each. I did this until the key had NO stickiness. I don't know if it could be done without this engraver actually.
Then I spent all day converting the Rohloff setup and my chain case. I took it out three times for 50 miles. It works PERFECTLY now. Yayyyy. So now it works as well or better than my 46/ 16T Rohloff, if only using gears 6, 8, 10, 12 and 14. LOL. SA is with 46/ 17T now so I can go try going 46 mph down my fave hill again soon. ha. This 5w is WAY faster than my new 3 speed. I LOVE this hub again.

SHAME SHAME on SA for putting me and likely many others thru this horrible ORDEAL.
.....But OTOH, I would have struggled with 35 to 92 GI in Vietnam with the SA 5w. LOL

Last edited by GamblerGORD53; 07-16-20 at 06:07 PM.
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Old 07-16-20, 06:47 PM
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shelbyfv 
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Good job, impressive!
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Old 07-17-20, 11:28 PM
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GamblerGORD53
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Why no other IGH comments?
Anyway, as promised another 46 mph video. Weeeeeeeee. LOL... 72 miles, 5Hr56 moving, 8 hr total, Avg. 12.3. I stopped for lunch at DQ and puttered thru 3 towns. Drops avg 2 mph usually.
30 miles into this stiff breeze @ 12/ 13 mph and going 19/ 20mph with the wind, not much effort. 18 miles in city and DT construction. Lots of miles on nice new MUPs too. One car was passing a SUV with me on a 4 foot shoulder and lots of semis. Maybe I should cry on A+S. LOL
At mile 13 I was riding with a 60 YO guy on a 20 lb hybrid. Left him behind. LOL
Kind of poor and boring compared to the first one. And dirty lens, ooops.

Last edited by GamblerGORD53; 11-27-20 at 12:59 PM.
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Old 07-18-20, 06:43 AM
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Originally Posted by GamblerGORD53 View Post
In 2012 I bought this RD5w hub from SJS, my first IGH. My spokes were slow coming, so I played with the shift chain several times. I kept wondering why it kept sticking going back in. I used it a year and liked it very much but, it didn't get any better. So the next annual take apart, I sanded the corners on the 2 key nubs. It was a little better, but still troublesome. The last time I tried it gears 2, 3, 4 wouldn't work at all, so I let it sit 3 years.

This week it was raining so I got it out again. I stripped it down to the axle and pinion planets assembly, HSA675. I put it in the vice horizontally and spent an hour yanking on the key chain till I figured it out. There are 6 rows of 4 nubs in the assembly, so there are 5 slots the key goes in/ out.
ONE of them was OK, the other 4 were NOT. This may be why so many of these hubs failed.
=====The SOLUTION turned out to be very EASY. I got out my diamond bit engraver to mark the bad slots. Then I got the bright idea to use it to lightly grind off the last 6 mm at the mouth end of the slots and round off the lip more. The grinder works very fast, so it just takes 30 seconds each. I did this until the key had NO stickiness. I don't know if it could be done without this engraver actually.
Then I spent all day converting the Rohloff setup and my chain case. I took it out three times for 50 miles. It works PERFECTLY now. Yayyyy. So now it works as well or better than my 46/ 16T Rohloff, if only using gears 6, 8, 10, 12 and 14. LOL. SA is with 46/ 17T now so I can go try going 46 mph down my fave hill again soon. ha. This 5w is WAY faster than my new 3 speed. I LOVE this hub again.

SHAME SHAME on SA for putting me and likely many others thru this horrible ORDEAL.
.....But OTOH, I would have struggled with 35 to 92 GI in Vietnam with the SA 5w. LOL
Well done. Your experience explains why the shifting function of these hubs often improves with use. These interfaces wear in over time and move more freely.
That said, the wide range version of the 5 speed is the most problematic of all versions I have worked with.
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Old 07-18-20, 11:41 AM
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Thanks Dan Burkhart. This hub gets me down the highway easier than anything I've had.
With my set up I have a super efficient middle gear like SS used 70%, with an uphill gear, headwind gear, tail wind gear and downhill flyer. I just don't get as tired as fast.
Imagine if I had it on a 30 bike + load. LOL. Then a couple days before, I was going down a dead end hill and decided to test my 2 drum brakes. 30 mph to dead stop in 30 or 32 feet I think. Very solid and they work like ABS, with a speck of skid.

=== So did you or Ascherer figure out if his SA 8 sp has a similar sticky key?

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Old 07-21-20, 10:53 AM
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Well, I'll bug you one more time. LOL. Yesterday I rode 107 miles on my 78 lb-er. GIs were 46/ 55/ 73.5/ 98/ 117.6. Clock time was 9:40 to 9:20. 7Hr36 moving, final avg. sagged to 14.0, the last 2 crowded crappy miles. I'm 66.5 years old also.

I had perfect weather for a ride south to Wetaskiwin, 45 miles away. The wind was a breeze, 4:00 angle tail wind going and a crosswind returning. At 45 miles I was at 14.72 avg. and just under 3 hours real time, BEST ever. Then I had a long lunch, 11 mile putter around and 90 minute visit with a lady. The avg sagged to 13.35 mph. 2 miles from home the avg was back up to 14.17. The road going was more rough and dirty. Coming home it was 95% good and all perfect and spotless the last 25 fast miles, WOW. I had a long ice-cream break at 67 miles too. My usual bonk point never came. At 80 miles I added a beautiful 4 mile MUP loop in Leduc.
=== I barely got tired except for my bum, very little cramps. Most of the way I was flying along 16+ mph. All I had to do in direct 3rd gear is move my legs and I was wizzing out at 17.6 mph. So I geared up to 4th a bunch and was going 20/ 21 on the flat. Didn't matter if there was a traffic breeze or not, on side streets. It's crazy how EASY this hub goes. ONLY this hub in my admittedly limited experience. Hills are another matter with 46 GI and 78 lbs of course. My last near century was on tour, Golden to Revelstoke BC, in 2018. That has 2 long cat 1 climbs and 3 miles walking, LOL.... Only one in 2017, 110 miles with a wicked east wind the whole way.
Yah I know lots can do that in 5:40 real time, but on under low 20s lb bikes for sure.
The SA RD5w is NOT just a city bike hub by any stretch.
===== EDIT
2 weeks later I rode a longest ever 133.66 mile loop in 12.5 hours clock time/ 9hr26 moving. I was at 16.08 avg at 59 miles, lunchtime. I was way less tired than usual on century+ mile rides.

Last edited by GamblerGORD53; 11-27-20 at 01:09 PM.
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Old 01-27-21, 04:05 AM
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@GamblerGORD53 Do you have any pictures of what you did?

My solution so far has been to solder two clutch springs together and put those in the hub with some nice and sticky Phil tenacious oil.
But I am always up for more improvements. I've been riding mine since spring and it's a nice little hub.




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