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SRAM 8-speed cassette reassembly

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SRAM 8-speed cassette reassembly

Old 11-23-08, 06:18 PM
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blue steal
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SRAM 8-speed cassette reassembly

A friend of mine asked if I would fix his wheel. He had broken a spoke, so I told him to go to the bike shop and have them cut a spoke and I would install it and true his wheel. I do quite a bit of broken spoke repair work and truing of wheels for the bike club. I removed the cassette, (to take off his dork disk), adjusted the cones, (bearing were loose), installed the spoke and trued up the wheel.
Here is my problem, for the life of me I can't seem to put the SRAM 8-speed cassette back together and lock it down with the lock ring. For some reason after each cog and spacer is put back on there is not enough room to start the lock ring to thread. I am used to Shimano cassetes ,(one piece units most of the time), but this one is really driving me crazy.
Any suggestions would be welcomed.
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Old 11-23-08, 06:28 PM
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could be the last cog has a built in spacer and your using one? got them all lined up right? I found the two biggest cogs can be a different thickness and need a thinner ring or something like that I remember having the same problem.
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Old 11-23-08, 06:34 PM
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I am using all the spacers I started with. cog/spacer/cog/spacer/etc., but the last three cogs did not use a spacer and the smallest cog seems to "nessle" ( fit slightly inside the next to last cog). They seems to line up okay....each spacer has a set of slighly raised pins that fit into the cog on each side of it. Seems to be off by maybe 2mm, just enough to be able to start threading in the lock ring.
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Old 11-23-08, 08:03 PM
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My experience is with lower end Shimano cassettes, but I think I know what the problem is-
I've found the spacers will compress a bit, extruding? little ridges. IF these ridges don't line up EXACTLY with the little depressions that caused them, the spacers will "act" thicker.

Using a piece of sand paper or emery cloth laid flat on a hard surface, give each spacer a couple strokes on each side to remove the high spots.
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Old 11-23-08, 08:48 PM
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I'll give that a try tomorrow. Sounds like that just might be it. All the cogs and spacers were extremely gunked up with maybe 6 years worth of crap. I told my friend that I only would do the spoke replacement and truing, but the cleaning of cogs, etc., and regreasing hub bearings was up to him.
I also noticed that a small pin (bolt) fell out when the cassette, (cogs), came off. It is, I think designed to hold all the cogs together. Do you think this piece is really needed?
Thanks for your help.
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Old 11-24-08, 03:22 PM
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no you dont need the bolt, I'm guessing that the nut to it is non-existant like mine was, just cinch the lock nut down and all will be well...You are right it was designed to hold the cluster together, but as long as you know how it goes back together you are OK . the gears HAVE to go back on the splined hub, and mine would only go one way, so no screw-ups were possible.
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Old 11-25-08, 12:17 PM
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I don't have any experience with SRAM cassettes, but it could be a spacer alignment thing. The one that goes on after the assembly (if there is one) may have notches cut out for the ends of the bolts and if you get it on the wrong way, it may not sit flat against the cog. Also make sure the raised pins are aligned property and are not causing the spacers to not sit flush. Also check that the cogs that "nessle" are doing that.
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Old 11-25-08, 02:14 PM
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Update: My friend cleaned up all the sprockets, ("cogs"), and spacers, lined them all up with the small bolt, which inserted from the largest sprocket and threaded into the smallest one. The now assembled cassette went back onto the spindle and was secured with the cassette lock ring tool.
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