dura ace 11-25 11 speed cassette

[smooth1978]

hi. first time poster, so play nicely!!


I recently upgraded to a 2013 cannondale evo dura ace di2. awesome bike, but on the second ride I noticed a noise from the cassette whilst applying power through the cranks. the noise was in the 3rd, 4th and 5th cogs (from the top) which is the section joined by a new carbon carrier.

after many tests the lbs confirmed that the noise was definitely coming from these cogs. shimano said they hadn't heard of the issue but sent a replacement cassette. the lbs fitted the cassette and I did a few passes up the footpath applying power as I rode past the mechanic. the noise was still there, and when I really powered through the cranks I actually smashed the carbon carrier to pieces.

shimano say it might be a bad batch and they are now sending another cassette. I know this is only early days for 9000 and 9070 but I was wondering if anyone else knows of any similar issues.

the bike is 63cm and I am 193cm and 94kg.

a bit of an open ended post but I just wanted to know if anyone has had (or heard of) and similar issues.

cheers

[smooth1978]

For those who care.... an update. I have posted the following on weight weenies where there are people with similar issues.

Righteo



I have been through five (5) 11 speed dura ace cassette's (all supplied by Shimano - who are aware of this problem through several stores in Australia). Cassette's were fitted by the LBS mechanic and I tested with him there.

Story to date
- Brand new SuperSix Evo Hi-Mod di2
- Noise in the cassette (11-25). To identify this, we swapped out my back wheel for a used wheel which had a 10 speed dura ace cassette. Tested through similar gears and no noise present. Took the 10 speed cassette of the used wheel, and put it on my new wheel (mavic 11 speed) with suitable spacers and tested. No noise apparent. Put the 11 speed dura ace cassette back onto my mavic wheel and the noise is again present. FEELING PRETTY CONFIDENT that it's the cassette.
- Shimano send a replacement cassette (11-25) which is fitted to my wheel. Noise is still present. At this stage I am riding up a slight incline, past the LBS mechanic and powering hard through the cranks as I pass him. He, i and other onlookers can clearly hear the noise! When I really crank down, the carbon section gives way...SMASHED.
-A guy at the LBS has a Giant tcr with 9000 fitted. I jump on this bike and I can replicate the sound on the carbon section of the cassette (but not the top 2 cogs).
-At this stage I will point out that there is also a similar noise on the top 2 cogs (on four of the tested cassette's, not the cassette fitted to the TCR), but as these are not joined by carbon I don't feel as worried about a catastrophic failure!!!
-Shimano send two (2) new cassette's (a 11-25 and 11-28). Both are fitted and tried, with the head mechanic, and other mechanics listening as I apply power whilst riding past them. Noise still there!
-Getting very frustrated.
-Mechanic starts to think outside the square...... Now that we have so many cassette's... he removed the carbon carrier section (cogs 3, 4 & 5) and replaces them with the same sized tiagra cogs, and spaces them correctly with spacers taken from the defective dura ace cassette's. And there we go....NO NOISE on those cogs.... But still a similar noise on the top two cogs (as I said before, I wasn't as concerned by this noise as I don't see the same potential for catastrophic failure as with the carbon carrier.
-In a bid to eliminate the noise in the top 2 cogs I am going to try two things (I have a 23-25 arrangement, and a 25-28 arrangement) to the different cogs. I will simply apply a liberal amount of lubrication to the 6 rivets holding these 2 cogs together and test. With the other, I will centre punch and then apply some loctite to each rivet.
If this works, maybe the noise in the carbon section was loose rivets, or rivets that have not been pressed enough in the shimano factory.

None of the above is a long term solution, and Shimano still need to address what is becoming a common problem.

Anyway, I'm sick of typing. I will provide another update if I have any luck.

Cheers

[darkelf921]

Let us know how you go and if you get any resolution.

[jacks1071]

There were after market 11sp cassettes on display at the Taipei Bike Show, maybe finding one of them would be a short-term solution?

I wasn't paying much attention to them as I always prefer to use the groupset cassette but I think RECON might have been one of the ones I saw.

http://www.recon-harry.com.tw/

[doggatas]

Hey mate I have also smashed the carbon mid-spider on an 11-25 cassette. Was replaced under warranty but with a 12-25 ( happy to forgo the 11 for the 18) and haven't had an issue yet. I have also purchased a 12-28 (for the Wellington TT, I think you're local so you'll know what I'm talking about) and have ridden that hard in the 23-21-19 without issue.

I did have a few noises at some stage but I removed cassette and re-torqued to 40, noise gone. Perhaps the locking rings are coming loose somehow.

Will keep you updated if you like.

P.S hot bike btw, I'm gonna get a di2 kit for my bike when they a readily available and saved enough cash.

[jacks1071]

Wow this is really unlike Shimano to have reliability issues.

To the people who've broken the spacers, do you know 100% for sure that your lock-rings were torqued to spec? Ie. Did you do it yourself or see it done?

[smooth1978]

thanks doggatas. yeah, I'm a hobart local. was that you I saw at the lights the orher day when I was trying to smash more cassettes?

ive got a 12-25 on the way so fingers crossed. if I have success with that I'll also get a 12-28 (riding from queenstown to hobart in june so the 28 will come in handy).


I'm loving the bike and the di2. it's totally unnecessary, but it's very nice.

goodluck in the Wellington TT.