Fixing a Mavic Ksyrium Pro Disc Freehub

Mavic build generally builds great wheels but some of their freehubs are badly designed. The issue in my case was part number 6/7 of the Mavic Ksyrium Pro Disc that I use (Picture below taken from Mavic Manual).

Instead of an roller bearing bearing Mavic decided to use a plastic sleeve bearing that, in my case, wears out every 1000 km (the shaft diameter is exactly 25 mm).

As a result of that the whole cassette can move somewhere from 0.5 to 1 mm radially, which under load leads to tilting as shown below:

This in turn makes the whole drivetrain noisy and wobbly because every revolution the cain moves slightly sideways on the sprockets.

Luckily there is space for a real roller bearing in the freehub :) One example is the 25357 25x32x7 roller bearing that fits just perfect. With access to a lathe an easy job:

The steel below the sleeve is surface-hardened, use the proper tool to get through that layer.

The result is almost zero play and no plastic ring that can wear out :)