How to Install, Adjust, and Maintain the Zipp 808 NSW Wheelset

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The Zipp 808 NSW [paid link] is a high-performance carbon wheelset designed for aerodynamic efficiency, stiffness, and speed. Whether you are a triathlete or a time trial specialist, these wheels are built to maximize speed and performance. However, proper installation, adjustment, and maintenance are essential to ensure longevity and optimal riding experience.

This guide provides a detailed step-by-step process to help you correctly install, adjust, and maintain your Zipp 808 NSW [paid link] wheels.

Tools Required

  • Torque wrench [paid link]
  • 4mm and 5mm hex keys [paid link]
  • Cassette lockring tool [paid link]
  • Chain whip
  • Tire levers
  • Pump with a pressure gauge
  • Tubeless sealant (if applicable)
  • Spoke tension meter (for wheel truing)

1. Installation of the Zipp 808 NSW Wheelset

1.1 Preparing Your Bike for Installation

Before installing your Zipp 808 NSW [paid link] wheels, ensure that:

  • Your frame and fork dropouts are clean and free from debris.
  • The brake calipers (rim brake version) or disc rotors (disc brake version) are aligned properly.
  • You have the correct freehub body for your cassette (Shimano, SRAM, or Campagnolo).

1.2 Installing the Cassette

  1. Secure the Zipp 808 [paid link] NSW rear wheel in a work stand.
  2. Place the cassette onto the freehub body, ensuring the splines align.
  3. Use a cassette lockring tool [paid link] to tighten the lockring to the manufacturer’s recommended torque (usually 40Nm).

1.3 Mounting the Tires

The Zipp 808 [paid link] NSW wheels are compatible with both clincher and tubeless-ready tires.

  • For clincher tires:
    1. Insert the inner tube into the tire.
    2. Use tire levers to seat the bead onto the rim carefully.
    3. Inflate the tube slightly before fully securing the bead.
  • For tubeless tires:
    1. Install one bead onto the rim.
    2. Pour the recommended amount of tubeless sealant into the tire.
    3. Fully seat the second bead and use a high-pressure pump to snap the bead into place.

1.4 Attaching the Wheels to the Bike

  1. Insert the Zipp 808 [paid link] NSW front wheel into the fork dropouts and the rear wheel into the frame dropouts.
  2. Tighten the quick-release skewer or thru-axle to the specified torque.
  3. Spin the wheels to ensure proper alignment.

2. Adjusting the Zipp 808 NSW Wheelset

2.1 Brake Adjustment

For Rim Brake Models:

  • Ensure that the brake pads contact the braking surface evenly.
  • Adjust the calipers using a 4mm hex key if needed.
  • Maintain a clearance of 1-2mm between the brake pads and rim.

For Disc Brake Models:

  • Check for rotor rubbing. If needed, loosen the caliper bolts, squeeze the brake lever, and retighten the bolts.
  • If the rotor is bent, use a rotor truing tool to correct it.

2.2 Checking Spoke Tension

  • The Zipp 808 NSW wheels are built with Sapim CX-Ray spokes for optimal tension balance.
  • Use a spoke tension meter to verify that all spokes are evenly tensioned.
  • If necessary, make small ¼-turn adjustments to even out the tension.

2.3 Hub Adjustment

  • The Axial Clutch 2.0 freehub system in the Zipp 808 NSW requires minimal maintenance, but periodic checks ensure smooth performance.
  • If you experience excessive lateral play, adjust the preload collar using a 5mm hex key [paid link].

3. Maintenance of the Zipp 808 NSW Wheelset

3.1 Regular Cleaning and Inspection

  • Use warm soapy water and a soft brush to clean the wheels.
  • Avoid pressure washing, which can force water into the hubs.
  • Inspect for cracks, loose spokes, or rim damage after rides.

3.2 Freehub and Hub Bearing Maintenance

  • Every 3,000-5,000 km, remove the freehub body and clean it with a degreaser.
  • Apply light grease to the pawls and reassemble.
  • If you notice rough rotation, replace the ceramic bearings.

3.3 Truing the Wheels

  • Place the wheel in a truing stand and check for lateral or radial deviation.
  • Adjust spoke tension in small increments using a spoke wrench.
  • Ensure even tension across all spokes to prevent stress points.

3.4 Tire and Sealant Replacement

  • Clincher tires should be replaced when tread wear becomes visible.
  • Tubeless tires require fresh sealant every 2-3 months.

4. Troubleshooting Common Issues

4.1 Noisy Freehub

  • If the Axial Clutch 2.0 freehub sounds excessively loud, clean and re-grease the pawls and ratchet mechanism.

4.2 Brake Rubbing

  • Adjust the calipers and check for any misalignment in the rotor (disc brake) or pads (rim brake).

4.3 Unstable Handling

  • Check spoke tension and ensure tires are seated correctly.
  • If instability persists, ensure proper torque on thru-axles or quick-release skewers.

5. Comparing the Zipp 808 NSW to Similar Models

Zipp 808 NSW vs. Zipp 404 NSW

  • 808 NSW: Deeper 82mm rim, optimized for max aerodynamic gains.
  • 404 NSW [paid link]: Shallower 58mm rim, better for climbing and crosswinds.

Zipp 808 NSW vs. Enve SES 7.8

  • Zipp 808 NSW: More aerodynamic with improved lateral stiffness.
  • Enve SES 7.8: Slightly lighter, better suited for mixed conditions.

Conclusion

The Zipp 808 NSW is an elite racing wheelset that demands proper installation, precise adjustment, and regular maintenance. By following the steps outlined in this guide, you can maximize performance and longevity, ensuring that your Zipp 808 NSW wheels remain in peak condition for every race or training ride.