Solution: Inmotion V11 Suspension Rail Clunk/Play

[EUC_user]

As discussed here: https://forum.electricunicycle.org/topic/21006-v11-suspension-lubrication/page/2/?tab=comments#comment-359891

The following thread is about a solution to the excessive play which causes the clunking noise found in the Inmotion V11's suspension rails. This solution was proposed by @mrelwood in the following thread, albeit with "a slice or two cut from a beverage can:" https://forum.electricunicycle.org/topic/16554-inmotion-v11-2020/?do=findComment&comment=346266

I wasn't interested in messing around with the sharp edges of and/or cutting up an Alumin[i]um can. So, I instead decided to use a disposable plastic microwave container that came with a meal.

I then cut the slice into pieces to fit the black plastic rail guides.

Unfortunately, this was too thick and I couldn't even slide the Alumin[i]um rail back onto the EUC with only one spacer on one side installed.

This got me thinking back to my original thought about using Alumin[i]um foil but had discounted it as being way too thin. Well, it turns out it is the solution that is needed.

Four (4) sheets per side in fact.

I essentially took one (1) sheet and folded it in half (that accounts for two (2) sheets) and then folded it in half again (that accounts for four (4) sheets). From there, I cut it to the size of the black plastic rail guide and made a hole in the middle.

The hardest/longest part, aside from removing the pedals (these long T-handle Allen/hex wrenches make it easier: https://www.amazon.com/dp/B07Y44JV6S), was making the holes. It shouldn't take more than an hour to complete this. I applied this fix to all eight (8) black plastic rail guides.

It's okay if the center hole rips. The Alumin[i]um foil is easy enough to work with where you can press it back together with a small flathead screw driver.

When screwing the black plastic rail guides to the Alumin[i]um rails, remember that you don't need to use too much force. You risk stripping the plastic threads if you overtorque it.

Understand that it's mainly the force of the black painted Alumin[i]um damper housings against the black plastic rail guides that keeps them (the black plastic rail guides) mostly in place inside of the Alumin[i]um rails. The screws just keeps them in place.

You can see the Alumin[i]um foil here. The white residue on the black plastic rail guide is dry lubricant. I have since moved to white lithium grease.

Installed and assembled. Using some white lithium grease instead. There may be some resistance when sliding the rail back on but nothing that requires excessive force. Remember, your body weight (mass times gravity or mass times acceleration) is a much stronger force.

I am happy to report that there is no more clunking for me.

I took the wheel on a 45 mile (72.42 km) ride on Saturday and have not had any clunking. I did end up needing to walk the wheel the remaining 500 feet (152.4 m) to my car; I did previously use the wheel before the trek though.

Oh also, on iOS, that "Low battery safety mode" switch's logic in the Inmotion app (version 7.7.6) is inverted. Toggle switch On = Off, Toggle switch Off = On. That was a fun little revelation when I was 10 miles (16.09 km) away from my car riding down a bridge as the wheel started to heavily tilt backward, instructing me to get off. This setting can only be changed when you're in low battery mode too.

At any rate, the problem is solved. And if the Alumin[i]um foil compresses/flattens over time and/or the black plastic rail guides wear down, I can simply add another single layer or two of Alumin[i]um foil to each black plastic rail guide.

Thank you @mrelwood for the idea.

Edited March 20, 2021 by EUC_user

[MrMonoWheel]

For what it's worth, I'm currently rebuilding my v11 after straightening the rim and I used layers of scotch tape on the back of the sliders. 2 layers on each was perfect for removing all clunk while still sliding smoothly.