freehub jiggle is caused by the "plastic" bushing used on the freehub assembly.

 

I've heard lots and lots of grousing about the nylon bushing...but this isn't my first set of Mavics. I've owned several sets, and have never had this issue. My other freehubs are solid, no wiggle, and they spin freely once clean and lubricated.

Is the thought that I just got a pair of lemon freehubs?

 

Yes but OP says his is brand new.

Didn't lose the washer did you?

 

Nope, washer is there; sitting atop the bearing where it should be.

 

I purchased the wheels used.

The freehub had a slight wiggle when I purchased the wheelset.

I got a new freehub.

New freehub has the same slight freeplay.

Asking the forum if there is anything I should be checking in terms of adjustment that I'm missing.

 

Every time I've seen a Ksyrium cassette wiggle, its the plastic bushing or the hub has worn at the spot that the plastic bushing wears against. Since the OP has a new freewheel, thus a new bushing I would be looking for wear on the hub. A micrometer will tell you everything you need to know. I've successfully used the Hub Doctor kit that fleabay has to fix this. As well, he sells oversize plastic bushings to accomodate worn hubs. It works quite well. I am still amazed that Mavic doesnt just adopt the same design and use a bearing there........I guess it will eat into their very small profit margin on these wheels........

 

from what I heard, Mavic used to use an actual bearing for this.

... where's maviczack to explain why the plastic bushing is better, aside from weight

 

So why the heck would a new one still have play...

Damaged hub seal?

Damaged axle?

Luck of the draw?

 

dunno.

Ask Maviczack. He's the Mavic Inc, USA Communications Guy

the only other thing I can think of... maybe remove the cassette and reinstall it?

 

OP sounds experienced. But just in case. It's not that a spacer was missed and it's the cassette, is it?

 

No spacer needed...it's an 11-speed hub and cassette. Everything's set solid.

goodboyr may be on to something with his thought about hub wear, but...the wheel had less than a couple months use, never in the rain, and wasn't very dirty at all when I disassembled it. I replaced the freehub just to eliminate what I thought were the most probable variables.

 

Like I said. If you "mic" the diameter of the hub where it interfaces with the bushing and then measure the diameter of the bushing you will find too much clearance. Hub doctor sells kits with oversize versions of the bushing to compensate for a worn hub surface.

 

So here's the magic question, of course: What is an acceptable clearance range?

 

You can buy 3 thou and 5 thou versions.

 

Goodboyr's right, no doubt it's hub bushing or journal wear, I've had it on two sets of Mavics. Those wheels were probably ridden a little more than you were told or got contaminated pretty quickly...

The Hubdoctor kit that replaces the plastic bushing with a ceramic ball bearing is the way to go, it's a permanent fix that will give you lower rolling resistance, and you dont have to worry about sizing a new bushing to the wear on the journal.