I’ve had my Wahoo KICKR Climb since launch, and overall it’s been a great piece of equipment, but I’ve run into a recurring issue over time.
The first time it started slipping, Wahoo replaced the unit entirely (great support), although I had to cover the international shipping to Brazil.
Since then, I’ve been doing regular maintenance. I ride consistently — around 10 hours per week, sometimes reaching 20 hours/week — so the unit gets a fair amount of use.
One recurring issue has been the belt, which I’ve needed to replace roughly once per year.
Now I’m facing a new problem:
The bronze worm gear (crown gear) inside the actuator appears to be worn out, likely due to long-term use and load.
Given that replacement parts are not readily available, I’ll be taking the worm screw and bronze gear to a machine shop to have a new part manufactured to spec.
Just sharing this here in case others with older Climb units start seeing similar sy
mptoms.
Hi Rogerio,
do you have a how-to for swapping the belt?
I followed a tutorial I found on YouTube at the time; it’s not that complicated. I’ve already changed the belt several times. I’m light, 68kg, but I cycle a lot indoors.
After almost 5 years of heavy use, the bronze gear on my Wahoo KICKR Climb finally started to wear out — most likely because it spends most of its life around the “zero” position, where the load and movement are constantly concentrated.
The good news is that the damage was limited to the crown gear itself, and a brand new one is already being machined by a local lathe shop for around $90.
I’ll be doing the full installation myself and will post the complete rebuild process and final results here soon. 
Well, after installing the bronze gear, I reassembled the entire Wahoo Climb system, and now it’s time to enjoy Zwift again. It’s worth remembering that I had already needed to hire a machinist to make a custom tensioner for my Wahoo Kickr trainer, and now I’ve also rebuilt and refinished my Climb. Both of these stories are also documented here in this community.
