Vasa Ergometer Pulley Upgrade

Upgrade Vasa Ergometer (https://vasatrainer.com) drive and rewind pulleys to smoother, lower friction pulleys. Improves rewind cord responsiveness and reduces localized drive and rewind cord wear. If your ergometer is more than a year old, this upgrade can dramatically smooth its operation. Stock bearings are simple metal sleeves that have more and more friction as they age. Even with cleaning and lubrication, stock sleeve bearings quickly degrade in functionality compared to roller bearings.

This pulley upgrade provides...

• Larger diameter drive pulley to reduce drive cord flex
• Real ball bearings instead of stock sleeve bushings that wear, gum up, and seize
• Lower friction pulley bearings allow ENTIRE rewind cord to stretch rather than just part of cord.
• Longer service interval at reduced friction.
• Improved pulley profiles to match round cords

Additional parts required

16 x R4-2RS (1/4"x5/8"x0.196") bearings
https://www.amazon.com/gp/product/B077SPSVD1

6 x 608-2RS (8mm x 22mm x 7mm) bearings https://www.amazon.com/gp/product/B07C6FL8TW

2 x 1/4 inch bolt, 3/4 inch length
2 x 1/4 inch nut
4 x 1/4 inch washers 1/2 to 5/8 inch diameter

Sanding of drive cord bracket pulley is easier with a 3 inch x 1/4 bolt, washers and nut combined with printed sanding clamp ends.

For a complete pulley system overhaul, print...

Preferably in polycarbonate or nylon
Drive cord bracket pulley (2 needed)

Remainder of parts can be in PETG...
Drive cord pulley sanding clamp end (2 needed)
Rewind stack pulley (16 needed)
Rewind director pulley (2 needed)
Rewind stack spacers (20 needed)
Drive cord bolt sleeve (2 needed)