Techs-Mechs: Campy Lever Rebuild- Update

by Mr Van P on Aug 3, 2009 2:16 PM EDT Comment 7 comments

I ordered alloy spring carriers,all the g springs, one teflon-coated washer for the right shifter and did the rebuild on both levers. I recabled the bike and took it out of a spin. The rebuild was definitely the ticket since the indexing is back to normal and the shifting feels like it's back to normal. HOWEVER, on my right shifter when I am shifting to one of my middle cogs (either the 4th to 5th or 5th to 6th, I didn't count it out, but lets just say in the middle), I am getting this ghost click and then I need to push the lever again to get it to shift. The ghost click does not feel at all metallic but more like a plastic on plastic. Also this is just with the finger shifter and not the thumb bar. Any thoughts? I plan on taking it all apart again until I can get it right.

When I did the rebuilds I did not remove the brake lever (although the video shows this as part of the process), and I am not 100% sure I have the tension right on coil spring (although it seems ok). I installed the Nokon cables and housing and I know those can be a little dicey getting all the beads and liner just right, but I ran the derailleurs through quite a workout and don't think the problem is cable related. I would appreciate any thoughts you guys might have on what could be causing the extra click.

Thanks

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Make sure you tension the hell out of the spring.

I’ve had weird similar problems with my centaur and the arm on the spring carrier was broken but you would’ve noticed that in your rebuild.

by brunopitton on Aug 3, 2009 6:38 PM EDT reply actions 0 recs

i tend to think it's the coil spring. any trick to getting that sucker tight?

The video shows this process starting with the paddle shifting all the way to what would be the largest cog, but then it shows somekind of winding motion, but as soon as I let go to add the washer and bolt it loosens a bit.

by Mr Van P on Aug 3, 2009 8:06 PM EDT via mobile up reply actions 0 recs

As a Campy ProShop Mechanic

I think the above the problem. It is really tricky. Definitely remove the lever and post it on a bench vise on an allen key. This will give you proper leverage.
The only other poss is you have mixed up some of the wide and narrow spacers in the cassette, but that would be visually obvious.
Bruno’s comment can be true, but not every generation has the post on the spring carrier.

Keep trying

by MavicMoto on Aug 4, 2009 7:49 AM EDT up reply actions 0 recs

yeah, I tried winding it up

a little tighter last night and it is better, but there is still that one phantom shift from the 5th to 6th cog. The left one could probably be tighter too. I will try it the way you suggested. I would really like to clean behind the lever anyway since it is pretty gunked up.

by Mr Van P on Aug 4, 2009 9:22 AM EDT up reply actions 0 recs