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Old 11-04-06, 09:49 AM   #1
greezychicken
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Installing Time Trial Brake Levers

I have a pair of Profile Design time trial handlebars and I'm trying to install some Nashbar brake levers on it. The levers aren't going in all the way with the expanding wedge plug and it looks like the bars are a little ovalized at the ends. They go about halfway in and I've tried hammering them. Does anyone have any suggestions on getting them in? Am I out of luck? Thanks.
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Old 11-04-06, 09:54 AM   #2
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Is the brake lever's set screw backed out all the way? Did you tighten the bolt without the lever on the bar any?
Can you close up the expansion plug on the brake lever at all?
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Old 11-04-06, 10:00 AM   #3
greezychicken
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With the expansion plug in and screwed, the lever's still about halfway in. The top part still sticks out.
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Old 11-04-06, 10:00 AM   #4
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I had the same problem with Profile Design levers and Scott mountain cowhorns. I had to trim the wedges at the bottom edge to get them all the way in. It has no effect on the function of the wedges.

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Old 11-04-06, 12:08 PM   #5
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MAke sure the wedge is not stuck on the body of the lever, in an expanded state. also, try putting an allen wrench in the bolt head and whacking that... stops the wedge getting pushed onto the lever & expanding.

If the bars are oval, you may be SOL. I don't know if they are.

Also, easy with that hammer. Al is not that hard to damage.
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Old 11-04-06, 12:47 PM   #6
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Do what I did. It works.
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