Join Date: Apr 2009
Location: New Rochelle, NY
Bikes: too many bikes from 1967 10s (5x2)Frejus to a Sumitomo Ti/Chorus aluminum 10s (10x2), plus one non-susp mtn bike I use as my commuter
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I built hundreds of these levers and it's very simple if you remember 2 key steps. Rember that you're trying to engage the thumblever bushing into it's mating notch on the main shaft.
1- after assembling on the thumblever, but before engaging the bushing be sure to shift the lever all the way to the low hear position (finger paddle), which is the slack position for the spiral spring.
2- you need to support the center shaft so that when you're pushing down on the thumblever bushing you don't push the shaft down and have nothing to engage,
Build levers on 5/16" or so rod stood in a vise on which to rest the shaft, so you can push down on the body to keep the other end of the shaft up. Also since this is new for you position the thumb lever bushing without the spiral spring and use a Philips screwdriver to rotate it until it engages, make a note of the orientation so you'll know where to look for engagement when you're doing it for real with the spring is on.
Pop it loose, drop the spiral spring on turn the bushing so the spring engages it's slot then use the Philips to turn the bushing about 3/8 turn to where it'll engage the other end of the shaft, when you feel the slot push down (be sure you're also pushing the entire lever body down so the shaft is pushed up by the vise support) and drop it in about 2mm into the slot.
Now you can let go and it'll all hold together by itself, carefully add the spring cover, and drop in the locking screw and without pushing the shaft back out tighten the screw.
It's easy, and I could have rebuilt 2 levers in the time it took to type this.
An ounce of diagnosis is worth a pound of cure.
“Never argue with an idiot. He will only bring you down to his level and beat you with experience.”, George Carlin
“One accurate measurement is worth a thousand expert opinions”
- Adm Grace Murray Hopper - USN
WARNING, I'm from New York. Thin skinned people should maintain safe distance
Last edited by FBinNY; 05-05-10 at 09:13 AM.