ElMono

When I try to shift from the 2nd largest cog to the largest cog, the shift lever feels like it is stuck. I can't seem to position the RD pulley beneath the large cog, with limit screws with the RD cable connected or by manually moving the RD. I also tested shifting levers and they seem to index correctly in both up and down (verified by checking for cable motion while shifting with RD cable disconnected).

Additional info: the RD and shifter are from the Ultegra 6500 series, the wheelset are the Performance Bike Titan, and the frame is a 2004 Kona Jake

Any suggestions?

Al1943

Was all of the cable out of the shifter with the shifter in the small cog position when the cable was attached? If you shift to the smallest cog and continue flipping the smaller shift lever there should be no slack in the cable.

Does the cable have enough tension? The derailleur should take the chain from the smallest cog to the next smallest cog on the first click.

oldbobcat

Can you get the chain up to that cog just by pulling on the cable (bowstring method)? If you can't, then your "L" limit screw is too tight. Loosen it enough so you can shift to the big cog by pulling on the cable, but no so much that you pull the chain or the derailleur into the spokes.. Then, if you can't shift onto that cog using the control lever, go to work on the cable tension. Shift down to the smallest cog, check the "H" limit screw, loosen both barrel adjusters almost completely (if you have two on the rear derailleur cable), loosen the pinch bolt on the derailleur, and pull the slack and re-tighten the pinch bolt. Adjust cable tension so you can ratchet up and down the cassette, fine-tune the limit screws, and you're done.

Yan 

Loosen the low limit screw.

HillRider

Start the setup from scratch.

1. Disconnect the shift cable at the rear derailleur

2. Try shifting the rear derailleur by hand all the way to the largest cog while turning the crank by hand.

3. If it won't shift to the biggest cog, loosen the low limit screw until it will but not so far as to spill the chain inside. Let the derailleur relax and shift it by hand several times to be sure the shift is solid but not too far.

4. While turning the crank, let the derailleur relax to be sure it will shift solidly to the smallest cog with out spilling the chain to the outside. Adjust the high limit screw if necessary.

5. Repeat steps 3-4 several times to be sure the limit screws are correctly set.

6. Shift the brifter's inner lever multiple times to be sure it is in the highest gear position.

7. Reattach the cable to the rear derailleur and pull out all of the slack before tightening the bolt. Be sure the cable is attached to the proper side of the bolt.

8. Try to shift from the smallest cog to the second smallest. Use the rear derailleur's adjusting barrel as needed until the shift is quick and repeatable with no grinding on either side.

9. When the 1 to 2 shift is good, try shifting all the way across the cassette, including into the largest cog. It should work properly or with only very slight adjustment of the cable slack. Do not readjust the limit screws at this point as they are already set correctly.

If it still won't shift to the largest cog, either your brifter is defective or the derailleur hanger alignment is off.

ElMono

Thanks for the help. Got it working! I think the problem was caused from me putting too much tension on the cable and/or not in correctly setting the L screw.