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Old 02-25-11, 09:11 AM   #1
maggiemaggie
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Inverse brake lever installation- help!

So I recently installed Dia Compe inverse brake levers (22.2mm) on my VO Montmartre handlebars (also 22.2mm). Now that I've routed the cables and hooked up the brakes, if I pull the brake lever, the entire thing starts pulling away from the end of the handlebar and the lever goes slack. I think it is because the mechanism does not fit inside the handlebar snugly enough.

My question is: why is it doing this even though the sizing is correct, and is there any way to make the fit tighter? I've wound the nut down on the bolt as far as I can using my own strength and am about at my wit's end!
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Old 02-25-11, 11:20 AM   #2
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I think it might help if you gave more details

Some specifics in your installation procedure in particular would help.

The bars and levers are definately compatible sizewise, but normally I`d expect to tighten a screw after installing the expansion plug.

You mention tightening a nut and still not ending up with enough retention force. Are you attempting to adjust the fit of these BEFORE inserting them in the barends - or AFTER fitting them in the barendss?
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Old 02-25-11, 11:59 AM   #3
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The lever plug that fits the bar is expandable. Did you tighten it properly? This is usually done with the cable off, some brands also require that you take the lever out of the body for access to the center bolt.
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Old 02-25-11, 01:28 PM   #4
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If ID of end of bar is so large that the expansion bolt bottoms out,
before it expands the attached part within the handle bar tube,
then you can shim the inside of the bar tube
till it's small enough to grip within the tube before the screw bottoms out,
trying to expand within the new smaller ID of the shim, inside the larger tube..
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Old 02-25-11, 02:10 PM   #5
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did you use a ferrule on the end of the housing that goes into the brake lever?
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Old 02-25-11, 02:15 PM   #6
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Hi Maggie:

I just tried the 22.2mm version of the D/C inverse levers on a 22.2mm Montmarte handlebar. It works just fine. Can you take some photos of the part of the lever that fits into the end of the bar? Maybe there's a part missing or something.
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