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Old 09-16-12, 09:09 AM   #1
jhess74
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Sun Tour bar end shifters - won't tighten securely in handlebar

I'm tearing down and rebuilding an old Takara, and am running into a problem with the bar end shifters. I removed them from the original drop bars and am trying to install them into a similar set of old drops that are in better shape. The problem is, they won't tighten up in the bars no matter how the screws are tightened/loosened - the expander just sits still and they fall right out.

Does anyone have any insight into what I'm doing wrong? It seems like this process should be pretty straightforward, but clearly I'm missing something. Thanks!
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Old 09-16-12, 09:26 AM   #2
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Take them apart, grease the threads the on the bolt, that screws into the body.

you tighten that CCW when it goes headfirst into the bar..
might try a piece of cotton tape where you put the shifters in the bars .
So the segments that expand, should not rotate when you turn the bolt.
to wedge them outward..

Then assemble the rest of the lever, and fit the cable, and housing then wrap the bars

after taping the housing down, in a smooth curved line..

opinions vary, as to how the housing run goes to the frame stop..

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Old 09-16-12, 09:27 AM   #3
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Originally Posted by jhess74 View Post
I'm tearing down and rebuilding an old Takara, and am running into a problem with the bar end shifters. I removed them from the original drop bars and am trying to install them into a similar set of old drops that are in better shape. The problem is, they won't tighten up in the bars no matter how the screws are tightened/loosened - the expander just sits still and they fall right out.

Does anyone have any insight into what I'm doing wrong? It seems like this process should be pretty straightforward, but clearly I'm missing something. Thanks!
I don't know if this will help you, but I had a similar if not identical problem. I had to adjust the screws so the expansion for the pod just barely fit into the bars, so when it went in I was actually slightly forcing it, after that they tightened right up.. and just to be sure, you're tightening counter clockwise?
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Old 09-16-12, 10:32 AM   #4
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Just checking that you understand that you first have to remove the lever assembly via the screw and nut on the side. That allows access to the recessed allen key screw that controls the expander unit. You turn this nut to the left, pulling the cone into the body and spreading the wedges. Before you do any of this Grease the expansion screw threads, and the conical parts where the wedges ride as they expand.

Once the body is properly oriented and tight to the bar, then you reinstall the lever unit, and adjust the tension.
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