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Old 09-05-10, 02:01 PM   #1
Zaphod Beeblebrox 
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Barcon Repair?

Is it possible to repair Suntour Barcons? Mine stopped ratcheting and now provide no resistance.


I just got done routing new housing under existing sew-on Leather bar wrap...don't ask me how hard that was...just ask the blisters on my thumbs. And put the barcons in...the ratchet sounded fine when i was holding it in my hand...hook it all up and go to shift it and it wont hold its position. It just slips right back to the bottom. No ratcheting sounds.

Having run cable and everything for these barcons, I'm not going back now...Can I fix these and restore the ratchet mechanism? If not, anybody got some bar end shifters (friction) they wanna get rid of?
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Old 09-05-10, 02:25 PM   #2
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are they tight enough? there is a thread where someone took either these or power ratchet shifters apart. I am not sure I would, I may really spray the you know what out of them wit WD40 then triflow
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Old 09-05-10, 02:49 PM   #3
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I had the same problem after putting on a new rear derailler. I discovered I just needed to tighten the screw on the outside to compensate for the stronger spring on the new derailler.
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Old 09-05-10, 03:20 PM   #4
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+1. I think you need to just tighten them up. Once they're installed there's no reason to have to undo anytihng other than undoing the inner wire from the derailleur.
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Old 09-05-10, 04:12 PM   #5
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If all else fails I have one with a broken lever that I got at the co-op for $1, my intention being to use it for parts. It's yours if you need it. You might be able to use some of the guts to repair yours. But, I would do the shoot it with WD-40 first. Wish you were close, we could run it through the ultrasonic too There is a diagram online too:



Might help with your dis/reassembly.
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Old 09-05-10, 04:24 PM   #6
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Just start by tightening screw #13 on the diagram above, there really isn't much else it could be unless something in the ratcheting mechanism (#2, 3, or 7) has suddenly gone bad. I seriously doubt thats the case since it was working fine prior to this. I discourage taking them apart. They are a pain to put back together.
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Old 09-05-10, 05:28 PM   #7
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Originally Posted by CMC SanDiego View Post
Just start by tightening screw #13 on the diagram above, there really isn't much else it could be unless something in the ratcheting mechanism (#2, 3, or 7) has suddenly gone bad. I seriously doubt thats the case since it was working fine prior to this. I discourage taking them apart. They are a pain to put back together.
I did a thread about taking them apart- I'm not the most mechanically inclined- however I had no problem in disassembly and reassembly- My thread was in the Bike Mechanics section. Probably from early spring.
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Old 09-05-10, 05:42 PM   #8
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http://www.bikeforums.net/showthread...=#post10692006
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Old 09-06-10, 09:33 AM   #9
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Thanks for the link, and Keith thanks for the Diagram...

A little more tinkering and it appears I'm missing a couple of parts although I'm having trouble imagining they are critical.

I appear to be missing nut #14 and washer #5 (the rightmost one that slides onto #4 first)

I'm thinking the problem is in the ratchet itself (I looked at it but it looks fine)...I say that because when I hold the lever/ratchet mech. in my hand and turn the post by hand the ratchet doesn't work. If I put the mech. in the bar end pod and tighten the heck out of it, it will work until I put the resistance from the Derailleur on it and then it fails.

I think it might just be shot
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Old 09-06-10, 09:36 AM   #10
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It's been a long time since I messed with these, but I'm pretty sure you need the #14 nut
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Old 09-06-10, 09:41 AM   #11
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A little more tinkering and it appears I'm missing a couple of parts although I'm having trouble imagining they are critical.
Boy, have I heard and said this before and it is the beginning of "it won't work", as often as not.
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Old 09-06-10, 09:43 AM   #12
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I suppose if it didn't need those parts they wouldn't have included them in the design, huh?
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Old 09-06-10, 11:37 AM   #13
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I pulled the #14 nut off the opposite lever and hooked it up... Perfect.

Thanks folks

So, note to anyone who's doing this in the future...make sure you've got all the parts.
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Old 09-06-10, 11:51 AM   #14
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and tighten the heck out of it, it will work
Thats because your missing washer #5 and nut #14. You can work around nut #14 but grinding/filing to fit a nut with the appropriate threads. Finding a suitable washer may be difficult, I'd take the one from the other side and hit up HD, Lowes and Ace hardware. As long as the thickness and inner hole diamter are close your good to go. If the OD is too big just grind it down.
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Old 09-06-10, 12:02 PM   #15
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I suppose if it didn't need those parts they wouldn't have included them in the design, huh?
I laughed out loud at this. Not out of mirth, but because it was funny.
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Old 09-06-10, 12:03 PM   #16
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Thats because your missing washer #5 and nut #14. You can work around nut #14 but grinding/filing to fit a nut with the appropriate threads. Finding a suitable washer may be difficult, I'd take the one from the other side and hit up HD, Lowes and Ace hardware. As long as the thickness and inner hole diamter are close your good to go. If the OD is too big just grind it down.
^+1^, and be sure to look in the PLUMBING section, maybe not the big boxers but a real plumbing shop: I have often found thin brass washers sold as stem shims or "friction rings" to be very useful in repairing shifters and RDs. These are washers but not called washers in the plumbing jargon.
And I've never had a SunTour barcon break on me (yet), they are very robust...but the #13 bolt and #14 nut are critical to how the ratchet performs, once you get it set right the #15 locknut should hold the setting, but a little blue Loctite on #15 is a great help, and helps prevent loss, too.
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Old 09-06-10, 04:36 PM   #17
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yep, I hit up Lowes just a lil while ago and I've got it all squared away now. Just a standard metric nut.
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Old 09-06-10, 04:43 PM   #18
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yep, I hit up Lowes just a lil while ago and I've got it all squared away now. Just a standard metric nut.
Gotta love these internetz don'tcha?
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Old 09-06-10, 09:19 PM   #19
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Well, looks like you've got quite a bit of really good information regarding the issue.....so, I'll just say this: I totally wish I had used your username before you did!!!!
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