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Old 07-09-13, 05:38 PM
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Before you install brake cables and housing, can you manually squeeze the calipers by hand against the rims? Now let go. Do the calipers spring back? If so, then you've eliminated the overly tight pivot bolt as the issue. Next, when you say that you squeeze the brake lever and the cable end pops out, do you mean the cable ceases to be attached to the DiaCompe aero lever? Or something slid out of the Cross lever? You have a two lever system. There is housing between the cross lever and the aero lever. Hopefully, that is only taped to the handlebars now and not wrapped. Are all housing segments the right length? Do you have the housing ends cut square and capped properly? Does the brake cable slide smoothly inside the housing? Did you coat the metal cable in grease first before threaded it through the housing? And did you thread the cable correctly out of the aero lever and into housing? Those are things to check that should reveal what is wrong with your rear brake install.
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