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Brake cable housing liner coming out?

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Brake cable housing liner coming out?

Old 05-16-16, 05:07 PM
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gary2112
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Brake cable housing liner coming out?

I was wondering if anyone had experience with this issue. I have a Specialized Tricross that has Ramhorn bars and has supplementary brake levers on the flat part of the handlebars. On the left supplementary lever, every time I engage the brakes it exposes a little more of what looks like spiral wound steel tubing from inside the black cable liner, causing the lever to stick. At this point, because of this exposed liner the brake handle has a loose play of about 5/8" or more before engaging. The bike is BRAND new...just bought it unused, new but old stock from a dealer a couple of weeks ago.

Is that something I could take off myself and just jam back inside the tube, or should I just go back to the dealer (bit of a haul from here) and get them to replace it? I tried to lightly do it with a flat screwdriver but it doesn't seem to want to budge.
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Old 05-16-16, 05:46 PM
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techsensei
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My guess is that the housing between the brifter and interrupter lever is too short. A quick fix would be to loosen the interrupter lever and move it slight outward so the end of the housing seats firmly into the body of the interrupter lever. That would get rid of the play you are experiencing. But ideally you would un-tape the bar, and replace the length of housing with a slightly longer piece.
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Old 05-16-16, 05:46 PM
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I'm having a hard time envisioning exactly what the issue is (there are two spiral wound parts- one is the brake cable, which is several thin wires wound around each other, then there's the housing which is another, thick, wound wire, like a long slinky, which is wrapped by the black casing), but it sounds to me like the housing has compressed, allowing more pull of the cable than you'd like (so much that it's allowing the housing to come out of its recess). The compression can be normal on a new build, though (assuming I'm correct about the issue,) I like to see the mechanic pre-stretch/compress the cables and housing a bit to keep this from happening.

I assume your bike came with a period of free tune up service. But as you said, it's a bit of a distance away? I would ride the bike a bit more, do a lot of braking and shifting and stretch/compress every cable on the bike. Be mindful about your weak front brake. Then take it back and have them readjust the bike. Make sure to point out the spot that's catching- if it keeps happening, it can mess up the end of the housing (if it hasn't happened already), and that piece of housing and possibly the cable may need to be replaced for smooth braking. let them know you're coming ahead of time, this should be something they can do in just a few minutes. Don't go jamming any tools in there.

Do you have pictures of the issue you described?

Edit: Techsensei's guess is my second choice, but if so, that's a pretty egregiously incorrect length of housing.

Last edited by Raiden; 05-16-16 at 05:52 PM.
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Old 05-16-16, 06:00 PM
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Hi there, thanks for the replies. I don't have a photo, but it's not the inner brake cable which is the inner steel braided wire strands, it looks like the housing of the cable which is wrapped by the black casing. Like a metal drinking straw surrounded by black vinyl or plastic.

The supplementary brake levers have the brake cable passing through them from the main calipers. It's like they only push on the outer cable casing to actuate the brakes instead of actually grabbing and pulling the inner wire itself, and every time I engage them it pushes a little more of that tubular hollow metal housing out of the outer black casing. Imagine trying to move a large fallen tree, but when you push it only the bark moves, sliding along exposing the bare wood.

It does come with a tune-up period, and it sounds like it's something that should be covered by their service policy. I guess I'll have to take a run over there to deal with it properly.
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Old 05-16-16, 06:12 PM
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Raiden
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Yeah that's a little more clear. And the lever sounds like it is working properly, even though there's an issue with the cable/housing. This is why they give those tune up periods. But like I said, go use the bike a bit more to they can check all of the cables when you take it in, rather than just the one. Possibly save yourself more trips.
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Old 05-16-16, 06:21 PM
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Sounds like good advice. Thanks!
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Old 05-16-16, 06:35 PM
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Originally Posted by Raiden View Post
Techsensei's guess is my second choice, but if so, that's a pretty egregiously incorrect length of housing.
It is bad, but in a way, it is not unexpected. The problem is if the bars come pre-wrapped from the factory, the housing has not been compressed beforehand. So it may seem like it is long enough ... until the brake cable is given a good hard squeeze. If the handlebar tape is wrapped tightly, it won't allow the housing to naturally seat into the brifter body and the body of the interrupter lever.

EDIT: I should say that even though it may have been delivered from the factory that way, it is the shop's fault for not picking up on the issue during assembly.

Last edited by techsensei; 05-16-16 at 06:59 PM.
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Old 05-16-16, 07:05 PM
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Originally Posted by gary2112 View Post
The supplementary brake levers have the brake cable passing through them from the main calipers. It's like they only push on the outer cable casing to actuate the brakes
That is exactly how they work; pushing the housing or pulling the inner wire (like your main brake lever does) have the same effect at the brake end.
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