KB12

Hello, so I am converting my trek 510's non aero bars to aero bars and am having some trouble. I replaced all the cables and housing. My trouble is this:

When I run the housing all the way up under the lever as far as it can go and hook up the brakes and squeeze the lever, the housing and the cable move at once and mess up my brakes. I have taped down the housing on the bars, still happens.

So then I decided to run the housing only to the very edge under the lever, exposing some of the cable. This works but the friction of the cable makes the lever very hard to squeeze.

Does anyone have any advice? This seems like a stupid problem but Ive been working on it for a long time and cant figure it out.

I bought really cheap brake housing and cables, could this be the problem?

Thanks.

OldRoadman

Pictures would make a big difference in giving you advice!

KB12

https://img94.imageshack.us/i/img5606h.jpg/

Here is a picture. Should the housing go all the way up there like that?

Torchy McFlux

Your housing should not pass through the hole in the lever body like that. Has someone drilled it out?

KB12

Thanks, got it. I added a little plastic tip to it so it wouldn't enter into the lever.

BCRider

That's still not right. There should be a saddle in there to retain the housing. You're not supposed to require a ferrule of any sort. Are they both the same? It's also possible that you're not seating the housing in the correct spot to catch the seat. If you peel back the hood and then press the lever you should be able to look into the opening and see a cable, not housing, sized hole. And the back side of that small hole should be a housing stop point. If all you see is a big housing sized opening then the levers have been ruined by someone.

zzyzx_xyzzy

Some levers come with an extra large ferrule to hold the housing at the body. Lose anything when taking them apart?