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Old 09-03-11, 02:39 PM   #1
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How far does cable housing seat into aero levers?

Strange as it may seem in this day and age, I've never had a bike with aero levers. I skipped them altogether and went straight from non-aero Suntour on my old Trek 760 to Ultegra brifters on my Madone. Now I'm building a bike from parts and decided to go the aero route. (The "new" bike is a mid-80s Trek 770 - I sense a pattern developing - I might have to buy a few more bikes to see if it holds up .)

I bought some used Shimano BL-R400 levers and have a Jagwire Racer cable kit. Feeding the cable in from the front of the lever is no problem. What I can't figure out is how far into the lever's body the cable housing is supposed to extend. It seems to me that if I stuff it in as far as it will go I'll just kink the housing. Is it supposed to seat against the lever body? I can't see how the cable will function without both ends secure, but it doesn't seem like the housing should be bent to seat all the way into the body.


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Old 09-03-11, 03:21 PM   #2
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Yeah, it's supposed to go in as far as it'll go. This pretty much takes care of itself if you set up the brake system while the cable housing's free to seat into place (as opposed to wrapped against the handlebar by the bar tape). Note that with the Shimano aero brake levers, you don't put a ferrule on the end of the housing that goes into the brake lever.
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Old 09-03-11, 03:29 PM   #3
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How far should the housing go?

To the bottom. Simply put, if you don't seat the housing against a hard stop, the tension of the working brake cable will do it for you. Of if the tape doesn't allow the housing to move, you'll have spongy brakes as the housing moves when you squeeze the levers.
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