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Sticky Rear Brake Cable with Aero Exage Brake Levers

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Sticky Rear Brake Cable with Aero Exage Brake Levers

Old 08-03-14, 09:45 AM
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yuyax
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Sticky Rear Brake Cable with Aero Exage Brake Levers

Working on a bike that has Shimano Exage aero road brake levers. Before I fully re-taped the handlebars, the rear brake lever was not sticking and was fully returning to the 'regular position' (when not squeezed). After I re-taped the bars, there is a lot of drag in the cable and the brake lever is not coming or snapping back all the way.

I removed the brake cable from the rear caliper and I can feel a lot of drag when I pull the cable back and forth. This drag is what is causing the brake lever and the brake caliper from releasing fully.

Any recommendations? The cable housing is kink free and smooth. The rear brake caliper has good tension and springs right back.

These are the same brake levers and calipers that I working on -> VeloBase.com - Component: Shimano BL-A251 Exage Motion

Thanks!
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Old 08-03-14, 11:07 AM
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FBinNY
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I assume you have lined housings, if not get them.

Usually there's decent action on these, unless they're packed with a stiff grease or oil which adds drag. The #1 cause of friction is a poor cut at the ends which has the wire dragging on a compressed bit of the spring coil. #2 is poor fit or alignment where housing meets the lever body (and at all fittings).

Note that cable friction is cumulative and the spring is light action so this may only be the final straw in a system that has friction in other places.
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Old 08-03-14, 11:19 AM
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die drawn cables are smoother , the die flattens the outer wires of the cable.

replace the housing too . then that friction will be reduced ..

the housing should take a smooth flowing line. , no sharp bends..
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Old 08-03-14, 11:58 AM
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Since it worked freely before you wrapped the bars and not after, it sounds like you dislodged a housing from a fitting somewhere when you wrapped the bars and the inner wire is dragging along a corner somewhere.
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Old 08-03-14, 09:24 PM
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Thank you for all of your replies.

Well... I looked into my bins of endless bike junk and found a slightly thinner brake cable. I am guessing the old one was 1.6mm and the new cable that I found is 1.5mm. The thinner cable works great and it is not binding inside the housing
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