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Anyone assembled a Windsor Tourist?

Old 03-13-08, 08:54 AM
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Anyone assembled a Windsor Tourist?

I just bought a new Windsor Tourist from bikesdirect.com and I assembled it with lights, fenders, and the rear rack that it came with. My concern is that I have some extra parts. I've had no prior bicycle mechanic experience. Anyhow, there is a small elbow-shaped metal tube with a clear plastic tube inside it. Anyone know what this is used for? I also have a small S-hook and a couple of extra screws. I don't think any of it is critical, but I am not sure. The only thing I think I have left to do at this point is adjust the derailleurs. The bike came with basically no assembly instructions. Only the technical service manuals from the shimano components were provided along with a generic "bicycle assembly manual" written in China-English.
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Old 03-13-08, 09:05 AM
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Originally Posted by m_yates
Anyhow, there is a small elbow-shaped metal tube with a clear plastic tube inside it. Anyone know what this is used for?
That part might be a cable guide for the rear brake caliper. Without photos it's hard to know.
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Old 03-13-08, 10:11 AM
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Originally Posted by n4zou
That part might be a cable guide for the rear brake caliper. Without photos it's hard to know.
I will post a photo tonight. I thought it may be a cable guide of some sort, but I now don't think that it is. The bike has cantilever brakes and the rear brakes were fully assembled, they only needed to be adjusted. Derailluer cables were also pre-installed. The only cable I had to run was to the front brakes, but I could see nowhere for this piece to go. It is tapered on one end and asymmetric, suggesting it is designed to be inserted into something. It will be much easier to describe with a picture....I will post back this evening.
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Old 03-13-08, 10:39 AM
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it sounds like a v-brake noodle. Course you have cantis -it might just be there by mistake (pure speculation on my part, but that's what boards are about, right?)

I have seen plastic like sheathing run under the bb before, but from your description it doesn't sound right. Also on one of my bikes (older one) there is a noodle like bit that has the brake cable that runs through a metal housing just before the rear brake, but from pictures of the Windsor Tourist, it doesn't look like that's the case either.

OK, bets are open: I'm going with v-brake noodle in there by mistake. Anyone else?
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Old 03-13-08, 10:46 AM
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It goes on the front brake cable at the brazed on stop on the fork if I understand your description correctly. It makes the cable routing cleaner. I can take a pic and email you or pm you if necessary.
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Old 03-13-08, 07:04 PM
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Originally Posted by staehpj1
It goes on the front brake cable at the brazed on stop on the fork if I understand your description correctly. It makes the cable routing cleaner. I can take a pic and email you or pm you if necessary.
Thank you for the reply. I'm still confused though. There is cable housing that goes into a stop that is on the headset. I'm not sure of the brazed on stop you are referring to. Here is a picture of the mystery part:



Here is a picture of the front of the bike showing how I routed the brake cables:



(sorry for the mess in my shop...you can see my wife's bike in pieces as well in the background )

The front brakes appear to work as they are, so maybe this part isn't critical? Also, I just changed my bike forum account settings to allow e-mails and PM. If you want to send or post a picture, that would be great.

Last edited by m_yates; 03-13-08 at 07:11 PM.
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Old 03-13-08, 07:57 PM
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This is a front brake noodle -- you can see the same part on the Surly LHT. Looks like you may not need it since your front brake cable routing has a fairly well rounded radius. Check out the Surly web site to see how the noodle is installed, or a closeup of other pictures of LHT's. Here is a picture of the noodle installed on my 1983 Specialized Expedition. This same design noodle is carried by my LBS in both silver and black, and comes with the headset bracket/holder. Sorry the picture is out of focus but you get the idea. Note that there is very little space to include both the noodle and the adjuster. Hope this helps.
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Old 03-13-08, 08:16 PM
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Originally Posted by DBC Steve
This is a front brake noodle -- you can see the same part on the Surly LHT. Looks like you may not need it since your front brake cable routing has a fairly well rounded radius. Check out the Surly web site to see how the noodle is installed, or a closeup of other pictures of LHT's. Here is a picture of the noodle installed on my 1983 Specialized Expedition. This same design noodle is carried by my LBS in both silver and black, and comes with the headset bracket/holder. Sorry the picture is out of focus but you get the idea. Note that there is very little space to include both the noodle and the adjuster. Hope this helps.
Thanks. I get it now! I guess I'll take a look at it tomorrow night and decide if I will install it. I took the bike for somewhat of a test spin (In slow circles in my basement) and the brakes seem to work OK as is. I guess the noodle is just for changing the direction of the cable routing. Thanks all for the helpful information!
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Old 03-13-08, 10:22 PM
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Originally Posted by m_yates
Thanks. I get it now! I guess I'll take a look at it tomorrow night and decide if I will install it. I took the bike for somewhat of a test spin (In slow circles in my basement) and the brakes seem to work OK as is. I guess the noodle is just for changing the direction of the cable routing. Thanks all for the helpful information!
My wife just got a 1995 Trek 520. It does not have the noodle but the cable routing is similar to yours -- i.e. wide enough radius. It probably depends on how close to the center of the handlebar you wrap the bar tape, the stiffness of the cable housing and the location of the adjuster.
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Old 03-14-08, 04:54 AM
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Originally Posted by m_yates
I'm not sure of the brazed on stop you are referring to.
Sorry for the confusion, no brazed stop. It sounds like you figured it out. How much it is needed depends on a lot of factors including frame size. Your frame is larger and bars higher so the piece is less needed than on mine. Your routing looks pretty clean as is.

Enjoy the new bike. Any big tours coming up?

We did the TA on three of these bikes and were very happy with them. I would suggest a few things:
1. The gearing is pretty high and we added a Sugino XD600 crank (46-36-26 at $80) and later changed the 26 to a 24. If you will be doing loaded touring in hilly areas or mountains at least the 26 is a must IMO.
2. The stock rack is a bit flimsy. Two of us upgraded to a Blackburn EX-1. The other used the stock rack for the 4244 mile tour. It held up fine but flexed and swayed.
3. The brakes themselves are fine, but the stock pads were less than optimum. We used then until they wore out, but they wear out suddenly when they still look like they have a bit of wear left, so carry spares on a long tour or change them early.

If interested you can probably glean a few more details from our journal at : https://www.crazyguyonabike.com/doc/staehling2007
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Old 03-14-08, 06:25 AM
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Originally Posted by staehpj1
Sorry for the confusion, no brazed stop. It sounds like you figured it out. How much it is needed depends on a lot of factors including frame size. Your frame is larger and bars higher so the piece is less needed than on mine. Your routing looks pretty clean as is.

Enjoy the new bike. Any big tours coming up?

We did the TA on three of these bikes and were very happy with them. I would suggest a few things:
1. The gearing is pretty high and we added a Sugino XD600 crank (46-36-26 at $80) and later changed the 26 to a 24. If you will be doing loaded touring in hilly areas or mountains at least the 26 is a must IMO.
2. The stock rack is a bit flimsy. Two of us upgraded to a Blackburn EX-1. The other used the stock rack for the 4244 mile tour. It held up fine but flexed and swayed.
3. The brakes themselves are fine, but the stock pads were less than optimum. We used then until they wore out, but they wear out suddenly when they still look like they have a bit of wear left, so carry spares on a long tour or change them early.

If interested you can probably glean a few more details from our journal at : https://www.crazyguyonabike.com/doc/staehling2007
I actually read your journal while researching the Windsor Tourist. It looks like the tour was a blast. It was re-assuring to see that the bike held up for such a long tour. I don't have any tour planned right now, but it is something I'd like to do one day. I bought some rear panniers, fenders, and lights. The immediate purpose of this bike is commuting. It is replacing my 15 year old mountain bike that I have commuted on for years. I live in Rochester and the majority of my 11 mile commute is on the Erie Canal trail that crosses New York state. I've been dreaming about riding the entire distance of the Erie Canal one day. I may possibly start by taking a weekend tour from my home to Niagara Falls sometime this summer. Right now, I am still waiting for the snow to melt off the trail. I don't ride in the winter, so it will be great when I can finally break in the new bike.
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