Problem with Shimano STI lever

[robin]

Hi

I have a fairly old 105 - STI lever on my bike.

Model ST1055

Problem is with the cable on the RH lever.

It is not installed correctly and now cant get cable to locate correctly in its slot.

Inside the lever housing is a grooved cog,
This cog has a receptor for the cable bell end to fit into.

The cable exits through a small slot on side of housing. (only wide enough for cable)

The cable has bell end but its NOT engaged into the mechanism, ie its on the wrong side receptor.
Guess previous owner put cable in but then pulled it hard to force it in on wrong side.
Cable moves but at present unable to get it out of entry hole as bell sticks to housing due to curvature of case.
I could remove the brake lever and housing but I dont know how to do that (how please )
Or any other ideas.
many thanks
Robin...

 

[RecordAceFromNew]

Hi Robin welcome to the forum! I have no experience in these levers, but someone here might. In case the parts diagram helps regarding explanation, component completeness check or refit etc., it is attached below.

 

[robin]

Thanks

I had managed to find this diagram earlier today (though smaller version ) but it gives me no clue as to how to remove the brake lever. (housing as I call it, item 10) to get to the innards and free the cable.

I have the outer cover off (cap, number 6).

cheers

robin...

 

[RecordAceFromNew]

As I said I have zero experience of working with or even using this lever, but if you take below observation with a bucket of salt, I have reason to believe one loosen screw 17 (which is kind of hidden under the lever pivot 18) and the lever pivot 18 could then be released from the side, which allows the whole assembly (1 of the diagram on the left) to be released.

Doesn't losing 3 release 10?

To add to the above warning, afaik servicing these things are not for the faint hearted and you would probably be better advised to get it done by a pro.

 

[robin]

No 3 only lets cap off.

i am cautious as I dont want a million bits on my hands.

I was wondering about screw 4 ?????

 

[andy_wrx]

Can you see the plum (I can't call it 'bell end' without giggling !) on the end of the cable ?

If you can see it and get to it 'from the other side', I'd be tempted to snip it off and remove it, then simply pull the cable out and replace with a new properly-installed cable.

I bought a pair of 2nd-hand Ultegra levers for my Winter bike a couple of years ago, only to find when I got them that they'd been removed from the previous bike by the simple method of snipping-off the cable flush where it went into the levers, leaving approx an inch of cable in the lever, then the gears had been worked up and down a few times, meaning that this inch of cable had frayed and splayed-out inside the lever.
It took me about 3/4 hour with two watchmakers screwdrivers, tweezers and WD40 to work the cable back into its groove and operate the gears so I could get the mechanism to rotate-around internally to allow me to get hold of the plum and pull it out though the access hole, accompanied by much swearing. Having done it I sent a suitably caustic email to the seller...

- what I certainly didn't dare to try was disassembling the shifters : apparently if you do undo that really-tempting looking bolt then the whole thing explodes into dozens of pieces and you need 4 hands and the appropriate spring-compressing tools used in the factory when assembling them...

 

[robin]

Hi

Sorry about the terminology :-)

I can see the plum. (bell)

It will not go round the inner spindle as the gap between spindle and inside housing is too tight. (as cable is not in grove)

So not sure cutting cable would help.

Your right about needing four pair of hands.

Going to have another go at it later today with an extra pair.

If the outer housing could come off easily then would do that but dont want to be left with a bunch of springs, washers etc


Going to get out my tweezers and small fine tools and see how i get on later.

thanks

 

[robin]

In for a penny !

the 2nd set of hands did not help so I decided to go to next stage !

First undid the pivot pin (small grub screw) and taped that out.

This splits the levers from the main body.

I could then move the small lever to one side and then undoing screw (no. 4 on above list) which holds the outer housing cover on. (well hidden up inside top of lever, has retainer on to stop it disappearing).

With cover off managed to extract cable.

Innards are all gummed up.


So soaking them in wd40 and other solvents to free it up so hopefully get back together in morning.

Pictures of innards :-