Transmission and safety devices, cables and housings require to be well « cut » to work perfectly. And that makes all the difference, so don’t deprive yourself!
Pictures © Frédéric Iehl
The tools
You will need a real cable cutter in good condition to perfectly cut cables and housings. Add a small flat file and a little fat. Never use cutting pliers, they are not « cruet » enough to clearly cut a cable.
Time and difficulties
Allow a short hour of work to cut and connect cables and sheaths. The average difficulty here lies in the finishing and « connection » of the cables.
Stage 1
We start with the brakes. The front is the simplest, we try to find the length that will give the right curvature.
For the rear brake, we do the same by remembering that you will have to turn the handlebars to 90°…
There is also a fluid curvature for the terminal housing of the rear brake.
Stage 2
The housings are then cut to the lengths found.
This does not prevent burrs. We’ll have to remove them…
So the burr is filed until it disappears.
The brake housing now comes in direct stop, on the levers but also on the brake calipers.
Stage 3
We look at the length of the derailleurs housings in the same way. Remembering that the handlebars are turning…
Stage 4
To cut the second sheath, it is best to use the first one as a template.
We cut the housings. They will then be crushed…
They are « recalibrated » with the dedicated part on the clamp.
End caps are placed on the end of housings of derailleurs.
They will be used to isolate the housings of the stops on the frame. But above all, they will allow the ducts to maintain their integrity by preventing the steel wires that compose them from moving.
There are also some at the rear derailleur.
There are also stops at the levers.
Stage 5
The derailleur cables are entered into the lever. We will have lowered all the speeds and the board before starting…
Stage 6
On the Ergopower lever you must choose the « road » of the cable. We will make this choice at the beginning of the cable. Because a small loop that will be pinched at the draw will form.
Stage 7
Before pulling the cable thoroughly, coat its head with grease. This will prevent it from getting stuck afterwards.
Stage 8
Most housings are pre-lubricated. So never put grease on the cable! He could « stick » into the sheath…
Stage 9
When the « front part » of the ducts is in place, we take care of passing the cables under the box.
Stage 10
The rear derailleur cable is then pulled to the maximum to compress the sheaths along their entire length.
We then fix the cable like this for a Campagnolo derailleur.
We lock the cable by pulling on its free part and if necessary we redo a tension and then a tightening.
Stage 11
We do the same for the front derailleur.
There is often a trace or imprint to fix the cable. The latter must marry him perfectly.
All that remains is to tighten the cable, wedge it, then tighten it and tighten it.
Stage 12
We pass the brake cable in the Ergopower lever.
We grease the head of the brake cable too.
Stage 13
After passing the sheaths, the cable is stretched at the level of the stirrup.
Here too there is a « path » for the cable.
We tighten the cable by holding the skates. It will have to be tightened after several test brakes.
Stage 14
Cables, brakes and derailleurs are cut about 3 cm from the tightening.
We set up the « leads » which are actually made of aluminum.
Using the cable cutter, the cable bit is « bited » in 2 or 3 places. We go there calmly because it is easy to cut.
