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Two six-packs and seven hours later, man does the impossible(8 posts)

Two six-packs and seven hours later, man does the impossiblerockbender
Jul 28, 2003 9:23 AM
Having never raced my road bike before, I thought I would give it a try at our local midweek criterium. To make a long story short, about 1/2 way through I clipped a pedal around a corner and went down for a nice slide - luckily I was at the back of the pack and didn't take anyone with me.

As a result of my mishap, I fared a bit of roadrash, while my bike now has a small dent in the top tube from the bar hitting it. The worst thing on my bike was a jammed shifter - the right Ultegra STI lever would downshift, but not upshift.

The following evening, I set out to do the impossible: completely disassemble a Shimano STI shifter. At the end of evening #1 and one six pack, I managed to get the shifter totally dissassembled, found a small piece of metal that had broken off of a washer, and reassemble. At the end of reassembly, I looked down between my legs to find a lone spring staring up at me from the garage floor. Shifter still did not work.

Evening #2: I went to work figuring I could get a exploded view of the shifter from a Shimano PDF file. Guess what? I suppose that since you are not supposed to take these apart they figure there is no reason to publish repair data on them. Armed with another six-pack, I sat down again, taking the shifter apart for about the 16th time to figure out where that missing spring went. I took a little more time to figure out exactly what was going on inside that little grey cylinder, which helped me understand where everything needed to be to function properly.

After about 5 more trial and error dissassemble and reassemble procedures, I got it right. I can't believe that I got the whole thing back together AND functioning! It feels just like it did before I modified it by ramming it into the asphalt at 25 mph!

I just wanted to let everyone know that while it requires a bit of patience (thank you, Deschutes Brewery!), it can be done.

The only bad part is that I was totally prepared to get a set of DA shifters to replace these. Perhaps I should order some anyhow, in case I question my wrenching skills!

ps - sorry I didn't take any pictures!
I'm impressedPaulCL
Jul 28, 2003 9:58 AM
Maybe you should draw the exploded view of the shifter and sell it to Shimano...oops...that won't work. Shimano doesn't want you to be able to fix it - only replace it.

My LBS owner says he rebuilt a Da lever once. Getting the parts is near impossible, so he said. YOu accomplished quite a feat particularly after drinking so many beers!
how did you know what i did last night?JS Haiku Shop
Jul 28, 2003 10:09 AM
two six packs and seven hours later, man does the impossible: i fell asleep watching the tour.

you've accruately described my sunday afternoon & evening.

nice - sounds like my sunday!rockbender
Jul 28, 2003 11:43 AM
Your sunday sounds much like mine - nice and lazy, and quite likely well deserved!

I, unfortuanately, don't have OLN though, so I just had to sit attentatively through baseball and golf highlights for them to show a 5 second clip of Lance's finish.

( I did go to the LBS to watch the ITT on Sat, though : )
I'm in awe and too late to help.pitt83
Jul 28, 2003 11:57 AM
Exploded diagrams at Shimano web-site

Link to group, then compnent from that URL.

Still, I'm in awe. I stripped off the covers and quit right there. Too many small parts and too detailed to spend my life on.
Don't worry, not too late!rockbender
Jul 28, 2003 1:08 PM
That is exactly the diagram I found before - it doesn't even come close to showing what is going on inside of the lever mechanism. All this shows is some bushings and plastic caps for the levers. Looking at the service instructions, the only advice I could get was "Do not disassemble any further as reassembly may not be possible."

I really wish I would have taken a picture - it really is kind of cool behind the cap! Now, don't get me wrong - if my shifter wasn't completely hosed to start with, there is NO way I would have taken apart a perfectly good shifter!

thanks for the time to look up the link, though - much appreciated.
It must have been the Black Butte PorterGFocker
Jul 28, 2003 1:01 PM
Speaking of trashed shifters....Jervis
Jul 28, 2003 4:47 PM
anybody have an old set (front and rear)they want to get rid of. Mind you I don't want them to work I just want a decent set of brakes for my tourer. I have the brake only aero hoods and they are uncomfortable as all heck. Sooo if anyone has a set of botched shifters they're confused about what to do with and want to unload......drop me a line and I'll see if I can take them off your hands.