Campagnolo Ergo (2nd Gen) Left Lever Rebuild Problem

[treve]

Hi guys,

I've been having real problems re-building my Left 2nd Gen (1999-2008) Campagnolo ergo lever.
Never had this problem before when rebuilding a right lever. Hope you can help!

Having stripped-down, cleaned and re-built most of the lever, I'm struggling with the last step: setting the correct tension on the flat coil spring EC-RE054.

There only seem to be 2 positions in which I can attach the coil spring to the central bushing EC-RE252.
I am finding that there is either too much tension (when attaching to the central bushing in the 4 o'clock position) or too little tension (when attaching to the central bushing in the 10 o'clock postion).

I have tried to show this problem in the following photos of my lever:
http://www.flickr.com/photos/31859768@N06/sets/72157627589428794

Can someone tell me what I am doing wrong?
I am facing this same problem in 2 of my left 2nd generation ergo levers ('99 Athena 9-speed and '04 Record 10-speed)

In my photo "Ergo 2" the index cog/cable holder (EC-RE314) will hold it's position in the low gear position when I apply pressure where the cable would push through. Would you expect everything to be OK when the cable is attached and hooked-up with the front derailleur on my bike?
i.e. does the ergo lever require the tension introduced by the front derailleur spring in order to function correctly?

I've read elsewhere that the flat coil spring EC-RE054 may not actually be required. Does anyone have any thoughts on this?

Thanks so much for your help!
T

[bikerjulio]

My experience lever building is pretty minimal. It looks to me like you are over estimating the amount of cable travel needed. I would guess that 1/4 rev is maximum. That's another way of saying that I think that you need to try a test installation, so that cable tension and travel is correct. Ergo 1 & 3 pics look like cable has traveled too far. Just my $0.02.

[treve]

Thanks Julio.
I will try a test installation some time soon. Was thinking that the lever mechanism will probably behave differently under tension from the cable and front derailleur.
Was just hoping that someone else has been through this already and might be able to put me right before I find out for myself that I've done something wrong!

[bikerjulio]

I took the cover off a brand new LH lever.

should be self explanatory. the spring end seems to grip the lever body tightly. maybe yours got opened up.

[treve]

Hey Julio - thanks for doing that!
Just to check, is that a 2nd Gen lever that you've opened up?
i.e. not Ultrashift or Powershift?

Also, were you applying any pressure on the thumb lever when you took the top photo?
I find that the cam wants to ping back anti-clockwise, due to the tension in the flat coil spring.

[bikerjulio]

yep - 2nd gen ergopower shifter. nothing touching the levers when the pictures taken.

sounds like you do not have the spring attached to the thumb lever which would engage it on the ratchet and prevent the anti clockwise movement you are having.

[treve]

Just to let you all know that I have rebuilt my lever with the flat coil spring attached as in my original photo Ergo 1 (link in first post).

When installed on my bike and with the cable under tension from the front derailleur it seems to behave as expected. Hopefully it'll be the same when I get out on the road!

Thanks for all your help!
T