Servicing ErgoLever - report

A few weeks ago I posted asking for any experiences
folks had servicing ergolevers and there was some
useful advice. I thought I'd let people know how
it went.

Tools used: 5mm T allen key, 3mm L allen key,
small needle nose pliers, sharp, pointy thingy
for pushing bits around (especially springs),
flat head screwdriver, small hammer, grease gun.

I had new G-springs, Index gear, Thumb button
spring and coil spring. I took the lever apart,
including removing the brake lever (no special
punch for this - I used an allen key and small
hammer). It was all pretty gummed up with grease
and dirt. I laid out the parts in order as
they came out. Most difficult part was getting
the damn rubber hood off - I was afraid of
ripping it.

I had some instructions to follow:
http://www.yellowjersey.org/ergo1.html
(I used pages 3, 4 and 5. The link to the PDF
at the bottom didn't work for me). These were
very useful but where incomplete - not all steps
are in there and there is no piece marked "O" in
the diagram so there are a few gaps. Anyone who
has followed these instructions will know what
I mean.

It was all going pretty well but I was having a
major problem getting the thumb spring to fit
properly. I finally got it all back together only
to find out the entire lever was completely jammed.
So, only thing to do, take it all apart again.
After much fiddling, looking at diagrams and trying
to figure out how it was *supposed* to work
I realised that Branford Bike had sent me a LEFT
HAND thumb return spring! Feck! No wonder it
didn't bloody work! So, I put the original spring
in, it all goes together much easier and works
fine when assembled. By now, I was so confident
that I took it apart again to make sure all the
appropriate bits were greased. It's now back on
the bike ready for it's maiden voyage tomorrow.

All in all, relatively painless. I couldn't have
done it without the instructions although they
were incomplete. It would have been much less hassle
if I had the correct parts when replacing old bits.

One thing that had me wondering for a while is the
coil spring that connects to the up-shift paddle
(finger operated). It's not "around" anything -
it just sits floating in the air with a hook on
the paddle and a spur into the body of the lever.
Doesn't seem as neatly designed as the rest of
the lever (or indeed campag stuff generally).

DeF.

--
e-mail: d.farrow@your finger.murdoch.edu.au
To reply, you'll have to remove your finger.