HANDLE CLAMP REPLACEMENT INSTRUCTION'S
We also made a youTube video which walks you through the procedure below.
- 3.0 mm (2.5 mm for older models) hex wrench
- 4.0 mm hex wrench
- Phillips head screwdriver
- Cable cutter (a wire cutter will work, but may fray the end of the cable)
- Remove the "quick release" lever from the old handle clamp.
- Using the 4 mm hex wrench, loosen the cable clamp bolt on the front brake pad and free the cable from the brake bolt. Remove the cable end (either by pulling it off with the pliers or cutting it off with the wire cutters) and pull the cable and housing (from the top) out of the lower handle assembly, paying attention to how the cable and housing are wrapped around the T-handle.
- Remove the old brake cable from the cable housing and disconnect the brake cable from the brake lever. To do this, turn the silver barrel adjuster on the brake lever so the slots in the barrel adjuster are alligned with the slot in the brake lever.
- Lower the handlebar all the way to provide better access to the three screws retaining the old handle clamp. Using the 3.0 mm (or 2.5 mm) hex wrench, remove the three screws from the handlecap. Separate the T-handle from the lower handle.
- If your T-handle has a brass bushing with a rivet near the lower end of the T-handle, clip the rivet off with a pair of wire cutters. If your T-handle has a Phillips head screw near the lower end of the T-handle, remove it with the screwdriver. Remove the old handlecap from the T-handle and discard.
- Slide the new handle clamp onto the T-handle, with the sloped side up (towards the top of the handlebar). Replace the screw at the bottom of the T-handle with the screw provided. (This screw prevents rotation and overextension of the handlebar.)
- Slide the new cable through the cable housing and then wrap the cable and housing around the T-handle (as noted in step 2) and slide the cable and housing (from the top) through the handle clamp, so that the wire cable is hanging free beneath the new handle clamp. Thread the new cable and housing down through the lower handle and through the 3 mm hole in the top of the fork. (This is a little bit fussy. A flashlight helps. Another trick is to take the old cable and thread it from the bottom out the top. Then tape the end of the new cable to the end of the old cable and use the old cable to pull the new cable through the hole.) Once you have threaded the new cable out the bottom, tie a loose overhand knot in it to prevent it from sliding back up.
- Using the 3.0 mm (or 2.5 mm) hex wrench, screw the new handle clamp down to the lower handle. Longer 2.5 mm screws are provided for older lower handles.
- Reconnect the new brake cable to the brake lever and tighten the barrel adjuster so none of the slots line up.
- Pull the cable tight from the bottom and around the brake cable bolt (counter-clockwise). Tighten the bolt. Test the brake out to make sure the cable is pulled adequately tight and that the brake cable bolt is tight. Cut the extra length off the cable and insert the cable end. If using wire cutters and your cable frays when you cut it, just retwist the cable with your pliers. Crimp the cable end onto the brake cable with the pliers.
- Replace the quick release lever.