geoffstanley

Hi again!

I'm finally giving my touring bike the look over it deserves, and I've found something (else) worrisome.

I have Dura Ace bar end shifters. Shimano SL-BS77 to be precise (default for the Surly LHT). The right shifter has a black plastic cap on the inside, sitting between the SIS/Friction switch ring and the actual shift lever itself. It's cracking. This happened to me last year, and upon exploring I cracked the rest of the plastic off and took a look inside. There's a thin metal circle piece in there, with little indents in it in around the circle. I think there were 9 of them, so you can guess what they're for! That metal piece was all twisted and cracked itself.

So I sent it in to Shimano and got a new one under warranty. Installed it (properly, as far as I know, including orienting piece number 2 properly.

The plastic is cracking again, and I'm scared to open it up and break something. It's working fine now, though it doesn't make a clicking noise with every shift -- sometimes it makes the shift smoothly but is quiet. I'm starting a tour soon and don't want it breaking on me in the middle of the tour. Who thinks it will break on me? Is the torque on the lever fixing screw (piece 1) too tight? I was conscious not to overdo it. It's snug but not super tight.

thanks again!
geoff