tomtomtom123

The torsion spring that keeps the ratchet paw engaged for the releasing lever (upshifting) broke. You can see the broken tip in the photo with the green arrow.
What's the possibility of finding a replacement that fits from a bike shop and replacing it?

The retainer clip is so tiny. I don't really have a tool that can pull it off. What's the best way to do it?

I looked at industrial supply websites and there are a couple options for around $8-9 for in stock springs, but not exactly the same shape. They're all fixed at 90 degree intervals, but this one in the photo appears to be wound to around 315 degrees. Should I get one at 0/360 (parallel legs) and then bend it by hand to 315? or would it weaken the wire and cause it to likely break off again?
The stock springs also have straight legs, so I'd also have to bend the legs here too.

I see a new shifter going for around $30-40.

curbtender

Can you rebend that one?
Won't hurt to try...

tomtomtom123

The tip is broken off. I guess I could just bend from the remaining end, but then it may exceed the max operating angle.

But first I need to get the retaining clip off. It's extremely small. Those slots are less than 0.5mm

squirtdad

Try, but plan on getting a new shifter, those things (like most stuff now) were not designed to be maintained and parts are not available

tomtomtom123

I was able to push off the retainer clip with small tweezers by pressing on the open end. I bent the end of the torsion spring and was able to get it working again, but because it's operating at a greater angle now, the legs aren't really seated perfectly in their tabs. It's kind of crooked, and it's so tiny that I couldn't bend it exactly 90 degrees perpendicular.

At least I don't think the spring would jump out ( hopefully). Even if I bought new torsion springs with straight legs, I think it's difficult to bend those legs at the correct angles with tiny tweezers.

If anyone's curious, here are the dimensions:
5.10mm inner diameter
0.35 to 0.37mm wire diameter
3 coils
right hand turn
not exactly 0/360 legs (parallel), but closer to 330 degrees (maybe 315?)

rccardr 

Take the clip off with the tip of a sharp awl inserted into the upper space. Be careful, it will fly if removed too quickly. It can replaced using very small needle nose pliers or strong tweezers.
Once you have the spring off, show pics with reference sizing. Someone may be able to suggest an alternative replacement.

However, as others have said, these are not intended ro be repaired. Set $30 aside for a new one, as your time involved here will likely be worth much, much more.

tomtomtom123

Here is a photo of the result.

tomtomtom123

You can see how the spring isn't a nice 3 layer coil anymore. The coils are crossing each other because of the greater operating angle (more tension) due to the shorter length of the wire, and also because I didn't bend the tip exactly 90 degrees (it's kind of pointing 20 degree inwards, which causes the top coil to push out)

curbtender

But does it work?

tomtomtom123

Yes it works, off the bike. I have to lubricate, reassemble the casing, and put it back on the bike with a new cable. I frayed the old cable cutting off the end cap. I'll finish tomorrow.