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Sheepdog's Brake Guide
By Sheepdog
|
Foreword |
| As a veteran of brake
tuning I have learned to many tricks and tips to brake dialing
over the years I hope this guide will show you all you will
need to know. This guide has been years in the making, and I
feel now is a good time to spew all I know on the subject, so
you don't have to go through what I and many others have.
This guide details the proper setup of front
and rear brakes. Including Gyro, dual cable (London Mod*)
setups, ways to make adjustment easier, and more beneficial. I
do not claim that any or all of it will be cheap to do. I try
to give pricing estimates where I can. I also cannot guarantee
your brakes will work like mine, well I pretty much can, but
lets face, some people are just not mechanically inclined.
Even seasoned veterans can gain from this guide. I
recommend reading as much as possible. Its very long, with
loads of pictures. By the time you are done, you should be a
master with brakes. I do not pretend that this guide is
complete as I will add to it when I learn something new. If
you know of a trick to add, please send it in so we may add to
it. While I consider this to be the definitive guide, it is a work in
progress. All opinions in here are just that, opinions. So if
a company thinks I am ripping on them, they can blow me, I can
easily back up all statement with simple demonstrations. *Note - From here on out it will only be referred
to as dual cable. Dual cables have been around since the first
Gyro's, I refuse to refer to it by someone's brand name, no
matter what their reason for the name is. No offense to
Odyssey or whomever claims to have invented it.
-----------------------------------------------------
General bullshit safety statement.. Anything you
see, copy, try or do here, or anywhere for that matter are at
your own risk Working and riding a bike is dangerous, if
you have not figured that out yet, your a dumb son of a bitch
who should take up needle point, and wear thick gloves when
you do it In other words, don't blame me.. |
|
First things first. Parts
selection. |
|
Lever -
Cables - Straddle Cable
- Gyro/Oryg - Brakes -
Brake Pads |
| Parts in your system are key to a good
working and low maintenance setup. Do not skimp on your brake
system, as you will only work on it more often and become
frustrated. Lets start with the lever, |
|
Levers |
|
Pretty much any will do. Dia-Compe tend to stay
tight in the hinge longer than others and are extremely strong.
Odyssey you can actually get parts to rebuild and freshen them up.
Dia-Tech has a ton of styles. Just try and get one that feels good
and will survive a few crashes and does not flex bad when pulled.
|
|
Cables |
|

People tend to go cheap here. This is a bad
place to skimp, especially since your only saving 2 or 3 dollars. Get something thick
and/or a decent brand name. Odyssey,
Dia-Compe, Giant and Shimano all make good cables. Generic cables
are often just that. Generic. Pay attention to the housing as well
as inner wire. That $1.50 cable from Kmart, Wal-Mart,
etc.. is not going to be the same as one of the above stated ones.
Go to your local shop and get a good one. It does make a difference.
They never feel as good, and do not last as long. They tend to snap
at the worst possible time.
I have been doing brakes for a long time, I have tried
literally hundreds of brake systems and setups (seriously), watched
fads come and go, cheap cables are one of your worst enemies. Some people will argue this 'till they are blue in the
face. The argument usually ends with them riding my bike and trying
my brakes. After that they usually end up coming to me to dial
theirs and get advice on upgrades. That may sound conceited, but
trust me on this. You need to invest in good cables (good brakes and
pads too, but we will get to that shortly).
Stainless cables. These are great, they do not
stretch as much and are very strong, however they have one major
flaw. When you pinch them in some pinch bolts on your brakes, after
once or twice the strands will start to break. The good news is that
by following this guide, you won't need to worry about that, since
you won't be messing with your brakes often at all once you are
done.
Gyro Cables. A good Gyro/Oryg setup is not cheap, but can
outperform single cable when built right, and require less
maintenance. SST cables are smoother than Odysseys but honestly,
they both suck. You need a you need an aftermarket cable setup to
get the most out of a Gyro/Oryg setup.
Primo Pervert. While not great, when it was
released was a jump in the right direction. Its design is a bit
dated now. I won't cover its install or adjustment as I feel
its outdated and pretty straight forward. If you have used a
Gyro/Oryg for a while, you can figure it out. I will tell you run it
as close to your lever as possible, people tend to do the opposite,
and that's wrong. Primo really needs to improve the instructions on
this. Basically you want to minimize as much single cable as
possible. Its useless on bottom, as dual cable is easier and cheaper
to hookup.
Dual cables.
First of all, let me say, anyone claiming dual
cable has more friction, is full of shit and has never tried it.
Stock cables are horrible. The splitters are full of friction. SST
and Odyssey put Teflon in the cables, but leave the aluminum bare in
the splitters, and it causes a lot of friction. Not to mention, the
cables bend all over trying to get to the splitter. Then people tie
the splitter down to avoid noise, only making the cable problem
worse.
Dual cables are straighter, and more direct, therefore
less friction. They also have less stress, stretch, flex and offer more adjustability. Each arm is adjusted separately
instead of together. With a small trick you can make the adjustable
together and separately (yes, I will show you how).
I do not recommend stock cables. I do not run them,
and frankly never plan to ever again. Dual is cheaper, easier, and
works better.
Dual upper cable systems. If your running a
Gyro/Oryg with stock cables, you do not have any clue what you
are missing. If you are running a standard lever get a hold of a
Dragonfly Gemini Cable. Ask your local Kink dealer, or call Kink, to
find out where you can get one. If you are running Odyssey
Modulevers, you already should be using the dual upper cables.
Derailleur cables for lower dual cable systems.
These have some good and bad points for dual cable systems. They
simplify things at the gyro assembly later as you will see later on.
However be aware, they are usually about 15% thinner than a regular
brake cable, and sometimes the ends are not secured as well as a
brake cable, since they are not designed for the amount of stress a
brake cable is subjected to. However, you are using two so stress is
much less than a single brake cable. I know people do it, I have as
well, but I still recommend regular and oversize for this
application whenever possible. I am not saying they are wrong, but I
am not saying they are right for the job either. Use at your own
discretion and against my advice.
Straddle Cables and Systems. People do some
weird things here. As do some companies. All have good and bad
points.
|
Type |
Picture |
Good |
Bad |
| Traditional |
 |
Cheap, curves the cable
gently, easy to get, light. Comes with many brakes. The
standard. |
The bend is not always
optimal until it works in a bit. |
| Odyssey |
 |
Cheap. Comes with Evolvers.
Doubles as an adjuster for Evolvers. |
Heavy. Curves the cable
over a sharp edge, small pinch bolt can damage the
cable. |
| Chain/Frankenbraker |
 |
No stretch, or flex. Can be
cheap if you make it yourself. |
Heavy, can cause the main
cable to sag. Have to modify almost ever brake to use. |
| Spokes |
Sorry, no pic of this.
They are rare and crude. Hopefully they stay that way.
Ghetto. |
No stretch, or flex. Can be
cheap if you make it yourself. |
Crude. Not very reliable,
or accurate. pain in the neck. Slight modification of
brakes necessary. |
| Avid |
 |
Light, allows more precise
adjustment. |
Hard to find, curves the
cable tight, small pinch bolts can damage the cables. |
|
|
Gyro and Oryg Systems |
| Odyssey Gyro |
 |
The original. Though
it has gone through some revisions. notably, the rounded ends
(Yeah!!!). Some also have down turned ends. They seem to spin
better than the SST units. The newer lower cable stops fit
over frames better too. Basically they have a better quality
bearing than SST, but use a non standard barrel adjuster.
which has good and bad points. Installation is a bit better
and easier, but they are non-standard. So if you run a Gyro
stem on top, you will have large adjusters on bottom, and
small on top. I prefer to keep them all the same.
Some models fit over King headsets, some don't. The models
change quickly and I cannot keep up with them, since you only
have one choice at a time usually. Check below for how to make
one fit a larger headset. |
|
Gyro GTX |
 |
A new design.
They work good, however you can buy 2 Gyros, or 3 Oryg's
for the price of one of these. They look awesome, offer more
adjustability. They also use the smaller barrel
adjusters. A bit late to the market, but the wait was
worth it. they spin smooth. I
recommend it for dirt jumpers as you guys tend to get dirt
into gyros easier than street guys. However, I do not
recommend it at all unless your bike is ALL TOP OF THE LINE. A
regular Gyro is fine. Concentrate on other things before
spending your money on one of these. These also
fit Over King headsets without modification (Yeah!!!). |
| SST Oryg |
 |
This is actually
very close to the first Gyro's. Why because Brian Scura
designed both. SST is his own company. This is modeled after
the original design. Which still works well. Newer Gyro's
actually work better for a few reasons. However, these come
with standard size barrel adjusters (good) but cause trouble
installing (bad), better cables than the Odyssey Gyro though,
but why would you want stock cables, they suck.. They work
fine, and can save you some money as the price is a bit less
than Gyro's. These do not fit over King and other large
headsets, however, they can be modified to. Check below for
how to make one fit a larger headset. |
| If you cannot tell, I prefer the
Odyssey center bearing unit, and SST cable stops. I actually
only use the lower as I prefer to use a Gyro Friendly stem,
eliminating the top plate. The stem, uses smaller adjusters by
the way. Most people never know the difference, but then,
their the ones with the brakes that almost always run
terrible. The more you know about brakes, the more you will be
able to dial them. Stems and frames with Gyro tabs are great!
They allow you to lower your stem, and have less flex than
stock cable stops. They are also often slotted. Allowing
easier assembly and disassembly. Making the larger barrel
adjusters not needed, which is good since most use smaller
barrels. Be aware of this if you buy a gyro with stock cables,
and sometimes, the adjusters are not interchangeable on the
cables they come with. Which means you will be buying a new
cable as soon as you pull it out of the box :(. Check before
you leave, as some shops will swap it for you if you need it.
If you have one put on at a shop, and have built-in cable
stops, ask them BEFORE you have them install it, or you may be
buying cables. I know it sounds cheap, but remember, most shop
employees are just like you. They learn by doing and many do
not even know how to tune a Gyro, much less realize there will
be a problem. I am not excusing them, but that's life.
Employees work for cheap just for the honor of working in a
shop. My advice, read this guide, and do it yourself, but
remember to ask for the other cable only if you need it!
|
|
Brakes |
| Here we go, now we get to the
interesting part. You probably skipped to this didn't you. I
suggest you read the parts before it as well. Especially
cables. Brakes have a huge impact on braking (duh!) as
well as how much maintenance you will be doing to keep your
brake dialed. Some brakes hold their settings better than
others. Some are easier adjust than others. Any brake has the
potential to work great though (well damn near any).
Side Pulls/Caliper brakes. I am sure most of you
know what these are. They come on cheap Kmart/Wal-Mart bikes,
but they used to be standard on everything. Run from them as
fast as possible. They suck. Plain and simple. You can get
them to work well with some of my tips, but the last guy I
told how to get his working well are no longer working. They
worked so well, the arms snapped off. They are crap, but back
in the day, it was all we had. The moral is, you can make any
brake grab, the question, is can it handle it. Sidepulls
cannot. By the way, its usually the center bolt snaps
before an arm.
V-Brakes. You have seen them on mountain bikes and
race bikes. Why not street. Two reasons. One, they can stick
out and snag you at the worst time. Two, as the above brakes,
they cannot handle the stress of street. Don't get me wrong,
they work great, but the posts and the way the posts are
mounted are not up to the task. For a race bike or MTB they
rule. Shimano rules this market. XTR's have been THE brake to
own for years, and for good reason. XT's are almost just as
good. New LX is right up there now too. Anything else is just
a substitute, don't try to fool yourself.. As has been said
though, you can get any brake to work decent though. its only
how much time, money, and effort you are willing to spend.
U-Brakes. These started on mountain bikes. Then V-brakes became the
norm. Just as u-brakes started catching on in bmx, U-brakes
were dead for mountain bikes. Since Shimano did not
really do much for BMX, they stopped making their wonderful
U-brakes. They are still around, but they have been out of
production for going on 15 years. Dia-Compe still makes
theirs, and has become the standard for U-brakes. Those that
remember, still long for Shimano's though.
Since the Shimano's demise many U-brakes have sprung up.
Some good, some not so good. The newcomer in it, is Odyssey.
They did their homework though. They based theirs off the
Shimano U-brake heavily and for good reason. The first batch
had a tolerance problem, but that appears to be over. if you
have a set of the old ones, and they mess up, send them in.
Odyssey has great customer service.
If you have a brake I do not recommend, or is not on the
list, do not fret. We can still get it to work well, but
keep this list in mind next time you have some money and are
willing to spend it on brakes.
Lets take a look at what's out there for U-Brakes.
|
Type |
Summary |
Shimano

 |
No longer available. But oh so nice.
Spring adjustment is odd, as you put them on, and rotate
them, then lock them down. That's it! Great leverage.
Lighter than they look. Beware of the cheapie
model.
Shimano had several models. One was steel plates with
molded plastic around them. They work good, but weigh an
awful lot. Most of these are gone, as the plastic got
damaged. Look for Exage (silver) or the rare XT's
(black). I have seen
people buy whole bikes just for these brakes (me
included, I paid $15, then sold it with a generic
brake for $80 a week later). These convert to dual pinch
bolt for dual cables really easy. See below.
The King of U-brakes, too bad he's
dead. |
Dia-Compe 990's
 |
Oldest U-brake on the
market. A bit tough to adjust, but once adjusted, you
will not mess with it again. The pads are held extremely
tight. Comes with good pads. Weird front brake
adapter though. A 990 properly adjusted can challenge
any brake for the crown for power. If you are willing to
spend a bit of time learning how to dial these, you will
be happy with them. Since it will probably be the last
time you mess with them for a long time.
This is bulletproof braking at its best. Possibly
the King of U-brakes. |
Odyssey Evolver
 |
The new kid on the block. A
really nice brake. Loads of options. Comes with great
pads. Excellent leverage. Easy to adjust and dial. It
even comes with 2 sets of springs, and instructions,
that are better than almost any other out there (still
lacking in my opinion). Certain pads have trouble
gripping these so the pad moves. Its not the brakes fault though, as you
will see in the pad section and during install. Some
people are also claiming the spring adjuster slips a
occasionally. A little extra strength when tightening
fixes that though. These are easy to get great braking
out of.
A little extra care and few tricks when installing
makes them even better. If you cannot find a Shimano, or
dial a 990, or just need the new cool parts, this is
your brake. If its not the King, its leading a hell of a
revolution. |
Dia-Tech 996
Hombre
 |
Not a bad brake for the
money. Easy to adjust, but tends to fall out of
adjustment quickly. Horrible springs. Turn the spring
adjuster too far one time and you'll be buying new
springs. Crappy pads toss them. They flex a bit, but if
you need a brake and your on a budget, these are not bad
to have. However, by the time you buy good pads, you
would have spent more than a 990 (its only about $3 more
for a 990 as it is), or been about $3 short of an
Evolver, that comes with better pads than both of those.
Braking power is ok, as they flex a bit more than the
brakes mentioned above. These can be great brakes, but
you can buy better brakes for less by the time you get
them working decent. |
|
Dia-Tech 996
Hombre with Fiesta Pack
 |
The Fiesta pack adds
different pads, and aluminum low profile spring plates
and lower bolts to the Hombre. If you have the chain
clearance, save the money and buy the regular Hombre.
Use the money to get better pads. This brake has all of
the previous problems, except it now has lighter,
lower spring plates. For the same price you can get
990's, and by the time you buy pads, you would have
spent more than an Evolver. Unless you need chain
clearance, and are on a budget, I would stay away from
these. |
Tektro FS20
 |
Worst springs you will ever
see. Its rare to see an older FS20, since the springs
break after an adjustment or two. The Hombre is just as
cheap. Get that instead. or spend $3 more and get a 990.
The pads, are just junk as well. As for its braking.
Mush is a good way to describe it. |
|
|
Brake Pads |
| Here is another place people disregard.
Thinking what ever comes with the brakes will work great.
WRONG! There are many , many pads out there, unfortunately most
people never experiment at all with them. When I was a
flatlander, there were times I had more types of pads than the
local shop. In fact, I still do, I think.
I am amazed at the lack of experimentation there is in brake
pads. Yet people constantly bitch about how bad their brakes
are. Shops are not much help. I asked and asked the local shop
to order me a certain set of pads for a year! No, I did not pay
for them up front, but I was regular and even knew the
managers, and had done this with
several other parts. Fact was, they felt a pad is a pad. I did
eventually get them, after I became a manager there. We also
sold countless numbers of those pads, when the former manager
could hardly move pads. There were times I could not keep them
in stock. I had 25 on order (a lot for a small shop) and half
were claimed in 2 days, while they were en route! Its not like
we were short on pads, we were just out of those ones.
Once you find a good pad, let your friends know, and make
sure the shops know, that way you can be sure to have them
available. After my shop closed, I recently tried to get a
pair. I called 6 shops in a 30 miles radius. Not one had the
pads I wanted. Yet, I was selling out of them. They refused to
carry them. Why? because people buy pads to match their bikes.
Nothing else is considered. How many times have you opened a
set and slid it across the counter to see how sticky it was? I
thought so. I did that at a shop with 5 sets of pads, the
owner got pissed and I was "politely" asked to hurry up. Some
shops are just not customer friendly.
Over the years I have found a few that work, and many that
don't. As well as some interesting things along the way.
Threaded pads. This makes them easy to adjust. It
often makes them self adjust, as well, meaning they change
themselves, causing your settings to be destroyed. You get to
adjust them often, so its a good thing they are easy right.
There is a way to stop them from moving though. Threaded posts
are also thinner than post type pads. I have bent them several
times.
Posted pads. These are what are used on 990's.
They make it a bit tougher to adjust. They are a bit stronger
as they are thicker. Even aluminum posts are very sturdy.
Some pads are available in one style only.
Fat pads Vs., Thin pads. Lately a
new trend has arisen out of the tall rim sidewall trend, fat
pads. Some examples are Phat Padds by Koolstop, and
2X4's from Odyssey. Odyssey, and Koolstop are just some of the
manufacturers making them. My advice, is to stay away from
them.
The idea behind them is that they
have more material to grab the rim with. Which works, for a
time. They work great when the rim is clean. That is where the
problem begins. How often is your rim completely clean. When
your rim gets dusty, the pads soak up the dust, making them
work like crap until you clean them again. With a thin pad,
the dirt gets pushed out of the way. A thin pad also has a
higher PSI (pounds per square inch), than a fat pad, which
allows it to push the dust off around the pads sides, and push
the dust into the pad and grab the rim. Basically your
brakes may not work as perfect when clean, but as soon as you
get a little dust on your rim, which is normal, your brakes
will work much better than with a fat pad. Go dirt jumping
with a fat pad, and your brakes won't work for shit when you
get back. With the right thin pads, you will hardly notice,
and after a few stops back on pavement, you will not even know
you went jumping.
|
Company |
Model |
Summary |
Threaded
or Post |
Simple Green compatibility |
| Dia-Compe |
990
 |
Comes with 990's. Not a bad pad really.
Most people under-rate it. |
P |
Works great |
| Dia-Tech |
Hombre
If you have them, you know what they look like. |
Not worth much. |
T |
Improves them |
| |
Dekka/Fiesta
 |
Just about as bad,
especially after they glaze over. Green only. |
T |
Improves them |
| Koolstop |
Salmon Compound

Eagle Claw II in Salmon |
This compound is available on all the
Koolstop pads listed. Great pad. Possibly the best, but
hard to find. Its an orange color as you can see.
*See below
for more. |
T and P |
BAD.. Very bad.
** |
|
Other colors |
|
| |
Thinline
 |
Awesome pad. A bit anemic though, as I
have bent the posts, the bodies more than once. One of
my favorites. |
T and P |
Works great |
| |
Phat Padd
 |
Not a good idea.
Suffers from obesity. See Fat
pad Vs,. Thin pad above. |
T and P |
Works great |
| |
Eagle Claw II
 |
Great alternative to Thinlines as its a
bit beefier. Not available posted in salmon. |
T and P |
Works great |
| |
BMX
 |
Black or mix. Mix uses some black,. and
some salmon. Though not quite as good. |
T |
Great to BAD.. Very
bad. ** |
| Odyssey |
1X4's
 |
Awesome pad. On par with the Koolstop
Salmons, without the shortcomings. Quickly becoming my
favorite pad. Great Job Odyssey. It even comes with
Evolvers. |
T and P |
Works great |
| |
2X4's
 |
Suffers from
obesity. See above about
Fat Vs. Thin. |
T and P |
Works great |
| |
Triax/New Wave
 |
Cheap Generic pad. Yet, works
Incredible. Very soft. Can make a brake feel squishy,
but will it ever work. We used to use them on sidepulls
and they worked. No guarantee on U-brakes though. White works best. |
T |
Works great |
| Shimano |
LX
 |
Great pad if you cannot get the others.,
Works great for V-brakes on silver rims. |
T |
Works great |
| Skyway |
 |
Compound is
the about same as a Koolstop. Becoming rare. but at one
time was considered a great pad back when Skyway was
still a player in the bmx market. |
T and P |
Improves them |
| Tektro |
 |
Not the worst
pad you will find, but FAR from the best. |
|
|
| Vans |
 |
Cool looking
and Rare, just avoid. Made by Koolstop. |
T and P |
Improves them |
My personal favorites are Koolstop Salmon Eagle Claws and
Thinlines, however Odyssey 1x4's are quickly growing on me.
Another alternative, that I like when I cannot get either of
these are the Shimano pads. On silver rims, I like these a
lot, as they collect less dirt than others, yet still work
great. Also, on V-brakes, these are hard to beat.
*A special note about Koolstop pads. People think
colors have some mysterious code, some do. For Koolstop, all
colors are the same, except Salmon (orange). This compound is
the same as the famous Scott/Matthauser pads in the 80's. The
stuff is incredible. Warning, do not use with Simple green,
they stick to it, and it builds up on the pads, making them
less effective when dust gets on your rim. If you are opposed
to orange pads, I suggest a sharpie permanent marker to color
the areas NOT touching the rim. personally, I could care less,
I just want good brakes, but I have heard people complain.
Also, Green is for Ceramic rims.
** Simple Green is a cleaner
for bathrooms and such. Many people put it on their rims
making the pads stick even better. A further explanation is
down below in the brake dialing are Many will think this is a joke, but after reading it,
and trying it, you
will see why its not...
Click here for brake pad tuning and
troubleshooting. |
|
Installation |
| Couple things you will need.
|
Equipment |
Lube
 |
Your going to need to
lubricate some parts. For this job, you will need some
grease, that is the minimum. Any grease will pretty much
do, but you should have some good bicycle grease for use
on other parts, and that is what I recommend here. I
recommend Phil Wood grease or Bullshot grease.
You will also need to lube your cables. For those who
do not know, yes, this makes a difference. Tri-Flow
works but leaves a lot of oily residue. Candle wax
rubbed on it works, but too much makes the cable
sluggish until it breaks in. Grease can be used but is
messy, since you put some on your thumb and index finger
and slide it through.
I recommend White Lightning. It goes in like a liquid
and then dries to a wax. You would be amazed what this
does for cables, especially older ones. if you have any
other lube in there, this stuff will clean it out and
replace it with its wax, takes only a moment to dry. It
does not collect dirt. Some people say it clogs, but
that due to not shaking properly or they left the cap
off and it has partially dried up.. |
Tools
No pic..
|
Depending on the brake,
levers and pads.. Allen wrenches. Your going to
need a 5mm. almost guaranteed. you may also need a 4mm.
and 2mm. depending on your brake and lever.
Wrenches. You will need a 10mm in most cases,
and often an 8mm.. For Evolvers you will need an 11mm.
For standard straddle cable systems, 2 10mm wrenches
make it easier.
Wire cutters.
Adjustable wrench (Crescent wrench). I know
most places will not recommend this, but in this case it
has merit and I will show you why in a bit.
Others...
Depending on what optional parts you have, setup, and
problems, you may also require tools to remove your
stem, File, sandpaper, razor blade, hack saw, Dremel or
rotary tool and more. |
| Cable tip
No pic, you should know what these are.
|
These are use to cover the
end of the cable so they do not get frayed and poke you.
You could also solder them.
|
|
|
Levers |
| Levers are usually the
simplest part of installation. I usually do it first to get
it out of the way. If you have a hinged lever, your in luck.
If not, you will need to remove your bar end, and grip
first. After that its pretty straightforward. Biggest thing
is the hold down bolt, or hinge bolt. Don't forget any
shims if you need them.


You want this bolt as tight as possible but still allow
the lever to turn on your handlebars if you put a lot of
effort into it. The reason is levers get hit when you crash.
Leaving this able to move under hard hits, will keep it from
being damaged. This is probably the only bolt I suggest
doing this with on your bike though.
|
|
Odyssey Modulever cables |
| Modulevers come with 2
cable adapters. The only difference is if you are using the
dual or single cable. The dual cable will work with single
cables too. So you really only need one. I included this
section because the cable install is completely different on
these compared to other levers.

Modulevers come with 2 cable adapters. The only difference
is if you are using the dual or single cable. The dual cable
will work with single cables too. So you really only need
one. I any case, the install is the same. Slide the adapter
over the cable.

Make sure the barrel adjuster is in all the way, so you have
room for adjustment later. Pull the lever back, then slide
the assembly into the barrel adjuster


Now slide the cable end into the hole, using the slot. Now
push the lever forward again.
|
|
Straight Cable |
| Easily the easiest setup
you can run. Though I do not agree it is the best.

Line up the barrel adjuster slots

Push the head of the cable into the slot on the lever and
into the hole.
(Bottom
View)
(Bottom View)
Slide the cable into the slots in the barrel adjuster by
swinging it toward it.

Put the barrel adjuster all the way in, and push the housing
up into it. Put it in completely, so you will have room to
remove slack in the cable later.
|
|
Stock Upper Gyro Cable |
XXXXXXXXXXXXXX
Line up the barrel adjuster slots
XXXXXXXXXXXX
Push teh head of teh cable into the slot on the lever and
into the hole.
XXXXXXXXXXXXXXXXXXXX
Slide the cable into the slots in the barrel adjuster
XXXXXXXXXXXXXX
Put the barrel adjuster all the way in, and push the housing
up into it. Put it in completely, so you will have room to
remove slack in the cable later.
XXXXXXXXXXXXXXX
Hook the other end into the upper gyro plate, and slide the
balls over the tabs of the gyro.
|
|
Dual Upper Cable/Dragonfly Gemini type |
| Par |
|
Stock Lower Gyro Cable |
| Par |
Tips, Tuning and
troubleshooting
|
Levers |
| Grease. You should
grease the bolt on the clamp. The pivot is optional. As it
will attract dirt and cause wear. This is a judgment call. I
usually lube them after they are old and start to feel like
crap. At that point you have little to lose. You should also
grease the cable end where the lever pulls it. Friction here
is what causes them to break here. Clamp. Do not over
tighten the clamp of your lever. Doing so increases the
likelihood of bending, breaking, or stripping your
lever. You want it so tight that it is hard for you to move on
purpose. This way, in a crash, it will move, and you can just
move it back. I had one lever too tight and it bent 90
degrees. It was only a week old, luckily it was soft enough to
bend back. A bit later in their lives I stripped the clamp
nut. probably due to how tight I ran them when they were new.
Pivot. Keep the lever pivot tight enough so your
lever handle does not flop around. that will make sure the
bushings inside do their job. make sure the lever handle is
still friction free or it will make your brakes sluggish.
| Shims. Many levers nowadays come with shims. I used
to laugh at Dia-Tech. The lever was hinged, but they gave you
a one piece shim. What is the point of that? New ones come
with a 2 piece one. Do yourself a favor, if you have an old
one, split it. |
 |
| Handlebar
bends. Does your lever sit on the bend of your bars.
You need to make your lever adjust to the curve. Best
thing to do is to make the lever adjust to it slowly..
Loosen it up as far as possible, slide it over the bend a
little. Now tighten it down, a little extra tight. Now
repeat after sliding it further down the bend. Eventually
you will get it where you want it, and the lever should be
fine with it. |
| If the lever uses shims, this
makes it even easier. Clamp the lever down on the bend
without shims, Then insert them and do the same as above.
Also grinding out the center of each shim will help also.
This can be done with a Dremel, Die Grinder, Hack
saw, or files. |
 |
Proper bending!
We get asked this a lot.
How to properly bend your brake lever for that "custom
feel".
First a warning. You can easily break your lever doing
this.
Second... NO HEAT. Aluminum is very reliant on heat
treating. Any heat, will damage this.
Third.. Plastic internal washers. These are the bearings for
your lever. By using any method other than the dual wrench
method you risk destroying these washers. Yes, even the seat
post method will do this. Then again, so will crashing...

Here is what they look like after a year as it is. Not
pretty. Using the wrong method will make them look like this
as soon as you bend it.
Proper method..
Using 2 box end wrenches is the best method, as the
first wrench holds the lever in place, and keeps the washers
safe. The second wrench (you could use your post here also),
does the actual bending.

Unlike in the picture, separate the wrenches by about 1/4in.
for best results. Go slow and apply steady pressure so the
lever does not snap
Secondary Method
While not as good as the dual wrench method, this
is the easiest method for bikers to use.

Simply find a seat post, yours will work.. and slide it over
the lever, and apply pressure. Go slow and apply steady
pressure so the lever does not snap
|
|
Cables |
| Lube your cables. White Lightning and
Tri-Flow and other liquids allow you to do this without
removing them. You want something that won't stay in liquid
form really, so grease and candle wax works good, but require
removal. That why White Lightening works so well, it goes on
like a liquid and dries to a solid that does not stick to
anything. it also has another good quality, it contains a
solvent to clean out your cables as it it lubes them. Some
people say it clogs, but that is due to not shaking properly or
they left the cap off and it has partially dried up..
Cable End. You need to grease the end that goes into your
lever. This prevents it from snagging the aluminum and being
cut, crimped etc.. You should also check this every now and
then, especially if you hear cracking or pops from here. This
is where most cables snap.
Gyro/Oryg Cables. On stock cables, Lube is extremely
important. the more you can get into the cable splitters the
better off you are. the rest of the cables need lube as well,
but the splitter are where the majority of friction on stock
cables. Also remember your end in your lever.
Straddle Cables. check your straddle cable if you
have one. Check where it bends as it leaves the assembly. The
tight bends can cause it to snap here.
Cable ends/tips, they keep you from being poked and
your cables from getting frayed. You can buy tips from your
shop for a nickel, or you can solder them a torch or high
powered soldering iron is necessary though), or use a spoke
nipple. If I have no tips, I just use spoke nipples since I
have a lot of them laying around. next time you see a cheap
rim being tossed out, grab it and strip it for nipples. Other
things I have seen used, tape, stickers, etc.. Nipples and
tips are easiest, just slide it on, and crimp it. Cable
routing. When running a gyro or front brake, always try to
run the cables under your handlebar crossbar. This keeps them
held more firmly and keeps them out of the way. Only reason to
avoid this is if you have a super low crossbar, and even then,
its still recommended. Crossing cables.
Kinked Cables
 |
Look familiar? This sucks.
It seriously hampers your braking. This
typically happens at the lever. All other places
are pretty avoidable with proper cable routing.
This is what the Dia Tech Flexie was designed for. It
allows the cable to flex, but not kink like this. Put
the Flexie into the barrel adjuster on your lever and
your cable will not do this again. I would strap the
Flexie to your handlebar though. |
|
Dia Tech Flexie
 |
Cable Ties Ways to control your
cables.
|
|
Good |
Bad |
| Zip Tie |
Wrap and clip. |
Quick.
Simple.
Cheap.
Can be re-used again and again if left loose. |
Minimal colors.
One use only.
Tie can slide around. |
| Electrical Tape |
Wrap a few times around.
Extra helps, since it may come in handy later. Stick a piece of
tape
or another sticker piece under where the cable runs
through. This allows it to slide in and out, and keeps
dirt and the cable from sticking to it. You can slide
the housing in and out. for maintenance. |
Quick.
Simple.
Cheap.
Re-usable in a jam. |
Shrinks and leaves gunk.
Minimal colors.
The cable needs to move slightly. This stops it. |
| Stickers |
Stick a piece of clear tape
or another sticker piece under where the cable runs
through. This allows it to slide in and out, and keeps
dirt and the cable from sticking to it. You can slide
the housing in and out. for maintenance. |
Does not shrink.
Creative.
Lots of colors.
Can be re-used again and again if done properly. |
Can take some time to do,
depending on how creative you want to get. |
|
|
Gyro/Oryg |
| No Lube. No
matter what, DO NOT LUBE YOUR GYRO!
This is a common
mistake. The bearing in it is designed to allow dirt to pass
through. By lubing it, you are inviting dirt to stay in it,
damaging the bearings. If you do get lube in it, remove it
from the bike and soak it in Simple Green, a Solvent Tank,
Gasoline, etc.. If Simple Green, or gas is what you tried and
that fails, try WD40, and then spray it out completely with
Simple Green to remove the WD40. You want nothing in there.
Where to lube. On stock cables, Lube is extremely
important. the more you can get into the cable splitters the
better off you are. the rest of the cables need lube as well,
but the splitter are where the majority of frictions on stock
cables. Also remember your end in your lever.
Cut Cable Removal Slots. Ever notice how stems
with Gyro tabs have slots to slide the cable in and out of.
This makes install and removal a breeze, especially with dual
cables. You can do this really easily to your gyro plates as
well. It only takes about 5 minutes. Easiest way is with a
Dremel and a cut off disk. Simply cut a slice into it and then
a second one in order to make the groove wide enough for the
cable to pass through. I have also done this with hack saws
Cut a slot then angle the blade to widen). I have used both
ways and done them both on and off the bike. Dremels make it
easier.
|
|
Dual Cables |
| Lube. They still need lube, especially
up in the lever, but other than that, there is not much to
these. They seem more complex at first, but in reality, are
more simple than stock cables and work better too. Crossing cables.
This also works with dual cables. But depends on your
setup. See the tip here.
|
Cut Cable Removal Slots |
 |
Ever notice how
stems with Gyro tabs have slots to slide the cable in
and out of. This makes install and removal a breeze. You
can do this really easily to your gyro plates as well.
It only takes about 5 minutes. Easiest way is with a
Dremel and a cut off disk. Simply cut a slice into it
and then a second one in order to make the groove wide
enough for the cable to pass through. I have also done
this with hack saws Cut a slot then angle the blade to
widen). I have used both ways and done them both on and
off the bike. Dremels make it easier. |
|
Friction Reduction |
|


 |
Using something to help
curve the cables is a good way of reducing friction.
These do not crack like housing can when bending tight and
are designed to have less drag allowing you to bend
the cables tighter.
The amount you need to trim is determined my how much bend you need.
This one is stock length. See the front
brake area for how to trim either one.
Dia-Tech Flexies were actually designed to stop your
cables from cracking and pinching at the lever, but they
work great here.
V-Brake noodles were designed to ease the cable bend on
V-Brakes. .
I thought of this setup after seeing Chris Duncan's
dual Dia Tech Flexie setup. Instead of V-brake noodles, he
used Dia Tech Flexies. I use these on my front brakes.
See here for my front brake Flexie.
V-brake noodles are cheaper and easier to find and are usually about $2 a piece. Flexies are $10 a
pair. You also can get V-Brake noodles that are
flexible. These will work great in this situation, since
there is adjustment already in other places. They are just
like a V-Brake noodle, but with a flexible center. Price
is about the same as a normal noodle. See teh black on on
my red frame to the left. |
|
|
Brakes |
|
Cable Slack.. Whenever possible try and leave enough
slack that you will be able to unhook your brakes if
necessary. You can always turn an adjuster and dial in the
exact amount of slack you want after. This way if a rim is
bent, you can loosen your brakes up and make it home, or
disconnect completely if needed during maintenance, such as
pad cleaning. Shimano
dual adapting
|
Evolver Cable Lug or Knaarps |
The cable lugs
on Evolvers have a few minor problems. I'll show you how
to improve them, and correct these problems.
| You will need.. |
2.5mm allen wrench (or
Std. equivalent)
11mm Box wrench
8mm box end wrench
Dremel, with a sanding drum (a file or a
grinder and some sandpaper also will work) |
|
|
|
Brake pads |
| You probably think this section is a joke.
Its not. in fact as you read you will discover why its
actually very important. Its funny, Koolstop has the
best compound, and great designs, but they have a lot of
stupid features and require the most work to make work
properly.
A good cleaning solution is crucial to your pad as well. It
will help clean it, and also if used after grinding, will help
break them in to your rims again. Since pads need to break in
and adjust to your rims shape a bit, even if they are
perfectly flat. I recommend Simple green for
this, on salmons, do that and then thin with water or dust if
its too strong after they break in. To break them in, just
follow the instructions on how to apply Simple Green and ride.
|
Ways to improve your pads. |
Nuts
 |
Ever seen these? They come on Koolstop
pads. They look like nice little brake nuts. Nice and
rounded. Nice too look at. Put them on a shelf and look
at them. Now go to the shop and get some real brake
nuts. These cause more pads to loosen than you can ever
imagine. The chroming on them allows them to slip and
slide all over the place and the coned shape makes it
almost impossible to remove them with vice grips or
anything else should the internal hex strip. They also
have few threads inside, so it allows them to strip the
brake posts, if the hex does not strip first. Even an
aluminum nut is preferable, in fact, the aluminum nuts
actually work pretty well. |
Mud Scraper
 |
See the flare at the end, that's bad.
Its designed to scrape mud and dust off your rim. I
don't ride in mud, neither should you. It makes the
brakes feel mushy and harder to dial. Why Koolstop
insists on leaving this on after all these years,
especially on bmx pads, is beyond me. You need to
grind the pad flat.
See below for how to do this.
|
Rims
 |
While not actually your brake system,
your rims have as much to do with it as anything else.
there are 2 opposite schools of thought on this. Some
feel chrome locks up better, but offers little
modulation, and requires more pressure to grab.
Others feel non-chrome rims offer better braking as they
offer more modulation, and dry faster when wet. My
theory is modulation is learned, and I try to avoid
water anyhow.
In my opinion chrome rims stay cleaner and do not
collect as much gunk like non-chrome rims do and offer
better braking. This has been the belief of flatlanders
since the beginning of freestyle.
I subscribe to the chrome theory, Seditious Canary
subscribes to the non-chrome theory.
Take your pick and run with it. |
| Glaze and wax removal show
grinding..
|
When brake pads are made, they are made
in a mold. In order to remove them from this mold, they
use a release agent similar to wax. You see it on new
tires and grips as well. They also get glazed
after use. Silver rims in particular. See below for ways top remove
this. |
|
Brake Boosting,
Cleaning and Additives to help stop faster. |
| One thing old flatlanders
knew was what worked to make pads stick well.
Whenever tours came through we always asked
what people were using for grip. Martin
Aparijo turned me on to Simple Green and has
been a part of my brake troubleshooting ever
since. I call them instant brake power.
Even when running Salmons I leave a bottle of
Simple Green in my car. You never know when
you or a buddy will need a bit of extra brake
power. You can always clean it off
later. It also works a bike cleaner. We used
to use it at our shop as it cost a quarter of
what bike wash does.
It does not take much so a small bottle
lasts a long time. I have a 22 ounce bottle
(cost me $8 I think) well over a year old and
its still half full (although its thinned
50/50). A quarter of it was lost when a
container I had it in broke. Your mileage may
vary.
|
Cleaners and additives. |
Coca-Cola
 |
get some on your finger, and wipe it onto the
rim. If you cannot wait for it to dry, roll around for a few minutes with
your brakes on. If you do that, it may take a few helpings to achieve the
desired effect. Your brakes will squeal like a goose with this stuff and
vibrate your bike. |
Super sticky, cheap, easy to get. |
Corrosive, remember science class. Also, pads
stick too well, Your springs may not be strong enough to release. This ma
seem like a non-issue until you are in a nose pick and need the wheel to
move freely or your going over. That initial stick can be crucial. Lacks
consistency. Some spots stop incredible, others only some. |
Eye Contact Cleaner
 |
Spray or wipe on (quickly, don't remove it
all), wipe off. Ride with brakes
on for a moment to dry completely. This gets your rim super clean. Multiple
applications makes it better as more dirt is removed from the rim and pads. |
Have not tried this, but it used to be rated
as better than Simple Green but not as good as Coke, however, it does not
cause the pad to stick. Consistent once dry. |
Expensive!! Nothing there to assist the brake
except bare rim. |
Simple Green
 |
Spray on, wipe off (quickly, don't remove it
all), ride with brakes on to dry.
Multiple applications makes it better as more dirt is removed from the rim
and pads. Thin to 50% or less with water, and put into small spray bottle. |
Leaves a clear glaze that makes your brakes
work killer. Can be re-activated with a little water/spit on your
finger.
Consistent once dry. |
Downsides?
None really.
Except that Koolstop Salmon gets glazed from it, which can be good and
bad, depending on how much dust is stuck in the glaze. Can be hard to find
in some places |
Fantastic Bathroom Cleaner
 |
Spray on, wipe off (quickly, don't remove it
all), ride with brakes on to dry.
Multiple applications makes it better as more dirt is removed from the rim
and pads. Thin to 50% or less with water, and put into small spray bottle. |
Does not leave as much residue as Simple
Green. Which is good and bad depending on the situation
Consistent once dry. |
Downsides?
None really.Can be hard to find in some places.
Not quite as good of braking as Simple Green. |
Window Cleaner
|
Spray on, wipe off (quickly, don't remove it
all), ride with brakes on to dry.
Best used with Koolstop Salmons, as it leaves no residue. |
Leaves rim clean.
Cheap and easy to find.
Consistent once dry.
Great for Salmon Koolstops. |
Does not leave as much residue as Simple
Green. Not quite as good of braking as Simple Green unless using Salmon
Koolstops. |
Tar
|
Roofing tar. You form it into a ball and
rub/grind it onto your rims. Grinding your rims first also helps. Its
suggested to keep this all in a film can or something so it does not make a
mess. I have not tried this, its a trials rider thing. |
Locks big time. |
It sticks to everything, and can make a mess
if your not careful. Lot of work.
Possibly same problem as coke with sticking after you release.
Inconsistent. |
| Sanding |
Basically just take some sand paper and rough
up the side walls. Obviously not in a circle around the rim. A disk grinder makes it
easier. |
Great modulation. Nothing to take with you.
|
Messy. Wears down your rim.
Wears out especially if it gets wet.
Inconsistent.
|
| Water |
Spray on/wipe on, wipe off (quickly, don't
remove it all), ride with brakes
on to dry. |
Cheap, easy to find. Leaves the rim clean. |
Only cleans the rim, and not as good as other
cleaners. |
|
|
Wax and glaze removal |
| Sidewalk method. |
This works great. Take the pad out to
the sidewalk, and rub it across the ground a few times until
it flat, and has lost all of its shine. Wipe off the dust. Do
this and then after the brakes are setup and dialed clean the
rims and pads. |
Easy, relatively accurate, can do almost
anywhere there is concrete. |
Must be off the bike, does not leave the pad
completely dirt free. |
| File |
This is the best way. Grip the pad firm and
run it back and forth across it a few times to smooth it out. |
Can often be done on the bike. Leaves the pad
dirt and grit free. Pad is straight. |
Sometimes cannot be done on the bike. Need a
file. |
| Bench grinder or wire wheel. |
Bad way. They are too small to grind without
being close. I have seen pads go flying across workshops this
way, after being ripped from the guys hands. |
Fast |
The pad will not be flat. Can also burn the
rubber. may not be clean afterwards. Sand and wired can stick
into it. Also, must remove the pad from the bike. |
| Sand Paper
|
Sand paper. Best way is to disconnect the
cables and use your thumb to rub it against the pads. If you
cannot disconnect, then just feed it between the rim and pad
and slide it back and forth. Keep your hand as close to the
tire as possible as this will help keep the paper from
removing the corners. Be sure that no grit is facing your rim
or it will get sanded as well. |
Can be done on the bike, often without
disconnecting cables even. |
Does not leave a flat surface, and can leave
sand embedded in the pad. good for an occasional cleaning, but
a file or sidewalk should be used occasionally to straighten
the pad. |
|
Trouble |
Bent Frame
 |
How many have seen this. The pad on the right
is a little bent, but look at the one on the left! Remember above, it said
your pads should be flat. These aren't. As a result my braking power
dropped. You can temp fix it by grinding the pad flat again, but that is
only a temporary fix. The problem is that the internal frame has bent, and
will now continue to do so, it is time for new ones though, as there is no
way of know when they will break, and when they do, it will damage your rim,
tire and tube. I have had this happen on several pads, not
just Koolstops. This shows how strong a good setup really can be. |
Bent Post
 |
This I have only had happen on Koolstops as
they are one of the only companies using an aluminum threaded posts.
Again this shows how strong a good setup can be. when your damaging brakes
and pads, you know you have some power going on. I am not expecting anyone
to do this. I have very strong fingers and a killer brake system. When
this happens its time to start looking for new pads. This is one reason I
like 990's so much. they use a thicker post to mount the pads on. Unless you
get into a car accident, you will never bend even an aluminum post on 990's
(or if you set them up wrong. |
Split Pad
 |
Here you can just start to see the frame
peaking out of the pad, I pulled it open a little so you could see it
better. I have had several pads do this as well as Koolstop. Why it happened
on this one, and this end, I am not sure, its brother did the same thing
(see bent frame pic above), but not as bad. What's weird is that is the back
side. Only thing I can think of was I either had the pad backwards
(unlikely) or I had been doing a lot of backwards stuff, which I tend to do. |
|
Glazing |
|
|
metal shavings |
|
|
|
Front Brakes |
Installation
Front brake install is the same as rear with the exception
of cable install. So for the rest of it, Simply
look at the rear brake install as
I will only be covering the cable installation and tips here.
Almost all tips general braking tips apply here as well,
obviously.
Leave the inner wire in and run the cable down through your
stem. Leaving the inner wire in, adds stiffness and reduces
the likelihood of kinking the housing. If your fork has a
cable guide, use it. Some brakes use a housing stop on
opposite sides from others. Dia Compe 990's are opposite from
Dia-Tech Hombres, so your fork may have mounting on only one
side. If this happens, use a zip tie to secure it to the fork
and away from the tire. Other methods will not hold it well
enough and are too hard to do, due to the tire being so close.
If it rubs it could become a serious problem.
I recommend looping the cable inside the fork leg. It keeps
it tucked inside and allows a wider loop that will not rob
movement since the housing operates one half of the brake.
many people prefer outside a it can sometimes offers a better
cable curve. I dislike that as it allows the cable to flop
around unless its extremely short, in which case, you negated
any improvement you made.
Your loop should have a 4 top 4and half inch diameter loop
and still have enough cable to reach the adjuster. A little
more or less is ok, as its not an exact science.
Measure it all out, double check it, mark it, REMOVE THE
INNER WIRE before cutting!!, or at least pull it safely
out of the way, and then cut it.
Feed the inner wire back in feed the housing to the
adjuster, and resume normal brake
installation.
Front
Brake tips and tricks
|
Friction Reduction |
| Using something to help
curve the cables is a good way of reducing friction.
These do not crack like housing can when bending tight
and are designed to have less drag allowing you to
bend the cables tighter. |
V-Brake Noodle
 |
These were designed to ease
the cable bend on V-Brakes. I trim mine, as you can see.
The amount you need is determined my how much bend you
need.
To trim, remove the end furthest from where the housing
enters the noodle.
just yank it off. Slide out the Teflon sleeve, then trim what you need
with a Dremel or hack saw, then re-install.
These are easy to find are usually about $2 a piece.
|
Dia-Tech Flexie
 |
These were designed to stop
your cables from cracking and pinching at the lever, but
they work great here. I have been using this setup
since the Dia Tech Flexie was first released. These also
do not crack like housing can when bending tight.
I like this better, it offers an extra adjustment
point.
I cut it down a little. Simply pull off the end going
into the brake, and trim what you need. I think mine is
cut 1/2in.-3/4in. Leave it long enough to point the
cable down, or close to it. Too long and the loop will
touch your axle. Too short and it will bend too sharp.
Assemble the brake, minus cable, hold this up to it, and
see how long you need before cutting.
Before this I was using a V-brake noodle, which are
cheaper, Flexies are about $10 a pair.
|
|
|
Gyro/Oryg & King
Headsets |
| Normally Gyros and Orygs will not fit on a
King headset. A few crafty people have managed to do it,
however most end up grinding the headset. Which I thought was
weird until I experienced why they did it that way. I have
however found a way that works without grinding the King
Headset. Here is the reason they were grinding the headset.
By grinding just the Gyro, the metal for holding the lower
cables becomes too thin. One night after a hard session I
noticed my brakes were weird, and noticed this. Catastrophic
failure of the lower cable bracket. I was bummed. I had spent
3 hours grinding it to work. have a look.
 |
The blue line is flat. Notice the tab the
red line is pointing too. Not good. |
From the failure though I started plotting a way to allow
to leave more metal. I was determined not to grind the
headset. I did not pay much for it, but it is a King and I
would be damned to chew one up for a $20 Gyro.
It did not take me long to find a way. In fact, counting
the amount of time I spent figuring out how to do it, and
grinding it, took less time than the first one. I think I
spent 110 minutes thinking it over, and 20 minutes grinding.
Doing this is at your own risk. It involves grinding very
close to your hand with a die-grinder or Dremel. I feel its
safe, but you may not. It is possible to clamp this into a
vice, but I do not recommend it, as you really need full
access to do it correctly and the pressure could damage the
gyro assembly. Do not complain to me. Also if you destroy your
Gyro, again, not my fault.
I have tried to explain it as best I can, and show you the
safest way possible. If you follow this guide, it WILL work.
You will need; a Die-Grinder or Dremel, and some
sanding/grinding stones, pliers, sandpaper, and White
Out / Liquid paper.
Basically what we are going to do , is use pry out
the lower tabs, then grind out the inside of the Gyro assembly
using White Out as a guide to show high and low spots that
clear and do not clear the headset. The reason for the White
out, is you want to remove as little metal as possible. When
we are done, there will be enough for about 2 sheets of paper
to slide between the cup and the Gyro. Its a tight fit to say
the least. It works though, and well.
First thing to do is bend the tabs. This is easily done
with some simple pliers. Channel Lock or Vice Grip style ones
will work as well. Make sure you pry against the upper
tab, and not the gyro itself. The upper tab will keep the
pliers from distorting the surface the bearings ride on. In
other words, you will warp it and it will not spin properly.


You want to pry them outwards. Like the Blue and green
arrows obviously.
| You do not need to do much. Just enough to move them the
slightest bit. Remember, your only doing this so you do not
have to grind them as much. Any movement should be enough. The
king only hits by about 1mm. Set it down over the King cup,
and see if the bottom of the tabs clear it. If they do,
then your done with this. It should slide down like
this.-----> As you can see it doesn't go all the way,
but only past part of the tabs. |
 |
Grinding. Now its time for power tools. This could
be done with a round file, but I would not recommend it,
unless you like torture. You could put a round file into a
drill and spin it to do the job if you have no die-grinder or
Dremel. However, I think its worth the $30 you would spend on
a cheap Dremel to get your $120 headset working right.
| Go in a circle in the direction that
causes the most friction. You will need to hold the tabs
also so it does not spin. You go in a circle while
removing most of the metal to hopefully reduce the amount
of high and low spots. As you grind you will need to check
your progress against the headset. Slide it over the cup,
and grind the high spots. |
 |
| As you get closer and start to see
daylight around some edges, now is time to break out the
White Out. Put a thick coat over the outermost edge of
your headset. Now pres the gyro back onto the cup, and
twist. When you remove it, the high spots inside the gyro
should have some white on them. Grind these spots, and
keep repeating. you may need to add more White Out.
Do not remove what White Out is on there. The idea is
that it will build up a thick layer. When the Gyro goes
over this thick layer, you will have sufficient clearance
over the headset. If you think it is getting too
thick, remove it, and start again.
As you can see, its a very tight fit, but it does work,
and the headset is still covered by King. |

 |
| When you are done, take some sandpaper,
or a sanding drum and smooth any hard edges, and smooth
out the inside. It should look similar to this. |
 |
Now take a cleaner, like glass cleaner or Simple green and
wipe off the White Out. it should come off relatively easy. If
not, scrape it with a fingernail.
The Gyro should slide freely over the headset, and not feel
as though it is grinding against it.
Now assemble as normal.
Since you are running a King, I highly suggest taking a
look at the King modification guide. It
documents how to make the King work like an normal headset,
and eliminate the wiggle due to the O-Ring. When you're done,
it will feel rock solid. |
Wrap up.
|
That's it. |
| Once you have performed these tips and tricks
on your bike, your braking should be much better and more
consistent. So much that you will be able to feel when
something is wrong. Even the slightest stretch will be
noticeable. this may sound like a burden, but in reality is a
good thing. You will now be able to tell when something is
wrong much sooner, and allow you to fix it before it becomes a
problem, but don't worry, if you followed the advice here, you
won't be even messing with them as much as when you did
not care about your brakes more than likely. The idea is
better brakes, with less effort. Not just better brakes.
As you can tell by the intro picture and
cable pictures, I have a few parts laying around. Those
pictures do not even show how much brake hardware I have
damaged, destroyed, got tired of screwing with, or
simply went through in the last 6 months or so. That's right,
6 months and that's just what I still have of it! You do not
even want to know how much I have gone through in the past 15+
years gaining this experience.
While most of my brake
dialing skills were honed over many years, I am always trying
something new. This guide represents a culmination of
that information.
As new information comes in, and new brake products come
out, I will update this guide to reflect that. If you have any
info or questions on this, e-mail me, I will be glad to help.
In the meantime, I can only hope that this will save you
time, money, and effort on your brakes.
Follow this guide and save the experimentation to those who
wish to. Thanks for reading. |
|