RCR40 Shifter w/ZF 5D-25-2
- Thread starter Rod Dittmar
- Start date
Randy Folsom
Supporter
Thx for the information. My cable travel maxes out at 19mm. That is as measured at the shifter box so no loss from cable play. I don’t see any way I can adjust it to increase it. Others report they also have about 35mm of travel. Guessing that is the root cause of my problems.
Chris Kouba
Supporter
Randy,
One of the things I had to do on mine (and the other 3-4 shifters I've worked on) is maximize the throws of each lever in the shifter. There are heim joints in the shifter and I extended them or retracted them as far as possible to get the max movement at the cable connections. If you haven't done this yet, I'd recommend you start with that.
For at least one shifter, I replaced the male heim with a longer one to get even more travel. Not sure you'll be able to double what you have (19 to 35mm) but you should be able to improve the total throw available.
Chris
One of the things I had to do on mine (and the other 3-4 shifters I've worked on) is maximize the throws of each lever in the shifter. There are heim joints in the shifter and I extended them or retracted them as far as possible to get the max movement at the cable connections. If you haven't done this yet, I'd recommend you start with that.
For at least one shifter, I replaced the male heim with a longer one to get even more travel. Not sure you'll be able to double what you have (19 to 35mm) but you should be able to improve the total throw available.
Chris
Randy Folsom
Supporter
Chris, Thx much. I was able to increase the travel to 38mm at the shifter box and 35mm at the cable end by increasing the lengths of the fulcrum arms. I added about 3/8” to the length of the larger arm with a jam nut and 1/8” to the smaller arm with a couple of spring washers. Cheers, Randy
Chris Kouba
Supporter
If you don't have sufficient travel yet, you can also mill down the face where the non-extended heim threads in. Stick an Allen screw in there first to ensure you keep the thread clear though.
Randy Folsom
Supporter
Yeah, shortening that arm would have significant impact. Thx much.
Randy Folsom
Supporter
Success (I think). I won’t know for sure until it’s running, but it seems I have solved the travel issues with help from the good folks on this forum.
I did have to make a new bracket for the long rotation cable. The new bracket moves the cable stop plate about 1” closer to the shifter linkage because with the provided bracket my cable was too short.
Summary of modifications:
Not directly related to the linkage, but made a huge difference when making adjustments, I removed the tubes on the shifter box and replaced them with brackets (thank you John Howard).
You may also notice that the shifter box is welded to the mounting feet at a slight rearward tilt. I notched the front and back of the box so it straddles the spine (1/2” in the back and 1/4” in the front). The mounting feet are the same as used for the parking brake.
I did have to make a new bracket for the long rotation cable. The new bracket moves the cable stop plate about 1” closer to the shifter linkage because with the provided bracket my cable was too short.
Summary of modifications:
- Cut 1” off the Quaife’s shifter rod
- Drilled out the hole in the Quaife shifter rod from 6mm to 1/4”
- Added a 3/4” x 7/16” spacer to standoff the push / pull bell crank
- Cut about 1/2” off the male end of the push / pull rod end so that the distance between rod end bores is 2-1/8”
- Fabricated a new bracket for the long rotation cable
- Trimmed 1/8” off the shifter’s 90 degree pivot block short arm*
- Extended the long arm of the 90 degree pivot block by 3/8” with a stop nut
- Extended the boss on the shifters rotation bar 1/8” with washers
Not directly related to the linkage, but made a huge difference when making adjustments, I removed the tubes on the shifter box and replaced them with brackets (thank you John Howard).
You may also notice that the shifter box is welded to the mounting feet at a slight rearward tilt. I notched the front and back of the box so it straddles the spine (1/2” in the back and 1/4” in the front). The mounting feet are the same as used for the parking brake.
