A better way to replace front brake cable

yakitori · July 15, 2024, 6:48pm

I previously replaced the rear brake cable on my Strida.

I have since replaced the front brake cable as well and it was very difficult. It was on Christmas day last year that I did it and I drew pictures explaining this today and I will ask questions about this work.

First, when I tried to pull that front brake cable out, the outer housing seemed to break in this position. (Actually, it may have ruptured when I pulled it out)
Therefore, all of these outer housings and inner wires had to be pulled out.

I then tried to insert the new brake cable into the front tube, but I could not insert the cable beyond this 90-degree bend in the front tube, and I had to remove a part in this area to continue the process.

I used a flathead screwdriver and pliers to remove this part, but I scratched this part.
I had to remove this part and manipulate the cable through the open hole as if I were a surgeon. This was also very difficult.

Then, after much effort, I was able to get the cable to penetrate to the wheel, but had a very difficult time getting the brake cable outward through the hole in the front tube. I worked on this for a long time and finally managed to get it out.

I cannot put thin pliers into this hole, nor can i use tweezers or other tools to grab the brake cable in the hole. In fact, I don’t remember how I took it out anymore.

The Strida manual states that the front brake cable should be inserted from the bottom up, and I tried to do it from that direction, but I just couldn’t get through the 90 degree bend in the front tube this way.

The brake cables will surely break if the Strida has been driven for several years. Therefore, if there is no mechanic nearby who is familiar with Strida, these tasks should have to be done by the owner at some point.

Is there an easier way to perform these tasks? I am particularly interested in the following two points

Is there any good way to remove part 215-15 without damaging it?
Is there some means or tool suitable for comfortably extracting the brake cable through the small hole in the Strida tube?

I will try to use these tools next time I do this work. (I don’t hold out much hope, as I have made and used one similar to this wire, but could not successfully get the brake wire out)
https://www.amazon.co.jp/dp/B07MVC9MX5?language=en_US

Blackstridaaustria · July 15, 2024, 7:42pm

I think yes.

I mean no, this part has to be replaced anyway.

I do believe so, it is an overlength brake cable ( ~ 3500 mm)!

Step 1: Remove the old brake cable.
Step 2: Thread the new cable housing over the extra long brake cable.
Step 3: Insert the extralong cable into the old housing!
Now, you can push and pull (at the same time - two helping hands recommended) the old housing out and the new housing into the tube - you have a perfect guide.
Step 4: Remove the old housing, then remove the extralong cable.
Step 5: Insert the new cable - done.

yakitori · July 15, 2024, 8:22pm

Hi Chris. Thanks for everything!
Ah, I see.
Writing this post I gradually remembered the situation at the time.
I did indeed try not to pull out the outer housing initially to avoid getting into trouble.
But the inner cable got caught on something and I just couldn’t get it out. So I gave up and pulled out the entire outer housing, and as you can see in this picture, the mangled brake wire was wrapped around the housing coil.

Would it be effective to replace the front brake cables earlier, before they deteriorate even slightly, in order to ensure that the method you describe works every time?

Blackstridaaustria · July 16, 2024, 7:17am

Dear yakitori,
I do understand that you were facing several problems at the same time!
Honestly I have no idea why your housing was damaged that way.
Of course, it would make sense to cut the wire properly before, giving the wire no chance to catch the housing’s steel coil.
Naturally - one is always more wise if you’re looking back.

Sorry, but I can’t tell - I’ve never before noticed such a weird housing issue. I can’t explain why your housing did this and I would not expect that because the bend you mentioned shouldn’t move. I’d expect that rather for the rear brake, that housing bends regularly while folding.

Oh, btw, I wrote above that part 215-15 has to replaced anway - that was meant for the rear brake, but not the front.
It is, for my meaning, very unusual that this part caused problems for the front housing.

yakitori · July 16, 2024, 9:30am

I see.

The reason I removed part 215-15 was to maneuver the cable through the area where the front tube bends when inserting the new cable. I think it is unlikely that this plastic part damaged the front brake housing in any way. Me too.

However, since this very narrow part 215-15 has both rear and front brake cables running through it, to be precise, I thought it might be possible that some damage could accumulate. For example, in pulling out the torn rear brake housing, it might have damaged the front brake housing, which was already deteriorating.

In any case, I am rather relieved that this case of mine seems to have been the worst case scenario in front brake cable replacement.

I had suspected that the front brake cable might be constantly under load on the bent part of the cable and frequently burst in this way, but thanks to you I know that this is not the case.

Blackstridaaustria · July 16, 2024, 2:13pm

If you look at this image it seems there is plenty of room for the front housing, the bend is nicely round and there’s no sharp corner - you experienced a really odd issue.

yakitori · July 17, 2024, 2:43am

Hmmm, I don’t like to think about it, but there may have been a sharp edge on the inside of the tube weldment.

I’ll add reference links to this post for the next time I do this work.