XTR brake lever help needed please

[Steven Knoetze (sk27)]

Hi Guys,

 

I have an issue with my XTR brake levers.

I bought them second hand so doubt I can do anything under warranty but it also doesn't seem like a major issue.

 

Basically the master cylinder has a plunger shaft. In this section of the lever housing there is a circlip and a washer,  I am not sure what they do but would imagine they keep everything in place when applying braking pressure.

The circlip here on my lever's keep popping loose.

You will see in the first photo's how it pushes the lever out at a very strange angle, far away from the bar. I have also attached a photo of the lever angle when the circlip is in.

This doesn't seem to affect the braking performance too much although they do perform better when all is well with the circlips. It is annoying with the lever so far away as you do compromise your grip on the bar. It is not that hard to pop the circlips back although it is a tight space, you do have to remove the levers from the bars to get access to these fiddly bits. I am not confident enough to start stripping apart the whole thing to get a better view, that would mean a trip to the LBS.

Any help would be appreciated.

 

This is with the lever standing out because of the circlip which has popped out

This is showing, as best I can, the circlip and washer which have popped loose

This is where the lever should be with the circlip snugly in place

And this is what the master cylinder shaft area should look like when the circlips are in

[Skinnyone]

If the circlips keep popping out then it means the groove that they are supposed to sit in have been damaged, looks like these levers were crashed - the reason they were pulled out under force...in that case not much can be done.

[Steven Knoetze (sk27)]

If the circlips keep popping out then it means the groove that they are supposed to sit in have been damaged, looks like these levers were crashed - the reason they were pulled out under force...in that case not much can be done.

 

The thing is they are in mint condition, no crash damage or scuffs for that matter.

I have considered that it might be the groove that the circlip sits in. As you say, if this is the case then there really is nothing I can do about it. It has no performance issues, but this could obviously change.

I will just keep monitoring it and then decide what to do.

Still trying to find an exploded view of the lever to see what the purpose of this circlip is exactly though.

[droo]

Take the clip to an engineering supplier and get a new one - it may be that the clip is a bit bent.

 

Also, circlips are stamped, and as such have a sharp side and a round side. Make sure the sharp side is facing outwards when you install it - it has less chance of popping out that way.