Shimano ultegra Di2

[eccc whippet]

If it just the springs that are missing why don't you take a sample down to your local spring maker and get them to make you some. Done this a few times for Freehud body springs.

i dont have the tool to strip the top part of the lever...that is why when the person at cool heat indicated that someone must have removed the spring (why someone would even consider it) ...i find it very strange because the only people who have the tool is cool heat.

[Spoke101]

Very strange why someone would go in there and remove a spring.

More likely someone had an off day at the factory and left one spring out.

 

Do you have any idea what tool is needed or what it looks like?

[Spoke101]

Oh by the way who did you speak to at Coolheat?

[eccc whippet]

it is listed under the tool list as a special E- ring removal tool...

i cant remember the person name at cool heat...might have been Steve or Ian  but i am not sure.

[shaper]

it is listed under the tool list as a special E- ring removal tool...

i cant remember the person name at cool heat...might have been Steve or Ian  but i am not sure.

https://www.sjscycles.co.uk/tools/shimano-st7900-tool-a-for-ering/

https://www.amazon.co.uk/e-Ring-Tool-Shimano-ST-7900%C2%A0y-6rt68000/dp/B0036EY72E/ref=sr_1_2?s=sports&ie=UTF8&qid=1468249257&sr=1-2&keywords=e+ring+tool+shimano

[eccc whippet]

A close up

 

 

spoke if you look at the close up the 2 small spring fit into the holes then the switch goes on top...but if you look in the holes you will see one big spring in the top hole but no spring in the bottom hole...what happens is if you press the smooth paddle which compresses that spring the rough paddle no longer has tension because there is no spring to hold it tight it rattles...hence the meridas new name rattlin red rocket.

[eccc whippet]

 

the 2 springs you see next to the lever are the same 2 springs illustrated on page 42 and page 70 and refered to as the switch springs....the problem is the spring which goes under that metal plate...which you need a special to to access once you have removed the clip and lever. 

[eccc whippet]

i would be really embarrassed if this was a product my company supplied  and i dont have the information on hand to assist a customer or the technical  knowledge to guide the customer ...but instead only an option to spend R6500 to replace it just because of 1 spring  missing which could have been a factory dud batch.

[EZZ99]

If you need to import, take a look at Merlin Cycles and Ribble Cycles, often cheaper than CRC

Is ribble a reliable website to purchase from

[shaper]

Is ribble a reliable website to purchase from

It is, although there are issues with shipping to SA at the moment, they list it as a shipping destination but on checkout you are unable to complete the purchase as it keeps saying not able to do at this moment in time.

 

I emailed them a while back asking what the issue was and they said they would look into it...yet to get a response and last time i tried got the same issue.

[Spoke101]

spoke if you look at the close up the 2 small spring fit into the holes then the switch goes on top...but if you look in the holes you will see one big spring in the top hole but no spring in the bottom hole...what happens is if you press the smooth paddle which compresses that spring the rough paddle no longer has tension because there is no spring to hold it tight it rattles...hence the meridas new name rattlin red rocket.

 

I see, I'm not sure if there is meant to be another big spring in the other hole according to the pic's in the service manual, will try swing passed my LBS and open up my old shifters to see.

As for Coolheat: Ian, Tyson or Jade are all great guys and normally try there best to help out. Not sure about a Steve. Maybe try them again and use extension 123 "Jade's" line (he's the main Tech) ask them to have another look or to keep you a spring next time a set come in.

[Spoke101]

Called by the shop and had a look at my old levers. When the smooth lever is depressed the rough one is still very firm and has no "free play" or rattle. There is definitely some sort of spring holdingit in place somewhere. I couldn't find a T5 torx to open up the switch and see the number of springs.

Next step is to find a T5 Torx.

[eccc whippet]

Called by the shop and had a look at my old levers. When the smooth lever is depressed the rough one is still very firm and has no "free play" or rattle. There is definitely some sort of spring holdingit in place somewhere. I couldn't find a T5 torx to open up the switch and see the number of springs.

Next step is to find a T5 Torx.

I have also checked other bikes with Di2...there is no free play. 

torx 5 is quite difficult to find...builder warehouse has a set which has a T5 torx 

the only way i am going to solve this problem is to find a damaged set of levers which i can strip and see what is missing. 

it seems this problem started in 2013...they must have upgraded the levers since then.

http://road.cc/content/forum/90312-di2-rattle-buzzing-noise

[eccc whippet]

and even further back to 2012

http://forums.roadbikereview.com/shimano/my-ultegra-di-2-levers-buzz-vibrate-291769.html

http://weightweenies.starbike.com/forum/viewtopic.php?t=113359

not sure if it is the same person...

and yeah this is going to be an endless thread until i sort out this issue or unload  the levers onto to some  poor sucker who doesnt know about this problem...wait for a while then sell it using another name ...if it is this difficult to get a a spring sorted out imagine to trying to fix a complex problem  

[Spoke101]

My old ones are 2012 so this seems to be an intermittent problem.

Just a quick one I picked up in those comments, my rear brake cable did get stiff and create some free play on the right brake lever which then caused a rattle.

[eccc whippet]

Finally i can close this thread...apparently there is no missing spring nor has someone taken the spring out the lever.

 

IT seems that shimano sent out this batch of levers...which if you detected the problem within the year of purchase could replace under warranty...if not sorry for you.

 

just to clear something up...i was never looking for a freebie...like the fulcrum wheels...i was happy to pay the R200 + then another R200 then return to the lbs 4 times and then pay  R650...just to fix the problem...to make it right... as with these levers...i would have been happy to pay a "fee"  to exchange the levers.,,even just the affected component.