So I’ve taken apart my bar end shifters to replace cables and housings. And I’m having trouble getting them back together. The shimano directions and diagrams aren’t too helpful. I’m not sure what the right orientation is for the shift lever and the inner washer-type thing. And the rear shifter appears to have more parts than are shown on the shimano diagram. Any tricks or tips?
It should go together like on the diagrams, just make sure to have the lever boss (washer thingy) oriented correctly. The square notch should be pointed down when the shifters are installed in the conventional direction. If you do that wrong, it still fits, but you won’t get the correct number of clicks when you shift.
Check out this post that I made a few months ago as I was having the same issue and received some helpful responses: http://forum.slowtwitch.com/gforum.cgi?post=976049;search_string=search_string;guest=9711073#976049
I think the trick is to put the shifter all the way down before mounting it (use a pair of pliers to hold the body so you can shift) and then mount it on the body so you can go through the full range of motion. The best way to do this is before you take it off, but it sounds like you didn’t do this beforehand (like me).
Good luck!