Installation & Tech Tips
- Chinese version for PowerCordz installation (PDF)
- French version for PowerCordz installation (PDF), for Swift Installation (PDF)
- Zylon Properties
- Liner Properties and tips
- Link to YouTube for Derailleur Installation (Prime + Standard)
- Link to YouTube for Brake Installation (Prime + Standard)
2006-2011 Installation Guides and videos (older but useful):
Derailleur Cables Install
- Gather Tools
Your will need sharp scissors or a sharp x-acto , cable cutters, allen wrenches, pliers and a spoke tool (or something pointed to open housing hole after cutting).
- Run Housing and/or cord as Normal
When replacing cables we recommend replacing the housing also. If you need new housing, we recommend using our complete system, which includes housing, ferrules, easy bends.
- Snug the Clasp on the cord
Use your left hand to pull the cord 180 degrees around the clasp bolt following the same path as you would for a steel cable and then tighten until snug.
- Torque Down
Use your left hand to try and stop the clasp from spinning as you tighten down the bolt. Depending on the clasp, it's sometimes better to simply keep pulling on the cord with your left hand to keep it snug against the clasp.
See Figures 1-3 below for more detail.
[ See Figure 1 ] [ See Figure 2 ] [ See Figure 3 ]
Note: You want to tighten the clasp enough to crush the outer coating down sufficiently so you are clamping the inner fibers. You can usually feel when this happens as there is some initial resistance from the outer coating and then the resistance lessens when the coating crushes and then increases again as you tighten against the flattened coating. Don't worry about completely crushing or even marring the outer coating as the coating is primarily important on Derailleur Cordz for reducing friction inside the housing - the outer coating essentially plays no role in the derailleur connection.
After successful installation, check the length of the cord for possible slippage and ensure that everything is secured tight.
Once installed Power Cordz™ do not stretch out or require re-adjustment.
Derailleur System Installation Part 1
Derailleur System Installation Part 2
Tips & Tricks - Derailleur Cordz
Power Cordz™ Safety
Brake Cables Installation
- Gather Tools
You will need sharp scissors or a sharp x-acto, cable cutters, allen wrenches, pliers and a spoke tool (or something pointed to open housing hole after cutting).
- Run Housing and/or cord as Normal
Run following path of old cable or replace the old cable with Power Cordz™ cable. Make sure the ferrules are firmly seated onto the housing. Visually inspect opening in inlet housing hole to ensure sufficient clearance for new cord to pass through.
- Remove Stock Clamping Washer
Screw in the barrel adjustor screw all the way, then out three or four turns. Next, remove the anchor bolt that is securing the stock clamping washer. This requires an Allen wrench.
- Run Cable Through Barrel Adjuster
Visually inspect opening in inlet housing hole to ensure sufficient clearance for new cord to pass through. Feed cord through barrel adjuster.
- Insert the Windsor Clasp
Insert the Windsor Clasp provided with the Power Cordz™ over the anchor bolt with the smooth side of the clasp resting against the head of the bolt and the channel cut side facing downward. Screw in anchor bolt slightly, leaving room for the cord wrap in the following steps. [ See Figure 1 ]
- Start the Loop
Secure pads on brake calipers against the wheel rim.
[ See Figure 2 ] Pull cord down tight next to the anchor bolt between anchor bolt and support lever [ See Figure 3 ]. Then pull the cord 180 degrees around the bolt setting the bend point [ See Figure 4 ]
- Start the Knot
Wrap cord under anchor bolt and back up between bike frame and first pass of the cord. [ See Figure 5 ]
- Complete the Knot
Loop cord around taut cord created by the first pull down and wrap completely around and thread back through the loop created. [ See Figure 6 ] When pulling the cord down through the loop ensure the cord stays on the same side of the bolt as the original cord path.
NOTE: When installing correctly, the cord loops greater than 360’ around the bolt and greater than 360’ around the cord itself [ See Figure 7 ].
- Sinch the Loop
Keep brake pads tight against the wheel rim and pull cord straight down and tighten slowly. As you continue to pull down and the loop gets smaller and tightens, ensure the cord is aligned in the inlet groove of the Windsor Clasp. Use your index finger to push against the loop as it gets smaller. [ See Figure 8 ] The cord must align in the inlet groove inthe Windsor Clasp for maximum performance. For reference see [ See Figure 9 ] for a view of the knot with the clasp removed.
- Tighten Down
Pull cord down tightly and screw in anchor bolt. Crank down tight (approximately 60-80 in-lbs). When completed the installation should appear as in. holding the clasp steady with your index finger. [ See Figure 10 ]
- Test Brakes
Remove the clamp and gently apply the brake to seat the cord. Ensure the brake pads clear the rim and there is clearance for tire removal. If needed, adjust barrel on the brake levers to create more slack. Only when the brake is working on multiple pulls should you cut the cable.
[ See Figure 10 ]. If not you can go back to step 6 above and repeat, this should only need to be done once.