Brake Cordz Installation with Shoulderbolt Clasp | Photos of Installed Power Cordz™ | Installation on SRAM X.0 Trigger shifters 

Installing Power Cordz™

When using other manufacturers housing, check for fit and parts needed. (Check compatibility here)

• New high quality housing
• New ferrules
• Liners an/or noodle liners for v-brakes

Tools needed:

• Sharp fabric scissors or X-acto® blade; for cutting the Cordz™.
• Allen wrench (4mm or 5mm).
• File or Dremel tool; for cutting and de-burring the housing.
• Awl or blunt fine point tool; to open up inner liner on the housing ends.
• Needle nose pliers; for grasping and pulling on to the Cordz™.

Housing considerations:

Check the housing and Cordz™ compatibility by inserting the cord into the housing. Different housings have different inner diameters, and as with conventional control cables, the lower the drag the better the Cordz™ will perform.

Brake Housing

• Brake Cordz™ diameter = 1.7mm (.068”)
• For brake Cordz™, certain compressionless / SIS housing are not compatible.
• Recommended housing: QBP Carbon Housing, 5mm compressionless with ferrules.

Derailleur Housing

• Derailleur Cordz™ diameter = 1.5mm (.060”)

Ferrule noodles and Liner considerations:

Check ferrules and liner compatibility with Cordz™ by inserting the cord through the ferrule and liners. The less the drag the better the Cordz will perform.

Ferrules:

• Use higher quality ferrules, which allow smooth actuation of the Cordz™.
• Avoid ferrules with sharp edges which could abrade or cut the Cordz™.

V-Brakes noodles:

• The noodle forms a tight bend and the liner in the noodle may be tight and cause drag.

Liners:

• Liners should be used if the Cordz™ line of operation rubs on any sharp edge; sometimes created by offset brazeons, cable hangers, and barrel adjusters.

INSTALLATION

Install tip: Each set of Cordz™ comes in equal lengths. Start with the rear, if a mistake or issue occurs, the Cord can then be used for front installation.

1. Gather all parts and tools needed for installation.
2. Carefully inspect the new housing segments. REMOVE ALL BURRS, make sure segment ends are open with NO SHARP EDGES OR ROUGH AREAS. Power Cordz™ are subject to damage from abrasion and sharp edges, so use care when preparing your cable housing.
3. Carefully inspect ferrules. Some ferrules have a thin metal edge that can damage the Cordz™ coating. Use ferrules that have a thicker, smooth lip, and remove any sharp edges that may catch the Cordz™.
4. Set your barrel adjuster ½ to ¾ of the way out. Insert the Power Cordz™ head into the component assembly, and thread the cord through the housing.

5. With some Derailleurs, the inlet hole is too small for the  Cordz™ to fit through. Solutions to such issues are listed at the bottom of this page. SRAM, X-O, Shimano LX and XT (see photos)

6. Wrap the cord 180 degrees around the anchor bolt to maximize the surface area under the bolt and washer.

7. While pulling the cord back around the bolt, tighten the bolt and washer enough to test for clearance and adjust as needed.
8. Once the Cordz™ are properly positioned, tighten the bolt to over 60 inch lbs. of torque, a bit more torque than you would use on a steel cable. The bolt must be tight enough to grip the fibers inside the coating. Caution: Repeated tightening at the same location on the cord can weaken or even cut the cord.
9. Leaving a few inches, cut off excess cord with X-acto® blade or sharp scissors and tuck in the remaining cord.

10. Check the exposed fibers for slippage. If the exposed fibers have slipped, readjust the cord if needed and tighten the bolt more. After successful installation, check the length of the fibers periodically for slippage.

Installing Power Cordz™ using the shoulder bolt clasp system

Replace the anchor bolt assembly with the shoulder bolt clasp. Tighten the shoulder bolt.

Feed the cord into the clasp from the bottom through the back hole.
The cord must be installed so that applying the brakes tightens the shoulder bolt.

Wrap the cord around the clasp twice and feed it downward through the front (clamping) hole.

Maintain your hold on the cord as you pull it through the hole with your hand; then pull it with needle nose pliers to remove any slack.

Check clearance for wheel removal then pull the cord tight.

Insert the set screw and tighten with an allen wrench.

Wrapping the cord around the top is incorrect
and may result in unscrewing the shoulder bolt with a
partial or total loss of braking force on the wheel.

Maintaining your Power Cordz™

Release your Power Cordz™ at the derailleurs and/or brakes at the mechanisms and wipe clean with soapy water or a degreaser.

Wipe your Power Cordz™ dry and apply a lubricant such as a dry wax or other light oil.

After reconnecting the housing to the bike frame make sure to get some lube on the rear derailleur's cable through hole.

Installation Notes:

Compressionless housing: some compressionless housing systems can curve inward against the ferrule, impacting and causing potential damage to the Cordz™.

Liners made of nylon / T-PFE can be stretched out slightly with a spoke or other small wire tool to increase the inner diameter of the liner. By inserting a wire or modified spoke tool inside the liners and forcing the liner onto the spoke this will reduce the drag and increase performance.

Shifters with inlet holes sized for smaller cables:

Note: The shifters which have inlet hole issues which we are aware of are the SRAM X.0, Shimano LX and XT. Please let us know if you encounter this issue on other mechanisms.

Solution 1:

Reduce the size of the end of cord to fit through the inlet and then pull the cord through the inlet. (this takes a bit of finesse to cut the cord length wise in half)

1. Using an X-acto® or other very sharp blade, cut the Cord lengthwise 2 inches (5 cm) or more.
2. Cut out the fibers.
3. Cut half of the coating diagonally to keep from catching while feeding the end through.
4. Feed the end through the inlet hole gently, using needle nose pliers to pull the Cord if needed.

Solution 2:

Enlarge the shifter inlet holes' diameter (because this procedure modifies other manufacturers parts, we cannot recommend this option. It may void your warranty and/or damage the shifter). The hole needs to be opened only slightly, Power Cordz™ are larger by 0.012 inches (0.3mm) in diameter.

• Use an old rough steel cable as a file, pulling it back and forth to open up the inlet.
• Heat a stiff wire, old cable or old spoke. Apply just enough heat (a lighter works well) to the wire to soften the plastic around the inlet hole and enlarge it.
• Drill out the hole with a 1/16” or 1.6mm drill bit.

When to replace:

• Power Cordz™ are produced from a durable synthetic fiber. Similar to synthetic fibers used in other industries (Climbing), Power Cordz™ have a recommended 2-year lifespan from the date manufactured.
• If the Cordz™ coating wears off and fibers become exposed it is time to replace your Cordz™.

Click here to register your Power Cordz™.

Thank you for choosing Io DuPont’s Power Cordz™!

3306 N 32nd St  Boise, ID 83703 (208) 336-0385 Fax (208) 343-2576

e-mail support@iodupont.com