I have had the over shift and noisy chain problem ever since mounting my ’04 Campy Record group. I tried everything, different cables, different housing, every adjustment possible and even checked my frame and hangar alignment on a brand new frame.
Nothing fixed it until I installed a new handlebar the other day. When I took of the Ergo levers, a little piece Campy calls the “Resin Insert” in the manual fell out. It’s the part you have to take out to install the Ergo Brain computer wiring.
Anyway, I inspected the part and it looked fine so I put it back in and finished installing everything and went on a ride. The shifting was worse than ever so I spend the following morning looking more closely at that part.
I discovered that when I tighten the levers to the bars to the proper torque, the “Resin Insert” would deform and the shifting mechanism inside the lever body would press against it. specifically, on the round ratcheted part of the shifting mechanism there is a little allen screw head sticking out which was pressing against the insert. I could see some wear on the insert so was sure I had found the problem. I shifted the bike with the lever loosened and voila, perfect shifting.
My solution was to drill clean through the insert and put a piece of thin, hard rubber between the bar and the very top of the Resin Insert to make clearance for the allen screw head. Enough so it doesn’t press against the bar. After playing with this for a while I got it just right and now my shifting is perfect every time with the Campy 10 hollow pin chain. Even under load!
If you are having shifting and noise issues check this piece in your lever to make sure it’s not rubbing on the shifting mechanism.
Good luck!
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