Customer presented us with a Specialized Roubaix Elite, about two years old. I didn't do the check in. On the tag it said the bike needed a tune up and the right shifter is noisy.
The owner of the bike is a competitive Nordic skier, although a health problem has limited her competitive activities for a while.
I've noticed something about skiers, whether cross-country or downhill. They tend to beat their bikes to death. They spend so much time on equipment with almost no moving parts that they forget to do any maintenance. At first glance this seemed to be the typically under-lubricated, road grimy bike, sticky with spilled energy drink. But the shifter noise was atypical and intriguing. It was a sort of grindy squeak.
On closer inspection I discovered that the shift cables had worn into the bottom bracket cable guide deeply enough to allow the cables to begin to saw into the fat down tube. They hadn't gone too far. I could easily fix it by pulling off the BB cable guide and replacing it with a thicker one. It's just held on with a single screw or bolt.
I worked slack into the cables and unscrewed the cable guide. The screw turned stiffly but never withdrew. I tried coaxing it out with a little cautious prying as I turned the screwdriver. That did no good. Clearly I would have to remove the crank and bottom bracket bearings to see what the other end of the screw or bolt looked like, rather than continue to pry or twist.
Getting the FSA SL-K crank off was another treat. The left crank arm is held on with an alloy bolt torqued to 36 foot-pounds. You're just as likely to strip out the hole in it as you are to break it loose after it has been sealed in with thread locker and then ridden in all weather. I got it out mostly intact. I may not put the same bolt back.
Inside the BB shell I saw that the cable guide is held with a bolt into a threaded insert in the BB shell. This insert has broken loose. The bolt can't be removed BECAUSE THE THREADS WERE NOT GREASED WHEN THE BIKE WAS ASSEMBLED.
There are no unimportant parts. I get a certain amount of crap for my meticulous assembly procedures, but then something like this proves my point. It's not even a rare occurrence.
I won't know until I get further into it tomorrow what I will have to do to graft on the new cable guide. Without it the cables will cut deeper and deeper into the carbon fiber, ultimately leading to failure.