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General Safety Information
Installation of the shifting lever
Install the shifting lever as shown in the illustration.
WARNING
– To avoid serious injuries:
Use a handlebar grip with a maximum outer
Obtain and read the service instructions
diameter of 32 mm.
carefully prior to installing the parts. Loose,
worn, or damaged parts may cause serious
Clamp bolt
injury to the rider.
We strongly recommend only using genuine
Shimano replacement parts.
Read these Technical Service Instructions
carefully, and keep them in a safe place for
later reference.
CAUTION
Tighten
– To avoid serious injuries:
5 mm Allen key
Be sure to shift the lever one gear at a time, and
Tightening torque:
reduce the force being applied to the pedals
5 – 7 N·m {50 – 70 kgf·cm}
during shifting. If you try to force operation of the
shifting lever while the pedals are being turned
strongly, your feet may come off the pedals and
the bicycle may topple over, which could result
Replacement and assembly
in serious injury.
of the indicator unit
NOTE:
Disassembly and assembly should only be carried
For maximum performance we highly
out when removing and replacing the indicator unit.
recommend Shimano lubricants and
maintenance products.
Removal
Parts are not guaranteed against natural wear
1.
or deterioration resulting from normal use.
Operate lever B 7 times or more to set it to
2.
Loosen and remove the two cover fixing screws
which are securing the indicator unit.
SI-6M20A
3.
Remove the indicator unit as shown in the
SL-S500
illustration.
Shifting Lever
CJ-8S20
Cassette Joint
Technical Service Instructions
Be sure to read these service instructions in
conjunction with the service instructions for
the SG-S500 hub or Inter-8 hub before use.
Shifting lever operation
Installation
4.
Check that the needle of the indicator is on the left
After you release your finger from lever A / lever B once
side (
1
position), and then install the indicator
shifting is complete, the lever will always return to its
unit so that it is facing straight upward. Insert the
original position.
pin of the change plate that is protruding from the
bottom of the indicator unit into the hole in the
Lever B:
winder unit at this time.
Pedaling becomes lighter.
(Indicator moves toward
1
)
Indicator unit
Pin of change plate
Hole in winder unit
(
1
position)
5.
Secure the indicator unit with the two cover fixing
Indicator
screws.
Lever A:
Tightening torque:
Pedaling becomes heavier.
0.3 – 0.5 N·m {3 – 5 kgf·cm}
(Indicator moves toward
8
)
6.
Operate lever A and lever B, and check their
operation. If they do not operate correctly, reinstall
the indicator unit while taking particular note of
step 4. above.
Do not disassemble the indicator unit or the
shifting lever unit. Disassembling them may
result in malfunctions.
Disconnecting the shifting cable when
removing the rear wheel from the frame
Disconnect the cable from the cassette joint
when removing the rear wheel from the
frame.
Handlebar
0
-8 S2
CJ
PA
N
JA
22.2 mm
Cassette joint
Grip
1.
Set the shifting lever to
1
.
Set to
1
1
.
2.
Pull the outer casing out from the outer
casing holder of the cassette joint, and then
remove the inner cable from the slit in the
bracket.
Bracket
Outer casing holder
Cover fixing screws
Pull out from outer
C J-
8 S
2 0
casing holder
JA
PA
N
1
Indicator unit
Slit
2
Remove from
the slit
3.
Remove the inner cable fixing bolt unit from
the cassette joint pulley.
Inner cable fixing bolt unit
Lever B
Cassette joint pulley
CJ-8S20
JAPAN
If it is difficult to pull the outer casing out
from the outer casing holder of the cassette
joint, insert a 2 mm Allen key or a #14
spoke into the hole in the cassette joint
pulley, and then turn the pulley to loosen
the inner cable. Then remove the inner
cable fixing bolt unit from the pulley first,
and after this remove the outer casing from
the outer casing holder.
Lever B
2
3
Remove the inner
Pull out from
cable fixing bolt unit
the outer
casing holder
CJ-8S20
JAPAN
1
Turn the
pulley
Pulley hole
2 mm Allen key
or #14 spoke
Note:
If reusing the cable, refer to steps 7 to 9 in
"Installation of the shifting cable".
5.
Pass the inner cable through the SIS-SP41/ SP40
Installation of the shifting
outer casing through the end with the plastic cap.
cable
Use a shifting cable with one inner cable drum.
Cable with one inner cable drum:
Aluminum cap
SIS-SP41/ SP40 (4 mm dia.)
If cutting the outer casing, cut it near the end
with the plastic cap while the cap is still
attached. Then make the cut end perfectly
1.
round and attach the plastic cap.
Set the shifting lever to
1
.
Set to
1
Shifting lever side
2.
Loosen and remove the wire end hooking cap.
Attach the plastic cap.
Cassette joint side
6.
After checking that the end of the outer casing is
Wire end hooking cap
sitting securely in the cable adjustment bolt of the
shifting lever, attach the inner cable fixing bolt unit
3.
Insert the inner cable into the groove in the winder
to the inner cable.
unit, and then pass it through the hole in the cable
adjustment bolt. Next, pull the inner cable so that
Inner cable fixing bolt unit
the inner cable drum fits into the hole in the
Note: Do not use this inner cable fixing bolt
winder unit.
unit with the CJ-4S30 cassette joint.
Hole in cable adjustment bolt
10 mm
Pass the inner cable through the hole.
Groove in winder unit
101 mm
Pull the inner cable while attaching
Inner cable drum
the inner cable fixing bolt unit.
Hole in winder unit
Tightening torque:
4.
Screw in the wire end hooking cap as shown in
3.5 – 5.5 N·m {35 – 55 kgf·cm}
the illustration until it stops. If it is turned any
further, it will damage the screw thread in the
cover.
7.
Bring the cable around to the cassette joint pulley,
In addition, the unit cover may become bent,
hold so that the inner cable fixing nut is facing to
which may cause an obstruction between the unit
the outside (toward the fork end), and then slide
cover and lever A, and lever A may not operate
the flats part of the inner cable fixing washer into
correctly. If lever A does not return properly,
the gap in the pulley.
loosen the wire end hooking cap slightly to make
a gap between lever A and the unit cover, and
Flats part of inner
check that this improves the returning of lever A.
cable fixing washer
Wire end hooking cap
unit cover
Inner cable
fixing nut
Tightening torque:
Lever A
0.3 – 0.5 N·m
{3 – 5 kgf·cm}
8.
Turn the cable 60 counterclockwise and attach it
to the hook.
Hook
(Lever side)
Plastic cap
CJ-8S20
Turn the
JAPAN
cable 60
9.
Attach the inner cable to the pulley as shown in
the illustration, pass the inner cable through the
slit in the cassette joint bracket, and then insert
the end of the outer casing securely into the outer
Plastic cap
casing holder.
Remove the plastic cap.
Inner cable
Make the cut end
perfectly round.
Pulley
Bracket
Bracket
Outer casing holder
Insert into the
outer casing
C J-
8 S
2 0
JA
holder.
PA
N
2
Slit
1
Pass through
the slit.
If first inserting the outer casing into the
outer casing holder is easier, then first insert
the outer casing into the outer casing holder,
Inner cable fixing nut
and then insert a 2 mm Allen key or a #14
spoke into the hole in the cassette joint
Inner cable fixing
pulley, and then turn the pulley so that the
washer
inner cable fixing bolt unit fits into the gap in
Inner cable fixing bolt
the pulley.
1
3
Insert into the
Insert the inner cable
outer casing
fixing bolt unit
holder
CJ-8S20
JAPAN
2
Turn the
pulley
Hole in pulley
2 mm Allen key
or #14 spoke
Note:
Check that the inner cable is correctly seated
inside the pulley guide.
CJ-8S20
JAPAN
Guide
Guide
OK
Not OK
Gap in pulley
10.
Secure the cable to the frame with the outer
casing bands.
Pulley
10 cm
15 cm
10 cm
Outer casing bands
CJ-8S20
JAPAN
Adjusting the cassette joint
1.
Set the shifting lever to
4
.
Check to be sure that the yellow setting lines on
the cassette joint bracket and pulley are aligned at
this time.
Yellow setting lines
JA
PA
N
CJ
S2
-8
0
Set to
4
The yellow setting lines on the cassette joint
are located in two places. Use the one that
is easiest to see.
When bicycle is standing up
Should be straight
Cassette joint
pulley
CJ-8S20
JAPAN
Cassette joint bracket
When bicycle is upside down
Should be straight
Cassette joint
pulley
JAPAN
CJ-8S20
Cassette joint bracket
If the yellow setting lines are not aligned, turn
the cable adjustment bolt of the shifting lever
to align the setting lines. After this, move the
shifting lever once more from
4
to
1
and
then back to
4
, and then re-check to be
sure that the yellow setting lines are aligned.
Cable adjustment bolt
2.
After adjusting the cassette joint, cut off the
excess length of inner cable and then install the
inner end cap.
Inner end cap
15 – 20 mm
CJ-8S20
JAPAN
CJ-8S20
These service instructions explain how to use and
JAPAN
maintain the Shimano bicycle parts which have been
used on your new bicycle. For any questions regarding
your bicycle or other matters which are not related to
Shimano parts‚ please contact the place of purchase or
the bicycle manufacturer.
These service instructions are printed on recycled paper.
Please note: Specifications are subject to change for improvement
without notice. (English)
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222
3-77 Oimatsu-cho, Sakai-ku, Sakai, Osaka 590-8577, Japan
C
May 2006 by Shimano Inc. PIT. SZK. Printed in Japan
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