Polaris EV206PH-B Technical And Service Manual page 12

ChApTEr 4
ShIFTEr ANd dErAILLEUr
WArrANTy NOTE: Shifter and derailleur fall under "non-electric" component warranty. applicable warranty
is 6 months from date of purchase. any service issue resulting from misuse of bicycle is not covered under
this warranty and user shall be responsible for all charges.
ShIFTEr rEmOVAL/INSTALLATION
removal
1. note the position of the shifter relative to the right handlebar grip. If necessary, measure the gap or make
a drawing so the shifter can be properly positioned during installation.
2. remove the left handlebar grip
3. loosen the brake lever clamp bolt and slide the brake lever from the handle bar.
4. loosen the shifter clamp bolt (a, Figure 4-1), and slide the shifter from the handlebar end.
B
Installation
1. Slide the shifter onto the handlebar end.
2. Completely install the handlebar grip.
3. move the shifter to its position relative to the handlebar grip as noted during removal. temporarily tighten
the clamp bolt (a, Figure 4-1) enough to hold the shifter in position.
4. If the brake lever was moved perform the following:
a. Slide the brake lever so its bracket rests against the shifter.
b. rotate the brake lever to the position noted during removal, and torque the brake lever clamp bolt (b,
Figure 4-1) to the specification in table 5.
5. rotate the shifter so its barrel seats against the brake lever, and torque the shifter set screw (a, Figure
4-1) to the specification in table 5.
18
Servicemanual_101212.indd 18-19
FIGUrE 4-1
A
C
ShIFTEr CABLE INNEr WIrE rEmOVAL/INSTALLATION
removal
the cable inner wire can be replaced without removing the cable housing.
1. operate the shifter and move the chain to the smallest cog (high gear).
2. Clip the cable ferrule from the cable end (a, Figure 4-2).
B
3. loosen the anchor bolt (b, Figure 4-2), and release the cable inner wire from the from the derailleur pinch
mechanism.
4. remove the cable housing and inner wire from the derailleur cable guide (C, Figure 4-2).
5. remove the hand grip from the left handlebar end.
6. loosen the shifter clamp bolt (a, Figure 4-1) and the brake lever clamp bolt (b, Figure 4-1). Slide the
brake lever out of the way.
7. Unscrew shifter cable cap.
8. push the inner wire into the shifter until the cable end emerges from the socket in the shifter drum
(Figure 4-4).
9. pull the inner wire from the shifter drum (Figure 4-3).
FIGUrE 4-2
C
A
FIGUrE 4-3
19
10/12/2012 12:25:53 am