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General Safety Information
SB-8S20
WARNING
– To avoid serious injuries:
BL-IM60
Obtain and read the service instructions
carefully prior to installing the parts. Loose,
CJ-8S20
worn, or damaged parts may cause serious
injury to the rider.
We strongly recommend only using genuine
Shimano replacement parts.
Technical Service Instructions
It is important to completely understand the
operation of your bicycle's brake system.
Improper use of your bicycle's brake system
may result in a loss of control or an accident,
which could lead to severe injury. Because
each bicycle may handle differently, be sure to
learn the proper braking technique (including
brake lever pressure and bicycle control
characteristics) and operation of your bicycle.
This can be done by consulting your
professional bicycle dealer and the bicycle's
Be sure to read these service instructions in
owners manual, and by practicing your riding
conjunction with the service instructions for
and braking technique.
the Inter-8 hub before use.
These brake levers are equipped with a mode
switching mechanism to make them
compatible with cantilever brakes and Roller
Revo-shift lever operation
Brakes or V-Brakes with power modulator.
If the incorrect mode is selected it
Turn the Revo-shift lever to shift to each of the eight
may cause either excessive or
gears.
insufficient braking force to occur,
which could result in dangerous
Indicator
accidents.
Be sure to select the mode in
accordance with the instructions
given in the table below.
Mode position
Applicable brake
C/R position
Cantilever brakes
Pedaling becomes lighter
Roller Brakes
Indicator moves toward 1
The C indicates the mode
position for compatibility
with cantilever brakes.
Installation of the lever
The R indicates the mode
position for compatibility
Install the lever as shown in the illustration.
with Roller Brakes.
V position
Clamp bolt
V-Brakes with power
modulator
The V indicates the mode
position for compatibility
with V-Brakes with power
modulator.
3
Tighten
Use the brake levers with mode switching
mechanism in the combinations given above.
Read these Technical Service Instructions
5 mm Allen key
carefully, and keep them in a safe place for
later reference.
Leave a gap of 0.5 mm
between the Revo-shift
lever and the half grip.
CAUTION
– To avoid serious injuries:
Tightening torque:
6 – 8 Nm {60 – 80 kgfcm}
Be sure to shift the lever one gear at a time, and
reduce the force being applied to the pedals
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
in serious injury.
2
NOTE:
For maximum performance we highly
recommend Shimano lubricants and
maintenance products.
Parts are not guaranteed against natural wear
or deterioration resulting from normal use.
Grip
SI-6J30A
Disconnecting the shifting cable when
removing the rear wheel from the frame
Revo-shift Lever
Disconnect the cable from the cassette joint
Brake Lever
when removing the rear wheel from the
frame.
Cassette Joint
20
C J-
8S
PA
N
JA
Cassette joint
1.
Set the Revo-shift lever to
1
.
Set to
1
Pedaling becomes heavier
Indicator moves toward 8
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.
Revo-shift lever
Bracket
Outer casing holder
Pull out from outer
C J-
8 S
2 0
JA
casing holder
PA
N
1
Slit
2
Remove from
the slit
3.
Remove the inner cable fixing bolt unit from
the cassette joint pulley.
Inner cable fixing bolt unit
Cassette joint pulley
In case of using Shimano
half grip, the straight
section of the handlebar
should be 166 mm or more
CJ-8S20
in length; attach the Revo-
JAPAN
shift lever to this straight
section.
If it is difficult to pull the outer casing out
1
from the outer casing holder of the cassette
joint, insert a 2 mm Allen key or a #14
Handlebar
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
2
the outer casing holder.
2
3
22.2 mm
Remove the inner
Pull out from
cable fixing bolt unit
the outer
casing holder
Half grip
CJ-8S20
JAPAN
Clamp bolt
1
1
Turn the
pulley
Pulley hole
3
2 mm Allen key
Tighten
or #14 spoke
22.2 mm
5 mm Allen key
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-SP40 outer
Installation of the shifting
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-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 Revo-shift lever to
1
.
Set to
1
Revo-shift lever side
2.
Loosen the cover fixing screw, and then remove
the upper cover.
Cover fixing screw
Upper cover
Attach the plastic cap.
Cassette joint side
6.
After checking that the end of the outer casing is
sitting securely in the cable adjustment bolt of the
Revo-shift lever, attach the inner cable fixing bolt
unit to the inner cable.
Inner cable fixing bolt unit
Note: Do not use this inner cable fixing bolt
unit with the CJ-4S30 cassette joint.
3.
Pass the inner cable through the hole in the cable
adjustment bolt. Next, hook the inner cable into
the groove of the pulley, and pull the inner cable
so that the inner cable drum fits into the hole in
the pulley.
Hole in cable adjustment bolt
10 mm
(Black)
1
Pass the inner cable through the hole.
101 mm
Pull the inner cable while attaching
the inner cable fixing bolt unit.
2
Tightening torque:
4 – 6 Nm {40 – 60 kgfcm}
7.
Bring the cable around to the cassette joint pulley,
Groove in pulley
hold so that the inner cable fixing nut is facing to
the outside (toward the fork end), and then slide
the flats part of the inner cable fixing washer into
the gap in the pulley.
Flats part of inner
cable fixing washer
3
Hole in pulley
4.
Replace the upper cover and tighten the cover
fixing screw.
Cover fixing screw
Inner cable
Upper cover
fixing nut
8.
Turn the cable 60 counterclockwise and attach it
to the hook.
(Lever side)
Hook
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
Plastic cap
the end of the outer casing securely into the outer
casing holder.
Remove the plastic cap.
Make the cut end
Inner cable
perfectly round.
Pulley
Bracket
Bracket
Outer casing holder
Insert into the
C J-
outer casing
8 S
2 0
JA
PA
holder.
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
Inner cable fixing
spoke into the hole in the cassette joint
washer
pulley, and then turn the pulley so that the
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 Revo-shift 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
Set to
4
JA
N
PA
CJ
S2
-8
0
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 Revo-
shift lever to align the setting lines. After this,
move the Revo-shift 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
JAPAN
These service instructions explain how to use and
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 CA 92618 U.S.A. Phone 949-951-5003
Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone 31-341-272222
3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone 072-223-3243
C
Mar. 2003 by Shimano Inc. PIT. SZK. Printed in Japan
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