DAHON NEXUS BL-IM65 - TECHNICAL Service Instructions

or #14 spoke Pulley hole Turn the pulley Pull out from the outer casing holder CJ-8S20 JAPAN LOCK 3 1 Remove the inner cable fixing bolt unit 2 CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK C R V V C R C R V V C R CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK SI-6FD0A SL-8S20 BL-IM65 CJ-8S20 2 1 1 2 3 CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK CJ-8S20 JAPAN LOCK Revo-shift Lever Cassette Joint Brake Lever 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. Pedaling becomes heavier Indicator moves toward 8 Indicator moves toward 1 Pedaling becomes lighter Indicator Revo-shift lever General Safety Information CAUTION WARNING – To avoid serious injuries: – To avoid serious injuries: 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. Obtain and read the service instructions carefully prior to installing the parts. Loose, worn, or damaged parts may cause serious injury to the rider. We strongly recommend only using genuine Shimano replacement parts. 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 owners manual, and by practicing your riding and braking technique. These brake levers are equipped with a mode switching mechanism to make them compatible with cantilever brakes and Roller Brakes or V-Brakes with power modulator. Use the brake levers with mode switching mechanism in the combinations given above. Read these Technical Service Instructions carefully, and keep them in a safe place for later reference. Technical Service Instructions Be sure to read these service instructions in conjunction with the service instructions for the Inter-8 hub before use. Revo-shift lever operation Turn the Revo-shift lever to shift to each of the eight gears. Mode position Applicable brake The V indicates the mode position for compatibility with V-Brakes with power modulator. V position C/R position The C indicates the mode position for compatibility with cantilever brakes. The R indicates the mode position for compatibility with Roller Brakes. If the incorrect mode is selected it may cause either excessive or insufficient braking force to occur, which could result in dangerous accidents. Be sure to select the mode in accordance with the instructions given in the table below. Tighten Tighten Handlebar Half grip 3 mm Allen key Clamp bolt Tightening torque: 6 – 8 N·m {60 – 80 kgf·cm} Installation of the lever Install the lever as shown in the illustration. 5 mm Allen key Clamp bolt Grip Tightening torque: 0.1 – 0.2 N·m {1 – 2 kgf·cm} V-Brakes with power modulator Cantilever brakes Roller Brakes Note: If reusing the cable, refer to steps 7 to 9 in "Installation of the shifting cable". Disconnect the cable from the cassette joint when removing the rear wheel from the frame. 1 Set the Revo-shift lever to . 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. Remove the inner cable fixing bolt unit from the cassette joint pulley. Disconnecting the shifting cable when removing the rear wheel from the frame Cassette joint Inner cable fixing bolt unit Cassette joint pulley Remove from the slit Pull out from outer casing holder Bracket Slit Set to 1 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. Outer casing holder CJ-8S20 JAPAN 2 1 Installation of the shifting cable Use a shifting cable with one inner cable drum. Cable with one inner cable drum / SIS-SP40 (4 mm dia.) Set to 1 Cover fixing screw Upper cover Hole in cable adjustment bolt Groove in cable guide Hole in winder unit Recess in winder unit Loosen the cover fixing screw, and then remove the upper cover. Pass the inner cable from the hole in the winder unit through the hole in the cable adjustment bolt. Next, insert the inner cable into the groove of the cable guide, and pull the inner cable so that the inner cable drum fits into the recess in the winder unit. Revo-shift lever side Cover fixing screw Upper cover Replace the upper cover and tighten the cover fixing screw. 101 mm Gap in pulley Bring the cable around to the cassette joint 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 Inner cable fixing nut Pulley 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. Cassette joint side Inner cable fixing bolt unit 10 mm Note: Do not use this inner cable fixing bolt unit with the CJ-4S30 cassette joint. Inner cable fixing nut Inner cable fixing washer (Black) Inner cable fixing bolt Pass the inner cable through the hole. Pull the inner cable while attaching the inner cable fixing bolt unit. Tightening torque: 4 – 6 N·m {40 – 60 kgf·cm} Pulley Bracket Guide OK Not OK Secure the cable to the frame with the outer casing bands. 10 cm 10 cm 15 cm Turn the cable 60 Hook Turn the cable 60 counterclockwise and attach it to the hook. 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 casing holder. Inner cable Slit Outer casing holder Pass through the slit. Note: Check that the inner cable is correctly seated inside the pulley guide. If first inserting the outer casing into the outer casing holder is easier, then first insert the outer casing into the outer casing holder, and then insert a 2 mm Allen key or a #14 spoke into the hole in the cassette joint pulley, and then turn the pulley so that the inner cable fixing bolt unit fits into the gap in the pulley. Hole in pulley Insert into the outer casing holder Insert the inner cable fixing bolt unit Guide Outer casing bands Bracket Insert into the outer casing holder. 2 mm Allen key or #14 spoke Turn the pulley Adjusting the cassette joint Set the Revo-shift lever to . Check to be sure that the yellow setting lines o the cassette joint bracket and pulley are aligne this time. After adjusting the cassette joint, cut off the excess length of inner cable and then install th inner end cap. 4 Inner end cap Cable adjustment bolt Cassette join pulley Cassette join pulley Yellow setting li 15 – 20 mm Should be straight Should be straight When bicycle is upside down When bicycle is standing up 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 to and then back to , and then re- check to be sure that the yellow setting line are aligned. The yellow setting lines on the cassette join are located in two places. Use the one that is easiest to see. Cassette joint bracket Cassette joint bracket Pass the inner cable through the SIS-SP40 outer casing through the end with the plastic cap. 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 round and attach the plastic cap. (Lever side) Remove the plastic cap. Make the cut end perfectly round. Attach the plastic cap. Aluminum cap Plastic cap Plastic cap 1 Set the Revo-shift lever to . 4 4 1 Apr. 2004 by Shimano Inc. PIT. SZK. Printed in Sing C 22.2 mm 22.2 mm In case of using Shimano half grip, the straight section of the handlebar should be 166 mm or more in length; attach the Revo-shift lever to this straight section. Leave a gap of 0.5 mm between the Revo-shift lever and the half grip. Tightening torque: 2 – 2.5 N·m {20 – 25 kgf·cm} Set to 4 ® One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003 Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-2 3-77 Oimatsu-cho, Sakai, Osaka 590-8577, Japan 1. 2. 1. 5. 8. 1. 2. 9. 10. 6. 7. 2. 3. 4. 3. These service instructions explain how to use and maintain the Shimano bicycle parts which have been used on your new bicycle. For any questions regardin your bicycle or other matters which are not related to Shimano parts‚ please contact the place of purchase the bicycle manufacturer.