Chain

Transcript

DM-GN0001-12 (English) Dealer's Manual General Operations CONTENTS IMPORTANT NOTICE........................................................................... 5 TO ENSURE SAFETY..............................................................................................................6 1 REAR DERAILLEUR......................................................................... 7 REAR DERAILLEUR FOR MTB / TREKKING...........................................................................8 REAR DERAILLEUR FOR ROAD..........................................................................................15 2 FRONT DERAILLEUR..................................................................... 21 FRONT DERAILLEUR FOR MTB / TREKKING......................................................................22 FRONT DERAILLEUR FOR ROAD........................................................................................34 MAINTENANCE...................................................................................................................42 3 CHAIN........................................................................................... 43 CHAIN CONNECTING PIN...................................................................................................46 QUICK-LINK........................................................................................................................47 4 BRAKE........................................................................................... 49 DISC BRAKE........................................................................................................................53 HYDRAULIC DISC BRAKE...................................................................................................56 --Installation.....................................................................................................................56 --Maintenance..................................................................................................................71 V-BRAKE.............................................................................................................................78 --Installation.....................................................................................................................78 --Maintenance..................................................................................................................82 --V-BRAKE and Hub roller brake.....................................................................................83 DUAL PIVOT CALIPER BRAKE............................................................................................84 --Installation.....................................................................................................................84 --Maintenance..................................................................................................................87 5 FRONT CHAINWHEEL................................................................... 88 INSTALLATION OF THE CHAINRINGS.................................................................................90 INSTALLATION OF THE FRONT CHAINWHEEL...................................................................92 --HOLLOWTECH II / 2 piece crankset...............................................................................92 --OCTALINK TYPE.............................................................................................................95 --SQUARE TYPE................................................................................................................96 PRESS-FIT BB.......................................................................................................................97 6 PEDALS (SPD-SL PEDALS / SPD PEDALS).................................. 100 SPD PEDALS......................................................................................................................101 SPD-SL PEDALS.................................................................................................................106 7 HUB DYNAMO........................................................................... 110 TO ENSURE SAFETY..........................................................................................................110 INSTALLATION..................................................................................................................111 CONNECTION OF THE CABLES.........................................................................................114 MAINTENANCE.................................................................................................................117 8 MULTIPLE FREEWHEEL............................................................... 118 INSTALLATION..................................................................................................................118 ••This dealer’s manual is intended primarily for use by professional bicycle mechanics. Users who are not professionally trained for bicycle assembly should not attempt to install the components themselves using the dealer’s manuals. If any part of the information on the manual is unclear to you, do not proceed with the installation. Instead, contact your place of purchase or a local bicycle dealer for their assistance. ••Make sure to read all instruction manuals included with the product. ••Do not disassemble or modify the product other than as stated in the information contained in this dealer’s manual. ••All dealer’s manuals and instruction manuals can be viewed on-line on our website (http://si.shimano.com). ••Please observe the appropriate rules and regulations of the country, state or region in which you conduct your business as a dealer. For safety, be sure to read this dealer's manual thoroughly before use, and follow it for correct use. The following instructions must be observed at all times in order to prevent personal injury and physical damage to equipment and surroundings. The instructions are classified according to the degree of danger or damage which may occur if the product is used incorrectly. DANGER Failure to follow the instructions will result in death or serious injury. WARNING Failure to follow the instructions could result in death or serious injury. CAUTION Failure to follow the instructions could cause personal injury or physical damage to equipment and surroundings. 5 IMPORTANT NOTICE IMPORTANT NOTICE TO ENSURE SAFETY IMPORTANT NOTICE WARNING ••When installing components, be sure to follow the instructions that are given in the instruction manuals. It is recommended that you use only genuine Shimano parts. If parts such as bolts and nuts become loose or damaged, the bicycle may suddenly fall over, which may cause serious injury. In addition, if adjustments are not carried out correctly, problems may occur, and the bicycle may suddenly fall over, which may cause serious injury. ••   Be sure to wear safety glasses or goggles to protect your eyes while performing maintenance tasks such as replacing parts. ••After reading the dealer’s manual thoroughly, keep it in a safe place for later reference. NOTE ••Products are not guaranteed against natural wear and deterioration from normal use and aging. ••For maximum performance we highly recommend Shimano lubricants and maintenance products. 6 WARNING • Obtain and read the dealer’s manual carefully prior to installing the parts. Loose, worn or damaged parts may cause the bicycle to fall over and serious injury may occur as a result. We strongly recommend only using genuine Shimano replacement parts. • Obtain and read the dealer’s manual carefully prior to installing the parts. If adjustments are not carried out correctly, the chain may come off and this may cause you to fall off the bicycle which could result in serious injury. NOTE • If gear shifting operations cannot be carried out smoothly, clean the derailleur and lubricate all moving parts. • If the amount of looseness in the links is so great that adjustment is not possible, you should replace the derailleur. • Grease the inner cable and the inside of the outer casing before use to ensure that they slide properly. • For smooth operation, use the specified outer casing and the bottom bracket cable guide. • You should periodically clean the derailleur and lubricate all moving parts (mechanism and pulleys). • If gear shifting adjustment cannot be carried out, check the degree of parallelism at the rear end of the bicycle. Also check if the cable is lubricated and if the outer casing is too long or too short. • If you hear abnormal noise as a result of looseness in a pulley, you should replace the pulley. • Use a frame with internal cable routing is strongly discouraged as it has tendencies to impair the SIS shifting function due to its high cable resistance. < For MTB / Trekking > Group marks • You should periodically wash the chainrings in a neutral detergent. In addition, cleaning the chain with neutral detergent and lubricating it can be an effective way of extending the useful life of the chainrings and the chain. ag - 18 T a g-15 T ag - 13 T • Always be sure to use the sprocket set bearing the same group marks. Never use in combination with a sprocket bearing a different group mark. IM SH O AN HYPERG L I DE -C • Use an outer casing which still has some length to spare even when the handlebars are turned all the way to both sides. Furthermore, check that the shifting lever does not touch the bicycle frame when the handlebars are turned all the way. • A special grease is used for the gear shifting cable. Do not use premium grease or other types of grease, otherwise they may cause deterioration in gear shifting performance. < For ROAD> 4-mm cap • The end of the outer casing which has the aluminum cap should be at the derailleur side. Derailleur side Aluminum cap 7 Plastic cap or 4-mm cap REAR DERAILLEUR 1 REAR DERAILLEUR REAR DERAILLEUR FOR MTB / TREKKING REAR DERAILLEUR „ Installation of the rear derailleur Standard type 5 mm Allen key Dropout Bracket Tightening torque: 8.0 - 10.0 N·m {70 - 87 in. lbs.} Bracket type < For BMX type > Frame Bracket nut Frame Bracket Bracket Bracket bolt Tightening torque: 3.0 - 4.0 N·m {26 - 35 in. lbs.} Note: Periodically check that there is no gap between the dropout and the bracket as shown in the illustration. If there is a gap between these two parts, problems with gear shifting performance may occur. 8 „ Stroke adjustment and cable securing Outer line of smallest sprocket Turn the top adjustment screw to adjust so that the guide pulley is in line with the outer line of the smallest sprocket when looking from the rear. B A B A Top adjustment screw 2. Low adjustment Turn the low adjustment screw so that the guide pulley moves to a position directly in line with the largest sprocket. B Largest sprocket Low adjustment screw Guide pulley A 9 A B REAR DERAILLEUR 1. Top adjustment 3. Chain length REAR DERAILLEUR Chain Largest sprocket Largest chainring + +2 links The length of A will vary depending on the movement of the rear suspension. Because of this, an excessive load may be placed on the drive system if the chain length is too short. Set the length of the chain by adding two links to the chain when the rear suspension is at a position where dimension “A” is longest and the chain is on the largest sprocket and the largest chainring. If the amount of movement of the rear suspension is large, the slack in the chain may not be taken up properly when the chain is on the smallest chainring and smallest sprocket. Add 2 links (with the chain on both the largest sprocket and the largest chainring) Note: The rear derailleur plate assembly is equipped with a pin or plate that prevents the chain from derailing. When passing the chain through the rear derailleur, pass it to the rear derailleur body from the side of the pin/plate for preventing chain derailment as shown in the illustration. If the chain is not passed through the correct position, damage may be caused to the chain or rear derailleur. Pin/plate for preventing chain derailment OK Not OK 10 4. Cutting the outer casing REAR DERAILLEUR 1. When cutting the outer casing, cut the opposite end to the end with the marking. After cutting the outer casing, make the end round so that the inside of the hole has a uniform diameter. 2. Attach the same outer end cap to the cut end of the outer casing. Outer end cap 3. Attach the sealed outer cap with tongue and the rubber shield to the outer casing stopper of the frame. Be careful not to bend Rubber shield Sealed outer cap with tongue Rubber shield *If the rear derailleur moves to a large degree, such as in bicycles with rear suspension, it is recommended that you replace the cap with the accessory aluminum cap. < Outer casing length for SHADOW RD > • Loosen the B-tension adjustment screw until it is in the position shown in the illustration. • Check that there is enough slack in the outer casing. Next, align the outer casing with the bottom edge of the outer casing holder at the rear derailleur and then cut of any excess length of outer casing. Outer casing holder Outer casing Note: The distance between the outer stopper to the outer casing holder of the rear derailleur may change when the rear suspension moves, so determine the length of the outer casing at the point where this length is at its greatest. 11 5. Connecting and securing of the cable REAR DERAILLEUR Connect the cable to the rear derailleur and, after taking up the initial slack in the cable, re-secure to the rear derailleur as shown in the illustration. Pull Note: • Be sure that the cable is securely in the groove. Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} Groove • Set the inner cable so that it protrudes by a length of less than about 30 mm, and then check that the inner cable does not interfere with the spokes of the wheel. Stop the wheel from turning while carrying out this step. Less than 30 mm 6. How to use the B-tension adjustment screw Mount the chain on the smallest chainring and the largest sprocket, and turn the crank arm to shift gears. Then turn the B-tension adjustment screw to adjust so that the guide pulley does not interfere with the sprocket but not so close that it touches the chain. Next, set the chain to the smallest sprocket and repeat the above to make sure that the pulley does not touch the sprocket. Largest sprocket Smallest sprocket A A B B B 12 A B-tension adjustment screw Set the rear derailleur to the largest sprocket and, with the wheel stopped, check that the distance between the tip of the guide pulley and the tip of the largest sprocket is within the range indicated in the table. When the lower gear uses the gear combination of 36T or 34T, set the distance to 5 to 6 mm. When the lower gear uses the gear combination of 32T, set the distance to 9 to 10 mm. Turn the crank arm to shift gears and check that there is no roughness in the feel. If the number of teeth for the cassette sprocket is changed, carry out this setting again. Gear combination 11-36T 11-34T 11-32T A A 5-6 mm 5-6 mm 9-10 mm 7. SIS Adjustment Operate the shifting lever several times to move the chain to the 2nd sprocket counting from the smallest sprocket. Then, while pressing the lever just enough to take up the play in the lever, turn the crank arm. 1. When shifting to the 3rd sprocket 1. When no sound at all is heard counting from the smallest sprocket 2. Loosen the outer casing adjustment barrel until the chain 2. Tighten the outer casing adjustment barrel until the touches the 3rd sprocket counting from the smallest sprocket and makes a noise. (counter clockwise) chain returns to the 2nd sprocket counting from the smallest sprocket. (clockwise) Adjustment barrel Adjustment barrel Outer casing adjustment barrel Outer casing adjustment barrel 13 REAR DERAILLEUR < SHADOW RD > Checking the distance between the largest sprocket and the guide pulley 3. Best setting REAR DERAILLEUR The best setting is when the shifting lever is operated just enough to take up the play and the chain touches the 3rd sprocket counting from the smallest sprocket and makes a noise. *Return the lever to its original position (the position where the lever is at the 2nd sprocket setting counting from the smallest sprocket and it has been released) and then turn the crank arm clockwise. If the chain is touching the 3rd sprocket counting from the smallest sprocket and making a noise, turn the outer casing adjustment barrel clockwise slightly to tighten it until the noise stops and the chain runs smoothly. Operate lever to change gears, and check that no noise occurs in any of the gear positions. For the best SIS performance, periodically lubricate all power-transmission parts. „ Replacing the pulley 3 mm Allen key Guide pulley Tension pulley E-ring Tightening torque: 2.5 - 5.0 N·m {22 - 44 in. lbs.} Note: When removing the tension pulley, remove the E-ring first. 14 REAR DERAILLEUR FOR ROAD When installing, be careful that deformation is not caused by the B-tension adjustment screw coming into contact with the dropout tab. Standard type 5 mm Allen key Dropout tab Tightening torque: 8.0 - 10.0 N·m {70 - 87 in. lbs.} B-tension adjustment screw Bracket type Bracket nut Frame Tightening torque: 3.0 - 4.0 N·m {26 - 35 in. lbs.} Bracket Bracket bolt „ Stroke adjustment and cable securing 1. Top adjustment Outer line of smallest sprocket Turn the top adjustment screw to adjust so that the guide pulley is below the outer line of the smallest sprocket when looking from the rear. B A B A Top adjustment screw Guide pulley 15 REAR DERAILLEUR „ Installation of the rear derailleur 2. Low adjustment REAR DERAILLEUR Turn the low adjustment screw so that the guide pulley moves to a position directly in line with the largest sprocket. Largest sprocket Guide pulley A B B Low adjustment screw 3. Chain length < When largest sprocket is 27T or smaller > Smallest sprocket Guide pulley Largest chainring Front double Chain Tension pulley 90 Right angle to the ground < When largest sprocket is 28T or larger > Add 2 links (with the chain on both the largest sprocket and the largest chainring) Largest chainring Largest sprocket Front double Chain + 16 +2 links A < For front triple, when largest sprocket is 30T or smaller > Chain Front triple Not OK OK 90 Right angle to the ground When installing chain using, place chain in largest chainring and smallest sprocket. Line up guide and tension pulley at 90° or more. Note: For RD-A070, follow the adjustment method in “For front triple, when largest sprocket is 32T or larger ” instead. < For front triple, when largest sprocket is 32T or larger > Add 2 links (with the chain on both the largest sprocket and the largest chainring) Largest chainring Largest sprocket Front triple Chain + +2 links Note: The rear derailleur plate assembly is equipped with a pin or plate that prevents the chain from derailing. When passing the chain through the rear derailleur, pass it to the rear derailleur body from the side of the pin/plate for preventing chain derailment as shown in the illustration. If the chain is not passed through the correct position, damage may be caused to the chain or rear derailleur. Pin/plate for preventing chain derailment OK Not OK 17 REAR DERAILLEUR Largest chainring Smallest sprocket 4. Cutting the outer casing REAR DERAILLEUR 1. When cutting the outer casing, cut the opposite end to the end with the marking. After cutting the outer casing, make the end round so that the inside of the hole has a uniform diameter. 2. Attach the same outer end cap to the cut end of the outer casing. Outer end cap 5. Connection and securing of the cable Connect the cable to the rear derailleur and, after taking up the initial slack in the cable, re-secure to the rear derailleur as shown in the illustration. Pull Note: Be sure that the cable is securely in the groove. Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} Groove 18 6. How to use the B-tension adjustment screw Largest sprocket Smallest sprocket A A B B B A B-tension adjustment screw 7. SIS Adjustment Operate the shifting lever several times to move the chain to the 2nd sprocket counting from the smallest sprocket. Then, while pressing the lever just enough to take up the play in the lever, turn the crank arm. 1. When shifting to the 3rd 3 Play 2 1. When no sound at all is heard sprocket counting from the smallest sprocket 2. Tighten the outer casing adjustment barrel until the 2. Loosen the outer casing adjustment barrel until the chain returns to the 2nd sprocket counting from the smallest sprocket. (clockwise) chain touches the 3rd sprocket counting from the smallest sprocket and makes a noise. (counter clockwise) Outer casing adjustment barrel Outer casing adjustment barrel 19 REAR DERAILLEUR Mount the chain on the smallest chainring and the largest sprocket, and turn the crank arm backward. Then turn the B-tension adjustment screw to adjust the guide pulley as close to the sprocket as possible but not so close that it touches. Next, set the chain to the smallest sprocket and repeat the above to make sure that the pulley does not touch the sprocket. 3. Best setting REAR DERAILLEUR The best setting is when the shifting lever is operated just enough to take up the play and the chain touches the 3rd sprocket counting from the smallest sprocket and makes a noise. *Return the lever to its original position (the position where the lever is at the 2nd sprocket setting counting from the smallest sprocket and it has been released) and then turn the crank arm clockwise. If the chain is touching the 3rd sprocket counting from the smallest sprocket and making a noise, turn the outer casing adjustment barrel clockwise slightly to tighten it until the noise stops and the chain runs smoothly. Operate lever to change gears, and check that no noise occurs in any of the gear positions. For the best SIS performance, periodically lubricate all power-transmission parts. „ Replacing the pulley Tightening torque: 2.5 - 5.0 N·m {22 - 44 in. lbs.} 3 mm Allen key 20 WARNING ••Obtain and read the dealer’s manual carefully prior to installing the parts. Loose, worn or damaged parts may cause the bicycle to fall over and serious injury may occur as a result. We strongly recommend only using genuine Shimano replacement parts. ••Obtain and read the dealer’s manual carefully prior to installing the parts. If adjustments are not carried out correctly, the chain may come off and this may cause you to fall off the bicycle which could result in serious injury. NOTE ••If gear shifting operations cannot be carried out smoothly, clean the derailleur and lubricate all moving parts. ••If the amount of looseness in the links is so great that adjustment is not possible, you should replace the derailleur. ••Grease the inner cable and the inside of the outer casing before use to ensure that they slide properly. ••For smooth operation, use the specified outer casing and the bottom bracket cable guide. < For MTB / Trekking > ••When the chain is in the position shown in the illustration, the chain may contact the front chainrings or front derailleur and generate noise. If the noise is a problem, shift the chain onto the next-larger rear sprocket or the one after. ••For frames with suspension, the chain stay angle will vary depending on whether the bicycle is being ridden or not being ridden. When the bicycle is not being ridden and the chain is positioned on the largest/larger chainring and on the smallest sprocket, the chain guide outer plate of the front derailleur may touch the chain. Double Triple Double Triple Front chainrings Rear sprockets < For Road > ••When the chain is in the position shown in the illustration, the chain may contact the front chainrings or front derailleur and generate noise. If the noise is a problem, shift the chain onto the next-larger rear sprocket or the one after. Front chainrings Rear sprockets 21 FRONT DERAILLEUR 2 FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB / TREKKING FRONT DERAILLEUR Note: When installing the components to carbon frame/handle bar surfaces, verify with the manufacturer of the carbon frame/ parts for their recommendation on tightening torque in order to prevent over tightening that can cause damage to the carbon material and/or under tightening that can cause lack of fixing strength for the components. „„INSTALLATION Adjust so that there is a clearance of 1 – 3 mm between the chain guide outer plate and the largest chainring. * Bicycles with suspensions are positioned differently between when a rider is off the bicycle and on the bicycle. By referring to the following illustration, perform installation and SIS adjustment with the bicycle fixed in a riding condition. 22 Band type Adapter Align Front band/Rear band • Be sure to use a metallic adapter for a front band which has a non-planar shape. Front band Planar shape Metallic adapter Non-planar shape • After tentatively tightening the clamp bolt, align the flat portion of the outer plate of the chain guide in parallel with the flat surface of the largest chainring. When the adjustment is complete, tighten the clamp bolt. Chain guide outer plate 5 mm Allen key 1 – 3 mm Largest chainring Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} Largest chainring 23 FRONT DERAILLEUR • When using the adapter, install it in the position shown in the illustration, relative to the front band or the rear band. Type E FRONT DERAILLEUR • Install as shown in the illustration. Front derailleur Front chainwheel , 2 Tightening torque: 35.0 - 50.0 N·m {306 - 437 in. lbs.} 1 Bolt 3 Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} Adapter Adapter Type E (models without BB plate) Bottom bracket mount fixing bolt Note: Shimano does not provide the bottom bracket mount fixing bolts. Bottom bracket mount Bracket Double: Largest chainring 38T Triple: Largest chainring 40T 24 Double: Largest chainring 40T Triple: Largest chainring 42T Direct mount type FRONT DERAILLEUR 5 mm Allen key Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} Double: 42T Double: 40T Triple: 42T Double: 38T 155.5 mm* (From bottom bracket center) * The mounting height varies depending on the position of the base on the frame. Double: 44T 159.5 mm* (From bottom bracket center) 25 Double: 42T Double: 40T Triple: 42T „ Fixing the cable and adjusting the SIS FRONT DERAILLEUR < Double > 1. Low adjustment Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. Smallest chainring Top swing 0 - 0.5mm Down swing Chain guide inner plate Largest sprocket Chain Low Cable index point 26 Top 2. Securing the cable Top Swing (Common to E type and band type) • Use a spanner or an Allen key to tighten the wire fixing bolt. < Top pull > < Down pull > Note: Pass the cable through as shown in the illustration. 5 mm Allen key (Some products can be tightened with a 8 mm spanner as well.) 5 mm Allen key (Some products can be tightened with a 8 mm spanner as well.) Wire fixing bolt Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} Down Swing (Band type) < Down pull > < Top pull > Note: Pass the cable through as shown in the illustration. Wire fixing bolt < Different shaped type > Wire fixing bolt 5 mm Allen key Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} 27 FRONT DERAILLEUR Use the shifting lever with a mode converter in exes mode. To shift from expo to exude, refer to the maintenance section of the dealer’s manual for the shifting lever Rapidfire plus. Down Swing (Direct mount type) FRONT DERAILLEUR < Down pull > < Top pull > Note: Pass the cable through as shown in the illustration. Wire fixing bolt < Different shaped type > Wire fixing bolt 5mm Allen key Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} • After taking up the initial slack in the cable, re-secure to the front derailleur as shown in the illustration. < Down pull > < Top pull > Pull Pull 28 3. Adjustment of the cable tension 0 - 0.5 mm Largest chainring Chain guide inner plate Chain Outer casing adjustment barrel Low 29 Largest sprocket Cable Adjuster Top FRONT DERAILLEUR Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. 4. Top adjustment FRONT DERAILLEUR Set so that the clearance between the chain guide outer plate and the chain is 0 - 0.5 mm. Largest chainring 0 - 0.5mm Top swing Down swing Chain guide outer plate Smallest sprocket Chain Low Top 5. Troubleshooting chart After completion of steps 1 - 4, move the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8 turn for each adjustment. If the chain falls to the crank side. Turn the top adjustment screw clockwise. Tighten the cable. If this does not improve the If shifting is difficult from the smallest chainring to the condition, turn the top adjustment screw largest chainring. counterclockwise. If shifting is difficult from the largest chainring to the Turn the low adjustment screw counterclockwise. smallest chainring. If the chain falls to the bottom bracket side. Turn the low adjustment screw clockwise. 30 < Triple > FRONT DERAILLEUR 1. Low adjustment Remove the Pro-Set alignment block. Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. Pro-Set alignment block Smallest chainring Top swing 0 - 0.5mm Down swing Chain guide inner plate Largest sprocket Chain Low Middle Top Cable index point 2. Securing the cable Use the shifting lever with a mode converter in x3 mode. To shift from x2 to x3, refer to the maintenance section of the dealer’s manual for the shifting lever Rapidfire plus. * A cable can be secured on each FD type in the same way as the double. Refer to page 25, 26. 31 3. Top adjustment FRONT DERAILLEUR Set so that the clearance between the chain guide outer plate and the chain is 0 - 0.5 mm. Largest chainring 0 - 0.5mm Top swing Down swing Chain guide outer plate Smallest sprocket Chain Low 32 Middle Top 4. Adjustment of the cable tension Middle chainring 0 - 0.5mm Chain guide inner plate Chain Outer casing adjustment barrel Low Largest sprocket Cable Adjuster Middle Top * Adjust the lever after operating it from top to middle, instead of low to middle. 5. Troubleshooting chart After completion of steps 1 - 4, move the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8 turn for each adjustment. If the chain falls to the crank side. Turn the top adjustment screw clockwise. Tighten the cable. If this does not improve the If shifting is difficult from the intermediate chainring condition, turn the top adjustment screw to the largest chainring. counterclockwise. If shifting is difficult from the largest chainring to the Loosen the cable. intermediate chainring. If the chain falls to the bottom bracket side. Turn the low adjustment screw clockwise. If the intermediate chainring is skipped when shifting Tighten the cable. from the largest chainring. If shifting is difficult from the intermediate chainring Turn the low adjustment screw counterclockwise. to the smallest chainring. 33 FRONT DERAILLEUR Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. FRONT DERAILLEUR FOR ROAD FRONT DERAILLEUR Note: When installing the components to carbon frame/handle bar surfaces, verify with the manufacturer of the carbon frame/parts for their recommendation on tightening torque in order to prevent over tightening that can cause damage to the carbon material and/or under tightening that can cause lack of fixing strength for the components. „ INSTALLATION • When using the adapter, install it in the position shown in the illustration, relative to the front band or the rear band. Adapter Align Front band/Rear band • Be sure to use a metallic adapter for a front band which has a non-planar shape. Front band Planar shape Metallic adapter Non-planar shape • Adjust so that there is a clearance of 1 – 3 mm between the chain guide outer plate and the largest chainring. After tentatively tightening the clamp bolt, align the flat portion of the outer plate of the chain guide in parallel with the flat surface of the largest chainring. When the adjustment is complete, tighten the clamp bolt. 5 mm Allen key Some products can be tightened with a 9 mm spanner as well. Chain guide outer plate 1 – 3 mm Largest chainring Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} 34 „ Fixing the cable and adjusting the SIS 1. Lever operation and cable index point Front shifting Front shifting < Standard type > < Thumb release type > Lever b From largest chainring to smallest chainring Lever b From largest chainring to smallest chainring Lever b Lever a From smallest chainring to largest chainring Lever a Low Top L-trim Lever a From smallest chainring to largest chainring Lever a Low T-trim Top L-trim T-trim When the lever b is operated When the lever a is operated : Cable index point 2. Securing the cable Check that the lever b is released to the low position by operating it 2 or more times before fixing the inner cable. After fixing the cable, remove the initial extension from the cable as shown in the illustration. After that, fix the cable again on the front derailleur. Pull Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} 35 FRONT DERAILLEUR < Double > 3. Low adjustment FRONT DERAILLEUR Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. Smallest chainring 0 - 0.5mm Chain guide inner plate Chain Largest sprocket Low Top L-trim T-trim 4. Adjustment of the cable tension Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. Largest chainring 0 - 0.5mm Chain guide inner plate Chain Largest sprocket Outer casing adjustment barrel Cable Adjuster Low Top L-trim 36 T-trim 5. Top adjustment Largest chainring 0 - 0.5 mm Chain guide outer plate Chain Smallest sprocket Low Top L-trim T-trim 6. Troubleshooting chart After completion of steps 1 - 5, move the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8 turn for each adjustment. If the chain falls to the crank side. Turn the top adjustment screw clockwise. Tighten the cable. If this does not improve the If shifting is difficult from the smallest chainring to the condition, turn the top adjustment screw largest chainring. counterclockwise. If shifting is difficult from the largest chainring to the Turn the low adjustment screw counterclockwise. smallest chainring. If the chain falls to the bottom bracket side. Turn the low adjustment screw clockwise. 37 FRONT DERAILLEUR Set so that the clearance between the chain guide outer plate and the chain is 0 - 0.5 mm. < Triple > FRONT DERAILLEUR 1. Lever operation and cable index point Front shifting Front shifting < Standard type > < Thumb release type > Lever b From largest chainring to smallest chainring Lever b From largest chainring to smallest chainring Lever b Lever a From smallest chainring to largest chainring Lever a Low Middle L-trim M-trim Lever a From smallest chainring to largest chainring Lever a Top Low T-trim Middle L-trim M-trim Top T-trim When the lever b is operated When the lever a is operated : Cable index point 38 2. Low adjustment FRONT DERAILLEUR Remove the Pro-Set alignment block. Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. Pro-Set alignment block Smallest chainring 0 - 0.5 mm Largest sprocket Chain guide inner plate Chain Low Middle L-trim 39 M-trim Top T-trim 3. Securing the cable FRONT DERAILLEUR Check that the lever b is released to the low position by operating it 3 or more times before fixing the inner cable. After fixing the cable, remove the initial extension from the cable as shown in the illustration. After that, fix the cable again on the front derailleur. Pull Tightening torque: 6.0 - 7.0 N·m {52 - 61 in. lbs.} 4. Top adjustment Set so that the clearance between the chain guide outer plate and the chain is 0 - 0.5 mm. Largest chainring 0 - 0.5 mm Chain guide outer plate Smallest sprocket Chain Low Middle L-trim 40 M-trim Top T-trim 5. Adjustment of the cable tension Middle chainring 0 - 0.5 mm Chain guide inner plate Chain Largest sprocket Outer casing adjustment barrel Low Cable Adjuster Middle M-trim L-trim Top T-trim * Adjust the lever after operating it from top to middle, instead of low to middle. 6. Troubleshooting chart After completion of steps 1 - 5, move the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8 turn for each adjustment. If the chain falls to the crank side. Turn the top adjustment screw clockwise. Tighten the cable. If this does not improve the If shifting is difficult from the intermediate chainring condition, turn the top adjustment screw to the largest chainring. counterclockwise. If shifting is difficult from the largest chainring to the Loosen the cable. intermediate chainring. If the chain falls to the bottom bracket side. Turn the low adjustment screw clockwise. If the intermediate chainring is skipped when shifting Tighten the cable. from the largest chainring. If shifting is difficult from the intermediate chainring Turn the low adjustment screw counterclockwise. to the smallest chainring. 41 FRONT DERAILLEUR Set so that the clearance between the chain guide inner plate and the chain is 0 - 0.5 mm. MAINTENANCE FRONT DERAILLEUR If shifting operation becomes less smooth, clean the front derailleur and lubricate the link sections shown in the illustration. Brazed on type Band type Links Links Links Links Type E Direct mount type Links Links 42 CHAIN 3 CHAIN WARNING “Maintenance interval depends on the usage and riding circumstances. Clean regularly the chain with an appropriate chain cleaner. Never use alkali based or acid based solvents such as rust cleaners. If those solvent be used chain might break and cause serious injury.” • In order to obtain good gear shifting performance, CN-HG900-11 / HG700-11 / HG600-11, CN-M981 / HG95 / HG75 / HG54, CN-7901 / 6701 / 5701 / 4601, CN-E6090-10 have a forward side and a reverse side, and the sides are marked so that the chain will face the correct way when installed. The proper design performance will be obtained when the chain is installed so that it faces the correct way. If it is installed so that it faces the opposite way, the chain may come off and the bicycle may fall over and serious injury may occur as a result. • Check the chain for any damage (deformation, cracks, or corrosion), elongation due to wear, skipping, or other abnormalities such as unintended gear shifting. If any problems are found, consult a dealer or an agency. If you continue to ride the bicycle in such a condition, the chain may break causing the bicycle to fall, and serious injury may result. • Always connect the chain with the tool and connecting pins of the model specified in the table. If unsuitable connecting pins or tools are used to connect the chain, sufficient connection force may not be obtained, which could cause the chain to break or fall off. Chain Reinforced connecting pin < 11-speed > CN-9000 / 6800 CN-HG900-11 / HG700-11 / HG600-11 TL-CN34 TL-CN28 5.8mm < For MTB / Trekking / E-bike> 10-speed super narrow chain Such as CN-M981 / HG95 / HG75 / HG54 / E6090-10 (CN-M980 / HG94 / HG74 EOL) < For ROAD double crank > 10-speed super narrow chain Such as CN-7901 / 6701 / 5701 / 4601 Chain tool with groove (2) 5.85mm ( ) with groove (3) 5.85mm < For ROAD triple crank > 10-speed super narrow chain Such as CN-7801 / 6600 / 5600 9-speed super narrow chain Such as CN-YM81 / 7701 / HG93 / E6070-9 Silver 6.5mm 8/7/6-speed narrow chain Such as CN-HG50 / HG40 Black 7.1mm 43 TL-CN34 TL-CN33 TL-CN32 TL-CN28 TL-CN27 CHAIN • If it is necessary to adjust the length of the chain due to a change in the number of sprocket teeth, make the cut at some other place than the place where the chain has been joined using a reinforced connecting pin. The chain will be damaged if it is cut at a place where it has been joined with a reinforced connecting pin. Reinforced connecting pin Link pin Link pin • When readjusting the length of the chain, be sure to insert the reinforced connecting pin from the same side as the chain cutter was inserted (the same direction as when the chain was cut). < 11/10-speed chain (ampoule pin type) > • Make sure that the connecting pin is aligned with the outer link surface from the side that the pin is inserted. It should feel smooth and flush when you run your finger over it. The pin will protrude slightly after the break off pin is removed. Link surface Slightly protruding Link surface Connecting pin Connecting pin < 9/8/7/6-speed chain > • Be sure to check that the connecting pin protrudes uniformly from both sides of the chain after the chain has been joined. * Should be uniform Connection location 44 NOTE • As illustrated in Fig. A , we strongly recommend to set the connecting pin in the hole of the outer link on the front side in the direction of travel. The chain’s level of strength is enhanced compared to the method in Fig. B . • You should periodically wash the chainrings in a neutral detergent. In addition, cleaning the chain with neutral detergent and lubricating it can be an effective way of extending the useful life of the chainrings and the chain. A Rotation of the crank Inner link Outer link B Connecting pin Inner link Outer link Connecting pin < For the CN-HG900-11 / HG700-11 / HG600-11, CN-M981 / HG95 / HG75 / HG54, CN-7901 / 6701 / 5701 / 4601, CN-E6090-10 > • In order to obtain good gear shifting performance, the CN-M981 / HG95 / HG75 / HG54, CN-7901 / 6701 /5701 / 4601 has a forward side and a reverse side, and the sides are marked so that the CN-M981 / HG95 / HG75 / HG54, CN-7901 / 6701 /5701 / 4601 will face the correct way when installed. The side with the mark shown in the illustration is the forward side (outer side). Forward (outer side) Reverse (inner side) CN-M981 / HG95 / HG75 / HG54 / E6090-10 (CN-M980 / HG94 / HG74 EOL) Forward (outer side) Reverse (inner side) CN-HG900-11 / HG700-11 / HG600-11 45 CN-7901 / 6701 / 5701 / 4601 CHAIN • CN-E6090-10 / CN-E6070-9 can be used only in combination with single front chainrings. CHAIN CONNECTING PIN CHAIN „ Method of use 1. Push in 2. Press 3. After pressing 4. Break off the excess part Chain tool • Set the chain on the chain cutting tool as shown in the figure when using the chain cutting tool. If the tool is used with the chain set incorrectly, the positioning plate will be damaged. 46 QUICK-LINK CHAIN WARNING • If it is necessary to adjust the length of the chain due to a change in the number of sprocket teeth, make the cut at some other place than the place where the chain has been joined using a QUICK-LINK. The chain cutter will be damaged if the chain is cut at a place where it has been joined with a QUICK-LINK. • If an already-used QUICK-LINK is used again, the chain may break and serious injury due to accidents may result, so always be sure to use a brand-new QUICK-LINK. • Obtain and read the service instructions carefully prior to installing the parts. We strongly recommend only using genuine Shimano replacement parts. If adjustments are not carried out correctly, the chain may come off and this may cause you to fall off the bicycle which could result in serious injury. • Read these Technical Service Instructions carefully, and keep them in a safe place for later reference. < Compatible chains: Shimano 6 / 7 / 8-speed > Model No. QUICK-LINK Chain SM-UG51 CN-HG91 CN-HG71 CN-HG50 CN-HG40 CN-UG51 „ Installing QUICK-LINK 1. Remove the outer link at the connection location so that both ends of the chain finish at an inner link. Inner link 2. Insert the connecting link with pins section of the QUICK-LINK as Inner link Connecting link with pins shown in the illustration. Inner link Inner link 3. Place the connecting link with hole onto one of the pins, and then slide the connecting link so that the pin is at the other end from the hole. (The side of the link plate with the depression should be facing toward the outside at this time.) Depression should be on the outside Hole Connecting link with hole 47 4. Turn the connecting link with hole until it overlaps the other pin. CHAIN Hole 5. Loosen the chain and insert the pin securely into the hole. 1 2 There should be no gap between the connecting link with pins and the inner link. Insert the pins into the hole while pushing the connecting link with hole. Inner link Connecting link with pins 6. Set both pins securely into the slot of the connecting link with hole, and check that both plates are parallel. Parallel 48 BRAKE 4 BRAKE WARNING ••Obtain and read the dealer’s manual carefully prior to installing the parts. Loose, worn or damaged parts may cause the bicycle to fall over and serious injury may occur as a result. We strongly recommend only using genuine Shimano replacement parts. < For Disc Brake > ••If the rotor is cracked or warped, be sure to replace it with a new rotor. ••If the rotor becomes worn down to a thickness of 1.5 mm or so that the aluminum surface becomes visible, be sure to replace the rotor with a new one. ••If any oil or grease do get on the pads, you should replace the pads. If any oil or grease gets on the rotor, you should clean the rotor. If this is not done, the brakes may not work correctly. < For Hydraulic Disc Brake > ••Use only genuine Shimano mineral oil. If other types of oil are used, it may cause problems with brake operation, and cause the system to be unusable. ••Be sure to use only oil from a freshly-opened container, and do not re-use oil which has been drained from the bleed nipple. Old oil or already-used oil may contain water which could cause vapor lock in the brake system. ••Be careful not to let water or air bubbles get into the brake system, otherwise vapor locks may occur. Be particularly careful when removing the bleed screws. ••If cutting the brake hose in order to adjust the length of the hose, or when changing over the brake hose from left to right or vice versa, be sure to bleed the air from the hose by carrying out steps (4), (8) to (12) given in “Adding mineral oil and bleeding air”. ••The disc brake is not designed to work with the bicycle upside down. If the bicycle is turned upside down or on its side, the brake may not work correctly, and a serious accident could occur. Before riding the bicycle, be sure to operate the brake lever a few times to check that the brakes operate normally. If the brakes do not operate normally, stop using the brakes and consult a dealer or an agency. If brake operation is sluggish when the lever is depressed Gently depress the brake lever several times and wait for the bubbles to return to the reservoir tank. It is recommended that you then remove the bleed screws and fill the reservoir tank with mineral oil until no air bubbles remain. If the brakes still operate sluggishly, bleed the air from the brake system. (Refer to “Adding mineral oil and bleeding air”.) 49 ••If the quick release lever is on the same side as the rotor, there is the danger that it may interfere with the rotor, so check that it does not interfere. BRAKE ••Shimano disc brake systems are not compatible with tandem bicycles. Because tandem bicycles have a high overall weight, the load on the brake system increases during brake operation. If hydraulic disc brakes are used with tandem bicycles, the oil temperature will become too high and vapor locks or ruptures in the brake hoses may occur, and this will cause the brakes to fail. ••If fluid leaks occur, immediately stop using the brakes and carry out the appropriate repairs. If you continue riding the bicycle while fluid is leaking, there is the danger that the brakes may suddenly stop working. < For Mechanical Disc Brake > ••Adjust the inner cable so that the protruding length is less than 20 mm (3/4 inch). If the protruding length is any longer, the end of the inner cable may become stuck in the rotor, which could cause the wheel to lock and the bicycle could fall forward causing serious injuries. ••Be careful not to allow any oil or grease to get onto the rotor and brake pads, otherwise the brakes may not work correctly. Less than 20mm < For V-BRAKE / Caliper Brake > ••Brakes designed for use as rear brakes should not be used as front brakes. ••Be careful not to allow any oil or grease to get onto the brake shoes. If any oil or grease do get on the shoes, you should replace the shoes, otherwise the brakes may not work correctly. < For Caliper Brake > ••Securely tighten the caliper brake mounting nuts to the specified tightening torque. · Use lock nuts with nylon inserts (self-locking nuts) for nut-type brakes. · For sunken nut type brakes, use sunken nuts of the appropriate length which can be turned six times or more; when reinstalling, apply sealant (locking adhesive) to the nut threads. If the nuts become loose and the brakes fall off, they may get caught up in the bicycle and the bicycle may fall over. Particularly if this happens with the front wheel, the bicycle may be thrown forward and serious injury could result. ••Check the brake cable for rust and fraying, and replace the cable immediately if any such problems are found. If this is not done, the brakes may not work correctly. CAUTION < For Hydraulic Disc Brake > ••Resin pads are designed to reduce the amount of noise generated between the pads and the rotor when the brakes are operated. A longer run-in period is required than for metal pads. 50 Handling the mineral oil ••Use gloves when handling. Contact with skin may cause a rash and discomfort. In the event of skin contact, wash well with soap and water. ••Inhalation of oil mist or vapors may cause nausea. Cover nose and mouth with a respirator type mask and use in a well ventilated area. If mist or vapor is inhaled, go immediately to an area with fresh air. Cover up with a blanket. Stay warm and stable and seek professional medical advice. ••Do not drink. May cause vomiting or diarrhea. ••Keep out of reach of children. ••Do not cut, heat, weld or pressurize the oil container, as this may cause explosion or fire. ••Disposal of Used Oil : Follow local county and/or state codes for disposal. Use care when preparing oil for disposal. ••Directions : Keep the container sealed to prevent foreign objects and moisture from getting inside, and store it in a cool, dark area away from direct sunlight or heat. < For V-BRAKE > ••The power modulator is a device that makes it easier to control braking by increasing the cable stroke at the brake lever within a certain constant range of braking force. If the effective operating range of the power modulator will be exceeded, the lever stroke and the brake will operate as a normal V-BRAKE (sensitive and powerful). In that case, the brakes may operate more powerfully than intended and may cause the wheel to lock up. Therefore it is essential that you fully understand and test the performance of the power modulator before use. The power modulator is not equipped with a function to prevent the wheel from locking up. Braking Performance Comparison (kg) Braking force at wheel w/o power modulator Effective operating range of the power modulator w/ power modulator Cable stroke at brake lever 51 BRAKE ••Use safety glasses when handling, and avoid contact with eyes. Contact with eyes may result in irritation. In the event of eye contact, flush with fresh water and seek medical assistance immediately. NOTE BRAKE < For Hydraulic Disc Brake > ••If the brake lever is depressed without the pad spacers installed, the pistons will protrude further than is normal. Use a flat-tipped screwdriver or similar tool to push back the brake pads, while being careful not to damage the surfaces of the brake pads. (If the brake pads are not installed, use a flat-shaped tool to push the pistons straight back in, while being careful not to damage them.) If it is difficult to push the brake pads or pistons back, remove the bleed screws and then try again. (Note that some oil may overflow from the reservoir tank at this time.) ••Use isopropyl alcohol, soapy water or a dry cloth when carrying out cleaning and maintenance of the brake system. Do not use commercially-available brake cleansers or silencing agents, as they can cause damage to parts such as seals. ••Do not remove the pistons when disassembling the calipers. < For Mechanical Disc Brake > ••If the brake caliper mounting boss and the dropout are not parallel, the rotor and caliper may touch. < For V-BRAKE > ••The optimum efficiency of the Multi-Condition Brake System can be realized by using the brakes and brake levers in the recommended set. ••If the brake shoes have worn down until the grooves are no longer visible, they should be replaced. 52 DISC BRAKE BRAKE „ Wheel spoke lacing Check that the spokes have been laced as shown in the illustration. A radial assembly cannot be used. Lace the spokes as shown in Figure 1 for the left side of the front wheel (the side where the rotor is installed), and the left and right sides of the rear wheel, and as shown in Figure 2 for the right side of the front wheel. Rotating direction of wheel Front left Rear left Rear right Fig. 1 Front right Fig. 2 „ Installation of the rotor For center lock type Tightening torque: 40.0 - 50.0 N·m {350 - 437 in. lbs.} Rotor fixing lock ring TL-LR15 53 For 6-bolt type BRAKE 1. Install the rotor and the rotor tightening plate to the hub, and then install and tighten the bolts. Tightening plate Rotor Tightening torque: 2.0 - 4.0 N·m {17 - 35 in. lbs.} Hub Rotor fixing bolts (Hexalobular #25) 2. While wearing gloves, apply a force to the rotor to turn it in a clockwise direction. While doing this, tighten the rotor fixing bolts in the order shown in the illustration. 3. Use a flat-tipped screwdriver or similar tool to bend the edges of the tightening plate over the heads of the bolts. 54 Tightening plate For 6-bolt type (with Lock Washer) Lock Washer Tightening torque: 2.0 - 4.0 N·m {17 - 35 in. lbs.} Rotor fixing bolt Note: ••Install the lock washer so that the letters “TOP” are visible. ••The lock washers cannot be reused. When installing the rotor, use a new one. ••Use the dedicated rotor mounting bolts. 2. While wearing gloves, apply a force to the rotor to turn it in a clockwise direction. While doing this, tighten the rotor fixing bolts in the order shown in the illustration. 55 BRAKE 1. Install the rotor and the rotor lock washer to the hub, and then install and tighten the bolts. HYDRAULIC DISC BRAKE BRAKE Installation „ Installation of the brake lever Secure the brake lever as shown in the illustration. (Check that the brake lever does not interfere with the shifting lever during operation. Some types might require the shifting lever to be installed first, due to the position of the shifting lever fixing bolts.) BL-M987/BL-M9000/BL-M9020 Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} Tightening torque: 4.0 - 6.0 N·m {35 - 52 in. lbs.} For open clamp band type Use a 2 mm Allen key to open the clamp band of the brake lever as shown in the illustration. Clamp band Push Note: • When installing the brake lever, be sure to use a spacer. Lock release hole • The spacer should only be removed when combining with an I-Spec II type shifting lever. For information on the combining procedure, refer to “shifting lever RAPIDFIRE Plus 11-speed” in the dealer’s manual. Spacer Note: When installing the components to carbon frame/handle bar surfaces, verify with the manufacturer of the carbon frame/parts for their recommendation on tightening torque in order to prevent over tightening that can cause damage to the carbon material and/or under tightening that can cause lack of fixing strength for the components. 56 „ Installation of the brake hose BRAKE Use a utility knife or similar tool to cut the hose. *Make sure that you handle the utility knife safely and correctly in accordance with the instructions which are provided with the utility knife. *If you are using TL-BH62, refer to the manual accompanying the product. 90 degrees 1. Pass the brake hose through the connecting bolt and the olive as shown in the illustration. Direction of insertion Cut end Cover Hose Olive Connecting bolt Attach the cover to the connecting bolt for the brake lever. Apply grease to the outside of the olive. Olive Premium grease 2. In order to check that the end of the brake hose are fitted securely into the base of the hose mounts of the calipers and brake lever, make marks on the hose beforehand as shown in the illustration. (As a guide, the length of hose inside the mounts should be approximately 11 or 14 mm, measured from the cut end of the hose.) < At brake lever end > Model No. Length Type SM-BH90-SB 11 mm Banjo type SM-BH90-SS 11 mm Straight type SM-BH59 14 mm Straight type SM-BH59-A 11 mm Straight type SM-BH80 14 mm Banjo type Model No. Length Type SM-BH90-SS 11 mm Straight type SM-BH59 14 mm Straight type SM-BH59-A 11 mm Straight type Mark Mark < At caliper end > 57 Mark Mark 3. Use an object such as a needle to smooth the inside of the cut end of the BRAKE hose, and then install the connector insert. Attach the hose to the TL-BH61 as shown in the illustration, and secure the TL-BH61 in a vise. Then use a hammer or similar tool to knock the connector insert in firmly until the base of the connector insert touches the end of the hose. If the end of the hose is not touching the base of the connector insert, the hose may become disconnected or fluid leaks may occur. Hose Connector insert Connector insert Hose Olive TL-BH61 SM-BH90 : 1 mm SM-BH59 / BH80(YM-BH81) : 4 mm Vise Note: If there is a marking as shown in the illustration, refer to the section “How to replace the brake hose (easy hose joint system)”. Marking 4. After checking that the olive is positioned as shown in the illustration, apply premium grease to the threads of the connecting bolts and then attach the hose to the brake lever as shown in the illustration. Model No. Length Color SM-BH90 11.2 mm Silver SM-BH59 / 80 13.2 mm Gold YM-BH81 13.2 mm Silver SM-BH90 : 2 mm SM-BH59 / BH80(YM-BH81) : 5 mm Hose Olive Do not let the hose become twisted. Make sure that the calipers and levers are in the positions shown in the illustrations. < For left lever > < For right lever > 5. While pushing the brake hose, tighten the connecting bolt. < At brake lever end > 8 mm spanner Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} Connecting bolt 58 Connector insert < At caliper end > Check that the O-rings are positioned in the grooves at both the top and bottom of the banjo, and then secure the banjo to the calipers as shown in the illustration. Make sure that the O-rings do not protrude from the grooves at this time. The O-ring has grease applied. Hose Banjo Allen key 3 mm Tightening torque 5.0 - 7.0 N·m {44 - 61 in. lbs.} Allen key 4 mm Tightening torque: 8.0 - 10.0 N·m {70 - 87 in. lbs.} O-rings Allen key 3 mm Allen key 4 mm Straight type Olive Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} Connecting bolt Caliper 59 BRAKE Banjo type „ Installation of the brake hose (easy hose joint system) BRAKE * This procedure for installation of the brake hose is directed at bicycle OEMs. < For MTB > Overview of the easy hose joint system Hose cap Brake caliper Lever stopper Brake hose connection port Brake lever 1. Pass the brake hose through each hole in the built-in frame. 2. Remove the hose cap. 3. Secure the brake lever in a vise or other similar device. Face the hose connection port upward when securing the brake lever. 4. Remove the seal plug. Cover the seal plug with a waste cloth as the oil applied to the seal plug may leak. 60 Seal plug 5. Pass the brake hose through the hose cover. Hose cover BRAKE 6. Insert the brake hose into the joint component. It comes with a built-in olive. Insert it while making sure that it will not get snagged on the olive. Check that the brake hose is inserted up to the line printed on the hose. * Use a waste cloth when inserting the brake hose as some oil inside may leak. 7. Tighten the connecting bolt with an 8 mm spanner. Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} 8. Clean any oil residue and attach the hose cover. 61 9. Remove the brake lever stopper. BRAKE * Move and pull on the lever stopper to remove it while being careful not to depress the lever. Lever stopper Note: After removing the lever stopper, check that the pad spacer is installed on the caliper side or that the caliper is installed to the bicycle and the disc brake rotor is between the two sides of the caliper, before depressing the lever. After installation to the bicycle, make sure to check that the lever stopper is removed. < For ROAD > Overview of the easy hose joint system Dual control lever Joint sleeve Brake caliper Lever stopper Hose cap 1. Pass the brake hose through each hole in the built-in frame. 2. Remove the hose cap. 3. Secure the joint component in a vise or other similar device. Face the hose connection port upward as shown in the illustration. 62 4. Remove the seal plug. Cover the seal plug with a waste cloth as the oil applied to the seal plug may leak. BRAKE 5. Pass the brake hose on the brake caliper side through the hose cover. Hose cover 6. Insert the brake hose on the brake caliper side into the joint component. It comes with a built-in olive. Insert it while making sure that it will not get snagged on the olive. Check that the brake hose is inserted up to the line printed on the hose. * Use a waste cloth when inserting the brake hose as some oil inside may leak. 7. Tighten the connecting bolt with two 8 mm spanners. Connecting bolt Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} 8. Clean any oil residue and attach the hose cover. Hose cover 63 „ How to replace the brake hose (easy hose joint system) BRAKE Check the shape of the connector insert. Incorrect combinations may cause oil leakage. Not OK OK SHIMANO CODE No. :Y8H298040 There is a groove in the head shaped part. Note: • Each connector insert has a differently shaped hole. • Be sure to use a dedicated connector insert. Use of any connector insert other than the specified one may produce a loose assembly, leading to oil leaks or other problems. 64 BRAKE Check the shape of the connector insert. Incorrect combinations may cause oil leakage. < When connecting to the joint sleeve > Note: When reconnecting the brake hose to the joint sleeve, make sure to use the dedicated connector insert supplied with SM-BH59-SB. Joint sleeve Not OK OK SHIMANO CODE No. :Y8H298040 There is a groove in the head shaped part. Note: • Each connector insert has a differently shaped hole. • Be sure to use a dedicated connector insert. Use of any connector insert other than the specified one may produce a loose assembly, leading to oil leaks or other problems. 65 < When connecting on the lever side > BRAKE Brake hose connection port Not OK OK * For a connector insert of this shape, only ST-R785 can be used. SHIMANO CODE No. :Y8H298040 There is a groove in the head shaped part. 66 „ Installation of the calipers and securing the hose BRAKE 1. Remove the spacer for bleeding (yellow), and then set the wheel which has the rotor onto the frame. Spacer for bleeding 2. Install the brake pads. • Set the pad presser spring as shown in the illustration. * Set the pad presser spring as shown in the illustration. (There are left (L) and right (R) marks on the spring.) Pad presser spring Pad with fins • The pads with fins have fins at the front and back, so install them as shown in the illustration. Snap ring Brake pads For split pin Split pin Tightening torque: 2.0 - 4.0 N·m {17 - 35 in. lbs.} 67 BRAKE For international-standard mounts, attach adapters to calipers for post-type mounts. (Separate front and rear adapters are available.) 1. First install the adapter, and then provisionally secure the calipers to the frame. (The calipers should be able to move sideways.) 2. Depress the brake lever so that the rotor is being clamped by the pads, and then tighten the caliper fixing bolts. International standard mounting type < Front > < Rear > Caliper fixing bolts Adapter fixing bolts Adapter Caliper Adapter fixing bolts Rotor Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} Caliper fixing bolts Post mounting type Provisionally install the caliper to the frame (so that the caliper can move sideways), depress the brake lever so that the rotor is being clamped by the pads, and then tighten the caliper fixing bolts. < Front > Caliper fixing bolts Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} 68 „ Cap and wiring method BRAKE Either a cap method or a wiring method can be used to stop the bolts from falling out. Use whichever method is suitable for the front fork and frame. Cap method < Front > < Rear > Caps Caps Post type Caps Wiring method < Front > < Rear > Wire Wire 69 Secure the two bolts with a length of wire as shown in the illustration in order to prevent the bolts from coming loose. BRAKE For post type Wire Bolt Wire Wind a wire around the fixing bolt between the adapter and the frame as shown in the illustration. Bolt 1 Bolt 2 If bolt 1 tries to loosen (turn in the counterclockwise direction), force is applied via the wire to turn bolt 2 in the tightening direction (clockwise). However, bolt 2 cannot turn any further in the tightening direction. Accordingly, this prevents bolt 1 from turning in the loosening direction because it is also connected via the wire. If either one of the bolts tries to loosen, this causes a force to be applied to the other bolt to turn it in the tightening direction. In other words, this system prevents the bolts from loosening. For C-shaped guides and the usual type of cable stoppers, use the special Shimano cable supporter (sold separately) to secure as shown in the illustration. < C-shaped guide > < Usual type of cable stopper > Tightening torque: 0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.} Operate the brake lever several times and check whether the brakes operate normally or not. Also check that there are no oil leaks visible. 70 Maintenance BRAKE „ Replacement of the brake pads Note: This brake system is designed so that as the brake pads become worn, the pistons gradually move outward to automatically adjust the clearance between the rotor and the brake pads. Therefore, you need to push the pistons back to their original positions when replacing the brake pads. If oil adheres to the brake pads after oil is added, or if the brake pads are worn down to a thickness of 0.5 mm, or if the brake pad presser springs are interfering with the rotor, replace the brake pads. 1. Remove the wheel from the frame, and remove the brake pads as shown in the illustrations. Brake pads Snap ring For split pin Split pin 2. Clean the pistons and surrounding area. 3. Use a flat-shaped tool to push the pistons straight back in as far as they will go, while being careful not to twist the pistons. Do not push the pistons with a sharp tool. The pistons may become damaged. Piston • Install the new brake pads and the bolt, and then install the pad spacers (red). Make sure that you do not forget to install the snap rings at this time also. * Set the pad presser spring as shown in the illustration. (There are left (L) and right (R) marks on the spring.) Brake pads Pad presser spring Snap ring Tightening torque: 2.0 - 4.0 N·m {17 - 35 in. lbs.} Bolt Pad spacer (red) 71 BRAKE • Install the new brake pads the split pin, and then install the pad spacers (red). After this, bend open the split pin. Brake pads Split pin Pad spacer (red) 4. Depress the brake lever several times to check that the operation becomes stiff. 5. Remove the pad spacers, install the wheel, and then check that there is no interference between the rotor and the caliper. If they are touching, adjust while referring to “Installation of the calipers and securing the hose”. „ Adjustment when the pistons are not operating correctly The caliper mechanism includes two pistons. If these pistons do not operate properly or if they protrude unevenly, or if the brake pads remain in contact with the rotor, adjust the pistons by the following procedure. 1. Remove the wheel and the brake pads. Clean the pistons and surrounding area. 2. Use a flat-shaped tool to push the pistons straight back in as far as they will go, while being careful not to twist the pistons. Do not push the pistons with a sharp tool. The pistons may become damaged. 3. Install the brake pads and the pad spacers (red). 4. Depress the brake lever as far as it will go, and then operate it several more times so that the two pistons all move to their initial positions. 5. Remove the pad spacer, install the wheel, and then check that there is no interference between the rotor and the brake pads. If they are touching, loosen the installation bolts and adjust so that they are no longer touching. 72 „ Reach adjustment Reach adjustment bolt Reach adjustment bolt Reach adjustment bolt „ Free stroke adjustment When the free stroke adjustment screw is loosened, the free stroke of the brake lever will increase, so that you can adjust it to the desired setting. Rotor Pad contact point Free stroke adjustment screw Pad Contact „ Mineral oil replacement It is recommended that you replace the oil inside the reservoir tank if it becomes severely discolored. Attach a tube with a bag to the bleed nipple, and then open the bleed nipple and drain out the oil. You can operate the brake lever at this time to help the oil to drain out. After draining the fluid, pour in fresh brake fluid while referring to “Adding mineral oil and bleeding air”. Use only genuine Shimano mineral oil. Dispose of the waste oil according to proper country and/or state disposal regulations. 73 BRAKE Tighten the adjust bolt (clockwise) to increase the stroke, and loosen it (counterclockwise) to decrease the stroke. „ Adding mineral oil and bleeding air BRAKE When carrying out the air bleeding operation for the caliper, you will need the SM-DISC (oil funnel and oil stopper). With the spacer for bleeding (yellow) still attached to the calipers, place the bicycle into a bicycle stand or similar as shown in the illustration. Hose Calipers 1. Set the brake lever so that it is in the riding position at a 45 degree angle to the ground, and then remove the upper bleed screw and the O-ring and insert the oil funnel. Do not insert the oil stopper at this time. Bleed screw Oil funnel O-ring 2. Set a 7 mm socket wrench in place, fill the syringe with oil, connect a tube to the bleed nipple, and then loosen the bleed nipple by 1/8 of a turn to open it. Push the plunger of the syringe to add oil. The oil will start coming out from the oil funnel. Continue adding oil until there are no more air bubbles mixed in with the oil that is coming out. Bleed nipple 3. Once there are no more air bubbles mixed in with the oil, temporarily close the bleed nipple. Do not continually squeeze and release the lever at this point. If this is not observed, air bubbles may remain mixed in with the oil inside the caliper, and it will take longer to bleed the air. (If the lever is continually squeezed and released, drain out all of the oil and then add oil again.) 74 4. Set a 7 mm socket wrench in place as shown in the illustration, and then attach the bag to the tube. Connect the tube to the Bag Air 5. The level of liquid inside the funnel will drop at this time, so keep filling the funnel with oil to maintain the level of liquid so that air is not drawn in (air does not get inside). 6. Once air bubbles stop coming out from the bleed nipple, temporarily tighten the bleed nipple. Bleed nipple 75 BRAKE bleed nipple and then loosen the bleed nipple. After a little while, the oil and air will flow naturally from the bleed nipple into the tube. In this way it will be possible to easily extract the greater part of the air remaining inside the brake system. It may help to shake the hose gently or to tap the reservoir tank or caliper gently with a screwdriver or move the position of the caliper at this time. 7. With the brake lever depressed, open and close the bleed nipple in rapid BRAKE succession (for approximately 0.5 seconds each time) to release any air bubbles which may be in the calipers. Repeat this procedure about 2 to 3 times. Then tighten the bleed nipple again. Tightening torque: 4.0 - 6.0 N·m {35 - 52 in. lbs.} 8. If the brake lever is then operated, air bubbles in the system will rise up through the port into the oil funnel. Once the bubbles stop appearing, depress the brake lever as far as it will go. The normal condition is for the lever to be stiff at this point. Lever operation Loose Slightly stiff Stiff 9. Set the lever unit to the horizontal position as shown in the illustration and tilt it in the direction of by 30 degrees, and then carry out step 8 to check that there is no air remaining. Next, tilt the lever unit 30 degrees in the direction of , and carry out step 8 again to check that there is no air remaining. If any air bubbles appear, repeat the above procedure until they stop appearing. 10. Plug the oil funnel with the oil stopper so that the side with the O-ring attached is Oil stopper facing downward. O-ring 76 11. Remove the oil funnel while it is still being plugged with the oil stopper, and then Tightening torque: 0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.} 12. Wipe away any oil which has flowed out. 77 O-ring BRAKE attach the O-ring to the bleed screw and tighten it until oil flows out to make sure that there are no air bubbles remaining inside the reservoir tank. * Do not operate the brake lever at this time, otherwise air may get inside the cylinder. V-BRAKE BRAKE Installation „ Installation of the brake lever Use a handlebar grip with a maximum outer diameter of 32 mm. In the case of carbon handlebars, it may be necessary to lower the tightening torque in order to prevent damage to the handlebar. Please consult the bicycle or handlebar manufacturer regarding the appropriate level of tightening torque for carbon handlebars. 4 mm Allen key 5 mm Allen key 4 mm Allen key 5 mm Allen key Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} 78 „ Installing the power modulator Note: When the brakes are applied, the power modulator will move about 8 mm toward the inner cable lead, so make sure that there is enough excess length in the outer casing for this to happen. < When brakes are not applied > < When brakes are applied > Outer casing SM-PM70 / SM-PM40 Inner cable lead Approx. 8 mm V-BRAKE brake „ Installation of the V-BRAKE 1. Insert the stopper pin of the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 5 mm Allen key Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} Spring hole Stopper pin Link fixing bolt 79 BRAKE Install the power modulator to the V-BRAKE brake as shown in the illustration. 2. While holding the shoe against the rim, adjust the amount of shoe protrusion by changing over the washer B (thick or thin) so that dimension A is kept at 32 mm or more. FORWARD Washer B (thick) Washer B (thin) FORWARD R Shoe fixing nut R BRAKE 32 mm or more Washer A Washer Washer A Shoe fixing link 3. While holding the shoe against the rim, tighten the shoe fixing nut. 5 mm Allen key Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} 1 mm 4. Pass the inner cable through the inner cable lead, and after setting so that the total of the clearances between the left and right shoes and the rim is 2 mm, tighten the cable fixing bolt. Inner cable lead Inner cable lead 5 mm Allen key 5 mm Allen key B + C = 2 mm B + C = 2 mm Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} 80 5. Adjust the balance with the spring tension adjustment screws. BRAKE Spring tension adjustment screw Spring tension adjustment screw 1 mm 1 mm 6. Depress the brake lever about 10 times until it touches the grip and check that everything is operating correctly and that the shoe clearance is correct before using the brakes. 81 Depress about 10 times Maintenance 1. Remove the shoe fixing pin, and then slide the shoe along the Shoe fixing pin groove to remove it from the shoe holder. Shoe 2. There are two different types of shoe and shoe holder to be used in the left and right positions respectively. Slide the new shoes into the grooves on the shoe holders while taking note of the correct directions and pin hole positions. < For the left > < For the right > Same at front and rear Same at front and rear Front Front Shoe Shoe Shoe holder FORWARD FORWARD FORWARD L R FORWARD Shoe holder L R BRAKE „ Replacement of the cartridge shoe Shoe insertion direction Shoe fixing pin Shoe fixing pin 3. Insertion of shoe fixing pin is very critical to keep shoe properly fixed in place. 82 V-BRAKE and Hub roller brake Four finger brake levers such as brake levers are equipped with a switch to change between the V-BRAKE with modulator mode and the caliper brake or roller brake mode. WARNING If the mode is not matched to the type of brake being used, this could result in inadequate or excessive braking power. Please proceed with caution when selecting the correct mode for the corresponding brake. < For V-BRAKE (with power modulator) mode > V-position Power Modulator V-position V-BRAKE with power modulator Roller brake / Caliper brake < For Caliper brake/Roller brake > Caliper/Roller (C R) brake-position V-BRAKE Caliper/Roller (C R) brake-position Roller brake / Caliper brake 83 BRAKE 1. Brake lever with switch interchangeability DUAL PIVOT CALIPER BRAKE BRAKE Installation 1. Installation of the brake itself Compress the arch‚ and set while the shoe is in firm contact with the rim. 5 mm Allen key Tightening torque: 8.0 - 10.0 N·m {70 - 87 in. lbs.} The usual position during installation is when the head of the centering adjustment bolt is as shown in the illustration. < For nut types > Tightening torque: 8.0 - 10.0 N·m {70 - 87 in. lbs.} 10 mm spanner Note: If the brake arm touches the frame when the handlebar is turned, attach the frame protection sticker which is included to the frame. 84 2. Brake shoe setting position Direction of rim rotation Toe-in 0.5 mm Direction of rim rotation 1 mm or more Shoe fixing bolt 4 mm Allen key Tightening torque: 5.0 - 7.0 N·m {44 - 61 in. lbs.} 3. Cable connection Set the quick release lever to the closed position; then adjust the shoe clearance (as shown in the illustration) and secure the cable. Tightening torque: 6.0 - 8.0 N·m {52 - 70 in. lbs.} 4. Centering of the brake shoe Make a minor adjustment by using the centering adjustment bolt. Centering adjustment bolt 3 mm Allen key Open Closed Quick release lever 85 + = 3 – 4 mm BRAKE After adjusting the brake shoe position so that the shoe surface and the rim surface are as shown in the illustration, tighten the shoe fixing bolt. 5. Readjustment of the shoe clearance BRAKE Turn the cable adjustment nut to readjust the shoe clearance. Cable adjustment nut + = 3 – 4 mm 6. Check Depress the brake lever about 10 times until it touches the grip and check that everything is operating correctly and that the shoe clearance is correct before using the brakes. Depress about 10 times For models with a CLOSE position mark on the quick release lever and brake body side, adjust the position of each mark so that they are aligned. At this time, check that you can feel a click. CLOSE position mark 7. Arch spring tension adjustment You can use the spring adjustment bolt to adjust the spring tension of the arch. 2 mm Allen key Weak Strong Spring adjustment bolt 86 Maintenance 1. Remove the fixing bolt. 2 mm Allen key Fixing bolt 2. Remove the shoe by sliding it along the groove of the shoe holder. Shoe 3. There are two different types of shoe and shoe holder to be used in the left and right positions respectively. Slide the new shoes into the grooves on the shoe holders while taking note of the correct directions and bolt hole positions. < For the left > < For the right > Same at front and rear Same at front and rear Front Front Shoe Shoe Shoe holder Shoe holder L R FORWARD FORWARD Shoe insertion direction Fixing bolt Fixing bolt Tightening torque: 1.0 - 1.5 N·m {9 - 13 in. lbs.} 4. Tighten the fixing bolt. 87 BRAKE „ Replacement of the cartridge shoe FRONT CHAINWHEEL 5 FRONT CHAINWHEEL WARNING “Maintenance interval depends on the usage and riding circumstances. Clean regularly the chain with an appropriate chain cleaner. Never use alkali based or acid based solvents such as rust cleaners. If those solvent be used chain might break and cause serious injury.” ••The two left crank arm mounting bolts should be tightened alternately in stages rather than each bolt being fully tightened all at once. Use a torque wrench to check that the final tightening torques are within the range of 12.0 - 14.0 N·m. Furthermore, after riding approximately 100 km (60 miles), use a torque wrench to re-check the tightening torques. It is also important to periodically check the tightening torques. If the tightening torques are too weak or if the mounting bolts are not tightened alternately in stages, the left crank arm may come off and the bicycle may fall over, and serious injury may occur as a result. ••If the inner cover is not installed correctly, the axle may rust and become damaged, and the bicycle may fall over and serious injury may occur as a result. ••Inspect the chain for possible deformity and abnormalities such as cracks or corrosions. If damage is detected, replace the chain immediately. Failure to do so may lead to chain breakage and can result in serious injury. ••Obtain and read the dealer’s manual carefully prior to installing the parts. Loose, worn or damaged parts may cause the bicycle to fall over and serious injury may occur as a result. We strongly recommend only using genuine Shimano replacement parts. ••Obtain and read the dealer’s manual carefully prior to installing the parts. If adjustments are not carried out correctly, the chain may come off and this may cause you to fall off the bicycle which could result in serious injury. NOTE ••In addition, if pedaling performance does not feel normal, check this once more. ••Before riding the bicycle, check that there is no play or looseness in the connection. Also, be sure to retighten the crank arms and pedals at periodic intervals. ••If a squeaking noise is heard coming from the bottom bracket axle and the left crank arm connector, apply grease to the connector and then tighten it to the specified torque. ••Do not wash the bottom bracket with high-pressure jets of water. ••If you feel any looseness in the bearings, the bottom bracket should be replaced. ••When installing the pedals, apply a small amount of grease to the threads to prevent the pedals from sticking. Use a torque wrench to securely tighten the pedals. Tightening torque: 35.0 - 55.0 N·m {306 - 481 in. lbs.}. The right-hand crank arm has a right-hand thread, and the left-hand crank arm has a left-hand thread. ••Use a neutral detergent to clean the crank arm and the bottom bracket. Using alkaline or acidic detergents may cause discoloration. ••If gear shifting operations do not feel smooth, wash the derailleur and lubricate all moving parts. ••If the amount of looseness in the links is so great that adjustment is not possible, you should replace the derailleur. 88 • For smooth operation, use the specified outer casing and the bottom bracket cable guide. Outer casing holders • A special grease is used for the gear shifting cable. Do not use premium grease or other types of grease, otherwise they may cause deterioration in gear shifting performance. • Grease the inner cable and the inside of the outer casing before use to ensure that they slide properly. • Operation of the levers related to gear shifting should be made only when the crankset is turning. • Do not disassemble the shifting lever unit, as this may damage it or cause mis-operation. < For MTB / Trekking> • For frames with suspension, the chain stay angle will vary depending on whether the bicycle is being ridden or not being ridden. When the bicycle is not being ridden and the chain is positioned on the largest/larger chainring and on the smallest sprocket, the chain guide outer plate of the front derailleur may touch the chain. • When installing the top route type, choose a frame that has three outer casing holders as shown in the illustration at right. • If the brake fluid used in the oil disc brakes is of a type which tends to adhere to the plastic parts of the shifting lever, this may cause the plastic parts to crack or become discolored. Therefore, you should make sure that the brake fluid does not adhere to these plastic parts. The mineral oil which is used in SHIMANO disc brakes does not cause cracking or discoloration if it adheres to plastic parts, but such parts should be cleaned with alcohol beforehand to prevent foreign particles from adhering. < For ROAD > • If the bottom bracket shell is not parallel, gear shifting performance will drop. • When installing the left and right adapters, be sure to install the inner cover too, otherwise the waterproofing performance will drop. • You should periodically wash the chainrings in a neutral detergent. In addition, cleaning the chain with neutral detergent and lubricating it can be an effective way of extending the useful life of the chainrings and the chain. • If you feel any looseness in the bottom bracket axle, the bottom bracket should be replaced. 89 FRONT CHAINWHEEL • Use an outer casing which still has some length to spare even when the handlebars are turned all the way to both sides. Furthermore, check that the shifting lever does not touch the bicycle frame when the handlebars are turned all the way. INSTALLATION OF THE CHAINRINGS FRONT CHAINWHEEL Smooth shifting will not be possible if the chainrings are incorrectly installed, so be sure to install the chainrings in the correct positions. < For ROAD > Double chainwheel set • With the marked surface of the larger chainring facing out, set the larger chainring so that the chain drop prevention pin is lined up with the crank arm position. Outer side Tightening torque : 12.0 - 14.0 N·m {105 - 122 in. lbs.} Chain drop prevention pin Crank arm • With the marked surface of the smaller chainring facing away from the crank arm, set the chainring so that the lined up with the crank arm position. mark is Inner side Tightening torque : 12.0 - 14.0 N·m {105 - 122 in. lbs.} Crank arm 90 Triple chainwheel set Crank arm < For MTB / Trekking > Triple chainwheel set Largest chainring / Intermediate chainring Tightening torque : 14.0 - 16.0 N·m {122 - 140 in. lbs.} Smallest chainring Tightening torque : 16.0 - 17.0 N·m {140 - 149 in. lbs.} Crank arm 91 < FC-5703 (39T) > FRONT CHAINWHEEL Tightening torque : 12.0 - 14.0 N·m {105 - 122 in. lbs.} INSTALLATION OF THE FRONT CHAINWHEEL FRONT CHAINWHEEL HOLLOWTECH II / 2 piece crankset Follow the procedure in the figure 1, 2. Use the TL-FC32/33/36 Shimano original tool to install the right adapter (counterclockwise thread) of the bottom bracket, the inner cover and the left adapter (clockwise thread) of the bottom bracket. Tightening torque: 35.0 - 50.0 N·m {306 - 437 in. lbs.} Note: < For MTB / Trekking > Spacers may be necessary depending on the bottom bracket shell width. For details, refer to “Spacer installation method”. 3. 4. Insert the right crank arm unit. Set section A of the left crank arm into the axle of the right crank arm unit where the groove is wide. Note: Insert a spacer for the triple specification of road bikes and the double guard specification of comfort bikes. 5. Use the TL-FC16/18 to tighten the cap. Tightening torque: 0.7 - 1.5 N·m {6 - 13 in. lbs.} 6. Push in the stopper plate and check that the plate pin is securely in place, and then tighten the bolt of the left crank arm. (5 mm Allen key) Note: Each of the bolts should be evenly and equally tightened to 12.0 - 14.0 N·m {105 - 122 in. lbs.}. 92 • Right adapter (A) Wide groove area Clockwise thread for 70 mm [M36] bottom brackets 4 3 1 5 TL-FC16 2 6 Plate pin Push up Stopper plate Inner cover Insert a spacer for the triple specification of road bikes and the double guard specification of comfort bikes. Note : Set the stopper plate in the right direction as shown in illustration. 93 FRONT CHAINWHEEL TL-FC32 „ Spacer installation method FRONT CHAINWHEEL < For MTB / Trekking> 1. Check whether the width of the bottom bracket shell is 68 mm or 73 mm. 2. Next, install the adapter while referring to the illustrations. 68 mm 73 mm Normal type Band Type 68 mm* A B C A 73 mm Bracket Type 68 mm A A BB mounttype bracket Spacer A 2.5 mm B C 1.8 mm 0.7 mm A 73 mm A * If using three 2.5 mm spacers with a band type and a bottom bracket shell having a width of 68 mm, install the three spacers so that there are two on the right and one on the left. Chain case specifications Band Type 68 mm A B ** C A 73 mm Chaincase Stay Type Chaincase stay 68 mm C A A 73 mm Bracket Type 68 mm A 73 mm A C ** 1.8 mm corresponds to the thickness of the chain case. 94 BB mounttype bracket A A OCTALINK TYPE Install using the Shimano original tool TL-UN74-S / TL-UN66. First install the main body, then the adapter. Adapter Tightening torque: 50.0 - 70.0 N·m {437 - 612 in. lbs.} Main body Aluminum or steel Plastic „ Installation of the front chainwheel Use an 8 or 10 mm Allen key to install the front chainwheel. Tightening torque: 35.0 - 50.0 N·m {306 - 437 in. lbs.} 8 or 10 mm Allen key 95 FRONT CHAINWHEEL „ Installation of the Bottom Bracket SQUARE TYPE FRONT CHAINWHEEL „ Installation of the Bottom Bracket Install using the Shimano original tool TL-UN74. First install the main body, then the adapter. Front chainwheel Adapter Tightening torque: 50.0 - 70.0 N·m {437 - 612 in. lbs.} Main body Aluminum or steel Plastic „ Installation of the front chainwheel Use an 8 or 10 mm Allen key to install the front chainwheel. Tightening torque: 35.0 - 50.0 N·m {306 - 437 in. lbs.} 8 or 10 mm Allen key Tighten securely Use a TL-FC10 / FC11 to install the front chainwheel. Tightening torque: 35.0 - 50.0 N·m {306 - 437 in. lbs.} TL-FC10 / FC11 Tighten securely 96 PRESS-FIT BB FRONT CHAINWHEEL „ Adapter Left hand adapter Right hand adapter Inner cover Bottom bracket shell width 2.5 mm spacer „ Assembly example Adapter type Inner cover cannot be installed If the frame has no openings inside the bottom bracket shell, it can be installed without the inner cover sleeve. ROAD MTB • Use for a bottom bracket shell width of 86.5 mm. • The 2.5 mm spacer is not needed for a bottom bracket shell width of 92 mm. • Use the inner cover. Inner cover can be installed If the frame has openings inside the bottom bracket shell, it should be installed with the inner cover sleeve to prevent possible contamination. • Use for a bottom bracket shell width of 86.5 mm. The 2.5 mm spacer is not needed. • Use the inner cover. • For a bottom bracket shell width of 89.5 mm, insert the 2.5 mm spacer into the right hand side (between the frame and the right hand adapter). • Use the inner cover. 97 „ Installation FRONT CHAINWHEEL 1. Insert the bottom bracket (BB) into the hanger. 2. Insert the installation tool into the BB. TL-BB12 3. Press fit the BB by tightening with a wrench while making sure that the rim of the BB stays parallel to the rim of the hanger. 4. Check to confirm that there is no gap between the BB and the hanger. 98 „ Removal TL-BB13 2. As shown in the illustration, hold down the flap with your fingers and push it in from the opposite side. (When pushed in, the flap opens.) While holding open the three flaps at the end of the removal tool, push the tool in from the other side until it locks in place. 3. Tap the removal tool with a plastic mallet until the end of the BB is ejected. 4. Tap out the other end of the BB in the same way. Note: Do not reuse the adapters as they can be damaged during removal. 99 FRONT CHAINWHEEL 1. Insert the removal tool into the bottom bracket (BB). PEDALS (SPD-SL PEDALS / SPD PEDALS) 6 PEDALS (SPD-SL PEDALS / SPD PEDALS) For information on the Click’R pedals and the flat pedals, refer to the dealer’s manual for each product. WARNING TO PARENT/GUARDIAN – To avoid serious injuries: USE OF THIS PRODUCT IN ACCORDANCE WITH THESE DEALER’S MANUAL IS ESSENTIAL FOR YOUR CHILD’S SAFETY. MAKE SURE YOU AND YOUR CHILD UNDERSTAND THESE DEALER’S MANUAL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY. WARNING Be sure to also inform users of the following: BE SURE TO READ AND FOLLOW THE BELOW WARNINGS CAREFULLY. If the warnings are not followed, your shoes may not come out of the pedals when you intend or they may come out unexpectedly or accidentally, and severe injury may result. „„Common descriptions regarding SPD-SL / SPD pedals ••SPD-SL/SPD pedals are designed to be released only when you intend to release. They are not designed to be released automatically when you have fallen off the bicycle. ••Before attempting to ride with these pedals and shoes, make sure you understand the operation of the engagement / release mechanism for the pedals and cleats (shoes). ••Before you attempt to ride with these pedals and shoes, apply the brakes, then place one foot on the ground and practice engaging and releasing each shoe from its pedal until you can do so naturally and with minimal effort. ••Ride on level ground first until you become adept at engaging and releasing your shoes from the pedals. ••Before riding, adjust the spring tension of the pedals to your liking. If the spring tension of the pedals is low, the cleats may become accidentally released and you may lose balance and fall off the bicycle. If the spring tension of the pedals is high, the cleats cannot be easily released. ••When riding at low speed or when there is a possibility that you might need to stop riding, (for example, when doing a U-turn, nearing an intersection, riding uphill or turning a blind curve), release your shoes from the pedal beforehand so that you can quickly put your feet onto the ground at any time. ••Use a lighter spring tension for attaching the pedal cleats when riding in adverse conditions. ••Keep cleats and bindings clear of dirt and debris to ensure engagement and release. ••Remember to check the cleats periodically for wear. When the cleats are worn, replace them. Always check the spring tension after replacing the pedal cleats and before riding. ••Be sure to attach reflectors to the bicycle when riding at night. Do not continue riding the bicycle if the reflectors are dirty or damaged, otherwise it becomes more difficult for oncoming vehicles to see you. ••Use only Shimano cleats and make sure that the mounting bolts are tightened securely to the shoes. Refer to the dealer’s manual for each product for applicable cleats. „„Descriptions regarding SPD-SL pedals ••Use only SPD-SL shoes with this product. Other types of shoes may not release from the pedals, or may release unexpectedly. „„Descriptions regarding SPD pedals ••Use only SPD shoes with this product. Other types of shoes may not release from the pedals, or may release unexpectedly. 100 CAUTION – To avoid serious injuries: PD-M324 can be fitted with toe clips, but the toe clips should be removed when using the pedals as SPD pedals. NOTE Be sure to also inform users of the following: ••Check that there is no looseness in any joints or connections before riding the bicycle. ••Check that there is no looseness in cleat or spacer before riding the bicycle. ••If pedaling performance does not feel normal, check this once more. ••If you experience any trouble with the rotating parts of the pedal, the pedal may require adjustment. Contact the place of purchase or a bicycle dealer. ••Be sure to retighten the crank arms and pedals at periodic intervals at the place of purchase or a bicycle dealer. ••Optional reflector sets are available. Reflector sets vary depending on the model of the pedals. Consult a dealer or an agency. ••Products are not guaranteed against natural wear and deterioration from normal use and aging. ••For maximum performance we highly recommend Shimano lubricants and maintenance products. SPD PEDALS Note: Single release mode cleats (SM-SH51) and multiple release mode cleats (SM-SH56) are available for use with these pedals. Each type of cleat has its own distinctive features, so be sure to follow these Instructions carefully and select whichever type of cleat best suits your riding style and the terrain and riding conditions which you will encounter. Other types of cleats such as single release mode cleats (SM-SH52) and multiple release mode cleats (SM-SH55) cannot be used, as they do not provide stable enough step-out performance or sufficient holding force. „„Engaging the cleats with the pedals Press the cleats into the pedals with a forward and downward motion. „„Releasing the cleats from the pedals The method of release varies according to the type of cleats you are using. (Check the model number and color of your cleats to determine the proper method of release.) 101 PEDALS (SPD-SL PEDALS / SPD PEDALS) < For SPD Pedals > Single release mode cleats: SM-SH51 (black) PEDALS (SPD-SL PEDALS / SPD PEDALS) ••These cleats only release when the heel is twisted outward. They will not release if the heel is twisted in any other direction. ••You are able to apply upward force to the pedal, since they will not release unless the foot is twisted outward. ••The cleats will not necessarily release if you lose your balance. Accordingly, for places and conditions where it looks as though you may lose balance, make sure that you have sufficient time to release the cleats beforehand. ••When you are pedaling vigorously, your heel may inadvertently twist outward and this may cause the cleat to release accidentally. If the cleat releases by accident, you may fall off the bicycle and serious injury may result. You can help to prevent this by adjusting the amount of force required to release the cleats, and you should practice until you are accustomed to the amount of force and the angle required to release the cleats. Single release mode Release the cleats from the pedals by twisting your heels outward. Note: It is necessary to practice releasing until you become accustomed to the technique. Multiple release mode cleats: SM-SH56 (silver, gold) ••The cleats can be released by twisting in any direction. ••Because the cleats can also be released by lifting your heel, they may become accidentally released when applying upward force on the pedals. These cleats should not be used for riding style which may involve pulling up on the pedals or for activities, such as jumping, in which pulling forces are applied to the pedals causing possible release from the pedals. ••Although the cleats can be released by twisting your heels in any direction or by lifting, they will not necessarily release if you lose your balance. Accordingly, for places and conditions where it looks as though you may lose balance, make sure that you have sufficient time to release the cleats beforehand. ••If the cleats release by accident, you may fall off the bicycle and serious injury may result. If the features of multiple release mode cleats are not sufficiently understood and if they are not used correctly, then they may release accidentally with a greater frequency than for single release mode cleats. You can help to prevent this by adjusting the amount of force required to release the cleats in any direction, and you should practice until you are accustomed to the amount of force and the angle required to release. 102 Multiple release mode PEDALS (SPD-SL PEDALS / SPD PEDALS) Release the cleats from the pedals by twisting your heels in any direction. Note: In multiple release mode, it is necessary to practice releasing until you become accustomed to the technique. Releasing by lifting your heel requires particular practice. „ Attaching the cleats 1. With a pair of pliers or a similar tool, pull off the rubber cover to expose the cleat mounting holes. Note: This step may not be necessary depending on the type of shoes. Rubber cover for cleat mounting holes SPD shoe 2. Remove the sockliner and position a cleat nut over the oval holes. Note: Cleat nut Sockliner This step may not be necessary depending on the type of shoes. 3. From the bottom of the shoe, position a cleat and then a cleat adapter over the cleat holes. The cleats are compatible with both left and right pedals. Provisionally tighten the cleat mounting bolts. 4 mm Allen key Cleat mounting bolts Cleat adapter Cleat Front Position the triangular portion of the cleat toward the front of the shoe. Tightening torque: 2.5 N·m {22 in. lbs.} 103 „ Adjusting the cleat position PEDALS (SPD-SL PEDALS / SPD PEDALS) 1. The cleat has an adjustment range of 20 mm front to back and 5 mm right to left. After provisionally tightening the cleat, practice engaging and releasing, one shoe at a time. Readjust to determine the best cleat position. 2. After you have determined the best cleat position, firmly tighten the cleat mounting bolts with a 4 mm Allen key. Tightening torque : 5.0 - 6.0 N·m {44 - 52 in. lbs.} „ Waterproof seal Remove the sockliner and attach the waterproof seal. Note: Waterproof seal The waterproof seal is supplied with Shimano shoes which require this step to be carried out. 104 Sockliner „ Mounting the pedals on the crank arms 2. Use a 15 mm spanner/8mm allen key to mount the pedals on the crank arms. • The right pedal has a right-hand thread; the left pedal has a left-hand thread. R Pay attention to the mark R: right pedal L : left pedal 8 mm Allen key 15 15 mm spanner Tightening torque : 35.0 - 55.0 N·m {306 - 481 in. lbs.} Tightening torque : 35.0 - 55.0 N·m {306 - 481 in. lbs.} 3. Remove any roughness or burrs on the joint, if detected. Note: A 6 mm Allen key cannot provide a sufficient tightening torque. Always be sure to use a 15 mm spanner. „ Adjusting the spring tension of the binding The spring force is adjusted by means of adjustment bolts. The adjustment bolts are located behind each of the bindings, and there are two adjustment bolts on each pedal. Equalize the tensions by referring to the adjustment plates and by counting the number of turns of the adjustment bolts. The spring tension can be adjusted in four steps for each turn of the adjustment bolt. Adjustment bolt Adjustment plate Increase Decrease Adjustment bolt When the adjustment bolt is turned clockwise, the spring tension increases, and when it is turned counterclockwise, the spring tension decreases. „ Cleat replacement Cleats wear out over time and should be replaced periodically. Cleats should be replaced when it becomes difficult to release, or it starts to release with much less effort than the when it was in new condition. 105 PEDALS (SPD-SL PEDALS / SPD PEDALS) 1. Apply a small amount of grease to the thread to prevent sticking. SPD-SL PEDALS PEDALS (SPD-SL PEDALS / SPD PEDALS) „„Cleat types SM-SH10 SM-SH11 (PD-R540-LA: standard) SM-SH12 (PD-9000: standard) Red Yellow Blue Wide Narrow Wide Fixed mode Self-aligning mode Front center pivot mode There is no play when the shoes are There is some sideways play when the There is some play centered on front of firmly engaged with the pedals. shoes are firmly engaged with the shoes. pedals. „„Engaging the cleats with the pedals Press the cleats into the pedals with a forward and downward motion. 106 „ Releasing the cleats from the pedals Note: Place one foot on the ground, practice engaging and releasing the cleat from the pedal several times, and set the spring tension to the tension you prefer when releasing the cleat. „ Attaching the cleats Set the cleat on the bottom of each shoe as shown in the illustration, and then provisionally tighten the cleat mounting bolts. Refer to the service instructions provided with your shoes for further details. 4 mm Allen key Cleat mounting bolt Cleat washer Cleat Note: When installing the cleats, use the cleat mounting bolts and the cleat washers that are provided with the cleats. If you use any other cleat mounting bolts, it may damage the cleats and cause problems with correct installation. 107 PEDALS (SPD-SL PEDALS / SPD PEDALS) Release the cleats from the pedals by twisting your heels outward. „ Adjusting the cleat position PEDALS (SPD-SL PEDALS / SPD PEDALS) 1. The cleats have an adjustment range of 15 mm front to back and 5 mm right to left. After provisionally tightening the cleats, practice engaging and releasing, one shoe at a time. Readjust to determine the best cleat positions. 2. After you have determined the best cleat position, firmly tighten the cleat mounting bolts with a 4 mm Allen key. Tightening torque: 5.0 - 6.0 N·m {44 - 52 in. lbs.} „ Mounting the pedals on the crank arms 1. Apply a small amount of grease to the thread to prevent sticking. 2. Use a 15 mm spanner/8mm allen key to mount the pedals on the crank arms. • The right pedal has a right-hand thread; the left pedal has a left-hand thread. Pay attention to the mark R: right pedal L: left pedal 8 mm Allen key 15 mm spanner Tightening torque: 35.0 - 55.0 N·m {306 - 481 in. lbs.} Tightening torque: 35.0 - 55.0 N·m {306 - 481 in. lbs.} 3. Remove any roughness or burrs on the joint, if detected. Note: A 6 mm Allen key cannot provide a sufficient tightening torque. Always be sure to use a 15 mm spanner. 108 „ Adjusting the spring tension of the binding 2.5 mm Allen key Decrease Increase Adjustment bolt Indicator Decrease Increase Do not turn the bolt past the point at which the indicator shows the maximum or minimum tension. Note: • In order to prevent accidental release from occurring, make sure all the spring tensions are properly adjusted. • The spring tensions should be adjusted equally for both right and left pedals. If they are not adjusted equally, it can cause the rider difficulty to engage or release from the pedals. • If the adjustment bolt is completely withdrawn from the spring plate, disassembly and reassembly will be required. If this occurs, ask a professional dealer for assistance. „ Cleat replacement Cleats wear out over time and should be replaced periodically. Cleats should be replaced when it becomes difficult to release, or it starts to release with much less effort than the when it was in new condition. Cleat Rear Front Section A Note: If the yellow (SM-SH11) or red (SM-SH10) or blue (SM-SH12) portions of the cleats become worn, replace the cleats with new ones. Front: Replace the cleats when the black layer underneath the cleats are visible. Rear: Replace when section A in the illustration becomes worn. „ Replacement of the body cover For information on how to replace the body cover, refer to the dealer’s manual for each product. „ Maintenance of the axle units If you experience any trouble with the rotating parts of the pedal, the pedal may require adjustment. „ Mounting the reflectors (optional) Use a reflector (separately sold) designed for each pedal. For information on installation, refer to the included manual. 109 PEDALS (SPD-SL PEDALS / SPD PEDALS) The spring force is adjusted by means of adjustment bolts at the rear of the pedals. Adjust the spring force to the optimum cleat holding force when releasing the cleats from the bindings. Equalize the spring tensions for both pedals by referring to the tension indicators and by counting the number of turns of the adjustment bolts. The spring tensions can be adjusted in four steps for each turn of the adjustment bolts, and each adjustment bolt can be turned up to three full turns. HUB DYNAMO 7 HUB DYNAMO TO ENSURE SAFETY WARNING Be sure to also inform users of the following: ••Check that the wheels are fastened securely before riding the bicycle. If the wheels are loose in any way, they may come off the bicycle and serious injury may result. ••Check that the light illuminates normally when riding at nighttime. For Installation to the Bicycle, and Maintenance: ••Depending on the hub dynamo, the compatible tire outer diameter of the wheel differs. Be sure to check the compatible size. If an incompatible size is used together, the wheels may be locked and you may lose balance and fall off the bicycle. ••If the total weight of the bicycle (bicycle + rider + luggage) is indicated on the hub body, the power modulator that controls an excessive braking effect is built in. Use the compatible brake lever together. If the total weight of the bicycle is heavier than the recommended range, braking may be insufficient; if lighter, braking will be too effective and the wheel may be locked, which may cause you to fall off the bicycle. The power modulator is not an anti-locking device of the wheel. CAUTION Be sure to also inform users of the following: ••The hub dynamo generates an extremely high voltage. Never touch the connection terminal of the hub dynamo directly while riding the bicycle or while the wheel is spinning. Touching the dynamo terminal may cause an electric shock. NOTE Be sure to also inform users of the following: ••Be sure to install the hub dynamo to the front fork so that the side with the connection terminal is on the right when facing toward the front of the bicycle. If the side with the connection terminal is facing toward the left, the hub dynamo may not turn properly while riding. ••Check that the hub dynamo connection terminal is securely connected before using the hub dynamo. ••If the bulb of either the front light or tail light blows, excessive voltage will be applied to the remaining light and shorten the operating life of the bulb, so any blown bulbs should be replaced as soon as possible. ••If the light is frequently turned on when riding at high speed ranges, it will shorten the operating life of the bulbs. ••Lights with electrical circuits such as automatic lights may become damaged if the bicycle is ridden at high speeds. ••The hub dynamo will cause the turning of the wheel to become slightly heavier because of the magnet inside the hub. 110 For Installation to the Bicycle, and Maintenance: ••Check the degree of parallel of the front fork end. If the front fork end is severely out of parallel, deformation of the hub axle may cause noise from an obstruction inside the hub dynamo to be generated. ••Compatible lights. < 3.0 W hub dynamo > < 2.4 W hub dynamo > Front light Tail light Front light Tail light 6.0 V/2.4 W 6.0 V/0.6 W 6.0 V/2.4 W − 6.0 V/3.0 W − 9.6 V/5.0 W − < 1.5 W hub dynamo > Use LED light only. < 0.9 W hub dynamo > Front light Tail light 6.0 V/0.9 W − ••Do not apply any lubricant to the inside of the hub, otherwise the grease will come out and it may cause problems with conductivity. INSTALLATION „„Installation of the rotor * Please refer to the DISC BRAKE section. „„Installation of the front wheel Install the wheel so that the side with the hub dynamo connection terminal is on the right side when looking toward the front of the bicycle, and so that the hub connection terminal is aligned with the front fork or with the basket stay. Then install by following the procedure shown in the illustration so that the connection terminal is facing upward. Do not force the connection terminal to turn after the quick release lever or the cap nut has been secured. If you force the connection terminal to turn, it may become damaged, or the wire inside the connection terminal may break. 111 HUB DYNAMO ••According to German regulations (StVZO), a hub dynamo in Germany requires overvoltage protection. This hub dynamo (3.0 W) does not have overvoltage protection inside the hub itself. Use an external overvoltage protector with a symbol to show that it complies with the German regulations (overvoltage protector product). For quick release type HUB DYNAMO Front fork Connection terminal Front fork Mudguard stay Connection Terminal Mudguard stay Quick release nut Quick release nut Volute spring Note: • Do not use the toothed axle washer with a quick release type. • Connect the two wires to ensure that the current flows smoothly. For nut type < For E2 type > Basket stay Connection terminal Connection terminal Front fork Front fork Mudguard stay Mudguard stay Basket stay Washer Tightening torque: 20.0 - 25.0 N·m {175 - 219 in. lbs.} Cap nut (M9) 112 < For J2 type > Front fork Mudguard stay Flange nut Toothed washer for axles Front-wheel anti-falloff fitting Basket stay Tightening torque: 20.0 N·m {175 in. lbs.} Washer < For J2-A type > Connection terminal Front fork Mudguard stay Flange nut Front-wheel anti-falloff fitting Basket stay Tightening torque: 20.0 N·m {175 in. lbs.} Washer Note: When tightening the cap nuts or flange nuts, tightening the cap/flange nut only on one side excessively may force the hub axle to turn tightening or loosening the lock nut excessively. Tighten both nuts alternately. 113 HUB DYNAMO Connection terminal CONNECTION OF THE CABLES HUB DYNAMO Connect the cables as shown in the illustration below. < For E2 type > Note: Frame connection terminal • Do not switch over the frame cable and the light cable by mistake. If the cables are connected incorrectly, the light will not illuminate. • Twist the cable wires before connecting them so that they stay together. • Recommended wire specifications Wire Light connection terminal Insulation Type Stranded Wire Size (AWG) 22 Diameter approx. 0.8 mm Insulation Diameter 1.8 - 2 mm Note: • Bend the cable wires and run them along the grooves. Frame cable Light cable Approx. 16 mm Insert Groove Approx. 16 mm Bend Connector cap (gray) • Do not allow the cable wires to touch each other. Connector cover (black) Note: • Set so that it faces the right way. Frame connection terminal Light connection terminal • Press in until you hear a click. Hub dynamo connection terminal 114 < For J2 type > Light cable Front fork Connect Light connection terminal (small) Frame (grounding) cord Connect Frame (grounding) connection terminal (large) * If the frame (grounding) connection terminal is fitted with a cover, remove it before connection. < For J2-A type > Note: • Open the connector using a slotted screwdriver or the like as shown in the figure. • Insert the cable with the marking into the ground side of the connector. Approx. 16 mm Approx. 16 mm Ground side Marking • Twist the cable wires, pass them through the connector, bend them, and run them along the grooves. Insert Groove Bend • Do not allow the cable wires to touch each other. Connector • Close the connector until you hear a click. Light connection terminal Hub dynamo connection terminal 115 HUB DYNAMO Basket stay Note: HUB DYNAMO • Secure the cable to the front fork or the basket stay so that it will not get caught in the spokes or any other parts while riding. If the position of the hub dynamo may change with respect to the light while riding, for example when using a suspension fork, make sure that the cable is connected so that it will not be too loose or too tight at any point within the range of movement. • Connect so that the current from the hub dynamo flows through the cable from the light connection terminal of the hub dynamo to the frame connection terminal. • To disconnect the light from the hub dynamo, remove the connector cover / light cord and frame (grounding) cord. • Do not ride the bicycle with the connector cover / light cord or frame (grounding) cord removed. The cord may be entangled in the wheel. • Remove the connector cover / light cord and frame (grounding) cord before removing the wheel. If the cables are pulled strongly, it may break the cable wires or cause poor contacts. Furthermore, when installing the wheel, first secure the wheel to the front forks and then connect the connector cover / light cord and frame (grounding) cord. Cable Connector cover Connector cover Remove Front fork Connect Light cable Frame (grounding) cord Cable Connect Light connection terminal (small) Remove Front fork Frame (grounding) connection terminal (large) „ Checking the light illumination Rotate the front wheel and check that the light illuminates. 116 MAINTENANCE 32 117 0 H1 -D TL N PA JA HUB DYNAMO 36 When replacing the internal parts of a hub dynamo, we recommend using a Shimano original tool TL-DH10 (Y-12009000). Tightening torque (53.96 N·m) MULTIPLE FREEWHEEL 8 MULTIPLE FREEWHEEL INSTALLATION „ Installation of the freewheel To install Freewheel removal tool TL-FW30 To disassemble Tightening torque: 30.0 N·m {262 in. lbs.} 118 Please note: specifications are subject to change for improvement without notice. (English) © Apr. 2015 by Shimano Inc. HTR