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Shimano Tiagra BL-4700 Brake Lever Dealer's Manual PDF
en
Summary of Content for Shimano Tiagra BL-4700 Brake Lever Dealer's Manual PDF
(English) DM-GN0001-26
Dealer's Manual
General Operations
2
CONTENTS IMPORTANT NOTICE ........................................................................................................... 7
TO ENSURE SAFETY ............................................................................................................ 8
REAR DERAILLEUR 9
TO ENSURE SAFETY .......................................................................................................... 10
REAR DERAILLEUR FOR MTB/TREKKING ......................................................................... 12 Installation of the rear derailleur ...................................................................................................................... 12
Stroke adjustment .............................................................................................................................................. 14
Securing the cable .............................................................................................................................................. 16
SIS adjustment .................................................................................................................................................... 21
Replacing the pulley ........................................................................................................................................... 23
REAR DERAILLEUR FOR ROAD ......................................................................................... 25 Installation of the rear derailleur ...................................................................................................................... 25
Stroke adjustment .............................................................................................................................................. 27
Securing the cable .............................................................................................................................................. 30
SIS adjustment .................................................................................................................................................... 32
Replacing the pulley ........................................................................................................................................... 34
FRONT DERAILLEUR 35
TO ENSURE SAFETY .......................................................................................................... 36
FRONT DERAILLEUR FOR MTB/TREKKING ....................................................................... 37 Installation .......................................................................................................................................................... 37
Fixing the cable and adjusting the SIS (Front double) ..................................................................................... 43
Fixing the cable and adjusting the SIS (Front triple) ........................................................................................ 49
FRONT DERAILLEUR FOR ROAD ....................................................................................... 53 Installation .......................................................................................................................................................... 53
Fixing the cable and adjusting the SIS (Front double) ..................................................................................... 55
Fixing the cable and adjusting the SIS (Front triple) ........................................................................................ 60
MAINTENANCE ................................................................................................................. 66
3
CHAIN 67
TO ENSURE SAFETY .......................................................................................................... 68
CHAIN CONNECTING PIN .................................................................................................. 71 Method of use .................................................................................................................................................... 71
QUICK-LINK ....................................................................................................................... 72 Installing a QUICK-LINK (SM-UG51) .................................................................................................................. 73
Installing a QUICK-LINK (SM-CN900-11) ............................................................................................................ 75
Removing a QUICK-LINK (SM-CN900-11) .......................................................................................................... 76
BRAKE 77
TO ENSURE SAFETY .......................................................................................................... 78
DISC BRAKE ....................................................................................................................... 82 Wheel spoke lacing ............................................................................................................................................ 82
Installation of the disc brake rotor ................................................................................................................... 82
INSTALLATION (HYDRAULIC DISC BRAKES) .................................................................... 87 Installation of the brake lever ........................................................................................................................... 87
Installation of the brake hose ........................................................................................................................... 89
Installation of the brake hose (easy hose joint system) ................................................................................... 93
Replacing the brake hose (easy hose joint system) ........................................................................................ 103
Preventing loosening of frame fixing bolts .................................................................................................... 107
MAINTENANCE (HYDRAULIC DISC BRAKES) ................................................................. 110 Brake pad replacement .................................................................................................................................... 110
Adjustment when the pistons are not operating correctly ........................................................................... 113
Lever stroke adjustment .................................................................................................................................. 114
Free stroke adjustment .................................................................................................................................... 114
Installation of the magnet holder ................................................................................................................... 115
Mineral oil replacement ................................................................................................................................... 115
Adding mineral oil and bleeding air ............................................................................................................... 116
INSTALLATION (V-BRAKE BRAKES) ................................................................................ 121 Installation of the brake lever ......................................................................................................................... 121
Installing the power modulator ...................................................................................................................... 121
Installation of V-BRAKE brakes ........................................................................................................................ 122
4
MAINTENANCE (V-BRAKE BRAKES) ............................................................................... 125 Replacement of the cartridge shoe ................................................................................................................. 125
BRAKE LEVER WITH SWITCH INTERCHANGEABILITY (V-BRAKE AND HUB ROLLER BRAKES) .......................................................................... 126
For V-BRAKE (with power modulator) mode ................................................................................................. 126
For Caliper brake/Roller brake ......................................................................................................................... 126
INSTALLATION (DUAL PIVOT CALIPER BRAKES) ........................................................... 127 Arch spring tension adjustment ...................................................................................................................... 130
MAINTENANCE (DUAL PIVOT CALIPER BRAKES) .......................................................... 131 Replacement of the cartridge shoe ................................................................................................................. 131
SPECIFICATIONS (CANTILEVER BRAKES) ....................................................................... 132 Cantilever brakes .............................................................................................................................................. 132
Brake lever ........................................................................................................................................................ 132
INSTALLATION (CANTILEVER BRAKES) .......................................................................... 133 Installation of the brake lever ......................................................................................................................... 133
Installation of the brake caliper ...................................................................................................................... 134
Installing SM-CB70 ............................................................................................................................................ 137
FRONT CHAINWHEEL 138
TO ENSURE SAFETY ........................................................................................................ 139
INSTALLATION (CHAINRINGS) ........................................................................................ 141 For ROAD .......................................................................................................................................................... 141
For MTB/Trekking ............................................................................................................................................. 142
INSTALLATION (FRONT CHAINWHEEL) .......................................................................... 143 HOLLOWTECH II / 2 piece crankset .................................................................................................................. 143
OCTALINK TYPE ................................................................................................................................................ 148
SQUARE TYPE ................................................................................................................................................... 149
INSTALLATION (PRESS-FIT BOTTOM BRACKET) ............................................................ 151 Adapter ............................................................................................................................................................. 151
Assembly example ............................................................................................................................................ 151
Installation ........................................................................................................................................................ 152
Removal ............................................................................................................................................................ 153
5
PEDALS (SPD-SL PEDALS/SPD PEDALS) 154
TO ENSURE SAFETY ........................................................................................................ 155
INSTALLATION (SPD PEDALS) ......................................................................................... 157 Engaging the cleats with the pedals ............................................................................................................... 157
Releasing the cleats from the pedals .............................................................................................................. 157
Attaching the cleats ......................................................................................................................................... 159
Mounting the pedals on the crank arms ........................................................................................................ 161
Adjusting the spring tension of the binding .................................................................................................. 162
Cleat replacement ............................................................................................................................................ 162
INSTALLATION (SPD-SL PEDALS) .................................................................................... 163 Cleat types ........................................................................................................................................................ 163
Engaging the cleats with the pedals ............................................................................................................... 164
Releasing the cleats from the pedals .............................................................................................................. 164
Attaching the cleats ......................................................................................................................................... 164
Mounting the pedals on the crank arms ........................................................................................................ 165
Adjusting the spring tension of the binding .................................................................................................. 166
Cleat replacement ............................................................................................................................................ 166
Replacement of the body cover ...................................................................................................................... 167
Maintenance of the axle units ......................................................................................................................... 167
Mounting the reectors (optional) ................................................................................................................. 167
HUB DYNAMO 168
TO ENSURE SAFETY ........................................................................................................ 169
INSTALLATION (HUB DYNAMO) ..................................................................................... 171 Installation of the disc brake rotor ................................................................................................................. 171
Installation of the front wheel ........................................................................................................................ 171
CONNECTION OF THE CABLES ....................................................................................... 175 For E2 type ........................................................................................................................................................ 175
For J2 type ......................................................................................................................................................... 176
For J2-A type ..................................................................................................................................................... 177
Note on the connection of the cables ............................................................................................................. 179
Checking the light illumination ....................................................................................................................... 179
6
MULTIPLE FREEWHEEL 180
INSTALLATION (MULTIPLE FREEWHEEL) ........................................................................ 181 Installation of the freewheel ........................................................................................................................... 181
7
IMPORTANT NOTICE
IMPORTANT NOTICE
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 manuals and technical documents are accessible online at https://si.shimano.com.
For consumers who do not have easy access to the internet, please contact a SHIMANO distributor or any of the SHIMANO offices to obtain a hardcopy of the User's Manual.
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.
8
TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
Be sure to follow the instructions provided in the manuals when installing the product. It is recommended to use genuine Shimano parts only. 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.
NOTICE
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.
REAR DERAILLEUR
10
REAR DERAILLEUR TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
Obtain and read the dealers 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. It is strongly recommended using only genuine Shimano replacement parts.
Obtain and read the dealers manual carefully prior to installing the parts. If adjustments are not carried out correctly, the chain may come off. This may cause you to fall off the bicycle which could result in serious injury.
NOTICE
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.
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 not too long or short.
If you hear abnormal noise as a result of looseness in a pulley, you should replace the pulley.
A high cable resistance on a frame with internal cable routing could impair the SIS shifting function. If some resistance is felt in the lever operation, SIS shifting does not function normally, or there is some other issue, check that there is no problem with the condition of the inner cable or the bending of the outer casing.
For MTB/Trekking The gears should be periodically washed with a neutral detergent. In addition, cleaning the chain with neutral detergent and lubricating it can be an effective way of extending the life of the gears and the chain.
Always be sure to use the sprocket set bearing the same group marks, and never use in combination with a sprocket bearing a different group mark.
ga -18T
-
S
H IM
ANO
HYPERGLIDE C
ag-15T ag-13T
Group marks
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. These may cause deterioration in gear shifting performance.
11
REAR DERAILLEUR TO ENSURE SAFETY
For ROAD The end of the outer casing which has the aluminum cap should be at the derailleur side.
Aluminum cap Plastic cap
Aluminum cap (4 mm)
Derailleur side
When the chain is in any of the position combinations shown in the table, the chain and sprocket may come into contact and generate noise. If the noise is a problem, shift the chain onto the next largest sprocket or the one after.
Double Triple
Chainring
Sprocket
12
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Installation of the rear derailleur
REAR DERAILLEUR FOR MTB/TREKKING
Installation of the rear derailleur
Standard type
(A)
(C)
(B)
Install the rear derailleur. (A) 5 mm hexagon wrench
(B) Dropout
(C) Bracket
Tightening torque
8 - 10 Nm
NOTICE
Periodically check that there is no gap between the derailleur hanger and the bracket as shown in the illustration. If there is a gap between these two parts, problems with gear shifting performance may occur.
13
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Installation of the rear derailleur
Bracket type
(B) (D)
(A)
(C)
For BMX type
(D)
(A)
(B)
(C)
(A) Dropout
(B) Bracket bolt
(C) Bracket nut
(D) Bracket
Tightening torque
3 - 4 Nm
NOTICE
Periodically check that there is no gap between the derailleur hanger and the bracket as shown in the illustration. If there is a gap between these two parts, problems with gear shifting performance may occur.
14
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Stroke adjustment
Stroke adjustment
Top adjustment
B A
B A
(A)
(B)
(C)
Turn the top adjustment bolt to adjust so that the guide pulley is in line with the outer line of the smallest sprocket when looking from the rear.
(A) Outer line of smallest sprocket
(B) Guide pulley
(C) Top adjustment bolt
Low adjustment
B A
BA
(B)
(C)(A)
Turn the low adjustment bolt so that the guide pulley moves to a position directly in line with the largest sprocket.
(A) Largest sprocket
(B) Guide pulley
(C) Low adjustment bolt
15
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Stroke adjustment
Chain length
1 (z)
(z)
The length of A will vary depending on the movement of the rear suspension.
Consequently, an excessive load may be placed on the drive system if the chain length is too short.
The rear suspension operates and stops when dimension A is at its greatest extension.
(z) A
2
+ (z)
(C)(A)
(B)
Mount the chain on to the largest sprocket and the largest chainring.
Next, add 2 links to set the length of the chain.
(z) +2 links
(A) Largest sprocket
(B) Chain
(C) Largest chainring
(D) Pin/plate for preventing chain derailment
NOTICE
If there is a lot of movement in the rear suspension, the slack in the chain may not be taken up properly when the chain is on the smallest chainring and smallest sprocket.
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.
(D) (D)
16
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Securing the cable
Securing the cable
Cutting the outer casing
1
When cutting the outer casing, cut the end opposite 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 (A) After cutting, attach the same sealed
outer cap to the end. (A) Outer cap
3
Install the sealed outer cap with tongue and the rubber shield onto the outer casing stopper of the frame.
(z) Be careful not to bend this section.
(A) Sealed outer cap with tongue
(B) Rubber shield
TECH TIPS
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.
(B)
(B)
(A) (z)
17
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Securing the cable
Outer casing length for SHADOW RD
1
(A)
If there is a B-tension adjust bolt, loosen it until it is in the position shown in the illustration.
(A) B-tension adjust bolt
2
(A)
(B)
Check that there is enough slack in the outer casing.
Next, align the outer casing with the bottom edge of the holder on the rear derailleur and then cut off any excess.
(A) Outer casing holder
(B) Outer casing
NOTICE
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.
18 To be continued on next page
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Securing the cable
Connecting and securing of the cable
1
(A)
(A)
Connect the inner cable to the rear derailleur.
(A) Groove
2
(z)
Remove the initial slack from the cable as shown in the illustration.
(z) Pull
19
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Securing the cable
3
(A)
(A)
Reconnect the inner cable to the rear derailleur.
(A) Groove
Tightening torque
6 - 7 Nm
NOTICE
Be sure that the cable is securely in the groove.
4
(z)
(z)
Set the inner cable so that the margin is approximately 30 mm or less.
Install the shift inner cap.
(z) 30 mm or less
NOTICE
Check that the inner cable does not interfere with the wheel spokes. Stop the wheel from turning while carrying out this step.
20
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Securing the cable
Using the B-tension adjust bolt
B A
A A
B
B
(C)(B)(A)
Mount the chain on the smallest chainring and the largest sprocket, and turn the crank arm for shifting.
Adjust the B-tension adjust bolt so that the guide pulley does not interfere with the sprocket but do not let the guide pulley come so close to the chain that they come into contact with each other.
Next, set the chain on the smallest sprocket.
Repeat the above to make sure that the pulley does not touch the sprocket.
(A) Largest sprocket
(B) Smallest sprocket
(C) B-tension adjust bolt
Checking the distance between the largest sprocket and the guide pulley (SHADOW RD)
1 [A]
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.
Gear combination [A]
11-42T 5 6 mm
11-36T 5 6 mm
11-34T 5 6 mm
11-32T 9 10 mm
TECH TIPS
When the lower gear uses the gear combination of 42T, 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.
2 Turn the crank arm to shift gears and ensure that the shift is smooth. NOTICE
If the number of teeth for the cassette sprocket is changed, try setting it again.
21
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
SIS adjustment
SIS adjustment
Confirming positioning on gear
1 Operate the shifting lever several times to move the chain to the 2nd sprocket counting from the smallest sprocket.
Then, while operating the lever just enough to close the gap in the lever, turn the crank arm.
2
The best setting is when the shifting lever is operated just enough to close the lever gap and the chain touches the 3rd sprocket counting from the smallest sprocket and makes noise.
Adjusting SIS
When the chain shifts to the 3rd sprocket from the smallest sprocket
Tighten the cable adjustment barrel until the chain returns to the 2nd sprocket counting from the smallest sprocket. (Clockwise)
(A) Cable adjustment barrel
(B) Adjustment bolt
(A)
(B)
22
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
SIS adjustment
When no sound at all is generated
1
Loosen the cable adjustment barrel until the chain touches the 3rd sprocket counting from the smallest sprocket and makes a noise. (Counterclockwise)
(A) Cable adjustment barrel
(B) Adjustment bolt
(A)
(B)
2
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 cable adjustment barrel clockwise slightly to tighten it until the noise stops and the chain runs smoothly.
Stop turning at the point where the noise just stops.
3 Operate lever to change gears, and check that no noise occurs in any of the gear positions. TECH TIPS
For the best SIS performance, periodically lubricate all power-transmission parts.
23
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Replacing the pulley
Replacing the pulley
Guide pulley
(A)
(B)
Replace the guide pulley. (A) Guide pulley
(B) 3 mm hexagon wrench
Tightening torque
2.5 - 5 Nm
NOTICE
Check the arrow direction on the pulley when installing it.
24
REAR DERAILLEUR REAR DERAILLEUR FOR MTB/TREKKING
Replacing the pulley
Tension pulley
1
(A)
If an E-ring is attached, remove it first. (A) E-ring
2
(A)
(B)
Replace the tension pulley. (A) Tension pulley
(B) 3 mm hexagon wrench
Tightening torque
2.5 - 5 Nm
NOTICE
Check the arrow direction on the pulley when installing it.
25
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Installation of the rear derailleur
REAR DERAILLEUR FOR ROAD
Installation of the rear derailleur When installing, be careful that deformation is not caused by the B-tension adjust bolt coming into contact with the B-tension stop.
Standard type
(A)
(C) (B)
Install the rear derailleur. (A) 5 mm hexagon wrench
(B) Hanger stop
(C) B-tension adjust bolt
Tightening torque
8 - 10 Nm
NOTICE
Make sure to insert the hexagon wrench all the way to the end of the bracket axle tool hole when tightening.
Do not use a ball point hexagon wrench.
Ball point hexagon wrench
If tightening is performed incorrectly, the following phenomena may result:
Deformation of the tool hole preventing installation or removal.
Suboptimal gear shifting performance.
26
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Installation of the rear derailleur
Bracket type
(A) (B) (C) (D)
(A) Bracket bolt
(B) Bracket
(C) Dropout
(D) Bracket nut
Tightening torque
3 - 4 Nm
27
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Stroke adjustment
Stroke adjustment
Top adjustment
B A
B A (C)
(A)
(B)
Turn the top adjustment bolt to adjust so that the guide pulley is below the outer line of the smallest sprocket when viewed from the rear.
(A) Outer line of smallest sprocket
(B) Guide pulley
(C) Top adjustment bolt
Low adjustment
B A BA
(B)
(C)(A)
Turn the low adjustment bolt so that the guide pulley moves to a position directly in line with the largest sprocket.
(A) Largest sprocket
(B) Guide pulley
(C) Low adjustment bolt
28
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Stroke adjustment
Chain length
When largest sprocket is 27T or smaller
(F) (D)
(E)
(z)
(C)(A)
(B)
90
(z) Right angle to the ground
(A) Smallest sprocket
(B) Chain
(C) Largest chainring
(D) Guide pulley
(E) Tension pulley
(F) Front double
TECH TIPS
When installing chain using, place chain in largest chainring and smallest sprocket. Set so that the line drawn through the guide pulley and tension pulley is 90 or greater to the ground.
When largest sprocket is 28T or larger
With the chain put on both the largest sprocket and the largest chainring, add 2 links to the "minimum number of links that can be connected".
(z) +2 links
(A) Largest sprocket
(B) Chain
(C) Largest chainring
(D) Front double
+ (z)
(D) (B)
(A) (C)
29
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Stroke adjustment
For front triple (when largest sprocket is 30T or smaller)
(D)
(z)
(C)(A)
(B)
90
(z) Right angle to the ground
(A) Smallest sprocket
(B) Chain
(C) Largest chainring
(D) Front triple
NOTICE
For RD-A070, follow the adjustment method in For front triple (when largest sprocket is 32T or larger) instead.
TECH TIPS
When installing chain using, place chain in largest chainring and smallest sprocket. Set so that the line drawn through the guide pulley and tension pulley is 90 or greater to the ground.
For front triple (when largest sprocket is 32T or larger)
+ (z)
(D)
(A) (C)
(B)
With the chain put on both the largest sprocket and the largest chainring, add 2 links to the "minimum number of links that can be connected".
(z) +2 links
(A) Largest sprocket
(B) Chain
(C) Largest chainring
(D) Front triple
(E) Pin/plate for preventing chain derailment
TECH TIPS
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.
(E) (E)
30 To be continued on next page
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Securing the cable
Securing the cable
Cutting the outer casing
1
When cutting the outer casing, cut the end opposite 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 (A) Attach the same outer cap to the cut end
of the outer casing. (A) Outer cap
Connecting and securing of the cable
1
(A)
Connect the inner cable to the rear derailleur.
(A) Groove
Tightening torque
6 - 7 Nm
2
(z)
Remove the initial slack from the cable as shown in the illustration.
(z) Pull
31
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Securing the cable
3 (A)
Reconnect the inner cable to the rear derailleur.
(A) Groove
Tightening torque
6 - 7 Nm
NOTICE
Be sure that the cable is securely in the groove.
Groove
Using the B-tension adjust bolt
B AB B
A A
(C)(B)(A)
Mount the chain on the smallest chainring and the largest sprocket, and turn the crank arm for shifting.
Then turn the B-tension adjust bolt 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 on the smallest sprocket and repeat the above procedure to make sure that the pulley does not come into contact with the sprockets.
(A) Largest sprocket
(B) Smallest sprocket
(C) B-tension adjust bolt
32
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
SIS adjustment
SIS adjustment
Confirming positioning on gear
1
(z) Operate the shifting lever several times to move the chain to the 2nd sprocket counting from the smallest sprocket.
Then, while operating the lever just enough to close the gap in the lever, turn the crank arm.
(z) Gap
2
The best setting is when the shifting lever is operated just enough to close the lever gap and the chain touches the 3rd sprocket counting from the smallest sprocket and makes noise.
Adjusting SIS
When the chain shifts to the 3rd sprocket from the smallest sprocket
Tighten the cable adjustment barrel until the chain returns to the 2nd sprocket counting from the smallest sprocket. (Clockwise)
(A) Cable adjustment barrel
(A)
33
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
SIS adjustment
When no sound at all is generated
1
Loosen the cable adjustment barrel until the chain touches the 3rd sprocket counting from the smallest sprocket and makes a noise. (Counterclockwise)
(A) Cable adjustment barrel
(A)
2
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 cable adjustment barrel clockwise slightly to tighten it until the noise stops and the chain runs smoothly.
Stop turning at the point where the noise just stops.
3 Operate lever to change gears, and check that no noise occurs in any of the gear positions. TECH TIPS
For the best SIS performance, periodically lubricate all power-transmission parts.
34
REAR DERAILLEUR REAR DERAILLEUR FOR ROAD
Replacing the pulley
Replacing the pulley
(A)
Replace the pulley using a 3 mm hexagon wrench.
(A) 3 mm hexagon wrench
Tightening torque
2.5 - 5 Nm
FRONT DERAILLEUR
36
FRONT DERAILLEUR TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
Obtain and read the dealers 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. It is strongly recommended using only genuine Shimano replacement parts.
Obtain and read the dealers manual carefully prior to installing the parts. If adjustments are not carried out correctly, the chain may come off. This may cause you to fall off the bicycle which could result in serious injury.
NOTICE
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 chainrings or front derailleur and generate noise. If the noise is a problem, shift the chain onto the next-larger sprocket or the one after.
Figure 1 Figure 2
Double Triple
Chainring
Sprocket
For frames with suspension, the chainstay angle will vary depending on whether the bicycle is being ridden or not.
When the bicycle is not being ridden and the chain is positioned on the largest chainring at the front and on the smallest sprocket at the rear, the chain may come into contact with the chain guide outer plate of the front derailleur.
For ROAD When the chain is in the position shown in the illustration, the chain may contact the chainrings or front derailleur and generate noise. If the noise is a problem, shift the chain onto the next-larger sprocket or the one after.
Double Triple
Chainring
Sprocket
37
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Installation
FRONT DERAILLEUR FOR MTB/TREKKING
NOTICE
When installing components to a carbon frame/handlebar, check the tightening torque recommended by the carbon frame or component manufacturer to avoid carbon material damage due to excessive tightening or insufficient component holding force resulting from insufficient tightening torque.
Installation
(z)
(B)
(A)
Adjust so that there is a clearance of 1 3 mm between the chain guide outer plate and the largest chainring. (Common to all types)
(z) 1 3 mm
(A) Chain guide
(B) Largest chainring
TECH TIPS
Bicycles with suspensions are positioned differently between when a rider is off the bicycle and on the bicycle. By referring to the illustration, perform installation and SIS adjustment while seated on the bicycle.
38 To be continued on next page
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Installation
Band type
1
When using the adapter, install it in the position shown in the illustration, relative to the front band or the rear band.
(z) Align
(A) Adapter
(B) Front band/Rear band
(z)
(A)
(B)
When using a non-planar front band
(A)
(B)
(y)
(z)
Be sure to use a metallic adapter for a front band which has a non-planar shape.
(y) Planar shape
(z) Non-planar shape
(A) Front band
(B) Metallic adapter
When using a planar front band
(A)
(B) (y)
(z)
Be sure to use a round-type plastic adapter when using a front band with a planar shape.
Square-type plastic adapters are not compatible.
(y) Planar shape
(z) Non-planar shape
(A) Front band
(B) Round-type plastic adapter
For the SM-AD16/SM-AD17
(y)(A) (A)
(B)
(z)
Peel off the double-sided tape from the band adapters (front and rear are interchangeable), and then secure the band adapters by press-fitting them to the fixing bands with the wider ends oriented toward the hinge, as shown in the illustration.
(y) Narrower
(z) Wider
(A) Band adapter
(B) Fixing band
NOTICE
These band adapters are available in two sizes: S size (SM-AD16S/AD17S/28.6 mm diameter) and M size (SM-AD16M/AD17M/31.8 mm diameter).
39
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Installation
2 (B)
(A)
(z)
(B)
(C)
After tentatively tightening the clamp bolt, align the at portion of the outer plate of the chain guide in parallel with the at surface of the largest chainring.
When the adjustment is complete, tighten the clamp bolt.
(z) 1 3 mm
(A) 5 mm hexagon wrench
(B) Largest chainring
(C) Chain guide outer plate
Tightening torque
5 - 7 Nm
NOTICE
Do not position the chain guide as shown in the below illustrations.
40
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Installation
E-type
1
(A)
(B)
(C)
Align the bracket of the front derailleur with the position of the bottom bracket and secure it with a bolt.
(A) Front derailleur
(B) Bolt
(C) Bottom bracket position
Tightening torque
5 - 7 Nm
2
Insert the bottom bracket adapter as in the illustration and tighten it. (A) Adapter
(B) Front chainwheel
Tightening torque
35 - 50 Nm
(A)(A)
(B)
41
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Installation
E-type (models without BB plate)
Secure with bottom bracket mount fixing bolts.
Positioning varies depending on number of gear teeth.
Refer to the illustration for correct positioning.
(z) Example: When using a hexagon wrench
(A) Bottom bracket mount fixing bolt
(B) Bottom bracket mount
(C) Bracket
NOTICE
Shimano does not provide the bottom bracket mount fixing bolts.
(C)(B)
(A)
(z)
Securing position
(y) (z) (y) Double: Largest chainring 38T Triple: Largest chainring 40T
(z) Double: Largest chainring 40T Triple: Largest chainring 42T
42
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Installation
Direct mount type
Adjust the height of the front derailleur.
The at section of the chain guide outer plate should be directly above and parallel to the largest chainring.
Secure with a hexagon wrench (5 mm).
(A) Chainwheel (largest chainring)
(B) Chain guide
(C) 5 mm hexagon wrench
Tightening torque
5 - 7 Nm
(A) (B) (C)
The mounting height varies depending on the position of the base on the frame. [1] 155.5 mm (From bottom bracket center)
(x) Double: 42T
(y) Double: 40T Triple: 42T
(z) Double: 38T
[2] 159.5 mm (From bottom bracket center)
(x) Double: 44T
(y) Double: 42T
(z) Double: 40T Triple: 42T
[2][1]
(x) (y) (z)
43
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front double)
Fixing the cable and adjusting the SIS (Front double)
Low adjustment
1 (x)
(z)
(y)
(A)
(B)
Set the chain on the smallest chainring at the front and the largest sprocket at the rear.
(x) Low
(y) Top
(z) Cable index point
(A) Smallest chainring
(B) Largest sprocket
2
(x)
(y)
(z)
(A) (B)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(x) Top swing
(y) Down swing
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
44
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front double)
Securing the cable
Use the shifting lever with a mode converter in x2 mode. To shift from x3 to x2, refer to the maintenance section of the dealers manual for the shifting lever RAPIDFIRE Plus.
Top Swing (Common to E-type and band type)
Down pull
(A)
Top pull
(A)
Use a spanner or a hexagon wrench to tighten the wire mounting bolt.
(A) 5 mm hexagon wrench/ 9 mm spanner
Tightening torque
5 - 7 Nm
NOTICE
Run the cable through as shown in the illustration.
Wire mounting bolt
45
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front double)
Down swing (Band type)
Down pull Use a hexagon wrench to tighten the wire mounting bolt.
Tightening torque
5 - 7 Nm
NOTICE
Run the cable through as shown in the illustration.
Wire mounting bolt
Different shaped type
Wire mounting bolt
Top pull Use a hexagon wrench to tighten the wire mounting bolt.
Tightening torque
5 - 7 Nm
46
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front double)
Down swing (Direct mount type)
1
Down pull Use a hexagon wrench to tighten the wire mounting bolt.
Tightening torque
5 - 7 Nm
NOTICE
Run the cable through as shown in the illustration.
Wire mounting bolt
Different shaped type
Wire mounting bolt
Top pull Use a hexagon wrench to tighten the wire mounting bolt.
Tightening torque
5 - 7 Nm
2
After taking up the initial slack in the cable, re-secure to the front derailleur as shown in the illustration.
(z) Pull
Down pull
(z)
Top pull
(z)
47
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front double)
Adjustment of the cable tension
1 (x) (y)
(z)
(A)
(B)
Set the chain onto the largest chainring and the largest sprocket.
(x) Low
(y) Top
(z) Cable index point
(A) Largest chainring
(B) Largest sprocket
2
(z)
(C) (D)
(A) (B)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
(C) Cable adjustment barrel
(D) Cable adjuster
48
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front double)
Top adjustment
1 (x) (y)
(z)
(A)
(B)
Set the chain on the largest chainring at the front and the smallest sprocket at the rear.
(x) Low
(y) Top
(z) Cable index point
(A) Largest chainring
(B) Smallest sprocket
2
(x)
(y)
(z)
(B) (A)
Set so that the clearance between the chain guide outer plate and the chain is 0 0.5 mm.
(x) Top swing
(y) Down swing
(z) 0 0.5 mm
(A) Chain guide outer plate
(B) Chain
Troubleshooting chart
After low adjustment, fixing the cable, cable tension adjustment and top adjustment, operate the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8th turn for each adjustment.
If the chain falls to the crank side. Turn the top adjustment bolt clockwise.
If shifting is difficult from the smallest chainring to the largest chainring.
Tighten the cable. If this does not improve the situation, turn the top adjustment bolt counterclockwise.
If shifting is difficult from the largest chainring to the smallest chainring.
Turn the low adjustment bolt counterclockwise. If this does not improve the situation, loosen the cable.
If the chain falls to the bottom bracket side. Turn the low adjustment bolt clockwise.
49
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front triple)
Fixing the cable and adjusting the SIS (Front triple)
Low adjustment
1 (A)
Remove the Pro-Set alignment block. (A) Pro-Set alignment block
2 (w) (x)
(z)
(y)
(A)
(B)
Set the chain on the smallest chainring at the front and the largest sprocket at the rear.
(w) Low
(x) Middle
(y) Top
(z) Cable index point
(A) Smallest chainring
(B) Largest sprocket
3
(x)
(y)
(z)
(A) (B)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(x) Top swing
(y) Down swing
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
50
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front triple)
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 dealers manual for the shifting lever RAPIDFIRE Plus.
TECH TIPS
The cable can be secured on each FD type in the same way as the double. Refer to Fixing the cable and adjusting the SIS (Front double).
Top adjustment
1 (w) (x)
(z)
(y)
(A)
(B)
Set the chain on the largest chainring at the front and the smallest sprocket at the rear.
(w) Low
(x) Middle
(y) Top
(z) Cable index point
(A) Largest chainring
(B) Smallest sprocket
2
(x)
(y)
(z)
(B) (A)
Set so that the clearance between the chain guide outer plate and the chain is 0 0.5 mm.
(x) Top swing
(y) Down swing
(z) 0 0.5 mm
(A) Chain guide outer plate
(B) Chain
51
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front triple)
Adjustment of the cable tension
1 (w) (x)
(z)
(y)
(A)
(B)
Set the chain onto the middle chainring and the largest sprocket.
(w) Low
(x) Middle
(y) Top
(z) Cable index point
(A) Middle chainring
(B) Largest sprocket
NOTICE
Adjust the lever after operating it from top to middle, not low to middle.
Low Middle Top
Cable index point
2
(z)
(C) (D)
(A) (B)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
(C) Cable adjustment barrel
(D) Cable adjuster
52
FRONT DERAILLEUR FRONT DERAILLEUR FOR MTB/TREKKING
Fixing the cable and adjusting the SIS (Front triple)
Troubleshooting chart
After low adjustment, fixing the cable, cable tension adjustment and top adjustment, operate the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8th turn for each adjustment.
If the chain falls to the crank side. Turn the top adjustment bolt clockwise.
If shifting is difficult from the middle chainring to the largest chainring. Tighten the cable. If this does not improve the situation, turn the top adjustment bolt counterclockwise.
If shifting is difficult from the largest chainring to the middle chainring. Loosen the cable.
If the chain falls to the bottom bracket side. Turn the low adjustment bolt clockwise.
If the middle chainring is skipped when shifting from the largest chainring.
Tighten the cable.
If shifting is difficult from the middle chainring to the smallest chainring.
Turn the low adjustment bolt counterclockwise.
53 To be continued on next page
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Installation
FRONT DERAILLEUR FOR ROAD
NOTICE
When installing components to a carbon frame/handlebar, check the tightening torque recommended by the carbon frame or component manufacturer to avoid carbon material damage due to excessive tightening or insufficient component holding force resulting from insufficient tightening torque.
Installation
1
When using the adapter, install it in the position shown in the illustration, relative to the front band or the rear band.
(z) Align
(A) Adapter
(B) Front band/Rear band
(z)
(A)
(B)
When using a non-planar front band
(A)
(B)
(y)
(z)
Be sure to use a metallic adapter for a front band which has a non-planar shape.
(y) Planar shape
(z) Non-planar shape
(A) Front band
(B) Metallic adapter
2 (z)
(B)
(A)
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 at portion of the outer plate of the chain guide in parallel with the at surface of the largest chainring.
(z) 1 3 mm
(A) Chain guide outer plate
(B) Largest chainring
NOTICE
Do not position the chain guide as shown in the below illustrations.
54
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Installation
3 (A)
When the adjustment is complete, tighten the clamp bolt.
(A) 5 mm hexagon wrench/ 9 mm spanner
Tightening torque
5 - 7 Nm
55
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front double)
Fixing the cable and adjusting the SIS (Front double)
Lever operation and cable index point
Front shifting (Standard type)
(u)(A) (A)
(t) (B)
(B)
When the lever [a] is operated
(v)
(x) (y)
(w)
(z)
(t) From largest chainring to smallest chainring
(u) From smallest chainring to largest chainring
(v) Low
(w) Top
(x) L-trim
(y) T-trim
(z) Cable index point
(A) Lever [a]
(B) Lever [b]
Font shifting (Thumb release type)
(A) (u) (A)
(t) (B)
When the lever [b] is operated
(v)
(x) (y)
(w)
(z)
(t) From largest chainring to smallest chainring
(u) From smallest chainring to largest chainring
(v) Low
(w) Top
(x) L-trim
(y) T-trim
(z) Cable index point
(A) Lever [a]
(B) Lever [b]
56
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front double)
Securing the cable
1 Check that the lever [b] is released to the low position by operating it 2 or more times before fixing the inner cable.
2
(z)
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.
(z) Pull
Tightening torque
6 - 7 Nm
57
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front double)
Low adjustment
1 (w) (x)
(A)
(B)
(y) (z)
Set the chain on the smallest chainring at the front and the largest sprocket at the rear.
(w) Low
(x) Top
(y) L-trim
(z) T-trim
(A) Smallest chainring
(B) Largest sprocket
2 (A)
(B)
(z)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
58
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front double)
Adjustment of the cable tension
1 (x)(w)
(A)
(B)
(y) (z)
Set the chain onto the largest chainring and the largest sprocket.
(w) Low
(x) Top
(y) L-trim
(z) T-trim
(A) Largest chainring
(B) Largest sprocket
2
(z)
(C) (D)
(A)
(B)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
(C) Cable adjustment barrel
(D) Cable adjuster
59
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front double)
Top adjustment
1 (w) (x)
(A)
(B)
(y) (z)
Set the chain on the largest chainring at the front and the smallest sprocket at the rear.
(w) Low
(x) Top
(y) L-trim
(z) T-trim
(A) Largest chainring
(B) Smallest sprocket
2
(z)
(B) (A)
Set so that the clearance between the chain guide outer plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide outer plate
(B) Chain
Troubleshooting chart
After low adjustment, fixing the cable, cable tension adjustment and top adjustment, operate the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8th turn for each adjustment.
If the chain falls to the crank side. Turn the top adjustment bolt clockwise.
If shifting is difficult from the smallest chainring to the largest chainring.
Tighten the cable. If this does not improve the situation, turn the top adjustment bolt counterclockwise.
If shifting is difficult from the largest chainring to the smallest chainring.
Turn the low adjustment bolt counterclockwise.
If the chain falls to the bottom bracket side. Turn the low adjustment bolt clockwise.
60
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front triple)
Fixing the cable and adjusting the SIS (Front triple)
Lever operation and cable index point
Front shifting (Standard type)
(s)(A) (A)
(r) (B)
(B)
When the lever [a] is operated
(t)
(w) (x) (y)
(v)(u)
(z)
(r) From largest chainring to smallest chainring
(s) From smallest chainring to largest chainring
(t) Low
(u) Middle
(v) Top
(w) L-trim
(x) M-trim
(y) T-trim
(z) Cable index point
(A) Lever [a]
(B) Lever [b]
Front shifting (Thumb release type)
(A) (s) (A)
(r) (B)
When the lever [b] is operated
(t)
(w) (x) (y)
(v)(u)
(z)
(r) From largest chainring to smallest chainring
(s) From smallest chainring to largest chainring
(t) Low
(u) Middle
(v) Top
(w) L-trim
(x) M-trim
(y) T-trim
(z) Cable index point
(A) Lever [a]
(B) Lever [b]
61
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front triple)
Low adjustment
1 (A)
Remove the Pro-Set alignment block. (A) Pro-Set alignment block
2
(A)
(B)
(t)
(w) (x) (y)
(v)(u)
(z)
Set the chain on the smallest chainring at the front and the largest sprocket at the rear.
(t) Low
(u) Middle
(v) Top
(w) L-trim
(x) M-trim
(y) T-trim
(z) Cable index point
(A) Smallest chainring
(B) Largest sprocket
3 (A)
(B)
(z)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
62
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front triple)
Securing the cable
1 Check that the lever [b] is released to the low position by operating it 3 or more times before fixing the inner cable.
2
(z)
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.
(z) Pull
Tightening torque
6 - 7 Nm
63
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front triple)
Top adjustment
1
(A)
(B)
(t)
(w) (x) (y)
(v)(u)
(z)
Set the chain on the largest chainring at the front and the smallest sprocket at the rear.
(t) Low
(u) Middle
(v) Top
(w) L-trim
(x) M-trim
(y) T-trim
(z) Cable index point
(A) Largest chainring
(B) Smallest sprocket
2
(B)
(z)
(A)
Set so that the clearance between the chain guide outer plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide outer plate
(B) Chain
64
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front triple)
Adjustment of the cable tension
1
(A)
(B)
(t)
(w) (x) (y)
(v)(u)
(z)
Set the chain onto the middle chainring and the largest sprocket.
(t) Low
(u) Middle
(v) Top
(w) L-trim
(x) M-trim
(y) T-trim
(z) Cable index point
(A) Middle chainring
(B) Largest sprocket
NOTICE
Adjust the lever after operating it from top to middle, not low to middle.
Low Middle Top
Cable index point
T-trimL-trim M-trim
2
(z)
(C) (D)
(A)
(B)
Set so that the clearance between the chain guide inner plate and the chain is 0 0.5 mm.
(z) 0 0.5 mm
(A) Chain guide inner plate
(B) Chain
(C) Cable adjustment barrel
(D) Cable adjuster
65
FRONT DERAILLEUR FRONT DERAILLEUR FOR ROAD
Fixing the cable and adjusting the SIS (Front triple)
Troubleshooting chart
After low adjustment, fixing the cable, cable tension adjustment and top adjustment, operate the shifting lever to check the shifting. (This also applies if shifting becomes difficult during use.) * Turn the bolt by 1/8th turn for each adjustment.
If the chain falls to the crank side. Turn the top adjustment bolt clockwise.
If shifting is difficult from the middle chainring to the largest chainring. Tighten the cable. If this does not improve the situation, turn the top adjustment bolt counterclockwise.
If shifting is difficult from the largest chainring to the middle chainring. Loosen the cable.
If the chain falls to the bottom bracket side. Turn the low adjustment bolt clockwise.
If the middle chainring is skipped when shifting from the largest chainring.
Tighten the cable.
If shifting is difficult from the middle chainring to the smallest chainring.
Turn the low adjustment bolt counterclockwise.
66
FRONT DERAILLEUR MAINTENANCE
Fixing the cable and adjusting the SIS (Front triple)
MAINTENANCE
If shifting operation becomes less smooth, clean the front derailleur and lubricate the link sections shown in the illustration.
Brazed-on type E-type (A) Links
(A)
(A)
(A)
Band type Direct mount type
(A)
(A) (A)
CHAIN
68
CHAIN TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
Intervals between maintenance depend on the use and riding circumstances. Clean the chain and QUICK-LINK regularly with an appropriate chain cleaner. Never use alkali based or acid based solvents, such as rust cleaners. If any of these are used, the chain or QUICK-LINK might break resulting in 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. For best chain performance make sure it is installed to face 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 and QUICK-LINK for any damage (deformations or cracks), chain skipping, or other abnormalities such as unintended gear shifting. If any problems are found, consult a dealer or an agency. There is a risk of the chain breaking or the QUICK-LINK disengaging, which may cause the bicycle to collapse.
Only use the tool and connecting pin models specified in the table to connect the chain. If unsuitable connecting pins or tools are used to connect the chain, the connecting pin force may not be sufficient, which could cause the chain to break or fall off. If using a QUICK-LINK to connect the chain, refer to the section "QUICK-LINK".
Chain Reinforced connecting pin / QUICK-LINK Tool
11-speed CN-9000/6800 CN-HG900-11/HG700-11/HG600-11 5.8 mm
TL-CN34
TL-CN28
All 11-speed chains TL-CN10
For MTB/Trekking/E-BIKE 10-speed super narrow chain CN-M981/HG95/HG75/HG54/E6090-10 etc. (CN-M980/HG94/HG74 EOL)
5.85 mm
5.85 mm
with groove [3]
with groove [2]
TL-CN34
TL-CN33
TL-CN32
TL-CN28
TL-CN27
For ROAD double crank 10-speed super narrow chain CN-7901/6701/5701/4601 etc.
For ROAD triple crank 10-speed super narrow chain CN-7801/6600/5600 etc.
9-speed super narrow chain CN-YM81/7701/HG93/E6070-9 etc.
6.5 mm
Silver
8/7/6-speed narrow chain CN-HG50/HG40 etc.
7.1 mm
Black
69
CHAIN TO ENSURE SAFETY
If it is necessary to adjust the length of the chain due to a change in the number of sprocket teeth, make the cut in a place other than 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 is joined with a reinforced connecting pin.
Reinforced connecting 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)
After adjustment, make sure that the connecting pin is as shown in the illustration by running your finger over it. (The pin will protrude slightly after the break off pin is removed)
Link surface
Connecting pin
Slightly protruding
Link surface
Connecting pin
9/8/7/6-speed chain
Be sure to check that the connecting pin protrudes equally from both sides of the chain after it has been joined.
Connection
Should be uniform
CN-NX10
Be sure to check that the connecting pin protrudes equally from both sides of the chain after it has been joined. Twist the connection area so that the chain moves smoothly.
* Should be uniform
Connection location
70
CHAIN TO ENSURE SAFETY
NOTICE
CN-E6090-10/CN-E6070-9 can be used only in combination with single front chainrings.
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 chains level of strength is enhanced compared to the method in Fig. [B].
[A]
[B]
Connecting pin
Rotation of the crank
Connecting pin
Outer link
Outer link
Inner link
Inner link
You should periodically wash the chainrings/sprockets in a neutral detergent and then lubricate them again. In addition, cleaning the chain and QUICK-LINK with a neutral detergent and lubricating it can be an effective way of extending its useful life.
For CN-HG900-11/HG700-11/HG600-11, CN-M981/HG95/HG75/HG54, CN-7901/6701/5701/4601, CN-E6090-10
In order to achieve good gear shifting performance, these have a forward side and a reverse side and must be fitted in the correct orientation. * 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)
CN-HG900-11/HG700-11/HG600-11
CN-7901/6701/5701/4601
71
CHAIN CHAIN CONNECTING PIN
Method of use
CHAIN CONNECTING PIN
Method of use
1
Insert the connecting pin.
2
(A) Press in the connecting pin using a chain tool.
(A) Chain tool
3
Break off the excess portion of the connecting pin.
NOTICE
Set the chain on the chain cutter as shown in the illustration when using the chain cutting tool. If the tool is used with the chain set incorrectly, the positioning plate will get damaged.
72
CHAIN QUICK-LINK
QUICK-LINK
WARNING
Do not reuse a QUICK-LINK that has been removed. If the QUICK-LINK is reused, there is a risk that it will loosen and become detached, causing the bicycle to fall over, which may cause serious injury. Intervals between maintenance depend on the use and riding circumstances. Clean the chain and QUICK-LINK regularly with an appropriate chain cleaner. Never use alkali based or acid based solvents, such as rust cleaners. If any of these are used, the chain or QUICK-LINK might break resulting in serious injury.
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.
Check the chain and QUICK-LINK for any damage (deformations or cracks), chain skipping, or other abnormalities such as unintended gear shifting. If any problems are found, consult a dealer or an agency. There is a risk of the chain breaking or the QUICK-LINK disengaging, which may cause the bicycle to collapse.
When replacing the chain with a new one, be sure to also replace the QUICK-LINK with a new one. If you do not replace it, the QUICK-LINK may break and you may fall.
When attaching the QUICK-LINK, make sure that the pins on the link plates are pushed all the way in and securely planted in the link holes.
Be sure to follow the instructions provided in the manuals when installing the product. It is recommended to use genuine Shimano parts only. 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.
QUICK-LINK compatible chains
Model No.
QUICK-LINK Compatible chains
SM-UG51 All 6, 7, and 8-speed chains
SM-CN900-11 All 11-speed chains
When attaching SM-CN900-11, be sure to attach it so that the arrow on the surface faces in the direction of rotation of the crank when viewed from the front. If not attached correctly, SM-CN900-11 could detach causing the bicycle to collapse.
Crank Arrow
QUICK-LINK
Read these instructions carefully, and keep them in a safe place for later reference.
NOTICE
You should periodically wash the chainrings/sprockets in a neutral detergent and then lubricate them again. In addition, cleaning the chain and QUICK-LINK with a neutral detergent and lubricating it can be an effective way of extending its useful life.
Shimano original tool is required to remove the QUICK-LINK. Consult a dealer or an agency.
73 To be continued on next page
CHAIN QUICK-LINK
Installing a QUICK-LINK (SM-UG51)
Installing a QUICK-LINK (SM-UG51)
1
(A)
Remove the outer link at the connection location so that both ends of the chain finish at an inner link.
(A) Inner link
2
(A)
(B)
Insert the connecting link with pins section of the QUICK-LINK as shown in the illustration.
(A) Connecting link with pins
(B) Inner link
3
(z)
(B)(A)
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.)
(z) Depression should be on the outside
(A) Hole
(B) Connecting link with hole
4 (A)
Turn the connecting link with hole until it overlaps the other pin.
(A) Hole
74
CHAIN QUICK-LINK
Installing a QUICK-LINK (SM-UG51)
5
Loosen the chain and insert the pin securely into the hole.
6 (z)
Set both pins securely into the slot of the connecting link with hole, and check that both plates are parallel.
(z) Parallel
75
CHAIN QUICK-LINK
Installing a QUICK-LINK (SM-CN900-11)
Installing a QUICK-LINK (SM-CN900-11)
1
(z)
(B) (C)
(A)
Insert the pins of the QUICK-LINK into the spaces in the inner link from both sides as shown in the illustration.
When using SM-CN900-11, be sure to install it so that the arrow on the surface faces in the direction of rotation of the crank when viewed from the front.
(z) Rotation of the crank
(A) Crank
(B) Arrow
(C) QUICK-LINK
2
Use Shimano original tool TL-CN10 to slide the pins and insert them firmly.
NOTICE
Check that both QUICK-LINK plates are firmly fastened in position as shown in the illustration.
76
CHAIN QUICK-LINK
Removing a QUICK-LINK (SM-CN900-11)
Removing a QUICK-LINK (SM-CN900-11)
RE MO
VE CONNECT
Set Shimano original tool TL-CN10 as shown in the illustration, slide the pins and remove the QUICK-LINK.
BRAKE
78
BRAKE TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
Obtain and read the dealers 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. It is strongly recommended using only genuine Shimano replacement parts.
For Disc Brake
If the disc brake rotor is cracked or warped, be sure to replace it with a new disc brake rotor.
If the disc brake rotor becomes worn down to a thickness of 1.5 mm or so that the aluminum surface becomes visible, be sure to replace the disc brake rotor with a new one.
If any oil or grease gets on the pads, replace the pads. If any oil or grease gets on the disc brake rotor, wipe clean the disc brake rotor. Otherwise, the brakes may not work correctly.
If noise occurs during brake operation, the brake pads may have been worn down to the usable limit. Check that the brake system temperature has been cooled down sufficiently, check the thickness of the brake pad. If the thickness is 0.5 mm or below, the brake pad needs to be replaced with a new one. Consult a dealer or an agency.
2 mm 0.5 mm
The calipers and disc brake rotor will become hot when the brakes are operated; do not touch them while riding or immediately after dismounting from the bicycle. Otherwise, you may get burned. Check that the brake components have cooled down sufficiently before attempting to adjust the brakes.
For Hydraulic Disc Brake
Use only Shimano genuine 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. Do not re-use oil which has been drained from the bleed nipple. Old or reused 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 when the bicycle is 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 are still sluggish, bleed the air from the brake system. (Refer to Adding mineral oil and bleeding air.)
If the quick release lever is on the same side as the disc brake rotor, there is the danger that it may interfere with the disc brake rotor, so check that it does not interfere.
Shimano disc brake systems are not compatible with tandem bicycles. Because tandem bicycles are heavier, the stress 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, causing the brakes to fail.
If uid leaks occur, immediately stop using the brakes and carry out the appropriate repairs. If you continue riding the bicycle while uid is leaking, there is the danger that the brakes may suddenly stop working.
79
BRAKE TO ENSURE SAFETY
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 disc brake rotor, which could cause the wheel to lock and the bicycle could fall forward causing serious injuries.
20 mm or less
Be careful not to allow any oil or grease to get onto the disc brake rotor and brake pads. Otherwise the brakes may not work correctly.
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 brakes
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 re-installing, 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. Otherwise, the brakes may not work correctly.
80
BRAKE TO ENSURE SAFETY
For cantilever brakes
Brake handling may vary slightly by model. Therefore, be sure to learn the proper braking technique (including brake lever pressure and bicycle control characteristics) and operation of your bicycle. Improper use of your bicycles brake system may result in loss of control or an accident, which could also lead to severe injury. For proper operation, consult a professional bicycle dealer or the bicycle's owner's manual. It is also important to practice riding and braking, etc.
For the unit link type of cantilever brake, the brake performance that the brake was designed to produce can be obtained if the mark in the center of the cable carrier is directly in line with the link wire. However, if the cable is bent with excessive force, it will hinder the smooth transmission of braking force, or it might make the cable rub against the frame or cause sharp bends in the cable, which will in turn cause the cable to break easily. In addition, if the unit link is forcibly set to the condition shown in the illustration, sufficient braking force will not be obtained and excessive force will be applied at points [A] and [B], which will also cause the cable to break easily.
[B]
[A]
Link wire
Unit link is curved
Accordingly, always make sure that the mark in the center of the cable carrier is directly in line with the link wire as shown in the illustration when the brake cable is being installed.
Link wire
Mark
Mark and link wire should be directly in line
CAUTION
For Hydraulic Disc Brake
Resin pads are designed to reduce the amount of noise generated between the pads and the disc brake rotor when the brakes are operated. A longer run-in period is required than for metal pads.
Handling the mineral oil
Use safety glasses when handling, and avoid contact with eyes. Contact with eyes may result in irritation. In the event of eye contact, ush with fresh water and seek medical assistance immediately.
Use gloves when handling. Contact with skin may cause a rash and discomfort. In the event of contact with skin, 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, let near 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 caution when preparing the 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.
81
BRAKE TO ENSURE SAFETY
For V-BRAKE brakes
The power modulator is a device that makes it easier to control braking by increasing the brake lever's cable stroke within a certain range of braking force. If the effective operating range of the power modulator is exceeded, the lever stroke and the brake will operate as V-BRAKE (responsive 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 Br
ak in
g fo
rc e
at w
he el
w/o power modulator
w/ power modulator
Effective operating range of the power modulator
(kg)
Cable stroke at brake lever
NOTICE
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 at-shaped 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 at-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 overow from the reservoir tank at this time.)
Use isopropyl alcohol, soapy water or a dry cloth when cleaning and carrying out 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 disc brake rotor and caliper may touch.
For V-BRAKE brakes
The Multi-Condition Brake System can reach maximum efficiency if the brakes and brake levers are used in the recommended combinations.
If the brake shoes have worn down to where the grooves are no longer visible, they should be replaced.
82
BRAKE DISC BRAKE
Wheel spoke lacing
DISC BRAKE
Wheel spoke lacing
Rotating direction of wheel
(w) (x) (y) (z)
Check that the spokes have been laced as shown in the illustration.
(w) Front left
(x) Rear left
(y) Rear right
(z) Front right
NOTICE
A radial assembly cannot be used.
Installation of the disc brake rotor
Center lock type
For quick release type
(A) (B)
(A) Disc brake rotor fixing lock ring
(B) Lock ring tightening tool
Tightening torque
40 - 50 Nm
Internally serrated type Externally serrated
type
Internally and externally serrated
type
Disc brake rotor fixing lock ring
Lock ring tightening tool
TL-LR15
Adjustable wrench TL-FC36
TL-FC36/TL-LR11
Adjustable wrench
83
BRAKE DISC BRAKE
Installation of the disc brake rotor
For nut type
(A) (B)
(A) Disc brake rotor fixing lock ring
(B) TL-LR10
Tightening torque:
40 - 50 Nm
84
BRAKE DISC BRAKE
Installation of the disc brake rotor
5 bolt type (with lock washers)
1
(A)
(B)
Attach the disc brake rotor and the disc brake rotor lock washers to the hub, and then tighten them on with bolts.
(A) Lock washer
(B) Disc brake rotor fixing bolt
Tightening torque
2 - 4 Nm
NOTICE
Fit the lock washers so that the marking "TOP" is visible.
Ensure that the hooked parts of the lock washer are securely caught on the notches in the disc brake rotor and then tighten on the lock washer with the disc brake rotor fixing bolt. If tightened while the hooked parts are against the surface of the disc brake rotor, the washer and its hooked parts will become deformed.
Hooked part of washer
Notch in disc brake rotor
The lock washers are not reusable. Always use new lock washers when installing/re-installing the disc brake rotor.
Use the dedicated disc brake rotor fixing bolts.
2
Wear gloves and turn the disc brake rotor clockwise with some force.
At this time, tighten on the disc brake rotor fixing bolts in the order indicated in the illustration.
85
BRAKE DISC BRAKE
Installation of the disc brake rotor
6 bolt type
1
(A) (B) (C) (D)
Install the disc brake rotor and the disc brake rotor tightening plate to the hub, and then install and tighten the bolts.
(A) Hub
(B) Tightening plate
(C) Disc brake rotor
(D) Disc brake rotor fixing bolt
Tightening torque
2 - 4 Nm
2
Wear gloves and turn the disc brake rotor clockwise with some force.
While doing this, tighten the disc brake rotor fixing bolts in the order shown in the illustration.
3
(A) Use a slotted screwdriver or similar tool to bend the edges of the tightening plate over the heads of the bolts.
(A) Tightening plate
86
BRAKE DISC BRAKE
Installation of the disc brake rotor
6 bolt type (with lock washers)
1
(A) (B)
Install the disc brake rotor and disc brake rotor lock washers to the hub and tighten the bolts.
(A) Lock washer
(B) Disc brake rotor fixing bolt
Tightening torque
2 - 4 Nm
NOTICE
Fit the lock washers so that the marking "TOP" is visible.
The lock washers are not reusable. Always use new lock washers when installing/ re-installing the disc brake rotor.
Use the dedicated disc brake rotor fixing bolts.
2
Wear gloves and turn the disc brake rotor clockwise with some force.
While doing this, tighten the disc brake rotor fixing bolts in the order shown in the illustration.
87
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake lever
INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake lever
NOTICE
When installing components to a carbon frame/handlebar, check the tightening torque recommended by the carbon frame or component manufacturer to avoid carbon material damage due to excessive tightening or insufficient component holding force resulting from insufficient tightening torque.
(A)
Secure the brake lever as shown in the illustration.
(A) 4 mm hexagon wrench/ 5 mm hexagon wrench
Tightening torque
6 - 8 Nm
BL-M987/BL-M9000/BL-M9020
Tightening torque
4 - 6 Nm
BL-MT200/BL-MT201/BL-MT401/BL-MT402-3A
Tightening torque
4 - 6 Nm
NOTICE
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.
88
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake lever
For open clamp band type
(A)
(B) (z)
[1]
[2]
Use a 2 mm hexagon wrench to open the clamp band of the brake lever as shown in the illustration.
(z) Push
(A) Clamp band
(B) 2 mm hexagon wrench
NOTICE
For models with the clamp band lock release hole on the outer side of the bracket body
When installing the brake lever, be sure to use a spacer.
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 dealers manual.
[1]
[2]
Lock release hole
Spacer
4 mm hexagon wrench/ 5 mm hexagon wrench
89 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose
Installation of the brake hose
1
90
(A)
Use a utility knife or similar tool to cut the hose.
(A) Utility knife
NOTICE
Use the utility knife safely and correctly in accordance with its instruction manual.
If you are using TL-BH62, refer to the manual accompanying the product.
2
(z)
(E)
(w)
(y)
(A)
(C)
(x)
(D)
(B) (C) Pass the brake hose through the connecting bolt and the olive as shown in the illustration.
(w) Direction of insertion
(x) Cut end
(y) Grease the outside of the olive.
(z) Attach the cover to the connecting bolt for the brake lever.
(A) Hose
(B) Connecting bolt
(C) Olive
(D) Premium grease
(E) Cover
90 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose
3
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.
(y) Mark
(z) Length
TECH TIPS
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 (y) (y)
(z)
At caliper end (y) (y)
(z)
Model No. Length Type
SM-BH90-SB 11 mm Banjo type SM-BH90-SS 11 mm* Straight type
SM-BH59-JK-SS 11 mm* Straight type SM-BH80 14 mm Banjo type
* 14 mm for BL-T675/T615/M445/T445.
Model No. Length Type
SM-BH90-SS 11 mm* Banjo type SM-BH59-JK-SS 11 mm* Straight type
* 14 mm for BR-T675/T615/M446.
4 (z)
(B)
(D)
(E)
(C)
(A)
(A)(B)
Use an object such as a needle to smooth the inside of the cut end of the 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 uid leaks may occur.
(z) SM-BH90: 1 mm SM-BH59/BH80 (YM-BH81): 4 mm
(A) Connector insert
(B) Hose
(C) Olive
(D) TL-BH61
(E) Vise
NOTICE
If there is a marking as shown in the illustration, refer to the section Replacing the brake hose (easy hose joint system).
Mark
91
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose
5
(z)
(A) (B) (C)
After checking that the olive is positioned as shown in the illustration, apply premium grease to the threads of the connecting bolts and attach the hose to the brake lever as shown in the illustration.
(z) SM-BH90: 2 mm SM-BH59/BH80 (YM-BH81): 5 mm
(A) Hose
(B) Olive
(C) Connector insert
Model No. Length Color
SM-BH90 11.2 mm Silver
SM-BH59/80 13.2 mm Gold
YM-BH81 13.2 mm Silver
6
Left lever
Right lever
Make sure that the brake hose is not twisted.
Make sure that the calipers and levers are in the positions shown in the illustrations.
7
(A)
(B)
While pushing the brake hose, tighten the connecting bolt.
(A) 8 mm spanner
(B) Connecting bolt
Tightening torque
5 - 7 Nm
92
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose
At caliper end (Banjo type)
(B)
(A)
(C)(D)
After checking that both O-rings are fitted in the top groove and bottom groove of the banjo, secure the banjo to the caliper as shown in the illustration.
At this point, check that the O-rings are in the grooves.
The O-rings are greased.
(A) Banjo
(B) Hose
(C) O-ring
(D) 3 mm hexagon wrench/ 4 mm hexagon wrench
For 3 mm hexagon wrench
Tightening torque
5 - 7 Nm
For 4 mm hexagon wrench
Tightening torque
8 - 10 Nm
At caliper end (Straight type)
(A)
(C)(B)
(A) Olive
(B) Connecting bolt
(C) Caliper
Tightening torque
5 - 7 Nm
93 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
Installation of the brake hose (easy hose joint system)
Overview of the easy hose joint system (For MTB)
(B)
(A)
(E)
(C) (D)
(A) Brake caliper
(B) Hose cap
(C) Brake hose connection port
(D) Lever stopper
(E) Brake lever
1 Route the brake hose into the final installation position. NOTICE
Do not remove the hose caps from the ends of the brake hoses.
2
Check the appropriate length of the brake hose.
Secure the brake lever in the position used when riding.
If the hose needs to be shortened, refer to "Cutting the hose" in "Installation of the brake hose" and cut the hose.
(A) Connecting bolt
NOTICE
If the hose length is insufficient, replace with a hose that has an appropriate length.
TECH TIPS
When checking the appropriate length of the brake hose, the end of the brake lever's connecting bolt should be the standard.
Connecting bolt
(A)
3 Remove the hose cap.
If the brake hose was cut, it is not necessary to remove the hose cap.
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BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
4
Secure the brake lever in a vise or another similar device.
Face the hose connection port upward when securing the brake lever.
5
(A) Remove the seal plug.
Cover the seal plug with a waste cloth as the oil applied to the seal plug may leak.
(A) Seal plug
6 (A) Pass the brake hose through the hose
cover. (A) Hose cover
7
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.
TECH TIPS
Use a waste cloth when inserting the brake hose as some oil inside may leak.
95
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
8 (A)
Tighten the connecting bolt with an 8 mm spanner while pushing the brake hose.
(A) 8 mm spanner
Tightening torque
5 - 7 Nm
9
Clean any oil residue and attach the hose cover.
10
(A) Remove the brake lever stopper. (A) Lever stopper
NOTICE
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.
TECH TIPS
Move and pull on the lever stopper to remove it while being careful not to depress the lever.
96 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
Overview of the easy hose joint system (For ROAD)
(B)(A)
(C)
(E)(D)
(A) Dual control lever
(B) Joint sleeve
(C) Lever stopper
(D) Hose cap
(E) Brake caliper
1 Route the brake hose into the final installation position. NOTICE
Do not remove the hose caps from the ends of the brake hoses.
2
Check the appropriate length of the brake hose.
Secure the dual control lever in the position used when riding.
If the hose needs to be shortened, refer to "Cutting the hose" in "Installation of the brake hose" and cut the hose.
NOTICE
If the hose length is insufficient, replace with a hose that has an appropriate length.
TECH TIPS
When checking the appropriate length of the brake hose, the end of the dual control lever's connecting bolt should be the standard.
Connecting bolt
3 Remove the hose cap.
If the brake hose was cut, it is not necessary to remove the hose cap.
4
Secure the joint component in a vise or another similar device.
Face the hose connection port upward as shown in the illustration.
97
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
5
Remove the seal plug.
Cover the seal plug with a waste cloth as the oil applied to the seal plug may leak.
6 (A) Pass the brake hose on the brake caliper
side through the hose cover. (A) Hose cover
7
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.
TECH TIPS
Use a waste cloth when inserting the brake hose as some oil inside may leak.
8 (B)
(A)
Tighten the connecting bolt with two 8 mm spanners while pushing the brake hose.
(A) Connecting bolt
(B) 8 mm spanner
Tightening torque
5 - 7 Nm
9 (A) Clean any oil residue and attach the hose
cover. (A) Hose cover
98 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
Cutting the hose
Use care when cutting the hose, as oil may leak when the hose is cut.
1
(A)
(B)
(B)
(A)
For ROAD
For MTB Determine the appropriate length and add a check mark on the brake hose. Add the mark so it is aligned with the edge of the connecting bolt.
(A) Check mark
(B) Connecting bolt
2
(C)
(A) (B)
Add a cut mark.
Mark the hose at a position 18 mm from the check mark on the end side of the hose if it is a MTB and 21 mm if it is a ROAD.
(A) Cut mark
(B) Check mark
(C) MTB: 18 mm ROAD: 21 mm
99 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
3
Prepare the Shimano original tool TL-BH62 for cutting the brake hose as follows.
Disassemble the Shimano original tool TL-BH62 as shown in the illustrations.
(A) Body of tool
(B) Hose cutter
(C) Press block
NOTICE
Do not move the lever indicated in the illustration before disassembling the Shimano original tool TL-BH62.
Make sure to also read the instruction manual for the Shimano original tool TL-BH62.
TECH TIPS
[1] [2]
[3] [4]
(C)
(A) (B)
100 To be continued on next page
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
4
Insert the brake hose into the tool as shown in the illustration.
Next, check that the cut mark is level with the groove on the tool, and then secure the brake hose in place.
(A) Cut mark
(B) Groove
NOTICE
When inserting the brake hose into the tool, align the mark for cutting with the groove in the tool.
(A) (B)
[1] [2]
5
Check that the hose is secure and then attach the hose cutter.
Press the hose cutter as shown in illustration [2] to cut the brake hose.
(A) Hose cutter
[1] [2]
(A)
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BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
6
Detach the hose cutter and check that the cut end is horizontal.
90 90
7
Prepare the connector insert for insertion into the brake hose as follows.
Attach the connector insert to the press block and then set the press block in the tool.
Make sure that the tip of the connector insert is correctly positioned inside the opening of the brake hose.
(A) Press block
(A) Connector insert
[1] [2]
(A)
(B)
102
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Installation of the brake hose (easy hose joint system)
8
Grip the lever on the tool to insert the connector insert into the brake hose, as shown in the illustrations.
Check that the connector insert has been inserted correctly, and then remove the brake hose from the tool.
[1] [2]
103
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Replacing the brake hose (easy hose joint system)
Replacing the brake hose (easy hose joint system)
For MTB BH59
Check the shape of the connector insert. Incorrect combinations may cause oil leakage.
(z) (z) SHIMANO CODE No.: Y8H298040 There is a groove in the head shaped part.
NOTICE
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.
104
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Replacing the brake hose (easy hose joint system)
For ROAD
Check the shape of the connector insert. Incorrect combinations may cause oil leakage.
When connecting to the joint sleeve
NOTICE
When reconnecting the brake hose to the joint sleeve, make sure to use the designated connector insert supplied with SM-BH59-SB.
(z)(A) (z) SHIMANO CODE No.: Y8H298040 There is a groove in the head shaped part.
(A) Joint sleeve
NOTICE
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.
When connecting on the lever side
(y)
(z)
(A) (y) SHIMANO CODE No.: Y8H298040 There is a groove in the head shaped part.
(z) For a connector insert of this shape, only ST-R785 can be used.
(A) Brake hose connection port
105
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Replacing the brake hose (easy hose joint system)
Installation of the calipers and securing the hose
1
Remove the spacer for bleeding (yellow), and then set the wheel which has the disc brake rotor onto the frame.
(A) Bleed spacer
(A)
2
(A)
(B)
For split pin
(C)
Install the brake pads. (A) Brake pad
(B) Snap ring
(C) Split pin
Tightening torque
2 - 4 Nm
TECH TIPS
Install the pad fixing spring as shown in the illustration. (There are left (L) and right (R) marks on the spring.)
Pad fixing spring
The pads with fins have fins at the front and back, so install them as shown in the illustration.
Pad with fins
106
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Replacing the brake hose (easy hose joint system)
International standard mounting type
NOTICE
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. TECH TIPS
The calipers should be able to move sideways.
2
Front
(E)
(B)
(C)(A)
(D)
Rear
(A)
(E)
Depress the brake lever so that the disc brake rotor is being clamped by the pads, and then tighten the caliper fixing bolts.
(A) Adapter fixing bolt
(B) Adapter
(C) Caliper
(D) Disc brake rotor
(E) Caliper fixing bolt
Tightening torque
6 - 8 Nm
107
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Preventing loosening of frame fixing bolts
Post mounting type
1 Provisionally install the caliper to the frame (so that the caliper can move sideways).
2
Front
(A)
Depress the brake lever so that the disc brake rotor is being clamped by the pads, and then tighten the caliper fixing bolts.
(A) Caliper fixing bolt
Tightening torque
6 - 8 Nm
Preventing loosening of frame fixing bolts 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
(A)
Post type
(A)
(A)
(A) Cap
108
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Preventing loosening of frame fixing bolts
Wiring method
Front Rear
(A) (A)
(A) Wire
(A)
(B)
(z)
Post type
(B)
Secure the two bolts with a wire as shown in the illustration in order to prevent the bolts from coming loose.
(z) Wind a wire around the fixing bolt between the adapter and the frame as shown in the illustration.
(A) Bolt
(B) Wire
TECH TIPS
If bolt [1] loosens (turns counterclockwise), 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 that turns it in the tightening direction. In other words, this system prevents the bolts from loosening.
Bolt [1]
Bolt [2]
109
BRAKE INSTALLATION (HYDRAULIC DISC BRAKES)
Preventing loosening of frame fixing bolts
Securing the cable
1
C-shaped guide
Usual type of cable stopper
[1]
[2]
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.
Tightening torque
0.3 - 0.5 Nm
2 Operate the brake lever several times and check whether the brakes operate normally or not.
Also check that there are no oil leaks.
110 To be continued on next page
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Brake pad replacement
MAINTENANCE (HYDRAULIC DISC BRAKES)
Brake pad replacement
NOTICE
This brake system is designed to automatically adjust the clearance between the disc brake rotor and the brake pads by the piston gradually protruding according to the wear of the brake pads; therefore, when you replace the brake pads, you need to push back the piston.
TECH TIPS
If oil adheres to the brake pads, 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 disc brake rotor, replace the brake pads.
1
(A)
(B)
For split pin
(C)
Remove the wheel from the frame, and remove the brake pads as shown in the illustration.
(A) Brake pad
(B) Snap ring
(C) Split pin
2 Clean the pistons and surrounding area.
111 To be continued on next page
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Brake pad replacement
3 (A)
Use a at-shaped tool to push the pistons straight back in as far as they will go, while being careful not to twist the pistons.
(A) Piston
NOTICE
Do not push the pistons with a sharp tool. The pistons may be damaged.
4
(A)
(C)
(B)
(D)
Install the new brake pads, the bolt, and the pad spacer (red).
At this point, make sure to install the snap ring as well.
(A) Brake pad
(B) Snap ring
(C) Bolt
(D) Pad spacer (red)
Tightening torque
2 - 4 Nm
TECH TIPS
Install the pad fixing spring as shown in the illustration. (There are left (L) and right (R) marks on the spring.)
Pad fixing spring
112
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Brake pad replacement
For split pin types
4
(B)
(C)
(A)
Install the new brake pads the split pin, and then install the pad spacers (red).
After this, bend open the split pin.
(A) Brake pad
(B) Split pin
(C) Pad spacer (red)
5 Depress the brake lever several times to check that the operation becomes stiff.
6 Remove the pad spacer, install the wheel, and then check that there is no interference between the disc brake rotor and caliper.
If they are touching, adjust while referring to Installation of the calipers and securing the hose.
113
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Adjustment when the pistons are not operating correctly
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 disc brake rotor, adjust the pistons by the following procedure.
1 Remove the wheel and brake pads.
Clean the pistons and surrounding area.
2 Use a at-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 be damaged.
3 Install the brake pads and the pad spacer (red).
4 Depress the brake lever as far as it will go, and then operate it several more times so that the two pistons move to their initial positions.
5 Remove the pad spacer, install the wheel, and then check that there is no interference between the disc brake rotor and brake pads.
If they are touching, loosen the mounting bolts and adjust so that they are no longer touching.
114
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Lever stroke adjustment
Lever stroke adjustment
Tighten the adjust bolt (clockwise) to increase the stroke, and loosen it (counterclockwise) to decrease the stroke.
(A) Reach adjustment bolt
(A) (A)
(A)
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.
(y) Contact
(z) Pad contact point
(A) Disc brake rotor
(B) Pad
(C) Free stroke adjustment screw
(D) Screwdriver
(z)
(C) (y)
(B)
(A)
(D)
115
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Installation of the magnet holder
Installation of the magnet holder If the magnet holder included with the disc brake rotor is separated, re-install it.
Insert the magnet holder's claw into the disc brake rotor and install it. Align the cylinder part of the magnet holder with the one recessed area of the disc brake rotor and then install the magnet holder.
WARNING
The calipers and disc brake rotor will become hot when the brakes are operated; do not touch them while riding or immediately after dismounting from the bicycle. Otherwise, you may get burned. Check that the calipers and disc brake rotor have cooled down sufficiently before attempting to re-install the magnet holder.
(A) Disc brake rotor
(B) Magnet holder
(C) Claw
(D) Cylinder part
(E) Recessed area
(A)
(B)
(C) (D)(E)
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 to drain out the oil. The brake lever can be operated at this time to help the oil drain out. After draining the uid, pour in fresh brake uid while referring to the "Adding mineral oil and bleeding air" section. Use only Shimano genuine mineral oil. Dispose of the waste oil according to proper country and/or state disposal regulations.
116 To be continued on next page
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Adding mineral oil and bleeding air
Adding mineral oil and bleeding air
(B)
(A)
With the spacer for bleeding (yellow) still attached to the calipers, place the bicycle into a bicycle stand, or the like, as shown in the illustration.
(A) Hose
(B) Caliper
NOTICE
When bleeding the air out of the caliper, you will need the SM-DISC (oil funnel and oil stopper).
1
45
Set the brake lever so that it is in riding position at 45 angle from the ground.
2
Remove the upper bleed screw and O-ring and insert the oil funnel. (A) Bleed screw
(B) O-ring
(C) Oil funnel
TECH TIPS
Do not insert the oil stopper at this time.
(C)
(B)
(A)
117 To be continued on next page
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Adding mineral oil and bleeding air
3
(A)
(B)
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 piston 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 in the oil that is coming out.
(A) Bleed nipple
(B) 7 mm socket wrench
4
Once there are no more air bubbles mixed in with the oil, temporarily close the bleed nipple. NOTICE
Secure the brake caliper in a vise to prevent the tube from being accidentally disconnected. Do not depress and release the lever repeatedly.
Oil without air bubbles may come out as a result of such operation, but air bubbles may remain in the oil inside the brake caliper, and it will take longer to bleed the air. (If you have depressed and released the lever repeatedly, drain out all of the oil and then add oil again.)
118 To be continued on next page
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Adding mineral oil and bleeding air
5
(B)
(A)
(z)
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 bleed nipple and loosen the bleed nipple.
After a little while, the oil and air bubbles will ow naturally from the bleed nipple into the tube.
This way it will be possible to easily extract the greater part of the air bubbles remaining inside the brake system.
(z) Air bubbles
(A) 7 mm socket wrench
(B) Bag
TECH TIPS
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.
6
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).
7
(A) (B) Once no more air bubbles come from the bleed nipple, temporarily close the bleed nipple.
(A) Bleed nipple
(B) 7 mm socket wrench
119 To be continued on next page
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Adding mineral oil and bleeding air
8 (A)
With the brake lever depressed, open and close the bleed nipple in rapid 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.
(A) 7 mm socket wrench
Tightening torque
4 - 6 Nm
9
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.
It is normal for the lever to be stiff at this point.
(x) Loose
(y) Slightly stiff
(z) Stiff
NOTICE
If the lever does not become stiff, repeat the procedures from step 5.
Lever operation
(x) (y)
(z)
120
BRAKE MAINTENANCE (HYDRAULIC DISC BRAKES)
Adding mineral oil and bleeding air
10
[1]
[2]
30
30
Set the lever unit to the horizontal position as shown in the illustration and tilt it in the direction of [1] by 30, and then carry out step 9 to check that there is no air remaining.
Next, tilt the lever unit 30 in the direction of [2], and carry out step 9 again to check that there is no air remaining.
If any air bubbles appear, repeat the above procedure until they stop appearing.
11 (B)
(A) Plug the oil funnel with the oil stopper so that the side with the O-ring attached is facing downward.
(A) Oil stopper
(B) O-ring
12 (A)
Remove the oil funnel while it is still being plugged with the oil stopper, and then attach the O-ring to the bleed screw and tighten it until oil ows out to make sure that there are no air bubbles remaining inside the reservoir tank.
(A) O-ring
Tightening torque
0.3 - 0.5 Nm
NOTICE
Do not operate the brake lever. If operated, there is a risk of air bubbles entering the cylinder.
13
Wipe away any oil that has overowed.
121
BRAKE INSTALLATION (V-BRAKE BRAKES)
Installation of the brake lever
INSTALLATION (V-BRAKE BRAKES)
Installation of the brake lever
Use a handlebar grip with a maximum outer diameter of 32 mm. (A) 4 mm hexagon wrench/ 5 mm hexagon wrench
Tightening torque
6 - 8 Nm
NOTICE
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.
(A)
(A)
Installing the power modulator
(B)
(A)
Install the power modulator to the V-BRAKE brake as shown in the illustration.
(A) Power modulator
(B) V-BRAKE brake
NOTICE
When the brakes are applied, the power modulator will move about 8 mm toward the inner cable lead; make sure that there is enough excess length in the outer casing for that.
When brakes are applied
Approx. 8 mm
Outer casing
SM-PM70/ SM-PM40
Inner cable lead
122 To be continued on next page
BRAKE INSTALLATION (V-BRAKE BRAKES)
Installation of V-BRAKE brakes
Installation of V-BRAKE brakes
1
(B) (C)
(A)
(D)
Insert the stopper pin of the brake caliper into the center spring hole in the frame mounting boss, and then secure the brake caliper to the frame with the link fixing bolt.
(A) 5 mm hexagon wrench
(B) Spring hole
(C) Stopper pin
(D) Link fixing bolt
Tightening torque
5 - 7 Nm
2
While pressing the shoe against the rim, adjust the amount of shoe protrusion by interchanging the washer B (thick or thin) so that dimension [A] is at 32 mm or more.
(z) 32 mm or more
(A) Washer B (thick)
(B) Shoe fixing link
(C) Washer B (thin)
(D) Shoe fixing nut
(E) Washer A
(F) Washer
FO R W A R D
R FO
R W A R D
R
(F)(E)
(z) [A]
(A) (B) (C) (D)
123 To be continued on next page
BRAKE INSTALLATION (V-BRAKE BRAKES)
Installation of V-BRAKE brakes
3
(z)
(A) While holding the shoe against the rim, tighten the shoe fixing nut.
(z) 1 mm
(A) 5 mm hexagon wrench
Tightening torque
6 - 8 Nm
4
Pass the inner cable through the inner cable lead, and after making sure the combined clearance between the left and right shoes and the rim is a total of 2 mm, tighten the cable fixing bolt.
(z) [B] + [C] = 2 mm
(A) Inner cable lead
(B) 5 mm hexagon wrench
Tightening torque
6 - 8 Nm (A) (B)
(z)
[B] [C]
(A) (B)
(z)
[B] [C]
124
BRAKE INSTALLATION (V-BRAKE BRAKES)
Installation of V-BRAKE brakes
5
Adjust the balance with the spring adjustment bolts. (z) 1 mm
(A) Spring adjustment bolt
(z)
(A)(A)
6 (z)
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.
(z) Depress about 10 times
125
BRAKE MAINTENANCE (V-BRAKE BRAKES)
Replacement of the cartridge shoe
MAINTENANCE (V-BRAKE BRAKES)
Replacement of the cartridge shoe
1
(A) (B) Remove the shoe fixing pin, and then slide the shoe along the groove to remove it from the shoe holder.
(A) Shoe fixing pin
(B) Shoe
2
There are two different types of shoes and shoe holders for 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.
Insert the shoe fixing pins.
(y) Shoe insertion direction
(z) Front
(A) Shoe
(B) Shoe holder
(C) Shoe fixing pin
NOTICE
It is very critical to insert the shoe fixing pin to keep the shoe properly fixed in place.
For left (same for front and rear)
L
FO R W A R D
FO R W A R D
L (y)
(z)
(C)
(B)
(A)
For right (same for front and rear)
R
FO R W A R D
FO R W A R D
R
(A)
(y)
(C)
(B)
(z)
126
BRAKE BRAKE LEVER WITH SWITCH INTERCHANGEABILITY (V-BRAKE AND HUB ROLLER BRAKES)
For V-BRAKE (with power modulator) mode
BRAKE LEVER WITH SWITCH INTERCHANGEABILITY
(V-BRAKE AND HUB ROLLER BRAKES)
Four finger brake levers are equipped with a switch to change between the V-BRAKE with modulator mode and the caliper or roller brake modes.
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
(y)
(z)
(A)(x)
(x)
(x) V-position
(y) V-BRAKE brakes with power modulator
(z) Roller brake/Caliper brakes
(A) Power modulator
For Caliper brake/Roller brake
(y)
(z)
(x)
(x)
(x) Caliper/Roller (CR) brake position
(y) V-BRAKE brakes
(z) Roller brake/Caliper brakes
127 To be continued on next page
BRAKE INSTALLATION (DUAL PIVOT CALIPER BRAKES)
For Caliper brake/Roller brake
INSTALLATION (DUAL PIVOT CALIPER BRAKES)
1
(A)
(z)
For nut type
(B)
Install the brake caliper.
Compress the arch and set while the shoe is in firm contact with the rim.
(z) The usual position during installation is when the head of the centering adjustment bolt is as shown in the illustration.
(A) 5 mm hexagon wrench
(B) 10 mm spanner
Tightening torque
8 - 10 Nm
NOTICE
If the brake arm touches the frame when the handlebar is turned, attach the included frame protection sticker to the frame.
128 To be continued on next page
BRAKE INSTALLATION (DUAL PIVOT CALIPER BRAKES)
For Caliper brake/Roller brake
2
(x)
(x)
(y)
(z)
(B)
(A)
Adjust the brake shoe position and then secure in place the brake shoe.
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.
(x) Direction of rim rotation
(y) Toe-in 0.5 mm
(z) 1 mm or more
(A) Shoe fixing bolt
(B) 4 mm hexagon wrench
Tightening torque
5 - 7 Nm
3 (x)
(y)
(A)
(C)
(B)
(z)
Move the quick release lever to the closed position and adjust shoe clearance as shown in the illustration.
(x) Open
(y) Close
(z) 1.5 2 mm (Adjust so that the shoe clearances on the left and right are the same)
(A) Centering adjustment bolt
(B) 3 mm hexagon wrench
(C) Quick release lever
4 (A)
Secure the brake cable. (A) 5 mm hexagon wrench
Tightening torque
6 - 8 Nm
129
BRAKE INSTALLATION (DUAL PIVOT CALIPER BRAKES)
For Caliper brake/Roller brake
5 (z)
(A) (B)
Fine adjust the centering of the brake shoe using the centering adjustment bolt.
(z) 1.5 2 mm (Adjust so that the shoe clearances on the left and right are the same)
(A) Centering adjustment bolt
(B) 3 mm hexagon wrench
6
(A)
(z)
Readjust shoe clearance.
Turn the cable adjustment nut to readjust shoe clearance.
(z) 1.5 2 mm (Adjust so that the shoe clearances on the left and right are the same)
(A) Cable adjustment nut
7 (z)
Check the brakes.
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.
(z) Depress about 10 times
TECH TIPS
For models with a CLOSE position mark on the quick release lever and brake caliper side, align the marks. At this time, check for a click.
CLOSE position mark
130
BRAKE INSTALLATION (DUAL PIVOT CALIPER BRAKES)
Arch spring tension adjustment
Arch spring tension adjustment
(y)
(z)
(B)
(A)
The spring adjustment bolt can be used to adjust the spring tension of the arch.
(y) Reduce spring force
(z) Increase spring force
(A) Spring adjustment bolt
(B) 2 mm hexagon wrench
131
BRAKE MAINTENANCE (DUAL PIVOT CALIPER BRAKES)
Replacement of the cartridge shoe
MAINTENANCE (DUAL PIVOT CALIPER BRAKES)
Replacement of the cartridge shoe
1 (B) (A)
Remove the mounting bolt. (A) 2 mm hexagon wrench
(B) Mounting bolt
2 (A) Remove the shoe by sliding it along the
groove of the shoe holder. (A) Shoe
3
There are two different types of shoes and shoe holders for 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.
Tighten the mounting bolt.
(y) Shoe insertion direction
(z) Front
(A) Shoe
(B) Shoe holder
(C) Mounting bolt
Tightening torque
1 - 1.5 Nm
For left (same for front and rear)
FO RW
A RD
L
(z)
(B)
(C)
(A)
(y)
For right (same for front and rear)
R FO
RW A RD
(A)
(y)
(B)
(C)
(z)
132
BRAKE SPECIFICATIONS (CANTILEVER BRAKES)
Cantilever brakes
SPECIFICATIONS (CANTILEVER BRAKES)
In order to realize the best performance, we recommend that the following combination be used.
Series CT90
Brake lever ST-CT90/ST-CT95 SB-CT90/SB-CT91
Cantilever brakes BR-CT91
Cable
Cantilever brakes
Model No. BR-CT91
Arch size M L
Link type Unit link (alignment type)
Link wire length
A/73 A/73
B/82 B/82
- C/106
- D/93
Brake lever
Model No. ST-CT90/ST-CT95/SB-CT90/SB-CT91
Clamp diameter 22.2 mm TECH TIPS
If the link length is the same, any link wire can be used even if the type is different.
If you have any questions about the use and maintenance of the product, consult the place of purchase.
133
BRAKE INSTALLATION (CANTILEVER BRAKES)
Installation of the brake lever
INSTALLATION (CANTILEVER BRAKES)
Installation of the brake lever
TECH TIPS
Use a handlebar grip with an outer diameter of 32 mm or less.
1
Install the brake lever. (A) 5 mm hexagon wrench
Tightening torque
6 - 8 Nm
ST-CT90/ST-CT95
(A)
SB-CT90/SB-CT91
(A)
2 Connect the brake cable.
3
Adjust the lever stroke. (only for ST-CT95)
134 To be continued on next page
BRAKE INSTALLATION (CANTILEVER BRAKES)
Installation of the brake caliper
Installation of the brake caliper
1
(A) Install the brake caliper to the frame. (A) 5 mm hexagon wrench
Tightening torque
5 - 7 Nm
2 [1]
[2] Set the cable onto the cable carrier.
3 (A)(z)
3 Temporarily tighten the cable so that the cable carrier is at the position in the illustration.
(z) Touching
(A) 5 mm hexagon wrench
Temporary tightening torque
0.5 - 1 Nm
4 (A)
Turn the spring adjustment bolt so that the cable carrier comes to a position directly below the outer casing holder.
(A) Screwdriver
135 To be continued on next page
BRAKE INSTALLATION (CANTILEVER BRAKES)
Installation of the brake caliper
5 (z)
(A)
(B)
Secure one of the shoes at a time.
Adjustment of shoe clearance is not necessary at this time.
(z) 1 mm
(A) 10 mm spanner
(B) 5 mm hexagon wrench
Tightening torque
8 - 9 Nm
NOTICE
When installing the shoes, make sure that they are facing the right way and are not back to front.
Viewed from the side of the bicycle after installation of the shoes is completed
6
(A)
(z)
(B)
Loosen the cable fixing bolt, move the brake caliper so that the clearance of the exible pipe is 2 3 mm, and then secure the inner cable.
(z) 2 3 mm
(A) Flexible pipe
(B) 5 mm hexagon wrench
Tightening torque
6 - 8 Nm
7
(C) (z)(y) (A)
(B)
Adjust so that the exible pipe touches the brake caliper.
(y) 20 mm or more
(z) Touches
(A) Outer casing holder
(B) Cable carrier
(C) Flexible pipe
136
BRAKE INSTALLATION (CANTILEVER BRAKES)
Installation of the brake caliper
8
If the cable carrier is in the position in the illustration, then setting is complete.
TECH TIPS
Check to be sure that there is a clearance of 20 mm or more between the outer casing holder and the cable carrier as shown in the illustration in step 7. This is to ensure that the cable carrier does not touch the outer casing holder as if it does touch, the brakes will not work.
9 (A)
If balance adjustment is necessary, adjust with the spring adjustment bolt.
(A) Screwdriver
10 (z)
Depress the brake lever about 10 times as far as the grip and check that everything is operation correctly before using the brakes.
(z) Depress about 10 times
137
BRAKE INSTALLATION (CANTILEVER BRAKES)
Installing SM-CB70
Installing SM-CB70
[1] [2] First, push [2] in the direction of the arrow as shown in the illustration, and then install to the cable.
TECH TIPS
Recommended outer casing combination: SHIMANO SLR
If [1] and [2] are separated
[1] [2]
Make sure the [1] logo is facing the right way.
Adjustment method
[1] Turn part [1] to adjust.
FRONT CHAINWHEEL
139
FRONT CHAINWHEEL TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
Intervals between maintenance depend on the use 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 in stages rather than fully tightened at once. Use a torque wrench to check that the final tightening torques are within the range of 12 - 14 Nm. 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. This may result in damage to the axle, the bicycle falling over and serious injury.
Inspect the chain for possible deformity and abnormalities such as cracks or corrosions. If damage is detected, replace the chain immediately. 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.
Obtain and read the dealers 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. It is strongly recommended using only genuine Shimano replacement parts.
If adjustments are not carried out correctly, the chain may come off. This may cause you to fall off the bicycle which could result in serious injury.
NOTICE
If pedaling performance does not feel normal, contact your place of purchase.
Before riding the bicycle, check that there is gap 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 - 55 Nm. 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 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.
For smooth operation, use the specified outer casing and the bottom bracket cable guide.
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.
Outer casing holder
140
FRONT CHAINWHEEL TO ENSURE SAFETY
A special grease is used for the gear shifting cable. Do not use premium grease or other types of grease. These 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.
Operate the gear shifting levers only while turning the crankset.
Do not disassemble the shifting lever unit, as this may damage it or cause mis-operation.
For MTB/Trekking For frames with suspension, the chainstay angle will vary depending on whether the bicycle is being ridden or not.
When the bicycle is not being ridden and the chain is positioned on the largest chainring at the front and on the smallest sprocket at the rear, the chain may come into contact with the chain guide outer plate of the front derailleur.
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 uid 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, make sure that the brake uid does not stick to these plastic parts. The Shimano genuine 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. Otherwise the waterproofing performance will worsen.
The gears should be periodically washed with a neutral detergent. In addition, cleaning the chain with neutral detergent and lubricating it can be an effective way of extending the life of the gears and the chain.
If you feel any looseness in the bottom bracket axle, the bottom bracket should be replaced.
141
FRONT CHAINWHEEL INSTALLATION (CHAINRINGS)
For ROAD
INSTALLATION (CHAINRINGS)
Smooth shifting will not be possible if the chainrings are incorrectly installed. Therefore, be sure to install the chainrings in the correct positions.
For ROAD
Double chainwheel set
1
With the marked surface of the largest chainring facing out, set the largest chainring so that the chain drop prevention pin is lined up with the crank arm position.
(z) Outer side
(A) Crank arm
(B) Chain drop prevention pin
Tightening torque
12 - 14 Nm
(z)
(A)
(B)
2
With the marked surface of the smallest chainring facing away from the crank arm, set the chainring so that the mark is lined up with the crank arm position.
(z) Inner side
(A) Crank arm
Tightening torque
12 - 14 Nm
(z)
(A)
142
FRONT CHAINWHEEL INSTALLATION (CHAINRINGS)
For MTB/Trekking
Triple chainwheel set
(A) (z)
(z) FC-5703 (39T)
(A) Crank arm
Tightening torque
12 - 14 Nm
For MTB/Trekking
Triple chainwheel set
(A)
(A) Crank arm
Largest chainring/middle chainring
Tightening torque
14 - 16 Nm
Smallest chainring
Tightening torque
16 - 17 Nm
143
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
HOLLOWTECH II / 2 piece crankset
To be continued on next page
INSTALLATION (FRONT CHAINWHEEL)
HOLLOWTECH II / 2 piece crankset
Installation of crank
1
(A)
(D)
(B) (C)
Grease the left and right hand adapters and use the Shimano original tool to install the right hand adapter of the bottom bracket, the inner cover and the left hand adapter of the bottom bracket.
(A) TL-FC32
(B) Inner cover
(C) Right hand adapter (counterclockwise thread)
(D) Left hand adapter (clockwise thread)
Tightening torque
35 - 50 Nm
NOTICE
Tighten TL-FC24/TL-FC25 by combining with TL-FC32/TL-FC33/TL-FC36.
TL-FC24/FC25 may become damaged and unusable after repeated use.
NOTICE
For MTB/Trekking
Spacers used vary according to the width of the bottom bracket shell. For details, refer to Spacer installation method (For MTB/ Trekking).
TECH TIPS
Turn the right hand adapter clockwise when the 70 mm [M36] bottom bracket is used (clockwise thread).
144 To be continued on next page
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
HOLLOWTECH II / 2 piece crankset
2
Fully insert the right crank arm unit until it touches the bottom bracket.
3 (B)
(A) Set the wide groove area of the left crank arm into the axle of the right crank arm unit where the groove is wide.
(A) Wide groove area (left crank arm)
(B) Wide groove area (axle)
NOTICE
Insert a spacer for the triple specification of road bikes and the double guard specification of comfort bikes.
4
(A)
(B)
(C)
Use the Shimano original tool to tighten the cap.
(A) TL-FC16
(B) Cap
(C) Left crank arm
Tightening torque
0.7 - 1.5 Nm
145
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
HOLLOWTECH II / 2 piece crankset
5
(A)
(B)
(z)
(C)
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.
(z) The illustration is of the left crank arm (cross-section)
(A) Plate pin
(B) Stopper plate
(C) Left crank arm
Tightening torque
12 - 14 Nm
NOTICE
Each of the bolts should be evenly and equally tightened.
Set the stopper plate in the correct direction as shown in illustration.
146
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
HOLLOWTECH II / 2 piece crankset
Spacer installation method (For MTB/Trekking)
1
(z)
Check whether the width of the bottom bracket shell is 68 mm or 73 mm.
(z) Bottom bracket shell width
2 Install the adapter. See the illustrations for the normal type or chain case type, depending on the type of your front chainwheel.
Normal type
68 mm 73 mm
Band type
[2] [3]
[1] [1]
[1] 2.5 mm spacer
[2] 1.8 mm spacer
[3] 0.7 mm spacer
TECH TIPS
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.
Bracket type
(A)[1]
[1]
(A) [1] 2.5 mm spacer
(A) BB mount-type bracket
147
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
HOLLOWTECH II / 2 piece crankset
Chain case specifications
68 mm 73 mm
Band type
[1]
[2] [3]
[1]
[1] 2.5 mm spacer
[2] 1.8 mm spacer * 1.8 mm corresponds to the
thickness of the chain case.
[3] 0.7 mm spacer
TECH TIPS
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.
Bracket type
[1]
(A)[1] (A) [1] 2.5 mm spacer
(A) BB mount-type bracket
Chain case stay type
(A)
[1]
[2] (A) [2] [1] 2.5 mm spacer
[2] 0.7 mm spacer
(A) Chain case stay
148
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
OCTALINK TYPE
OCTALINK TYPE
Installation of the bottom bracket
(A) (B)
Apply grease to the main body, and install using the Shimano original tool.
First install the main body, then the adapter.
(A) Adapter
(B) Body
Tightening torque
50 - 70 Nm
NOTICE
If the adapter is made of aluminum or steel
Apply grease to the adapter.
If the adapter is made of plastic
Do not apply grease to the adapter.
Installation of the front chainwheel
(A)
Use a hexagon wrench to install the front chainwheel.
(A) 8 mm hexagon wrench/ 10 mm hexagon wrench
Tightening torque
35 - 50 Nm
149
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
SQUARE TYPE
SQUARE TYPE
Installation of the bottom bracket
(A) (B)
(C) Install using the Shimano original tool.
First install the main body, then the adapter.
(A) Adapter
(B) Body
(C) Front Chainwheel
Tightening torque
50 - 70 Nm
NOTICE
If the main body and adapter are made of aluminum or steel
Apply grease to the main body and adapter.
If the main body and adapter are made of plastic
Do not apply grease to the main body or adapter.
150
FRONT CHAINWHEEL INSTALLATION (FRONT CHAINWHEEL)
SQUARE TYPE
Installation of the front chainwheel
If using a hexagon wrench
(A)
Use a hexagon wrench to install the front chainwheel.
(A) 8 mm hexagon wrench/ 10 mm hexagon wrench
Tightening torque
35 - 50 Nm
If using a Shimano original tool
(A)
(B)
Use the Shimano original tool to install the front chainwheel.
(A) TL-FC10/TL-FC11
(B) 15 mm spanner
Tightening torque
35 - 50 Nm
151
FRONT CHAINWHEEL INSTALLATION (PRESS-FIT BOTTOM BRACKET)
Adapter
INSTALLATION (PRESS-FIT BOTTOM BRACKET)
Adapter
(A) (B) (C)
(D) (z)
(z) Bottom bracket shell width
(A) Left hand adapter
(B) Inner cover
(C) Right hand adapter
(D) 2.5 mm spacer
Assembly example
Adapter type ROAD MTB
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.
Use for a bottom bracket shell width of 86.5 mm.
-
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 necessary.
Use the inner cover.
The 2.5 mm spacer is not needed for a bottom bracket shell width of 92 mm.
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.
152
FRONT CHAINWHEEL INSTALLATION (PRESS-FIT BOTTOM BRACKET)
Installation
Installation
1
Insert the bottom bracket into the bottom bracket shell.
2
(A) Insert the Shimano original tool into the bottom bracket.
(A) TL-BB12
3
(A)(B)
Press fit the bottom bracket by tightening with a spanner while making sure that the contact surface of the bottom bracket stays parallel to the contact surface of the bottom bracket shell.
(A) 8 mm hexagon wrench
(B) 17 mm spanner
4
Check to confirm that there is no gap between the bottom bracket and the bottom bracket shell.
153
FRONT CHAINWHEEL INSTALLATION (PRESS-FIT BOTTOM BRACKET)
Removal
Removal
1 (A)
Insert the Shimano original tool into the bottom bracket.
(A) TL-BB13
2
As shown in the illustration, hold down the ap with your fingers and push it in from the opposite side. (When pushed in, the ap opens.)
TECH TIPS
While holding down the end of the removal tool, push the tool in from the other side until it locks in place.
3 (A)
Tap the Shimano original tool with a plastic mallet until the end of the bottom bracket is ejected.
(A) Plastic mallet
4
(A)
Tap the opposite end of the bottom bracket in the same way and remove it.
(A) Plastic mallet
NOTICE
Do not reuse the adapters as they can be damaged during removal.
PEDALS (SPD-SL PEDALS/SPD PEDALS)
155
PEDALS (SPD-SL PEDALS/SPD PEDALS) TO ENSURE SAFETY
TO ENSURE SAFETY
For information on the ClickR pedals and the flat pedals, refer to the dealers manual for each product.
WARNING TO PARENT/GUARDIAN
To avoid serious injuries: USE OF THIS PRODUCT IN ACCORDANCE WITH THESE DEALERS MANUAL IS ESSENTIAL FOR YOUR CHILDS SAFETY. MAKE SURE YOU AND YOUR CHILD UNDERSTAND THESE DEALERS MANUALS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY.
WARNING
Be sure to also inform users of the following:
If the warnings below 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 intended. 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 accustomed to 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 out of dirt and debris to ensure proper engagement and release.
Remember to check the cleats periodically for wear. When the cleats are worn, replace them, and always check the spring tension before riding and after replacing the pedal cleats.
Reectors have to be mounted to the bike at any time as soon as traveling on public roads. Do not continue riding the bicycle if the reectors are dirty or damaged. Otherwise, it becomes more difficult for others to see you.
Use only Shimano cleats and make sure that the mounting bolts are tightened securely to the shoes. Refer to the dealers manual for each product for applicable cleats.
156
PEDALS (SPD-SL PEDALS/SPD PEDALS) TO ENSURE SAFETY
Descriptions regarding SPD-SL pedals Use only SPD-SL shoes with this product. Other types of shoe may not release from the pedals, or may release unexpectedly.
Descriptions regarding SPD pedals Use only SPD shoes with this product. Other types of shoe may not release from the pedals, or may release unexpectedly.
CAUTION
To avoid serious injuries:
SPD PEDALS PD-M324 can be fitted with toe clips, but the toe clips should be removed when using the pedals as SPD pedals.
NOTICE
Be sure to also inform users of the following:
Before riding the bicycle, check that there is no play or looseness between connecting parts.
Check that there is no looseness in cleat or spacer before riding the bicycle.
If pedaling performance does not feel normal, check the bicycle once more.
If you experience any trouble with the rotating parts of the pedal, the pedal may require adjustment. Consult a dealer or an agency.
Be sure to retighten the crank arms and pedals at periodic intervals at the place of purchase or a bicycle dealer.
Optional reector sets are available. Reector sets vary depending on the model of the pedals, therefore, 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.
157
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD PEDALS)
Engaging the cleats with the pedals
INSTALLATION (SPD PEDALS)
NOTICE
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.)
Single release mode cleats: SM-SH51 (black)
These cleats only release when the heel is moved outward. They will not release if the heel is twisted in any other direction.
Upward force may be applied 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. You should practice until you are accustomed to the amount of force and the angle required to release the cleats.
Single release mode
These cleats only release when the heel is moved outward.
NOTICE
It is necessary to practice releasing until you become accustomed to the technique.
158
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD PEDALS)
Releasing the cleats from the pedals
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 such riding styles, 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 cleat releases by accident, you may fall off the bicycle and serious injury may result. If the use of the multiple release mode cleats are not sufficiently understood or used correctly, they may release accidentally more frequently than single release mode cleats. You can help to prevent this by adjusting the amount of force required to release the cleats. You should practice until you are accustomed to the amount of force and the angle required to release.
Multiple release mode
Release the cleats from the pedals by twisting your heels in any direction.
NOTICE
It is necessary to practice releasing until you become accustomed to the technique. Releasing by lifting your heel requires particular practice.
159
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD PEDALS)
Attaching the cleats
Attaching the cleats Set the cleat on the bottom of each shoe as shown in the illustration, and then tighten the cleat mounting bolts, temporarily.
1 (A)
(B)
With a pair of pliers or a similar tool, pull off the rubber cover to expose the cleat mounting holes.
(A) Rubber cover for cleat mounting holes
(B) SPD shoe
NOTICE
This step may not be necessary depending on the type of shoe.
2
(B)(A) Remove the sockliner and position a cleat nut over the oval holes.
(A) Cleat nut
(B) Sockliner
NOTICE
This step may not be necessary depending on the type of shoe.
3
(A)
(B)
(C)
(D)
(z)
Position the cleat then the cleat adapter on to the bottom of the shoe and then tighten with the cleat mounting bolts.
The cleats are compatible with both left and right pedals.
(z) Position the triangular portion of the cleat toward the front of the shoe.
(A) 4 mm hexagon wrench
(B) Cleat mounting bolt
(C) Cleat adapter
(D) Cleat
Provisional tightening torque for cleat mounting bolts
2.5 Nm
160
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD PEDALS)
Attaching the cleats
Adjustment of cleat position
1
The cleat has an adjustment range of 20 mm front to back and 5 mm right to left.
After temporarily fixing the cleats, adjust them by repeatedly engaging and releasing the cleats, one by one, to determine the optimal necessary cleat positions.
2 After you have determined the best cleat position, firmly tighten the cleat mounting bolts with a 4 mm hexagon wrench.
Tightening torque
5 - 6 Nm
Waterproof seal
(A) (B) Remove the sockliner and attach the waterproof seal.
(A) Waterproof seal
(B) Sockliner
NOTICE
The waterproof seal is supplied with Shimano shoes that require this step to be carried out.
161
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD PEDALS)
Mounting the pedals on the crank arms
Mounting the pedals on the crank arms
1 Apply a small amount of grease to the thread to prevent sticking.
2
(A)
(B)
(z)
Use an 8 mm hexagon wrench or a 15 mm spanner to install the pedals to the cranks.
(z) Note the markings R: Right pedal, L: Left pedal
(A) 8 mm hexagon wrench
(B) 15 mm spanner
Tightening torque
35 - 55 Nm
NOTICE
A 6 mm hexagon wrench cannot provide a sufficient tightening torque. Always be sure to use a 15 mm spanner.
TECH TIPS
The right pedal has a right-hand thread; the left pedal has a left-hand thread.
3 Remove any roughness or bumps on the joint, if detected.
162
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD PEDALS)
Adjusting the spring tension of the binding
Adjusting the spring tension of the binding
(y)
(z)
(A)
(A)(B) 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 by four steps each turn of the adjustment bolt.
(y) Increase
(z) Decrease
(A) Adjustment bolt
(B) Adjustment plate
TECH TIPS
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.
163
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD-SL PEDALS)
Cleat types
INSTALLATION (SPD-SL PEDALS)
Cleat types
SM-SH10 SM-SH11
(PD-R540-LA: standard) SM-SH12
(PD-9000: standard)
Red Yellow Blue
Wide Narrow Wide
Fixed mode There is no looseness when the shoes are firmly engaged with the pedals. There is no looseness.
Self-aligning mode There is some sideways looseness when the shoes are engaged with the pedals.
Front center pivot mode There is some sideways looseness centered on the front of the shoes.
164
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD-SL PEDALS)
Engaging the cleats with the pedals
Engaging the cleats with the pedals
Press the cleats into the pedals with a forward and downward motion.
Releasing the cleats from the pedals
These cleats only release when the heel is moved outward.
NOTICE
Place one foot on the ground and practice engaging and releasing the cleat from the pedal several times. Set the spring tension to the tension you prefer when releasing the cleat.
Attaching the cleats
(B)
(C)
(D)
(A) Set the cleat on the bottom of each shoe as shown in the illustration, and then tighten the cleat mounting bolts.
Refer to the Service Instructions provided with your shoes for further details.
(A) 4 mm hexagon wrench
(B) Cleat mounting bolt
(C) Cleat washer
(D) Cleat
NOTICE
When installing the cleats, use the provided cleat mounting bolts and washers. If you use any other cleat mounting bolts, it may damage the cleats and cause problems with installation.
165
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD-SL PEDALS)
Mounting the pedals on the crank arms
Adjustment of cleat position
1 The cleat has an adjustment range of 15 mm front to back and 5 mm right to left.
After provisionally tightening the cleat, practice engaging and releasing, one shoe at a time.
2
After you have determined the best cleat position, firmly tighten the cleat mounting bolts with a 4 mm hexagon wrench.
Tightening torque
5 - 6 Nm
Mounting the pedals on the crank arms
1 Apply a small amount of grease to the thread to prevent sticking.
2 (A)
(B)
(z)
Use an 8 mm hexagon wrench or a 15 mm spanner to install the pedals to the cranks.
(z) Note the markings R: Right pedal, L: Left pedal
(A) 8 mm hexagon wrench
(B) 15 mm spanner
Tightening torque
35 - 55 Nm
NOTICE
A 6 mm hexagon wrench cannot provide a sufficient tightening torque. Always be sure to use a 15 mm spanner.
TECH TIPS
The right pedal has a right-hand thread; the left pedal has a left-hand thread.
3 Remove any roughness or bumps on the joint, if detected.
166
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD-SL PEDALS)
Adjusting the spring tension of the binding
Adjusting the spring tension of the binding
(B)
(C)
(A)
(y) (z)
(y)
(z)
The spring force is adjusted with the adjustment bolts.
Adjust the spring force to the optimal 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 tension can be adjusted by four steps each turn of the adjustment bolts; each adjustment bolt can be turned up to three full turns.
(y) Decrease
(z) Increase
(A) 2.5 mm hexagon wrench
(B) Adjustment bolt
(C) Indicator
NOTICE
In order to prevent accidental release, make sure all the spring tensions are properly adjusted.
The spring tensions for the right and left pedals should be adjusted so they are equal. If the cleats are not adjusted equally, it can cause the rider difficulty in engaging or releasing 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.
Do not turn the bolt past the point at which the indicator shows the maximum or minimum tension.
Cleat replacement
(x)
(y)
(z)
(A) 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.
(x) Front
(y) Rear
(z) A
(A) Cleat
NOTICE
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 base layer underneath the cleats starts to be visible.
Rear: Replace when section A in the illustration becomes worn.
167
PEDALS (SPD-SL PEDALS/SPD PEDALS) INSTALLATION (SPD-SL PEDALS)
Replacement of the body cover
Replacement of the body cover For information on how to replace the body cover, refer to the dealers 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 reector (separately sold) designed for each pedal. For information on installation, refer to the included manual.
HUB DYNAMO
169
HUB DYNAMO TO ENSURE SAFETY
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 cause serious injury.
Check that the light illuminates normally when riding at nighttime.
For Installation to the Bicycle, and Maintenance: Depending on the hub dynamo, the tire diameter of the compatible wheel may differ. Be sure to check the compatible size. If an incompatible size is used, the wheels may lock 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.
If the axle release lever is on the same side as the disc brake rotor, there is a possibility they may interfere. Make sure that even if the axle release lever is tightened with your palm with all your strength, the axle release lever does not interfere with the disc brake rotor. If the lever interferes with the disc brake rotor, stop using the wheel and consult a dealer or an agency.
Axle release lever
Disc brake rotor
The disc brake calipers and disc brake rotor will become hot when the brakes are operated, so do not touch them while riding or immediately after dismounting from the bicycle. Otherwise you may get burned. Check that the brake components have cooled down sufficiently before attempting to adjust the brakes.
Be sure to also carefully read the Service Instructions for the disc brakes.
If the axle release lever is not used correctly, the wheel may come off the bicycle and serious injury could result.
For details on the E-THRU Axle, refer to the E-THRU Axle user's manual.
The E-THRU hub dynamo can be used in combination with the special front fork/frame and the through axle only. If it is used in combination with any other front fork/frame or through axle, it may cause the wheel to become detached from the bicycle while you are riding and result in serious bodily injury.
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.
NOTICE
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 burns out, excessive voltage will be applied to the remaining light and shorten the operating life of the bulb, so any burned out 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.
170
HUB DYNAMO TO ENSURE SAFETY
For Installation to the Bicycle, and Maintenance: According to German regulations (StVZO), a hub dynamo in Germany requires overvoltage protection. This hub dynamo (3.0W) 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).
Check that the front dropout is aligned. If the front dropout is severely misaligned, deformation of the hub axle may cause noise from an obstruction inside the hub dynamo.
Do not lubricate the internal parts of the hub. Otherwise the grease will come out and it may cause problems with conductivity.
Compatible lights
3.0W hub dynamo
Front light Tail light
6.0V/2.4W 6.0V/0.6W
6.0V/3.0W -
9.6V/5.0W -
2.4W hub dynamo
Front light Tail light
6.0V/2.4W -
1.5W hub dynamo Use LED light only.
0.9W hub dynamo
Front light Tail light
6.0V/0.9W -
171
HUB DYNAMO INSTALLATION (HUB DYNAMO)
Installation of the disc brake rotor
INSTALLATION (HUB DYNAMO)
Installation of the disc brake 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 following the procedure shown in the illustration so that the connection terminal is facing up. Do not force the connection terminal to turn after the quick release lever, hub nut, or E-THRU lever has been secured. If you force the connection terminal to turn, it may become damaged, or the wire inside the connection terminal may break.
For quick release type
Before installing
(A)(C)
(D)
(B)
(E)
After installing
(A)
(B)
(D)
(C)
(A) Front fork
(B) Connection terminal
(C) Mudguard stay
(D) Quick release nut
(E) Volute spring
NOTICE
Do not use the toothed axle washer with a quick release type.
Connect the two wires to ensure that the current ows smoothly.
172
HUB DYNAMO INSTALLATION (HUB DYNAMO)
Installation of the front wheel
For nut type
For E2 type
Before installing
(E)
(F)
(D)(C)(A) (B)
After installing
(F)(C)
(E)
(D)
(A) Hub nut (M9)
(B) Washer
(C) Basket stay
(D) Mudguard stay
(E) Front fork
(F) Connection terminal
Tightening torque
20 - 25 Nm
For J2 type
(F) (G)(D) (E)(A)
(H)
(B) (C)
(A) Flange nut
(B) Washer
(C) Basket stay
(D) Mudguard stay
(E) Front-wheel anti-falloff fitting
(F) Front fork
(G) Toothed washer for axles
(H) Connection terminal
Tightening torque
20 Nm
173
HUB DYNAMO INSTALLATION (HUB DYNAMO)
Installation of the front wheel
For J2-A type
(F)(D) (E)(A)
(G)
(B) (C)
(A) Flange nut
(B) Washer
(C) Basket stay
(D) Mudguard stay
(E) Front-wheel anti-falloff fitting
(F) Front fork
(G) Connection terminal
Tightening torque
20 Nm
NOTICE
When tightening the hub nuts or ange nuts, tightening the hub nut only on one side excessively may force the hub axle to turn, tightening or loosening the lock nut excessively; therefore, tighten both nuts alternately.
174
HUB DYNAMO INSTALLATION (HUB DYNAMO)
Installation of the front wheel
For E-THRU type
Before installing
(A)
(C)
(B)
After installing
(A) (B)
(A) Front fork
(B) Connection terminal
(C) E-THRU axle
NOTICE
For information on installing the E-THRU lever, refer to the instruction manual included with the E-THRU lever.
175
HUB DYNAMO CONNECTION OF THE CABLES
For E2 type
CONNECTION OF THE CABLES
If you wish to replace the connector or change the length of the cable, perform the following procedure.
For E2 type
1
Hub dynamo connection terminal
(A)
(C)
(E)
(F)
(D)
(G)
(B)
(H)
(z) (z)
Twist the conducting wires of the cable together before connecting them so that they stay together.
(z) Approx. 16 mm
(A) Frame connection terminal
(B) Light connection terminal
(C) Frame cable
(D) Light cable
(E) Connector cap (gray)
(F) Connector cover (black)
(G) Frame connection terminal
(H) Light connection terminal
NOTICE
Do not mix up the frame cable and the light cable by mistake. If the cables are connected incorrectly, the light will not turn on.
TECH TIPS
Recommended wire specification
Wire
Insulation
Type Stranded
Wire Size (AWG) 22 Diameter: approx. 0.8 mm
Insulation Diameter: 1.8 2 mm
To be continued on next page
176
HUB DYNAMO CONNECTION OF THE CABLES
For J2 type
2
(y)
(z)
(A)
Bend the cable wires and run them along the grooves.
(y) Insert
(z) Bend
(A) Groove
NOTICE
Do not allow the cable wires to touch each other.
3
(A)
(B)
Press in until you hear a click. (A) Connector cap (gray)
(B) Connector cover (black)
NOTICE
Set so that it faces the right way.
For J2 type
(C)
(E)
(A)
(B)
(D)
(F)
(z)(z)
(z) Connect
(A) Basket stay
(B) Front fork
(C) Light cable
(D) Frame (grounding) cord
(E) Light connection terminal (small)
(F) Frame (grounding) connection terminal (large)
TECH TIPS
If the frame (grounding) connection terminal is fitted with a cover, remove it before connection.
177
HUB DYNAMO CONNECTION OF THE CABLES
For J2-A type
For J2-A type
1
Hub dynamo connection terminal
(A)
(B)
(C)
Twist the conducting wires of the cable together before connecting them so that they stay together.
(A) Mark
(B) Connector
(C) Connection terminal
2
Open the connector using a slotted screwdriver or similar tool as shown in the illustration.
3
(y)(y)
(z)
Insert the cable with the marking into the ground side of the connector.
(y) Approx. 16 mm
(z) Ground side
To be continued on next page
178
HUB DYNAMO CONNECTION OF THE CABLES
For J2-A type
4 (y)
(z)
(A)
Twist the cable wires, pass them through the connector, bend them, and run them along the grooves.
(y) Insert
(z) Bend
(A) Groove
NOTICE
Do not allow the cable wires to touch each other.
5
Close the connector until you hear a click.
179
HUB DYNAMO CONNECTION OF THE CABLES
Note on the connection of the cables
Note on the connection of the cables 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 changes 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.
Connect so that the current from the hub dynamo ows through the cable from the light connection terminal 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 connection. 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.
(y) (z)
(A) (A) (B)
(C)
(y) Remove
(z) Connect
(A) Connector cover
(B) Cord
(C) Front fork
(z) (y)
(B)(A)
(E)
(F) (D)(C)
(y) Remove
(z) Connect
(A) Light cable
(B) Frame (grounding) cord
(C) Light connection terminal (small)
(D) Frame (grounding) connection terminal (large)
(E) Cord
(F) Front fork
Checking the light illumination
Rotate the front wheel and check that the light illuminates.
MULTIPLE FREEWHEEL
181
MULTIPLE FREEWHEEL INSTALLATION (MULTIPLE FREEWHEEL)
Installation of the freewheel
INSTALLATION (MULTIPLE FREEWHEEL)
Installation of the freewheel
(y)
(z)
(A)
(y) Installation
(z) Removal
(A) Freewheel removal tool (TL-FW30)
Tightening torque
30 N
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