Shimano AI-3S10 Service Instructions

WARNING

Obtain and read the service instructions carefully prior to
installing the parts. Loose, worn, or damaged parts may
cause serious injury to the rider. We strongly recommend
only using genuine Shimano replacement parts.

CAUTION

The Automatic Inter-3 is an automatic gear shifting system
in which the shifting points are determined by the speed of
the bicycle (the rotating speed of the wheels). Because of
this, gear shifting can occur independently of the rider's
intentions, and so shocks may be felt during shifting. Make
sure that you understand and become accustomed to these
shifting characteristics before using the system extensively.

Make sure that the bicycle has been secured in a stable
position before replacing the batteries or adjusting the bell
crank or the magnet. If the bicycle is not stable, it may
cause injury, or the main unit may not operate correctly.

SERVICE INSTRUCTIONS

AI-3S10

Before use‚ read these instructions carefully‚ and follow them for correct use.

Automatic Inter-3

SI-AI3UD

NOTE

The Automatic Inter-3 returns to 1st gear when the bicycle stops.
When riding the bicycle, a beep will be heard before a gear shift

occurs to notify the rider that a gear shift is about to take place.
When the battery is nearly spent, a long beep (about three seconds),

and the gear mechanism will return to 1st gear. If you continue to
use the unit with spent batteries still inserted, the unit will not operate
correctly, and the batteries may leak. Replace spent batteries with
new alkali batteries as soon as possible.

Some types of batteries may become spent more quickly than usual
when used in cold temperature conditions.

Replacement of the battery

Note:

When replacing the batteries, secure the bicycle wheels so that
they cannot rotate. In addition, do not rotate the wheels until at
least four seconds have passed after inserting the batteries.
If the wheels are rotated within this time the motor unit will
switch to sleep mode, which will prevent the unit from operating
for two minutes.

Do not mix old and new batteries or batteries of different types.

Use a Phillips screwdriver to loosen the two cover fixing screws,

1.

and then remove the
main unit cover.

Cover fixing screw

Cover fixing screw

Main unit cover

Remove

Use a Phillips screwdriver to loosen the battery box cover fixing

2.

screw, and then remove the battery box cover.

Battery box cover

Remove

Battery box cover
fixing screw

Insert the new batteries (four alkali AA batteries), making sure that

3.

the polarities are correct.

Alkali AA batteries
(4 pcs.)

Insert the tab on the battery box cover into the battery box, and then

4.

tighten the battery box cover fixing screw.

Battery box cover

Install

Battery box cover
fixing screw

Tab

Tightening torque:

0.5 – 1 Nm
{5 – 10 kgfcm}

Install the main unit cover, and then securely tighten the two cover

5.

fixing screws.

Cover fixing screw

Main unit cover

Install

Tightening torque:
1 – 1.5 Nm
{10 – 15 kgfcm}

Cover fixing screw

Bell crank (N position) adjustment

Rotate the wheel so that the magnet which has been attached to the

1.

spoke is aligned with the speed sensor ( mark position). Make a
note of which side of the mark on the speed sensor the magnet is
aligned at this time.

Magnet

Main unit

Speed sensor

Magnet

Set Magnet Position
for shifting mode

Loosen the magnet fixing bolt, and remove the magnet from the

2.

magnet holder. Next, push the magnet against the mark
(N position) of the speed sensor, and then remove the magnet from
the mark. A beeping sound will be heard and the motor unit will
shift to the 2nd gear position.

Set Magnet Position

Magnet fixing bolt

Set Magnet Position
for shifting mode

Magnet

for shifting mode

Insert the magnet into the magnet holder. Move the magnet so that

4.

its center is aligned with the original position ( mark) on the speed
sensor and so that there is a space of 1 – 5 mm between the magnet
and the speed sensor, and then use a coin to tighten the magnet
fixing bolt.

Tightening torque:
2 – 3 Nm
{20 – 30 kgfcm}

Magnet

Magnet holder

Turn the cable adjustment bolt of the bell crank counterclockwise so

3.

that the end of the hub axle and the red line on the push rod are
aligned.

Magnet fixing bolt

"D" and "Ds" modes

Move the magnet to the "D" or "Ds" position for automatic gear
shifting in accordance with the bicycle speed.

In "D" mode, slow automatic shifting is carried out.
In "Ds" mode, quick automatic shifting is carried out.

Turn the front chainwheel to rotate the wheels, and check that the

5.

gears change from 1st to 2nd to 3rd. If the gear does not change
from 2nd to 3rd, stop rotating the wheel and turn the cable
adjustment bolt of the bell crank half a turn clockwise. Turn the front
chainwheel again to rotate the wheels, and check that the gears shift
to all stages.

After adjusting the bell crank, secure the cable adjustment bolt by

6.

tightening the cable adjustment nut.

Red line on
push rod

Yellow line

Yellow line

End of hub axle

SET

Yellow section of link

SET

SET

Cable adjustment bolt

Align the red line with
the end of the hub axle

SET

If the red line on the push rod
is not visible, adjust so that
the yellow section of the link is
between the two yellow lines
on the window.

Note:

Look at the two yellow lines
from directly above during
adjustment.

Troubleshooting

For any questions regarding installation or adjustments, please contact the place of purchase.

Symptom

Gear shifting is not possible.

Buzzer does not sound.

Gear shifting timing is not
correct.

A long beep (about three
seconds) sounds and no
gear shifting occurs.

These service instructions explain how to use and maintain the Shimano
bicycle parts which have been used on your new bicycle. For any questions
regarding your bicycle or other matters which are not related to Shimano
parts‚ please contact the place of purchase or the bicycle manufacturer.

These service instructions are printed on recycled paper.
Please note: Specifications are subject to change for improvement without notice. (English)

Are the batteries installed correctly ?
Are the batteries spent ?
Are the correct type of batteries being used ?
Is the magnet installed in the correct position ?
Is the gear shifting cable installed correctly ?

Is the magnet installed in the correct position ?
Is the gear shifting cable installed correctly ?

Are the batteries spent ?
Is the gear shifting cable installed correctly ?
Are the bell crank, motor unit or cable blocked

with mud ?

Check

Insert the batteries so that the polarities are correct.
Replace with new batteries.
Use alkali AA batteries.
Install the magnet in the correct position.
Adjust the N position.
Align the magnet with the mark on the speed sensor

which matches the number of teeth on the rear sprockets.
Adjust the N position.
Replace with new batteries.
Adjust the N position.

Remove the cause of the problem.

Align the center of the
magnet with the mark
on the speed sensor.

Set Magnet Position
for shifting mode

Magnet

1 --- 5 mm

Cable adjustment nut

SET

SET

Magnet holder

Tightening torque:

1.5 – 2.5 Nm
{15 – 25 kgfcm}

Remedy

One Holland Irvine CA 92618 U.S.A. Phone [phone]

Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone [phone]

3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone [phone]

C

Sep. 2002 by Shimano Inc. PIT. SZK. Printed in Singapore