Shimano SL-3S35-E, Bell Crank III, Bell Crank IV Service Instructions Manual

WARNING

Obtain, read and carefully service instructions when installing
parts. A loose, worn, or damaged parts may cause injury to the
rider. We strongly recommend that only genuine Shimano
replacement parts be used.

Installation of the lever

Install the lever as shown in the illustration.

Use a brake lever band with a thickness of

4.3 mm or less so that it does not obstruct
the brake lever and the Revo-shift lever.

SERVICE INSTRUCTIONS

SL-3S35-E
Bell Crank
Bell Crank

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

Be sure to read these service instructions in conjunction
with the service instructions for the Inter-3 hub before
use.

lll

lV

Revo-shift Lever

Bell Crank

SI-6E80B

CAUTION

Be sure to shift the lever one gear at a time, and reduce the
force being applied to the pedals during shifting. If you try to
force operation of the shifting lever while the pedals are being
turned strongly, your feet may come off the pedals and the
bicycle may topple over, which could result in serious injury.

Never place your foot on the bell crank. Doing so may cause
problems with gear shifting.

Revo-shift lever operation

Turn the Revo-shift lever to shift to each of the three gears.

The straight section of the

Brake lever

1

4

Tighten

4 mm Allen key

Clamp bolt

Leave a gap of 0.5 mm
between the Revo-shift
lever and the half grip.

Tightening torque:

2.5 – 4 Nm {25 – 40 kgfcm}

handlebar should be 158 mm
or more in length; attach the
Revo-shift lever to this straight
section.

Handlebar

22.2 mm

2

3

Half grip

Installation of the shifting cable

Use a cable with one inner cable drum as the shifting
cable.

SIS-SP40 (4 mm dia.)

Indicator

Pedaling becomes lighter

Indicator moves toward

……

Starting/Riding on sandy or rough road surfaces/

1

Riding up slopes/Carrying heavy loads/
Riding into head winds/When the light is illuminated

……

Riding on flat road surfaces

2

……

Riding at high speeds

3

1

Pedaling becomes heavier

Indicator moves toward

Revo-shift lever

3

Set to

1

1

Set the Revo-shift lever to .

1.

Revo-shift lever side

Loosen the cover fixing screw, and then remove the indicator

2.

cover.

Cover fixing screw

Indicator cover

Set the inner cable onto the pulley.

3.

1)

Insert the inner cable into groove (A) from the inside of the
projection on the pulley, and then pass it through the hole in the
outer casing holder.

Note: Check that the inner cable is correctly routed

along the inside of the projection on the pulley.

Groove (A) in pulley

Bell crank side

Loosen the cover fixing screw, and then remove the bell crank

5.

cover.

Cover fixing screw

JAPAN

Projection
on pulley

OK Not OK

Hole in outer casing
holder

2)

Hook the inner cable into groove (B) in the pulley, and pull the
inner cable so that the inner cable drum fits into the hole (B) in
the pulley. After this, insert the outer casing into the outer
casing holder.

1

Bell crank cover

JAPAN

Set the inner cable into the link of the main bell crank unit.

6.

1)

Loosen the inner cable fixing nut on the main bell crank unit.
Next, pass the inner cable from the cable adjusting bolt along
the groove in the link and then in between the link and the
inner cable fixing plate.

Be sure to pass the inner cable

Cable adjusting bolt

through the groove in the link.

Groove (B) in pulley

3

2

Outer casing holder

Hole (B) in pulley

Replace the indicator cover and tighten the cover fixing screw.

4.

Loosen

OK

Link

Inner cable fixing plate

Inner cable fixing nut

Not OK

2)

Set the Revo-shift lever to .
Next, pull the inner cable so that the edges of the link on the
main bell crank unit are between the two yellow lines on the
window, and then tighten the inner cable fixing nut at that
position.

2

Tightening torque:
4 – 6 Nm {40 – 60 kgfcm}

Inner cable
fixing nut

Set to

2

Tighten

Installation of bell crank

Insert the push rod into the hub axle.

1.

Approx. 14 mm

Push rod

Yellow line Yellow line

After tightening the inner
cable fixing nut, cut off any
excess inner cable.

Edge of link

The edges of the link
should be between the
yellow lines.

Within
4 mm

Replace the bell crank cover and tighten the cover fixing screw.

7.

Pull

The end of the push rod should project from
the end of the hub axle by approximately 14
mm.

While pushing the main bell crank unit onto the hub axle, align the

2.

serrations inside the main bell crank unit with the flange nut, and
then push the main bell crank unit on until it touches the end of
the hub axle. In this position, tighten the main unit installation bolt
onto the hub axle.

Tightening torque:
3 – 5 Nm {30 – 50 kgfcm}

Main unit
installation bolt

5 mm Allen key
or 10 mm
spanner

SET

SET

Edge of
window

SET

Flange nut

The edge of the window and
the end of the hub axle

SET

should be aligned.

End of hub axle

Adjusting bell crank

Securing the shifting cable to the frame

Set the Revo-shift lever to .

1.

Next, turn the cable adjusting bolt

2

until the red line on the push rod
is aligned with the end of the hub
axle.

2

Set to

The red line on the push rod and the end of
the hub axle should be aligned.

End of hub
axle

Red line on
push rod

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.

SET

SET

Note:

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

Cable adjusting
bolt

SET

SET

Push rod

Yellow line

Yellow line

Yellow section
of link

Secure the cable to the frame with the outer casing bands.

There should be enough
slack so that the cable is
not pulled too much
when the handlebars
are turned.

20 – 25 cm

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.

Please note: Specifications are subject to change for improvement without notice. (English)

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

Industrieweg 24 NL- 807 1 CT Nunspeet‚ Holland Phone [phone]

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

C

Mar. 2000 by Shimano Inc. PIT. SZK. Printed in Singapore

Outer casing bands

While turning the crank arm, move the Revo-shift lever from to

2.

and then from back to two or three times to check the

1

1

3
gear shifting.
Set the Revo-shift lever back to and check that the red line on

2

the push rod is aligned with the end of the hub axle.

If they are not aligned, turn the cable adjusting bolt to make
fine adjustments.

After adjusting the bell crank, tighten the cable adjusting nut to

3.

secure the cable adjusting bolt.

Cable adjusting nut

SET

SET

3