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SI-6P1RA-001-00
Set to
General Safety Information
WARNING
– To avoid serious injuries:
● 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.
● Read these Technical Service Instructions
carefully, and keep them in a safe place for later
reference.
CAUTION
– To avoid serious injuries:
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.
NOTE:
For maximum performance we highly recommend ●
Shimano lubricants and maintenance products.
Parts are not guaranteed against natural wear or ●
deterioration resulting from normal use.
SI-6P1RA-001
SL-3S41-E
CJ-NX40
Revo-shift Lever
Cassette joint
Technical Service Instruction
Be sure to read these technical service instructions
in conjunction with the technical service instructions
for the Inter-3 hub.
Revo-shift lever operation
Turn the Revo-shift lever to shift to each of the three
gears.
Pedaling becomes heavier
Indicator moves toward
Indicator
3
Revo-shift lever
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.
The straight section of
Brake lever
1
Tighten
4
Clamp bolt
3 mm Allen key
Leave a gap of 0.5 mm between the
Revo-shift lever and the half grip.
Tightening torque:
2 – 2.5 N·m {17 – 22 in. lbs.}
the handlebar should be
158 mm or more in length;
attach the Revo-shift lever
to this straight section.
Handlebar
22.2mm
2
3
Installation of the shifting cable
Use a shifting cable with one inner cable drum.
Set the Revo-shift lever to
1.
Loosen the two cover fixing screws, and then
2.
remove the cover.
OT-SP40 (4 mm dia.)
1
.
Set to
Cover fixing screw
Half grip
Pass the inner cable from the hole in the winder unit
3.
through the hole in the outer casing holder. Next,
insert the inner cable into the groove of the cable
guide.
Hole in outer casing holder
2
Groove in cable guide
Hole in winder unit
3
1
Pull the inner cable so that the inner cable drum fits
4.
into the recess in the winder unit.
Recess in winder unit
Insert the outer casing into the outer casing holder.
5.
Outer casing holder
Replace the cover and tighten the two cover fixing
6.
screws.
Tightening torque:
0.1 – 0.2 N·m {1 – 2 in. lbs.}
Cover fixing screw
Cover
Cover fixing screw
If cutting the outer casing, cut it near the end with
the plastic cap while the cap is still attached. Then
make the cut end perfectly round and attach the
plastic cap.
Plastic cap
Remove the plastic cap.
Wipe off the grease stuck on the inner cable and
8.
pass it through the cable adjustment bolt.
Then insert the outer casing into the cable
adjustment bolt.
* Push the outer casing in firmly until it comes in contact
with the cable adjustment bolt.
Outer casing holder Outer casing
Inner cable
After checking that the end of the outer casing is
9.
fully inserted into the end of the outer casing holder
of the shift lever, attach the fixing clamp bolt to the
inner cable.
Inner cable fixing bolt unit
Note: Do not use this inner cable fixing bolt unit with
the CJ-4S30 cassette joint.
Inner cable fixing nut
Inner cable fixing washer
Inner cable fixing bolt
10mm
Pass the inner cable through the hole.
127mm
Pull the inner cable while attaching the inner
cable fixing bolt unit.
Tightening torque:
3.5 – 5.5 N·m {30 – 48 in. lbs.}
Bring the cable around to the cassette joint pulley,
10.
hold so that the inner cable fixing nut is facing to the
outside (toward the fork end), and then slide the flats
part of the inner cable fixing washer into the gap in
the pulley.
Flats part of inner cable
fixing washer
Inner cable fixing nut
Gap in pulley
Pulley
Mount the inner cable to the pulley as shown in the
12.
following figure. While holding the cover section
(A) of the cable adjustment bolt, press-fit the outer
casing holder into the slit of the outer casing holder
holding section of the cassette joint bracket firmly.
Inner cable
Outer casing holder
holding section
Pulley
Outer casing holder
Outer casing holder
holding section
Set the protruded section of the outer casing holder to
the slit of the outer casing holder holding section.
If it is easier to press-fit the outer casing holder
into the outer casing holder holding section of the
cassette joint beforehand, insert the outer casing
holder into the outer casing holder holding section of
the cassette joint, insert a 2mm Allen key or a #14
spoke into the hole of the pulley and turn the pulley,
and then press-fit the inner fixing bolt unit into the
gap in the pulley.
3
Insert the inner cable
fixing bolt unit
2
Turn the
pulley
2 mm Allen key
or #14 spoke
Note:
Check that the inner cable is correctly seated inside
the pulley guide.
1
Slit
Press-fit the cable
adjustment bolt.
2
Press-fit the cable
adjustment bolt.
Hole in pulley
1
Adjusting the cassette joint
Move the Revo-shift lever to shift from
1.
Check to be sure that the yellow setting lines on the
cassette joint bracket and pulley are aligned at this
time.
The yellow setting lines on the cassette joint are located
in two places. Use the one that is easiest to see.
When bicycle is standing up
Should be straight
Cassette joint
bracket
When bicycle is upside down
Should be straight
Cassette joint
bracket
If the yellow setting lines are not aligned, turn the
cable adjustment bolt of the cassette joint to align
the setting lines. After that, move the Revo-shift
lever once more from
1
3
to
, and then recheck to be sure that the yellow
setting lines are aligned.
After adjusting the cassette joint, cut off the excess
2.
length of inner cable and then install the inner end
cap.
15 − 20 mm
3
1
to
and then back from
Inner end cap
1
to 3.
Yellow setting lines
Cassette joint
pulley
Cassette joint
pulley
Pedaling becomes lighter
Indicator moves toward
……
Starting/Riding on sandy or rough road
surfaces/Riding up slopes/Carrying
heavy loads/Riding into head winds/
When the light is illuminated
……
Riding on flat road surfaces
……
Riding at high speeds
Cover fixing screw
Cover
1
Attach the cable adjustment bolt to the outer casing
7.
holder.
Outer casing holder
* When attaching the outer adjustment bolt, tighten the
bolt fully and then loosen the bolt by 3 to 4 turns.
Make the cut end
perfectly round.
Attach the plastic cap.
Cable adjustment bolt
Turn the cable 60° counterclockwise and attach it to
11.
the hook.
Hook
Turn the
cable 60°
Guide Guide
OK Not OK
Secure the cable to the frame with the outer casing
13.
bands.
15cm10cm
10cm
Outer casing bands
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.
* Service Instructions in further languages are available at:
http://techdocs.shimano.com
Please note: specifications are subject to change for
SHIMANO AMERICAN CORPORATION
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
SHIMANO EUROPE B.V.
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222
SHIMANO INC.
3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan
improvement without notice. (English)
© Mar. 2011 by Shimano Inc. AWS. Printed in Singapore
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