Shimano BL-IM60, SB-8S20 Service Instructions

Page 1
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.
It is important to completely understand the operation of your bicycle's brake system. Improper use of your bicycle's brake system may result in a loss of control or an accident, which could lead to severe injury. Because each bicycle may handle differently, be sure to learn the proper braking technique (including brake lever pressure and bicycle control characteristics) and operation of your bicycle. This can be done by consulting your professional bicycle dealer and the bicycle's owners manual, and by practicing your riding and braking technique.
These brake levers are equipped with a mode switching mechanism to make them compatible with cantilever brakes and Roller Brakes or V-Brakes with power modulator.
If the incorrect mode is selected it may cause either excessive or insufficient braking force to occur, which could result in dangerous accidents. Be sure to select the mode in accordance with the instructions given in the table below.
Mode position
C/R position
V
V
C R
C R
The C indicates the mode position for compatibility with cantilever brakes.
The R indicates the mode position for compatibility with Roller Brakes.
V position
V
V
C R
C R
The V indicates the mode position for compatibility with V-Brakes with power modulator.
Use the brake levers with mode switching mechanism in the combinations given above.
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.
Applicable brake
Cantilever brakes
Roller Brakes
V-Brakes with power modulator
SI-6J30A
SB-8S20 BL-IM60 CJ-8S20
Revo-shift Lever
Brake Lever
Cassette Joint
Technical Service Instructions
Be sure to read these service instructions in conjunction with the service instructions for the Inter-8 hub before use.
Revo-shift lever operation
Turn the Revo-shift lever to shift to each of the eight gears.
Indicator
Pedaling becomes lighter
Indicator moves toward
Installation of the lever
Install the lever as shown in the illustration.
Clamp bolt
3
Tighten
5 mm Allen key
Leave a gap of 0.5 mm between the Revo-shift lever and the half grip.
Tightening torque: 6 – 8 Nm {60 – 80 kgfcm}
2
Grip
Pedaling becomes heavier
Indicator moves toward
Revo-shift lever
1
In case of using Shimano half grip, the straight section of the handlebar should be 166 mm or more in length; attach the Revo­shift lever to this straight section.
1
Handlebar
22.2 mm
Half grip
Clamp bolt
1
3
Tighten
22.2 mm
5 mm Allen key
8
2
Disconnecting the shifting cable when
removing the rear wheel from the frame
Disconnect the cable from the cassette joint when removing the rear wheel from the frame.
LOCK
CJ-8S20
JAPAN
Cassette joint
Set the Revo-shift lever to .
1.
Set to
Pull the outer casing out from the outer
2.
casing holder of the cassette joint, and then remove the inner cable from the slit in the bracket.
Bracket
Outer casing holder
CJ-8S20
JAPAN
Slit
2 Remove from the slit
Remove the inner cable fixing bolt unit from
3.
the cassette joint pulley.
Inner cable fixing bolt unit
Cassette joint pulley
If it is difficult to pull the outer casing out from the outer casing holder of the cassette joint, insert a 2 mm Allen key or a #14 spoke into the hole in the cassette joint pulley, and then turn the pulley to loosen the inner cable. Then remove the inner cable fixing bolt unit from the pulley first, and after this remove the outer casing from the outer casing holder.
2 Remove the inner cable fixing bolt unit
1 Turn the pulley
2 mm Allen key or #14 spoke
Note:
If reusing the cable, refer to steps 7 to 9 in "Installation of the shifting cable".
1
1
Pull out from outer casing holder
1
LOCK
CJ-8S20
JAPAN
LOCK
CJ-8S20
JAPAN
Pulley hole
3
Installation of the shifting cable
Use a shifting cable with one inner cable drum.
Cable with one inner cable drum / SIS-SP40 (4 mm dia.)
Set the Revo-shift lever to .
1.
Set to
Revo-shift lever side
Loosen the cover fixing screw, and then remove
2.
the upper cover.
Upper cover
Pass the inner cable through the hole in the cable
3.
adjustment bolt. Next, hook the inner cable into the groove of the pulley, and pull the inner cable so that the inner cable drum fits into the hole in the pulley.
Hole in cable adjustment bolt
1
Groove in pulley
Hole in pulley
Replace the upper cover and tighten the cover
4.
fixing screw.
Upper cover
1
1
Cover fixing screw
2
3
Cover fixing screw
Pass the inner cable through the SIS-SP40 outer
5.
casing through the end with the plastic cap.
(Lever side)
Aluminum cap
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
Plastic cap
Remove the plastic cap.
Make the cut end perfectly round.
Attach the plastic cap.
Cassette joint side
After checking that the end of the outer casing is
6.
sitting securely in the cable adjustment bolt of the Revo-shift lever, attach the inner cable fixing bolt unit 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
Pulley
LOCK
Inner cable fixing bolt
Gap in pulley
CJ-8S20
JAPAN
10 mm
(Black)
Pass the inner cable through the hole.
101 mm
Pull the inner cable while attaching the inner cable fixing bolt unit.
Tightening torque: 4 – 6 Nm {40 – 60 kgfcm}
Bring the cable around to the cassette joint pulley,
7.
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
Turn the cable 60 counterclockwise and attach it
8.
to the hook.
Hook
LOCK
CJ-8S20
Turn the cable 60
Attach the inner cable to the pulley as shown in
9.
the illustration, pass the inner cable through the slit in the cassette joint bracket, and then insert the end of the outer casing securely into the outer casing holder.
LOCK
CJ-8S20
JAPAN
Inner cable
Pulley
Bracket
Outer casing holder
CJ-8S20
J
AP
AN
Bracket
JAPAN
Insert into the outer casing holder.
2
Slit
1 Pass through the slit.
If first inserting the outer casing into the outer casing holder is easier, then first insert the outer casing into the outer casing holder, and then insert a 2 mm Allen key or a #14 spoke into the hole in the cassette joint pulley, and then turn the pulley so that the inner cable fixing bolt unit fits into the gap in the pulley.
3 Insert the inner cable fixing bolt unit
1 Insert into the outer casing holder
LOCK
CJ-8S20
JAPAN
2 Turn the pulley
2 mm Allen key or #14 spoke
Note:
Check that the inner cable is correctly seated inside the pulley guide.
Guide
LOCK
CJ-8S20
Hole in pulley
LOCK
JAPAN
Guide
OK Not OK
Secure the cable to the frame with the outer
10.
casing bands.
10 cm
10 cm
15 cm
Outer casing bands
CJ-8S20
Adjusting the cassette joint
Set the Revo-shift lever to .
1.
Check to be sure that the yellow setting lines on the cassette joint bracket and pulley are aligned at this time.
4
Set to
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
JAPAN
CJ-8S20
LOCK
Cassette joint bracket
If the yellow setting lines are not aligned, turn the cable adjustment bolt of the Revo­shift lever to align the setting lines. After this, move the Revo-shift lever once more from
4 41
to and then back to , and then re-check to be sure that the yellow setting lines are aligned.
Cable adjustment bolt
After adjusting the cassette joint, cut off the
2.
excess length of inner cable and then install the inner end cap.
15 – 20 mm
LOCK
JAPAN
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)
One Holland Irvine CA 92618 U.S.A. Phone 949 -951-5003
Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone 31-341-272222
3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone 07 2-223-3243
C
Mar. 2003 by Shimano Inc. PIT. SZK. Printed in Japan
4
LOCK
Inner end cap
CJ-8S20
JAPAN
Yellow setting lines
JA
PAN
CJ-8S
20
LOCK
Cassette joint pulley
CJ-8S20
JAPAN
Cassette joint
pulley
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