Page 1
(English)
DM-SG0004-09
Dealer's Manual
ROAD MTB Trekking
INTER-11
INTER-8
City Touring/
Comfort Bike
URBAN SPORT E-BIKE
Page 2
CONTENTS
IMPORTANT NOTICE .............................................................................................. 3
TO ENSURE SAFETY ............................................................................................... 4
LIST OF TOOLS TO BE USED ................................................................................ 10
INSTALLATION ..................................................................................................... 12
Installation of the sprocket to the hub ..................................................................................................... 12
Installation of the CS-S500 sprocket with chain guard ............................................................................ 13
Installation of the cassette joint to the hub ............................................................................................. 14
Installation of the disc brake rotor ...........................................................................................................16
Installation of the hub to the frame ......................................................................................................... 17
Installing the shifter ...................................................................................................................................19
Installation of the shifting cable ...............................................................................................................19
ADJUSTMENT ...................................................................................................... 32
Adjusting the cassette joint ....................................................................................................................... 32
MAINTENANCE .................................................................................................... 36
Replacement and assembly of the indicator unit ....................................................................................36
For internal 8-speed (oil maintenance kit: Y00298010) ........................................................................... 40
For internal 11-speed (oil maintenance kit: Y13098023) ......................................................................... 44
2
Page 3
IMPORTANT NOTICE
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.
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
distributor for 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.
3
Page 4
TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
•
Be sure to follow the instructions provided in the manuals when installing the product.
Only use SHIMANO genuine parts. If a component or replacement part is incorrectly assembled or adjusted, it can lead to component failure and cause
the rider to lose control and crash.
•
Wear approved eye protection while performing maintenance tasks such as replacing components.
Be sure to also inform users of the following:
•
Because each bicycle may handle slightly differently depending on the model, 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 bicycle's brake system may result in a loss of control,
which could lead to serious injury due to a fall or collision.
•
Check that the wheels are fastened securely before riding the bicycle. You may fall or collide and be seriously injured.
Brake
•
Do not apply the front brake too strongly. If you do so, the front wheel may lock and the bicycle may fall forward, and serious injury may result.
•
Because the required braking distance will be longer during wet weather, reduce your speed and apply the brakes early and gently. You may fall or
collide and be seriously injured.
•
A wet road surface may cause tires to lose traction; therefore, to avoid this, reduce your speed and apply the brakes early and gently. If the tires lose
traction, it may result in serious injury due to a fall or collision.
Disc brake
•
Keep your fingers away from rotating disc brake rotors. Disc brake rotors are sharp enough to severely injure your
fingers if caught within the openings of a disc brake rotor.
•
Do not touch the calipers or disc brake rotor while riding or immediately after dismounting from the bicycle. The calipers and disc brake rotor will
become hot when the brakes are operated, so you may get burned if you touch them.
•
Do not allow any oil or grease to get onto the disc brake rotor and brake pads. Riding the bicycle with oil or grease on the disc brake rotor and brake
pads may prevent the brakes from operating and result in serious injury due to a fall or collision.
•
Check the thickness of the brake pads and do not use them if they have a thickness of 0.5 mm or less. Doing
otherwise may prevent the brakes from operating and result in serious injury due to a fall or collision.
•
Do not use the disc brake rotor if it is cracked or warped. The disc brake rotor may break, and result in serious injury due to a fall.
•
Do not use the disc brake rotor if its thickness is 1.5 mm or less. Also do not use it if the aluminum surface becomes visible. The disc brake rotor may
break, and result in serious injury due to a fall or collision.
0.5 mm2 mm
4
Page 5
TO ENSURE SAFETY
For installation to the bicycle and maintenance
•
When installing the hub to the frame, be sure to install the correct non-turn washers to the left and right sides, and securely tighten the hub nuts to
the specified torques. If the non-turn washers are installed on one side only, or if the hub nuts are not tightened sufficiently, the non-turn washer may
fall out, which could cause the hub axle to rotate and the cassette joint to turn, resulting in the handlebars being accidentally pulled by the gear
shifting cable and an extremely serious accident.
•
Assemble the wheel with 3x or 4x lacing, and do not spoke the wheel radially. Otherwise, the spokes or the wheel may get damaged, or noise may
occur when braking.
< CT-S500 / CT-S510 >
•
Never use alkali- or acid-based solvents such as rust cleaners. If those solvents are used the chain might break and cause serious injury.
•
Clean the chain with an appropriate chain cleaner regularly. Intervals between maintenance depend on the use and riding circumstances.
•
Use the reinforced connecting pin only for connecting the narrow-type chain. If connecting pins other than reinforced connecting pins are used, or if a
reinforced connecting pin or tool which is not suitable for that type of chain is used, sufficient connection force may not be obtained, which could
cause the chain to break or skip.
•
If it is necessary to readjust 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 reinforced connecting pin or an end pin. The chain will be damaged if it is cut at a place where it has been
joined with a reinforced connecting pin or an end pin.
End pin
•
Check that the tension of the chain is correct and that the chain is not damaged. If the tension is too weak or the chain is damaged, the chain should
be replaced. If this is not done, the chain may break and cause serious injury.
Link pin Reinforced connecting pin
5
Page 6
TO ENSURE SAFETY
CAUTION
Be sure to also inform users of the following:
•
Shift the shifter one or two gears at a time. During shifting, reduce the pedal pressure. If you try to force operation of the shifter or suddenly shift
three or more gears while the pedals are being turned strongly, your feet may come off the pedals and the bicycle may fall over, which could result in
serious injury.
Operating the shifter to multi-shift to a light gear may also cause the outer casing to spring out of the shifter. This does not affect the capabilities of
the shifter because the outer casing returns to the original position after shifting.
Disc brake
•
Disc brakes have a bed-in period, and the braking force will gradually increase as the bed-in period progresses. You may lose control of the bicycle,
which can result in serious injury due to a fall or collision.
The same thing will happen when the brake pads or disc brake rotor are replaced.
NOTICE
Be sure to also inform users of the following:
•
The gears can be shifted while lightly pedaling, but on rare occasions the pawls and ratchet inside the hub may produce some noise afterwards as part
of normal gear shifting operation.
•
The internal geared hub is not completely waterproof. Avoid using the hub in places where water might get inside and do not use high-pressure jets
of water to clean the hub, otherwise the internal mechanism may rust.
•
The internal geared hub has a built-in mechanism to support shifting, and when this support mechanism operates during shifting, noise or vibration
may occur. Depending on the gear position, gear shifting may give different feels.
Noise may also occur if the gear is positioned at 5 to 8 (internal 8-speed hub) or 7 to 11 (internal 11-speed hub), when the crank is turned backward or
when the bicycle is pushed backward.
All of these phenomena occur due to the internal gear shifting mechanism and are not the failure of the internal components.
•
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.
6
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TO ENSURE SAFETY
For Installation to the Bicycle, and Maintenance:
•
The cassette joint should only be used with sprockets from 16T to 23T.
•
It is recommended that the chain ring of the front be set to the following gear ratio.
Front Rear
Sprocket
ratio
11-speed 1.8 - 2.0
Model No. Chainring
14 15 16 17 18 19 20 21 22 23 18 20
38T - - - - - X X X - - - -
39T - - - - - - X X - - - -
FC-S501
42T - - - - - - - X X X - -
45T - - - - - - - - - X - -
45T - - - - - - X X X - - X
SM-GEAR CS-S500
8-speed 2.0 - 2.25 FC-S501
•
In order to maintain proper performance, it is recommended that you carry out maintenance such as replacing the oil and applying grease to the
internal unit after riding 1,000 km from the start of use, then after about once every year (or once about every 2,000 km if the bicycle is used very
frequently). If the bicycle is used under harsh conditions, more frequent maintenance is required.
Also, for carrying out maintenance, the use of SHIMANO internal geared hub grease or a lubrication kit is recommended. If SHIMANO grease or a
SHIMANO lubrication kit is not used, problems such as a malfunction in shifting unit may occur.
•
If the wheel becomes stiff and difficult to turn, perform an inspection.
•
The chainrings and sprockets should be periodically washed with a neutral detergent and lubricated. In addition, cleaning the chain with neutral
detergent and lubricating it can be an effective way of extending the life of the chainrings, sprockets, and the chain.
42T - - - - - X X X - - - X
39T - - - - X X - - - - X -
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Page 8
TO ENSURE SAFETY
•
If the chain keeps skipping during use, replace the chainrings, sprockets, and the chain.
•
If using a chain tensioner, use the special CS-S500 18T or 20T sprocket with chain guard. Do not use any other types of sprockets, otherwise the chain
may come off the sprockets.
< SG-S7001-11 >
•
When you perform oil maintenance, use the SG-S700 OIL or TL-S703 maintenance kit.
When you replace the oil, follow the manual for TL-S703. When you replace the seal on the right side, use TL-S704.
If SG-S700 OIL is not used, problems such as an oil leakage and gear shifting malfunction may occur.
< CT-S500 / CT-S510 >
•
Clean the chain tensioner periodically and lubricate all moving parts and pulleys.
•
If there is a large amount of play in the pulleys and an abnormal amount of noise is generated while riding, replace the pulleys.
•
Do not disassemble the pulley unit.
•
If the tension applied is too strong, noise may be generated while riding.
•
If the chain becomes elongated and excessive looseness occurs, readjust the chain tension.
< CT-S510 >
Applicable hubs Applicable sprockets Supported rear dropout thickness Supported rear dropout shape
Internal 7-speed / 8-speed 16 - 23T 4 - 9 mm Vertical
•
This product is for single front chainrings only.
The actual product may differ from the illustration because this manual is intended chiefly to explain the procedures for using
the product.
8
Page 9
LIST OF TOOLS TO BE USED
Page 10
LIST OF TOOLS TO BE USED
LIST OF TOOLS TO BE USED
The following tools are required to assemble the product.
Tool Tool Tool
3 mm hexagon wrench 15 mm spanner TL-S700-B
4 mm hexagon wrench Adjustable wrench TL-LR10
10 mm spanner Screwdriver
10
Page 11
INSTALLATION
Page 12
INSTALLATION
Installation of the sprocket to the hub
INSTALLATION
Installation of the sprocket to the hub
Place the right-hand dust cap B/right-hand dust cap C onto the driver on the right side of
the hub body.
Next, install the sprocket and secure it in place with the snap ring.
(A)
(B)
(C)
(D)
(E)
(F)
Note the orientation of the right-hand dust
cap.
Specification A
If the sprocket is an inward assembling
sprocket with 19T or fewer or for belt drive
specifications, right-hand dust cap A will come
into contact with the chain or pulley so
specification B should be used instead.
Specification B
If the sprocket is an inward assembling
sprocket with 16T and 3 mm teeth or for belt
drive specifications, remove right-hand dust
cap B before use.
Specifications
A
B
(A)
(B)
Applicable sprockets
Outward assembling Inward assembling
16T-23T
16T-23T
Outward assembling Inward assembling
20T-23T
(D) (E)
Specification A Specification B
(F)
Snap ring
Sprocket
Driver
Right-hand dust cap C
Right-hand dust cap B
Right-hand dust cap A
NOTICE
(C)
Specification A Specification B
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Page 13
INSTALLATION
Installation of the CS-S500 sprocket with chain guard
Installation of the CS-S500 sprocket with chain guard
1
(z)
(A)
(B)
(C) (D)
Install the chain guard to the right hand
dust cap of the hub body, and then
install right hand dust cap B to the
driver.
Install the right-hand dust cap B in the
orientation (z).
(A)
Right hand dust cap B
(B)
Chain guard
(C)
Right hand dust cap
(D)
Driver
2
(B)
(C) (A)
(D)
Install the CS-S500 sprocket to the driver
on the right side of the hub body with
the guard plate facing outward, and
secure it in place with the snap ring.
13
(A)
Driver
(B)
Snap ring
(C)
Guard plate
(D)
CS-S500 Sprocket
Page 14
INSTALLATION
(A)
Installation of the cassette joint to the hub
Installation of the cassette joint to the hub
1
(B)
(z)
Install the driver cap to the driver on the
right side of the hub body.
Install the driver cap in the orientation
(z).
(A)
(B)
Driver cap
Driver
2
(A)
(B)
(C)
Turn the cassette joint pulley in the
direction of the arrow in the illustration
to align the red marks on the pulley
and the bracket.With the cassette joint
in this condition, install it so that the red
mark on the cassette joint is aligned
with the red mark on the right side of
the hub body.
(A)
Pulley
(B)
Bracket
(C)
Cassette joint
To be continued on next page
14
Page 15
INSTALLATION
Installation of the cassette joint to the hub
3
LOCK
Secure the cassette joint to the hub with
the cassette joint fixing ring.
(B)
(A)
LOCK
(B)
When installing the cassette joint fixing
ring, align the yellow mark with the
yellow mark on the cassette joint
pulley, and then turn the cassette joint
fixing ring 45° clockwise.
(A)
Pulley
(B)
Cassette joint fixing ring
15
Page 16
INSTALLATION
Installation of the disc brake rotor
Installation of the disc brake rotor
Install the disc brake rotor as shown in the illustration.
SG-S7001-8
(A) (B) (C)
SG-S7001-11
(A)
Disc brake rotor
(B)
Disc brake rotor installation ring
(C)
TL-LR10
Tightening torque
40 N·m
(A)
Disc brake rotor
(B)
Rotor spacer
(C)
Disc brake rotor installation ring
(D)
TL-LR10
(A) (B) (C) (D)
Tightening torque
40 N·m
16
Page 17
INSTALLATION
Installation of the hub to the frame
Installation of the hub to the frame
1
LOCK
LOCK
(A) (B)
(C)
When not using the chain tensioner
Mount the chain on the sprocket, then
set the hub axle into the rear dropout.
When using the chain tensioner
Mount the chain on the sprocket, then
set the hub axle into the rear dropout.
(A)
Hub axle
(B)
Rear dropout
(C)
Chain tensioner
NOTICE
When using the chain tensioner, be sure to
read these instructions in conjunction with
the instructions for the CT-S500 chain
tensioner.
2
(B) (A)
(A) (B)
LOCK
7R
Place the non-turn washers onto the
right side and left side of the hub axle.
At this time, turn the cassette joint so
that the protrusions of the non-turn
washers fit into the grooves in the rear
dropout and align the joint to be almost
parallel to the chainstay.
(E)(D)(C)
Non-turn washer
Rear dropout
5R/Yellow 5L/Brown ϴ ≤ 20°
Standard
Reversed 6R/Silver 6L/White ϴ = 0°
Reversed
(full chain case)
Vertical 8R/Blue 8L/Green ϴ = 60° - 90°
7R/Black 7L/Gray
9R/Light green 9L/Light brown
5R/Yellow 5L/Brown ϴ = 0°
Mark / Color
Right Left
Size
20° ≤ ϴ ≤ 38°
(A)
Non-turn washer (for left side)
(B)
Rear dropout groove
(C)
Chainstay
(D)
Cassette joint
(E)
Non-turn washer (for right side)
TECH TIPS
•
Use a non-turn washer that matches the
shape of the rear dropout. Different
non-turn washers are used for the left and
right sides.
•
The protrusion should be on the rear
dropout side.
•
Install the non-turn washer so that the
protrusion fits securely in the rear dropout
groove at the front and back sides of the
hub axle.
Mark
θ
To be continued on next page
17
Page 18
INSTALLATION
Installation of the hub to the frame
3
7R
K
LOC
(A) (B)
(A) (C) (D)
6R
Take up the slack in the chain and secure
the wheel to the frame with the cap
nuts.
When installing a part such as a
mudguard stay to the hub axle, install in
the order shown in the illustration.
(A)
Non-turn washer
(B)
Cap nut
(C)
Carrier stay
(D)
Washer
(E)
Mudguard stay
Tightening torque
30 - 45 N·m
NOTICE
When installing the hub to the frame, the
chain guard may come off, so check that the
chain guard is securely installed so that it will
not come off.
If it is not fully installed, noise may be
generated.
Chain guard
7R
LOCK
(E) (B)
18
Page 19
INSTALLATION
Installing the shifter
Installing the shifter
1
2
(A)
(z)
Mount the shifter on to the handlebar.
(z)
Φ22.2
Mount the grip on to the handlebar and
secure the shifter.
NOTICE
Use a handlebar with an outer diameter of
Φ22.2 mm.
(A)
4 mm hexagon wrench
Tightening torque
5 - 7 N·m
NOTICE
Use a handlebar grip with a maximum outer
diameter of Φ32 mm.
Installation of the shifting cable
For internal 8-speed
Shifter side
1
Set the shifter to 8 .
NOTICE
•
Use a shifting cable with one inner cable
drum.
Cable with one inner cable drum: OT-SP41
•
Make sure that the sealed outer cap is at
the shifter end.
To be continued on next page
19
Page 20
INSTALLATION
Installation of the shifting cable
2
3
(A)
(A) (B)
Loosen and remove the inner hole cap.
Insert the inner cable into the winder
unit cable fixing groove, then pass it
through the hole in the cable adjustment
barrel.
(A)
Inner hole cap
(A)
Hole in cable adjustment barrel
(B)
Winder unit cable fixing groove
4
5
(A) (B)
(A)
Pull the inner cable so that the inner
cable drum fits into the hole in the
winder unit.
Screw in the inner hole cap as shown in
the illustration until it stops.
If it is turned any further, it will damage
the screw thread in the cover.
In addition, the unit cover may become
bent, which may cause an obstruction
between the unit cover and the main
lever, and the main lever may not
operate correctly.
(C)(B)
If the main lever does not return
properly, loosen the inner hole cap
slightly to make a gap between the main
lever and the unit cover, and check that
this improves the returning of the main
lever.
(A)
Inner cable drum
(B)
Hole in winder unit
(A)
Inner hole cap
(B)
Unit cover
(C)
Main lever
To be continued on next page
20
Page 21
INSTALLATION
Installation of the shifting cable
(A) (B)
6
Pass the inner cable through the OT-SP41
outer casing through the end with the
plastic cap.
(A)
Aluminum cap
(B)
Plastic cap
TECH TIPS
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
Make the cut end perfectly round.
Attach the plastic cap
21
Page 22
INSTALLATION
Installation of the shifting cable
Cassette joint end
1
(x)
(y)
(A)
(z)
(B)
(C)
(D)
After checking that the end of the outer
casing is sitting securely in the cable
adjustment barrel of the shifter, attach
the inner cable fixing bolt unit to the
inner cable.
Then, pull the inner cable while
attaching the inner cable fixing bolt unit.
(x)
10 mm
(y)
145 mm
(z)
63 mm or less
(A)
Inner cable fixing bolt unit
(B)
Inner cable mounting nut
(C)
Inner cable fixing washer
(D)
Inner cable fixing bolt
Tightening torque
3.5 - 5.5 N·m
NOTICE
Do not use this inner cable fixing bolt unit
with the CJ-4S30 cassette joint.
TECH TIPS
When installing the inner cable fixing bolt
unit, use the setting tool TL-S700-B.
2
(A)
(B)
(z) (y)
Bring the cable around to the cassette
joint pulley, hold it so that the inner
LOCK
cable mounting nut is facing outwards
(towards the rear dropout), then slide
the flats part (z) of the inner fixing
washer into the notch (y) in the pulley.
(A)
Inner cable mounting nut
(B)
Pulley
To be continued on next page
22
Page 23
INSTALLATION
Installation of the shifting cable
3
4
(A)
(B) (A)
Turn the cable 60˚ counterclockwise and
attach it to the hook.
LOCK
Set the inner cable in the pulley as
(C)
shown in the figure and, while holding
the rubber cover, insert the rubber
bellows of the inner cable into the slit in
the cassette joint bracket (y) and securely
set the outer casing holder body into the
outer casing holder section of the
cassette joint (z).
(A)
Hook
(A)
Pulley
(B)
Inner cable
(C)
Bracket
(D)
Outer casing holder section
(E)
Slit
NOTICE
Check that the inner cable is correctly seated
inside the pulley guide.
Guide Guide
5
(E)
(y)
(y)
(A)
(C)
(D)
(z)
Secure the cable to the frame with the
outer casing bands.
(y)
10 cm
(z)
15 cm
LOCK
(A)
Outer casing bands
LOCK
23
Page 24
INSTALLATION
Installation of the shifting cable
Disconnecting the shifting cable when removing the rear wheel from the frame
1
(A)
Disconnect the cable from the cassette
joint when removing the rear wheel
from the frame.
Set the shifter to 8 .
(A)
Cassette joint
(A) (B) (C)
2
3
(A) (B)
LOCK
Pull out the outer casing from the outer
casing holder section of the cassette
joint, and remove the inner cable from
the slit in the bracket.
Remove the inner cable fixing bolt unit
from the cassette joint pulley.
(A)
Bracket
(B)
Outer casing holder section
(C)
Slit
(A)
Inner cable fixing bolt unit
(B)
Cassette joint pulley
NOTICE
If reinstalling the cable, refer to steps 2 to 4 in
"Cassette joint end".
24
Page 25
INSTALLATION
Installation of the shifting cable
For internal 11-speed
Shifter side
1
2
(A)
Set the shifter to 11.
Loosen and remove the inner hole cap.
NOTICE
•
Use a shifting cable with one inner cable
drum.
Cable with one inner cable drum: OT-SP41
•
Make sure that the sealed outer cap is at
the shifter end.
(A)
Wire end hooking cap
3
4
(A)
(A)
(B)
(B)
Insert the inner cable into the hole in the
winder unit, and then pass it through
the hole in the cable adjustment barrel.
Pull the inner cable so that the inner
cable drum fits into the hole in the
winder unit.
(A)
Hole in cable adjustment barrel
(B)
Hole in winder unit
(A)
Inner cable drum
(B)
Hole in winder unit
To be continued on next page
25
Page 26
INSTALLATION
Installation of the shifting cable
5
(A) (B)
(A)
Screw in the inner hole cap as shown in
the illustration until it stops.
If it is turned any further, it will damage
the screw thread in the cover.
In addition, the unit cover may become
bent, which may cause an obstruction
between the unit cover and the main
lever, and the main lever may not
operate correctly.
(C)(B)
(z)
If the main lever does not return
properly, loosen the inner hole cap
slightly to make a gap between the main
lever and the unit cover, and check that
this improves the returning of the main
lever.
Pass the inner cable through the OT-SP41
outer casing through the end with the
plastic cap.
(z)
Lever side
(A)
Inner hole cap
(B)
Unit cover
(C)
Main lever
(A)
Aluminum cap
(B)
Plastic cap
Tightening torque
0.3 - 0.5 N·m
TECH TIPS
6
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
Make the cut end perfectly round.
Attach the plastic cap
26
Page 27
INSTALLATION
Installation of the shifting cable
Cassette joint end
1
2
(A) (B) (C)
(D) (E)
(E)
(A) (C)
(B) (F)
Install the rubber cover and rubber
bellows to the outer casing holder body.
Wipe away any grease which may be on
the inner cable and, while holding the
end of the rubber bellows, pass the inner
cable through. Be careful not to pierce
the rubber bellows with the end of the
inner cable at this time.
Slide the rubber bellows onto the inner
cable.
After this, insert the outer casing into
the rubber cover and set it into the outer
casing holder body. Push the outer
casing so that it securely touches the
holder body.
(A)
Rubber bellows
(B)
Outer casing holder body
(C)
Rubber cover
(A)
Rubber bellows
(B)
Outer casing holder body
(C)
Rubber cover
(D)
End of rubber bellows
(E)
Inner cable
(F)
Outer casing
NOTICE
Use a new inner cable. Do not use a cable
which has had the end cut off.
Pay attention to the end of the inner cable.
To be continued on next page
27
Page 28
INSTALLATION
Installation of the shifting cable
3
(x)
(A)
(y)
(z)
(B)
(C)
(D)
After checking that the end of the outer
casing is sitting securely in the cable
adjustment barrel of the shifter, attach
the inner cable fixing bolt unit to the
inner cable.
Then, pull the inner cable while
attaching the inner cable fixing bolt unit.
(x)
10 mm
(y)
184 mm
(z)
75 mm or less
(A)
Inner cable fixing bolt unit
(B)
Inner cable mounting nut
(C)
Inner cable fixing washer (Black)
(D)
Inner cable fixing bolt (Black)
Tightening torque
3.5 - 5.5 N·m
NOTICE
This inner cable fixing bolt unit is designed
only for CJ-S700. 7-step and 8-step fixing bolt
units cannot be used.
TECH TIPS
When installing the inner cable fixing bolt
unit, use the setting tool TL-S700-B.
4
5
(A)
(A)
(B)
(z)
Turn the lever of the pulley clockwise.
In the following steps 5 and 7, continue
to work in this condition.
Bring the cable around to the cassette
joint pulley, hold it so that the inner
cable mounting nut is facing outwards
(towards the rear dropout), then slide
the flats part (z) of the inner fixing
washer into the notch (y) in the pulley.
(A)
Pulley lever
(A)
Inner cable mounting nut
(B)
Pulley
(y)
To be continued on next page
28
Page 29
INSTALLATION
Installation of the shifting cable
6
(A)
(A)
(z)
(B)
(H)
(y)
(G)
(C)
Turn the cable 60˚ counterclockwise and
attach it to the hook.
Set the inner cable in the pulley as
shown in the figure and, while holding
the rubber cover, insert the rubber
bellows of the inner cable into the slit in
the cassette joint bracket (y) and securely
set the outer casing holder body into the
outer casing holder section of the
cassette joint (z). Be careful not to
damage the rubber bellows at this time.
(A)
Hook
(A)
Rubber bellows
(B)
Outer casing holder body
(C)
Rubber cover
(D)
Inner cable
(E)
Pulley
(F)
Bracket
(G)
Slit
(H)
Outer casing holder section
NOTICE
Check that the inner cable is correctly seated
inside the pulley guide.
Guide Guide
7
8
(E)
(y)
(D)
(y)
(z)
(F)
Secure the cable to the frame with the
outer casing bands.
(y)
10 cm
(z)
15 cm
(A)
Outer casing bands
(A)
29
Page 30
INSTALLATION
11
Installation of the shifting cable
Disconnecting the shifting cable when removing the rear wheel from the frame
1
(A)
(A)
Disconnect the cable from the cassette
joint when removing the rear wheel
from the frame.
Set the shifter to
Press the lever of the pulley clockwise to
loosen the inner cable. In the following
steps 3 and 4, continue to work in this
condition.
.
(A)
Cassette joint
(A)
Pulley lever
2
3
4
(A)
(D) (E)
(A)
(B)
(B)
(z)
(C)
(y)
Remove the outer casing holder body
from the outer casing holder section of
the cassette joint (y).
Remove the inner cable the rubber
bellows is attached to from the slit in the
bracket (z). Be careful not to damage the
rubber bellows at this time.
Remove the inner cable fixing bolt unit
from the cassette joint pulley.
(A)
Rubber bellows
(B)
Outer casing holder section
(C)
Outer casing holder body
(D)
Bracket
(E)
Slit
(A)
Inner cable fixing bolt unit
(B)
Cassette joint pulley
NOTICE
If reinstalling the cable, refer to steps 4 to 7 in
"Cassette joint end".
30
Page 31
ADJUSTMENT
Page 32
ADJUSTMENT
(B)
4
Adjusting the cassette joint
ADJUSTMENT
Adjusting the cassette joint
For internal 8-speed
Set the shifter from 8 to 4 .
Check to be sure that the yellow setting
lines on the cassette joint bracket and
pulley are aligned at this time.
If the yellow setting lines are not
aligned, turn the cable adjustment barrel
of the shifter to align the setting lines.
After this, move the shifter again from
to 8 then back to 4 , and re-check
that the yellow setting lines are aligned.
(A)
Yellow setting lines
(B)
Cable adjustment barrel
TECH TIPS
•
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 aligned
Pulley
1
(A)
LOCK
Bracket
< When bicycle is upside down >
Should be aligned
LOCK
Bracket
Pulley
To be continued on next page
32
Page 33
ADJUSTMENT
Adjusting the cassette joint
2
(z)
LOCK
(A)
After adjusting the cassette joint, cut off
the excess length of inner cable.
Then install the inner end cap.
(z)
15 - 20 mm
(A)
Inner end cap
33
Page 34
ADJUSTMENT
6
6
Adjusting the cassette joint
For internal 11-speed
Set the shifter from 11 to
Check to be sure that the yellow setting
lines on the cassette joint bracket and
pulley are aligned at this time.
.
(A)
Yellow setting lines
(B)
Cable adjustment barrel
1
(A)
If the yellow setting lines are not
aligned, turn the cable adjustment barrel
of the shifter to align the yellow setting
lines.
After this, move the shifter again from
to 11 then back to 6 , and re-check
that the yellow setting lines are aligned.
TECH TIPS
•
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 pulley
Cassette joint pulley
2
(z)
(B)
(A)
After adjusting the cassette joint, cut off
the excess length of inner cable.
Then install the inner end cap.
After installing the inner end cap,
slightly bend the inner cable outward
(towards the rear dropout) so that it
does not touch the chain.
(z)
25 - 30 mm
Cassette joint bracket
(A)
Inner end cap
34
Page 35
MAINTENANCE
Page 36
MAINTENANCE
8
Replacement and assembly of the indicator unit
MAINTENANCE
Replacement and assembly of the indicator unit
Disassembly and assembly should only be carried out when removing and replacing the indicator unit.
For internal 8-speed
Removal
1
2
(A)
(A)
Operate the release lever 7 times or
more to set it to
Loosen and remove the two cover fixing
screws which are securing the indicator
unit.
.
(A)
Release lever
(A)
Cover fixing screws
To be continued on next page
36
Page 37
MAINTENANCE
Replacement and assembly of the indicator unit
3
(A)
Remove the indicator unit as shown in
the illustration.
(A)
Indicator unit
37
Page 38
MAINTENANCE
Replacement and assembly of the indicator unit
Installation
(A)
(B)
(C) (D)
1
2
(A)
Check that the needle of the indicator is
on the left side ( 8 position), and then
install the indicator unit so that it is
facing straight upward.
Insert the pin of the change plate that is
protruding from the bottom of the
indicator unit into the hole in the winder
unit at this time.
Secure the indicator unit with the two
cover fixing screws.
(A)
Indicator unit
(B)
Pin of change plate
(C)
Hole in winder unit ( 8 position)
(D)
Release lever
(A)
Cover fixing screws
Tightening torque
0.3 - 0.5 N·m
Operate the main and the release levers, to check their operation.
3
If they do not operate correctly, reinstall the indicator unit while taking particular note of
step 1.
38
Page 39
MAINTENANCE
11
Replacement and assembly of the indicator unit
For internal 11-speed
Removal
(A)
Installation
(A)
(B)
1
(C)
(B)
(B)
(F)
(E)
(D)
(C)
Operate the release lever 10 times or
more to set it to
Loosen and remove the three cover
fixing screws which are securing the
indicator unit.
Remove the indicator unit as shown in
the illustration.
Check that the needle of the indicator is
on the left side ( 11 position), and then
install the indicator unit so that it is
facing straight upward.
At this time, check that the main axle is
installed in the cam unit hole and that
the pin of the cam unit is installed in the
winder unit hole, and then insert the
indicator shaft protruding from the
bottom of the indicator unit into the
groove of the cam unit.
.
(A)
Release lever
(B)
Cover fixing screws
(C)
Indicator unit
(A)
Indicator shaft
(B)
Cam unit groove ( 11 position)
(C)
Cam unit pin
(D)
Indicator unit
(E)
Cam unit hole
(F)
Main axle
(G)
Winder unit hole
(G)
Secure the indicator unit with the three cover fixing screws.
2
Operate the main and the release levers, to check their operation.
3
If they do not operate correctly, reinstall the indicator unit while taking particular note of
step 1.
39
Tightening torque
0.3 - 0.5 N·m
Page 40
MAINTENANCE
For internal 8-speed (oil maintenance kit: Y00298010)
For internal 8-speed (oil maintenance kit: Y00298010)
Content of kit: WB maintenance oil, container
Important safety information
WARNING
•
When lubricating the internal unit, be careful that no oil gets on the disc brake rotor, pads, on the rim when using rim brakes, etc.
If oil gets on any of these parts, there is a danger that brake performance may be reduced. Take care of this problem according to the procedures in
the brake instruction manual.
•
Since there is a risk of explosion or fire, do not smoke, eat, or drink while using this oil. In addition, keep it away from ignition sources such as heat,
sparks, open flames, or high temperatures and prevent it from catching fire due to static electricity sparks or other sparks.
•
Use only outdoors or in a well-ventilated area. Inhalation of oil mist or vapors may cause nausea. Be careful to provide ventilation and use a respirator
type mask. 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.
Cautions regarding handling of WB maintenance oil:
•
Use appropriate eye protection when handling, and avoid contact with eyes. In the event of eye contact, flush with fresh water and seek medical
assistance immediately. Contact with eyes may result in irritation.
•
Use gloves when handling. In the event of skin contact, wash well with soapy water. Contact with skin may cause a rash and discomfort.
•
Do not drink. If it is drunk by mistake, do not induce vomiting; make the affected person drink 1 to 2 cups of water and seek medical assistance
immediately.
If the affected person loses consciousness, do not give the person anything by their mouth. If vomiting occurs naturally, tilt the body to prevent
inhalation.
•
After use, be sure to wash hands thoroughly.
•
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.
•
Keep out of reach of children.
•
Dispose of used oil, old oil, or oil used for cleaning in accordance with the method stipulated by the law.
•
To maintain the product in good working order, lubricate the internal unit after the first 1,000 km from the start of use of the product, and once every
year thereafter (after every 2,000 km if bicycle is ridden frequently).
•
Do not use oil other than WB maintenance oil. Problems such as an oil leakage and gear shifting malfunction may occur.
•
Disposal of used oil: Follow local county and/or state codes for disposal. Use caution when preparing the oil for disposal.
•
Read this manual carefully, and keep it in a safe place for later reference.
•
For the latest product safety data sheets, check the website https://si.shimano.com.
40
Page 41
MAINTENANCE
For internal 8-speed (oil maintenance kit: Y00298010)
1
(z)
2
Fill the bottle with WB oil to a height of
95 mm.
(z)
95 mm
(z)
Immerse the internal unit into the oil
from the left side. Immerse until the oil
reaches up to ring gear unit 1.
(z)
Ring gear unit 1
3
Keep the internal unit immersed as
illustrated for approximately 90 seconds.
To be continued on next page
41
Page 42
MAINTENANCE
For internal 8-speed (oil maintenance kit: Y00298010)
4
5
Remove the internal unit from the oil.
Let the excess oil drain off for
approximately 60 seconds.
6
After lubrication is complete, reassemble
by following the usual procedure.
TECH TIPS
<Maintenance oil>
•
The maintenance oil is reusable.
Refill it as needed.
•
Store it with the lid closed after use.
To be continued on next page
42
Page 43
MAINTENANCE
For internal 8-speed (oil maintenance kit: Y00298010)
NOTICE
After oil maintenance, it is recommended that you apply Grease (Y04130100) to the ball retainers, snap ring, brake shoe, and pinion gears.
Pinion gears
Ball retainer
The illustration shows an example.
Brake shoe
Snap ring
Ball retainer
43
Page 44
MAINTENANCE
For internal 11-speed (oil maintenance kit: Y13098023)
For internal 11-speed (oil maintenance kit: Y13098023)
Content of kit: syringe, tube, bleed nipple, O-ring, container
Important safety information
WARNING
•
When replacing the oil, be careful that no oil gets on the disc brake rotor, pads, on the rim when using rim brakes, etc.
If oil gets on any of these parts, there is a danger that brake performance may be reduced.
Take care of this problem according to the procedures in the brake instruction manual.
•
Since there is a risk of explosion or fire, do not smoke, eat, or drink while using this oil. In addition, keep it away from ignition sources such as heat,
sparks, open flames, or high temperatures and prevent it from catching fire due to static electricity sparks or other sparks.
•
Use only outdoors or in a well-ventilated area. Inhalation of oil mist or vapors may cause nausea. Be careful to provide ventilation and use a respirator
type mask.
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.
Cautions regarding handling of SG-S700 OIL:
•
Use appropriate eye protection when handling, and avoid contact with eyes. In the event of eye contact, flush with fresh water and seek medical
assistance immediately. Contact with eyes may result in irritation.
•
Use gloves when handling. In the event of skin contact, wash well with soapy water. Contact with skin may cause a rash and discomfort.
•
Do not drink. If it is drunk by mistake, do not induce vomiting; make the affected person drink 1 to 2 cups of water and seek medical assistance
immediately.
If the affected person loses consciousness, do not give the person anything by their mouth. If vomiting occurs naturally, tilt the body to prevent
inhalation.
•
After use, be sure to wash hands thoroughly.
•
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.
•
Keep out of reach of children.
•
Dispose of used oil, old oil, or oil used for cleaning in accordance with the method stipulated by the law.
•
To maintain the product in good working order, replace the oil after the first 1,000 km from the start of use of the product, and once every year
thereafter (after every 2,000 km if bicycle is ridden frequently).
•
Do not use oil other than SG-S700 OIL. Problems such as an oil leakage and gear shifting malfunction may occur.
•
Disposal of used oil: Follow local county and/or state codes for disposal. Use caution when preparing the oil for disposal.
•
Read this manual carefully, and keep it in a safe place for later reference.
•
For the latest product safety data sheets, check the website https://si.shimano.com.
TECH TIPS
When using a 1L can of oil, it may become impossible to suck out oil with a syringe when there is only a little oil left. First, transfer all oil to a
different container.
44
Page 45
MAINTENANCE
For internal 11-speed (oil maintenance kit: Y13098023)
Internal geared hub: Oil replacement
Draining out the old oil
Using a stand, etc., enable the rear wheel to
turn while performing work.
1
(A)
(A)
Rotate the wheel slowly until the oil port
is facing up.
Remove the oil port screw and O-ring.
(A)
Oil port
(A)
3 mm hexagon wrench
(B)
Oil port screw
(C)
O-ring
2
To be continued on next page
(B)
(C)
NOTICE
Be careful that the oil port is facing up; if the
oil port screw is loosened when it is not facing
up, the oil inside may leak out.
45
Page 46
MAINTENANCE
For internal 11-speed (oil maintenance kit: Y13098023)
3
4
(A) (B)
(C) (D)
(A)
(B)
Attach the bleed nipple with tube
attached to the hub shell.
With the piston of the syringe pushed
fully in, firmly connect the syringe to the
tube.
(A)
Hub shell
(B)
Tube
(C)
10 mm spanner
(D)
Bleed nipple
Tightening torque
1 - 3 N·m
TECH TIPS
Check that the O-ring is properly installed on
the bleed nipple.
(A)
Tube
(B)
Syringe
Insert the syringe between the spokes,
and slowly turn the wheel forward until
the oil port is facing down.
(z)
Turn in forward direction
5
(z)
Wait about 5 minutes with the hub kept still and not turning so that the oil settles.
6
To be continued on next page
46
Page 47
MAINTENANCE
For internal 11-speed (oil maintenance kit: Y13098023)
7
8
(A)
Pull the piston out slowly to draw out
the oil inside the hub shell.
Rotate the wheel slowly until the oil port
is facing up.
(A)
Piston
NOTICE
If the piston is pulled out quickly, air is likely
to be mixed in.
NOTICE
To make sure that the syringe does not get
caught by the chain case, etc., store the
syringe between the spokes when turning the
wheel.
9
10
(A)
(B)
While being careful that the tube does
not come off the syringe, remove the
bleed nipple.
Remove the old oil from the syringe.
(A)
Bleed nipple
(B)
10 mm spanner
47
Page 48
MAINTENANCE
For internal 11-speed (oil maintenance kit: Y13098023)
Cleaning the inside
Attach the bleed nipple to the hub shell.
1
Suck 25ml of new oil into the syringe and connect it firmly to the tube.
2
Push the piston to inject the new oil into
the inside of the hub.
(A)
3
Tightening torque
1 - 3 N·m
TECH TIPS
If the syringe or tube becomes dirty when
removing old oil or cleaning the inside of the
hub, clean the syringe and tube using parts
cleaner, etc., if necessary.
(A)
Piston
TECH TIPS
When the oil is forced in, the internal pressure
will increase and the piston may push back. If
the piston is periodically pulled back to
reduce the pressure inside the hub, the oil will
be easier to inject into the inside of the hub.
After pulling back the piston to reduce the internal pressure, remove the bleed nipple.
4
Install the O-ring and the oil port screw.
(A)
5
(B)
(C)
TECH TIPS
If the bleed nipple is removed without pulling
back the piston, the oil may flow back into
the piston together with air from inside the
tube and spill out of the piston.
(A)
3 mm hexagon wrench
(B)
Oil port screw
(C)
O-ring
Tightening torque
2 - 3 N·m
To be continued on next page
48
Page 49
MAINTENANCE
For internal 11-speed (oil maintenance kit: Y13098023)
While performing gear-change operations, turn the pedals to turn the wheel for about 1
minute.
6
Keep the wheel still without rotating for about 1 minute.
7
Remove the oil from inside by following the procedures in Draining out the old oil above.
8
Injecting new oil
Inject 25ml of new oil into the hub by following steps Cleaning the inside 1 - 5 above.
1
Clean off any oil that may have gotten on the hub, etc.
2
49
Page 50
Please note: specifications are subject to change for improvement without notice. (English)
© Nov. 2023 by SHIMANO INC. ITP
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