Front Drive System
General Safety Information
Technical Service Instructions
SI-F520B
Adjust and then install the front derailleur as shown in the illustration.
Do not remove the Pro-Set alignment block at this time.
WARNING
9-speed super narrow chain
such as
CN-7701 / CN-HG93
8-/7-/6-speed narrow
chain such as
CN-HG50 / CN-IG51
Operate lever (B) 2 or more times, check on the indicator that the
low position is correct, and then secure the inner cable.
After completion of steps 1 - 4, move the shifting lever to
check the shifting. (This also applies if shifting becomes
difficult during use.)
Pro-Set alignment block
• Use neutral detergent to clean the chain. Do not use alkali-based or acid based
detergent such as rust cleaners as it may result in damage and/or failure of the chain.
• Use the reinforced connecting pin only for connecting the narrow type of chain.
• There are two different types of reinforced connecting pins available. Be sure to check
the table below before selecting which pin to use. If connecting pins other than
reinforced connecting pins are used, or if a reinforced connecting pin or tool which is
not suitable for the type of chain is used, sufficient connection force may not be
obtained, which could cause the chain to break or fall off.
Chain
5. Troubleshooting chart
2. Connection and securing of the inner cable
Reinforced
connecting pin
Chain tool
Pro-Set gauge
3
Cap
1 mm
In order to realize the best performance, we recommend that the following
combination be used.
Series
Silver
TL-CN31/TL-CN22
Black
TL-CN31/TL-CN22 and
TL-CN30/TL-CN21
7.1mm
• If it is necessary to adjust 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
Tightening torque:
5 - 7 N·m {44 - 60 in. lbs.}
SL-MC40
Outer casing
SP40
Front derailleur
FD-CT92-E
FD-C102
Front chainwheel
FC-TX70
FC-TX71
Bottom bracket
BB-UN25
BB-TY30
Chain
CN-UG51 / CN-HG50
Bottom bracket cable guide
SM-SP18 / SM-BT18
The level section of the chain guide
outer plate should be directly above
and parallel to the largest chainring.
Secure using a 5 mm Allen key.
Chainwheel
(largest
chainring)
Chain guide
Tightening torque:
5 - 7 N·m {44 - 60 in. lbs.}
When cutting the outer casing, cut the opposite end to the end with
the marking. After cutting the outer casing,
make the end round so that the inside of the
hole has a uniform diameter.
RA-A
DU
Model number
Normal type
FD-C102
S
S
Top route type
S
S
Top gear tooth
42T
48T
Front chainwheel tooth difference
18T
20T
Min. difference between top and intermediate
8T
10T
S, M
Front derailleur installation band diameter
L
S, M, L
S, M
66°- 69° 66°- 69° 63°- 66°
66°- 69°
Applicable chain line
47.5 mm
47.5 mm
50 mm
50 mm
50 mm
47.5 mm
Chainstay
angle
Installation band diameters:
S (28.6 mm), M (31.8 mm), L (34.9 mm)
For IG, chains, insert the chain gauge
(TL-CN24) into the inner link which is
next to the chain connecting pin to
check that the inner link width is correct.
Check that the connecting pin pro-trudes
past the outer link by the same amount
2.38mm
on both sides, and that the amount of
Connecting pin
protrusion is 0.2 mm or more.
Applicable Bottom Bracket
BB-UN25
BB-UN25
Stamped marking
D-NL
47.5 mm
47.5 mm
BC 1.37" X 24 T.P.I. (68mm)
BC 1.37" X 24 T.P.I. (68mm)
Chain line
Thread dimensions
BB-TY30
D-NL
Incorrect
Installation of the Front Derailleur,
Bottom Bracket and Front Chainwheel
Front Derailleur
Use the special tools (TL-UN65 and TL-UN74-S) to install
the bottom bracket ➀ and the front derailleur so that they
face as shown in the illustration. Install the adapter ➁,
and then use the TL-FC10 to install the front chainwheel.
➂ Front Chainwheel
Loosen the top adjustment screw
counterclockwise
(about 1/8 turn).
If the intermediate chainring is Loosen the outer casing
skipped when shifting from the adjustment barrel
largest chainring.
counterclockwise (1 or 2 turns).
If there is interference between Tighten the outer casing
adjustment barrel clockwise
the chain and front derailleur
(1 or 2 turns).
inner plate when the rear
sprocket is shifted to the
largest sprocket when the
chainwheel is at the
intermediate chainring position.
Tighten the low adjustment
screw clockwise (about 1/2 turn).
To shift from a large chainring to a smaller chainring
Top route type
When lever (B) is pressed once, there is a shift of one step
from a large chainring to a smaller chainring.
Example:
from largest chainring to
intermediate chainring.
Pull
Installation of the shifting lever
Use a handlebar grip with a maximum
outer diameter of 32 mm.
Lever (B)
Tightening torque:
5 N·m {44 in. lbs.}
<FD-CT92-E>
If there is interference
between the chain and the
front derailleur outer plate at
the largest chainring.
After taking up the initial slack in the cable, re-secure to the front
derailleur as shown in the illustration.
Normal type
2
3
Because of the different construction of the new link,
the positions of the top and low adjustment bolts on
the FD-CT92-E/FD-C102 are reversed from the
positions on previous front derailleurs.
1
5 mm Allen key
Install the brake lever in a position where it will not obstruct brake
operation. Do not use in a combination which causes brake operation
to be obstructed.
3. Top adjustment
Set so that the clearance between the chain guide outer plate and
the chain is 0-0.5 mm.
Chain position
Smallest
sprocket
A
B
Largest
chainring
B A
Top
adjustment screw
SIS adjustment
➁ Adapter
➀ Bottom Bracket
Chain guide
outer plate
Chain
Be sure to follow the sequence described below.
1. Low adjustment
First remove the Pro-Set alignment block .
Next, set so that the clearance between the chain guide inner plate
and the chain is 0-0.5 mm.
<FD-C102>
Pro-Set
alignment block
Install using the special tool TL-UN74-S.
First install the main body, then the adapter.
B A
Low
adjustment screw
Adapter / bottom bracket tightening torque:
50 - 70 N·m {435 - 608 in. lbs.}
Chain position
Adapter
Main body
Largest
sprocket
Smallest
chainring
A
Chain
Use the cotterless crank extractor (TL-FC10) to
install the front chainwheel.
S
When carrying out adjustment, set the
chain to the largest sprocket, and at the
front, set the chain to the intermediate
chainring. Adjust using the outer casing
adjustment barrel so that the clearance
between the chain guide inner plate and
the chain is 0-0.5 mm.
B
Chain guide
inner plate
B
Largest
sprocket
Intermediate
chainring
3
2
A
This service instruction explains 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.
Chain
Chain position
Chain guide
inner plate
1
G
F
NA
n
C or
h
a
i
OW
y
RRn l
o
Outer casing
adjustment barrel
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
MA
SH
SHI
Front chainwheel tightening torque:
35 - 50 N·m {305 - 435 in. lbs.}
NO
I MA
NO
SG
SG
E
-3
0
LOW
4. Adjustment of the intermediate
chainring
E-
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222
40
HIGH
Correct
Outer link
Pull
Model number
Tighten the top adjustment screw
clockwise (about 1/8 turn).
Tightening torque:
5 - 7 N·m {44 - 60 in. lbs.}
BB-TY30
Bottom Bracket
If there is interference
between the chain and the
front derailleur inner plate at
the largest chainring.
When lever (A) is pressed once, there is a shift of one step
from a small chainring to a larger chainring.
Example:
Lever (A) initial position
from intermediate chainring to
largest chainring.
5 mm allen key
Wire fixing
bolt
SHIMANO JAPAN
CHAIN GAUGE
BC 9/16" X 20 T.P.I. (English thread)
Loosen the low adjustment
screw counterclockwise
(about 1/4 turn).
To shift from a small chainring to a larger chainring
Note:
Pass the cable
through as shown
in the illustration.
160 mm, 170 mm
Pedal thread dimensions
If shifting is difficult from the
intermediate chainring to the
smallest chainring.
Both lever (A) and lever (B) always return to the initial position
when they are released after shifting.
When operating one of the levers, always be sure to turn the
crank arm at the same time.
Pin
1=2.38mm
TL-CN24
Connecting pin
SHIMANO JAPAN
CHAIN GAUGE
48T-38T-28T
Loosen the top adjustment screw
counterclockwise
(about 1/8 turn).
If the chain falls to the bottom
bracket side.
Cut off any unnecessary cable, attach an end cup
and hook it onto the pin.
Inner link
FC-TX71
42T-32T-22T
Crank arm length
Chain gauge
TL-CN24
B
Chainwheel
Chainwheel tooth combination
If shifting is difficult from the
intermediate chainring to the
largest chainring.
Gear shifting operation
Checking the chain connection
A
FC-TX70
Attach the same outer end cap to the cut end of the outer casing.
Tighten the top adjustment screw
clockwise (about 1/4 turn).
Chain
A, B Q 0.2mm
Model number
Largest chainring
If the chain falls to the crank
side.
Outer end cap
1=2.38mm
TL-CN24
Chainstay angle (a)
Adapter / bottom bracket tightening torque:
50 - 70 N·m {435 - 608 in. lbs.}
Front chainwheel tightening torque:
35 - 50 N·m {305 - 435 in. lbs.}
FD-CT92-E/FD-C102 Adjustment Bolts
FD-CT92-E
Largest sprocket
Add 2 links (with the chain on both the
largest sprocket and the largest chainring)
1=2.38mm
TL-CN24
• In addition, if pedaling performance does not feel normal, check this once more.
• Check that there is no looseness in any joints or connections before riding the bicycle.
(BB-FC, FC-PD)
• Do not wash the bottom bracket with high-pressure jets of water.
• If you feel any looseness in the bottom bracket axle, the bottom bracket should be
replaced.
• If gear shifting operations do not feel smooth, wash the derailleur and lubricate all
moving parts.
• If the amount of looseness in the links is so great that adjustment is not possible, you
should replace the derailleur.
• Apply grease to the bottom bracket before installing it.
• For smooth operation, use the specified outer casing and the bottom bracket cable
guide.
• You should periodically wash the chainrings in a neutral detergent and then lubricate
them again. In addition, cleaning the chain with neutral detergent and lubricating it can
be an effective way of extending the useful life of the chainrings and the chain.
• If the chain keeps coming off the chainrings during use, replace the chainrings and the
chain.
Outer casing holders
• This front derailleur is for triple front chainwheel use only. It
cannot be used with the double front chainwheel, as the shifting
points do not match.
• When installing the top route type, choose a frame that has three
outer casing holders as shown in the illustration at right.
• Use an outer casing which still has some length to spare even
when the handlebars are turned all the way to both sides.
Furthermore, check that the shifting lever does not touch the
bicycle frame when the handlebars are turned all the way.
• Grease the inner cable and the inside of the outer casing before use to ensure that they
slide properly.
• Operation of the levers related to gear shifting should be made only when the front
chainwheel is turning.
• Parts are not guaranteed against natural wear or deterioration resulting from normal
use.
• For maximum performance we highly recommend Shimano lubricants and maintenance
products.
• For any questions regarding methods of installation, adjustment, maintenance or
operation, please contact a professional bicycle dealer.
Front Derailleur
SHIMANO JAPAN
CHAIN GAUGE
Note
Insert the inner cable into the outer casing from the end with the
marking on it. Apply grease from the end with the marking in order
to maintain cable operating efficiency.
Marking
Chain length
• Be careful not to let the cuffs of your clothes get caught in the chain while riding,
otherwise you may fall off the bicycle.
• 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.
• Check that there are no cracks in the crank arms before riding the bicycle. If there are
any cracks, the crank arm may break and you may fall off the bicycle.
• Obtain and read the service instructions carefully prior to installing the parts. Loose,
worn, or damaged parts may cause 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.
Inserting the inner cable
Cutting the outer casing
Specifications
E
C
1
While firmly pulling the inner cable, secure by tightening the fixing
bolt with a 5 mm Allen key.
3 mm
Reinforced
Connecting Pin
Link Pin
2
ALIVIO
Rapidfire Plus
6.5mm
Lever (B)
Gear teeth
should come
within this range
Front Drive System
3-77 Oimatsu-cho, Sakai, Osaka 590-8577, Japan
Securely tighten
Please note: specifications are subject to change for improvement without notice. (English)
© Oct. 2003 by Shimano Inc. XBC SZK Printed in Singapore
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