SERVICE MANUAL SHIMANO NEXUS 8-SPEED HUB

English t

SHIMANO NEXUS 8-SPEED HUB

SG-8R20

SERVICE MANUAL vol.

2

2

Contents

Disassembly of the Inter-8 hub

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •  

3

Assembly of the Inter-8 hub

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

10

Cassette Joint & Mesurement Tool

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

17

Spare parts list (SG-8R20 / BR-IM70-R / C J-8S20)

• • • • • • • • • • • • • • • • • • • • • •

18

Spare parts list (SB-8S20)

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

19

Spare parts list (CJ-8S40)

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

20

Spare parts list (BL-IM60)

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

21

Spare parts list (ST-8S20)

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

22

Spare parts list (BL-IM65)

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

23

Disassembly of the Inter-8 hub

1.

Hold the two bevelled surfaces of the hub axle on the sprocket side in a vice.

2.

Remove the lock nut for left hand cone with 14 X14mm spanners.

3.

Remove the left hand cone.

Lock nut for left hand cone

(Y-31Z 06020)

Left hand cone

(Y-308 98070)

3

4.

Remove the ball retainer P

(3/16"X13).

5.

Remove the hub shell.

6.

Remove the right hand dust cap.

4

7.

Remove the stop ring with screwdriver.

At this time, the stop ring come off with great force. Be careful of the safety using cloth and so on.

Ball retainer P

(Y-34R 98070)

Right hand dust cap

(Y-34R 98110)

Stop ring

(Y-34R 79000)

8.

Remove carrier unit and ring gear unit at the same time without tuning them to the left and right.

9.

Remove the ring gear stop ring with a screwdriver.

Ring gear stop ring

(Y-34R 80000)

Carrier unit

(Y-34R 98020)

Ring gear 1

(Y-34R 47000)

Ring gear stop ring

(Y-34R 80000)

5

6

10.

Remove ball retainer O

(3/16"X26).

11.

Then hold the axle unit upside down in a vice.

12.

Remove the right hand lock nut with 17mm spanner.

13.

Remove stop washer.

Ball retainer O

(Y-34R 98030)

Right hand lock nut

(Y-33Z 07020)

Stop washer

(Y-34R 09000)

14.

Remove lock washer.

15.

Remove driver plate.

16.

Support the driver by the vice.

Set the tool and hit it with hammer untill right hand cone and axle unit is separate.

If you try to disassemble the right hand cone without using this tool, the return spring in the axle unit may disengage.

Set the tool into the groove so that the pawl A is on the surface of the tool.

Lock washer

(Y-34R 98090)

Driver plate

(Y-34R 12000)

Tool TL-8S10

(Y-70800100)

A

7

8

17.

Remove right hand cone.

18.

Remove ball retainer P

(3/16"X13).

19.

Remove driver unit.

20.

Remove return spring.

Driver unit

(Y-34R 98060)

Return spring

(Y-34R 21000)

Right hand cone

(Y-34R 98080)

Ball retainer P

(Y-34R 98070)

21.

Remove the clutch unit while turning it counterclockwise and fixing two pawls to two grooves as shown in the picture.

Clutch unit

(Y-34R 98050)

9

10

Assembly of the Inter-8 hub

1.

When installing the clutch unit, align two pawls of the clutch unit with two grooves. After installing the clutch unit, turn it clockwise.

2.

Install the return spring while aligning it with the blue line shown in the picture.

Be careful not to install it upside-down.

(The bigger part is downside.)

3.

Set the drive unit while align the shallow side of groove of driver unit and wider portion of swelling on the clutch unit.

4.

Install the ball retainer P

(3/16"X13).

Clutch unit

(Y-34R 98050)

Return spring

(Y-34R 21000)

Ball retainer P

(Y-34R 98070)

GREASE

(Y-041 20600)

Set drive unit while turn it counterclockwise.

5.

When installing the right hand cone, adjust two serration as shown in the picture.

Set the tool and hit it untill it stops.

Make sure that seal is installed equally, and install right hand cone properly.

6.

Install the driver plate. Be careful of the setting direction asshown in the picture.

7.

Install lock washer.

seal

Right hand cone

(Y-34R 98080)

Tool TL-8S20

(Y-70800200)

Driver plate

(Y-34R 12000)

Lock washer

(Y-34R 98090)

11

8.

When installing the stop washer, align two pawls of the stop washer with the grooves of lock washer.

9.

Install the right hand lock nut

(3.4mm) with 17mm spanner.

Take care that the stop washer does not turn.

10.

Then hold the axle unit upside down in a vice.

12

11.

Install the ball retainer O

(3/16"X26) while pressing in pawl on the driver & axle unit.

Ball retainer O

(Y-34R 98030)

GREASE

(Y-041 20600)

Stop washer

(Y-34R 09000)

Tightening torque:

25 - 30 N·m {218 - 261 in.lbs}

Right hand lock nut

(Y-33Z 07020)

12.

How to install the carrier unit and ring gear.

(Without any tools)

Align three marks of the ring gear with three grooves as shown in the picture.

Tool TL-8S30

(Y-70800300)

(With tool)

Align the grooves of the tool with the marks of the ring gear.

Carrier unit

(Y-34R 98020)

GREASE

(Y-041 20600)

Ring gear 1

(Y-34R 47000)

GREASE

(Y-041 20600)

Install the ring gear stop ring with a screwdriver.

Ring gear stop ring

(Y-34R 80000)

13

14

13.

Aligh the swelling of ring gear/carrier unit and the groove of axle unit.

After installing ring gear and carrier unit, turn units firmly and check that pawls are in their position.

To proceed this section, it is important to set four pawls in their position.

Use flat blade screwdriver to push pawls as shown in the instruction then install ring gear and carrier unit slowlly.

GREASE

(Y-041 20600) pawls

No good

Pawls are not in their proper position

14.

Insert the stop ring.

15.

Install the hub shell unit while turning it counterclockwise.

16.

Insert ball retainer P

(3/16"X13) in the hub shell.

17.

Install the left hand cone.

Stop ring

(Y-34R 79000)

Ball retainer P

(Y-34R 98070)

GREASE

(Y-041 20600)

Left hand cone

(Y-308 98070)

15

18.

Install the lock nut for left hand cone with 14X14mm spanners.

Adjust the hub with the left hand cone so that there is a small amount of play.

This play should disappear after tightening the locknut.

19.

Install the right hand dust cap.

Make sure that the seal of dust cap also installed correctly.

GREASE

(Y-041 20600)

Tightening torque:

25 - 30 N·m {218 - 261 in.lbs}

Lock nut for left hand cone

(Y-31Z 06020)

Right hand dust cap

(Y-34R 98110)

16

This completes assembly of the Inter-8 hub.

Cassette Joint

CJ-8S20

for 8 speed

CJ-NX10

for 7 speed

CJ-8S40

for 8 speed

CJ-7S40

for 7 speed

Mesurement Tool

TL-CJ10

for CJ-8S20

TL-CJ40

for CJ-8S20

TL-CJ40

for CJ-8S40

CJ-8S20

CJ-NX10

101mm

101mm

124mm

17

18

Spare parts list

21

17 19

7L

22

20

23

24

JA

PA

N

27

25

For w/o Roller Brake

(SG-8R20-VS)

26

28 29 11

SHIMANO NEXUS 8-SPEED HUB w/Hi-Power Roller Brake

SG-8R20

BR-IM70

-R

Inter-8 Hub

Inter-M Brake

CJ-8S20

1

33

30 31 32

Internal Assembly

34 35 36 18 17

41

Grease

42

SG-8R20 JAPAN VIA

2 3 4 5 6

1

7 8 9

37

10 11 12 13 14 15 16

38

TL-8S30

39

TL-8S20

40

TL-8S10

Q'TY

ITEM

NO.

12

13

14

15

16

17

10

11

8

9

4

5

6

7

1

2

3

18

*

*

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

* 38

* 39

40

41

42

SHIMANO

CODE NO.

Y-75M 98050

Y-33F 98090

Y-75M 98060

Y-33F 98100

Y-75E

Y-75F

Y-75F

Y-75E

Y-75T

Y-34R

Y-31Z

Y-308

98010

11000

98020

98020

05000

98100

06020

98070

Y-34R

Y-322

Y-322

Y-322

Y-322

Y-330

Y-330

Y-321

98110

03220

03420

03520

03620

60000

60100

20100

Y-74Y

Y-74Y

Y-74Y

98120

18000

98130

Y-34R 98010

Y-34R

Y-34R

Y-34R

Y-34R

79000

98020

47000

80000

Y-34R

Y-34R

Y-34R

Y-34R

Y-34R

Y-34R

Y-34R

Y-34R

98030

98040

98050

21000

98060

98070

98080

12000

Y-34R

Y-34R

Y-33Z

98090

09000

07020

Y-314

Y-33Z

14010

20500

Y-33M 39600

Y-33M 39700

Y-33M 39510

Y-33M 39610

Y-33M 39710

Y-75V 13041

Y-33Z

Y-74Y

Y-708

Y-708

Y-708

Y-041

Y-041

Y-041

98020

98030

00300

00200

00100

20600

20400

40020

DESCRIPTION

Internal Assembly (Axle Length 184 mm)

Stop Ring ( 12 mm)

Carrier Unit

Ring Gear 1

Ring Gear 1 Stop Ring

Ball Retainer O (3/16" x 26)

Hub Axle Unit (Axle Length 184 mm)

Clutch Unit

Return Spring A

Driver Unit

Ball Retainer P (3/16" x 13)

Right Hand Cone w/Seal

Driver Plate

Lock Washer

Stop Washer

Right Hand Lock Nut (3.4 mm)

Cap Nut (3/8")

Non-turn Washer 5R (Yellow)

Non-turn Washer 6R (Silver)

Non-turn Washer 7R (Black)

Non-turn Washer 5L (Brown)

Non-turn Washer 6L (White)

Non-turn Washer 7L (Gray)

Brake Unit Fixing Nut (7.2 mm)

Brake Arm Clip Unit ( 15 mm)

Brake Arm Clip Unit (5/8")

Brake Arm Clip Unit (11/16")

Brake Arm Clip Unit (3/4")

Brake Cable Adjusting Bolt Unit

Grease Hole Cap

Inner Cable Fixing Bolt & Nut

Link Unit

Seal Ring for Brake

Left Hand Dust Cap Unit

Lock Nut for Left Hand Cone

Left Hand Cone w/Dust Cap

Right Hand Dust Cap A w/Seal

Sprocket Wheel 16T (Silver)

Sprocket Wheel 18T (Silver)

Sprocket Wheel 19T (Silver)

Sprocket Wheel 20T (Silver)

Sprocket Wheel 21T (Silver)

Sprocket Wheel 22T (Silver)

Snap Ring C

CJ-8S20 Cassette Joint Unit

Driver Cap

CJ-8S20 Cassette Joint

Cassette Joint Fixing Ring

Inner Cable Fixing Bolt Unit

TL-8S30 Carrier Unit Tool

TL-8S20 Right Hand Cone Installation Tool

TL-8S10 Right Hand Cone Removal Tool

Internal Hub Grease (Net. 100 g)

Roller Brake Grease (Net. 100 g)

Roller Brake Grease (Net. 10 g)

IL /SG Printed in Japan 0306-2236A

Spare parts list

SHIMANO NEXUS Revo-Shift Lever

SB-8S20

For 8-Speed

8

2

9

3

V

C R

4

5

7

6

10

2000m

1.2

mm m x10 0pcs

SH

IM AN

TO

TA

IN TE

INN

GR

AT

ER

O

IO

N E

CA

BL

SH

IM

TE

INN

AN

GR

O

AT

ER C IO

ABL

1.2 mm 2000 mm

(100 pcs.)

11

SERVIC E INST

RUCTIO NS

SI-SP40

Before correc

userea t use.

Notes:

cable o an inn d thes ter cas f 1.1 m er cabl e instr

Shiman o SIS^S is not g lt in po

Install

Outer uction s caref ully, an w them

for ing is s e of 1.

inner

MARK

reased he out or shif to the atery ) iamete

2 mm

Casing y desig f 1.1 m cable o

P36 ou

intern r; it ca in diam ter cas er casi ng or c

-SP36 s rear de ally. Yo ality.

ealed o ing in

SI-SP36

ned fo eter m in d iameter u must r side o railleu r an in bulk p

install uter ca ner

for ackagi p ( sold ng able re sistanc

grease e will r esu f the o

separ uter ca sing.

12

10 m / 32.8 ft.

1.2 mm

(100 pcs.)

13

14

1

Q'TY

ITEM

NO.

8

9

6

7

10

3

4

1

2

5

11

12

13

14

SHIMANO

CODE NO.

Y-6J3

Y-6J3

Y-8TS

Y-8S8

Y-89E

Y-61W 98030

Y-8SB

Y-6J3

10000

04000

Y-61X

Y-600

14010

98510

Y-6Z2

Y-620

Y-6Z2

Y-6Z1

98010

98030

98010

98010

05010

98100

98030

98010

90010

DESCRIPTION

Indicator Cover & Fixing Screws (M3 x 5)

Upper Cover & Fixing Screw (M3 x 5)

R.H. Adjustment Block & Screw

Brake Cable Adjusting Bolt (M10 x 19) & Nut

Reach Adjusting Screw (M4 x 10.8)

Cable Adjusting Bolt Unit

Clamp Bolt (M6 x 14.8)

Shift Actuator (Black)

Half Grip ( 22.2 mm / Black)

Inner Cable Box (Stainless / 100 pcs.) for Shift

SIS-SP40 Outer Casing (Black) for Shift

Inner End Caps ( 1.2 mm / 100 pcs.)

SIS-SP40 Sealed Outer Caps (Revo-Shift Lever Side / Black / 6 mm / 100 pcs.)

SIS-SP40 Sealed Outer Cap (Cassette Joint Side / Silver / 6 mm)

IL/SB Printed in Japan 0302-2238

19

20

Spare parts list

SHIMANO NEXUS Cassette Joint

CJ-8S40

4

1

3

2

9

8

CJ

-8S

40

JA

PA

N

7

5

6

Q'TY

ITEM

NO.

1

7

8

9

4

5

2

3

6

SHIMANO

CODE NO.

Y-74Y 98160

Y-74Y

Y-74Y

Y-74Y

Y-74Y

Y-33Z

Y-74Y

Y-74Y

Y-74Y

27000

28000

30200

98140

98020

98150

18000

98030

DESCRIPTION

Outer Casing Holder Unit

Rubber Cover

Outer Casing Holder

Rubber Bellows

Cassette Joint Unit

Cassette Joint Fixing Ring

Cassette Joint

Driver Cap

Inner Cable Fixing Bolt Unit

IL/CJ Printed in Japan 0302-2237

Spare parts list

SHIMANO NEXUS Brake Lever

BL-IM60

For Left Hand / 4-Finger

5

4

3

1

2

Q'TY

ITEM

NO.

1

4

5

2

3

SHIMANO

CODE NO.

Y-8TS 98020

Y-8S8

Y-89E

98010

05010

Y-8SB 10000

Y-89M 08010

DESCRIPTION

L.H. Adjustment Block & Screw

Cable Adjusting Bolt (M10 x 19) & Nut

Reach Adjusting Screw (M4 x 10.8)

Clamp Bolt (M6 x 14.8)

Grip ( 22.2 mm / Black)

IL/BL Printed in Japan 0302-2239

21

22

Spare parts list

SHIMANO NEXUS Tap-Fire Lever

ST-8S20

For 8-Speed

4

3

2

1

11 8

8

7

11

2000 mm

1.2

mm x100p

SH IM

TO

TA

IN

TE

INN

GR

ER

AN

O

AT

IO

CA

N

BLE

SH

TO

TE

IM

TA

GR

O

AT

INN

ER C

IO

ABL

1.2 mm 2000 mm

(100 pcs.)

12

E INST

SERVIC

RUCTIO

SI-SP4

userea d these

0

instruc

NS

Outer tions ca

Casing

This ou ter cas ing is s peciall in diam eter

SI-SP36

and fo llow th em for cable o an inn is not g nside t f 1.1 m

MARK

o SIS^S reased he out lt in po m in d inner

2 mm cable o

P36 ou ter cas

intern or shif the SIS y desig r; it ca f 1.1 m m in di ally. Yo er casi ng or c ealed o n not b r an in ner e used ameter ing in bulk p ng ackagi u must install able re sistanc

for

grease e will r esu atery ) to the rear de uter ca railleu p ( sold

separ uter ca sing.

10 m / 32.8 ft.

13

6

5

9

1.2 mm

(100 pcs.)

14 15

10

Q'TY

ITEM

NO.

1

2

10

11

8

9

12

5

6

3

4

7

13

14

15

SHIMANO

CODE NO.

Y-6JB

Y-8TS

98010

98010

Y-6JB

Y-6JB

98030

98040

Y-61W 98030

Y-6JB

Y-6JB

98050

98060

Y-8SB

Y-6JB

Y-6JB

Y-600

Y-6Z2

Y-620

Y-6Z2

Y-6Z1

10000

98070

98080

98510

98100

98030

98010

90010

DESCRIPTION

Indicator Unit

R.H. Adjustment Block & Screw

Reach Adjusting Screw (M4 x 47) w/Cap

Brake Cable Adjusting Bolt (M10 x 19) & Nut

Cable Adjusting Bolt Unit

Cable Cover & Cover Fixing Screw (M2.5 x 4)

Tap Cover & Fixing Screw (M3 x 4)

Clamp Bolt (M6 x 14.8)

Lower Cover & Cover Fixing Screw (M3 x 12)

Main Lever Cover & Fixing Screw (M3 x 4)

Inner Cable Box (Stainless / 100 pcs.) for Shift

SIS-SP40 Outer Casing (Black) for Shift

Inner End Caps ( 1.2 mm / 100 pcs.)

SIS-SP40 Sealed Outer Caps (Shift Lever Side / Black / 6 mm / 100 pcs.)

SIS-SP40 Sealed Outer Cap (Cassette Joint Side / Silver / 6 mm)

IL/ST Printed in Japan 0305-2244

Spare parts list

SHIMANO NEXUS Brake Lever

BL-IM65

For Left Hand / 3-Finger

5

4 3

1

2

Q'TY

ITEM

NO.

3

4

1

2

5

SHIMANO

CODE NO.

Y-8TS

Y-6JB

Y-89E

Y-8SB

98020

98040

05010

10000

Y-89M 08010

DESCRIPTION

L.H. Adjustment Block & Screw

Cable Adjusting Bolt (M10 x 19) & Nut

Reach Adjusting Screw (M4 x 10.8)

Clamp Bolt (M6 x 14.8)

Grip ( 22.2 mm / Black)

IL/BL Printed in Japan 0305-2245

23

SHIMANO AMERICAN CORPORATION

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003 Fax: +1-949-768-0920

Specifications are subject to change for improvement without notice.

This publication is printed on recycled paper.

MA34RB © Jan. 2004 Shimano Inc.

UCI official neutral technical support t