Shimano SL-4S35 Shifting Lever Service Instructions

 | À WARNING |
Obtain, read and carefully service instructions
when installing parts. A loose, worn, or damaged
parts may cause injury to the rider.
We strongly recommend that only genuine
Shimano replacement parts be used.
SERVICE INSTRUCTIONS SI-6E60A
S L-4$535 Revo-shift Lever
Before use, read lhese instructions carefully, and follow them for
correct use.
Be sure to read these service instructions in
conjunction with the service instructions for the
Inter-4 hub before use.
| À CAUTION
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.
Revo-shift lever operation
Turn the Revo-shift lever to shift to each of the four gears.
[ Pedaling becomes heavier |
| Indicator moves toward [4] |
Revo-shilt lever
Indicator moves toward [1] |
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 the
handlebar should be 158 mm
or more in length; attach the
Revo-shift lever to this straight
section.
Brake levar
4 mm Allen key
Clamp bolt
Leave a gap of 0.5 mm
between the Revo-shift
lever and the half grip.
Tightening torque:
~~ 2.5-4 Nm {25 - 40 kgfcm}
F— A
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,
Casselle joint
1 Set the Revo-shift lever to [1].
Pull the outer casing out from the outer casing
“ holder of the cassette joint, and then remove the
inner cable from the slit in the bracket.
Outer casing holder
Sit
=
Remove from
A the slit
ff; "a,
oll i
gl ty
a
1 >
Pull out from outer 2»
casing holder
Bracket!
Remove the inner cable fixing bolt unit from the
" cassette joint pulley.
inner cable fixing bolt unit
A Casselte 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,
=> 3
Remove the Pull out from
inner cable the outer
fixing bolt 6 casing holder
ЕЙ,
Зе
: 3
= —
; »a =
S»
Pulley hole
Turn the
pulley
p—— 2 mm Allen key
= or #14 spoke
Note:
If reusing the cable, refer to steps 8 to 10 in
"Installation of the shifting cable".
Installation of the shifting
cable
Use a shifting cable with one inner cable drum.
Cable with one inner cable drum /
SIS-SP (5 mm dia.)
IM N [(T >
E Revo-shift lever side
1 Set the Revo-shift lever to [2].
Loosen the cover fixing screw, and then remove the
“indicator cover.
Insert the inner cable into groove A from the inside of
“the projection on the pulley, and then pass it through
the hole in the cable adjustment bolt.
Note: Check that the inner cable is correctly
routed along the inside of the projection
on the pulley.
Groove Ain pulley
Hole in cable
adjustment bolt
Hook the inner cable into groove B in the pultey, and
" pull the inner cable so that the inner cable drum fits
into the hole in the pulley. After this, insert the outer
casing into the cable adjustment bolt.
Cable adjustment boll
Hola in pulley
Replace the indicator cover and tighten the cover
"fixing screw.
EM Cassette joint side
6 Set the Revo-shifi lever to [1 |.
7, After checking that the end of the outer casing is
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-4530 cassette joint.
ст O Inner cable fixing nut
Dr” Inner cable fixing washer
==
10 mm y Inner cable fixing bott
(Black) eS
| Pass the inner cable through the hole. |
Lai:
Ne
Pull the inner cable while attaching
the inner cable fixing bolt unit.
Y
101 mm
( Tightening torque:
4 — 6 Nm {40 — 60 kgfcm}
8. Bring the cable around to the cassette joint pulley,
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 nui
Gap in pulley
Casselte joint pulley
Turn the cable 60° counterclockwise and attach it to
the hook.
Turn the
cable 60°
10. Attach the inner cable to the pulley as shown in 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.
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
Hole in pulley
Turn the
pulley
—— 2 mm Allen key
or #14 spoke
If the inner cable fixing bolt unit cannot easily
be pushed into the gap in the pulley using a
finger, insert a 2 mm Allen key or a #14 spoke
into the hole in the inner cable fixing bolt unit,
and then insert the inner cable fixing bolt unit
into the gap in the pulley.
Hole in inner cable
fixing boll uni Se
nam! „2
2 mm Allen kay
or #14 spoke
Gap in pulley
1
5" Pass
through
the slit.
a
Insert into the
outer casing holder.
Note:
Check that the inner cable is correctly seated
inside the pulley guide.
Inner cable
Pulley
Brackel
1 1 Secure the cable to the frame with the outer casing
“bands.
Adjusting the cassette joint
_ Set the Revo-shift lever to [4],
Check to be sure that the red setting lines on the
cassette joint bracket and pulley are aligned at this
time.
Red setling lines
The red setting lines on the cassette joint are
located in two places. Use the one that is
easiest to see.
(When bicycle is upside down —
Should be straight
Cassette joini
-— À \ pulley
Casselte joint bracket
( When bicycle is standing up)
Should be straight
ve BY Te Cassette joint
Mea pullay
Cassette joint bracket
If the red setting lines are not aligned, turn the
cable adjustment bolt of the Revo-shift lever to
align the setting lines, After this, move the
Revo-shift lever once more from [4] to [1] and
then back to [4], and then re-check to be sure
that the red setting lines are aligned.
Cable adjusiment bolt
2. After adjusting the cassette joint, cut off the excess
length of inner cable and then install the inner end
cap.
Inner end cap
These service instruclions explain how to use and maintain the
Shimano bicycle paris 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.
Please nole: Specificalions are subject lo change lor improvement wilhoul notice
(English)
SHIMANO
SHIMANO AMERICAN CORPORATION
One Hollünd Irvine CA 92618U S A Phone 949-951-5003
SHIMANO EUROPA
Induslrieveg 24 NL-6071 CT Munspest Holland Phoro 31-3412-72222
X
SHIMANO INC. ES
3-77 QOumalsucho, Sakal, Osaka. Japan Phone 0722-23-3243
(©) Jul. 1999 by Shimano Inc. PIT. SZK. Printed in Singapore
— a dd