Shimano ST-7700 Shifting/Brake Lever Service Instructions

 SERVICE INSTRUCTIONS
ST-7700
SI-6BDOC
Shimano Total
Integration
Before use, read these instructions carefully, and follow them for correct use.
SHIMANO
TOTAL
INTEGRATION
DURA/ICE
Shimano Total integration
(Dura-Ace) Features
The Shimano Total integration Dura-Ace series features a dual
action control lever which actuates the brakes like a conventional
brake lever, and shifts the gears when moved inward toward the
center line of the bicycle. Gear shifting is now possible without
ever taking your hands off the brake hoods or drops.
Rear
Lever À :
Lever (6)
Lever (a)
Shifts from smaller to larger rear sprocket.
Lever ® : Shifts from larger to smaller rear sprocket.
Lever (a) : Shifts from smaller to larger chainring.
Lever 65):
Shifts from larger to smaller chainring.
In order to realize the best performance, we recommend that
the following combination be used.
Series DURA-ACE
Shifting lever ST-7700 / SL-7700 / SL-BS77
Outer casing SIS-SP40
Front derailleur FD-7700 a
Front chainwheel FC-7700
Bottom bracket BB-7700
Operation of rear derailleur levers
* Lever (A): Shifts from smaller to larger rear sprocket.
Lever (A) has a click stop at positions (1), O), and ©).
Lever (A)
Lever (A)- start position
(1): Shifts one sprocket 4 3
Ex.: from 3rd to 4th | | || |
=
м | =
En
(9): Quick-shifts two sprockets
Ex.: from 3rd to 5th
г
E
=
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(3): Quick-shifts three sprockets
Ex.: from 3rd to 6th
on
—
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baton}
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* Lever ®): Shifts from larger to smaller rear sprocket.
Press lever (B) once to shift from a larger to one smaller
sprocket.
Lever
start position
Ex.: from 4th to 3rd
ta)
a o. US A E UU MMS
==
J
Caution on operation
Lever @) will also move when lever (A) is operated, but be careful
not to apply pressure to lever (B). Similarly be careful not to press
lever (A) when operating lever (B). Gears will not shift when both
levers are pressed simultaneously.
Operation of front derailleur levers
* Lever (a): Shifts from smaller to larger front chainring.
Lever @
start position
If operation of lever (a) does not
complete the chainring shift stroke,
operate lever (a) again for the
distance (x') to complete that part of
the lever stroke (X) which was short.
y
Full gear shift stroke VA
/ Actual
Ai stroke
X
*
Lever 6)
start position
When lever (b) is operated, there is
one click where trimming (the noise
prevention mechanism) engages,
and a second stronger click when
the gear shift stroke is completed.
After trimming, the next push will
complete the gear shift stroke to
the smaller front chainring.
Gear shift Й
complete stroke 7
Click
Trim operation
Trimming (noise prevention operation)
If the chain is on the large front chainwheel and the large rear
sprocket, the chain will rub in the front derailleur plate, producing a
characteristic noise. When this happens, press lever (b) lightly (to the
point where it clicks); this causes the front derailleur to move slightly
towards the smaller chainwheel, thereby eliminating the noise.
Movement of the
front derailleur
Chain position
Г:
Cautions on operation
Lever (b) will also move when lever (a) is operated, but be careful
not to apply pressure to lever (po). Similarly be careful not to press
lever a when operating lever (b). Gears will not shift when both
levers are pressed simultaneously.
Installation
Installation to the handlebar
Secure the assembly
with the installation nut
on the outside of the
bracket. Pull the bracket
cover back and use a
5 mm Allen key to
tighten the bolt.
Bracke! cover
5 mm Allen key
Installation nul
i ; >,
C 6 - 8 Nim (50-70 n. 168) |
Installation of the brake cable
Cable used
$1. Gna
e Inner cable (stainless steel) ......................
y $ 5mm
*SLR outer CasSiNG .......0000000000 OLE
1. Tilt the lever in (as when shifting) to make it easier to pass the
cable through the cable hook.
Note: The front lever cannot be
tilted to the inside until
lever (b) is pushed once
or twice.
№
y
a)
wn
N
—
=
D
—
=
®
=
©
jab]
o
D
—
=>
=
o
с
O
=
Cable hook
——— Inner cable
Maintenance
As long as the mechanism is functioning smoothly, maintenance
is not required. Dissemble for maintenance as described
below. Do not disassemble any further.
* ST-7700-R for rear sprockets
| a
dma = | L DAN o If the chain is on the large front chainwheel and the large rear
Lever (A) = “эт Lever @ sprocket, the chain will rub in the front derailleur plate, producing a . Pass the inner le thr
Lever (B) : characteristic noise. When this happens, press lever (b) lightly (to the 2 eee CE lee
| Lever E) |. point where it clicks); this causes the front derailleur to move slightly
Lever ® : Shifts from smaller to larger rear sprocket. start position towards the smaller chainwheel, thereby eliminating the noise. Cable hook
Lever @ : Shifts from larger to smaller rear sprocket.
Lever (@) : Shifts from smaller to larger chainring. Movement of the
Lever (p) : Shifts from larger to smaller chainring. Chai ti front derailleur
ain position
———— Inner cable
EX.: from 4th to 3rd
ww
© All levers return+td the staitihg position wh
a m |
=
su =
Е
аи
—
In order to realize the best performance, we recommend that
the following combination be used.
=
Maintenance
Series DURA-ACE
i 3 : = Caution on operation Cautions on ti
Shifting lever ST1-7700/SL-7700 / SL-BS77 = ; o As long as the mechanism is functioning smoothly, maintenance
Outer casing SIS-SP40 Lever (8) will also move when lever @® is operated, but be careful Lever ©) will also move when lever (@) is operated, but be careful is not required. Dissemble for maintenance as described
derail FD-77 not to apply pressure to lever 6). Similarly be careful not to press not to apply pressure to lever (©). Similarly be careful not to press below. Do not disassemble any further.
Front derailleur 00 : :
- lever (A) when operating lever 6). Gears will not shift when both lever a when operating lever b). Gears will not shift when both
Front chainwheel FC-7700 levers are pressed simultaneously. levers are pressed simultaneously. * ST-7700-R for rear sprockets
Bottom bracket BB-7700
Chain CN-7700
Bottom bracket cable guide SM-SP17 =
Rear derailleur RD-7700 Adjustment
Freehub FH-7700 = . :
ra = SIS adjustment Front gear shift adjustment
E Operate the lever (A) to set the chain to the second from top
Cassette sprocket CS-7700 sprocket. 1. Set the chain on the largest rear sprocket and the largest
The ST-7700 can also be used with the Dura Ace 8-speed set. 32 1 321 front chainwheel.
321 Largest Smallest Largest Largest
sprocket chainwheel sprocket chainwheel
Note | | | =
* For smooth operation, always be sure to use the specified outer >
casing and the bottom bracket cable guide. +
* Grease the inner cable and the inside of the outer casing before
use to ensure that they slide properly.
* Because the high cable resistance of a frame with internal cable Contacts third sprocket, No née Contacts top sprocket,
routing would impair the SIS function, this type of frame should not making noise. making noise.
be used.
* For any questions regarding methods of installation, adjustment, Trimming
maintenance or operation, please contact a professional bicycle (noise prevention mechanism)
dealer.
Press lever (b) lightly to the click-
stop. (For details, see the section * ST-7700-F for chainwheel
Lever ® lon operation.)
Adjustment
bolt men 3. After trimming, adjust the gap between the chain and chain
Turn the rear derailleur adjust- Turn the rear derailleur adjust- guide to the minimum setting (0 — 0.5 mm) using the cable
MENA Cock NEP ment bolt counterclockwise until stopper outer adjustment bolt. Bracket and lever disassembly
i ise. i
IS NO noise there is no noise.
Ls SZ
Adjustment bolt : 321
1. Use a 2 mm Allen key to remove the
lever stud set screw on the bottom of
the bracket. £
Lever stud set screw |
Best setting
Turn the crank forward while turn-
ing the rear derailleur adjustment
bolt slowly counterclockwise. Stop
just before noise is produced (the
These service instructions are printed on chain contacts the third sprocket).
©, El | m A Г) O recycled paper and can be recycled again ” © ® 9 | AN r mil
oy = . nsert a 25 mm Allen key or similar
== Cal tool into the lever stud hole, and ta
" " я Р
SHIMANO AMERICAN CORPORATION * Adjustment with the cable it gently with a plastic mallet to push
One Shimano Drive PO. Box 19615 Irvine California U.S.A. 92623-9615 Phone 714-951-5003 stopper is also possible while Cable adjustment bolt out the lever stud. When the lever
CY : d comes out, the bracket bod
ИНО EUROPA riding. Tilt the rear outer Default position stu y
g 24 NL-8071 CT Nunspeet Holland Phone 31-3412-72222 stopper lever to achieve the for lever and lever body can be disassembled.
SHIMANO INC. same effect as turning the
77 Oimatsu-cho 3-cho Sakai Osaka 590-77 Japan Phone 0722-23-3243 rear derailleur adjustment
Please note: specilicalions are subject to change for improvement without notice. (English) bolt counterclockwise.
© Feb. 1997 by Shimano Inc. XBC SZK Printed in Japan.
Installation
Installation to the handlebar
Secure the assembly
with the installation nut
on the outside of the
bracket. Pull the bracket
cover back and use a
5 mm Allen key to
tighten the bolt.
Brackel cover
5 mm Allen key
Installation nut
Г ле
Tightening torque: 2”
_ 6-8Nm {50 - 70 in. bs.) -.
Installation of the brake cable
Cable used
e Inner cable (stainless.steel)...................... #1. бя
ÿ $ 5 пп
eSLR outer casing .......................——.._..————. 6 so SLX
1. Tilt the lever in (as when shifting) to make it easier to pass the
cable through the cable hook.
3. Fix the outer guide to the inner cable, and set the angled
member in the bracket.
Note: Do not wipe the grease on the inner cable off. Also, be
careful that the inner cable does not pick up dust and foreign
matter. :
i
Angled member of
Outer guide Inner cable
Bracket
Ощег guide
Note: The front lever cannot be
tilted to the inside until
lever (b) is pushed once
or twice.
Cable hook
Inner cable
Maintenance
4. Set the outer casing on the inner cable, and in the bracket
along the outer guide.
Quler casing
Make sure that the inner
end is firmly seated in
the cable hook.
O Cable hook
Inner end
© >
Cable quide
Outer holder
Installing the shifting cable
Cable used
* Inner cable (stainless steel)
—
<For Dura-Ace> wR |
* SP40 sealed outer casing (1D) — MN
| Le 7 IN 7
pi ») e @P4D SEALED Й \ Al \
C= = 1X E | >
« SP40 outer casing (2) | D Ö / 1 \ /
‚ #4 тп N À =“ A
(0 J swmano_seswo = Wire lead
#
Inserting the inner cable
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.
Cutting the outer casing Marking
When cutting the outer casing, cut the opposite end to the end
with the marking. After cutting the outer 0
casing, makPd round so that the inside of
the hole has a uniform diameter.
SHIMANO SIS-5P | |
\“ Outer end cap
Attach the same outer
!
end cap to the cut end of Le
Г}
a —
sumano SIS-SP С
the outer casing.
SUIMANO 5I5-5P
* Rear lever
Confirmation hole
Make sure that the outer casing is firmly
seated in the outer holder. Pull the bracket
cover back to reveal the hole in the side of
the bracket through which the seating can
be confirmed.
Push lever(B at least 8 times
to make sure the
mechanism is in
top gear before installing.
Lever
5. Bring the outer casing along the front of the handlebar and
cover it with the outer guide. Now cut the outer guide to the
length of the handlebar, and tape it temporarily in place.
Outer quide
Quler casing
6. Finally, wrap the handlebar with the finish tape.
1. Depress the brake lever, and then
pass the inner cable through the
cable hole.
2. Pass the inner cable through
the indicator, and place the
indicator against the outer
casing holder.
A)
Outer casing \®
holder
Inner cable
|
Indicator
3. Attach the outer casing to the indicator.
Indicator
If the cable hook does not align with the shifting cable hole,
press lever ® again until it does, and then install the cable.
Cable hook
=
Inner and
Make sure that the
inner end is firmly
seated in the cable
hook.
® Front lever
Push lever b) at least two - three
times before installing.
Lever b)
Operate at least 2 - 3 times
Uy
Pull the brake lever (as when Shifting cable hole )
braking) to pass the inner cable
through the shifting cable hole,
and set it in the outer casing.
Inner cable
1. Install the outer stopper to the down tube.
* Quter stopper
Direct mount seat (M5)
Install the outer stopper for the
rear chainwheels with the
handle in the default position.
2. Pass the inner cable through, and set the outer casing.
Fj. | 4 я К Tel | gh ==
Be suré led0é some excess in the outer casiñif even if
cutting it to the full length of the handlebars.
EA A E de EE AR NE E FA À
—
Confirm
Make sure the outer casing is
firmly seated in the outer
stopper.
Outer stopper Outer casing
Inner cable
As long as the mechanism is functioning smoothly, maintenance
is not required. Dissemble for maintenance as described Fol
below. Do not disassemble any further.
* ST-7700-R for rear sprockets
| a
Lever and bearing assembly disassembly
1. Remove the cable hook.
OO Cable hook
Assembling the bracket and lever
1. Put the cable hook in to the bearing member, and set the return
spring.
Cn
| Сы! the end of the enrina |
5. Remove the return spring installation tool with pliers.
2. Pass the inner cable through
the indicator, and place the
indicator against the outer
casing holder.
2. Pass the inner cable through.
A
e
o.
Cable hook
Tape À Outer casing \}
Outer casing Inner cable — a" holder
Indicator
Inner cable
3. Attach the outer casing to the indicator.
6. Finally, wrap the handlebar with the finish tape.
Outer casing.
Indicator
Maintenance
Confirm
Make sure the outer casing is
firmly seated in the outer
stopper.
Outer casing
Inner cable
A
As long as the mechanism is functioning smoothiy, maintenance
is not required. Dissemble for maintenance as described oi)
below. Do not disassemble any further.
Lever and bearing assembly disassembly Assembling the bracket and lever
1. Remove the cable hook. 1. Put the cable hook in to the bearing member, and set the return
* ST-7700-R for rear sprockets Spring.
05)-—— Cable hook
Set the end of the spring
in the hole in the bearing
member. Note that the
spring has a right and left
side.
2. Set the special
installation tool for
the return spring.
Retum spring installation tool
(TL-5T02)
rein
Special tool (TL-ST01)
5 mm Allen key
3. Assemble the bracket and lever. Be careful that the end of-the
return spring does not protrude from the hole in the bearing
member at this time.
» ST-7700-F for chainwheel 3. Disassemble as shown.
Lever
Bracket and lever disassembly
1. Use a 2 mm Allen key to remove the
lever stud set screw on the bottom of
the bracket.
Make sure the spring is properly positioned.
® Use kerosene to wash the
lever index member as
shown below.
Laver stud sel screw
2. Insert a 25 mm Allen key or similar
tool into the lever stud hole, and tap
it gently with a plastic mallet to push
out the lever stud. When the lever
stud comes out, the bracket body
and lever body can be disassembled.
Lever stud
set screw
* Be sure to regrease
after cleaning.
The correct position is for the
round hollow on the lever
stud to be aligned with the
lever stud set screw.
5. Remove the return spring installation too! with pliers.
Return spring installation too!
6. Tighten the lever stud set screw until it is even with the surface of
the bracket.
2 mm Allen key
Lever stud set screw
Replacing the bracket cover
The tabs on the bracket cover each fit to a matching slot on the
bracket.
Note the markings:
R: for right
F: for left
Wipe a little rubbing alcohol inside the bracket cover to make
installation easier.