Shimano ST-7400 Shifting/Brake Lever Service Instructions

Service Instructions
Shimano
Total
Integration
Before use, please read these instructions carefully and follow them for correct use.
SHIMANO
TOTAL
INTEGRATION
JUICE
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.
Operation of the levers related to gear shifting should be
made only when the front chainwheel is turning.
Operation
Rear Front
Lever ‚| Lever (b)
Lever (4) —— = — Lever (a)
Lever (À): Shifts from smaller to larger rear sprocket.
Lever (B): Shifts from larger to smaller rear sprocket.
Lever (@): Shifts from smaller to larger chainwheel.
Lever (b): Shifts from larger to smaller chainwheel.
All levers return to the starting position when released.
Combinations Chart
Eee ENS Dee A Y
Operation of rear derailleur levers
e Lever (A): Shifts from smaller to larger rear sprocket.
Lever (À has a click stop at positions M), O), and (9).
Lever (A)
start position
(1): Shifts one sprocket
Ex.: from 3rd to 4th
——
|
W
4
. f=
in
@: Quick-shifts two sprockets
Ex.: from 3rd to 5th
re
| поннннНие
= ==. asus
—
ee
1
(3): Quick-shifts three sprockets
Ex.: from 3rd to 6th
—
=
Е
=" — ©)
=>—=
|
e Lever B): 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
La
|
mo
EZ
=
I
Caution on operation
Lever (B) will also move when lever (®) is operated, but be careful
not to apply pressure to lever ®. Similarly be careful not to press
lever (À when operating lever @. Gears will not shift when both
levers are pressed simultaneously.
Adjustment
SIS adjustment
Operation of front derailleur levers
* Lever (a): Shifts from smaller to larger front chainring.
Lever (a)
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.
Full gear
shift stroke
Lever (b)
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.
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
e +;
Cautions on operation
Lever (b) 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.
Front gear shift adjustment
Installation
Installation to the handlebar
Secure the assembly
with the installation bolt
on the outside of the
bracket. Pull the bracket
cover back and use a
5 mm Allen key to tighten
the bolt.
Bracket cover
Installation bolt
Tightening torque:
60 — 80 kgfem (50 —70 in.ibs.)
Installation of the brake cable
Cable used
* Inner cable (stainless steel) ...................... Oz
: y #5mm
SLR outer casing ee... o знало == Y
!
Be sure to leave some excess cable, even if cutting it to the full
length of the handlebars.
1. Tilt the lever in (as when shifting) to make it easier to pass the
cable through the cable hook
3. Fix the outer ¢
member in the
Note: Do not w
careful th
matter.
Angled member
of outer guide
A
N
Bracket \
Note: The front lever cannot be
tilted to the inside until
lever (b) is pushed once
or twice.
Maintenance
As long as the mechanism is functioning smoothly, maintenance
is not required. Disassemble for maintenance as described
below. Do not disassemble any further.
+ ST-7400-R for rear sprockets a
2
4. Set the outer ¢
along the oute
Make sure th
end is firmly
the cable ho
5. Bring the out
cover it with t
length of the
6. Finally, wrap tf
Leverand b
1. Remove the c:
5 !
ainring.
us Lever (a)
start position
ual stroke
-
Xx 1
ainring.
Trim operation
> large rear
ate, producing a
r ©) lightly (to the
r to move slightly
; the noise.
nent of the
[=
but be careful
ful not to press
ft when both
Installation
Installation to the handlebar
Secure the assembly
with the installation bolt
on the outside of the
bracket. Pull the bracket
cover back and use a
5 mm Allen key to tighten
the bolt.
Bracket cover
—5 mm Allen key
Installation bolt
Tightening torque:
60 — 80 kgfem (50 —70 in.lbs.)
Installation of the brake cable
Cable used
! + $1. 60m
e Inner cable (stainless steel) EEE zz
|
{ $ 5 пп
eSLR outer casing o sumeano SL
Be sure to leave some excess cable, even if cutting it to the full
length of the handlebars.
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.
Angled member
of outer guide
X
\ V E
Inner cable
Bracket Outer guide
Note: The front lever cannot be
tilted to the inside until
lever (b) is pushed once
or twice.
IT Ti
2. Pass the inner cable through.
Cable hook
— Inner cable
Maintenance
As long as the mechanism is functioning smoothly, maintenance
is not required. Disassemble for maintenance as described
below. Do not disassemble any further.
e ST-7400-R for rear sprockets = =
Ea
4. Set the outer casing on the inner cable, and in the bracket
along the outer guide.
Outer casing
Make sure that the inner
end is firmly seated in
the cable hook.
Cable hook
О
Inner end
x >
Confirmation hole A
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.
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 guide hd
Outer casing
6. Finally, wrap the handlebar with the finish tape.
Lever and bearing assembly disassembly
1. Remove the cable hook.
— Cable hook
Installing the shifting cable
Cable used
) | PA
— 7 e
— Wire lead
e Inner cable (stainless steel)........................ O
| ] y $ 5 mm
* SIS shield outer casing (()....................... 6) JI sumano sis Q
Y $ 5mm
* SIS-SP shield outer casing (2) ................. €) sumeno sis SP 8
e Rear lever
Push lever (8) at least seven times
to make sure the mechanism is in
top gear before installing.
i) Operate at
least 7 times
Lever (B) —
Pull the brake lever (as when
braking) to reveal the shifting
cable hole. Pass the inner
cable through this hole and
set it in the outer casing.
Shifting cable hole
/ Outer casing
Inner cable
If the cable hook does not align with the shifting cable hole, press
lever (B) again until it does, and then install the cable.
Cable hook
=
Inner end
Cable hook
Make sure that the
inner end is firmly
seated in the cable
hook.
Bearing member ~~
Assembling the bracket and lever
1. Put the cable hook in to the bearing member, and set the
return spring.
I _ 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.
Return spring
Front lever
Push lever (b) at least two ~ three
times before installing.
Operate at
Pull the brake lever (as
when braking) to pass
the inner cable through /Q
the shifting cable hole, oer casing |
and set it in the outer
casing.
Inner cable
Outer stopper
1. Install the outer stopper to the down tube.
Direct mount seat (M5)
a Outer stopper
Fa
7 Installation bolt
e La „и
y o 3 mm Allen key
( Tightening torque: 15 ~ 20 kgfcm (13 ~ 18 in.Ibs.) )
Install the outer stopper for the
rear chainwheels with the handle
in the default position.
up
_ Handle default
position
2. Pass the inner cable through, and set the outer casing.
Be sure to leave some excess in the outer casing, even if
cutting it to the full length of the handlebars.
Confirm
Make sure the outer casing is
firmly seated in the outer
stopper.
ra
5. Remove the return spring installation tool with pliers.
a \
Return spring installation tool
— Lever (b)
—Lever (a)
Lever (A): Shifts from smaller to larger rear sprocket.
Lever (8): Shifts from larger to smaller rear sprocket.
Lever (a): Shifts from smaller to larger chainwheel.
Lever (b): Shifts from larger to smaller chainwheel.
All levers return to the starting position when released.
Combinations Chart
La
ST-7400
SIS SUPER-SLR
2) 9) sumano SiS sp S
PF
df SL MEXO.E
BR-7403 Wire lead (under mount) E
SUPER-SLR SM-SP55
2
a = ) e f
> FD-7403 RD-7402
Shimano SG SIS
Æ |
TF ed NEN
EE SE
NÉE ==! ЮЖ
FC-7402-SG - FH-7403
Shimano SG SIS HG
SIS HG Shimano SG
Please note: specifications are subject to change for improvement without
notice. (English
SHIMANO
SHIMANO AMERICAN CORPORATION
One Shimano Drive, PO. Box 19615, Irvine, California U.S.A. 92713-9615 Tel, (714) 951-5003
SHIMANO (EUROPA) GmbH.
Kleinhúlsen 1-3, 4010 Hilden, Germany Tel. 02103-5005-0
SHIMANO INC.
3-77 Qimalsucho, Sakai, Osaka, Japan Tel. (0722) 23-3243
© Mar. 1991 by Shimano Inc. U-008A XBC SHS Printed in Japan
sprocket.
Ex.: from 4th to 3rd
Caution on operation
Lever (8)
start position
Lever B® will also move when lever (A) is operated, but be careful
not to apply pressure to lever 8). Similarly be careful not to press
lever (A) when operating lever 6). Gears will not shift when both
levers are pressed simultane
ously.
the smaller front chainring.
stroke
Blick 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
. e: front derailleur
Chain position
a
LE ES UN ET UN ESE
Adjustment
Cautions on operation
Lever (b) 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.
SIS adjustment
Operate the lever (A to set the chain to the second from top
sprocket.
32 1 321 321
| | | | I | *
a
Contacts third sprocket,
making noise.
No noise
Contacts top sprocket,
making noise.
Achusiment
bolt
Turn the rear derailleur adjust-
ment bolt clockwise until there
IS NO noise.
y
Adjustment
bolt
Turn the rear derailleur adjust-
ment bolt counterclockwise until
there is no noise.
NA
Best setting
Turn the crank forward while turn-
ing the rear derailleur adjustment
bolt slowly counterclockwise. Stop
just before noise is produced (the
chain contacts the third sprocket).
Adjustment bolt
* Adjustment with the cable
stopper is also possible while
riding. Tilt the-rear outer
stopper lever to achieve the
same effect as turning the
rear derailleur adjustment
bolt counterclockwise.
_—— Default position
for lever
Front gear shift adjustment
1. Set the chain on the largest rear sprocket and the largest
front chainwheel.
Largest Smallest
sprocket chainwheel
2. Complete the trimming operation.
Largest
sprocket
Largest
chainwheel
Trimming
(noise prevention mechanism)
Press lever (b) lightly to the click-
stop. (For details, see the section
on operation.)
3. After trimming, adjust the gap between the chain and chain
guide to the minimum setting (0 ~ 0.5 mm) using the cable
stopper outer adjustment bolt.
= Chain
© О ^
Chain guide ——
|
© A DC |
a 2 СЕ
Cable adjustment bolt
RI à
NS Y e | — Lever (b)
Pull > \
| : X `
Ti
Cable hook
Inner cable
Maintenance
As long as the mechanism is functioning smoothly, maintenance
IS not required. Disassemble for maintenance as described
below. Do not disassemble any further.
*ST-7400-R for rear sprockets — S—
e ST-7400-F for chainwheel
Bracket and lever disassembly
1. Loosen the lever stud set
screw on the bottom of the
bracket with a 2 mm Allen
key.
2 mm Allen key
Lever stud sei screw
2. Insert the Allen key or
similar tool to push the lever
stud out. The bracket and
lever will come apart.
5. Bring the ot
cover it with
length of th:
6. Finally, wrap
Lever and |
1. Remove the
2. Disassemble
~
/
Spec
3. Disassemble
Do not dis:
possible.
e Use keroser
index mem
Do not smo
open flames
with kerose
* Be sure to r
cleaning.
| | Trim operation
2 large rear
ate, producing a
r (b) lightly (to the
r to move slightly
] the noise.
ment of the
derailleur
, but be careful
ful not to press
ft when both
1 the largest
Largest
chainwheel
7
E
lightly to the click-
ils, see the section
nain and chain
ing the cable
~~ {Nal | — ever (9)
Pull / К i 5. Bring the outer casing along the front of the handlebar and
o NS cover it with the outer guide. Now cut the outer guide to the
| length of the handlebar, and tape it temporarily in place.
— Tilt
Outer quide 4%
2. Pass the inner cable through. \
Cable hook
RE
& Outer casing
sy —— Inner cable
6. Finally, wrap the handlebar with the finish tape.
Maintenance
As long as the mechanism is functioning smoothly, maintenance
IS not required. Disassemble for maintenance as described
below. Do not disassemble any further.
¢ ST-7400-R for rear sprockets =
za © 1
Lever and bearing assembly disassembly
1. Remove the cable hook.
JD —— Cable hook
Torque tightening during assembly:
80 — 100 kgfem (70 — 85 in.lbs.)
AN
1
== 4}
(Cas
Special t | (TL-ST01) )
lal too ON
5 mm Allen key
3. Disassemble as shown.
e ST-7400-F for chainwheel
Bracket and lever disassembly
1. Loosen the lever stud set
screw on the bottom of the
bracket with a 2 mm Allen
key.
Do not disassemble any further as reassembly may not be
possible.
¢ Use kerosene to wash the lever
index member as shown below.
Lever stud set screw
Do not smoke or use any
open flames when cleaning
with kerosene.
2. Insert the Allen key or
similar tool to push the lever
stud out. The bracket and
i .
lever will come apart. Be sure to regrease after
cleaning.
If the cable hook does not align with the shifting cable hole, press
lever (B) again until it does, and then install the cable.
Cable hook
=
Inner end
Cable hook
Make sure that the
inner end is firmly
seated in the cable
hook.
Assembling the bracket and lever
1. Put the cable hook in to the bearing member, and set the
return spring.
Set the end of the spring
in the hole in the bearing
member. Note that the
spring has a right and left
side.
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.
Make sure the lever stud
in inserted in the proper
direction.
The narrow end of the
stud should be at the
position of the lever stud
set screw.
2. Pass the inner cable through, and set the outer casing.
Be sure to leave some excess in the outer casing, even if
cutting it to the full length of the handlebars.
Confirm
Make sure the outer casing is
firmly seated in the outer
stopper.
DA
5. Remove the return spring installation tool with pliers.
Return spring installation tool
6. Tighten the lever stud set screw to complete the assembly.
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
L: for left
Wipe a little rubbing alcohol inside the bracket cover to make
installation easier.
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