Shimano SG-3R40 Internal Geared Hub Service Manual

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Shimano SG-3R40 Internal Geared Hub Service Manual | Manualzz

S E R V I C E M A N U A L

SG-3R40

SG-3C41

SG-3D55

Ver.1.1

©Aug. 2020 by Shimano Inc. ITP

CONTENTS

Introduction of INTER-3 / Explain the technologies

………………………

2

Dealer's Manual

………………………………………………………………………………………………………………………

3

  

SG-3R40, SG-3C41, SG-3D55

     • INSTALLATION

    • MAINTENANCE

T roubleshooting

………………………………………………………………………………………………………………………

32

Disassembly & Assembly

………………………………………………………………………………………………

34

  

Tools

  

Disassembly of the Inter-3 hub (Roller Brake Spec.)

  

Assembly of the Inter-3 hub (Roller Brake Spec.)

Service Parts

…………………………………………………………………………………………………………………………………

46

Interchangeability

…………………………………………………………………………………………………………………

48

Hub dimensions

…………………………………………………………………………………………………………………………

50

EV / Spare Parts List

………………………………………………………………………………………………………………

52

1

Return to index page

SG-3R40

INTER-3 Rear Hub (3-speed)

• Internal Gear Shifting

» Gear shifting action is independent of pedaling.

You can shift gears anytime, while standing still,

pedaling or coasting

• Gear Change Support

• Weight: 885g

• Color options: Black, Silver, White

SG-3C41

INTER-3 Rear Hub (3-speed)

• Internal geared hub for Coaster Brake version

• Integral Coaster Brake

• Gear Change Support Mechanism

• Weight: 1,120g

SG-3D55

INTER-3 Rear Hub (3-speed)

• Internal geared hub for Disc Brake version

• Gear Change Support Mechanism

• Aluminum hub shell

• CENTER LOCK Rotor mount system

• Weight: 945g

• Color options: Black, Silver

TECHNOLOGIES

Gear Change Support

SHIMANO gear change support mechanism utilizes some portion of pedaling force at down shifting. The result is a quick and precise downshift with very light feeling.

Coaster Brake

The SHIMANO NEXUS coaster brake is operated by pedaling backward in a similar way as ordinary types. Its uniqueness is that braking power transmitted to the wheel directly for the SHIMANO NEXUS internal coaster brake is independent of the gear shifting mechanism built into the hub. Also it always generates the same braking force regardless of gear position to actualize comfortable and reliable riding. It actualizes the braking force to meet the ISO 4210 standard.

Equal braking force in each gear

Hub shell

Sprocket

Actuator

Brake shoe

Brake roller Braking cam

Surface Treatment

What is the difference between the Standard and the DX version?

• The Standard version is designed to use under normal climate conditions.

• The DX version features a clear coated finish and/or stainless steel material.

This finish is offering an advanced protection against corrosion and is therefore recommended to use under more severe climate conditions.

2

Dealer's Manual

SG-3R40

SG-3C41

SG-3D55

Return to index page

3

Return to index page

WARNING

When securing the brake arm to the frame, be sure to use an arm clip that matches the size of the chainstay, and securely tighten it with the clip bolt and clip nut to the specified tightening torque. Use a lock nut with a nylon insert (self-locking nut) for the clip nut. It is recommended that Shimano made clip bolts, clip nuts, and arm clips be used. Use an arm clip that matches the chainstay.

If the clip nut comes off the brake arm, or if the clip bolt or arm clip becomes damaged, the brake arm may rotate on the chainstay and cause the handlebars to jerk suddenly, or the bicycle wheel may lock and the bicycle fall over, causing serious injury.

INSTALLATION

„

Installation of the lever

Installation of the REVOSHIFT lever

1

(A) (B)

Install the brake lever

(B)

.

(z)

Use

Φ

22.2 mm handlebars.

(A)

Brake lever band

(B)

Brake lever

(C)

Handlebar

Tightening torque

6 - 8 N·m

(z)

(C)

TECH TIPS

Use a brake lever with a band having a thickness of 4.3 mm or lower to prevent the brake lever and REVOSHIFT lever from interfering with each other.

(A)

REVOSHIFT lever

(A)

Install the REVOSHIFT lever

(A)

.

2

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Install the half grip

(A)

.

Leave a gap

(B)

of 0.5 mm between the

REVOSHIFT lever and the half grip.

(A)

Half grip

(B)

Gap between the REVOSHIFT lever and the half grip

3

(A)

(B)

4

Tighten the REVOSHIFT lever.

(A)

Fixing bolt

Tightening torque

2 - 2.5 N·m

2 - 4 N·m

(A)

Installation of the shifting lever (RAPIDFIRE PLUS)

Secure the shifting lever using the clamp screw (A).

(A)

Clamp screw

Tightening torque

5

N·m

(A)

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„

Installation of the bell crank type hub

Installation of the shifting cable

REVOSHIFT lever

(A)

Insert the outer casing into the outer casing holder

(A)

.

(A)

Outer casing holder

1

RAPIDFIRE PLUS

(A)

2

(A)

(B)

(C)

(D)

Fit the inner cable into the link

(B)

in the bell crank.

Loosen the inner cable mounting nut

(D)

on the bell crank.

Pass the inner cable through the cable adjustment barrel

(A)

along the groove in the link and between the link and inner cable mounting plate

(C)

.

(A)

Cable adjustment barrel

(B)

Link

(C)

Inner cable mounting plate

(D)

Inner cable mounting nut

NOTICE

Make sure to pass the inner cable through the groove in the link.

REVOSHIFT lever

3

RAPIDFIRE PLUS

Set the shifting lever to 2.

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With the inner cable kept tight, tighten the inner cable mounting nut while positioning the end of the link between the two white lines on the window.

(y)

White lines

(z)

Position the end of the link between the white lines.

4

(y) (y)

(z)

5

(z)

After tightening the inner cable mounting nut, cut off the excess length of inner cable.

(z)

Within 4 mm

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6

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(A)

Tighten the bottom cover (B) with the bottom cover fixing screw (A).

(B)

(A)

Bottom cover fixing screw

(B)

Bottom cover

Tightening torque

0.4 - 0.7 N·m

(SM-BC03)

0.35 - 0.55 N·m

(SM-BC04/SM-BC06)

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Installation of the sprocket to the hub (SM-GEAR)

(A)

(B)

(z)

Place the right-hand waterproof cap B

(C)

onto the driver

(D)

on the right side of the hub body.

Next, install the sprocket

(B)

and secure it in place with the snap ring

(A)

.

(z)

Note the direction

(C)

(A)

Snap ring

(B)

Sprocket

(C)

Right-hand waterproof cap B

(D)

Driver

(E)

Right-hand waterproof cap A

(D)

(E)

Installation of the sprocket to the hub (CS-S500 sprocket with chain guard)

(A)

(B)

(z)

Install the chain guard

(B)

to the right-hand waterproof cap A

(D)

of the hub body, and then install the righthand waterproof cap B

(A)

to the driver

(C)

.

(z)

Note the direction

(A)

Right-hand waterproof cap B

(B)

Chain guard

(C)

Driver

(D)

Right-hand waterproof cap A

NOTICE

Do not use an inward assembling sprocket with 16T or less, otherwise the right-hand waterproof cap A will come into contact with the sprocket.

1

(C)

(D)

(A)

(B)

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2

(A)

(B)

(C)

(D)

Return to index page

Install the CS-S500 sprocket

(C)

to the driver

(D)

on the right side of the hub body with the guard plate

(B)

facing outward, and secure it in place with the snap ring

(A)

.

(A)

Snap ring

(B)

Guard plate

(C)

CS-S500 Sprocket

(D)

Driver

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Installation of the hub to the frame (for disc brakes)

Install the disc brake rotor

(A)

to the hub.

(A) (B) (C)

1

(A)

Disc brake rotor

(B)

Disc brake rotor mounting ring

(C)

TL-LR10

Tightening torque

40 N·m

< When not using the chain tensioner >

2

(A)

(B)

Mount the chain on the sprocket, and then set the hub axle

(B)

into the dropout

(A)

.

(A)

Dropout

(B)

Hub axle

< When using the chain tensioner >

2

(A)

Mount the chain on the sprocket, and then set the hub axle into the dropout.

When using the chain tensioner

(A)

, be sure to read the attached instruction manual for the CT-S500 chain tensioner.

(A)

Chain tensioner

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3

(z)

(A)

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Place the non-turn washer

(A)

onto the left side of the hub axle from the outer side.

At this time, turn the hub axle and install the non-turn washer so that the protrusion of the washer fits into the groove in the dropout.

(z)

The protrusion should be on the dropout side.

Install the non-turn washer so that the protrusion fits securely in the dropout groove at the front and back sides of the hub axle.

(A)

Non-turn washer

NOTICE

Use a non-turn washer that matches the shape of the dropout.

Dropout

Standard

Reversed

Reversed (full chain case)

Vertical

Non-turn washer (for left side use)

Mark / Color Size

ϴ

≤ 20°

ϴ

≤ 38°

2 / Yellow

ϴ

= 0°

8L / Green

ϴ

= 0°

ϴ

= 60° - 90°

Mark

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4

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(B)

(A)

Take up the slack in the chain and secure the wheel to the frame, using a 3.2 mm washer

(A)

and a 9 mm hub nut

(B)

on the right side and a cap nut on the left side of the hub axle.

(A)

Washer (3.2 mm)

(B)

Hub nut (9 mm)

Tightening torque

30 - 45 N·m

NOTICE

Make sure that the hub axle on the right side protrudes about 8 to 13 mm from the end face of the hub nut.

Sprocket Dropout

Washer (3.2 mm)

8 - 13 mm

Hub axle

Hub nut

(9 mm)

Total width of the dropout and chain tensioner: 6.5 to 10 mm

When installing the hub to the frame, the chain guard may come off, so check that the chain guard is securely installed so that it will not come off.

If installation is incomplete, noise may be generated.

Chain guard

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Installation of the hub to the frame (for roller brakes)

1

(z)

Engage the splines on the hub body

(B)

with the splines on the inter-M brake

(A)

, and then provisionally tighten the brake unit fixing nut.

(z)

Align the splines

(A)

Inter-M brake

(B)

Hub body

NOTICE

Fully tightening the brake unit fixing nut may make the wheel difficult to turn when the arm clip is attached later.

Refer to the instruction manual for the inter-M brake for details on installing the inter-M brake.

(A) (B)

2

(A)

(B)

Mount the chain on the sprocket, and then set the hub axle

(A)

into the dropout

(B)

.

(A)

Hub axle

(B)

Dropout

3

(A) (z)

Place the non-turn washer

(A)

onto the left side of the hub axle from the outer side.

At this time, turn the hub axle and install the non-turn washer so that the protrusion of the washer fits into the groove in the dropout.

(z)

The protrusion should be on the dropout side.

Install the non-turn washer so that the protrusion fits securely in the dropout groove at the front and back sides of the hub axle.

(A)

Non-turn washer (gold)

NOTICE

When installing a stand to the hub axle, place the non-turn washer onto the stand from the outer side so that the protrusion fits into the groove in the stand.

When installing a part such as a mudguard stay to the hub axle, place it onto the outer side of the non-turn washer.

Stand

Non-turn washer

Mudguard stay

Carrier stay

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4

5

(A) (B)

(C)

< For a 170.3 mm long axle >

(A)

(D)

Install the brake arm

(C)

of the inter-M brake to the chainstay

(A)

using the arm clip

(B)

and temporarily tighten the clip bolt and clip nut loosely.

Then, tighten the brake unit fixing nut

(D)

.

(A)

Chainstay

(B)

Arm clip

(C)

Brake arm

(D)

Brake unit fixing nut

Tightening torque

20 - 25 N·m

NOTICE

If it is impossible to temporarily attach the brake arm to the chainstay due to misalignment of the brake arm as shown in the illustration, loosen the brake unit fixing nut and turn the brake arm before temporarily attaching it to the chainstay.

Then, tighten the brake unit fixing nut.

Take up the slack in the chain and secure the wheel to the frame with the flange nut

(A)

.

(A)

Flange nut

Tightening torque

30 - 45 N·m

NOTICE

Make sure that the hub axle on the right side protrudes 8 to 13 mm from the end face of the flange nut.

Sprocket

Dropout

8 - 13 mm

Hub axle

Flange nut

(11 mm)

Total width of the dropout and chain tensioner: 4 to 7.5 mm

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< For a 189.4 mm long axle >

(A) (B)

5

(C) (C) (D)

(A) (B) (E)

(F)

(C) (D)

(A)

(E)

(B) (G) (H)

If the total width of the dropout and other parts such the stand and mudguard stay

(B)

, on the right side of the hub axle, is 8.5 to 11.5 mm

Secure the right side of the hub axle with two 3.2 mm washers

(C)

and a 9 mm hub nut

(D)

.

Secure the left side of the hub axle with a 3.2 mm washer and a 9 mm hub nut.

Example: Mount the parts in the order shown in the illustration.

If the total width of the dropout and other parts such the stand and mudguard stay, on the right side of the hub axle, is 11.5 to 14.5 mm

Secure the both side of the hub axle with a 3.2 mm washer

(C)

and a 9 mm hub nut

(D)

.

Example: Mount the parts in the order shown in the illustration.

(A)

Chain tensioner

(B)

Mudguard stay

(C)

Washer (3.2 mm)

(D)

Hub nut (9 mm)

(E)

Carrier stay

(F)

Stand

(G)

Washer (2 mm)

(H)

Hub nut (7 mm)

Tightening torque

30 - 45 N·m

NOTICE

In any of the cases described in this step, make sure that the hub axle on the right side protrudes 8 to 13 mm from the end face of the hub nut.

If the total width of the dropout and other parts such the stand

(F)

and mudguard stay, on the right side of the hub axle, is 14.5 to 17 mm

Secure both sides of the hub axle with a

2 mm washer

(G)

and a 7 mm hub nut

(H)

.

Example: Mount the parts in the order shown in the illustration.

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6

(A) (B)

(z)

(C)

Fix the brake arm

(C)

of the inter-M brake securely to the chainstay

(A)

with the arm clip

(B)

.

(z)

If excessive force is applied to the brake arm, the wheel will become difficult to turn.

Be careful not to apply excessive force when installing.

(A)

Chainstay

(B)

Arm clip

(C)

Brake arm

Tightening torque

2 - 3 N·m

NOTICE

When installing the arm clip, securely tighten the clip bolt while holding the clip nut with a 10 mm spanner.

After installing the arm clip, check that the clip bolt protrudes about 4 mm from the end face of the clip nut.

Clip nut Brake arm

Arm clip

Clip bolt

(M6 × 16 mm)

About 4 mm

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Installing the brake cable

(A) (B)

Place the cable adjustment barrel

(A)

so that it is 15 – 17 mm from the end of the brake arm

(B)

, and then pass the inner cable through the cable adjustment barrel of the brake arm and then through the hole in the inner cable fixing bolt

(C)

.

(z)

Should be 15 – 17 mm

(A)

Cable adjustment barrel

(B)

Brake arm

(C)

Hole in the inner cable fixing bolt

1

(z)

(C)

2

(z)

Check that both ends of the outer casing are securely inserted into the cable adjustment barrels

(A)

of both the brake lever and brake arm.

(z)

Both ends of the outer casing should be securely inserted.

(A)

Cable adjustment barrel

3

(B)

(A)

(z)

(A)

(C)

Pull the link

(A)

back until it stops. Then, while pulling the inner cable

(C)

to apply the full amount of tension to the cable, tighten the inner cable fixing nut

(B)

.

(A)

Link

(B)

Inner cable fixing nut

(C)

Inner cable

Tightening torque

6 - 8 N·m

NOTICE

Set the inner cable so that it passes below the link as shown in illustration

(z)

.

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Adjusting the brake cable

1

(z)

(z)

2

(A)

After checking that the wheel does not easily turn while the brake cable is being pulled, depress the brake lever about 10 times as far as the grip in order to run in the brake cable.

(z)

Depress about 10 times

NOTICE

If the brake cable is not run in, it will need to be adjusted again after only a short period of use.

(A)

Cable adjustment barrel Turn the cable adjustment barrel

(A)

so that there is about 15 mm of gap

(z)

in the brake lever.

* The amount of brake lever gap is the distance from the position where the brake lever is not operated to the position where a force is felt suddenly when the brake lever is pulled.

3

After depressing the brake lever to check the braking performance, secure the cable adjustment barrel with the cable adjusting nut

(A)

.

(A)

Cable adjusting nut

Tightening torque

1 - 2 N·m

(A)

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Installation of the hub to the frame (for coaster brakes)

1

(A)

(B)

Mount the chain on the sprocket, and then set the hub axle

(A)

into the dropout

(B)

.

(A)

Hub axle

(B)

Dropout

2

3

(A) (z)

(A) (B)

(D) (E)

Place the non-turn washer

(A)

onto the left side of the hub axle from the outer side.

At this time, turn the hub axle and install the non-turn washer so that the protrusion of the washer fits into the groove in the dropout.

(z)

The protrusion should be on the dropout side.

Install the non-turn washer so that the protrusion fits securely in the dropout groove at the front and back sides of the hub axle.

(C)

Install the brake arm

(A)

to the chainstay

(D)

using the arm clip

(E)

and temporarily tighten the clip bolt

(C)

and clip nut

(B)

loosely.

Then, tighten the brake unit fixing nut.

(A)

Non-turn washer (yellow)

(A)

Brake arm

(B)

Clip nut

(C)

Clip bolt

(D)

Chainstay

(E)

Arm clip

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4

(A)

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Take up the slack in the chain and secure the wheel to the frame with the flange nut

(A)

.

(A)

Flange nut

Tightening torque

30 - 45 N·m

NOTICE

Make sure that the hub axle on the right side protrudes 8 to 12.5 mm from the end face of the flange nut.

Sprocket

Dropout

8 - 12.5 mm

Hub axle

Flange nut

Total width of the dropout and other parts such the stand and mudguard stay:

4 to 7.5 mm (Axle length: 168 mm / 175 mm)

9 to 12.5 mm (Axle length: 178 mm)

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5

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(A) (B) (C)

(D) (E)

Fix the brake arm

(A)

securely to the chainstay

(D)

with the arm clip

(E)

.

(A)

Brake arm

(B)

Clip nut

(C)

Clip bolt

(D)

Chainstay

(E)

Arm clip

Tightening torque

2 - 3 N·m

NOTICE

When installing the arm clip, securely tighten the clip bolt while holding the clip nut with a 10 mm spanner.

After installing the arm clip, check that the clip bolt protrudes about 2 to 3 mm from the end face of the clip nut.

Clip nut

Brake arm

Arm clip

Clip bolt

(M6 × 16 mm)

About 2 to 3 mm

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Installation of the bell crank

1

(z)

(A)

Insert the push rod

(A)

into the hub axle.

(z)

About 14 mm

The push rod should protrude about 14 mm from the end face of the hub axle.

(A)

Push rod

2

(A)

(B)

While pushing the bell crank into the hub axle, align the splines inside the bell crank with the hub nut

(C)

, and continue push until the crank comes into contact with the end face

(E)

of the hub axle.

While keeping the parts in this position, tighten the bell crank fixing bolt

(A)

onto the hub axle.

Make sure that the edge

(D)

of the window is aligned with the end face of the hub axle.

(A)

Bell crank fixing bolt

(B)

5 mm hexagon wrench or 10 mm spanner

(C)

Hub nut

(D)

Edge of the window

(E)

End face of the hub axle

Tightening torque

3 - 5 N·m

(C)

(D)

(E)

Securing the shifting cable to the frame

(y)

(z)

Secure the cable to the frame with the outer casing bands

(A)

.

(y)

20 - 25 cm

(z)

Slacken the cable to prevent strain from being placed on the cable when turning the handlebars.

(A)

Outer casing bands

(A)

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ADJUSTMENT

„

For bell cranks

REVOSHIFT lever

Set the shifting lever to 2.

Next, turn the cable adjustment barrel

(A)

to align the red line

(D)

on the push rod with the end

(C)

of the hub axle.

(A)

Cable adjustment barrel

(B)

Push rod

(C)

End of the hub

(D)

Red line on the push rod

(E)

Yellow lines

(F)

Yellow part of the link

NOTICE

During adjustment, check the two yellow lines through the window from above.

1

RAPIDFIRE PLUS

(A)

(C)

(D)

(B)

(E)

(F)

(E)

2

While turning the crank, move the shifting lever from 3 to 1 then back to 3. Repeat this two or three times and check that the gears are being shifted. Move the shifting lever from 1 to

2 again and make sure that the red line on the push rod is aligned with the end of the hub axle. If they are not aligned, perform readjustment.

After adjusting the bell crank IV, fix the cable adjustment barrel with the cable adjustment nut

(A)

.

(A)

3

SET

S ET

(A)

Cable adjustment nut

Tightening torque

1.5 - 2.5 N·m

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MAINTENANCE

„

Replacement of the shifting cable

REVOSHIFT lever (In the case of 3S41-E/3S42-E)

Set the REVOSHIFT lever to 1.

(z)

Set to 1

1

(z)

Loosen the two cover fixing screws

(A)

and remove the cover

(B)

.

TECH TIPS

Use a shifting cable with one inner cable drum.

*

The shape differs depending on the model.

Cassette joint side

Shifting lever side

Plastic cap Plastic cap

(A)

Cover fixing screw

(B)

Cover

2

(A)

(A) (B)

2

(A) (B) (C)

3

3

1

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Pass the inner cable from the hole in the winder unit

(C)

through the hole in the outer casing holder

(A)

.

Next, insert the inner cable into the groove of the cable guide

(B)

.

(A)

Hole in outer casing holder

(B)

Groove of cable guide

(C)

Hole in winder unit

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Pull the inner cable so that the inner cable drum fits into the recess in the winder unit

(A)

.

(A)

Recess in winder unit

4

(A)

(A)

Insert the outer casing into the outer casing holder

(A)

.

(A)

Outer casing holder

5

6

(A) (B)

Fasten the cover

(B)

with the 2 cover fixing screws

(A)

.

(A)

Cover fixing screw

(B)

Cover

Tightening torque

0.1 - 0.2 N·m

(A)

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Return to index page

REVOSHIFT lever (In the case of 3S35-E)

(z)

Set the REVOSHIFT lever to 1.

(z)

Set to 1

1

(A)

(B)

Loosen the cover fixing screw

(A)

, and then remove the indicator cover

(B)

.

TECH TIPS

Use a shifting cable with one inner cable drum.

*

The shape differs depending on the model.

Cassette joint side

Shifting lever side

Plastic cap Plastic cap

(A)

Cover fixing screw

(B)

Indicator cover

2

3

(A)

(B)

(C)

Set the inner cable onto the pulley.

Insert the inner cable into groove

(B)

from the inside of the projection on the pulley

(C)

, and then pass it through the hole in the outer casing holder

(A)

.

(A)

Hole in outer casing holder

(B)

Groove in pulley

(C)

Projection on pulley

NOTICE

Check that the inner cable is correctly routed along the inside of the projection on the pulley.

Click here for the latest Dealer's Manual https://si.shimano.com/DM/SG0005

Return to index page

(A)

1

Hook the inner cable into groove in the pulley

(A)

, and pull the inner cable so that the inner cable drum fits into the hole in the pulley

(C)

.

After this, insert the outer casing into the outer casing holder

(B)

.

4

3

(C)

2

(B)

5

Replace the indicator cover and tighten the cover fixing screw.

Shifting lever (RAPIDFIRE PLUS)

Set the REVOSHIFT lever to 1.

(z)

Set to 1

1

(z)

Remove the inner hole cap (A).

(A)

Groove in pulley

(B)

Outer casing holder

(C)

Hole in pulley

(A)

Inner hole cap

2

(A)

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Return to index page

Pass the inner cable through and install the inner hole cap.

3

„

Replacement of the cover (RAPIDFIRE PLUS)

Remove the four mounting screws, and replace the cover.

(A)

Cross head screwdriver [#1]

(B)

Cross head screwdriver [#2]

(A)

Cross head screwdriver [#1]

(B)

Cross head screwdriver [#2]

Tightening torque (A) (C)

0.1 - 0.3 N·m

Tightening torque (B) (D)

0.3 - 0.6 N·m

(B)

(A)

(D)

(C)

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Return to index page

„

Oil maintenance of the internal assembly

To maintain the product in good working order, it is recommended to have a bicycle dealer or nearest agency carry out maintenance such as lubrication of the internal parts about once every two years from the first time of use (once about every 5,000 km if the bicycle is used very frequently). Also, for carrying out maintenance, the use of Shimano internal geared hub grease or a lubrication kit is recommended. If Shimano grease or a Shimano lubrication kit is not used, problems such as a malfunction in gear shifting may occur.

(A)

WB maintenance oil set

(Y00298010)

1

(A)

Fill the bottle with maintenance oil to a height of 95 mm.

(z)

95 mm

(z)

(z)

Immerse the internal unit into the oil from the left side until the oil reaches up to ring gear unit 1, as shown in the illustration.

(z)

Ring gear unit 1

2

3

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Keep the internal unit immersed for approximately 90 seconds.

4

5

6

Return to index page

Remove the internal unit from the oil.

Let the excess oil drain off for approximately 60 seconds.

After lubrication is complete, reassemble the hub.

TECH TIPS

<Maintenance oil>

Maintenance oil is reusable.

Refill it as needed.

Store it with the lid closed after use.

Click here for the latest Dealer's Manual https://si.shimano.com/DM/SG0005

Troubleshooting

Return to index page

32

10

27

28

29

30

31

32

33

34

17

22

23

24

25

18

19

20

21

ITEM NO.

10

11

7

8

9

12

13

14

15

16

1

2

3

4

5

6

26

PART NO.

07000

90220

05000

52001

03200

21830

21930

22030

22130

22230

22330

20010

98080

98180

98290

95100

98010

57000

98020

98030

20600

20400

70020

03000

06000

06040

20200

13000

13010

16010

98050

98090

98060

98100

98050

98060

06020

37000

90700

98270

90710

19000

90400

90300

90220

98040

98280

98050

90200

90210

90500

08100

30100

15010

Y-31Z

Y-321

Y-33R

Y-33R

Y-322

Y-73T

Y-73T

Y-73T

Y-73T

Y-73T

Y-73T

Y-321

Y-33R

Y-33S

Y-33S

Y-33S

Y-33S

Y-33S

Y-33S

Y-33S

Y-041

Y-041

Y-321

Y-200

Y-220

Y-220

Y-33Z

Y-75V

Y-75V

Y-75V

Y-75M

Y-33F

Y-75M

Y-33F

Y-75Y

Y-75Y

Y-31Z

Y-33M

Y-33S

Y-33S

Y-33S

Y-33Y

Y-33S

Y-33S

Y-33R

Y-33S

Y-33S

Y-33S

Y-33S

Y-33R

Y-33R

Y-33R

Y-325

Y-220

Exploded view and parts list

For Axle Length

189.4 mm

12 13

18

14 15

MIN.2Nm

JAP

AN

17

GREASE

16

SHIMANO NEXUS 3-SPEED HUB w/Hi-Power Roller Brake

SG-3R40

Inter-3 Hub

BR-IM31

-R

Inter-M Brake

20 21 22 23

1

Internal Assembly

24 25

34

Grease

For Axle Length

170.3 mm / 176.8 mm

11

19

26

27

For Axle Length

189.4 mm

13 12

28

29

Bell Crank lll

30

2 3 4 5

1

6 7 8 9 10

For Axle Length

170.3 mm / 176.8 mm

11

32

SET

SET

31

33

DESCRIPTION

Internal Assembly (Axle Length 170.3 mm)

Internal Assembly (Axle Length 176.8 mm)

Internal Assembly (Axle Length 189.4 mm)

Stop Ring ( 9.6 mm)

Carrier Unit

Ring Gear Unit

Ball Retainer K (7/32" x 10)

Axle Unit (Axle Length 170.3 mm)

Axle Unit (Axle Length 176.8 mm)

Axle Unit (Axle Length 189.4 mm)

Driver Unit

Ball Retainer J (7/32" x 8)

Right Hand Cone w/Dust Seal

Right Hand Lock Nut (5 mm) for Axle Length 170.3 mm / 189.4 mm

Right Hand Lock Nut (9.9 mm) for Axle Length 176.8 mm

Flange Nut for Axle Length 170.3 mm / 176.8 mm

Hub Nut (7 mm) for Axle Length 189.4 mm

Hub Nut (9 mm) for Axle Length 189.4 mm

Washer (2 mm) for Axle Length 189.4 mm

Washer (3.2 mm) for Axle Length 189.4 mm

Non-turn Washer 2 (Yellow)

Brake Unit Fixing Nut (8.2 mm) for Axle Length 170.3 mm / 189.4 mm

Brake Unit Fixing Nut (9.7 mm) for Axle Length 176.8 mm

Grease Hole Cap

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 & Nut

Inner Cable Fixing Bolt & Nut

Lock Nut for Left Hand Cone

Left Hand Cone

Left Hand Dust Cap

Ball Retainer A (1/4" x 7)

Right Hand Dust Cap A

Right Hand Dust Cap B

Sprocket Wheel 16T (Black)

Sprocket Wheel 18T (Black)

Sprocket Wheel 19T (Black)

Sprocket Wheel 20T (Black)

Sprocket Wheel 21T (Black)

Sprocket Wheel 22T (Black)

Sprocket Wheel 23T (Black)

Snap Ring C

Push Rod (81.85 mm) for Axle Length 170.3 mm

Push Rod (86.85 mm) for Axle Length 176.8 mm

Push Rod (90.75 mm) for Axle Length 189.4 mm

Bell Crank Unit

Cable Adjusting Bolt & Nut

Bell Crank Body Fixing Bolt

Bell Crank Cover & Fixing Screw

Inner Cable Fixing Bolt Unit

Internal Hub Grease (Net. 100g)

Roller Brake Grease (Net. 100g)

Symptom

Mechanism spins freely or slips when in top 3 gear.

Mechanism spins freely or slips when in normal

2 gear.

Mechanism spins freely or slips when in low 1 gear.

Gear shifting is not possible.

Push rod does not move.

Return to index page

Cause and remedy

Malfunction of the internal assembly. Replace with a new one.

Internal assembly

Malfunction of the axle unit and driver unit. Replace with new ones.

Axle unit / Driver unit

Malfunction of pawls B. Replace the ring gear unit with a new one.

Ring gear unit

Malfunction of pawls A. Replace the driver unit with a new one.

Driver unit

Malfunction of pawl D or the planetary gear.

Replace the carrier unit with a new one.

Carrier unit

Damaged ball retainer K (7/32" x 10), J (7/32" x 8) or A (1/4" x 7). Replace the damaged part with a new one. Apply grease to the new part when replacing.

Ball retainer Internal hub grease

K (7/32" x 10) J (7/32" x 8) A (1/4" x 7)

Part no. Y-041 20800

Incorrect installation of right hand dust cap A.

Install right hand dust cap correctly to the hub shell.

Right hand dust cap A

Malfunction of the bell crank unit.

Replace the bell crank unit with a new one.

Bell crank unit

Incorrect installation of the bell crank . Install the bell crank correctly.

Damaged or malfunctioning cable. Replace the cable with a new one of a type recommended by Shimano.

Damaged or malfunctioning push rod.

Replace the push rod with a new one.

Push rod

11

33

Return to index page

Disassembly and Assembly

34

Tools a: TL-HS20

Hub spanners

Part no. Y-320 90010

15 mm/17 mm (2 pcs.) b: TL-HS10

Hub spanners

Part no. Y-230 90010

13 mm x 14 mm (2 pcs.) c: Slotted Screwdriver

a b c

Return to index page

35

Return to index page

Disassembly of the INTER-3 Hub (Roller Brake Spec.)

1.

Hold the two beveled surfaces of

the hub axle in a vise.

Vise

NOTICE

Do not damage the threads of the hub axle.

2.

Remove the right hand dust cap A

with a slotted screwdriver.

Right hand dust cap A

Slotted screwdriver

3.

Hold the two beveled surfaces

of the hub axle on the driver

side in a vise.

Driver

NOTICE

Do not damage the threads of the hub axle.

36

4.

Hold the left hand cone, and then

remove the lock nut for left hand

cone. Next, remove the left hand

cone.

Return to index page

Disassembly of the Inter-3 hub

TL-HS10(14 mm)

TL-HS10(14 mm)

Lock nut for left hand cone

Left hand cone

5.

Remove the hub shell.

Now it can be replaced with the new internal assembly.

Hub shell

Internal assembly for quick replacement

Part no.

Y-33S 90700

Y-33S 98270

Y-33S 90710

Axle length

170.3 mm

176.8 mm

189.4 mm

37

6.

Remove the stop ring with a

slotted screwdriver

At this time, the stop ring come off with great force.

Be careful of the safety using cloth and so on.

Stop ring

(9.6 mm dia.)

Slotted screwdriver

Return to index page

Disassembly of the Inter-3 hub

7.

Remove the carrier unit and the

ring gear unit at the same time

while turning the ring gear unit

slightly to the left and right.

Carrier unit

Ring gea unit

8.

Remove ball retainer K while

pressing in pawl A-1 and pawl A-2

   on the driver unit with your

fingers.

 

Pawl A-1

Pawl A-2

Ball retainer K

Carrier unit

Ring gear unit

After removing them at the same time, remove the carrier unit from the ring gear unit.

38

Return to index page

Disassembly of the Inter-3 hub

9.

Turn the axle unit with driver

upside down and hold the two

beveled surfaces of the axle in

a vise.

Axle unit with driver

NOTICE

Do not damage the threads of the hub axle.

10.

Remove the right hand lock

nut and the right hand cone

with dust seal from the hub

axle.

TL-HS20

(17 mm)

11.

Remove ball retainer J from

the driver unit.

TL-HS20

(15 mm)

Right hand lock nut

Right hand cone with dust seal

Ball retainer J

Driver unit

39

Return to index page

Disassembly of the Inter-3 hub

12.

Turn the driver unit clockwise

to remove it from the axle unit.

Turn the driver unit clockwise

Driver unit

NOTICE

Do not disassemble the axle unit, otherwise it may cause problems with gear shifting.

This completes the disassembly of the Inter-3 hub.

40

Return to index page

Assembly of the INTER-3 Hub (Roller Brake Spec.)

1.

Hold the two beveled surfaces

of the axle unit on the gear side

in a vise.

Vise

Gear

2.

Install the driver unit onto the

axle unit.

Clutch

Axle unit

NOTICE

Do not damage the threads of the hub axle.

Smaller indents inside the driver unit

Driver unit

Axle unit

Smaller projections at top of clutch

NOTICE

Align the two smaller indents inside the driver unit with the two smaller projections at the top of the clutch when installing the driver unit.

3.

Place ball retainer J onto the

driver unit

Ball retainer J

Driver unit

NOTICE

Be careful of the setting direction.

Apply a liberal coating of internal hub grease.

(Y04120800)

41

Return to index page

Assembly of the Inter-3 hub

4.

Screw the right hand cone with

dust seal onto the hub axle as

far as it will go.

Then turn the right hand cone

counterclockwise by 120 degree,

and then secure it by tightening

the right hand lock nut.

120º

5.

Turn the axle unit with driver

upside down and hold the two

beveled surfaces of the axle on

the driver side in a vise.

Right hand lock nut

Right hand cone with dust seal

TL-HS20

(17 mm)

TL-HS20

(15 mm)

Tightening torque:

12 - 20 N·m {104 - 174 in.lbs}

Axle unit with driver

NOTICE

Do not damage the threads of the hub axle.

42

Return to index page

Assembly of the Inter-3 hub

6.

Install ball retainer K while

pressing in pawl A-1 and pawl A-2

   on the driver unit with your

Fingers.

 

Pawl A-1

Pawl A-2

7.

While pushing the two pawls B

on the ring gear unit with your

fingers, push the two pawls A-1

and the two pawls A-2 on the

driver unit one by one with a

slotted screwdriver and install the

ring gear unit to the driver unit.

Pawl A-2

Pawl A-1

Driver unit

Ball retainer K

NOTICE

Be careful of the setting direction.

Apply a liberal coating of internal hub grease.

(Y04120800)

Ring gear unit

Pawl B

Internal ratchet mechanism

Slotted screwdriver

NOTICE

Be careful of the directions of the two pawls B.

Apply a liberal coating of internal hub grease.

Check that pawls B are not hooked onto the clutch.

Check that pawls A-1 and A-2 care engaged with the ratchet mechanism in the ring gear unit.

Apply a liberal coating of internal hub grease to the gear inside the ring gear unit.

OK Not O K

43

Return to index page

Assembly of the Inter-3 hub

8.

Engage the teeth of the planetary

gear of the carrier unit with the

teeth of the ring gear unit while

turning the carrier unit slightly to

the left and right and pushing it

onto the ring gear unit.

9.

Insert the stop ring into the

groove of the hub axle.

10.

While turning the hub shell

counterclockwise slightly,

place it onto the internal

assembly.

Teeth of ring gear unit

Stop ring

(9.6 mm dia.)

Teeth of carrier unit planetary gear

Check

Check that the stop ring groove of the hub axle is visible from the edge of the carrier unit after the carrier unit has been installed.

NOTICE

Apply a liberal coating of internal hub grease to the planetary gear (in 4 places) inside the carrier unit.

Carrier unit

NOTICE

After inserting the stop ring, check that there is a small amount of play in the carrier unit in the vertical direction. If there is no vertical play and the carrier unit turns stiffly, turn the internal assembly upside down and hold the hub axle in a vice. Then loosen the right hand lock nut and the right hand cone with dust seal to adjust until there is sufficient play.

Groove of hub axle

Hub shell

Internal assembly

44

11.

Screw on the left hand cone to

adjust so that the hub shell can

be turned smoothly without any

play. After adjusting, secure the

left hand cone with the lock nut

for left hand cone.

Tightening torque:

12 - 20 N·m {104 - 174 in.lbs}

12.

Turn the hub upside down and

hold the two beveled surfaces

of the axle in a vise.

13.

Install right hand dust cap A to

the hub shell.

This completes the assembly of the Inter-3 hub

Return to index page

Assembly of the Inter-3 hub

TL-HS10(14 mm)

TL-HS10(14 mm)

Lock nut for left hand cone

Left hand cone

Driver

NOTICE

Do not damage the threads of the hub axle.

Right-hand lock nut

Check

After installing right hand dust cap A to the hub shell, turn the hub shell clockwise and check that it turns smoothly. If the hub shell does not turn smoothly, re-install right hand dust cap A.

NOTICE

Apply a coating of internal hub grease to the inside of right hand dust cap A to waterproof it.

Push right hand dust cap A firmly onto the hub shell until it clicks.

45

Service Parts

Return to index page

46

Return to index page

Service Parts

Bell Crank

No image

SM-BC03 SM-BC04 SM-BC06

Non-Turn Washer

The shape of the dropout determines which NTW to choose. In the illustration below, you can see the result for various frame dropouts in combination with the chosen NTW .

Dropout

Except vertical type

Vertical type

Non-Turn Washer (for left side use)

Mark / Color Size

2 / Yellow =0° 60°

8L / Green =60° 90

Mark

47

Interchangeability

Return to index page

48

Return to index page

Interchangeability

Compatible Products

SG-3R40 SG-3R40

Internal Unit SG-3C41 SG-3C41

SG-3D55 SG-3D55

(NOTE) *The specifications differ depending on the length of the axle etc. Therefore, follow the compatibility of the axle

length and such.

49

Hub dimensions

(Over Locknut Dimensions and Axle)

Return to index page

50

Return to index page

Hub dimensions

(Over Locknut Dimensions and Axle)

C-275

 

 

 

 

 

12

Series

Series

Model No.

Speed

Gear ratio: Total

C

D

A

B

E

F

G

K

L

H

J

D

 

E

 

C

A

B

 

 

 

F

Brake type

Hub shell material

Hub shell material

Spoke size

Over locknut dim. / O.L.D. (mm)

Axle length (mm)

Push rod length (mm)

Flange distance (mm)

Flange distance (mm)

Spoke hole P.C.D. (mm)

Butterfly spoke hole

Flange diameter (mm)

Flange width (mm): F1 (left)

Flange width (mm): F2 (right)

H

J

K

Flange width (mm): F2 (right)

G Chain line (mm)

15T (flat gear) use

Inward assembly

Chain line (mm)

Outward assembly

Offset (mm)

L Axle size

Axle length from hub (right)

Axle size

N Rear dropout mounting width (left, includes stay etc.)

Q

stay etc.)

Non-turn washer width

R

R

Non-turn washer width

Spoke hole diameter (mm)

S

S

SG-3R40

SG-3R40

NEXUS

NEXUS

3

SG-3C41

SG-3C41 SG-3D55

SG-3D55 SG-3R75-B

42.2

39.7

44.7

0.8

44.7

0.8

32.7

36.3

22.5

27.5

40.5

38

43

40.5

2.5

24.5

31.4

186%

All

All

177

81.85

90.75

86.85

53

53

90.75

86.85

81.85

74

74

-

84

127

177

84

Steel

127

183

2.3

2.3

Steel

130

183.5

#13 / #14

130

120

2.3

Coaster brake

-

67.5

Coaster brake

178

168

81.85

57.5

86.85

59

127

175

Aluminum

178

57.5

59

67.5

135

193

90.75

53.5

65

77.6

3.2

3.2

127

175

22.5

27.4

22.5

27.4

32.7

36.3

22.5

27.5

45.5

43

48

22.5

31.4

2.3

45.5

43.7

41.2

43

46.2

1.2

27

30.8

26

32

21

27

42.2

39.7

44.7

2.7

26

32

44.5

42

47

1.7

26.2

31.4

42.2

39.7

44.7

2.7

21

122

174.0

51.1

83.5

92.5

2.7

2.3

-

-

-

43.9

3.6

26

Disc brake

brake

Steel

BC3 / 8 TPI

26.6

158%

26

26

135

193

90.75

53.5

65

77.6

3.2

3.2

44.5

42

47

1.7

26.2

31.4

4.0 -

7.5

4.0 -7.5

8.5 -

17.0

8.5 -17.0

4.0 -

7.5

8.0 -

11.5

4.0 -7.5

4.0

4.0

7.5 -

11.0

4.0 -

7.5

8.0 -11.5

7.5 -11.0

9.0 -

12.5

4.0 -7.5

4.0 -

7.5

6.5 - 10.0

9.0 -12.5

4.0 - 9.0

4.0 -7.5

6.5 - 10.0

2.7

105°

2.7

105°

4.0

2.9

90°

6.4

Left: 2.7

Right: 2.8

105°

4.0 or 6.4

2.9

90°

51

Ver. 2.4, Apr. 9, 2019, SHIMANO INC.

EV / Spare Parts List

Return to index page

52

Return to index page

Spare parts list

NEXUS 3-SPEED HUB w/Hi-Power Roller Brake

SG-3R40

inter -3 Hub

/ BR-IM31

-R

inter -M Brake

17

35

34

Grease

For Axle Length

189.4 mm

12 13

18

14 15

MIN.2Nm

JAPAN

16

GREASE

20 21 22 23

1

Internal Assembly

24 25

For Axle Length

170.3 mm / 176.8 mm

2

11

3

19

4 5

1

6 7 8 9 10

φ

ITEM NO.

SHIMANO CODE NO.

DESCRIPTION

Y33S90700 Internal Assembly (Axle Length 170.3 mm)

1

2

3

Y33S98270

Y33S90710

Y33Y19000

Y33S90400

Internal Assembly (Axle Length 176.8 mm)

Internal Assembly (Axle Length 189.4 mm)

Stop Ring (

φ

9.6 mm)

Carrier Unit

4

5

6

Y33S90300

Y33R90220

Y33S98040

Y33S98280

Y33S98050

Ring Gear Unit

Ball Retainer K (7/32" x 10)

Axle Unit (Axle Length 170.3 mm)

Axle Unit (Axle Length 176.8 mm)

Axle Unit (Axle Length 189.4 mm)

7

8

9

10

11

12

13

14

15

16

17

18

Y33S90200

Y33R90210

Y33R90500

Y33R08100

Y32530100

Y22015010

Y32170020

Y20003000

Y22006000

Y22006040

Y33Z20200

Y75V13000

Y75V13010

Y75F11000

Y75M98050

Y33F98090

Y75M98060

Y33F98100

Y75Y98050

Driver Unit

Ball Retainer J (7/32" x 8)

Right Hand Cone w/Dust Seal

Right Hand Lock Nut (5 mm) for Axle Length 170.3 mm / 189.4 mm

Right Hand Lock Nut (9.9 mm) for Axle Length 176.8 mm

Flange Nut for Axle Length 170.3 mm / 176.8 mm

Hub Nut (7 mm) for Axle Length 189.4 mm

Hub Nut (9 mm) for Axle Length 189.4 mm

Washer (2 mm) for Axle Length 189.4 mm

Washer (3.2 mm) for Axle Length 189.4 mm

Non-turn Washer 2 (Yellow)

Brake Unit Fixing Nut (8.2 mm) for Axle Length 170.3 mm / 189.4 mm

Brake Unit Fixing Nut (9.7 mm) for Axle Length 176.8 mm

Grease Hole Cap

Brake Arm Clip Unit (

φ

15 mm)

Brake Arm Clip Unit (5/8")

Brake Arm Clip Unit (11/16")

Brake Arm Clip Unit (3/4")

Brake Cable Adjusting Bolt & Nut

26

27

13 12

For Axle Length

170.3 mm / 176.8 mm

11

28

29

SM-BC06

30

33

SET

SET 31

32

29

Bell Crank 3

30

33

31

32

ITEM NO.

SHIMANO CODE NO.

DESCRIPTION

19 Y75Y98060 Inner Cable Fixing Bolt & Nut

20

21

Y31Z06020

Y33M37000

Lock Nut for Left Hand Cone

Left Hand Cone

22

23

24

25

Y31Z07000

Y32190220

Y33R05000

Y33R52001

Left Hand Dust Cap

Ball Retainer A (1/4" x 7)

Right Hand Dust Cap A

Right Hand Dust Cap B

26

Y32203200

Y73T21830

Y73T21930

Y73T22030

Y73T22130

Y73T22230

Y73T22330

Sprocket Wheel 16T (Black)

Sprocket Wheel 18T (Black)

Sprocket Wheel 19T (Black)

Sprocket Wheel 20T (Black)

Sprocket Wheel 21T (Black)

Sprocket Wheel 22T (Black)

Sprocket Wheel 23T (Black)

27

28

29

30

31

32

33

34

35

Y32120100

Y33R98080

Y33S98180

Y33S98290

Y6P198030

Y33S95100

Y33S98010

Y33S74000

Y33S57000

Y33S98030

Y6P198040

Y33S98020

Y04120800

Y04120400

Y04140020

Snap Ring C

Push Rod (81.85 mm) for Axle Length 170.3 mm

Push Rod (86.85 mm) for Axle Length 176.8 mm

Push Rod (90.75 mm) for Axle Length 189.4 m

SM-BC06 Bell Crank Unit

Bell Crank 3 Unit

Cable Adjusting Bolt & Nut

Bell Crank Body Fixing Bolt for SM-BC06

Bell Crank Body Fixing Bolt for Bell Crank 3

Inner Cable Fixing Bolt Unit

Bell Crank Cover & Fixing Screw for SM-BC06

Bell Crank Cover & Fixing Screw for Bell Crank 3

Internal Hub Grease (Net. 100g)

Roller Brake Grease (Net. 100g)

Roller Brake Grease (Net. 10g)

53

Return to index page

Spare parts list

NEXUS 3-SPEED HUB w/Coaster Brake

SG-3C41

SG-3C41

Inter-3 Hub

Left Side Non-turn Washer Spec.

18

17

19

16 20

21 22

23

24

31

Internal Hub Grease

(For coaster brake also)

1

Internal Assembly

12 13 14 15

26

27

SM-BC06

26

Bell Crank 3

27

1

12 25

2 3 4 5 6 7 8 9 10 11

SET

SET

28 28

30

29

30

29

DESCRIPTION

ITEM NO.

1

2

SHIMANO CODE NO.

*

1

2

3

4

5

6

Y35U98010

Y33R98020

Y33R90600

Y32532000

Y35U98020

Y35U98060

Internal Assembly (Axle Length 168 mm)

Internal Assembly (Axle Length 175 mm)

DESCRIPTION

Brake Shoe Unit

Internal Assembly (Axle Length 175 mm)

Ring Gear Unit

Ball Retainer K (7/32" x 11)

3

4

5

6

*

7

8

9

Y33R90700

Y35U98060

10

Y32532000

Y33R90400

Y35U98070

Y33R90500

Stop Ring (ø9 mm)

Carrier Unit

Driver Unit

Ball Retainer K (7/32" x 11)

Right Hand Cone w/Dust Seal

7

8

9

10

11

12

13

14

15

16

17

ITEM NO.

SHIMANO CODE NO.

DESCRIPTION

18

19

20

21

22

23

11

12

13

Y22015010

Y33R90400

Y33R49010

Axle Unit (Axle Length 175 mm)

Flange Nut

Non-turn Washer 2 (Yellow)

Right Hand Cone w/Dust Seal

14

Y33R90500

15

16

17

Y33R48010

Y32530100

Stop Nut (3 mm)

Brake Arm Unit

Brake Arm Clip Unit (5/8")

Brake Arm Clip Unit (3/4")

Y33F98090

Y33F98100

Flange Nut

18

Y33Z20200

Y33R49010

Non-turn Washer 2 (Yellow)

21

22

Y33R05000

Y33R52001

Left Hand Lock Nut (3 mm) for Axle Length 168 mm/178 mm

Right Hand Dust Cap A

Right Hand Dust Cap B

25

26

27

28

29

Y35U98040

Y33F98090

Brake Arm Unit

23

Y33F98100

Brake Arm Clip Unit (5/8")

Brake Arm Clip Unit (3/4")

Sprocket Wheel 21T (Black)

24

25

26

27

Y73T22130

Y73T22230

Y73T22330

Y32120010

Y33R98080

Y33S98180

Y6P198030

Y33S95100

28

29

30

31

Y33S98010

Y33S74000

Y33S57000

Y33S98030

Y6P198040

Y33S98020

Y04120800

30

31

Sprocket Wheel 22T (Black)

Sprocket Wheel 23T (Black)

Snap Ring C

Push Rod (81.85 mm) for Axle Length 168 mm

Push Rod (86.85 mm) for Axle Length 175 mm/178 mm

SM-BC06 Bell Crank Unit

Bell Crank 3 Unit

Cable Adjusting Bolt & Nut

Bell Crank Body Fixing Bolt for SM-BC06

Bell Crank Body Fixing Bolt for Bell Crank 3

Inner Cable Fixing Bolt Unit

Bell Crank Cover & Fixing Screw for SM-BC06

Bell Crank Cover & Fixing Screw for Bell Crank 3

Internal Hub Grease (Net. 100g)

Y75M06000

Y31727200

Y33R90200

Y33R05000

Y33R52001

Y32203200

Y73T21830

Y73T21930

Y73T22030

Y73T22130

Y73T22230

Y73T22330

Y32120100

Y33R98080

Y33S98180

Y6P198030

Y33S95100

Y33S98010

Y33S74000

Y33S57000

Y33S98030

Y6P198040

Y33S98020

Y04120800

Clip Screw (M6 x 16)

Clip Nut

Ball Retainer L (3/16" x 14)

Right Hand Dust Cap A

Right Hand Dust Cap B

Sprocket Wheel 16T (Black)

Sprocket Wheel 18T (Black)

Sprocket Wheel 19T (Black)

Sprocket Wheel 20T (Black)

Sprocket Wheel 21T (Black)

Sprocket Wheel 22T (Black)

Sprocket Wheel 23T (Black)

Snap Ring C

Push Rod (81.85 mm) for Axle Length 168 mm

Push Rod (86.85 mm) for Axle Length 175 mm/178 mm

SM-BC06 Bell Crank Unit

Bell Crank 3 Unit

Cable Adjusting Bolt & Nut

Bell Crank Body Fixing Bolt for SM-BC06

Bell Crank Body Fixing Bolt for Bell Crank 3

Inner Cable Fixing Bolt Unit

Bell Crank Cover & Fixing Screw for SM-BC06

Bell Crank Cover & Fixing Screw for Bell Crank 3

Internal Hub Grease (Net. 100g)

Apr.-2010-2330B

©

Shimano Inc. I

Specifications are subject to change without notice.

54

Return to index page

Spare parts list

NEXUS 3-Speed Internal Hub

SG-3D55

11 12 13 14

15

16

17 18

NEXUS 3-Speed Internal Hub

SG-3D55

1

Internal Assembly

19 20 21 22

2 3 4 5

1

6 7 8 9 10

TL-AF30

32

Internal Hub Grease

33

23 24 25 26

27

28

SM-BC06

SET

SET

29

31

30

SG-3R40 SG-3R55 SG-S500

27

28

29

30

23

24

25

26

31

32

33

Y-35Z

Y-35Z

Y-35Z 19000

18

19

20

21

Y-377

Y-32T

Y-36U

Y-36U

22

Y-36U

Y-33R

Y-1ZN

Y-1ZN

Y-321

Y-220

Y-200

Y-33S

Y-6P1

Y-33S

Y-33S

Y-33S

Y-6P1

Y-708

Y-041

1

2

3

4

5

6

7

8

9

10

11

12

Y-34R

Y-33Z

14

15

16

17

DESCRIPTION

ITEM NO.

SHIMANO CODE NO.

DESCRIPTION

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

*

*

*

*

*

Y-36U

Y-33Y

Y-35E

Y-35H

Y-33R

Y-36U

Y-33S

Y-33R

Y-33R

Y-325

Y-24Z

Y-314

98010

19000

98020

90300

90220

98020

90200

90210

90500

30120

02000

14010

85000

20200

19000

98060

10000

08100

98030

09000

10000

52001

98010

98020

20010

06010

03000

98290

98030

98010

74000

98030

98040

11000

20800

Internal Assembly (Axle Length 192.6 mm)

Stop Ring ( 9.6 mm)

Carrier Unit

Ring Gear Unit

Ball Retainer K (7/32" x 10)

Axle Unit (Axle Length 192.6 mm)

Driver Unit

Ball Retainer J (7/32" x 8)

Right Hand Cone w/Dust Seal

Right Hand Lock Nut (9.9 mm)

Rotor Mount Cover

Cap Nut (3/8")

Non-turn Washer 8L (Dark Green)

Non-turn Washer 2 (Yellow)

Left Hand Serated Lock Nut (10.7 mm)

Left Hand Cone w/Dust Cap & Seal Ring

Seal Ring

Left Hand Inner Dust Cap

Ball Retainer (7/32" x 9)

Right Hand Dust Cap A

Chain Guard

Right Hand Dust Cap B

Sprocket Wheel 18T w/Guard Plate (CS-S500)

Sprocket Wheel 20T w/Guard Plate (CS-S500)

Snap Ring C

Washer (3.2 mm)

Hub Nut (9 mm)

Push Rod (90.75 mm)

SM-BC06 Bell Crank Unit

Cable Adjusting Bolt & Nut

Bell Crank Body Fixing Bolt

Inner Cable Fixing Bolt Unit

Bell Crank Cover & Fixing Screw

TL-AF30 Left Hand Inner Dust Cap Installation Tool

Internal Hub Grease (Net. 100g)

A: Same parts.

B: Parts are usable, but differ in materirals, appearance, finish, size, etc.

Absence of mark indicates non-interchangeability.

31

32

33

28

29

30

ITEM NO.

SHIMANO CODE NO.

DESCRIPTION

18 Y-36U 98030

19

20

21

22

23

24

25

26

27

Y-36U 09000

Y-36U 10000

Y-33R 52001

Y-1ZN 98010

Y-1ZN 98020

Y-321 20100

Y-220 06010

Y-200 03000

Y-33S 98290

Y-6P1 98030

A A

A

Chain Guard

Right Hand Dust Cap B

A

A A

Sprocket Wheel 18T w/Guard Plate (CS-S500)

Snap Ring C

A

A A

Washer (3.2 mm)

A

B

Hub Nut (9 mm)

Push Rod (90.75 mm)

A

A

A

Y-33S 98010

Y-33S 74000

Y-33S 98030

Y-6P1 98040

Y-708 11000

Y-041 20800

Bell Crank Body Fixing Bolt

Inner Cable Fixing Bolt Unit

A

A

A

A

A

Internal Hub Grease (Net. 100g)

A

A

A

A

A

A A

B A

A

A

0807-2723A

55

NEXUS Revo-Shift Lever

(For 3-Speed)

SL-3S42E

NEXUS REVOSHIFT Lever (For 3-Speed)

SL-3S41E / SL-3S42E

2

4

1

2

6

5

SM-BC06

SET

SET

7

3

8

9

ITEM NO.

1

2

3

4

5

6

7

8

9

SHIMANO CODE NO.

Y-6P1 98010

Y-6F0 04000

DESCRIPTION

Cover & Fixing Screw

Cover Fixing Screw

ITEM

NO.

1

2

3

4

7

8

5

6

9

Y-6F4 09000

Y-65P 03110

Y-6P1

Y-6F0

Y-6F4

Y-65P

Y-6FD

Y-6P1

Y-33S

Y-33S

Y-33S

Y-6P1

98010

04000

09000

03110

14000

98030

98010

74000

98030

98040

Clamp Screw (M4 x 23.5)

DESCRIPTION

Cover & Fixing Screw

Cover Fixing Screw

Clamp Screw (M4 x 23.5)

Grip for SL-3S41E

Grip for SL-3S42E

SM-BC06 Bell Crank Unit

Cable Adjusting Bolt & Nut

Bell Crank Body Fixing Bolt

Inner Cable Fixing Bolt Unit

Bell Crank Cover & Fixing Screw

A: Same parts.

B: Parts are usable, but differ in materirals, appearance, finish, size, etc.

Absence of mark indicates non-interchangeability.

Return to index page

Spare parts list

SL-8S20 SL-7S20 Bell Crank 4

INTERCHANGE-

ABILITY

A A

A A

A B

A

A

A

0707-2730

56

NEXUS REVOSHIFT Lever

SL-3S35

-E

For 3-speed

5

6

3

ITEM NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

2

4

1

7 8 9

2000m

1.2

mm mx100pc

TOTAL

INNER CABLE

TOTA

INTEGRATION

INNER CABLE

1.2 mm 2000 mm

(100 pcs.)

SHIMANO CODE NO.

Y6E898010

Y65P98040

Y65U04000

Y6CK10000

Y65P03110

Y61X14000

Y61X14010

Y60098630

Y60B98030

Y60B98020

Y62098030

Y6SJ98060

Y61W98030

Y6SJ03000

Y74Y98170

Y74Y98030

INSTRUCTIONS

SIS-SP Cable e in orde

Cap installation

Use the cable cutter on of

(TL-CT10) for installati the SIS-SPcabie.

(TL-CT10)

ngth.

cutter to cut to

(1) Use the cable e liner repair the distortion of th

(2) After cutting, use the hex

the necessary le agonal part of

the cable cutter to

If the cap is not securely attached to the liner, the SIS might not move properly.

e cap at the hexagonal part, clamp the inner edge of th and then secure it.

SIS-SP Cable

Cap sh) ct to change for improvement without notice. (Engli

Please note: Specifications are subje

7.62 m / 25 ft.

With Outer Caps

( 6 mm: 30 pcs.)

1.2 mm

(100 pcs.)

14

DESCRIPTION

Indicator Cover & Fixing Screw (M2.5 x 7)

Indicator

Outer Casing Holder

Clamp Bolt (M4 x 16)

Shift Actuator (Black)

Half Grip (ø22.2 mm / Gray)

Half Grip (ø22.2 mm / Black)

Inner Cable Box (Stainless / 100 pcs.)

SIS-SP Outer Casing (Black) w/Outer Caps

SIS-SP Outer Casing (Silver) w/Outer Caps

Inner End Caps (ø1.2 mm / 100 pcs.)

Cable Adjusting Bolt Unit & Outer Casing Holder

Cable Adjusting Bolt Unit

Outer Casing Holder

CJ-NX40 Cassette Joint

Inner Cable Fixing Bolt Unit

For SG-3R75

13

CJ-NX4

JAP

AN

0

12

10

11

Return to index page

Spare parts list

57

11

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Key Features

  • Internal geared hub for Coaster Brake version
  • Gear change support mechanism for quick and precise downshifts
  • Integral Coaster Brake for efficient and easy braking
  • Aluminum hub shell for durability
  • CENTER LOCK Rotor mount system for easy rotor installation and removal

Related manuals

Frequently Answers and Questions

What is the difference between the SG-3R40 and the SG-3C41?
The SG-3C41 is an internal geared hub for Disc Brake version, while the SG-3R40 is for Coaster Brake version.
What is the gear change support mechanism?
The gear change support mechanism utilizes some portion of pedaling force at down shifting, resulting in a quick and precise downshift with very light feeling.
How do I install the SG-3R40?
Refer to the 'Installation' section of the dealer's manual for detailed installation instructions.