SERVICE MANUAL SHIMANO NEXUS 7-SPEED HUB
Contents
1. SHIMANO NEXUS 7 SPEED HUB SG RAG SHIMANO SG 7R46 hh TL HS10 Plier Screwdriver Hub spanners Part no Y 230 90010 13 mm x 14 mm 2 pcs 1 Hold the two bevelled surfaces of the hub axle on the sprocket side in a vice Note Do not damage the threads of the hub axle 2 Remove the lock nut for left hand cone and the left hand cone with dust cap from the hub axle Note Be careful not to damage the sections A of the lock nut for left hand cone when using the spanner Left hand cone with dust cap 3 Remove the ball retainer from the hub shell Ball retainer Hub shell 4 Remove the right hand dust cap with a screwdriver Screwdriver Right hand dust cap 5 Remove the hub shell Hub shell Internal assembly Internal assembly For 182 mm axle length Part no Y 35D 9801 For 201 mm axle length Part no Y 35D 9802 6 Use pliers or similar to remove the stop spring for carrier guide 2 Stop spring for carrier guide 2 Plier Stop spring Note Cover the internal assembly with a cloth to prevent the stop spring for carrier guide 2 from flying off during removal Plier Q After removing Carrier guide2 them at the same time remove carrier unit 2 and carrier guide 2 from ring gear unit 2 Remove ring gear unit 2 carrier unit 2 and carrier guide 2 at the same time while turning ring gear unit 2 slight2. 1 while turning sun gear unit 2 amp 3 slightly to the left and right and then press in carrier unit 1 Teeth of sun gear unit 2 amp 3 Teeth of planet pinion in carrier unit 1 Note Apply a liberal coating of internal hub grease to the teeth of sun gear unit 2 amp 3 Cm daN Y 041 20800 Be careful of the setting direction If the setting is reversed installation will not be possible If undue force is applied the pawls inside will become damaged which will cause operation problems The gear with the smooth ring section is at the top Place ring gear unit 2 onto carrier unit 1 Ring gear unit 2 Note Apply a liberal coating of internal hub grease to the teeth of ring gear unit 2 io dag Y 041 20800 Carrier unit 1 Set so that the part with the teeth is at the top Groove in stop ring for carrier guide 2 should be visible Engage the teeth of the planet pinion in carrier unit 2 carrier guides 2 and the teeth of ring gear unit 2 while turning carrier unit 2 slightly to the left and right and then press in ring gear unit 2 Note Apply a liberal coating of internal hub grease to the teeth of the planet pinion 3 places in carrier unit 2 If undue force is applied the pawls inside will become damaged which will cause operation problems Check Check that the groove in the stop spring for carrier guide 2 is visible from the edge of carrier unit 2 while carrier u
3. neutral technical support
4. Be careful not to damage the sections A of the lock nut for left hand cone when using the spanner Sections A Left hand cone with dust cap 11 Hold the two bevelled surfaces of the hub axle in a vice Der g Note Do not damage the threads of Vice the hub axle 12 Install the right hand dust cap Y 041 20800 Check After installing right hand dust cap 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 This completes the assembly of the Inter 7 hub Spare parts list SHIMANO NEXUS 7 SPEED HUB w Hi Power Roller Brake SG 7R46 mezu BR IMA 7 2 inter arate TL 7S40 B 4 0 I Grease paragat 1 LAMO 9900900 0 10 ITEM SHIMANO Q TY CODE NO DESCRIPTION 6 o Y 35D 98030 Y 35D 98040 Internal Assembly Axle Length 182 mm Internal Assembly Axle Length 201 mm Stop Ring for Carrier Guide 2 Carrier Guide 2 Carrier Unit 2 Ring Gear Unit 2 Sun Gear Unit 2 amp 3 Carrier Unit 1 Carrier guide 2 Axle amp Driver Unit Axle Length 182 mm Carrier guide 2 Axle amp Driver Unit Axle Length 201 mm Ball Retainer M 3 16 x 26 Right Hand Dust Cap B Right Hand Dust Cap C Axle Unit Axle Length 182 mm Axle Unit Axle Length 201 mm Return Spring A Gear Shifting Cam Feed Cam Driver Unit w Right Hand Dust Cap B amp C Driver Uni
5. ly to the left and right Carrier guide 2 Carrier unit 2 Ring gear unit 2 Ring gear unit 2 8 Note If undue force is applied during removal the pawls inside will become damaged which will cause operation problems Remove sun gear unit 2 amp 3 while turning them slightly to the left and right Sun gear unit 2 amp 3 Remove carrier unit 1 Carrier unit 1 10 Remove ball retainer M from the driver unit Be careful not to bend ball Ball retainer M retainer M Driver unit This completes the disassembly of the Inter 7 hub 1 Hold the two bevelled surfaces of the hub axle on the sprocket side in a vice Note Do not damage the threads of the hub axle Vice 2 Place ball retainer M onto the Note driver unit Be careful of the setting direction Apply a liberal coating of internal hub grease Q diN Y 041 20800 Ball retainer M Be careful not to bend ball retainer M Driver unit Note Apply a liberal coating of internal hub grease to the planet pinions 3 places in carrier unit 1 3 Engage the teeth of the planet pinion in carrier unit 1 with the teeth of the driver unit and then press in the driver unit while turning it slightly to the left and right eS Teeth of driver unit Teeth of planet pinion in carrier unit 1 4 Engage the teeth of sun gear unit 2 amp 3 with the teeth of the planet pinion in carrier unit
6. nit 2 is pushed down Teeth of planet pinion Teeth of ring gear in carrier unit 2 unit 2 J While pushing down carrier guide 2 insert the stop spring 2 Insert into the hub axle groove at the surface of carrier guide 2 Stop spring memme Hub axle groove Carrier guide 2 Note Be careful of the setting direction A Insert securely as far as While it will go pushing S f down A A i OK Not OK a Install the internal assembly while turning the hub shell slightly to the right and left so that seal spring R of the hub shell is sitting in the right hand dust cap of the internal assembly Hub shell Internal assembly E e Note Apply a liberal coating of internal hub grease to the grease groove of the hub shell fam CIS y 041 20800 If seal spring R hooks into the wrong part of the right hand dust cap push seal spring R with a screwdriver Check After installing the hub shell turn the hub shell counterclockwise and check that it turns smoothly 9 Place ball retainer onto the hub shell Ball retainer 10 Screw the left hand cone with dust cap to adjust so that the hub shell can be turned smoothly without any play After adjusting secure the left hand cone with dust cap with the lock nut for left hand cone Note Be careful of the setting direction Apply a liberal coating of internal hub grease N Gt Y 041 20800 Hub shell Note
7. t Ball Retainer F 3 16 x 12 Right Hand Cone w Seal Right Hand Cone Seal Driver Plate w Seal Driver Plate Seal Lock Washer Stop Washer Right Hand Lock Nut 6 mm Cap Nut 3 8 Washer 3 2 mm for Axle Length 201 mm Non turn Washer 5R Yellow Non turn Washer 6R Silver Non turn Washer 7R Black Non turn Washer 5L Brown Non turn Washer 6L White Non turn Washer 7L Gray Brake Unit Fixing Nut 8 2 mm Grease Hole Cap Brake Arm Clip Unit 5 8 Brake Arm Clip Unit 3 4 Brake Cable Adjusting Bolt Unit Inner Cable Fixing Bolt Unit Lock Nut for Left Hand Cone Left Hand Cone w Dust Cap Ball Retainer 3 16 x 11 Sprocket Wheel 16T Silver Sprocket Wheel 18T Silver Sprocket Wheel 19T Silver Sprocket Wheel 20T Silver Sprocket Wheel 21T Silver Sprocket Wheel 22T Silver Snap Ring C CJ 7S40 Cassette Joint Unit Cassette Joint Pulley Cassette Joint Bracket Cassette Joint Fixing Ring Inner Cable Fixing Bolt Unit for CJ 7S40 TL 7S40 B Right Hand Cone Tool Internal Hub Grease Net 100g Roller Brake Grease Net 100g Roller Brake Grease Net 10g IL SG Printed in Japan 0202 2128 11 SHIMANO www shimano com SHIMANO AMERICAN CORPORATION One Holland Irvine California 92618 U S A Phone 1 949 951 5003 Fax 1 949 768 0920 Specifications are subject to change for improvement without notice This publication is printed on recycled paper MA35DA Jan 2004 Shimano Inc UCI official
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