2005 Front drive system service manual E.indd
Contents
1. SR SUNTOUR Front drive system Thank you for choosing SR SUNTOUR products In order to maximize the shifting performance please kindly read this instruc tion sheet carefully before starting to use the SR Suntour drive train SERVICE MANUAL Key features L Double action front derailleur L Cable saver system Twist shifter L PowerFlo Front index shifting design chainwheel Front Compatible ring Compatible speed Compatible shift lever FD XCR706 46 32 22T DSM XCR61 71 DR DSC NCX60 70 DR SL DURO27E L3 FD XCR704 504 44 32 22T DSM XCR61 71 DR DSC NCX60 70 DR SL DURO27E L3 FD XCR502 42 32 22T SRAM Shimano FD XCR508 48 38 28T FD CR318 FD XCC312 42 32 22T FD CR328 48 38 28T 24S DSM XCR51 DR DSC NCX50 DR TS NCX CRS500 L3 SRAM Shimano FD XCC322 42 32 22T FD XCC202 FD CR208 48 38 28T FD XCC102 FD XR TP17 FD XR TPOS 48 38 28T 42 34 24T SRAM Shimano Square LL113 48 38 28T XCC150 XR series 42 34 24T Square 122 5mm XCC100 series 48 38 28T i __ Fe AA TII 4 j oar twraacntroalionotinY leei In Stal auon EUNE BEB CUCERECE CRAY II Using the 8mm Allen wrench install the chainwheel onto the bottom bracket axle For such chainwheel models as NEX XCC150 100 and XR series please use the fixing bolts furnished with your bottom brackets Suggested tightening torque Nuttype 45 55Nm 450 550kegf cm Bolt type 35 45Nm 350 450kef cm Chainline tolerance is 1 5mm Note Above torque values apply2. in case of no grease on the B B axle taper Level Front derailleur position With the outer cage directly over and parallel to the outer chain ring be sure to adjust the clearance between the level section of the outer cage and outer chainring to be 1 3mm as shown A For easier installation first position the front derailleur on the smallest chainring temporarily so that the clearance between the outer cage and outer chainring is about 1mm as shown B NOTE all Front derailleurs except for FD XR TP series Dual diameter compatible clamp design allows you to choose Outer ring Outer cage either 31 8 or 34 9mm seat tube Before you install the front derail leur check the seat tube diameter to have correct clamp If it is 34 9mm then remove the plastic adaptor from the clamp band Insert the control to the handle bar as described below Note DSC type controls When using DSC type controls please be sure to use the grip length that is more than 62mm for proper grip TS type control Before installing grips be sure to put the 0 5mm slide washers between the controls and grips After installing grips adjust the position of the controls making sure not to push them too hard against grips Otherwise it may affect the shifting function and make the operation heavier When using the SR SUNTOUR Control it is necessary to maintain straight section L at the handlebar ends as shown below Please select handlebars acco
3. le take out the old cable OEN 0A A 0 E E SR SUNTOUR warrants the drive train to be free from defects in materials and workmanship under normal use for a period of two years from the date of purchase In no event shall this limited warranty apply to any defect of the drive train caused by im proper installation disassembly reassembly intentional breakage or damage alterations or modifications to the drive train by the user or other party or any unreasonable use or abuse of the product or any use for which this product was not intended The obligation of this limited warranty shall be limited to repairing or replacing the drive train or any part for which there is a defect in materials or workmanship during the two years following the date of purchase To validate this limited warranty the purchaser must submit this warranty card to SR SUNTOUR within 30 days after purchase of the drive train Any alteration of or tampering with the warranty card automatically terminates this limited warranty SR SUNTOUR makes no express or implied warranties of fitness or merchatability of any kind except as set forth above SR SUNTOUR s liability hereunder is expressly limited to repair or replacement of the product Under no circumstances will SR SUNTOUR be liable for incidental or consequential damages Some jurisdictions do not allow the exclusion or limitation of liabi lity of incidental or consequential damages so the above e
4. nt Set the chain onto the largest rear sprocket and center chainring i Ad Adjust the position of the front ye fA 0 5 1 0mm derailleur using the outer casing clearance adjustment barrel on the control so that the clerance between the Inner plate and the chain to be at around 0 5 1 0mm ao o DSM DSC types SL DURO type Top adjustment Turn the Top adjustment screw so that the clearance between the Outer plate and the chain to be at Around 0 5 1 0mm B A i 0 5 1 0mm gay clearance 10 After completing the above steps move the shift lever to see the shifting performance If shifting from the center chainring to the outer ring is difficult Turn the top adjustment screw on the front derailleur counter clockwise about 1 4 turns If shifting from the outer chainring to the center ring is difficult Turn the outer casing adjustment barrel on the control clockwise about 1 4 turns If the chain falls to the bottom bracket side Turn the low adjustment screw on the front derailleur clockwise about 1 4 turns When operating the controls always be sure to turn the crank arm at the same time Rotate the movable grip to the A direction to shift from smaller chainring to a larger ring and to the B direction to shift from a larger chainring to a smaller ring 1 Return the control to stopper position 2 Open the indicator window by a finger or a screw driver For TS type Loosen the cap screw counter clockwise
5. rding to the dimensions shown here S L DURO type 13mm Brake bracket size A Grip length Pp gt n i DSM typi Brake bracket size A 54mm Grip length o DSC type Brake bracket size A 88mm B should be d 2 more than 62mm 72mm Grip length In order to get maximum shifting performance please follow the points below to determine the proper chain length Chainwheel 42T 44T 46T or 48T outer ring Chainwheel 42T 44T 46T or 48T outer ring Rear largest sprocket 30T or 32T Rear largest sprocket 34T Add 4 links after putting the chain on the front Add 2 links after putting the chain on the front and rear largest sprockets and rear largest sprockets Front chainwheel 1 Set the control to the stopper position as shown in the indicator 1 2 This Dual pull system allows to have down pull cable routing or top pull cable routing So choose the proper cable routing as shown here 3 After taking up the initial slack of cable connect the inner cable to the front derailleur 4 Tighten the inner cable fixing bolt with a 5mm Allen wrench Suggested tightening torque 5 7 Nm Inner cable fixing bolt Down pull cable connection Top pull cable connection 1 Shifting range s f Around Low adjustment a 0 5 1 0mm l Turn the Low adjustment screw Cea onee so that the clearance between the Inner plate and the chain is at 0 5 1 0mm B y Center adjustme
6. with a 2 5mm allen wrench 3 Push out the old inner cable and install the new inner cable At this time check to see if the control is at the stopper position 4 Close the indicator window For TS type Tighten the cap screw clockwise with a 2 5mm allen wrench Suggested tightening torque is 0 05Nm Then close the cable replacement port Ist step Return the lever to the 3rd step Take out the stopper position 2nd step Open the cable nipple indicator window DAA apo K 4th step Push down the nipple stopper and take out the old cable Insert the new cable eplacing 1 Return the control to stopper position 2 Open the indicator window by a finger or a screw driver For TS type Loosen the cap screw counter clockwise with a 2 5mm allen wrench 3 Push out the old inner cable and install the new inner cable At this time check to see if the control is at the stopper position 4 Close the indicator window For TS type Tighten the cap screw clockwise with a 2 5mm allen wrench Suggested tightening torque is 0 05Nm Then close the cable replacement port a CABLE NIPPLE Stopper position NIPPLE STOPPER 2 5 Allen key LIMITED WARRANTY 2nd step Open the indicator win SL DURO type Ist step Return the lever to the stopper position dow using a flat screwdriver Sth step Push down the nipple ZA stopper in order to release the ca Jo ble nipp
7. xclusion may not and you may have other rights which vary from jurisdiction to jurisdiction Drive Train Warranty Card Date of purchase Model name Term of limited warranty Two years from the date of purchase Dealer Name Address Purchaser Address This warranty is void without proof of purchase SR SUNTOUR INC No 7 Hsing Yeh Road Fu Hsing Industrial Zone Changhua 50606 Taiwan R O C Tel 00886 4 7695 115 Fax 00886 4 769 4028 E mail orders srsuntour com tw SR SUNTOUR USA P O Box 61988 Vancouver WA 98666 Tel 1 360 737 6450 Fax 1 360 737 6452 E mail service usulcorp com apply to you This warranty gives you specific rights Phone Phone SR SUNTOUR EUROPE S A Chaussee de Tervueren 43 1410 Waterloo Belgium Tel 0032 2 3544676 Fax 0032 2 354 7835 E mail service srsuntoureurope com SR SUNTOUR INC Specifications are subject to change without notice Printed in TAIWAN
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