SERVICE MANUAL
Contents
1. 1 419 1 615 Hub Shell Material Aluminum Spoke Hole 36H Spoke Size 13 14 Flange Dist mm 58 3 Flange Width mm 3 2 Sprocket Teeth 16T 18T 19T 20T 21T 22T 23T Sprocket Thickness mm 2 3 1 2 X1 8 or 1 2 X3 32 Chain Line mm 16 23T 42 85 47 85 Dishing Distance mm 2 55 Shifting Lever Al 5 8520 ST 8520 SL 8520 Cassette Joint Motor Uni CJ 8520 CJ 8540 X available SHIMANO NEXUS INTER 8 Coaster Hub SG 8 20 Internal Hub Grease For coaster brake also S20 NE 9 07 mr eR AN BE 1 9 TL 8S11 ITEM SHIMANO NO CODE NO DESCRIPTION l Internal Assembly Axle Length 184 mm 2 Brake Shoe Unit 3 Stop Ring 2 9 6 mm 4 Ring Gear Unit 5 Carrier Unit 6 Ring Gear 1 7 Ring Gear Slide Spring 8 Ball Retainer O 3 16 x 26 9 Hub Axle Unit Axle Length 184 mm 10 Clutch Unit 11 Return Spring A 12 Driver Unit 13 Ball Retainer P 3 16 x 13 14 Right Hand Cone w Seal 15 Driver Plate 16 Lock Washer 17 Stop Washer 18 Right Hand Lock Nut 3 4 mm 19 Cap Nut 3 8 Non turn Washer 5L Brown 20 Non turn Washer 6L White Non turn Washer 7L Gray 21 Left Hand Lock Nut 3 mm 22 Stop Nut 23 Brake Arm Unit 24 Ball Retainer B 3 16 x 16 25 Hub Shell Slide Spring 26 Right Hand Dust Cap A w Seal Sprocket Wheel 16T Silver Sprocket Wheel 18T Silver 27 Sprocket Wheel 19T Silver Sprocket Wheel 20T Silver Sprocket Wheel 21T2. Align the three marks which are on the planetary gears as shown in the picture Carrier unit Ring gear 1 Y 35P 98040 Y 041 20800 Y 35P 11000 Tool TL 8530 i Y 708 00300 With tool Align the grooves of the tool with the marks on the planetary gears The purpose of the tool is to fix the planetary gear s position Now you can install the ring gear Y 041 20800 Install the ring gear slide spring with a screwdriver Ring gear 1 stop ring Y 34R 80000 13 Align the internal tooth the ring gear and carrier unit with the groove in the hub axle unit Install ring gear and carrier unit slowly Y 041020800 NOTE Be careful to fit A to and to of the driver unit and the hub axle unit as shown in the picture Important To set all four pawls in the correct position Use a flat blade screwdriver to depress pawls as shown during assembly Turn unit and check that all pawls are in the proper position SHIMANO Nexus INTER 8 Y 041 20600 2 14 Insert the stop ring NOTE If there is no visible groove to receive the stop ring it is likely that the ring gear and carrier unit are not properly assembled return to assembly step 13 L5 Install the brake shoe unit 16 Install the hub shell unit while turning it counter clockwise 17 Place ball retainer B onto the hub shell Ball retainer B Y 330 98110 Y 0410208
3. Phone 39 331 467 311 Fax 39 331 464 790 NIKOS MANIATOPOULOS S A Greece and Cyprus Phone 30 2610 993 045 Fax 30 2610 990 424 PAUL LANGE amp CO Germany Phone 49 711 2588 02 Fax 49 711 2588 305 PAUL LANGE OSTRAVA 5 Czech Republic Phone 420 597 444 160 Fax 042 597 444 150 PAUL LANGE OSLANY S R O Slovak Republic Phone 42 46 549 2344 Fax 42 46 549 2350 R amp PPAWLAK Poland Phone 48 61 878 7335 Fax 48 61 878 7266 SABA DOCHARKH CYCLE CO LTD Iran Phone 98 21 878 0651 2 Fax 98 21 878 7278 SHIMANO BENELUX B V The Netherlands Belgium and Luxembourg Phone 31 341 272 327 Fax 31 341 272 291 000 SHIMANO EURASIA Russia and Belarus Phone Fax 7 095 101 34 88 SHIMANO FRANCE COMPOSANTS CYCLES France Phone 33 321 73 2525 Fax 33 321 55 8427 SOC COMERCIAL DO VOUGA LDA Portugal Phone 351 234 601 500 Fax 351 234 601 159 THALINGER LANGE GMBH Austria Phone 43 7242 4970 Fax 43 7242 4972 48 VELOTRADE KFT Hungary Phone 36 1 455 8000 Fax 36 1 455 8019 SHIMANO www shimano com
4. Silver Sprocket Wheel 22T Silver 28 Snap Ring C 29 CJ 8S20 Cassette Joint Unit 30 Driver Cap 31 CJ 8S20 Cassette Joint 32 Cassette Joint Fixing Ring 33 Inner Cable Fixing Bolt Unit Non turn Washer 5R Yellow 34 Non turn Washer 6R Silver Non turn Washer 7R Black 35 Brake Arm Clip Unit 5 8 Brake Arm Clip Unit 3 4 36 Clip Screw M6 x 16 37 Clip Nut 38 TL 8S30 Carrier Unit Tool 39 TL 8520 Right Hand Cone Installation Tool 40 TL 8S11 Right Hand Cone Removal Tool 41 Internal Hub Grease Net 100g 32 SHIMANO NEXUS 8 speed Revo Shift Lever 51 8520 SHIMANO NO CODE NO DESCRIPTION 1 Bracket Cover amp Fixing Screw Cover Fixing Screw 2 3 Y 61W 98030 Cable Adjusting Bolt Unit 4 Y 6F4 09000 Clamp Screw M4 x 23 5 SHIMANO Nexus INTER 8 33 SHIMANO NEXUS Cassette Joint CJ 8540 DESCRIPTION Outer Casing Holder Unit Rubber Cover Outer Casing Holder Rubber Bellows Cassette Joint Unit Cassette Joint Fixing Rino Cassette J oint Driver Cap Inner Cable Fixing Bolt Unit SHIMANO NEXUS Brake Lever BL IM 65 For Left Hand 3 Finger 3 SHIMANO CODE NO DESCRIPTION L H Adjustment Block amp Screw Cable Adjusting Bolt M10 x 19 amp Nut Reach Adjusting Screw M4 x 10 8 Clamp Bolt M6 x 14 8 Grip 222 2 mm Black SHIMANO Nexus INTER 8 35 BJARNE EGEDES A S Denmark Iceland and Greenland Phone 45 63 16 8001 Fax 45 63 16 8004 BJARNE E
5. and braking technique When securing the brake arm to the frame be sure to use a brake arm clip that matches the size of the chainstay and securely tighten them with the clip screw 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 re commended that standard Shimano parts be used for the clip screw clip nut and brake arm clip In addition use a brake arm clip that matches the size of the chainstay If the clip nut comes off the brake arm or if the clip screw or brake 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 may fall over causing serious injury When installing the hub to the frame be sure to install the correct non turn washers to the left and right sides and securely tighten the hub nuts to the specified torques If the non turn washers are installed to one side only or if the hub nuts are not tightened sufficiently the non turn washer may fall out which could cause the hub axle to rotate and the cassette joint to turn This may then cause the handlebars to be accidentally pulled by the shifting cable and an extremely serious accident could result Obtain and read the service instructions carefully prior to installing the parts Loose worn or damaged parts may cause serious injury to the rider We strongly recommend only us
6. hub axle unit and carrier unit Except 4 8 Replace the carrier unit Gear Unsmooth 48 Replace the hub axle unit and carrier unit Except 4 8 Replace the carrier unit Cone Unsmooth Replace the right hand cone and driver While not Free rotation 15 stiff Replace the shell ball retainer and pedaling driver unit Following treatment is for 8C Trouble condition Remedy Braking is too sudden Replace the brake shoe unit Driver yale nit amp axle unit braking j Braking force Is weak Replace the brake shoe unit Pedal turning angle for brake Replace the brake shoe unit Driver to operate is too large unit amp axle unit Wheels lock when bicycle is pushed back Replace carrier unit driver unit and ward clutch unit A squeaking sound caused by lack of lubrica Apply grease or replace the brake tion can be heard shoe unit Brakes do not release Replace the brake shoe unit and carrier unit 13 14 SG 8C20 Note Unit parts should never be disassembled If they are problems may result When replacing parts replace the whole internal assembly or whole unit part Tools Note Unit parts should never be disassembled If they are problems may result When replacing parts replace the whole internal assembly or whole unit part Note For internal unit replacement only tools e and f are necessary 1 Hold the two bevelled surfaces of the hub axle on the brake arm side in a
7. projecting parts should be on the fork end side Install the non turn washers so that the projecting parts is securely in the fork end grooves on either side of the hub axle 3 Take up the slack in the chain and secure the wheel to the frame with the cap nuts Tightening torque 30 45 N m 960 390 in Ibs 0 JET Non turn washer SHIMANO Nexus INTER 8 4 Fix the brake arm securely to the chain stay with the brake arm clip Clip nut Brake arm Clip screw When installing the brake arm clip securely tighten the dip screw while holding the dip nut with a 10 mm spanner Tightening torque 2 3N m 17 26 in lbs After installing the brake arm clip check that the dip screw protrudes about 2 3 mm from the surface of the dip nut Brake arm ye Brake arm dip Clip screw M6 x 16 mm era 5 Before using the Coaster Brake check that the brake works properly and that the wheel turns smoothly 1 Set the Revo shift lever to f Be sure to read these service instructions in conjunction with B Revo shift lever side 2 Loosen the cover fixing screw and then remove the upper cover amp gt Cover fixing screw General Safety Information SI 6FDOA Disconnecting the shifting cable Installation of the f when removing the rear wheel from avoid serious Shifting cable WAR
8. the hub in combination with a seperate brake system such as V Brakes labyrinth seal Robust Construction Durable planetary and step up gear sets assure long trouble free service ST 8S20 shifter with 3 finger Brake Lever BL IM 65 3 finger Brake Lever 5 8520 Shifter with 4 finger Brake Lever SL 8S20 shifter BL IM 60 4 finger Brake Lever Fast and Light Shifting In combination with the Gear Change Support Mechanism the shifting action is quick and light even during hight pedaling loads Easy to read Gear Indicator Larger more visible indicator numbers make gear positions easier to read Additionally indicator symbols help to understand the direction of shifting progression INTER 8 SG 8C20 3090 more braking power compared to INTER 7 ii INTER 8 6 3 4 9 2 5 2 2 0 INTER 7 1 0 0 0 mn INTER 7 INTER 8 General Safety Information To avoid serious A WARNING injuries It isimportant to completely understand the operation of your bicyde s brake system Improper use of your bicycle s brake system may result in a loss of control or an accident which could lead to sever injury Because each bicycle may handle differently be sure to learn the proper braking technique including bicycle control characteristics and operation of your bicycle This can be done by consulting your professional bicycle dealer and the bicycle owner s manual and by practicing your riding
9. turn the pulley to loosen the inner cable Then remove the inner cable fixing bolt unit from the pulley first and after this remove the outer casing holder from the outer casing 1 While holding the end of the rubber bellows insert holder section the inner cable Be careful not to pierce the rubber bellows with the end of the inner cable at this time A Not OK Not OK 2 Hold the rubber cover and pull the outer casing holder out from the outer casing holder section of the cassette joint Then remove the inner 2 a inet Cente cable attached to the rubber bellows from the Remove the inner 3 slit in the bracket Be careful not to damage the cable fixing bolt unit Remove the 4 rubber bellows at this time _ outer casing holder Rubber bellows Pull out the outer casing holder 2 Slide the rubber bellows onto the inner cable Rubber cover Turn the Remove the pulley Rubber bellows rubber bellows from the slit or 14 spoke Note Note Do not remove the cable by pulling the outer If reusing the cable refer to steps 6 to 8 in casing Insallation of the shifting cable 3 Push the outer casing on so that it securely touches the outer casing holder Inner cable Outer casing holder Outer casing Rubber bellows Rubber cover After checking that the end of the outer casing is sitting securely in the cable adjust ment bolt of the shifting lever attach the inner cable fixing bol
10. vice and remove the dust cap 2 Turn the hub upside down and 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 mm 24 d a Hammer b TL 8S11 Right Hand Cone Removal Tool Part No Y 708 00600 c TL 8S20 Right Hand Cone Installation Tool Part No Y 708 00200 d TL 8S30 Carrier Unit Alignment tool Part No Y 708 00300 e Screw driver f TL 7S20 Hub Spanners 17mm x 22mm 2 pcs Part No 3 130 9890 We recommend the use of protective glasses during disassembly and assembly Note Do not damage the threads of the hub axle Vice Remove the left hand locknut from the hub axle and then remove the stop nut a J d Locknut 17mm Y 35P 28000 Q Stop Nut 22mm Y 35P 22000 TL 7S20 SHIMANO Nexus INTER 8 3 Remove the brake arm unit and ball retainer B from the hub axle Brake arm unit 4 Remove the hub shell Hub shell lt Internal assembly Now it can be replaced with the new internal assembly Disassembly and assembly can be carried out quickly Part No 36P 98010 15 1 Remove the brake shoe unit re Brake shoe unit 2 Carefully remove the stop ring with screwdriver Because the stop ring will tend to come off with some force use piece of cloth to prevent loss EE Screw driver Stop ring Y 33Y 19000 3
11. 0 SL 8520 SG 8C20 Crankset 4 finger SB 8S20 Coaster Brake Brake lever 4 finger SG 8R25 VS Brake lever SG 8R20 VS V Brake N TE R CONDITION SG 8R25 Premium Version for Roller Brake SG 8R20 Roller Brake Version SG 8R25 VS Version SG 8R20 VS v Brake Version SG 8C20 coaster Brake Version Gear Change Support Mechanism Shimano s gear change support mechanism uses pedaling power to aid down shifting The result is fast and accurate down shifting with an tionally light feeling Mechanical shifting resist ance is notably reduced so shifting is not affected under high loads shifting torque driver rotation torque Smooth Gear Change The smaller idling angle realizes shockless smoother shifting for stressless comfortable gear change GC Cu v 20 909 e Smoother Rotation Shimano s precise manufacturing abilities construct an internal hub that rotates with significantly less drag than previous models Close Ratio Wider Range The INTER 8 hub has increased its gear ratio to 30796 compared to 24496 of the INTER 7 hub SHIMANO Nexus INTER 8 Better Sealing The INTER 8 hub has adopted labyrinth seal system that shuts out water and dirt to extend the service life and maintain smooth shifting in all circumstances Optionally waterproof dust cap can be installed ex factory on the non drive side before shipment in case you wish to use
12. 00 26 Stop ring Y 33Y 19000 Y 041020800 Brake shoe unit Y 35P 98020 Hub shell Internal assembly Note Be careful of the setting direction Apply liberal coating of internal hub grease Hub shell SHIMANO Nexus INTER 8 18 Place the brake arm unit onto the hub axle and turn it E Brake arm unit Y 35P 98080 to the left and right so that Brake shoe unit Y 35 98020 the serrations of the brake Serrations shoe and brake arm unit engage with each other Then push the brake arm unit fully into the brake shoe unit Note Apply a liberal coating of internal hub grease to the inside and out side of the brake shoe unit Y 041020800 19 Screw the stop nut to adjust so that the hub shell can be turned smoothly without any play After adjusting secure the stop nut with the locknut TL 7S20 Stop nut 22mm Back side Y 35P 22000 20 Install the dust cap Y 041020800 This completes the assembly of the INTER 8 coaster hub 27 CJ 8520 for 8 speed CJ 8540 for 8 speed 101mm TL CJ 10 for 8520 ER 101mm TL CJ 40 for CJ 8520 127mm TL CJ 40 for CJ 8540 SHIMANO Nexus INTER 8 8R20 type Ring gear 2 Red Line 8R25 45 type Ring gear 2 Hub Shell Internal Unit CHAIN DRIVE SG 8R20 Mass production YES Possible standard amp replacement not recommended Inter
13. 20 16 Remove the clutch unit by turning it counterclockwise and aligning the two teeth to the two grooves as shown This completes the disassembly of the INTER 8 coaster hub Y 35P 98060 SHIMANO Nexus INTER 8 NOTE During the assembly procedures coat all seals gears and pawl assemblies with a thin coat of Nexus specific grease Where indicated by blue grease icon apply grease liberally 1 With the hub axle unit mount ed in a vice align the two teeth on the clutch unit with the two notches in the hub J axle unit Turn the clutch unit clockwise until it is in its final position as shown 1 l Clutch unit A 1 Y 35P 98060 E GREASE Y 041020800 2 Install the return spring with the largest coil downward The spring should sit in the groove on the clutch unit shown as a blue line in the picture Be careful not to install the return spring A upside down Return spring A Y 34R 21000 3 Assemble the driver unit by aligning the more shallow notch on the driver unit with the wider tooth on the clutch unit Rotate the driver counterclockw ise to hold the compressed spring in position NOTE Assemble the driver unit while pushing pawls B as shown in the picture Clutch unit 7 Y 34R 98050 Set drive unit while turn it counterclock wise 21 22 4 Install the ball retainer P 3 16 X13 5 When installing the right hand cone align
14. GEDES BALTICS Estonia Latvia and Lithuania Phone 371 7 29 3688 Fax 371 7 31 2042 COOLHEAT S A LTD South Africa Phone 27 11 807 5282 Fax 27 11 807 2998 EBSAT LASTIK VE YEDEK PARCA TIC LID STl Turkey Phone 90 232 483 13 87 Fax 90 232 483 46 63 EUROTRADE LTD Balkans region ind Romania and Moldavia Phone 30 2610 911450 911451 911452 Fax 30 2610 911453 ALBIMI N T P Phone 381 280 20305 Fax 381 280 28540 CS EUROTRADE Slovenia and Croatia Phone 386 7 49 02 500 Fax 386 7 49 02 549 PLANET BIKE D O O Serbia amp Montenegro Bosnia amp Herzegovina Macedonia Phone 4381 11 3149 033 Fax 381 11 3149 101 ROMVELO S R L Romania Phone 440 723 550 003 Fax 40 723 550 020 VELOMANIA LTD Bulgaria Phone 3592 812 7060 Fax 3592 812 7061 FUCHS MOVESA AG Switzerland Phone 441 56 464 46 46 Fax 441 56 464 46 47 HALLMAN SPORTS AB Sweden Phone 46 18 561 600 Fax 46 18 500 395 HALLMAN SPORTS AS Norway Phone 447 66778010 Fax 47 66778011 HALLMAN SPORTS OY Finland Phone 358 20 1550 800 Fax 358 20 1550 801 MACARIO LLORENTE S A Spain Phone 34 91 329 5070 Fax 34 91 329 2594 91 329 2039 Specifications are subject to change for improvement without notice MA34RA February 2005 Shimano Inc MADISON CYCLES PLC UK and Ireland Phone 44 208 385 3385 Fax 44 208 385 3443 M I C MILAN INTERNATIONAL COMMERCE SpA Italy Malta and Tunesia
15. NING iniuries Revo shift the frame juries SL 8S20 L ur ever m n Disconnect the cable from the Use a shifting cable with one ions carefully prior to installing the er i parts Loose worn or damaged BL IM 65 Brake Lever cassette joint when removing the inner cable drum parts may cause serious injury to the rear wheel from the frame Cable with one inner cable drum rider J 515 5 40 4 We strongly recommend only using 8520 Cassette Joint Op i genuine Shimano replacement parts _ _ Ly It is important to completely under Technical Service Instructions stand the operation of your bicycle s brake system Improper use of your bicyde s brake system may result in a SHIMANO loss of control or an accident which could lead to severe injury Because EXLIS each bicyde may handle differently be sure to learn the proper braking INTER technique induding brake lever pressure and bicycle control charac teristics and operation of your bicy This can be done by consulting NS your professional bicyde dealer and the service instructions for the the bicycle s owners manual and by Inter 8 hub before use practicing your riding and braking technique These brake levers are equipped Revo shift lever operation with a mode switching mechanism to make them compatible with cantilever brakes and Roller Brakes Turn the Revo shift lever to shift to or V Brakes with power modulator each of the e
16. Remove carrier unit and ring gear by lifting straight up Do not rotate to disengage 4 Remove the ring gear slide Carrier unit Y 35P 98040 spring with a screwdriver Ring gear slide spring Y 35P 12000 N 1 bag Y 35P 11000 Ring gear slide spring Y 35P 12000 16 SHIMANO Nexus INTER 8 5 Remove ball retainer 3 16 X26 while pushing pawls t ____ 1 Ball retainer Y 34R 98030 Pawls B 6 Reverse axle unit in vice to access the drive side cone assembly 7 Remove the locknut with a 17mm hub spanner ID Right hand locknut Y 33Z 07020 8 Remove the stop washer Stop washer Y 34R 09000 17 9 Remove the lock washer 10 Remove the driver plate 11 Support the driver assembly on the vice as shown Set cone removal tool TL 8S11 into the groove such that the pawl is contacting the notch in the tool see detail Strike the tool with the hammer until cone and axle unit are separated 18 Y 34R 98090 m I Driver plate Y 34R 12000 Tool TL 8S11 Y 708 00600 SHIMANO Nexus INTER 8 12 Reverse the right hand cone Y 34R 98080 13 Remove the ball retainer P 3 16 X13 Y 34R 98070 14 Remove the driver unit Ni Driver unit Y 35P 98070 15 Remove the return spring A NL Return spring A Y 34R 21000 19
17. arks to install Right side of the hub body 3 1 Secure the cassette joint to the hub with the cassette joint fixing ring When installing the cassette joint fixing ring align the yellow amp mark with the yellow amp mark on the cassette joint pulley Cassette joint fixing ring Align the yellow marks to install Cassette joint pulley 3 2 After installing the cassette joint fixing ring turn it 459 clockwise Turn 459 on Cassette joint fixing ring Fit the cassette joint bracket securely Installation of the hub to frame 1 Mount the chain on the sprocket and then set the hub axle into the fork ends Hub axle 2 Place the non turn washers onto the right side and left side of the hub axle At this time turn the cassette joint so that the projecting parts of the non turn washers fit into the grooves of the fork ends If this is done the cassette joint can be installed so that it is almost parallel to the chainstay Non turn washer for left side Cassette joint fork end Non turn washer for right side Different types of left and right non turn washers are available for use with standard and reversed fork ends Use whichever non turn washers are suit able Fork end Mark Color Size Standard Yellow 7R Black 7UGray 7 0 Reversed full chain 5R Yellow 5L Brown case a Gu NS Je The
18. ction of the cassette joint and then insert a 2mm Allen key or a 14 spoke into the hole in the cassette joint pulley and then turn the pulley so that the inner cable fixing bolt unit fits into the gap in the pulley 3 Insert the inner cable fixing bolt 1 Attach the outer casing holder Turn the pulley Hole in pulley 2 mm Allen key or 14 spoke Note Check that the inner cable is correctly seated inside the pulley guide 9 Secure the cable to the frame with the outer casing bands SHIMANO Nexus INTER 8 Adjusting the cassette joint 1 Set the shifting lever to Check to be sure that the yellow setting lines on the cassette joint bracket and pulley are aligned at this time M Yellow setting lines Set to The yellow setting lines on the cassette joint are located in two places Use the one that is easiest to see When bicycle is standing up Should be straight Nam Cassette joint pulley Cassette joint bracket When bicyde is upside down Should be straight Cassette joint bracket If the yellow setting lines are not aligned turn the cable adjustment bolt of the shifting lever to align the setting lines After this move the shifting lever once more from amp to O and then back to amp and then re check to be sure that the yellow setting lines are aligned Cable adjustment bolt 2 After adjusting the cassette joint cut off the excess length of inner cable an
19. d then install the inner end cap 0 Inner end cap 12 SHIMANO NEXUS INTER 8 Coaster Hub SG 8C20 Internal Hub Grease For coaster brake also 8520 TL 8S11 Same treatment of 8R20 Abnormal noise Cable is incorrectly Set the shift lever to 4th Then turn the cable occurs adjusted adjusting barrel to align the red setting lines on the cassette joint bracket and pulley Shift down to the 15 gear up to the 4th again and recheck the adjusment Abnormal noise While Shifting 1632 Replace the hub axle unit and still occurs after shifting position carrier unit adjusting cable 24 33 and carrier unit While Shifting All Replace the driver unit hub axle unit pedaling position and carrier unit SHIMANO Nexus INTER 8 Gear shift Cable is incorrectly Set the shift lever to 4th Then turn the 15 not adjusted cable adjusting barrel to align the red possible setting lines on the cassette joint bracket and pulley Remove the wheel Gear shifting is Replace the shifting lever from the frame and possible check whether gear When the shifting Shifting 15 possible lever doesn t operate Gear shifting 15 not Replace the carrier unit and possible hub axle unit When the hub doesn t work While Shifting lever indicator doesn t match hub Replace the carrier unit and hub axle pedaling shifting position unit Turning is stiff 4 8 Replace the
20. grip ing bolt unit outer casing Replace the upper cover and tighten the cover fixing screw 2 2 5 Nm Q0 25 Clamp bolt in serious injury e 7 Pulley hole 1 Cover fixing screw NOTE 2 3 gt 2 mm Allen key or I For maximum performance we high p Tighten 14 GN Upper caver ly recommend Shimano lubricants mee FIA i and maintenance products 2 22 2 mm NOTE 2 ff aaa If reusing the cable refer to steps natural wear or deterioration result Tightening torque 7to9 in Installation of the shift ing from normal use 6 8 N m 60 80 kgf cm ing cable Parts are not guaranteed against 5 Pass the inner cable through the SIS SP40 outer casing through the end with the plastic cap mm Aluminium Plastic If cutting the outer casing cut it near the end with the plastic cap while the cap is still attached Then make the cut end perfectly round and attach the plastic cap CCW IA Plastic cap Remove the plastic cap p Cte 9 Maket perfectly round Attach the plastic cap GI ll Cassette joint side 6 After checking that the end of the outer casing is sitting securely in the cable adjustment bolt of the Revo shift lever attach the inner cable fixing bolt unit to the inner cable Inner cable fixing bolt unit Note Do not use this inner cable fixing bolt unit with the CJ 4S30 cassette joi
21. i T 1 1 at P ax Wn did SHIMANO Nexus INTER 8 SHIMANO NEXUS INTER 8 COASTER HUB 509 0640 SHIMANO Contents The new standard in internal geared hubs Technical Service Instructions SG 8C20 CJ 8520 SL 8S20 BL IM65 Troubleshooting Chart Replacement of the internal unit Disassembly of the internal unit Assembly of the INTER 8 coaster hub Cassette Joint amp Measurement tool NEXUS non turn washers Hub dimensions O L D and axle Spare parts list SG 8C20 Spare parts list SL 8S20 Spare parts list CJ 8S40 Spare parts list BL IM 65 SHIMANO Nexus INTER 8 12 14 16 21 28 30 31 32 33 34 35 SHIMANO Nexus INTER 8 e SG 8R25 i j 67 8520 ur 4 ar E BL IM 65 BL IM 65 SL 8S20 The new standard in internal geared hubs The NEXUS 8 speed system delivers a new level of design quality and function Our designers have updat ed the conventional internal hub with a refreshing new design inspired by the concepts of beauty innova tion and integrity Many technical advances have been achieved like incorporating Shimano s unique gear change support mechanism that makes a real low effort shifting BR IM 70 R SG 8R25 Small Parts Set FC NX60 BB UN25 BL IM 65 51 8520 Roller Brake Premium version 33 38T 3 finger 3 finger SG 8R20 FC NX80 Brake lever Brake lever Roller Brake HOLLOWTECH BL IM 6
22. ight gears If the incorrect mode is selected it a Pull the outer casing out from may cause either excessive or insuffi Pedaling becomes heavier the outer casing holder of the Upper cover cient braking force to occur which cassette joint and then remove could result in dangerous accidents Indicator Indicator moves toward the inner cable from the slit in Be sure to select the mode in accor the bracket dance with the instructions given in the table below Mode Applicable position brake C R position Revo shift lever Outer casing holder Pull out from outer casing holder 3 Pass the inner cable from the hole in the winder unit through the Remove from the slit hole in the cable adjustment bolt 3 Remove the inner cable fixing Next insert the inner cable into Indicator moves toward bolt unit from the cassette joint the groove orte guida pulley and pull the inner cable so that the inner cable drum fits into the recess in the winder unit T ti f th Inner cable fixing bolt unit nstallation o e lever Cassette joint pulley Hole cable Z N e Cantilever brakes The C indicates the Roller mode position for com Brakes patibility with can tilever brakes The R indicates the mode position for com patibility with Roller Brakes Pedaling becomes lighter 2 adjustment bolt Install the lever as shown in the illustra tion 3 Hole in In case of usi
23. ing genuine Shimano replacement parts Check that the wheels are fastened securely before riding the bicycle If the wheels are loose in any way they may come off the bicycle and serious injury may result Read these Technical Service Instructions carefully and keep them in a safe place for later reference To avoid serious A CAUTION injuries e Avoid continuous application of the brakes when riding down long slopes as this will cause the internal brake parts to become very hot and this may weaken braking performance It may also cause a reduction in the amount of brake grease inside the brake and this can lead to problems such as abnormally sudden braking e Spin the wheel and confirm that the braking force of the coaster brake is correct e If the brakes are used frequently the brake drum may become hot Do not touch the brake drum for at least 30 minutes after you finish riding the bicycle Brake drum e You can shift gears while pedaling but on rare occasions the pawls and ratchet inside the hub may produce some noise afterwards as part of normal gear shift ing operation e The CJ 8520 cassette joint should only be used with sprockets from 16T to 23T If the wheel becomes stiff and difficult to turn you should replace the brake shoes or lubricate with grease Do not apply any lubricant to the inside of the hub otherwise the grease will come out You should periodicall
24. llen key or 14 spoke Check that the inner cable is correctly seated inside the pulley guide 10 Secure the cable to the frame with the outer casing bands Adjusting the cassette joint 1 Set the Revo shift lever to Check sure that the yellow setting lines on the cassette joint bracket and pulley are aligned at this time Yellow setting lines SHIMANO 8SPEED The yellow setting lines on the cassette joint are located in two places Use the one that is easiest to see When bicycle is standing up Should be straight Cassette Ea joint pulley Cassette joint bracket When bicycle is upside down Should be straight g Y gt Cassette SDH joint pulley Cassette joint bracket If the yellow setting lines are not aligned turn the cable adjustment bolt of the Revoshift lever to align the setting lines After this move the Revo shift lever once more from 4 to and then back to and then recheck to be sure that the yellow setting lines are aligned SHIMANO 8SPEED 4 Cable adjustment bolt 2 After adjusting the cassette joint cut off the excess length of inner cable and then install the inner end cap Inner end cap SHIMANO Nexus INTER 8 10 General Safety Information Installation of the cassette joint Installation of the shifting cable A WARNING Refer to the Service Instructions for the INTER 8 hub for ae details on installati
25. nal SG 8R25 Premium Replacement 56 8645 CYBER NEXUS 8R20 type Ring gear 2 possible but not the same performance as orginal spec BELT DRIVE _ ee ee standard amp replacement not recommended Internal SG 8R25 Premium Replacement SG 8R45 for CYBER NEXUS 8R20 type Ring gear 2 possible but not the same performance as orginal spec Hub Shell Internal Unit CHAIN DRIVE SG 8C20 SG 8C45 Internal SG 8C20 Mass production YES Unit standard amp replacement j SG 8C45 Mass production YES for CYBER NEXUS amp replacement 29 NEXUS non turn washers NEXUS non turn washer application chart For right For left hand side hand side 7R Black NR not recommend 30 SHIMANO Nexus INTER 8 JOINT NUT LA NON TURN WASHER NON TURN WASHER SPEC MARKING COLOR SPEC MARKING COLOR FOR REVERSED FORK FOR REVERSED FORK SPANNER W 22 END AND FULL 5R YELLOW CHAIN CASE END AND FULL 5L BROWN CHAIN CASE FOR REVERSED FORK SILVER FOR REVERSED FORK WHITE END END FOR STANDARD 7R BLACK FOR STANDARD GRAY SPANNER W 17 FORK END FORK END SURFACE TREATM ENT US S STANDARD BOTH USE FOR 13 14 ALVER PAINTING Specifications Speed Model No SG 8C20 Silent Clutch Gear Change Support Mechanism S Brake Over Locknut Dim OLD mm X X Coaster 132 3 Axle Length mm 184 2 0 644 0 748 4 0 851 es es Gear Ratio
26. ng Shimano Leave a gap winger unit half grip the straight of 0 5 mm section of the handlebar between the should be 166 mm or Revo shift more in length attach lever and the the Revo shift lever to half grip this straight section V Brakes with power modulator If it is difficult to pull the outer casing out from the outer casing holder of the cassette joint insert a 2 mm Allen key or a 14 spoke into the hole in the cassette joint pulley and then turn the pulley to loosen the inner cable Then Handlebar remove the inner cable fixing bolt unit from the pulley first and after this remove the outer casing 2 from the outer casing holder gt x 2 3 To avoid 3 mm Allen T CAUTION serious injuries key 22 2 mm Remove the Pull out Recess in winder unit inner cable fix from the Be sure to shift the lever one gear at a time and reduce the force being applied to the pedals during shifting If you try to force operation of the shifting lever while the pedals are being turned strongly your feet may come off the pedals and the bicyde may topple over which could result The V indicates the mode position for compatibility with V Brakes with power modulator Clamp bolt Use the brake levers with mode switching mechanism in the combina tions given above Read these Technical Service Instructions carefully and keep them in a safe place for later reference Tightening torque Half
27. nt Inner cable fixing nut x SN Inner cable fixing 8 2 ee washer S Inner cable fixing 10 mm Black Pass the inner cable through the hole Pull the inner cable while attaching the inner cable fixing bolt unit Tightening torque 4 6 N m 40 60 1 Bring the cable around to the cassette joint pulley hold so that the inner cable fixing nut is facing to the outside toward the fork end and then slide the flats part of the inner cable fixing washer into the gap in the pulley Flats part of inner cable fixing washer Inner cable fixing nut 8 Turn the cable 602 counterclockwise and attach it to the hook Turn the cable 602 9 Attach the inner cable to the pulley as shown in the illustration pass the inner cable through the slit in the cassette joint bracket and then insert the end of the outer casing securely into the outer casing holder Bracket Bracket Outer casing holder Insert into the outer 2 casing Pass through the slit If first inserting the outer casing into the outer casing holder is easier then first insert the outer casing into the outer casing hold er and then insert a 2 mm Allen key or a 14 spoke into the hole in the cassette joint pulley and then turn the pulley so that the inner cable fixing bolt unit fits into the gap in the pulley 3 1 Insert the inner Insert into the cable fixing bolt outer casing Hole in pulley 2 mm A
28. on of the cassette joint to the hub Use a shifting cable with one inner cable drum To avoid serious injuries and installation of the non turn washer SIS SP 4 mm or 5 mm dia Obtain and read the service instructions carefully prior to installing the parts Loose worn or damaged parts may cause serious injury to the rider We strongly recommend only using genuine Shimano replacement parts Read these Technical Service Instructions carefully and keep them in a safe place for later reference Shifting lever end Note Different types of left and right non turn wash ers are available for use with standard and reversed fork ends Use whichever non turn washers are suitable Cassette joint end Shield cap Note Make sure that the shield cap is at the shifting lever end Non turn Nontumwasher Fork end M mM Shifting lever side 0538 1 Reversed 6R Silver 6Lmhite Connect the shifting cable to the shifting lever Reversed Refer to the Service Instructions which are ic 5R Yellow 5L Brown provided with the INTER 8 shifting lever Cassette joint side 2 Set the shifting lever to D NOTE The CJ 8540 cassette joint should only be used with sprockets from 16T to 23T e When lubricating the chain or the sprock ets be careful not to get any oil on the rubber bellows or the rubber cover of the cassette joint For maximum performance we highl
29. t unit to the inner cable Inner cable fixing bolt unit Note Do not use this inner cable fixing bolt unit with the CJ 4530 cassette joint Inner cable fixing nut Inner cable fixing washer lt Inner cable fixing bolt 63 mm or less Pull the inner cable while attaching the inner cable fixing bolt unit Tightening torque 4 6 N m 40 60 kgfcm 6 Bring the cable around to the cassette joint pulley hold so that the inner cable fixing nut is facing to the outside toward the fork end and then slide the flats part of the inner cable fixing washer into the gap in the pulley Flats part of inner cable fixing washer Inner cable fixing nut 7 Turn the cable 60 counterclockwise and attach it to the hook cable 60 8 Attach the inner cable to the pulley as shown in the illustration pass the part of the inner cable which has the rubber bellows attached through the slit in the cassette joint bracket and then insert the outer casing holder securely into the outer casing holder section Be careful not to damage the rubber bellows at this time Inner cable Bracket Outer casing holder section Slit gt Insert the 1 rubber bellows into the slit D 2 Attach the A outer casing holder If first inserting the outer casing holder into the outer casing holder section of the cas sette joint is easier then first insert the outer casing holder into the outer casing holder se
30. the two serrations with the grooves in the axle as shown Set the cone instal lation tool TL 8S20 and strike it until it comes to a stop NOTE Make sure the right hand cone is completely seated as shown and the seal is installed equally 6 Install the driver plate Be careful of the setting direction as shown in the picture Driver plate Y 34R 12000 a Y 34R 98070 GREASE Y 041020800 Right hand cone Y 34R 98080 Tool TL 8S20 Y 708 00200 7 Install the lock washer 8 When installing the stop washer align the two teeth with the two grooves of the lock washer 9 Install the right hand locknut with a 17mm hub spanner NOTE If either the lock washer or driver plate rotates during this step return to assembly step 5 and make sure that the cone is cor rectly seated 10 Reverse the axle unit in the vice to complete assembly SHIMANO Nexus INTER 8 Lock washer Y 34R 98090 Stop washer Y 34R 09000 Tightening torque 25 30 N m 1218 261 in Ibs Right hand locknut Y 33Z 07020 Y 041020800 23 24 11 Install the retainer 3 16 X 26 while pushing pawls B one by one Be careful not to displace pawls B on the driver unit Pawls B Ball retainer O Y 34R 98030 GREASE Y 041 20800 12 How to align the three planetary gears and install the ring gear Without any tools
31. y recommend Shimano lubricants and maintenance products Parts are not guaranteed against natural wear or deterioration resulting from normal use Set to SI 74YOA The projecting parts should be on the fork end side Install the non turn washers so that the project i ing parts are securely in the fork end grooves 8540 Cassette Joint on either side of the hub axle 3 Install the rubber cover and rubber bellows to Technical Service Instructions the outer casing holder Disconnecting the shifting cable when removing the rear wheel from the frame 3 Remove the inner cable fixing bolt unit from EON holder Disconnect the cable from the cassette joint when the cassette joint pulley removing the rear wheel from the frame T Inner cable fixing bolt unit 0000000000000 3 Cassette joint pulle e d joint pulley Z 2 7 S P7 4 Wipe away any grease which may be on the inner cable and then passthe inner cable through the rubber bellows After this insert the outer casing into the rubber cover and set it into the outer casing holder Use a new inner cable Do not use a cable which has had the end cut off Be careful of the inner cable end If it is difficult to pull the outer casing holder out from the outer casing holder section of the cassette joint insert a 2mm Allen key or a 14 spoke into the hole in the cassette joint pulley and then
32. y wash the sprock ets in a neutral detergent and then lubricate them again In addition clean ing the chain with neutral detergent and lubricating it can be a effective way of extending the useful life of the sorockets and the chain If the chain keeps coming off the sprock ets during use replace the sprockets and the chain Parts are not guaranteed against natural wear or deterioration resulting from normal use For maximum performance we highly recommend Shimano lubricants and maintenance products For any questions regarding methods of handling or adjustment please contact the place of purchase SI 35P0A INTER 8 Hub with Coaster Brake SG 8C20 Cassette Joint CJ 8520 Technical Service Instructions SHIMANO INTER Be sure to read these service instructions in conjunction with the service instructions for the INTER 8 shifting lever before use Installation of the cassette joint to the hub 1 Install the driver cap to the driver on the right side of the hub body direction 2 Turn the cassette joint pulley in the direction of the arrow in the illustration to align the red marks on the pulley and the bracket With the cassette joint in this condition install it so that the red mark on the cassette joint is aligned with the red mark on the right side of the hub body Should be aligned Pulley Bracket Align the red marks to install red 6 m
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