Shimano GY-DV5001 Service Instructions

Browse online or download pdf Service Instructions for Bicycle Accessories Shimano GY-DV5001. Shimano GY-DV5001 2 pages. Inter-8 hub; cassette joint

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General Safety Information

WARNING

– To avoid serious injuries:

When securing the brake arm to the frame, be sure to

securely tighten the clip screw and clip nut to the

specified tightening torque. Use lock nuts with nylon

inserts (self-locking nuts) for the clip nut. It is

recommended that standard Shimano parts be used for

the clip screw, clip nut and brake arm clip. 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 using 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.

NOTE:

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 shifting operation.

The CJ-8S20 cassette joint should only be used with

sprockets from 16T to 23T.

If the wheel becomes stiff and difficult to turn, you should

lubricate it with grease.

Do not apply any grease to the inside of the hub,

otherwise the grease will come out again.

You should periodically wash the sprockets in a neutral

detergent and then lubricate them again. In addition,

cleaning the chain with neutral detergent and lubricating it

can be a effective way of extending the useful life of the

sprockets and the chain.

If the chain keeps coming off the sprockets 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.

SG-8R20

Inter-8 Hub

SG-8R25

CJ-8S20

Cassette joint

Technical Service Instructions

Be sure to read these service instructions in conjunction

with the service instructions for the Inter-M Brake and the

Inter-8 shifting lever before use.

Installation of the cassette joint to

the hub

Install the driver cap to the driver on the right side of the

hub body.

Driver cap

Driver

Driver cap

Turn the cassette joint pulley in the direction of the

arrow in the illustration to align the red

pulley and the bracket. With the cassette joint in this

condition, install it so that the red

cassette joint is aligned with the red

side of the hub body.

Should be aligned

CJ-8S20

JAPAN

Cassette joint

Align the red

marks to install.

Right side of

the hub body

Secure the cassette joint to the hub with the cassette

joint fixing ring. When installing the cassette joint fixing

ring, align the yellow

mark with the yellow

the cassette joint pulley, and then turn the cassette joint

fixing ring 45° clockwise.

SI-34R0B

Align the

yellow

marks

to install.

Cassette joint pulley

Turn 45°

Cassette joint fixing ring

CJ-8S20

JAPAN

Fit the cassette joint

bracket securely.

Installation of the hub to the frame

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

axle into the fork ends.

Note the

direction

JAPAN

CJ-8S20

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)

marks on the

mark on the

mark on the right

Chainstay

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

Pulley

suitable.

Bracket

Fork end

5R / Yellow

Standard

7R / Black

Reversed

6R / Silver

Reversed

5R / Yellow

(full chain case)

CJ-8S20

JAPAN

Mark

7 R

Align the red

marks to install.

The 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.

Install the brake arm of the Inter-M brake to the

chainstay with the brake arm clip, provisionally tighten

the clip screw and clip nut, and then tighten the brake

unit fixing nut.

mark on

Note:

If the brake arm is in the incorrect position as

shown in the illustration so that it cannot be

provisionally installed to the chainstay, loosen the

Cassette joint

fixing ring

brake unit fixing nut and turn the brake arm. Then,

after provisionally securing the brake arm to the

chainstay, tighten the brake unit fixing nut.

Brake arm clip

Chainstay

CJ-8S20

JAPAN

Brake arm

Tightening torque:

20 – 25 Nm {174 – 217 in. lbs.}

Take up the slack in the chain and secure the wheel to

the frame with the cap nuts.

Hub axle

Fork end

Note:

When installing a part such as a mudguard stay to

the hub axle, install in the order shown in the

illustration below.

Cassette joint

Groove of fork end

Non-turn

washer

(for right side)

J-

Fix the brake arm of the Inter-M brake securely to the

chainstay with the brake arm clip.

Brake arm clip

Non-turn washer

Mark/Color

Size

Right

Left

5L / Brown

7L / Gray

6L / White

= 0

5L / Brown

= 0

Chainstay

Note:

When installing the brake arm clip, securely

tighten the clip screw while holding the clip nut

with a 10 mm spanner.

Tightening torque:

2 – 3 Nm {17 – 26 in. lbs.}

After installing the brake arm clip, check that the

clip screw protrudes about 2 – 3 mm from the

surface of the clip nut.

These service instructions explain how to use and maintain

the Shimano bicycle parts which have been used on your

new bicycle. For any questions regarding your bicycle or

other matters which are not related to Shimano parts‚ please

contact the place of purchase or the bicycle manufacturer.

Please note: Specifications are subject to change for improvement without

notice. (English)

Brake unit fixing nut

One Holland Irvine CA 92618 U.S.A. Phone 949-951-5003

Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone 31-341-272222

3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone 072-223-3243

Tightening torque:

30 – 45 Nm

{260 – 390 in. lbs.}

J-

Cap nut

Non-turn washer

J-

Washer

Cap nut

Mudguard stay

Carrier stay

If excessive force is

applied to the brake

arm, the wheel will

become difficult to

turn. Make sure that

you don't apply

excessive force

when installing.

Brake arm

Clip nut

Brake arm clip

Clip screw

2 – 3 mm

(M6

16 mm)

Jul. 2003 by Shimano Inc. PIT. SZK. Printed in China