Shimano CJ-8S40 Operating instructions

SI-74Y0A
CJ-8S40
Cassette Joint
General Safety Information
WARNING
– To avoid serious injuries:
NOTE:
The CJ-8S40 cassette joint should only be
used with sprockets from 16T to 23T.
When lubricating the chain or the sprockets, be
careful not to get any oil on the rubber bellows
or the rubber cover of the cassette joint.
For maximum performance we highly
recommend Shimano lubricants and
maintenance products.
Parts are not guaranteed against natural wear
or deterioration resulting from normal use.
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.
Technical Service Instructions
Left
Fork end
Non-turn washer
Reversed
Standard 5R / Yellow
6R / Silver
5L / Brown
6L / White
Mark / Color Size
Right
7R / Black 7L / Gray
Reversed
(full chain case) 5R / Yellow = 0
= 0
5L / Brown
7R
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.
Mark
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 suitable.
Installation of the cassette joint
Refer to the Service Instructions for the Inter-8 hub for
details on installation of the cassette joint to the hub and
installation of the non-turn washer.
Note:
20
38
t

CJ-8S40
JAPAN
LOCK
1
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
1
LOCK
CJ-8S40
JAPAN
Cassette joint
Disconnecting the shifting cable when removing the rear wheel from the frame
If it is difficult to pull the outer casing holder out
from the outer casing holder section 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 remove the inner cable fixing bolt unit from
the pulley first, and after this remove the outer
casing holder from the outer casing holder
section.
Note:
Do not remove the cable by pulling the outer
casing.
Note:
If reusing the cable, refer to steps 6 to 8 in
"Installation of the shifting cable".
Remove the inner cable fixing bolt unit from the
cassette joint pulley.
1
Set the shifting lever to .
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 cable attached
to the rubber bellows from the slit in the bracket. Be
careful not to damage the rubber bellows at this time.
Set to 1
Rubber cover
Rubber bellows
Pull out the
outer casing
holder
Cassette joint pulley
Inner cable fixing bolt unit
2 mm Allen key
or #14 spoke
Pulley hole
2
3
Remove the inner
cable fixing bolt unit Remove the
outer casing
holder
Turn the
pulley
Remove the
rubber bellows
from the slit
Disconnect the cable from the cassette joint when
removing the rear wheel from the frame.
2
1.
2.
3.

1.
2.
3.
4.
5.
Use a shifting cable with one inner cable drum.
SIS-SP (4 mm or 5 mm dia.)
Shifting lever end
Cassette joint end
Refer to the Service Instructions which are
provided with the Inter-8 shifting lever.
Note:
Make sure that the shield cap is at the shifting lever
end.
OK Not OK Not OK
Use a new inner cable. Do not use a cable which
has had the end cut off.
Installation of the shifting
cable
Shifting lever side
Connect the shifting cable to the shifting lever.
Cassette joint side
1
Set the shifting lever to .
Install the rubber cover and rubber bellows to the outer
casing holder.
Wipe away any grease which may be on the inner
cable, and then pass the inner cable through the
rubber bellows. After this, insert the outer casing into
the rubber cover and set it into the outer casing holder.
Be careful of the inner cable end
While holding the end of the rubber bellows, insert
the inner cable. Be careful not to pierce the rubber
bellows with the end of the inner cable at this time.
1)
Slide the rubber bellows onto the inner cable.
2)
Shield cap
Set to 1
Rubber bellows Outer casing holder Rubber cover
End of rubber bellows Inner cable
Rubber bellows
Inner cable fixing nut
Inner cable fixing washer
Inner cable fixing bolt
Inner cable fixing bolt unit
Note: Do not use this inner cable fixing bolt unit
with the CJ-4S30 cassette joint.
127 mm
63 mm or less
Pass the inner cable through the hole.
Pull the inner cable while attaching
the inner cable fixing bolt unit.
After checking that the end of the outer casing is
sitting securely in the cable adjustment bolt of the
shifting lever, attach the inner cable fixing bolt unit to
the inner cable.
Tightening torque:
4 – 6 Nm {40 – 60 kgfcm}
10 mm
(Black)
Push the outer casing on so that it securely touches
the outer casing holder.
3)
Outer casing holder
Rubber cover
Rubber bellows
Inner cable Outer casing

7.
6.
8.
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
Gap in pulley
Flats part of inner cable
fixing washer
Inner cable
fixing nut
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.
Turn the cable 60 counterclockwise and attach it to
the hook.
Hook
Turn the
cable 60
Pulley
CJ-8S40
JAPAN
LOCK
2
2
1
CJ-8S40
JAPAN
CJ-8S40
JAPAN
LOCK
If first inserting the outer casing holder into the
outer casing holder section of the cassette joint
is easier, then first insert the outer casing holder
into the outer casing holder section of the
cassette joint, 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.
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.
Pulley
Bracket
Inner cable
Outer casing holder section
Rubber cover
Rubber bellows
Slit
Outer casing holder
Attach the
outer casing
holder
2 mm Allen key
or #14 spoke
Hole in pulley
1
Attach the
outer casing
holder
Turn the
pulley
3
Insert the inner cable
fixing bolt unit
Insert the rubber
bellows into the slit
9.
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
Note:
Check that the inner cable is correctly seated
inside the pulley guide.
OK Not OK
Secure the cable to the frame with the outer casing
bands.
Guide Guide
10 cm
10 cm 15 cm
Outer casing bands

LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
Cassette joint
pulley
Cassette joint bracket
Cassette joint
pulley
Cassette joint bracket
Yellow setting lines
After adjusting the cassette joint, cut off the excess
length of inner cable and then install the inner end cap.
Should be straight
Should be straight
When bicycle is upside down
When bicycle is standing up
Adjusting the cassette joint
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.
4
4 1
4
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 to and then back to
, and then re-check to be sure that the yellow
setting lines are aligned.
Cable adjustment bolt
Inner end cap
15 – 20 mm
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.
One Holland Irvine CA 92618 U.S.A. Phone [phone]
Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone [phone]
3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone [phone]
These service instructions are printed on recycled paper.
Please note: Specifications are subject to change for improvement without
notice. (English)
Set to 4
The yellow setting lines on the cassette joint are
located in two places. Use the one that is easiest
to see.
Mar. 2003 by Shimano Inc. PIT. SZK. Printed in Japan
C
1.
2.
t