Shimano SG-8C20 User manual

SSGG--88CC2200
vol. 1
SERVICE MANUAL
GB
SHIMANO NEXUS INTER-8 COASTER HUB
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Lay_INTER-8_GB 05 23.12.qxd 23.12.2004 13:39 Uhr Seite 2

Contents
The new standard in internal geared hubs 4
Technical Service Instructions 6
SG-8C20, CJ-8S20, SL-8S20, BL-IM65
Troubleshooting Chart 12
Replacement of the internal unit 14
Disassembly of the internal unit 16
Assembly of the INTER-8 coaster hub 21
Cassette Joint & Measurement tool 28
NEXUS non-turn washers 30
Hub dimensions (O.L.D. and axle) 31
Spare parts list (SG-8C20) 32
Spare parts list (SL-8S20) 33
Spare parts list (CJ-8S40) 34
Spare parts list (BL-IM65) 35
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44
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-IM70-R
Roller Brake SG-8R25 Premium version
SG-8R20
Roller Brake
SG-8C20
Coaster Brake
SG-8R25-VS
SG-8R20-VS
V-Brake
Small Parts Set FC-NX60
33/38T
FC-NX80
HOLLOWTECH
Crankset
BL-IM65
3-finger
Brake lever
BL-IM60
4-finger
Brake lever
ST-8S20
3-finger
Brake lever
SL-8S20
SB-8S20
4-finger
Brake lever
BB-UN25
SG-8C20
SG-8R25
SB-8S20 ST-8S20
BL-IM65
SL-8S20
BL-IM65
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INTER-7
INTER-8
INTER-7
INTER-8
• Better Sealing
The INTER-8 hub has adopted a labyrinth seal
system that shuts out water and dirt to extend
the service life and maintain smooth shifting in all
circumstances. Optionally a waterproof dust cap
can be installed ex factory on the non-drive side
before shipment, in case you wish to use the hub
in combination with a seperate brake system such
as V-Brakes.
55
shifting torque
labyrinth seal
driver rotation torque
SG-8R25 Premium Version for Roller Brake
SG-8R20 Roller Brake Version
SG-8R25-VS V-Brake 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 exep-
tionally light feeling. Mechanical shifting resist-
ance is notably reduced so shifting is not affected
under high loads.
• Robust Construction
Durable planetary and step-up gear sets assure
long trouble-free service.
• Smooth Gear Change
The smaller idling angle realizes shockless
smoother shifting for stressless comfortable gear
change.
• 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
307%, compared to 244% of the INTER-7 hub.
ST-8S20 Shifter with 3-finger Brake Lever
BL-IM65 3-finger Brake Lever
SB-8S20 Shifter with 4-finger Brake Lever
SL-8S20 Shifter
BL-IM60 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): 30% more braking
power compared to INTER-7
3.0
30% more powerful
2.5
2.0
1.0
0.0 12345678
307%
low-high
difference
2.0
0.5
1.0
1.5
1st 8th7th6th5th 4th 3rd2nd
0.74 (27T) 0.84 (24T) 0.99 (20T) 1.15 (17T)
1.34 (15T)
1.55 (13T)
0.63 (32T)
0.53 (38T)
0.64 (31T) 0.75 (27T) 0.85 (24T) 1.00 (20T)
1.22 (16T)
1.42 (14T)
1.61 (12T)
244%
low-high
difference
20~90º
10~30º
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CJ-8S20
JAPAN
6
General Safety Information
• It is important to completely understand
the operation of your bicycle'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
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 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.
• 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.
• Spin the wheel and confirm that the
braking force of the coaster brake is
correct.
• 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.
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 shift-
ing 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 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 periodically 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 sprockets
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.
WARNING – To avoid serious
injuries: CAUTION – To avoid serious
injuries:
Brake drum Driver cap
Installation of the cassette joint
to the hub
1. Install the driver cap to the driver on the
right side of the hub body.
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.
Driver
Driver cap
CJ-8S20
JAPAN
Pulley
Bracket
Note the
direction
Should be aligned
Cassette joint
Align the
red ● marks
to install.
Align the
red ● marks
to install.
Right side of
the hub body
Technical Service Instructions
Be sure to read these service instructions in
conjunction with the service instructions for
the INTER-8 shifting lever before use.
INTER-8 Hub
with Coaster Brake
SG-8C20
CJ-8S20
SI-35P0A
Cassette Joint
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R7
0
2S
8-
J
C
N
A
P
A
J
KCO
L
CJ-8S20
JAPAN
K
C
OL
R
7
0
2
S
8
-
J
C
N
A
PA
J
K
C
O
L
R
7
CJ-8S20
JAPAN
K
C
O
L
CJ-8S20
JAPAN
K
C
OL
Cap nut
Non-turn washer
Chainstay
7
Cassette joint fixing ring
Cassette joint
pulley
Align the
yellow ●
marks to
install.
Turn 45º
Cassette joint
fixing ring
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 ● mark with the
yellow ● mark on the cassette joint
pulley.
3. 2) After installing the cassette joint fixing
ring, turn it 45º clockwise.
Fit the cassette joint bracket
securely.
Cassette joint
Groove of
fork end
Non-turn
washer (for
right side)
Chainstay
Non-turn washer
(for left side)
Installation of the hub
to the frame
Hub axle
Fork end
1. Mount the chain on the sprocket, and
then set the hub axle into the fork ends.
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.
4. Fix the brake arm securely to the chain-
stay with the brake arm clip.
5. Before using the Coaster Brake, check
that the brake works properly and that
the wheel turns smoothly.
Clip nut
Brake arm
Brake arm clip
Clip screw
Tightening torque:
2 – 3 N·m {17 – 26 in. lbs.}
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.
NOTE:
• When installing the brake arm clip,
securely tighten the clip screw while
holding the clip nut with a 10 mm
spanner.
• After installing the brake arm clip,
check that the clip screw protrudes
about 2 – 3 mm from the surface of the
clip nut.
Clip nut
Brake arm
Brake arm clip
Clip screw
(M6 x 16 mm)
2 – 3 mm
Mark
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.
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
{260 – 390 in. lbs.}
5R/Yellow
7R/ Black
6R/Silver
5R/Yellow
5L/Brown
7L/Gray
6L/White
5L/Brown
LeftRight Size
Fork end
Standard
Reversed
Reversed
(full chain
case)
Mark/Color
Non-turn washer
θθ20º º®
θθ38
θθ=0 
θθ=0 
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CJ-8S20
JAPAN
LOCK
CJ-8S20
JAPAN
K
C
O
L
0
2
S
8
-
J
C
N
A
P
AJ
0
2
S8
-
J
C
N
A
PA
J
K
C
OL
CR
V
V
R
C
CR
V
V
R
C
8
General Safety Information
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 bicycle
may topple over, which could result
in serious injury.
WARNING – To avoid serious
injuries:
CAUTION
The C indicates the
mode position for com-
patibility with can-
tilever brakes.
The R indicates the
mode position for com-
patibility with Roller
Brakes.
Revo-shift lever operation
Installation of the lever
Install the lever as shown in the illustra-
tion.
Revo-shift
Lever
Brake Lever
Cassette Joint
SL-8S20
BL-IM65
CJ-8S20
SI-6FD0A
NOTE:
• For maximum performance we high-
ly recommend Shimano lubricants
and maintenance products.
• Parts are not guaranteed against
natural wear or deterioration result-
ing from normal use.
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.
Mode
position Applicable brake
V position
• V-Brakes
with
power
modulator
• Cantilever
brakes
• Roller
Brakes
Indicator
Pedaling becomes heavier
Indicator moves toward ➇➇
Revo-shift lever
Indicator moves toward ➀➀
Pedaling becomes lighter
Clamp bolt
3 mm Allen
key
Half grip
Grip
Handlebar
Leave a gap
of 0.5 mm
between the
Revo-shift
lever and the
half grip.
In case of using Shimano
half grip, the straight
section of the handlebar
should be 166 mm or
more in length; attach
the Revo-shift lever to
this straight section.
22.2 mm
1
2
Tighten
Tightening torque:
2 – 2.5 N·m
{20 – 25 kgf·cm}
Technical Service Instructions
1
23
Tighten
Clamp bolt
Tightening torque:
6 – 8 N·m {60 – 80 kgf·cm}
3
5 mm Allen
key
22.2 mm
Disconnecting the shifting cable
when removing the rear wheel from
the frame
Disconnect the cable from the
cassette joint when removing the
rear wheel from the frame.
NOTE:
If reusing the cable, refer to steps
7 to 9 in "Installation of the shift-
ing cable".
Cassette
joint
3. Remove the inner cable fixing
bolt unit from the cassette joint
pulley.
Inner cable fixing bolt unit
Cassette joint pulley
2. Pull the outer casing out from
the outer casing holder of the
cassette joint, and then remove
the inner cable from the slit in
the bracket.
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
remove the inner cable fixing bolt
unit from the pulley first, and
after this remove the outer casing
from the outer casing holder.
Remove the
inner cable fix-
ing bolt unit
2
1
3
Pulley hole
2 mm Allen key or
#14 spoke
Slit
Bracket Outer casing holder
1
2
Pull out from
outer casing
holder.
Remove from the slit.
Use a shifting cable with one
inner cable drum.
Cable with one inner cable drum /
SIS-SP40 (4 mm dia.)
Set to ➀➀
1. Set the Revo-shift lever to ➀➀.
2. Loosen the cover fixing screw, and
then remove the upper cover.
3. Pass the inner cable from the hole
in the winder unit through the
hole in the cable adjustment bolt.
Next, insert the inner cable into
the groove of the cable guide,
and pull the inner cable so that
the inner cable drum fits into the
recess in the winder unit.
4. Replace the upper cover and
tighten the cover fixing screw.
■Revo-shift lever side
Cover fixing screw
Upper cover
Hole in
winder unit
Groove in cable guide
2
3
1
4
Recess in winder unit
Tightening torque:
0.1 – 0.2 N·m {1 – 2 kgf·cm}
Cover fixing screw
Upper cover
• Obtain and read the service instruc-
tions 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.
• It is important to completely under-
stand the operation of your bicycle'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 severe injury. Because
each bicycle may handle differently,
be sure to learn the proper braking
technique (including brake lever
pressure and bicycle control charac-
teristics) and operation of your bicy-
cle. This can be done by consulting
your professional bicycle dealer and
the bicycle's owners manual, and by
practicing your riding and braking
technique.
• These brake levers are equipped
with a mode switching mechanism
to make them compatible with
cantilever brakes and Roller Brakes
or V-Brakes with power modulator.
If the incorrect mode is selected it
may cause either excessive or insuffi-
cient braking force to occur, which
could result in dangerous accidents.
Be sure to select the mode in accor-
dance with the instructions given in
the table below.
The V indicates the
mode position for
compatibility with
V-Brakes with power
modulator.
C/R position
Pull out
from the
outer casing
holder
Installation of the
shifting cable
Hole in cable
adjustment bolt
Set to ➀➀
– To avoid
serious injuries:
Turn the
pulley
1.Set the Revo-shift lever to ➀➀.
Be sure to read these service
instructions in conjunction with
the service instructions for the
Inter-8 hub before use.
Turn the Revo-shift lever to shift to
each of the eight gears.
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Set to ➃➃
0
2S
8
-
J
C
N
A
P
A
J
K
CO
L
CJ-8S20
JAPAN
KCO
L
CJ-8S20
JAPAN
K
CO
L
CJ-8S20
JAPAN
K
CO
L
10 cm
10 cm 15 cm
CJ-8S20
JAPAN
K
C
O
L
CJ-8S20
JAPAN
K
C
O
L
CJ-8S20
JAPAN
KC
O
L
0
2S
8
-
J
C
NA
P
A
J
0
2
S
8
-
JC
N
A
PA
J
K
C
O
L
CJ-8S20
JAPAN
K
C
O
L
CJ-8S20
JAPAN
K
CO
L
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 ➃➃to ➀➀and then back to ➃➃,
and then recheck to be sure that the yellow
setting lines are aligned.
Inner cable fixing bolt unit
Note: Do not use this inner cable fixing bolt
unit with the CJ-4S30 cassette joint.
9
5. Pass the inner cable through the
SIS-SP40 outer casing through the
end with the plastic cap.
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.
7. 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.
■Cassette joint side
Plastic cap
Attach the plastic cap.
Remove the plastic cap.
Aluminium cap
Inner cable fixing
nut
Inner cable fixing
washer
Inner cable fixing
bolt
Inner cable
fixing nut Pulley
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.
Plastic cap
10 mm
(Black)
Pass the inner cable
through the hole.
101 mm
Pull the inner cable while attaching the inner
cable fixing bolt unit.
Tightening torque:
4 – 6 N·m {40 – 60 kgf·cm}
Flats part of inner
cable fixing washer
Gap in pulley 10. Secure the cable to the frame with
the outer casing bands.
8. Turn the cable 60º counterclockwise
and attach it to the hook.
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.
Hook
Turn the
cable 60º
Bracket
Inner cable Pulley
Bracket
Slit
Outer casing holder
Pass through the slit
2
1
Insert into
the outer
casing
holder
Make the cut end
perfectly round.
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.
Note:
Check that the inner cable is correctly seated
inside the pulley guide.
2 mm Allen key or #14 spoke
Insert the inner
cable fixing bolt
unit.
Turn the
pulley
Insert into the
outer casing
holder.
Hole in pulley
2
31
Outer casing bands
OK Not OK
Guide Guide
2. After adjusting the cassette joint, cut
off the excess length of inner cable
and then install the inner end cap.
Cable adjustment bolt
1. Set the Revo-shift lever to ➃➃.
Check to be sure that the yellow setting
lines on the cassette joint bracket and
pulley are aligned at this time.
Adjusting the cassette joint
Inner end cap
Yellow setting lines
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
When bicycle is upside down
Cassette joint
bracket
Cassette joint
bracket
Cassette
joint pulley
Should be straight
Cassette
joint pulley
15 – 20 mm
Should be straight
Lay_INTER-8_GB 05 23.12.qxd 23.12.2004 13:39 Uhr Seite 9

CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
7R
SI-74Y0A
CJ-8S40
.
10
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
7R
SI-74Y0A
CJ-8S40
.
10
10
General Safety Information
– To avoid serious injuries:
• 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.
NOTE:
• The CJ-8S40 cassette joint should only be
used with sprockets from 16T to 23T.
• 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 highly
recommend Shimano lubricants and
maintenance products.
• Parts are not guaranteed against natural
wear or deterioration resulting from normal
use.
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. Use a shifting cable with one inner cable drum.
SIS-SP (4 mm or 5 mm dia.)
• The projecting parts should be
on the fork end side.
• Install the non-turn washers so that the project-
ing parts are securely in the fork end grooves
on either side of the hub axle.
WARNING
Disconnecting the shifting cable when removing the rear wheel from the frame
Disconnect the cable from the cassette joint 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 2mm 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.
Cassette joint
Rubber bellows
Rubber cover
Pull out the
outer casing
holder
Remove the
rubber bellows
from the slit
1.Set the shifting lever to ➀➀.
1.Connect the shifting cable to the shifting lever.
2.Set the shifting lever to ➀.
3.Install the rubber cover and rubber bellows to
the outer casing holder.
4.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.
1) 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.
2) Slide the rubber bellows onto the inner cable.
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
cable attached to the rubber bellows from the
slit in the bracket. Be careful not to damage the
rubber bellows at this time.
Note:
Do not remove the cable by pulling the outer
casing.
Note:
Make sure that the shield cap is at the shifting
lever end.
■ Shifting lever side
■ Cassette joint side
Note:
If reusing the cable, refer to steps 6 to 8 in
“Installation of the shifting cable”.
3. Remove the inner cable fixing bolt unit from
the cassette joint pulley.
Inner cable fixing bolt unit
Cassette joint pulley
Shifting lever end
Cassette joint end
Shield cap
Rubber bellows Outer casing
holder Rubber cover
Remove the inner
cable fixing bolt unit Remove the
outer casing
holder
Pulley hole
Mark
2mm Allen key
or #14 spoke
Installation of the cassette joint Installation of the shifting cable
Refer to the Service Instructions which are
provided with the INTER-8 shifting lever.
Use a new inner cable. Do not use a cable
which has had the end cut off.
End of rubber bellows
Rubber bellows
Inner cable
CJ-8S40 Cassette Joint
Technical Service Instructions
Set to ➀➀
Set to ➀➀
23
1
1
2
Turn the
pulley
5R/Yellow
7R/ Black
6R/Silver
5R/Yellow
5L/Brown
7L/Gray
6L/White
5L/Brown
LeftRight
θθ20
θθ38
θθ=0 
θθ=0 
Size
Fork end
Standard
Reversed
Reversed
(full chain
case)
Mark/Color
Non-turn washer
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.
Be careful of the inner cable end.
Not OKOK Not OK
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CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
127 mm
10 mm
10 cm
10 cm 15 cm
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
127 mm
10 mm
10 cm
10 cm 15 cm
11
LOCK
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
CJ-8S40
JAPAN
LOCK
CJ-8S40
JAPAN
LOCK
15 – 20 mm
OK
Insert the inner
cable fixing bolt
unit
Attach the
outer casing
holder
Not OK
Insert the
rubber bellows
into the slit
Attach the
outer casing
holder
Turn the
cable 60°
Outer casing bands
Inner cable Outer casing holder
Rubber bellows Rubber cover
Outer casing
Inner cable
Pulley
Outer casing holder section
Slit Yellow setting lines
Rubber bellows
Outer casing holder
Rubber
cover
Cassette joint bracket
Cassette joint bracket
Bracket
3) Push the outer casing on so that it securely
touches the outer casing holder.
5. 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 bolt unit to the inner cable.
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.
7. Turn the cable 60° counterclockwise and
attach it to the hook.
Inner cable fixing bolt unit
Note: Do not use this inner cable fixing bolt unit
with the CJ-4S30 cassette joint.
Pass the inner cable through the hole.
Flats part of inner
cable fixing washer
Gap in pulley
Inner cable
fixing nut
Pulley
Hole in pulley
Guide Guide
2 mm Allen key or #14 spoke
Hook
Tightening torque:
4 – 6 N·m (40 – 60 kgfcm)
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.
1.Set the shifting lever to ➃➃.
Check to be sure that the yellow setting lines
on the cassette joint bracket and pulley are
aligned at this time.
2.After adjusting the cassette joint, cut off the
excess length of inner cable and then install
the inner end cap.
9.Secure the cable to the frame with the outer
casing bands.
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
section 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.
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 ➃➃to ➀➀and then
back to ➃➃, and then re-check to be sure that
the yellow setting lines are aligned.
The yellow setting lines on the cassette joint
are located in two places. Use the one that is
easiest to see.
Note: Check that the inner cable is correctly
seated inside the pulley guide.
Adjusting the cassette joint
When bicycle is standing up
When bicycle is upside down
Inner end cap
Cable adjustment bolt
Should be straight
Should be straight
Cassette joint
pulley
Cassette joint
pulley
Inner cable fixing nut
Inner cable fixing
washer
Inner cable fixing bolt
(Black)
63 mm or less
Pull the inner cable while attaching
the inner cable fixing bolt unit.
Set to ➃➃
Turn the
pulley
2
31
2
1
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12
Troubleshooting Chart
Abnormal noise
occurs. Cable is incorrectly adjusted. Set the shift lever to 4th. Then turn the cable
adjusting barrel to align the red setting lines
on the cassette joint bracket and pulley.
Shift down to the 1st gear, up to
the 4th again and recheck the adjustment.
Replace the hub axle unit, clutch unit
and carrier unit.
Replace the driver unit, hub axle unit
and carrier unit.
Trouble condition Remedy
04
PE-LD
1
1
2 3
4
5 6 7
8 9 10 11 12 13 14 15 16 17 18
19 19 20 21 22 23 24
25 26 27 28 29
30 31 32
33
34
35
36 37
38
39
40
41
SHIMANO NEXUS INTER-8 Coaster Hub
SG-8C20
Internal Assembly
CJ-8S20
Internal Hub
Grease
(For coaster brake also)
TL-8S30
TL-8S20
TL-8S11
Abnormal noise
still occurs after
adjusting cable.
Replace the hub axle unit and
carrier unit.
While
shifting Shifting position
While
pedaling Shifting position
12
23
34
67
78
56
All
Same treatment of 8R20
Lay_INTER-8_GB 05 23.12.qxd 23.12.2004 13:39 Uhr Seite 12

Shifting lever indicator doesn’t match hub
shifting position. Replace the carrier unit and hub axle unit.
13
Troubleshooting Chart
Gear shift
is not
possible.
Remove the wheel
from the frame and
check whether gear
shifting is possible.
Turning is stiff.
Gear shifting is
possible:
When the shifting
lever doesn’t
operate.
Cable is incorrectly
adjusted.
Cone Unsmooth
Free rotation is stiff.
Braking is too sudden.
Set the shift lever to 4th. Then turn the
cable adjusting barrel to align the red
setting lines on the cassette joint
bracket and pulley.
Trouble condition Remedy
While
braking.
Replace the shifting lever.
Replace the shell, ball retainer and
driver unit.
Gear shifting is not
possible.
When the hub
doesn’t work.
Replace the carrier unit and
hub axle unit.
While not
pedaling.
Gear Unsmooth
Replace the hub axle unit and
carrier unit.
Replace the carrier unit.
Replace the hub axle unit and
carrier unit.
4.8
Except 4.8
4.8
Except 4.8
Replace the right hand cone and
driver.
Replace the brake shoe unit, Driver
unit & axle unit.
Braking force is weak. Replace the brake shoe unit.
Pedal turning angle for brake
to operate is too large. Replace the brake shoe unit, Driver unit& axle unit.
Wheels lock when bicycle is pushed back-
ward. Replace carrier unit, driver unit and clutch unit.
A squeaking sound caused by lack of lubrica-
tion can be heard. Apply grease or replace the brake shoe unit.
Brakes do not release. Replace the brake shoe unit and
carrier unit.
Trouble condition Remedy
While
pedaling.
Replace the carrier unit.
Following treatment is for 8C
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14
Replacement of the internal unit
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.
Locknut 17mm (Y-35P 28000)
Stop Nut 22mm (Y-35P 22000)
TL-7S20
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.
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:
For internal unit replacement
only tools "e" and "f" are
necessary.
a: Hammer
b: TL-8S11
Right Hand Cone Removal Tool
Part No. Y-708 00600
a
bcef
d
1. Hold the two bevelled
surfaces of the hub axle on
the brake arm side in a 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.
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: Screwdriver
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)
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15
Brake arm unit
Ball retainer B
3. Remove the brake arm unit
and ball retainer B from the
hub axle.
4. Remove the hub shell.
Hub shell
Internal assembly
Now it can be replaced
with the new internal
assembly.
Disassembly and assembly can be
carried out quickly.
Part No. 36P 98010
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16
Ring gear slide spring
(Y-35P 12000)
2. Carefully remove the stop ring
with a screwdriver. Because
the stop ring will tend to
come off with some force,
use a piece of cloth to prevent
loss.
4. Remove the ring gear slide
spring with a screwdriver.
3. Remove carrier unit and ring
gear by lifting straight up.
Do not rotate to disengage.
Screwdriver
Stop ring
(Y-33Y 19000)
Ring gear 1
(Y-35P 11000)
Ring gear slide spring (Y-35P 12000)
Carrier unit (Y-35P 98040)
Brake shoe unit
1. Remove the brake shoe unit.
Disassembly of the internal unit
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17
5. Remove ball retainer O
(3/16"X26) while pushing
pawls B.
7. Remove the locknut with a
17mm hub spanner.
6. Reverse axle unit in vice to
access the drive side cone
assembly.
Stop washer
(Y-34R 09000)
Right hand locknut
(Y-33Z 07020)
8. Remove the stop washer.
Ball retainer O
(Y-34R 98030)
Pawls B
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18
Tool TL-8S11
(Y-708 00600)
11. Support the driver assembly
on the vice, as shown. Set
cone removal tool (TL-8S11)
into the groove such that
the pawl A is contacting the
notch in the tool, see detail.
Strike the tool with the
hammer until cone and
axle unit are separated.
AA
9. Remove the lock washer.
10. Remove the driver plate.
Lock washer
(Y-34R 98090)
Driver plate
(Y-34R 12000)
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19
Driver unit
(Y-35P 98070)
Right hand cone
(Y-34R 98080)
Return spring A
(Y-34R 21000)
13. Remove the ball retainer P
(3/16"X13).
12. Reverse the right hand cone.
14. Remove the driver unit.
15. Remove the return spring A.
Ball retainer P
(Y-34R 98070)
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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.
Clutch unit
(Y-35P 98060)
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