User manual DAHON ALFINE SL-S500 TECHNICAL SERVICE INSTRUCTIONS

[. . . ] General Safety Information WARNING ­ 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. [. . . ] Operate lever B 7 times or more to set it to 1 . screws which are securing 3. Remove the indicator unit as shown in the illustration. Cover fixing screws 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. Bracket Outer casing holder CJ -8S PA JA JA 20 N Cassette joint side Wire end hooking cap Insert into the outer casing holder. 2 1 Pass through the slit. Cassette joint bracket When bicycle is upside down Should be straight Cassette joint pulley LOCK CJ-8S20 JAPAN the end casing is 6. After checking thatthe cable of the outer bolt of the sitting securely in adjustment Slit SL-S500 CJ-8S20 Shifting Lever Cassette Joint 3. 20 N Indicator unit Pull out from outer casing holder 1 Insert the inner cable into the groove in the winder unit, and then pass it through the hole in the cable adjustment bolt. Next, pull the inner cable so that the inner cable drum fits into the hole in the winder unit. Hole in cable adjustment bolt shifting lever, attach the inner cable fixing bolt unit to the inner cable. Note: Do not use this inner cable fixing bolt unit with the CJ-4S30 cassette joint. Inner cable fixing nut Inner cable fixing washer Inner cable fixing bolt Inner cable fixing bolt unit Technical Service Instructions Slit 2 Remove from the slit cable 3. fixing bolt unit from the cassette joint 10 mm Pass the inner cable through the hole. Groove in winder unit If first inserting the outer casing into the outer casing holder is easier, then first insert the outer casing into the outer casing holder, 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. Cassette joint bracket Be sure to read these service instructions in conjunction with the service instructions for the SG-S500 hub or Inter-8 hub before use. Lever B Inner cable fixing bolt unit Cassette joint pulley 3 Insert the inner cable fixing bolt unit LOCK 1 Insert into the outer casing holder 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 4 to 1 and then back to 4 , and then re-check to be sure that the yellow setting lines are aligned. 101 mm LOCK CJ-8S20 JAPAN Shifting lever operation After you release your finger from lever A / lever B once shifting is complete, the lever will always return to its original position. Installation CJ-8S20 JAPAN 4. Lever B: Pedaling becomes lighter. (Indicator moves toward 1 ) Check that the needle of the indicator is on the left side ( 1 position), and then install the indicator unit so that it is facing straight upward. Insert the pin of the change plate that is protruding from the bottom of the indicator unit into the hole in the winder unit at this time. Indicator unit Pin of change plate Hole in winder unit ( 1 position) Inner cable drum Lever B 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. Hole in winder unit Pull the inner cable while attaching the inner cable fixing bolt unit. 2 Turn the pulley Cable adjustment bolt Hole in pulley the cassette cut 2. After adjustingof inner cablejoint, thenoff the the excess length and install inner end cap. Inner end cap hooking as shown 4. If itcapturned any in the illustration until it is Tightening torque: 3. 5 ­ 5. 5 N·m {35 ­ 55 kgf·cm} the cable 7. Bringso that the around to the cassetteisjoint pulley, hold inner cable fixing nut 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 2 mm Allen key or #14 spoke 2 Remove the inner cable fixing bolt unit 3 Pull out from the outer casing holder LOCK further, it will damage the screw thread in the cover. [. . . ] Printed in Japan LOCK 20 8S CJ- N PA JA LOCK cable to the in 9. Attach the innerpass the innerpulley as shownthe the illustration, cable through LOCK LOCK LOCK LOCK LOCK [. . . ]