User manual DAHON NEXUS BL-IM65 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. [. . . ] Set the Revo-shift lever to 1 . Set to 1 2. Loosen the cover fixing screw, and then remove the upper cover. Cover fixing screw Revo-shift lever side CJ-8S JAPA N When bicycle is standing up Should be straight Cassette joint pulley Make the cut end perfectly round. Attach the plastic cap. Inner cable Pulley Bracket Bracket Outer casing holder Cassette joint bracket LOCK Revo-shift lever operation Turn the Revo-shift lever to shift to each of the eight gears. CJ -8S PA C / R position V V CR JA 20 N Pull out from outer casing holder 1 the inner 3. Passthrough thecable from the hole in the winder unit 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. Hole in cable adjustment bolt Groove in cable guide Hole in winder unit 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 unit Slit CR Cantilever brakes Roller Brakes The C indicates the mode position for compatibility with cantilever brakes. The R indicates the mode position for compatibility with Roller Brakes. Pedaling becomes lighter Indicator moves toward 1 2 Remove from the slit cable 3. fixing bolt unit from the cassette joint Inner cable fixing bolt unit Cassette joint pulley 10 mm (Black) Inner cable fixing bolt 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 Installation of the lever Install the lever as shown in the illustration. 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. Clamp bolt Pass the inner cable through the hole. 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 Revoshift lever to align the setting lines. After this, move the Revo-shift lever once more from 4 to 1 and then back to 4 , and then recheck to be sure that the yellow setting lines are aligned. 101 mm V position V V CR CJ-8S20 JAPAN CR V-Brakes with power modulator Leave a gap of 0. 5 mm between the Revo-shift lever and the half grip. CJ-8S20 JAPAN The V indicates the mode position for compatibility with V-Brakes with power modulator. Handlebar Use the brake levers with mode switching mechanism in the combinations given above. Read these Technical Service Instructions carefully, and keep them in a safe place for later reference. 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. 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 Tightening torque: 4 ­ 6 N·m {40 ­ 60 kgf·cm} the cable 7. [. . . ] 2 1 Pass through the slit. When bicycle is upside down Should be straight Cassette joint pulley Revo-shift lever Slit CJ-8S20 JAPAN LOCK 20 8S CJ- N JA PA LOCK cable to the in 9. Attach the innerpass the innerpulley as shownthe the illustration, cable through LOCK LOCK LOCK LOCK LOCK [. . . ]