SERVICE MANUAL SHIMANO NEXUS 3-SPEED HUB
Contents
1. SHIMANO NEXUS 3 SPEED HUB S 3C41 SHIMANO SG 3C41 Note Unit parts should never be disassembled If they are problems may result When replacing parts replace the whole internal assembly or unit part Tools Note Before carrying out disassembly have ready the hub spanners TL 7S20 TL HS20 and internal hub grease Screwdriver Left TL 7 20 center Hub spanners Part No 130 9890 17mm x 22mm 2 pcs TL HS 20 Right Hub spanners Part No 320 9001 15mm 17mm 2 pcs 1 Hold the two bevelled surfaces of the hub axle on the brake arm side in a vice and remove the dust cap with a screwdriver Screwdriver Vice Note Do not damage the threads of the hub axle N Turn the brake arm unit upside down and hold m 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 Remove the left hand lock nut from the hub axle and then remove the stop nut Left hand lock nut Stop nut 3 Remove the brake arm unit A Brake arm unit 4 Remove the hub shell lt Internal assembly Now it can be replaced with the new internal assembly Internal assembly for quick disassembly and assembly Part No SG 3C41 Y 35U 98010 Axle Length 168 mm Y 33R 98020 Axle Length 175 mm Y 35U 98020 Axle Length 178 mm SG 3C41 DX2. Y 35U 98010 Axle Length 168 mm Y 33R 98020 Axle Length 175 mm 5 Remove the brake shoe unit 6 Remove the stop ring with a screwdriver At this time the stop ring come off with great force Be careful of the safety using cloth and so on Stop ring 9mm dia After removing them at the same time remove the carrier unit from the ring gear unit J Remove the carrier unit and the ring gear unit at the same time while turning the ring gear unit slightly to the left and right Carrier unit Carrier unit Ring gear unit Ring gear unit 8 Remove ball retainer K while Note pressing in pawl A 1 and pawl C Be careful not to bend ball on the driver unit a screwdriver retainer K Screwdriver Pawl A 1 Pawl C ball retainer K Remove the right hand lock nut and the right hand cone with dust seal from the hub axle TL HS20 Right hand lock nut 9 Turn the axle unit with driver unit upside down and hold the two bevelled surfaces of the axle in a vice Note Do not damage the threads of the hub axle Axle unit with driver unit Right hand cone with dust seal 10 Remove ball retainer J from the driver unit C A Ball retainer J EEE Driver unit 11 While pushing the two pawls C on the driver unit with your fingers remove the driver unit Note Be careful not to let pawl pin B fall out lt Pawl C Pawl A 1 Driver unit h Wh
3. are aligned with the four projections on the brake arm unit cone Note Apply a liberal coating of internal hub grease to the brake shoe unit Indents of brake shoe unit Projection of brake arm unit TYI Y 041 20800 12 Pass the brake arm unit with brake shoe over the hub axle align the notch in the brake shoe unit with the end of the slide spring on the carrier unit and then install the brake arm unit to the hub shell lt Brake arm unit Notch in brake shoe unit End of slide spring 13 Screw on the stop nut to adjust so that the hub shell can be turned smoothly without any play After adjusting secure the stop nut with the left hand lock nut TL 7S20 Tightening torque 12 20 Nm 120 200 kgfcm O Left hand lock nut Stop nut 14 Turn the sprocket side upside down and hold the two bevelled surfaces of the hub axle on the brake arm in a vice and install the dust cap to hub shell Check After installing right hand dust cap A to the hub shell turn the hub shell counterclockwise and check that it turns smoothly If the hub shell does not turn smoothly re install right hand dust cap A This completes the assembly of the Inter 3 hub Note Apply a coating of internal hub grease to the inside of right hand dust cap A to waterproof it Push right hand dust cap A firmly onto the hub shell until it clicks Apply grease GNI Y 041 20800
4. liberal coating of internal in a vice hub grease Install ball retainer K while Be careful not to bend ball pressing in pawl A 1 and pawl retainer K C on the driver unit with a screwdriver Pawl A 1 KL Screwdriver Pawl C Ball retainer K Q diN Y 041 20800 While pushing the two pawls B on the ring gear unit with your fingers push the two pawls A 1 and the two pawls C on the driver unit one by one with a screwdriver and E install the ring gear unit to a Internal ratchet mechanism the driver unit i Tai Ring gear unit Pawl B Driver unit Note Check that pawl B is not hooked onto the clutch Check that pawls A 1 and the pawls C are engaged with the ratchet mechanism in the ring gear unit Ring gear unit Clutch Driver unit Screwdriver Pawl A 1 Pawl C Turn the ring gear to the left and right while pushing down on the sprocket and check that it has an angle of play of approximately 10 Apply a liberal coating of internal hub grease to the gear ae Ring gear unit inside the ring gear unit Approx 10 of play 7 Check Check that the stop ring groove of the hub axle is visible from the edge of the carrier unit after the carrier unit has been installed Engage the teeth of the planetary gear of the carrier unit with the teeth of the ring gear unit while turning the carrier unit slightly to the left and right and pushing it onto the ring gear
5. unit Note Apply a liberal coating of internal hub grease to the planetary gear in 4 places inside the carrier unit Teeth of carrier unit planetary gear Teeth of ring gear unit Om GiT Y 041 20800 2 Note After inserting the stop ring check that there is a small amount of play in the carrier unit in the vertical direction While pushing down carrier unit 2 insert the stop ring into the hub axle groove at the surface of carrier unit 2 If there is no vertical play and the carrier unit turns stiffly turn the internal assembly upside down and hold the hub axle in a vice Then loosen the right hand lock nut and the right hand cone with dust seal to adjust until there is sufficient play Stop ring Carrier unit 2 Check Check to be sure that the stop ring groove on the hub axle is visible from the edge of carrier unit 2 while carrier unit 2 is pushed down Stop ring groove of hub axle should be visible While turning the hub shell counterclockwise slightly place it onto the internal assembly Hub shell lt Internal assembly 10 Place ball retainer L onto the brake arm unit Note Be careful of 9 4 the setting direction Apply a liberal coating of internal hub grease Ball retainer L gt a a Brake arm unit gt GNI Y 041 20800 11 Install the brake shoe unit to the brake arm unit so that the four indents of the brake shoe unit
6. 10 Spare parts list SHIMANO NEXUS 3 SPEED HUB w Coaster Brake SG 3C41 Inter 3 Hub Left Side Non turn Washer Spec Q TY SS A zs O FL Sati ITEM NO SHIMANO CODE NO Y 35U 98010 33R 98020 35U 98020 33R 90600 325 32000 33R 90700 33R 90800 33R 90220 33R 98050 33R 98040 35U 98030 33R 90400 33R 90210 33R 90500 321 39040 325 30100 220 15010 33Z 20200 33R 49010 33R 49020 33R 48010 35U 98040 33F 98090 33F 98100 75M 06000 317 27200 33R 90200 33R 05000 33R 52001 322 03200 Y 73T 21830 Y 73T 21930 Y 73T 22030 Y 73T 22130 73T 22230 Y 73T 22330 321 20010 Y 33R 98080 Y 33S 98180 Y 33S 95100 27 Y 33S 98010 _ ice oO oO gt NIO N ojal A Jjo Mm gt O N 0j BY GO NM DESCRIPTION Internal Assembly Axle Length 168 mm Internal Assembly Axle Length 175 mm Internal Assembly Axle Length 178 mm Brake Shoe Unit Stop Ring 9 mm Carrier Unit Ring Gear Unit Ball Retainer K 7 32 x 10 Axle Unit Axle Length 168 mm Axle Unit Axle Length 175 mm Axle Unit Axle Length 178 mm Driver Unit Ball Retainer J 7 32 x 8 Right Hand Cone w Dust Seal Right Hand Lock Nut 4 5 mm for Axle Length 168 mm 178 mm Right Hand Lock Nut 9 9 mm for Axle Length 175 mm Flange Nut Non turn Washer 2 Yellow Left Hand Lock Nut 3 mm for Axle Length 168 mm 178 mm Left Hand Lock Nut 5 mm for Axle Length 175 mm Stop Nut 3 mm Brake Arm Unit
7. Brake Arm Clip Unit 5 8 Brake Arm Clip Unit 3 4 Clip Screw M6 x 16 Clip Nut Ball Retainer L 3 16 x 14 Right Hand Dust Cap A Right Hand Dust Cap B Sprocket Wheel 16T Black Sprocket Wheel 18T Black Sprocket Wheel 19T Black Sprocket Wheel 20T Black Sprocket Wheel 21T Black Sprocket Wheel 22T Black Sprocket Wheel 23T Black Snap Ring C Push Rod 81 85 mm for Axle Length 168 mm Push Rod 86 85 mm for Axle Length 175 mm 178 mm Bell Crank I Unit Cable Adjusting Bolt amp Nut Bell Crank Body Fixing Bolt Bell Crank Cover amp Fixing Screw Inner Cable Fixing Bolt Unit Internal Hub Grease Net 100g Internal Hub Grease For coaster brake also a i M Bell Crank I 11 Spare parts list SHIMANO NEXUS 3 SPEED HUB w Coaster Brake SG 3C41 px Inter 3 Hub Left Side Non turn Washer Spec ITEM SHIMANO zi a suso Y 33R 98020 2 33R 90600 ase mae om o 33R 90210 i rr z Y 322 03420 yar 03520 03520 23 yeaa 0320 03620 S0 0o00 60000 S0 e000 60100 e 60200 26 Internal Hub Grease For coaster brake also i gt Bell Crank I sy DESCRIPTION Internal Assembly Axle Length 168 mm Internal Assembly Axle Length 175 mm Brake Shoe Unit Stop Ring 9 mm Carrier Unit Ring Gear Unit Ball Retainer K 7 32 x 10 Axle Unit Axle Length 168 mm Axle Unit Axle Length 175 mm Driver Unit Ball Retainer J 7 32 x 8 Right Han
8. d Cone w Dust Seal Right Hand Lock Nut 4 5 mm for Axle Length 168 mm Right Hand Lock Nut 9 9 mm for Axle Length 175 mm Cap Nut 3 8 Non turn Washer 2 Yellow Left Hand Lock Nut 3 mm for Axle Length 168 mm Left Hand Lock Nut 5 mm for Axle Length 175 mm Stop Nut 3 mm Brake Arm Unit Brake Arm Clip Unit 5 8 Brake Arm Clip Unit 3 4 Clip Screw M6 x 16 Clip Nut Ball Retainer L 3 16 x 14 Right Hand Dust Cap A Right Hand Dust Cap B Sprocket Wheel 16T Silver Sprocket Wheel 18T Silver Sprocket Wheel 19T Silver Sprocket Wheel 20T Silver Sprocket Wheel 21T Silver Sprocket Wheel 22T Silver Sprocket Wheel 23T Silver Snap Ring C Flange Nut Push Rod 81 85 mm for Axle Length 168 mm Push Rod 86 85 mm for Axle Length 175 mm Bell Crank I Unit Cable Adjusting Bolt amp Nut Bell Crank Body Fixing Bolt Bell Crank Cover amp Fixing Screw Inner Cable Fixing Bolt Unit Internal Hub Grease Net 100g SHIMANO www shimano com SHIMANO AMERICAN CORPORATION One Holland Irvine California 92618 U S A Phone 1 949 951 5003 Fax 1 949 768 0920 Specifications are subject to change for improvement without notice This publication is printed on recycled paper MA35UA Sep 2004 Shimano Inc UCI official neutral technical support
9. ile pushing pawls C with your fingers A Note Do not disassemble the axle unit otherwise it may cause problems with gear shifting This completes the disassembly of the Inter 3 hub 1 Hold the two bevelled surfaces of the axle unit on the gear side in a vice Axle unit gt Gear ee ae Note Do not damage the threads of the hub axle Vice SS 2 While pushing the two pawls i C on the driver unit with your fingers place the driver unit onto the axle unit Note Be careful not to let pawl pin B fall out h Driver unit While pushing pawls C with your fingers lt Pawl C Pawl A 1 Cus GitZ93 Y 041 20800 Note Be careful of J 4 the setting direction Apply a liberal coating of internal 3 Place ball retainer J onto the driver unit A hub grease Ball retainer J Axle unit with driver unit Cm du79 y 041 20800 4 Screw the right hand cone with dust seal onto the hub axle as far as it will go and then secure it by tightening the right hand lock nut Install the right hand lock nut and the right hand cone with dust seal onto the hub axle c TL HS20 Right hand lock nut ee Axle unit with driver unit Right hand cone with dust seal 5 di Turn the axle unit with driver unit upside down and hold the two bevelled surfaces of the axle on the sprocket side Note Be careful of 9 4 the setting direction Apply a
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