BOX ONE 11 SPEED PUSHPUSH SHIFTER Technicians Service Manual

Transcription

1 BOX ONE 11 SPEED PUSHPUSH SHIFTER Technicians Service Manual All trademarks remain property of their respective holders. Their use in no way indicates any relationship between Box Components and the holders of said trademarks. Patents are pending. 2016, Box Components. REV.001

2 SERVICE & ADJUSTMENT OPERATIONS The BOX One PushPush Shifter features a single trigger (patent pending) function with two unique motions to initiate shifting. Push the lever forward to shift from a small cassette cog to a larger cassette cog. Push the lever inward to shift from a large cassette cog down to a smaller cassette cog. PARTS & TOOLS REQUIRED ALLEN WRENCH 4mm CABLE CUTTERS SAFETY GLASSES GLOVES TORQUE WRENCH With : 4mm Hex Bits MAINTENANCE Do not use a pressure washer or harsh chemicals to clean this product. Use only mild soap and water, denatured alcohol or mild degreaser. ONLINE WARRANTY For the full Box Components warranty policy, visit WARNING IT IS RECOMMENDED THAT THIS PRODUCT IS INSTALLED BY A CERTIFIED PROFESSIONAL BICYCLE TECHNICIAN. IF YOU ARE UNSURE OF THE CORRECT INSTALLATION, PLEASE CONTACT YOUR LOCAL BICYCLE DEALER/SHOP. PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE USE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE. NOTE: Incorrect installation, disassembly or modification of this product will void any warranty and may lead to injury/death. This product s warranty does not cover natural wear and tear due to normal use and age and/or crash/impact damage. When operating the shift lever, ensure that the cranks are rotating forwards while shifting, do not back pedal. Prior to riding, always give your bicycle a safety inspection, check for strange noises, loose components etc. Do not use a pressure washer or harsh chemicals to clean this product. Use only mild soap and water. Always wear a helmet and wear the appropriate safety wear for the conditions that you ride in. THIS PRODUCT IS PATENT PENDING. Note: Product specifications are subject to change without notice for improvement purposes Box Components Page.01

3 PUSHPUSH SHIFTER INSTALLATION 1. Remove the handlebar grip and brake lever assembly, clean handlebar. 2. Slide the BOX PushPush assembly and clamp on to the handlebar. 3. Rotate the shifter assembly to your preferred position and tighten the socket head clamping screw using 4mm Hex wrench (tighten max Nm). 4. Push the shift lever inward until it is in the highest gear position. 5. Remove rubber plug from the cable access port. 6. To install the shifter cable, feed the cable through the cable access port until the cable head is seated inside the shifter housing. Re-install the cable access port plug (replace if damaged or missing). NOTE: CABLE CAN BE INSTALLED WITH ASSEMBLY IN PLACE OR BY REMOVING THE ASSEMBLY FROM ITS BAR CLAMP USING A 4MM HEX WRENCH. Page.02

4 7. Install the rear shifter cable through the housing to the rear derailleur. (use 4mm Hex wrench if Box One Rear Derailleur) 8. Following the derailleur manufacturer s installation instructions, adjust the gear indexing. 9. From the rear derailleur s shifter cable clamp, retain a minimum of 30mm of shifter wire and trim with cable cutters and install a new cable end cap and crimp to prevent cable fraying. 10. Re-install brake lever assembly (if previously removed) and tighten to the manufacturer s recommended torque specification. Re-install handlebar grip. WARNING NEVER INSTALL HANDLEBAR GRIPS USING LUBRICANTS OR SOLVENTS. FOLLOW THE GRIP MANUFACTURER S INSTALLATION RECOMMENDATIONS AND NEVER RIDE WITH LOOSE OR SLIPPING GRIPS. PUSHPUSH REMOVAL AND CABLE RENEWAL 1. Push the shift lever inward until it is in the highest gear position. 2. Remove cable from rear derailleur cable clamp (use 4mm Hex wrench if Box One Derailleur) and remove the outer cable housing from the derailleur cable. Check the condition of the outer cable housing, replace if damaged. Page.03

5 3. Use a 4mm Hex wrench to remove the shifter assembly from its bar clamp. 4. Remove rubber plug from the cable access port. 5. To remove the cable end from the shifter, push the cable from the barrel adjuster until the cable head exits the cable access port. Remove the cable by pulling the cable head, and discard the old cable. 6. To install a new cable, feed the cable through the cable access port until the cable head is seated inside the shifter housing. Re-install the cable access port rubber port (replace if damaged or missing) REMOVE CABLE INSTALL CABLE 7. Re-install the outer cable housing and Install the rear shifter cable to the rear derailleur (use 4mm Hex wrench if Box One Rear Derailleur) 8. Following the rear derailleur manufacturer s installation instructions, adjust the gear indexing. 9. From the rear derailleur s shifter cable clamp, leave a minimum of 30mm of shifter wire and trim with cable cutters and install a new cable end cap and crimp to prevent cable fraying. PUSHPUSH SHIFTER LEVER REPLACEMENT 1. Remove the two shift lever screws using a 2.5mm Hex wrench. 2. Install new lever, re-install the two mounting screws and tighten to 3-4 Nm torque using 2.5mm Hex wrench. Page.04

6 PUSHPUSH SHIFTER INTERNAL CLEANING 1. Remove shifter from its bar clamp and remove the shift cable (see installation and cable renewal section for instructions) 2. To remove the shifter housing, remove the shifter lever (see shifter lever replacement instructions) and remove the four mounting screws using a #1 Phillips screwdriver. (See A) 3. Use compressed air first to remove dirt and dust from the internal shift mechanism. (See B) 4. Remove the shift mechanism from the shifter housing and clean with denatured alcohol. WARNING IF THE SHIFTER S INTERNAL RATCHET STACK MECHANISM REQUIRES DISASSEMBLY, PLEASE REFER TO YOUR NEAREST BOX SERVICE CENTER. DISASSEMBLY OF THE RATCHET STACK WILL VOID ANY WARRANTY. 5. Use mild soap and water to clean the shifter housing. 6. Apply only a small amount of lubricant to the shift mechanism assembly. (See C) 7. Re-install shifter housing and tighten the four mounting screws to 2-3 Nm. 8. Re-install shifter lever with its two mounting screws and tighten to 3-4 Nm torque using 2.5mm Hex wrench. 9. Re-install the shifter cable and remount the shifter to its bar clamp (see installation and cable renewal section for instructions). Page.05