Step by step guide; Adjusting a Shimano Inter 3 with a click box
The Shimano Nexus 3 gear system consists of several parts:
the shift lever on the handlebars, the inner and outer cables, the click box mounted on the axle, the push rod in the axle and the gear hub in the wheel.
The gears can only be adjusted by manually tensioning the cable, by using the cable adjuster screw on the click box, and sometimes by using the cable adjuster screw on the shift lever, depending on the type of shift lever.
Shimano Nexus 3 shifters come in a number of different versions and they all look slightly different.
They all work the same though, and are all interchangeable.
A few brands, like Batavus and Sunrace, have manufactured shift levers that are also suitable for use with Shimano Nexus 3 gear hubs. Those are interchangeable as well.
Another part of the gear system that may be different, is the push rod or shifting rod.
The push rod is available in different lengths and should be selected using the total length of the gear hub axle.
The Shimano Nexus 3 push rod is available in three different lengths: 81.85mm, 86.85mm and 90.75mm.
Each push rod length is suitable for different axle lengths.
These lengths are divided as follows:
81.85mm for 168 / 170mm axles
86.85mm for 177 / 188mm axles
90.75mm for 189 / 192mm axles
Step 1 : Adjustment with the cable adjuster screw on the click box
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There are two ways to adjust the Shimano Nexus 3. On the push rod, you will find a thin red stripe and a slightly thicker yellow stripe. If the position of the click box is slightly off because of an added axle ring, the yellow indicator stripe may also deviate slightly from its standard position. In this case, the red indicator stripe is leading.
To adjust the shift lever, you will first need to put it in second gear. (1)
Use the adjuster screw on the click box to adjust the gear. (2)
Use a 10 mm spanner to remove the lock nut from the adjuster screw.
The red indicator stripe should be aligned with the end of the axle. (3)
Twist the adjuster screw to the left to turn the indicator inwards.
Twist the adjuster screw to the right to turn the indicator outwards.
Step 2 : Adjustment with the cable adjuster screw on the click box
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The yellow indicator stripe should be positioned exactly between the two white stripes. (2)
Twist the adjuster screw to the left to turn the indicator inwards.
Twist the adjuster screw to the right to turn the indicator outwards.
Once you’re satisfied with the gear adjustment, tighten the lock nut again.
Step 3 : Manual adjustment
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Use the 10 mm spanner to loosen the bolt on the back of the click box. (1)
Use a small Phillips screwdriver to remove the black cover on the bottom of the click box. (2)
You can now separate the cable from the click box by undoing the cable clamp, using an 8mm spanner. (3)
Step 4 : Manual adjustment
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Make sure the shift lever is in first gear and the cable adjuster screw is about halfway inside the click box.
Once the click box has been opened up, the bottom of the cable clamp should be visible. (1)
The cable clamp can be undone with an 8mm spanner.
Make sure the cable adjuster screw is about halfway inside the click box before pulling the inner cable out as far as possible, using pincers.
With the upside-down click box in hand, push the indicator as far to the right as possible, while the inner cable is mounted using the cable clamp. (1)
A more precise adjustment with the cable adjuster screw may be needed. (2)
When the shift lever has a cable adjuster screw, it’s also possible to adjust the gears while cycling. The cable adjuster screw works the same way as the cable adjuster screw on the click box, the only difference being that the bolt on the shift lever does not have a lock nut.
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Step 1 : Adjustment with the cable adjuster screw on the click box
