Cable routing

Shifter cables

The shifter cables each comprise of a spirally wound steel outer housing (diameter 4.7mm) with integrated nylon liner, a 1.1mm stainless-steel shifter cable with cylindrical nipple (diameter 4x5mm) and four sealed cable housing ferrules.

The cable housing ferrule reduces the chances of dirt and moisture entering both the shifter cables and twist shifter.
 

When mounting, make sure the shifter cable housings are not pinched before mounting the ferrules. This will ensure the cables are well protected from dirt and moisture.

Attention

The shifter cables are to be mounted dry (free from oil or grease). The nylon-stainless steel combination runs service free.

Cable Manager Kit

A special Cable Manager Kit (Art. #5201) is available consisting of 3 cable ties, 2 double sided sticky tabs and 2 guides that secure the SPEEDHUB shifter cables to the frame. One kit will hold a cable secure in two positions - a great way to secure cables to frames without brazed-on guides.

Alternativ kann man die beiden Halterungen hintereinander anbringen. Dadurch verlaufen die Schaltzüge dichter aneinander, man benötigt jedoch zwei der langen Kabelbinder.

Pointer

The spiral housing of the shifter cables gives a positive feeling to the gear change through the twist shifter. Other shifter cable housings (e.g. SIS cables) reduce this positive Feeling.

    

    

Internal gear mech

Cable routing via the brake boss

With the internal gear mech the shifter cables run from the twist shifter to the cable guide, which can be mounted to the left hand brake boss or clamped to the left hand chainstay. The internal gear mech involves the use of two hub cables. They must be connected to the shifter cables by the use of bayonet connectors which allow a quick separation for wheel removal.

The internal gear mech is not compatible with the use of a rear disc brake as the hub cables and bayonet connectors may rub on the disc.

The diagrams show examples of the internal gear mech routed via the brake boss with standard, OEM and OEM2 axle plates.

The hole pattern in the axle plate allows the adjustment of the gear mech in steps of 30°. Therefore, an optimum cable routing can be achieved for nearly all frame types.

Attention

The minimum distance from the axle to the cable guide is 240mm.

When pulling the shifter cable 1, lower gears are engaged. When pulling the shifter cable 14, higher gears are engaged. Gear cable 1 lies to the front of the twist shifter as well as to the front of the cable guide. Gear cable 14 lies to the back of the twist shifter as well as to the back of the cable guide.

When routing the shifter cables of the internal gear mech along the top tube, the cable guide is mounted to the brake boss. Prior to routing the cables, the cable guide must be secured to the left side brake boss. The original brake boss securing bolt must be removed (this will be replaced with the new bolt supplied). All other parts of the brake remain in place.

Cable guide 13°:
A  Cable guide
B  Mounting bolt (M6x25)
C  Cable adjuster (2x)
D  Spacer
Spacer D must be used when:
- Mounting bolt is too long for securing to the brake boss
- Cable guide A interferes with the smooth running of the brake operation (eg parallel push linkage certain types of V-brake system).

 

Fit the mounting bolt through the cable guide (and spacer, when necessary) and screw into the brake boss with a little grease (4mm allen key, tightening torque: 6Nm/51in.lbs.). Hold the cable guide in position with a 13mm wrench.

With a little grease on the bolt, screw the cable stop onto the brake boss. The cable stop should be held in position with a 13mm wrench during this process. This ensures that the cable adjusters face in the correct position once the cable stop is secure.

Thread shifter cable 1 from the twist shifter into the cable adjuster 1 at the cable guide. Do the same for shifter cable 14 into cable adjuster 14.

Select gear #14. Do this by holding the rear hub cable 14 by the bayonet connector and pulling this through all the gears until the end stop is reached (end position = gear #14).

Pull both shifter cables to the end stop in turn to make sure that the cable housings sit correctly in the cable stops. When pulling shifter cable 14, the twist shifter should turn in the direction of gear indicator #1. When pulling shifter cable 1 the twist shifter should turn in the direction of gear indicator #14. Should this not be the case, switch over the cables within the cable guide.

Pointer

The shifter cable measurement tool (Art. #8506) can be used for easy and precise measurement of the shifter cable length.

The following steps show how to correctly measure the shifter cable length without the help of this special tool.

Pull shifter cable 1 to the end stop. The twist shifter will turn over gear indicator #14 to its end stop and shifter cable 14 gets pulled back.

Pull shifter cable until the gear indicator #14 on the twist shifter meets up with the red dot of the twist shifter Body.

Pointer

Both cable adjusters must be unscrewed approx. two turns from the cable guide.

Pull hub cable 14 out by the bayonet connector until its end stop and hold it up against shifter cable 14. Cut the shifter cable at the point level with the top of the bayonet connector.

Unscrew both the headless screws of the female connector by approx. 2mm. Place the female connector over the male bayonet connector.

Thread the shortened shifter cable 14 fully into the hole of bayonet connector 14 (approx. 10mm deep).

Tighten up one of the headless screws until it is flush with the outside of the female connector. Now tighten up the other headless screw. (M4x4 - 2mm allen key, tightening torque 1.5Nm/12in.lbs.).

Pull hub cable 1 out by the bayonet connector until its end stop. The connected shifter cable 14 will automatically be pulled in the other direction. Pull shifter cable 1 tight, so that the cable is tensioned and hold it up against hub cable 1. Cut the shifter cable at the point level with the top of the bayonet connector.

Open the male/female connectors of cables 14, so that joining shifter cable 1 with a female connector becomes easier. Place the female connector over the male bayonet connector and thread the shortened shifter cable 1 fully into the hole of the bayonet connector 1 (10mm deep), tighten up the headless screws. Rejoin the disconnected cables 14.

Turn the twist shifter back and forth several times to make sure that the shifter cables are sitting correctly within the cable guides. For a lighter shifting, set the cable tension (by the use of the cable adjusters), so that the twist shifter has about 2mm play. Winding out the cable adjusters increases the shifter tension, winding the cable adjusters in decreases the shifter Tension.

Check that all 14 gears are available (14 gears = 13 clicks of the twist shifter) by rotating the twist shifter forwards to the end stop (gear #14) and backwards to the end stop (gear #1).

Cable routing via the chainstay

When routing the shifter cables via the chainstay, the 0° cable guide (Art. #8260) must be mounted at a minimum distance of 240mm away from the hub's axle. This should be mounted in a position, so that the hub cables run in the straightest line possible towards the shifter cables.

The diagram shows an example of the internal gear mech routed via the chainstay with the standard axle plate and long torque arm using the 0° cable guide and frame clamp.

By pulling hub cable 1, the gearbox shifts gears in direction of gear #1 (smaller gears). By pulling hub cable 14, the gearbox shifts gears in direction of gear #14 (larger gears). Hub cable 1 lies in the lower position at the gearbox and at the front position on the twist shifter. Hub cable 14 lies in the higher position at the gearbox and at the rear position on the twist shifter. The connecting of the shifter cables to the hub cables is explained in chapter 7.2.1

External gear mech

With the external gear mech the shifter cables run directly from the twist shifter to the cable box. There is no separate cable stop necessary. For quick and easy removal of the rear wheel, the cable box can be removed from the external transfer box. All disc brake versions (DB) of the Rohloff SPEEDHUB 500/14 are equipped with the external gear mech. The hole pattern in the axle plate allows the adjustment of the gear mech in steps of 30°. Therefore, an optimum cable routing can be achieved for nearly all frame types.

Mounting options

Mounting options with external gear mech and the standard axleplate with long torque arm

Mounting options with external gear mech and an OEM axleplate

Mounting options with external gear mech and an OEM2 axleplate

Cable routing via the chainstay

By pulling hub cable 1, the gearbox shifts gears in direction of gear #1 (smaller gears). By pulling hub cable 14, the gearbox shifts gears in direction of gear #14 (larger gears). Hub cable 1 lies in the lower position at the cable box and at the front position on the twist shifter. Hub cable 14 lies in the higher position at the cable box and at the rear position on the twist shifter.

Secure the cable box to the external transfer box (which should be in the correct, preadjusted position) with the knurled headed screw. Insert the two cable adjusters into the cable box. The diagram shows the gear transfer box mounted in line with an OEM axle plate but the type and position of axle plate can vary from that illustrated.

Route the shifter cables from the twist shifter in the direction of the cable box and cut the housing to the appropriate length and mount a cable housing cap on each end.

Insert the shifter cable completely into the cable housing and check that the cable housing is sitting correctly in all cable stops. Do not mount the cable adjuster yet.

Pull shifter cable 1 completely out of the cable housing and cut the cable at a distance of 200mm from the end of the housing cap. Do the same for cable 14.

Pointer

The 200mm measuring pipe (Art.No. 8712) can be used for quick and precise measurement of the shifter cables.

Insert the shifter cables into the cable adjusters. Pull out shifter cable 14 as far as possible, the twist shifter will rotate in the direction of end stop 1. Pull out shifter cable 1 as far as possible, the twist shifter will rotate in the direction of end stop 14. To make sure that the gear display doesn't get reversed, check that the lower shifter cable on the twist shifter is fed into the top adjuster on the cable box.

Remove the cable box from the external transfer box. Remove both torx screws (M4x10 - Torx TX20). Remove the cover of the cable box and remove the cable pulley.

Loosen both headless screws approx. three turns (2mm allen key). Insert shifter cable 1 fully into cable pulley hole 1 and shifter cable 14 fully into cable pulley hole 14. Make sure that the front side of the cable pulley is facing upwards during this process (as in the diagram).

Tighten up the headless screw 1 from behind and the headless screw 14 from the front (M4x4 - 2mm allen key, tightening torque 1.5Nm/12in.lbs.).

Wind shifter cable 1 clockwise around the cable pulley (making sure that the cable sits correctly within the cable runs).

Wind shifter cable 14 anticlockwise around the cable pulley (making sure that the cable sits correctly within the cable run). The cable pulley runs must be completely filled by the gear cables.

 

Place the cable pulley with the cable adjusters back into the cable box. Rotate the twist shifter from gear position 1 to gear position 14 and back to check that the cable pulley rotates freely.

With a little grease, use both torx screws (M4x10  Torx TX20) to reattach the cable box cover to the cable box (tightening torque: 3Nm/25in.lbs.).

Turn the hexagonal peg H on the external transfer box J in an anticlockwise direction with the use of an 8mm wrench. This will put the gearbox into gear #14. Lightly grease the brass bearing ready for the cable pulley.

Rotate the twist shifter into gear position 14 and using the two locating pegs C and D, place the cable box over the external transfer box.

Connect the cable box securely to the gear transfer box and tighten up the knurled head screw K. For a lighter shifting between gears, set the cable tension (by the use of the cable adjusters E), so that the twist shifter has about 2mm of play for a lighter shifting between gears.

Cable routing via the top tube

The cutting of the shifter cables, nylon liner and the cable housing as with the mounting of the cable pulley are to be carried out the same as in chapter 7.2.1 (Cable routing via the brake boss).

By pulling hub cable 1, the gearbox shifts gears in direction of gear #1 (smaller gears). By pulling hub cable 14, the gearbox shifts gears in direction of gear #14 (larger gears). Hub cable 1 lies in the front position at the cable box and on the twist shifter. Hub cable 14 lies in the rear position at the cable box and on the twist shifter.

Adjusting the gear display

The gear display is to be found on the body of the twist shifter. The twist shifter rubber itself has the numbers 1 - 14. The gear display can be correctly aligned with the help of the cable adjusters on the cable guide (internal gear mech) or on the cable box (external gear mech).
 

After the cable tension has been correctly adjusted, the gear display can be adjusted by winding one cable adjuster in and the other outwards by equal amounts.

Check that all 14 gears are available (14 gears = 13 clicks of the twist shifter) by rotating the twist shifter forwards to the end stop (gear #14) and backwards to the end stop (gear #1).

Attention

If all 14 gears are not reachable after connecting the cable box to the external transfer box, then the gearbox or the twist shifter were not in gear position 14 while connecting. To correct this, see page 16, paragraph 3.2. "Maintenance and care".