Shimano 600 Right (Rear) Reassembly

I put it off for a day, but now I’m ready to reassemble the 600 Right (rear) shifter.  This is much more complicated than the left (front) shifter, and took more time.  However I did it on my first try and I think you can too.  Maybe I am delusional because I am still in the warm afterglow of finishing the reassembly correctly!  Here are the parts:

I want to answer one quick question I had from a friend: Are all the parts fully disassembled?  No.  In the exploded pictures I have left the pawls, springs and pins on the platforms.  You will need to take them off, clean them, lube them, and reassemble to improve (repair) shifting performance, but this is straightforward.  I will show the process below for one pawl, but it is the same for the rest.  Ok… starting with the primary screw with cross cut we add the pewter colored shift cable stop and align the spring.

I use a small screw driver to load the spring an put it in place.  Next we add the two pewter pawl catches.  These are impossible to add in the incorrect alignment because they have different spline sizes just like a cassette on a rear hub.

Next comes the platform for the long release pawls.  This is the only piece to be added from the left.  Again I load the spring with a small screwdriver.

Great, now we add the brass washer and the axle platform.  Notice that there is a washer and clip to hold the washer in place.

Once this clip is in place the first spring is nicely held in position.  Ok… now we add the black release ring, centering washer and brass washer.

The release spring is loaded onto the black release ring as shown below.

Next comes a sliver colored platform that has tabs which catch the release spring.  I took a z-axis shot to clarify the alignment.

The next platform contains a pawl, spring and clip.  I show them disassembled below, so you can the post you must lube before reassembly.  The pawls should spring quickly and tightly on the pivot posts.  Most shifters I have  fixed have not functioned because these pawls were slow to swing into place.  Once you have disassembled and thoroughly cleaned and lubed these posts you will notice that the shifters shift like new.  Cleaning the posts and lubing them is a big reason why. After the silver platform with the pawl comes a centering washer.

Next you must add the pawl spring.  This must be loaded so that it pushes down on the pawls.  There is a grove that shows you where the spring integrates with the pawls.

After the spring is a sliver platform that aligns with the pivot post of the pawl spring.  You see that the platform is correctly aligned when the pivot post neatly fits into the platform and prevents the pawl spring from slipping off.

Now we will add the return shift arm.  You must hold the pawl on the shift arm out of the way to assemble the arm.  Remember to have the pawl loaded with potential energy using the spring.

Here are a couple of shots for you to examine the correctly assembled shifting mechanism with the release arm in position.

Now we need to load the return spring.  This is much easier than on the left (front) shifter.  Once the spring is in place I added the two washers, then grabbed the loose end of the spring with needle nose pliers and correctly positioned it.

 

Notice that the return arm spring washer has a bump that aligns with the shifting mechanism.  Ensure this is aligned, and ensure that the return pawl spring post is still in the  silver platform from above.  If these are not in place then your shifter is not correctly aligned, will not work, and may brake or bend a piece.

Once you ensure that everything is aligned add the brake cable stop holder and screw in the primary fixing bolt.  I use needle nose pliers.

Next we add the upshift lever with the phillips screw, and add the brake cable stop.

  

At this point you can test the shifter to ensure everything is working correctly.  Once you confirm functionality we add the shifter face and the handle.  Don’t forget the washer that protects the return spring in the shifter face.  You will need an 8mm socket driver.

Finally we are ready to add the handle.  Position the two black bushings, and align the brake lever spring.  Slide the handle into position and use a metal punch or screw driver to correctly position the brake lever spring.  Than add the pivot pin and fix it in place with the 2.5 mm hex screw.

That is it, you are done!  Time to take a final look and then test.

Clean and crisp, this shifter sounds and works perfectly.

http://youtu.be/pxs5QkfBFhQ