Disc Brake System

Disc Brake System
SI-8FF0A-002-00
■ Wheel spoke lacing
General Safety Information
WARNING
• Downhill bicycle riding and freeriding are inherently dangerous activities. There
is a risk of being involved in an accident that can result in a serious injury or
even death. It is strongly recommended that riders wear protective head and
body gear and perform thorough safety checks of their bicycles before riding.
Please remember that you are riding at your own risk and that you have to
consider your experience and your skills very carefully.
• The M810 brake system is designed for downhill bicycle riding and freeriding, and its
braking performance is much higher than for other brakes. Riders must become
accustomed to the higher performance of this brake in a controlled environment before
riding the bicycle as described above. If you do not familiarize yourself with the
performance level of this brake, you may be involved in an accident that could result in
serious injury or even death.
Furthermore, the performance of the brakes makes them unsuitable for riding on city
streets. If riding the bicycle on streets is unavoidable, take extreme care while doing so.
• Please use extra caution to keep your fingers away from the rotating disc brake rotor
during installing or servicing the wheel. The rotor is sharp enough to
inflict severe injury to your fingers if caught within the openings of
moving rotor.
• The calipers and rotor will become hot when the brakes are operated, so
do not touch them while riding or immediately after dismounting from the bicycle, otherwise
you may get burned. Check that the brake components have cooled down sufficiently
before attempting to adjust the brakes.
• The required braking distance will be longer during wet weather.
Reduce your speed and apply the brakes early and gently.
• If the road surface is wet, the tires will skid more easily. If the tires skid, you may fall off the
bicycle. To avoid this, reduce your speed and apply the brakes early and gently.
• Always make sure that the front and rear brakes are working correctly before you ride the
bicycle.
• Be careful not to allow any oil or grease to get onto the rotor and brake pads, otherwise the
brakes may not work correctly.
• If any oil or grease do get on the pads, you should replace the pads. If
any oil or grease gets on the rotor, you should clean the rotor. If this is
not done, the brakes may not work correctly.
• Before riding the bicycle, check that the thickness of each pad is 0.5
mm or more.
• Vapor lock may occur if the brakes are applied continuously. To relieve
this condition, momentarily release the lever.
Vapor lock is a phenomenon in which the oil inside the brake system becomes heated,
which causes any water or air bubbles inside the brake system to expand. This can then
result in a sudden increase in the brake lever stroke.
• Use only genuine Shimano mineral oil. If other types of oil are used, it may cause problems
with brake operation, and cause the system to be unuseable.
• Be sure to use only oil from a freshly-opened container, and do not re-use oil which has
been drained from the bleed nipple. Old oil or already-used oil may contain water which
could cause vapor lock in the brake system.
• Be careful not to let water or air bubbles to get into the brake system, otherwise vapor lock
may occur. Be particularly careful when removing the cover of the reservoir tank.
• If cutting the brake hose in order to adjust the length of the hose, or when changing over
the brake hose from left to right or vice versa, be sure to bleed the air from the hose by
carrying out steps (5), (8) to (10) given in “Adding mineral oil and bleeding air” in the
Service Instructions.
• When turning the bicycle upside down or on its side the brake system may have some air
bubbles inside the reservoir tank which are still there when the reservoir tank cover is
replaced, or which accumulate in various parts of the brake system when it is used for long
periods. The M810 disc brake system is not designed to be turned upside down. If the
bicycle is turned upside down or on its side, the air bubbles inside the reservoir tank may
move in the direction of the calipers. If the bicycle is ridden in this condition, there is the
danger that the brakes may not operate and a serious accident could occur.
If the bicycle has been turned upside down or on its side, be sure to operate the brake
lever a few times to check that the brakes operate normally before riding the bicycle. If the
brakes do not operate normally, adjust them by the following procedure.
< If brake operation is sluggish when the lever is depressed >
Set the brake lever so that it is parallel to the ground, and then gently depress the brake
lever several times and wait for the bubbles to return to the reservoir tank. It is
recommended that you then remove the reservoir tank cover and fill the reservoir tank
with mineral oil until no bubbles remain.
If the brakes still operate sluggishly, bleed the air from the brake system.
(Refer to "Adding the mineral oil and bleeding air".)
• If fluid leaks occur, immediately stop using the brakes and carry out the appropriate
repairs. If you continue riding the bicycle while fluid is leaking, there is the danger that the
brakes may suddenly stop working.
• If the quick release lever is on the same side as the rotor, there is the danger that it may
interfere with the rotor, so check that it does not interfere.
• It is important to completely understand the operation of your bicycle's brake system.
Improper use of your bicycle's brake system may result in a loss of control or an accident,
which could lead to severe injury. Because each bicycle may handle differently, be sure to
learn the proper braking technique (including brake lever pressure and bicycle control
characteristics) and operation of your bicycle. This can be done by consulting your
professional bicycle dealer and the bicycle's owners manual, and by practicing your riding
and braking technique.
• If the front brake is applied too strongly, the wheel may lock and the bicycle may fall
forward, and serious injury may result.
• The M810 disc brakes are designed for optimum performance when used in combination
with the BR-M810 (calipers), BL-M810 (brake lever), SM-RT79/M/L (rotor) and Shimano
pad unit.
• Shimano disc brake systems are not compatible with tandem bicycles. Because tandem
bicycles have a high overall weight, the load on the brake system increases during brake
operation. If hydraulic disc brakes are used with tandem bicycles, the oil temperature will
become too high and vapor locks or ruptures in the brake hoses may occur, and this will
cause the brakes to fail.
Technical Service Instructions
• Obtain and read the service instructions carefully prior to installing the
parts. Loose, worn or damaged parts may cause the bicycle to fall over and
serious injury may occur as a result. We strongly recommend only using
genuine Shimano replacement parts.
• Read these Technical Service Instructions carefully, and keep them in a safe
place for later reference.
■ Handling the mineral oil
• Use safety glasses when handling, and avoid contact with eyes. Contact with
eyes may result in irritation.
In the event of eye contact, flush with fresh water and seek medical
assistance immediately.
• Use gloves when handling. Contact with skin may cause a rash and
discomfort.
In the event of skin contact, wash well with soap and water.
• Inhalation of oil mist or vapors may cause nausea. Cover nose and mouth
with a respirator type mask and use in a well ventilated area.
If mist or vapor is inhaled, go immediately to an area with fresh air. Cover up
with a blanket. Stay warm and stable and seek professional medical advice.
• Do not drink. May cause vomiting or diarrhea.
• Keep out of reach of children.
• Do not cut, heat, weld or pressurize the oil container, as this may cause
explosion or fire.
• Disposal of Used Oil : Follow local county and/or state codes for disposal.
Use care when preparing oil for disposal.
• Directions : Keep the container sealed to prevent foreign objects and
moisture from getting inside, and store it in a cool, dark area
away from direct sunlight or heat.
Rotor
• When using the special tool (TL-FC36) to remove and install the rotor
mounting ring, be careful not to touch the outside of the rotor with your
hands. Wear gloves to protect your hands from getting cut.
Note
• In order to increase the braking force, the BR-M810 calipers utilize pistons
(4) and they have a narrow gap between the rotor and the pads. Because of
this, the rotor and the pads may sometimes interfere with each other.
• If the brake caliper mounting boss and the dropout are not parallel, the rotor
and caliper may touch.
• When the bicycle wheel has been removed, it is recommended that pad
spacers should be installed. The pad spacers will prevent the piston from
coming out if the brake lever is depressed while the wheel is removed.
• If the brake lever is depressed without the pad spacers installed, the pistons
will protrude further than is normal. Use a flat-tipped screwdriver or similar
tool to push back the brake pads, while being careful not to damage the
surfaces of the brake pads. (If the brake pads are not installed, push the
pistons straight back in, while being careful not to damage them.)
If it is difficult to push the brake pads or pistons back, remove the reservoir
tank cover and then try again. (Note that some oil may overflow from the
reservoir tank at this time.)
• Use isopropyl alcohol, soapy water or a dry cloth when carrying out cleaning
and maintenance of the brake system. Do not use commercially-available
brake cleansers or silencing agents, as they can cause damage to parts
such as seals.
• Do not remove the pistons when disassembling the calipers.
• If the rotor is worn, cracked or warped, it should be replaced.
• This product is not warranted against damage resulting from use such as
jumping while riding or if the bicycle falls over, except if such malfunctions
result from non conforming materials or manufacturing methods.
• Parts are not guaranteed against natural wear or deterioration resulting from
normal use.
• For maximum performance we highly recommend Shimano lubricants and
maintenance products.
Hose
■ Installation of the rotor
< Front >
step (1) in "Adding mineral oil".
• SM-RT79L (203mm)
• SM-RT79M (180mm)
• SM-RT79 (160mm)
4. Push the piston back in as far as it will
For international-standard mounts, attach adapters to calipers for post-type mounts.
(Separate front and rear adapters are available.)
CAUTION
When using the special tool (TL-FC36) to remove and install the rotor
mounting ring, be careful not to touch the outside of the rotor with your hands.
Wear gloves to protect your hands from getting cut.
Tool
Rotor installation ring
TL-LR10 / LR15, TL-FC36
Brake lever fixing bolt
Allen key 4 mm
Caliper fixing bolt / Adapter fixing bolts
Allen key 5 mm
SM-DB-OIL
Brake hose fixing bolt
8 mm wrench / Allen key 3 mm
Reservoir tank cover
Phillips screwdriver #1
Cable supporter
Phillips screwdriver #2
Bleed nipple
Socket wrench 7 mm
Piston
1. Loosen the caliper fixing bolts so that the caliper can move sideways, and then install the
adapter to the frame.
2. Depress the brake lever so that the rotor is being clamped by the pads, and then tighten the
caliper fixing bolts.
Please note: specifications are subject to change for improvement without notice. (English)
© Sep. 2010 by Shimano Inc. XBC IZM Printed in Japan.
Snap ring
5. Install the new brake pads, and then
● International standard mounting type
● Post mounting type
< Front >
Adapter
Adapter
fixing bolts
Provisionally install the caliper to the
frame (so that the caliper can move
sideways), depress the brake lever so
that the rotor is being clamped by the
pads, and then tighten the caliper fixing
bolts.
install the pad spacers (red). Make
sure that you do not forget to install the
snap rings at this time also.
Tightening torque:
2 - 4 N·m {18 - 35 in. lbs.}
TL-FC36
< Front >
Rotor fixing lock ring
Pad spacer (red)
Tightening torque:
40 - 50 N·m {350 - 435 in. lbs.}
6. Depress the brake lever several times to
check that the operation becomes stiff.
7. Remove the pad spacers, install the wheel, and then check that there is no interference
between the rotor and the caliper. If they are touching, adjust while referring to
"Installation of the caliper".
Caliper
< Rear >
Rotor
Rotor fixing
lock ring
Tightening torque:
40 - 50 N·m {350 - 435 in. lbs.}
8. After checking the oil level, replace the reservoir tank cover.
9. Return the brake lever to its original position.
Caliper
fixing bolts
< Rear >
TL-LR10 / LR15
■ Adjustment when the pistons are not operating correctly
Adapter
fixing bolts
Caliper
fixing bolts
The caliper mechanism includes four pistons. If these pistons do not operate properly or if
they protrude unevenly, or if the brake pads remain in contact with the rotor, adjust the
pistons by the following procedure.
1. Remove the wheel and the brake pads.
Clean the pistons and surrounding area, and remove the reservoir tank cover.
2. Push the piston back in straight, without bending it. Note that some oil may overflow
from the reservoir tank at this time.
■ Installation of the brake lever (BL-M810)
3. Install the brake pads and the pad spacers (red).
4. Depress the brake lever as far as it will go, and then operate it several more times so
Secure the brake lever as shown in the illustration.
(Check that the brake lever does not interfere
with the shifting lever during operation. Refer to
the Service Instructions for the shifting lever
also. Some types might require the shifting lever
to be installed first, due to the position of the
shifting lever fixing bolts.)
that the four pistons all move to their initial positions.
5. Remove the pad spacers, install the wheel, and then check that there is no interference
between rotor and the calipers. If they are touching, adjust using shims.
Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
6. After checking the oil level, replace the reservoir tank cover.
Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
■ Reach adjustment
Tighten the reach adjustment bolt
(clockwise direction) to make the
reach narrower, and loosen it
(counterclockwise direction) to make
the reach wider.
Either a cap method or a wire ring method can be used to stop the bolts from turning.
Use whichever method is suitable for the front fork and frame.
Brake lever Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
Cap method
< Front >
< Rear >
Post type
Reach
adjustment bolt
Caps
Caps
Caps
When the free stroke adjustment screw
is loosened, the free stroke of the brake
lever will increase, so that you can
adjust it to the desired setting.
Wire ring method
< Front >
< Rear >
Free stroke
adjustment screw
Wire
At brake lever end
At caliper end
Tightening torque:
5 - 7 N·m {44 - 60 in. lbs.}
Tightening torque:
5 - 6 N·m {44 - 53 in. lbs.}
Pad contact
point
Wire
8 mm wrench
This service instruction explains how to use and maintain the Shimano bicycle
parts which have been used on your new bicycle.
For any questions regarding your bicycle or other matters which are not related to
Shimano parts, please contact the place of purchase or the bicycle manufacturer.
Pad
Hose
Contact
Banjo
■ Mineral oil replacement
O-rings
Allen key 3 mm
For C-shaped guides and the usual
type of cable stoppers, use the special
Shimano cable supporter (sold
separately) to secure as shown in the
illustration.
< C-shaped guide >
< Usual type of cable stopper >
Tightening torque:
0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan
go, while being careful not to twist it.
(Note that some oil may overflow from
the reservoir tank at this time.)
Rotor
Mineral Oil
* Service Instructions in further languages are available at : http://techdocs.shimano.com
Brake pads
3. Remove the reservoir tank cover while referring to the
Tightening torque:
2 - 4 N·m {18 - 35 in. lbs.}
Refer to the Service Instructions for the SM-BH80-SB brake hose (SI-8H40) for
details on installing the hose. Do not let the hose become twisted when
installing.
BL-M810
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222
Brake pads
■ Free stroke adjustment
Allen key 3 mm
SM-BH80-SB
Spacer for bleeding
(yellow)
■ Installation of the hose
Brake pad fixing shaft
D02S
2. Clean the pistons and surrounding area.
Fig. 2
When installing the components to carbon frame/handle bar surfaces, verify with
the manufacturer of the carbon frame/parts for their recommendation on
tightening torque in order to prevent over tightening that can cause damage to
the carbon material and/or under tightening that can cause lack of fixing strength
for the components.
SM-HANG
Metal Pads
Fig. 1
• SM-RT79L (203mm)
• SM-RT79M (180mm)
• SM-RT79 (160mm)
Cable Supporter
Brake pad unit
Front right
the pistons gradually move outward to automatically adjust the clearance between
the rotor and the brake pads. Therefore, you need to push the pistons back to
their original positions when replacing the brake pads.
If oil adheres to the brake pads after oil is added, or if
the brake pads are worn down to a thickness of 0.5 mm,
or if the brake pad presser springs are interfering with
the rotor, replace the brake pads.
■ When cleaning with a compressor
• If disassembling the caliper body to clean the internal parts using a
compressor, note that moisture from the compressed air may remain on the
caliper components. Let the caliper components dry sufficiently before
reassembling the calipers.
BR-M810
SM-RT79/M/L
Rear left Rear right
■ Burn-in period
• Disc brakes have a burn-in period, and the braking force will gradually
increase as the burn-in period progresses. Make sure that you are aware of
any such increases in braking force when using the brakes during the burnin period. The same thing will happen when the brake pads or rotor are
replaced.
Usage location
Brake Lever
Front left
Note: The M810 brake system is designed so that as the brake pads become worn,
Snap ring
brake pads as shown in the illustration.
The following tools are needed to assemble this product.
In order to realize the best performance, we recommend that the following
combination be used.
Rotating
direction of
wheel
■ Brake pad replacement
CAUTION
SI-8FF0A-002
Disc Brake System
Lace the spokes as shown in Figure 1 below for the left side of the front wheel
(the side where the rotor is installed), and the left and right sides of the rear
wheel, and as shown in Figure 2 below for the right side of the front wheel.
Maintenance
• Remove the spacer for bleeding (yellow), and then install the brake pads.
• Set the wheel which has the rotor onto the frame.
1. Remove the wheel from the frame, and remove the
Installation
Caliper
■ Installation of the calipers (BR-M810)
Check that the spokes have been laced as shown in the illustration.
A radial assembly cannot be used.
Operate the brake lever several times and check whether the brakes operate normally or not.
Also check that there are no oil leaks visible.
It is recommended that you replace the oil inside the reservoir tank if it becomes severely
discolored.
Attach a tube with a bag to the bleed nipple, and then open the bleed nipple and drain out
the oil. You can operate the brake lever at this time to help the oil to drain out. After
draining the fluid, pour in fresh brake fluid while referring to "Adding the mineral oil and
bleeding air". Use only genuine Shimano mineral oil.
Dispose of the waste oil according to proper country and/or state disposal regulations.
Be sure to read the service instructions for the “Adding mineral oil and
bleeding air” in conjunction with these service instructions.
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