General Safety Information
WARNING
– To avoid serious injuries:
Improper use of your bicycle's brake system may result in a loss of control or an accident, which could lead to a severe injury. Because each bicycle may handle differently, be sure to learn the proper braking technique (including brake lever pressure and bicycle control characteristics) for your bicycle.
Consult your bicycle dealer and the bicycle's owners manual, and practice your riding and braking technique.
Securely tighten the caliper brake mounting nuts to the specified tightening torque.
Use lock nuts with nylon inserts (self-locking nuts) for nut-
type brakes.
For sunken nut type brakes, use sunken nuts of the
appropriate length which can be turned six times or more;
when re-installing, apply sealant (locking adhesive) to the
nut threads.
If the nuts become loose and the brakes fall off, they may get caught up in the bicycle and the bicycle may fall over.
Particularly if this happens with the front wheel, the bicycle may be thrown forward and serious injury could result.
Brakes designed for use as rear brakes should not be used as front brakes.
Obtain and read the service instructions carefully prior to installing the parts.
Loose, worn, or damaged parts may cause serious injury to the rider. We strongly recommend only using genuine Shimano replacement parts.
Be careful not to allow any oil or grease to get onto the brake shoes. If any oil or grease do get on the shoes, you should replace the shoes, otherwise the brakes may not work correctly.
Check the brake cable for rust and fraying, and replace the cable immediately if any such problems are found. If this is not done, the brakes may not work correctly.
Always make sure that the front and rear brakes are working correctly before you ride the bicycle.
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.
Read these Technical Service Instructions carefully, and keep them in a safe place for later reference.
NOTE:
If using SHIMANO's road brake shoes in combination with ceramic rims, the brake shoes will wear more quickly than normal.
If the brake shoes have worn down until the grooves are no longer visible, they should be replaced.
Parts are not guaranteed against natural wear or deterioration resulting from normal use.
For maximum performance we highly recommend Shimano lubricants and maintenance products.
For any questions regarding methods of handling or maintenance, please contact the place of purchase.
1.
Installation of the brake lever
SI-8A00A-001
BR-7800
Caliper Brake
Technical Service Instructions
In order to realize the best performance, we recommend that the following combination be used.
Series
Brake lever
Caliper Brake
DURA-ACE
ST-7800/BL-R600
BR-7800
Brake cable
3.
Temporarily secure the outer casing to the handlebar (by using tape or similar material).
Outer casing
4.
Then wrap the handlebar with handlebar tape.
Note:
Cut the cable at the length at which it is not pulled tight when the handlebar is turned all the way to the left and right.
If a squeaking noise occurs after a long period of use, lubricate the parts.
A
Tape
A
5 mm Allen key
Tightening torque:
6 – 8 N·m
{52 – 69 in. lbs.}
In the case of carbon handlebars, it may be necessary to lower the tightening torque in order to prevent damage to the handlebar. Please consult the bicycle or handlebar manufacturer regarding the appropriate level of tightening torque for carbon handlebars.
2.
Cable hook
Inner cable end
Outer casing
Installation of the brake
1.
Installation of the brake itself
Compress the arch‚ and set while the shoe is in firm contact with the rim.
Tightening torque:
8 – 10 N·m {69 – 87 in. lbs.}
5 mm Allen key
Outer casing
Inner cable end
Installation bolt
Cable hook
Checking the outer casing
The usual position during installation is when the head of the centering adjustment bolt is as shown in the illustration.
Check to be sure that the outer casing has been completely and correctly inserted.
Note:
If the brake arm touches the frame when the handlebar is turned, attach the frame protection sticker which is included to the frame.
2.
Brake shoe setting position
After adjusting the brake shoe position so that the shoe surface and the rim surface are as shown in the illustration, tighten the shoe fixing bolt.
Direction of rim rotation
Toe-in
0.5 mm
Direction of rim rotation
Note:
The BR-7800 allows the angle of contact between the shoe and the rim (toe-in) to be adjusted. Adjusting the toe-in makes it possible to obtain smoother braking operation.
6.
Check
Depress the brake lever about 10 times as far as the grip and check that everything is operating correctly and that the shoe clearance is correct before using the brakes.
Depress about
10 times
7.
Arch spring tension adjustment
You can use the spring adjustment bolt to adjust the spring tension of the arch.
2 mm Allen key
Weak
1 mm or more
Shoe fixing bolt
4 mm Allen key
Tightening torque:
5 – 7 N·m {43 – 61 in. lbs.}
3.
Cable connection
Set the quick release lever to the closed position; then adjust the shoe clearance (as shown in the illustration below) and secure the cable.
Cable bolt tightening torque:
6 – 8 N·m {52 – 69 in. lbs.}
4.
Centering of the brake shoe
Make a minor adjustment by using the centering adjustment bolt.
Centering adjustment bolt
2
3 mm Allen key
Open
1
= B
Closed
Quick release lever 2
2
1
1
5.
Readjustment of the shoe clearance
Turn the cable adjustment bolt to readjust the shoe clearance.
3
4
Cable adjustment bolt
2.
Replacement of the cartridge shoe
1.
Remove the fixing bolt.
Fixing bolt
Strong
Spring adjustment bolt
2 mm Allen key
Remove the shoe by sliding it along the groove of the shoe holder.
Shoe
3.
There are two different types of shoe and shoe holder to be used in the left and right positions respectively. Slide the new shoes into the grooves on the shoe holders while taking note of the correct directions and bolt hole positions.
For the left
Same at front and rear
For the right
Same at front and rear
Front
Shoe
Front
Shoe
Shoe holder Shoe holder
Shoe insertion direction
Fixing bolt
4.
Tighten the fixing bolt.
Tightening torque: 1 – 1.5 N·m {9 – 13 in. lbs.}
Fixing bolt
These service instructions are printed on recycled paper.
Please note: Specifications are subject to change for improvement without notice. (English)
= B
4
3 3
4
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222
3-77 Oimatsu-cho, Sakai-ku, Sakai, Osaka 590-8577, Japan
C Apr. 2007 by Shimano Inc. PIT. IZM. Printed in Japan
