Shimano BR-7700 Caliper Brake Service Instructions

WARNING

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.

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.

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.

SERVICE INSTRUCTIONS

BR-7700

BR-6500

BR-5500

BR-5501

SI-8FA0H

Caliper Brake

Before use‚ read these instructions carefully‚ and follow them for correct use.

In order to realize the best performance, we recommend that the folowing combination be used.

Series

Brake lever

DURA-ACE

ST-7700-C

ST-7700-B

ULTEGRA

ST-6510

105

ST-5500-CA

ST-5510

ST-R600/BL-R600

Caliper Brake BR-7700 BR-6500

BR-5500

BR-5501

Brake cable t

NOTE

If using SHIMANO's road brake shoes in combination with ceramic rims, the brake shoes will wear more quickly than normal.

The thickness of the BR-7700 brake shoe has been increased by

1 mm from the previous thickness. If the width of the tire is greater than 23 mm, the tire may interfere with the shoes and cause an obstruction when installing and removing the wheel, even when the quick release lever is in the open position.

When these brake shoes are installed with the BR-6500/BR-5500/

BR-5501 brakes, they may cause an obstruction when installing and removing the wheel if the tire width is greater than 26 mm.

For maximum performance we highly recommend Shimano lubricants and maintenance products.

1.

Installation of the brake lever

2.

2

Outer casing

5 mm Allen key

Tightening torque:

6 – 8 Nm {52 – 69 in. lbs.}

Cable hook Inner cable end

1

Outer casing

Inner cable end

Installation bolt

Cable hook

Checking the outer casing

Check to be sure that the outer casing has been completely and correctly inserted.

3.

Temporarily secure the outer casing to the handlebar (by using tape or similar material).

Outer casing

Tape

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

A

A A

1.

Installation of the brake

Installation of the brake itself

Compress the arch‚ and set while the shoe is in firm contact with the rim.

Tightening torque:

8 – 10 Nm {69 – 87 in. lbs.}

5 mm Allen key

The usual position during installation is when the head of the centering adjustment bolt is as shown in the illustration.

BR-7700

BR-6500

BR-5500

BR-5501

Note:

If the brake arm touches the frame when the handlebar is turned, attach the frame protection sticker which is included to the frame. (BR-7700)

2.

Brake shoe setting position

1 mm or more

4 mm Allen key

Tightening torque:

5 – 7 Nm {43 – 61 in. lbs.}

Direction of rim rotation

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 Nm {52 – 69 in. lbs.}

4.

Centering of the brake shoe

Make a minor adjustment by using the centering adjustment bolt.

2

Centering adjustment bolt

2

BR-7700

BR-6500

1

BR-5500

BR-5501

Open

1

= B

3 mm Allen key

Closed

Quick release lever

2

1 2

1

5.

Readjustment of the shoe clearance

Turn the cable adjustment nut (or bolt) to readjust the shoe clearance.

Cable adjustment nut

Cable adjustment bolt

3

4

3

BR-7700

4

BR-6500

BR-5500

BR-5501

= B

4

3 3

4

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

Replacement of the cartridge shoe

1.

Remove the set screw.

BR-7700

BR-6500

2 mm Allen key

BR-5500

BR-5501

Set screw

2.

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 screw 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

Set screw

4.

Tighten the set screw.

Tightening torque: 1 – 1.5 Nm {9 – 13 in. lbs.}

Set screw

These service instructions are printed on recycled paper.

Please note: Specifications are subject to change for improvement without notice. (English)

One Holland Irvine CA 92618 U.S.A. Phone 949-951-5003

Industrieweg 24 NL-8071 CT Nunspeet‚ Holland Phone 31-341-272222

3-77 Oimatsucho‚ Sakai‚ Osaka‚ Japan Phone 072-223-3243

C Jan. 2002 by Shimano Inc. PIT. SZK. Printed in Japan t