INSTALLATION. Shimano BR-RS805, SM-BH59-SB, BR-R785, ST-R785

INSTALLATION

Wheel spoke assembly

INSTALLATION

This dealer’s manual describes how to install on road disc brake.

For information on how to install other products, refer to the appropriate dealer's manual for each product.

„

Wheel spoke assembly

Direction of wheel rotation

(w) (x) (y) (z)

[1] [2]

(w)

Front left

(x)

Rear left

(y)

Rear right

(z)

Front right

NOTICE

Check that the spokes have been laced as shown in the illustration.

A radial assembly cannot be used.

Refer to

[1]

for the spoke patterns of the left side of the front wheel (disc brake rotor mounted side) and both sides of the rear wheel. Refer to

[2]

for the spoke pattern of the right side of the front wheel.

„

Installation of the disc brake rotor

Center lock type

TL-LR15

(A)

Disc brake rotor fixing lock ring

(B)

TL-LR15

TL-LR15

Tightening torque

40 - 50 N·m

(A)

(B)

14

INSTALLATION

Installation of the disc brake rotor

6-bolt mounting type (with lock washers)

1

(A)

Install the disc brake rotor and rotor lock washers to the hub and tighten the bolts.

(A)

Lock washer

(B)

Disc brake rotor mounting bolt

Tightening torque

2 - 4 N·m

NOTICE

•

Install the lock washers so that the side labeled "TOP" faces toward you.

•

Do not reuse old lock washers.

Use new lock washers when installing a disc brake rotor.

•

Use the dedicated disc brake rotor mounting bolts for installation.

(B)

2

Wear gloves and turn the disc brake rotor clockwise with some force.

Then, tighten the disc brake rotor mounting bolts in the order shown in the illustration.

15

INSTALLATION

Installation of the dual control lever

„

Installation of the dual control lever

Unhook both the right and left tabs of the bracket cover and open up the bracket cover as shown in the illustration.

1

2

(A)

Install the dual control lever to the handlebar and tighten the clamp nut with an hexagon wrench.

(A)

Clamp nut

Tightening torque

6 - 8 N·m

NOTICE

•

With a carbon handle, even the recommended tightening torque may cause damage to the handle or insufficient fixation of the handle. For the appropriate torque value, consult with the manufacturer of the completed bicycle or the manufacturer of the handle.

•

The clamp band, clamp nut, and clamp bolt of ST-R785 have no compatibility with other products. Do not use components that are used in other products together.

16

INSTALLATION

Installation of the brake hose

„

Installation of the brake hose

(z)

1

Use a utility knife or other cutting tool to cut the brake hose.

(z)

90 degrees

NOTICE

Use the utility knife safely and correctly in accordance with its instruction manual.

TECH TIPS

If you are using TL-BH62, refer to the manual accompanying the product.

2

3

(A)

(z)

(y)

(D)

(z)

(C)

(E)

(C)

(B)

Put a mark on the brake hose beforehand as shown in the illustration so that you can check if the ends of the brake hose are secured to the hose mounts of the brake caliper and the dual control lever.

(As a guide, the length of the portion of the brake hose that is inside the mount is approximately 11 mm.)

(z)

11 mm

Pass the brake hose through the connecting bolt and olive, as shown in the illustration.

(y)

Direction of insertion

(z)

Grease the outside of the olive.

(A)

Brake hose

(B)

Cut end

(C)

Olive

(D)

Connecting bolt

(E)

Grease

NOTICE

For installation to the built-in type frame, first connect to the frame caliper the end of the brake hose to which the banjo is not attached.

To be continued on next page

17

INSTALLATION

Installation of the brake hose

After checking that the olive is positioned as shown in the illustration, grease the threads of the connecting bolt.

Model No.

SM-BH59-SB

SM-BH59-JK-SS

Length

13.2 mm

Color

Gold

(z)

4

(G)

(F)

(H)

(z)

2 mm

(F)

Olive

(G)

Brake hose

(H)

Connector insert

NOTICE

Use the dedicated connector insert supplied with SM-BH59-SB / SM-BH59-JK-SS.

Use of any connector insert other than the one supplied may produce a loose assembly, leading to oil leaks or other problems.

TL-BH61

5

(I)

(J)

(z)

(J)

(I)

(K)

(L)

(M)

Use a tapered tool to smooth out the inside of the cut end of the brake hose, and mount the connector insert.

Connect the brake hose to TL-BH61 and secure TL-BH61 in a vise, as shown in the illustration.

Then, hammer down the connector insert until the connector insert mount comes into contact with the end of the brake hose.

If the end of the brake hose is not in contact with the connector insert mount, the brake hose may be disconnected or cause fluid leaks.

(z)

1 mm

(I)

Brake hose

(J)

Connector insert

(K)

Olive

(L)

TL-BH61

(M)

Vise

To be continued on next page

18

INSTALLATION

Installation of the brake hose

Make sure that the brake hose is not twisted.

Make sure that the brake calipers and dual control levers are in the positions shown in the illustrations.

Left lever

(N)

Brake caliper

(N)

6

Right lever

(N)

7

(O)

Secure the dual control lever to the handlebar or in a vise and insert the brake hose straight.

Tighten the connecting bolt with a spanner while pushing the brake hose.

At this point, make sure that you are pushing the brake hose straight.

(O)

Connecting bolt

Tightening torque

5 - 7 N·m

NOTICE

When installing the brake hose with the dual control lever secured to the handlebar, adjust the angle of the bracket to make it easier to turn the spanner.

At that time, be careful not to damage the handlebar and other parts.

To be continued on next page

INSTALLATION

Installation of the brake hose

Temporarily secure the brake hose to the handlebar (by using tape or similar material).

(P)

Brake hose

(Q)

Tape

8

(P)

(Q)

End of the brake hose on the brake caliper side

Banjo type

After checking that both O-rings are fitted in the top groove and bottom groove of the banjo, secure the banjo to the caliper as shown in the illustration.

At this point, check that the O-rings are in the grooves.

(R)

(S)

(T)

(R)

Brake hose

(S)

Banjo

(T)

O-rings

Tightening torque

8 - 10 N·m

TECH TIPS

The O-rings are greased.

Straight type

Attach the connector insert to the brake hose.

After that, while pushing the brake hose, tighten the connecting bolt.

(U)

Brake hose

(V)

Connecting bolt

(W)

Olive

(X)

Connector insert

Tightening torque

5 - 7 N·m

(U) (V) (W) (X)

20

INSTALLATION

Installation of the brake hose (easy hose joint system)

„

Installation of the brake hose (easy hose joint system)

Overview of the easy hose joint system

(A)

(B)

(E)

(C)

(D)

(A)

Dual control lever

(B)

Joint sleeve

(C)

Lever stopper

(D)

Hose cap

(E)

Brake caliper

About the easy hose joint system

This is a list of components comprising the easy hose joint system.

For information on how to install and replace the brake hose, refer to the brake section of General

Operations.

(A)

(A)

Joint sleeve

(A)

21

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

„

Adding Shimano genuine mineral oil and bleeding air

With the bleed spacer (yellow) attached to the brake caliper, place the bicycle in the work stand as shown in the illustration.

(A)

Brake hose

(B)

Brake caliper

NOTICE

When bleeding the brake caliper, you need

SM-DISC (oil funnel and oil stopper).

(A)

(B)

1

(D)

(C)

Mount the bleed spacer (yellow).

(C)

Bleed spacer

(D)

Pad axle

Tightening torque

0.1 - 0.3 N·m

(E)

Open up the bracket cover and remove the name plate fixing screw.

Hold the lower part of the name plate while gripping the lever, and pull up the name plate to remove it as shown in the illustration.

(E)

Name plate fixing screw

NOTICE

The name plate fixing screw is very small. Be careful not to lose the screw while removing it.

2

To be continued on next page

22

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

Adjust the position of the bleed screw so that its surface is parallel to the ground.

3

Remove the bleed screw.

(F)

(G)

(F)

Bleed screw

(G)

O-rings

4

(H)

Mount the oil funnel.

(H)

Oil funnel

5

6

Secure the brake caliper in a vise while bleeding.

To be continued on next page

23

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

(I)

7

(J)

(J)

(I)

BR-R785/RS805

Set a 7 mm socket wrench in place.

Fill the syringe with sufficient oil, connect the syringe tube to the bleed nipple, and fasten it with the tube holder so that the tube will not be disconnected.

Loosen the bleed nipple by a 1/8 of a turn to open it.

BR-RS785

Fill the syringe with sufficient oil.

Attach the adapter provided with this product or Shimano original tool to the end of the tube, connect the tube to the bleed boss, and fasten it with the tube holder so that the tube will not be disconnected.

Loosen the bleed screw by 1/8 of a turn to open it.

Push the plunger of the syringe to add oil.

The oil then starts coming out from the oil funnel.

Continue adding oil until there are no more air bubbles mixed in with the oil that is coming out.

(I)

Tube holder

(J)

Bleed nipple

(K)

Bleed screw

(L)

Bleed boss

(M)

Adapter

NOTICE

Secure the brake caliper in a vise to prevent the tube from being accidentally disconnected.

Do not depress and release the lever repeatedly.

Oil without air bubbles may come out as a result of such operation, but air bubbles may remain in the oil inside the brake caliper, and it will take longer to bleed the air. (If you have depressed and released the lever repeatedly, drain out all of the oil and then add oil again.)

(K)

(L)

(I)

(M)

To be continued on next page

24

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

8

Once there are no more air bubbles in the oil in the funnel, temporarily close the bleed nipple / screw.

Remove the syringe while covering the end of the syringe tube with a waste cloth to prevent oil from spattering.

9

(N)

(O)

Tie the supplied tube and bag with rubber bands.

Set a 7 mm socket wrench as shown in the illustration, connect the tube to the bleed nipple, and loosen the bleed nipple / screw.

At this point, make sure that the tube is secured to the bleed nipple / screw.

After a little while, the oil and air bubbles will flow naturally from the bleed nipple/boss into the tube.

In this way it will be possible to easily extract the greater part of the air bubbles remaining inside the brake system.

It may be effective to shake the brake hose gently, to tap the lever bracket or brake calipers gently with a screwdriver, or to move the position of the calipers at this time.

The level of liquid inside the oil funnel drops at this time, so keep filling the funnel with oil to maintain the level of liquid so that air is not drawn in.

(N)

Bag

(O)

Air bubbles

10

To be continued on next page

25

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

(J)

BR-R785/RS805

Once no more air bubbles come from the bleed nipple, temporarily close the bleed nipple.

BR-RS785

Once no more air bubbles come from the bleed boss, temporarily close the bleed screw.

(J)

Bleed nipple

(K)

Bleed screw

(L)

Bleed boss

11

(L)

(K)

To be continued on next page

26

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

BR-R785/RS805

With the brake lever depressed, open and close the bleed nipple in rapid succession (for approximately 0.5 seconds each time) to release any air bubbles which may be in the brake calipers.

Repeat this procedure about 2 to 3 times.

Then tighten the bleed nipple.

BR-RS785

With the brake lever depressed, open and close the bleed screw in rapid succession (for approximately 0.5 seconds each time) to release any air bubbles which may be in the brake calipers.

Repeat this procedure about 2 to 3 times.

Then tighten the bleed screw again.

12

Tightening torque

4 - 6 N·m

To be continued on next page

27

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

If the brake lever is then operated, air bubbles in the system will rise up through the port into the oil funnel.

Once the bubbles stop appearing, depress the brake lever as far as it will go.

Under the normal condition, the lever action should feel stiff at this point.

(x)

Loose

(y)

Slightly stiff

(z)

Stiff

13

Lever operation

14

15

(x)

(Q)

(z)

(z)

(y) (z)

Tilt the handlebar in the up/down directions by 30 degrees as shown in the illustration, and then perform step 13 to check that there is no air bubble remaining.

If any air bubbles appear, repeat steps 9 to 13 until they stop appearing.

(z)

30°

Plug the oil funnel with the oil stopper so that the O-ring mounted side is facing downward.

(P)

O-ring

(Q)

Oil stopper

NOTICE

Tilt the handlebar in the up/down directions as shown in the illustration, and then secure the handlebar and stem.

For information on how to secure the handlebar and stem, refer to the installation procedures provided with those parts.

(P)

To be continued on next page

28

INSTALLATION

Adding Shimano genuine mineral oil and bleeding air

16

Remove the oil funnel while it is still being plugged with the oil stopper, and then attach the O-ring to the bleed screw and tighten it while letting oil flow out to make sure that there are no air bubbles remaining inside the reservoir tank.

At this point, use a waste cloth to prevent oil from flowing out to the surrounding areas.

Tightening torque

0.5 - 1 N·m

NOTICE

Do not operate the brake lever. Otherwise, air bubbles may enter the cylinder.

Wipe away any oil which has flowed out.

17

29

INSTALLATION

Installing the brake caliper and securing the brake hose

„

Installing the brake caliper and securing the brake hose

Remove the bleed spacer (yellow).

(A)

Bleed spacer

1

(A)

2

(D)

(B)

(C)

Install the new brake pads and bolts. At this point, make sure to install the snap ring as well.

Install the pads as shown in the illustration.

(B)

Brake pad

(C)

Snap ring

(D)

Pad axle

Tightening torque

0.1 - 0.3 N·m

NOTICE

When using a pad with fins, take note of the left (L) and right (R) markings to set it.

TECH TIPS

Pad fixing spring

Install the pad fixing spring as shown in the illustration. (The spring of the BR-R785/RS785 has markings on the left side (L) and the right side (R).)

30

INSTALLATION

Installing the brake caliper and securing the brake hose

Check the length of converter fixing bolt (BR-R785/RS785)

Rear (same for both 140 mm and 160 mm)

(A)

(z)

Insert the converter fixing bolts into the frame mount area, and check that the lengths of the protruding sections of the converter fixing bolts are 13 mm.

(z)

13 mm

(A)

Converter fixing bolt

NOTICE

•

When using a bolt length selector, check whether the tip of the converter fixing bolt is within the range

A

.

Converter fixing bolt

Bolt length selector

A

•

Do not use a washer when checking the length of the converter fixing bolt.

•

The length of the converter fixing bolt used vary depending on thickness of the frame.

Use converter fixing bolt that are suitable for the thickness of the frame.

Frame thickness

Converter fixing bolt length

Frame thickness

10 mm

15 mm

20 mm

25 mm

30 mm

35 mm

Converter fixing bolt length

16.8 mm

21.8 mm

26.8 mm

31.8 mm

36.8 mm

41.8 mm

Y-part

Y81743100

Y81743150

Y81743200

Y81743250

Y81743300

Y81743350

31

INSTALLATION

Installing the brake caliper and securing the brake hose

Check the length of brake caliper mounting bolt C (BR-RS805)

Rear (same for both 140 mm and 160 mm)

(A)

(z)

Insert the brake caliper mounting bolts C into the frame mount area, and check that the lengths of the protruding sections of the brake caliper mounting bolts C are 13 mm.

(z)

13 mm

(A)

Brake caliper mounting bolt C

NOTICE

•

When using a bolt length selector, check whether the tip of the brake caliper mounting bolt C is within the range

A

.

Brake caliper mounting bolt C

Bolt length selector

A

•

Do not use a washer when checking the length of the brake caliper mounting bolt C.

•

The length of the brake caliper mounting bolt C used vary depending on thickness of the frame.

Use brake caliper mounting bolt C that are suitable for the thickness of the frame.

Frame thickness

Brake caliper mounting bolt C length

Frame thickness

10 mm

15 mm

20 mm

25 mm

30 mm

35 mm

Brake caliper mounting bolt C length

23 mm

28 mm

33 mm

38 mm

43 mm

48 mm

Y-part

Y8N208000

Y8N208050

Y8N208010

Y8N208020

Y8N208030

Y8N208040

32

INSTALLATION

Installing the brake caliper and securing the brake hose

BR-R785/RS785

Temporarily install the brake caliper to the frame.

Depress the brake lever, and tighten the brake caliper fixing bolts while pressing the brake pads against the disc brake rotor.

Front

(E)

(G)

(H)

(E)

Adapter fixing bolts

(F)

Disc brake rotor

(G)

Adapter

(H)

Caliper

(I)

Brake caliper fixing bolts

Tightening torque

6 - 8 N·m

TECH TIPS

Make sure that the brake caliper can move sideways before installing it.

(I)

(F)

(I)

33

INSTALLATION

Installing the brake caliper and securing the brake hose

BR-RS805

In the case of a disc brake rotor for a 140 mm front wheel

Attach the adapter to the brake caliper.

(C)

(A)

(A)

Adapter

(B)

Brake caliper mounting bolts B

(C)

Bolt fixing pin

Tightening torque

6 - 8 N·m

NOTICE

•

Be sure to attach the bolt fixing pin.

Check that the bolt fixing pin is fully inserted all the way to the rear.

1

(B)

•

Observe the direction indicated on the adapter when installing it.

To be continued on next page

34

INSTALLATION

Installing the brake caliper and securing the brake hose

(D)

Attach the adapter temporarily to the frame.

Depress the brake lever, and tighten the brake caliper mounting bolts A while pressing the brake pads against the disc brake rotor.

2

(D)

Brake caliper mounting bolts A

Tightening torque

6 - 8 N·m

NOTICE

Be sure to attach a snap ring when installing the brake caliper mounting bolts A.

*

The snap ring installation positions is different for 140 mm and 160 mm.

(Drawing shows 140 mm)

Snap ring

35

INSTALLATION

Installing the brake caliper and securing the brake hose

In the case of a disc brake rotor for a 160 mm front wheel

Attach the adapter to the brake caliper.

(C)

(A)

(A)

Adapter

(B)

Brake caliper mounting bolts B

(C)

Bolt fixing pin

Tightening torque

6 - 8 N·m

NOTICE

•

Be sure to attach the bolt fixing pin.

Check that the bolt fixing pin is fully inserted all the way to the rear.

1

(B)

•

Observe the direction indicated on the adapter when installing it.

To be continued on next page

36

INSTALLATION

Installing the brake caliper and securing the brake hose

(D)

Attach the adapter temporarily to the frame.

Depress the brake lever, and tighten the brake caliper mounting bolts A while pressing the brake pads against the disc brake rotor.

2

(D)

Brake caliper mounting bolts A

Tightening torque

6 - 8 N·m

NOTICE

Be sure to attach a snap ring when installing the brake caliper mounting bolts A.

*

The snap ring installation positions is different for 140 mm and 160 mm.

(Drawing shows 160 mm)

Snap ring

37

INSTALLATION

Installing the brake caliper and securing the brake hose

In the case of a disc brake rotor for a 140 mm rear wheel

Attach the brake caliper to the frame.

(A)

(B)

(A)

Bolt fixing pin

(B)

Brake caliper mounting bolts C

Tightening torque

6 - 8 N·m

NOTICE

Be sure to attach the bolt fixing pin.

In the case of a disc brake rotor for a 160 mm rear wheel

Attach the adapter to the brake caliper.

(A)

1

(B)

(C)

(A)

Bolt fixing pin

(B)

Adapter

(C)

Brake caliper mounting bolts B

Tightening torque

6 - 8 N·m

NOTICE

•

Be sure to attach the bolt fixing pin.

•

Observe the direction indicated on the adapter when installing it.

To be continued on next page

38

INSTALLATION

Installing the brake caliper and securing the brake hose

Attach the adapter to the frame.

(D)

2

(E)

(F)

(D)

Adapter

(E)

Washers

(F)

Brake caliper mounting bolts C

Tightening torque

6 - 8 N·m

NOTICE

•

Be sure to use the washers when installing the adapter.

•

Be sure to attach a snap retainer when installing the brake caliper mounting bolts

C.

Snap retainer

39

INSTALLATION

Temporary tightening of the frame fixing bolts

„

Temporary tightening of the frame fixing bolts

The snap ring method, the fixing pin insertion method, or the wiring method can be used to prevent loosening of the bolts.

Choose whichever method is suitable for the model, front fork and frame.

Snap ring method

Front Rear

(A)

(A)

(z)

Post type

(A)

Snap rings

(z)

Fixing pin insertion method

Front Rear

(B)

Bolt fixing pin

Wiring method

(C)

Front

(B)

(B)

(C)

Rear (C)

Wire

40

CONNECTION OF THE ELECTRIC WIRES