Shimano XT M785 Hydraulic Brake Lever User Manual
Contents
1. 4 mm Bleed nipple 7 mm socket wrench Bleeding SM DISC Syringe E Wheel spoke lacing Check that the spokes have been laced as shown in the illustration A radial assembly cannot be used 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 Rotating Front left Rear left Rear right Front right direction of wheel lt lt gt gt E Installation of the rotor SM RT81L RT67L 203mm SM RT81M RT67M 180mm SM RT81S RT67S 160mm Rotor fixing lock ring Tightening torque 40 50 N m 350 435 in Ibs H Installation of the brake lever 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 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 B2. GO3S FO3C pads E Handling the mineral oil e 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 e 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 Technical Service Instructions SI 8JZ0A 004 Disc Brake System In order to realize the best performance we recommend that the following combination be used BR M785 BR S700 Mineral Oil SM DB OIL Caliper BR M666 BL M785 BL T785 Brake pad unit Without fins With fins Brake Lever BL S700 BL M666 Rotor SM RT81 RT67 Resin Pads G01A G01S FOIA Hose SM BH90 SB Metal Pads G03S FO3C The BR S700 is for use with resin pads GO1A GO1S FO1A Cable Supporter SM HANG ony i wi in pads e 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 e Do not drink May cause vomiting or diarrhea e Keep out of reach of children e Do not cut heat weld or pressurize the oil container as this may cause explosion or fire e Disposal of Used Oil Follow local county and or
3. 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 use a flat shaped tool to 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 bleed screws and then try again Note that some oil may overflow from the reservoir tank at this time e 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 e Do not remove the pistons when disassembling the calipers e Parts are not guaranteed against natural wear or deterioration resulting from normal use e For maximum performance we highly recommend Shimano lubricants and maintenance products Installation The following tools are needed to assemble this product Usage location Tool Rotor fixing lock ring TL LR15 Brake lever fixing bolt Allen key 4 mm Caliper fixing bolt Allen key 5 mm Adapter post type fixing bolt Allen key 5 mm Brake pad fixing shaft Allen key 3 mm Radio pliers Brake lever bleed screw Allen key 2 5 mm Cable supporter Phillips screwdriver 2 Brake hose fixing bolt 8 mm wrench Allen key 3 mm
4. DEORE XT Brake Lever B L M 785 For Disc Brake E e SFF x Y amp Ta SEMAN DESORPTION ee 1 Y8VC98010 Bleed Screw M5 x 4 7 amp O Ring B A PD Y8VC98050 Lid Fixing Bolt M3 2 pcs A A i 3 Y8VC04000 R H Lid B A Y8VC04010 L H Lid B A 4 Y8VC98060 Separator Unit A A 5 Y8VC05000 Lever Axle 5 6 Y8VC98020 Stroke Adjust Screw M4 x 12 amp Plate 7 Y8VC98030 R H Lever Member Unit Y8VC98040 L H Lever Member Unit 8 Y8V398040 Lever Axle Fixing Bolt amp Cap A 9 Y8VC10000 Clamp Bolt M5 x 18 A A 10 ESMDISCBP Funnel amp Oil Stopper A A A A Same parts Dec 2011 3158A B Parts are usable but differ in materirals appearance finish size etc Shimano Inc I Absence of mark indicates non interchangeability Specifications are subject to change without notice S H l m A n 8 SI 8JZ0A 004 00 General Safety Information A WARNING e The 203 mm and 180 mm rotors provide a higher braking force than the 160 mm rotors Make sure that you have a complete feel for the braking characteristics before using the brakes e Please use extra caution to keep your fingers away from the rotating disc E 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 2 rotor SIS The calipers and rotor will become hot when the brakes are operated so do not touch them whi
5. d 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 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 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 e Read these Technical Service Instructions carefully and keep them in a safe place for later reference A CAUTION e GO1A G01S FO1A brake pads are designed to reduce the amount of noise which is generated between the pads and the rotor when the brakes are operated A longer running in period is required for this type of pad compared to
6. 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 lt If brake operation is sluggish when the lever is depressed gt 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 bleed screws and fill the reservoir tank with mineral oil until no air 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 lea
7. erence between the rotor and the caliper If they are touching adjust while referring to Installation of the caliper E Adjustment when the pistons are not operating correctly The caliper mechanism includes two 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 2 Use a flat shaped tool to push the pistons straight back in as far as they will go while being careful not to twist the pistons Do not push the pistons with a sharp tool The pistons may become damaged 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 that the two pistons all move to their initial positions 5 Remove the pad spacer install the wheel and then check that there is no interference between the rotor and the brake pads If they are touching loosen the installation bolts and adjust so that they are no longer touching Reach adjustment Tighten the adjust bolt clockwise to increase the stroke and loosen it counterclockwise to decrease the stroke Reach adjustment bolt 2 a lt BL M785 M666 gt lt BL T785 S700 gt E Free stroke adjustment When the free stroke adjustment screw is loosened
8. ich 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 get into the brake system otherwise vapor locks may occur Be particularly careful when removing the bleed screws 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 4 8 to 12 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 bleed screws are replaced or which accumulate in various parts of the brake system when it is used for long periods This 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
9. isionally secure the calipers to the frame The calipers should be able to move sideways 2 Depress the brake lever so that the rotor is being clamped by the pads and then tighten the caliper fixing bolts International standard mounting type lt Front gt lt Rear gt Adapter Caliper fixing fixing bolts bolts Adapter jb Caliper fixing bolts Rotor A ae Tightening torque bi ppenmng C 6 8 N m 53 69 in Ibs Post mounting type lt Front gt 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 Caliper fixing bolts Tightening torque 6 8 N m 53 69 in Ibs Install the accessory caps as shown in the illustration to prevent the bolts from loosening lt Rear gt Caps lt Front gt Post type Caps 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 lt C shaped guide gt lt Usual type of cable stopper gt Operate the brake lever several times and check whether the brakes operate normally or not Also check that there are no oil leaks visible Tightening torque 0 3 0 5 N m 2 7 4 4 in Ibs Maintenance E Brake pad replacement Note This brake system i
10. le 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 If the rotor is cracked or warped be sure to replace it with a new rotor If the rotor becomes worn down to a thickness of 1 5 mm or so that the aluminum surface becomes visible be sure to replace the rotor with a new one 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 be sure to replace them with new Brn Sint 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 gt 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 wh
11. rake lever Tightening torque 6 8 N m 53 69 in Ibs H Installation of the hose Refer to the Service Instructions for the SM BH90 SB brake hose SI 8JAOA for details on installing the hose Do not let the hose become twisted when installing Make sure that the calipers and levers are in the positions shown in the illustrations Caliper lt For left lever gt p lt For right lever gt At brake lever end 8 mm wrench Connector insert Allen key 3 mm Allen key 4 mm Connecting bolt Tightening torque 5 7 Nm 44 60 in Ibs Allen key 3mm 5 7 N m 44 60 in Ibs Tightening torque Allen key 4 mm 8 10 N m 69 87 in Ibs E Installation of the calipers and securing the hose e Remove the spacer for bleeding yellow and then set the wheel which has the rotor onto the frame e Install the brake pads Set the pad presser spring as shown in the illustration There are left L and right R marks on the spring Spacer for bleeding Pad with fins The pads with fins have fins at the front and back so install them as shown in the illustration Tightening torque 2 4N m 18 35 in Ibs For international standard mounts attach adapters to calipers for post type mounts Separate front and rear adapters are available 1 First install the adapter and then prov
12. s designed so that as the brake pads become worn 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 1 Remove the wheel from the frame and remove the brake pads as shown in the illustration Brake pads M666 L Split pin 2 Clean the pistons and surrounding area 3 Use a flat shaped tool to push the pistons straight 2 back in as far as they will go while being careful not cy to twist the pistons Do not push the pistons with a i i sharp tool The pistons may become damaged 4 4 4 lt BR M785 S700 gt Install the new brake pads and then install the pad spacers red Make sure that you do not forget to install the snap rings at this time also lt BR M666 gt Install the new brake pads and then install the pad spacers red After this bend open the split pin Tightening torque 2 4 N m 18 35 in Ibs 5 Depress the brake lever several times to check that the operation becomes stiff 6 Remove the pad spacers install the wheel and then check that there is no interf
13. state codes for disposal Use care when preparing oil for disposal e 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 E Burn in period e 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 burn in period The same thing will happen when the brake pads or rotor are replaced E When cleaning with a compressor e 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 Note e The 203 mm and 180 mm rotors have a larger diameter than the 160 mm rotors for cross country bicycles and so the flexing of these rotors is greater As a result they will interfere with the brake pads e If the brake caliper mounting boss and the dropout are not parallel the rotor and caliper may touch e 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 e If the brake lever is depressed without the pad spacers installed the
14. the free stroke of the brake lever will increase so that you can adjust it to the desired setting lt BL M785 gt Rotor P Pad contact point Free stroke adjustment screw Pad Contact E Mineral oil replacement 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 Refer to the Adding the mineral oil and bleeding air and Adding the mineral oil and bleeding air when using the caliper bleed screw Service Instructions in conjunction with these Service Instructions E Installation of the SL M780 I and the BL M785 T785 S700 M666 1 Use a 2 mm Allen key to open the clamp band of the brake lever as shown in the illustration Clamp band 2 Insert the hook of the shifting lever bracket into the hole in the brake lever bracket and then provisionally tighten the special nut and special bolt to install it to the handlebar Note Do not install
15. the nut upside down If it is installed upside down it will not be possible to secure the brake lever to the handlebars and damage may occur 3 Use a 4 mm Allen key to secure the shifting lever to the brake lever Tightening torque 4 N m 35 in Ibs 4 Use a 4 mm Allen key to secure the clamp band of the brake lever Tightening torque 6 8 N m 53 69 in Ibs 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 SHIMANO SHIMANO AMERICAN CORPORATION One Holland Irvine California 92618 U S A Phone 1 949 951 5003 SHIMANO EUROPE B V Industrieweg 24 8071 CT Nunspeet The Netherlands Phone 31 341 272222 SHIMANO INC 3 77 Oimatsu cho Sakai ku Sakai shi Osaka 590 8577 Japan Service Instructions in further languages are available at http techdocs shimano com Please note specifications are subject to change for improvement without notice English Nov 2011 by Shimano Inc XBC SZK
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