"user manual"
Contents
1. Secure the two bolts with a length of wire as shown in the illustration in order to prevent the bolts from coming loose For post type Wind a wire around the fixing bolt between the adapter and the frame as shown in the illustration If bolt tries to loosen turn in the counterclockwise direction force is applied via the wire to turn bolt in the tightening direction clockwise However bolt 2 cannot turn any further in the tightening direction Accordingly this prevents bolt from turning in the loosening direction because it is also connected via the wire If either one of the bolts tries to loosen this causes a force to be applied to the other bolt to turn it in the tightening direction In other words this system prevents the bolts from loosening ES Bot Bolt Bolt 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 oa 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 The M985 brake system is designed so that as the brake pads become worn the pistons gradually move outwa2. e Remove the spacer for bleeding yellow and then set the wheel which has the rotor onto the frame e Install the brake pads Spacer for bleeding Tightening torque 0 2 0 4 N m 1 8 3 5 in Ibs Set the pad presser spring as shown in the illustration There are left L and right R marks on the spring The pads with fins have fins at the front and back so install them as shown in the illustration 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 provisionally 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 Adapter fixing bolts Adapter van Caliper Rotor Caliper fixing bolts lt Rear gt Tightening torque Adapter 6 8 N m 53 69 in Ibs fixing bolts Post mounting type 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 i os re Y lt Fro bolts nt gt Caliper fixing bolts C Tightening torque 6 8 N m 53 69 in Ibs
3. 8071 CT Nunspeet The Netherlands Phone 31 341 272222 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 May 2010 by Shimano Inc XBC SZK Printed in Japan Tightening torque ET 4 6 Nem 35 53 in Ibs IN
4. 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 2mm 0 5mm If any oil or grease do get on the pads be sure to replace them with new 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 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
5. special nut and special bolt to install it to the handlebar Note Do not install 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 3 N m 26 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 SI 0113A 001 00 Technical Service Instructions SI 0113A 001 5 The level of liquid inside the funnel will drop at this time so keep filling
6. 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 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 GO3Ti 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 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 Do not drink May cause vomiting or diarrhea SI 8J70A 005 Technical Service Instructions SHIMANO XTE Disc Brake System In order to realize the best performance we recommend that the following combinat
7. SI 8J70A 005 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 GE 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 r 2 rotor N7 y 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 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
8. 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 4 mm Adapter post type fixing bolt Allen key 4 mm Brake pad fixing shaft Flat tipped screwdriver 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 mm Bleed nipple 7 mm socket wrench Caliper bleed screw option Allen key 3 mm TL BR25 SM DISC Syringe Bleeding adapter option Bleeding 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 RT98 SM RT98L 203mm SM RT98M 180mm SM RT98S 160mm SM RT98SS 140mm The RT98SS 140 mm rotor is for rear use only Rotor fixing lock ring Tightening torque 40 50 N m 350 435 in Ibs E Installation of the brake lever BL M985 M988 Secure the brake lever as shown in the illustration Check that the brake lever
9. 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 The M985 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 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 leak
10. 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 E Installation of the hose Brake lever Tightening torque 6 8 N m 53 69 in Ibs 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 the positions shown in the illustrations lt For left lever gt BL M985 M988 evers are in BR M985 lt For right lever gt BR M985 At brake lever end 8 mm wrench Tightening torque 5 7 N m 44 60 in Ibs Connecting bolt At caliper end Allen key 3 mm Allen key 4 mm Tightening torque Allen key 3 mm 5 7 N m 44 60 in Ibs Allen key 4 mm 8 10 N m 69 87 in Ibs E Installation of the calipers BR M985 and securing the hose
11. e brake pads or rotor are replaced 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 140 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 If the brake caliper mounting boss and the dropout are not parallel the rotor and caliper may touch 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 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 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 normal use maintenance products Installation The following tools
12. f 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 E Reach adjustment lt BL M988 gt Tighten the adjust bolt clockwise to increase the stroke and loosen it counterclockwise to decrease the stroke lt BL M985 gt Using a 2 mm Allen key tighten the adjust bolt clockwise to increase the stroke and loosen it counterclockwise to decrease the stroke ach adjustment bolt E Free stroke adjustment 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 lt BL M988 gt Rotor Free stroke adjustment sc
13. ion be used Caliper BR M985 Mineral Oil SM DB OIL Brake Lever BL M985 BL M988 N Wee Brake pad unit Without fins With fins Rotor SM RT98 Hose SM BH90 SB Resin Pads GO1A FOIA Cable Supporter SM HANG Metal Pads GO3Ti FO3C e Keep out of reach of children e Do not cut heat weld or pressurize the oil container as this may cause e Disposal of Used Oil Follow local county and or state codes for disposal Use e Directions Keep the container sealed to prevent foreign objects and moisture E Burn in period e Disc brakes have a burn in period and the braking force will gradually increase E When cleaning with a compressor Note e The 203 mm and 180 mm rotors have a larger diameter than the 160 mm and e When the bicycle wheel has been removed it is recommended that pad spacers e Use isopropyl alcohol soapy water or a dry cloth when carrying out cleaning e Do not remove the pistons when disassembling the calipers e Parts are not guaranteed against natural wear or deterioration resulting from e For maximum performance we highly recommend Shimano lubricants and explosion or fire care when preparing oil for disposal from getting inside and store it in a cool dark area away from direct sunlight or heat 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 th
14. rd 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 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 2 Clean the pistons and surrounding area 3 Use a flat shaped tool to push the pistons straight back in as far as they will go while being careful not Iz 4 to twist the pistons Do not push the pistons with a sharp tool The pistons may become damaged 4 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 Pad spacer red Tightening torque FY amp 0 4 N m 1 8 3 5 in ts q a i 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 interference 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 i
15. rew Pad contact point 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 The bleed nipple of the BR M985 can be replaced with the included caliper bleed screw in order to reduce weight If using the caliper bleed screw it will be necessary to use the TL BR25 bleeding adapter and the SM DISC oil funnel and oil stopper when carrying out air bleeding operations 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 H Installation of the SL M980 I and the BL M985 M988 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
16. s 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 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
17. th oil to maintain the level of liquid so that air is not drawn in air does not get inside 13 Wipe away any oil which has flowed out 4 Set a 7 mm socket wrench in place as shown in the illustration and then attach the bag to the tube Connect the tube to the bleed nipple and then loosen the bleed nipple After a little while the oil and air will flow naturally from the bleed nipple into the tube In this way it will be possible to easily extract the greater part of the air remaining inside the brake system It may help to shake the hose gently or to tap the reservoir tank or caliper gently with a screwdriver or move the position of the caliper at this time 12 Wipe away any oil which has flowed out lt Replace the bleed nipple with the bleed screw gt Remove the brake calipers from the frame palate 3 K SHIMANO 6 Once air bubbles stop coming out from the Hold the calipers so that the bleed nipple is facing upward and Bee nipple bleeding adapter temporarily tighten the bleeding then remove the bleed nipple and install the bleed screw At this adapter SHIMANO AMERICAN CORPORATION time tighten the bleed screw until oil flows out to make sure that One Holland Irvine California 92618 U S A Phone 1 949 951 5003 there are no air bubbles romanna inside the calipers After this g SHIMANO EUROPE B V SHIMANO INC wipe away any oil which has flowed out Industrieweg 24
18. the funnel with oil to E When using the bleed screw 7 With the brake lever depressed open and close the bleeding maintain the level of liquid so that air is not drawn in air does not get inside adapter in rapid succession for approximately 0 5 seconds each time to release any air bubbles which may be in the calipers Repeat this procedure about 2 to 3 times Then tighten the bleeding adapter again 1 Set the brake lever so that it is in the riding position at a 45 degree angle to the ground and then remove the upper bleed screw and the O ring and insert the oil funnel Do not insert the oil stopper at this time Bleed screw Oil funnel on Adding mineral oil and bleeding air When carrying out the air bleeding operation for the BR M985 you will need the SM DISC oil funnel and oil stopper 8 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 The normal condition is for the lever to be stiff at this point Lever operation 6 Once air bubbles stop coming out from the bleed nipple temporarily ua With the spacer for bleeding Note a aL A yellow still attached to the Carry out the steps within the calipers place the bicycle into a following range so that the end with bicycle stand or similar as shown the bleed nipple is facing downward in the illus
19. the lever unit 30 degrees in the direction of and carry out step 8 again to check that there is no air remaining If any air bubbles appear repeat the above procedure until they stop appearing 5 Bleeding adapter Bleed screw 2 Set a 7 mm socket wrench in place g adap fill the syringe with oil connect a tube to the bleed nipple and then loosen the bleed nipple by 1 8 of a turn to open it Push the plunger of the syringe to add oil The oil will start 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 4 Attach a bag to the tube Connect the tube to the bleeding adapter and then loosen the bleeding adapter After a little while the oil and air bubbles will flow naturally from the bleeding adapter 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 help to shake the hose gently or to tap the reservoir tank or calipers gently with a screwdriver or move the position of the calipers at this time 11 Set the bleeding adapter so that it is facing upward and then remove it and then insert and tighten the bleed screw At this time tighten the bleed screw until oil flows out to make sure that there are no air bubbles remaining inside the calipers t S C Tightening torque wr 4 6 N m 35 53 in Ibs Oil stopper 10 Plug
20. the oil funnel with the oil stopper so that the side with the O ring attached is facing downward Bleed nipple 12 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 until oil flows out to make sure that there are no air bubbles remaining inside the reservoir tank Do not operate the brake lever at this time otherwise air may get inside the cylinder Tightening torque 0 3 Once there are no more air bubbles mixed in with the oil temporarily close the bleed nipple 11 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 until oil flows out to make sure that there are no air bubbles remaining inside the reservoir tank Do not operate the brake lever at this time otherwise air may get inside the cylinder Tightening torque 0 3 0 5 N m 2 7 4 4 in Ibs Do not continually squeeze and release the lever at this point If this is not observed air bubbles may remain mixed in with the oil inside the caliper and it will take longer to bleed the air If the lever is continually squeezed and released drain out all of the oil and then add oil again 3 0 5 Nm 2 7 4 4 in Ibs 5 The level of liquid inside the funnel will drop at this time so keep filling the funnel wi
21. tration as shown in the illustration If the Bleed nipple steps are outside this range complete air bleeding may not be possible 2 Remove the bleed screw of the bleed unit from the calipers and install the 7 With the brake lever depressed open and close the bleed nipple in amp bleeding adapter Fill the syringe with oil and connect a tube to the bleeding U rapid succession for approximately 0 5 seconds each time to t adapter and then opaan the bleeding adapter by 1 8 of a turn to open it f f release any air bubbles which may be in the calipers Repeat this Push the plunger of the syringe to add oil The oil will start coming out from f i procedure about 2 to 3 times Then tighten the oil funnel Continue adding oil until there are no more air bubbles mixed in Loose P Slightly stiff gt Stiff the bleed nipple again with the oil that is coming out Bleeding adapter gt Tightening torque Calipers C 4 6 N m 35 53 in Ibs OF Bleed nipple 9 Set the lever unit to the horizontal position as shown in the illustration and tilt it in the direction of by 30 degrees and then carry out step 8 to check that there is no air remaining Next tilt the lever unit 30 degrees in the direction of and carry out step 8 again to check that there is no air remaining If any air bubbles appear repeat the above procedure until the
22. y stop appearing 8 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 The normal condition is for the lever to be stiff at this point E When using the bleed nipple 1 Set the brake lever so that it is in the riding position at a 45 degree angle to the ground and then remove the upper bleed screw and the O ring and insert the oil funnel Do not insert the oil stopper at this time f Oil stopper Bleed screw Oil funnel 10 Plug the oil funnel with the oil stopper so that the side with the O ring attached is facing downward 3 Once there are no more air bubbles mixed in with the oil temporarily close the bleeding adapter Do not continually squeeze and release the Loose Slightly stif Stiff lever at this point If this is not observed air bubbles may remain mixed in with the oil inside the caliper and it will take longer to bleed the air If the lever is continually squeezed and released drain out all of the oil and then add oil again 9 Set the lever unit to the horizontal position as shown in the illustration and tilt it in the direction of by 30 degrees and then carry out step 8 to check that there is no air remaining Next tilt
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