Shimano BL-M785 User Manual

DEORE XT Brake Lever

BL-M785

For Disc Brake

Y8VC98010

Bleed Screw (M5 x 4.7) & O-Ring BA

Y8VC98050

Lid Fixing Bolt (M3) 2 pcs. AA

Y8VC04000

R.H. Lid BA

Y8VC04010

L.H. Lid BA

Y8VC98060

Separator Unit AA

Y8VC05000

Lever Axle ø5

Y8VC98020

Stroke Adjust Screw (M4 x 12) & Plate

Y8VC98030

R.H. Lever Member Unit

Y8VC98040

L.H. Lever Member Unit

Y8V398040

Lever Axle Fixing Bolt & Cap A

Y8VC10000

Clamp Bolt (M5 x 18) AA

ESMDISCBP

Funnel & Oil Stoppe

AAA

A: Same parts.

Dec.-2011-3158A

Shimano Inc. I

Absence of mark indicates non-interchangeability.

Specifications are subject to change without notice.

B: Parts are usable, but differ in materirals, appearance, finish, size, etc.

CODE NO.

SHIMANO

ITEM

NO.

DESCRIPTION

INTERCHANGE-

ABILITY

The BR-S700 is for use with resin pads (G01A, G01S, F01A) only.

Pad spacer (red )

Snap ring

M666

Split pin

Brake pads

Spacer for bleeding

M666

Brake pads

M666

Snap ring

Split pin

■ Installation of the rotor

SM-RT81L / RT67L (203mm) SM-RT81M / RT67M (180mm) SM-RT81S / RT67S (160mm)

The following tools are needed to assemble this product.

Usage location

Rotor fixing lock ring

Brake lever fixing bolt

Caliper fixing bolt

Brake pad fixing shaft

Brake lever bleed screw

Cable supporter

Brake hose fixing bolt

Bleed nipple

Bleeding

TL-LR15

Allen key 4 mm

Allen key 5 mm

Adapter (post type) fixing bolt Allen key 5 mm

Allen key 3 mm / Radio pliers

Allen key 2.5 mm

Phillips screwdriver #2

8 mm wrench / Allen key 3 mm, 4 mm

7 mm socket wrench

SM-DISC, Syringe

Tool

Tightening torque:

40 - 50 N·m {350 - 435 in. lbs.}

Tec h n ic a l Se r v i ce I n st r u ct i o ns SI-8JZ0A-004

Disc Brake System

Caliper

Brake Lever

Rotor

Hose

Cable Supporter

BR-M785/BR-S700*

BR-M666

BL-M785 / BL-T785 BL-S700 / BL-M666

SM-RT81 / RT67

SM-BH90-SB

SM-HANG

Mineral Oil

Brake pad unit Without fins With fins

Resin Pads

Metal Pads

SM-DB-OIL

G01A / G01S

G03S

F01A

F03C

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

■ Installation of the hose

■ 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.

Brake lever Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Rotor fixing lock ring

TL-LR15

For C-sh aped gui des and the u sual type of cable stoppers, use the special Shimano cable supporter (sold separately) to secure as shown in the illustration.

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. lbs.}

< C-shaped guide > < Usual type of cable stopper >

■ Brake pad replacement

Maintenance

Note: This brake system is 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.

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".

■ 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.

■ 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 countr y and/or state disposal regulations.

■ 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.

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.

3. Use a 4 mm Allen key to secure the

shifting lever to the brake lever.

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.

Refer to the Service Instructions for the SM-BH90-SB brake hose (SI-8JA0A) 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.

Installation

■ 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 r ight side of the front wheel.

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.

Free stro ke adjustment screw

Rotor

Pad

Contact

Pad contact point

■ 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.

Reach adjustment bolt

■ Reach adjustment

Tighten the adjust bolt (clockwise) to increase the stroke, and loosen it (counterclockwise) to decrease the stroke.

< BL-M785 >

< BL-M785 / M666 >

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.

Hook

Push

Clamp band

Bolt (M5 x 17.5 mm)

Nut

Tightening torque: 4 N·m {35 in. lbs.}

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. lbs.}

General Safety Information

WARNING

•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.

•Please use extra caution to keep your fingers away from the rotating disc brake rotor during installing or servicing the wheel. The rotor is shar p enough to inflict severe injury to your fingers if caught within the openings of moving rotor.

•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 ear ly 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 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.

•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 syste m.

•Be careful not to let water or air bubbles get into the brake system, otherwise vapor locks may occur.Be par ticularly 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 insid e the rese rvoir tank which are still there when the bleed screws are repla ced, 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 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 procedu re.

•If fluid leaks occur, immediately stop using the brakes and carry out the appropriate repairs.If you continue riding th e bicycle while fluid is leakin g, there i s the dange r 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 dur ing 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 stron gly reco mmend o nly usin g genui ne Shima no repl acement parts.

•Read these Technical Service Instructions carefully, and keep them in a safe place for later reference.

•G01A, G01S, F01A 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 G03S/F03C pads.

■

Handling the mineral oil

•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.

•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.

CAUTION

Vapor l ock is a ph eno men on in wh ich th e o il in sid e t he br ake sy ste m b eco mes h eat ed, 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.

< If brake operation is sluggish when the lever is depressed >

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".)

•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.

•Keep out of reach of children.

•Do not cut, heat, weld or pressurize the oil container, as this may cause explosion or fir e.

•Disposal of Used Oil :Follow local county and/or state codes for disposal.Use

care when preparing oil for disposal.

•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.

■ Burn-in period

•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.

■ When cleaning with a compressor

•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

•The 203 mm and 180 mm rotors have a larger diameter than the 160 mm rotors for cros s-countr y bicyc les, and so th e flexing of th ese rot ors 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.

•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.

•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 reser voir tank at this time.)

• Use isopropyl alcohol, soapy water or a dry cloth when carr ying 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.

•Do not remove the pistons when disassembling the calipers.

•Parts are not guaranteed against natural wear or deterioration resulting from normal use.

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

SI-8JZ0A-004-00

Rotating direction of wheel

Front left Rear left Rear right Front right

Fig. 2Fig. 1

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-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

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.

< For right lever >

Caliper

Brake lever

< For left lever >

■ Installation of the calipers and securing the hose.

•Remove the spacer for bleeding (yellow),

and then set the wheel which has the rotor onto the frame.

•Install the brake pads.

Tightening torque:

2 - 4 N·m {18 - 35 in. lbs.}

Pad with fins

The pads with fins have fins at the front and back, so install them as shown in the illustration.

Set the pad presser spring as shown in the illustration. (There are left (L) and right (R) marks on the spring.)

At brake lever end At caliper end

Hose

Banjo

O-rings

Connecting bolt

Connector insert

Olive

Cover

8 mm wrench

Pad presser spring

Tightening torque:

5 - 7 N·m

{44 - 60 in. lbs.}

< Front > < Rear >

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Caliper

Rotor

Adapter

Caliper fixing bolts

Adapter fixing bolts

● International standard mounting type

● 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 bolts.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

< Front >

Caliper fixing bolts

Install the accessory caps as shown in the illustration to prevent the bolts from loosening.

< Front > < Rear >

Caps

Post type

1. Remove the wheel from the frame, and remove

the brake pads as shown in the illustration.

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 spr ings are interfering with the rotor, replace the brake pads.

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 to twist the pistons. Do not push the pistons with a sharp tool. The pistons may become damaged.

4. < BR-M785/S700 >

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.

< BR-M666 >

Install the new brake pads, and then install the pad spacers (red). After this, bend open the split pin.

Piston

Tightening torque:

2 - 4 N·m {18 - 35 in. lbs.}

Reach adjustment bolt

< BL-T785 / S700 >

Brake pads

M666

Split pin

Allen key 3 mm Allen key 4 mm

Tightening torque Allen key 3 mm : 5 - 7 N·m {44 - 60 in. lbs.} Allen key 4 mm : 8 - 10 N·m {69 - 87 in. lbs.}

Shimano BL-M785 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual