Shimano SI-8E80A Service Instructions

■ Installation of the brake lever

■ Installing the calipers

Use a handlebar grip with a maximum
outer diameter of 32 mm.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

1. Install the bicycle wheel. Loosen the

caliper fixing bolts, and then install
the calipers to the frame so that the
calipers work at the left and right.

Caliper clamp bolt

Caliper fixing bolts

2. While wearing protective gloves, apply pressure to the adapter in the

counterclockwise direction while tightening the caliper clamp bolt.

3. Securing the cable

Pass the inner cable through the
cable adjusting bolt, and then
tighten the cable fixing bolt.

6. Depress the brake lever about 10 times until it touches the grip, and check that

there are no problems with any components, and also that the rotors and the
pads do not interfere with each other when the wheel is rotated.

7. Turn the cable adjusting bolt to take up any slack in the

cable.

Caliper clamp bolt

Adapter

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

4. While depressing the brake lever, set the calipers to the required position and

then tighten the caliper fixing bolts.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Cable fixing bolt

Inner cable

Depress about
10 times

Depress about

10 times

Secure the three bolts with a cap as shown in the illustration in order to
prevent the bolts from coming loose.

Caps

< Front > < Rear >

■ For post type

Caps

■ Adjusting when the pads are worn

Use a 3 mm Allen key to tighten the pad adjustment screw on the calipers so that
clearances (A) and (B) are both 0.2 – 0.4 mm.

If the brake pads are worn down to a thickness of 0.5 mm, replace the brake pads.

Replacing the brake pads

1. Remove the bicycle wheel from the frame, and then remove the brake pads as

shown in the illustration.

2. Loosen the pad adjusting screw

and turn the cable adjusting bolts at
the caliper body clockwise to
loosen them.

Cable adjusting bolt

Caliper

Brake Lever

Rotor

Brake cable

BR-R505

BL-R770 / ST-6600 / ST-5600

SM-RT61, SM-RT62

Brake pad unit (Metal Pads)

M06

General Safety Information

WARNING

• Please use extra caution to keep your fingers away from the rotating
disc 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 rotor.

• Adjust the inner cable so that the protruding length is less than 20 mm
(3/4 inch). If the protruding length is any longer, the end of the inner
cable may become stuck in the rotor, which could cause the wheel to
lock and the bicycle could fall forward causing serious injuries.

• 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.

• Always make sure that the front and rear brakes are working correctly
before you ride the bicycle.

• Before riding the bicycle, check that the thickness of each pad is 0.5 mm
or more.

• 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, you should replace the 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.

• Check the brake cable for rust and fraying, and replace the cable immediately if any such
problems are found. If this is not done, the brakes may not work correctly.

• 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.

• Check that the quick release lever is on the right side (the opposite side to the rotor). 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.

• The R505 disc brakes are designed for optimum performance when used in combination
with the BR-R505 (calipers), BL-R770/ST-6600 (brake lever), SM-RT61, SM-RT62 (rotor)
and Shimano pad unit (M06). Use 2.5 finger levers for canti brakes such as the BL-R770
or STI levers such as the ST-6600 for road bikes as the brake levers. Do not use in
combination with V-BRAKE brake levers. If used in combination with V-BRAKE brake
levers, it will not be possible to obtain sufficient braking force. If using in combination
with 4-finger levers such as the BL-T400/ST-T400, the braking force will be higher.
Accordingly, under some conditions such as certain riding positions or overall weight, the
bicycle may fall over and injury may result if proper care is not taken.

• 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.

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

• 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.

Note

• If the brake caliper mounting boss and the dropout are not parallel, the rotor and caliper
may touch.

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

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

CAUTION

Technical Service Instructions SI-8E80A-002

Disc Brake System

(For road bikes)

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

Less than
20mm

4. After checking that the brake pad and

the rotor are not touching each other,
check that there are no problems when
the brake lever is depressed.

A

A

B

B

A

A

B

B

Pad adjusting screw

Cable adjusting bolt

Pad adjusting screw

(0.2 – 0.4 mm)(0.2 – 0.4 mm)

3. Install the new brake pads. Be careful

not to forget to install the snap ring at
this time.

Tighten the pad adjusting screw so that
the clearance between the brake pad
and the rotor is 0.2 – 0.4 mm.

Tightening torque:

2 - 4 N·m {18 - 35 in. lbs.}

Cable adjusting
bolt

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 right side of the front wheel.

■ Installation of the rotor
<SM-RT61>

Install the rotor and the rotor tightening
plate to the hub, and then install and
tighten the bolts as shown in Fig. 1.

While wearing gloves, apply a force to the
rotor to turn it in a clockwise direction as
shown in Fig. 2. While doing this, tighten
the rotor fixing bolts in the order shown in
the illustration.

Use a flat-tipped screwdriver or similar tool to
bend the edges of the tightening plate over
the heads of the bolts as shown in Fig. 3.

Rotating
direction of
wheel

Front left Rear left Rear right Front right

Fig. 1 Fig. 2

Fig. 1

Tightening plate

Rotor

Hub

Rotor fixing bolts

(#T25 torx)

Tightening torque:

2 - 4 N·m {18 - 35 in. lbs.}

Fig. 2 Fig. 3

Tightening plate

<SM-RT62>

<BL-R770>

Use a 5 mm Allen key to install.

<BL-R770> <ST-6600 / ST-5600>

Rotor installation ring

TL-LR15

Tightening torque:

40 - 50 N·m {350 - 435 in. lbs.}

<ST-6600 / ST-5600>

Secure the assembly with the installation
nut on the outside of the bracket. Pull
the bracket cover back and use a 5 mm
Allen key to tighten the bolt.

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.

5 mm Allen key

5 mm Allen key

installation nut

bracket cover

One Holland, Irvine, California 92618, U.S.A. Phone: [phone]

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: [phone]

3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Jap

* Service Instructions in further languages are available at :

http://techdocs.shimano.com

Please note: specifications are subject to change for improvement without notice.(English)
© Sep. 2010 by Shimano Inc. XBC IZM Printed in Malaysia.

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.

Brake padSnap ring3 mm Allen key

5. Loosen the pad adjustment screw by two clicks.

Pads

Rotor

Pad adjusting screw

SI-8E80A-002-00