Shimano SI-8G40A Service Instructions

• Remove the spacer for bleeding (yellow), and then set the wheel which has the rotor onto the
frame.

• Install the brake pads. After this, bend open the split pin.

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 sharp 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 early and gently.

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

• 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.

• 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 system.

• Be careful not to let water or air bubbles to get into the brake system, otherwise vapor lock may
occur. Be particularly careful when removing the cover of the reservoir tank.

• 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 (5), (8) to (10) 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 reservoir tank cover is replaced,
or which accumulate in various parts of the brake system when it is used for long periods. The
M595 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.

• 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
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 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.

• A01S 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 running­in period is required for this type of pad compared to M06 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.

• 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 fire.

• 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.

CAUTION

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.

< 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 reservoir tank cover and fill the
reservoir tank with mineral oil until no bubbles remain.
If the brakes still operate sluggishly, bleed the air from the brake system.
(Refer to "Adding the mineral oil and bleeding air".)

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, 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)
© 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.

■ Installation of the calipers (BR-M595) and securing the hose.

< Front >

< Front >

< Rear >

Technical Service Instructions SI-8G40A-002

Disc Brake System

Caliper

Hose

Rotor

Brake Lever

BR-M595

SM-BH59

SM-RT53 / SM-RT62

BL-M595

Cable Supporter

Mineral Oil

Brake pad unit

Resin Pads

Metal Pads

SM-HANG

SM-DB-OIL

A01S

M06

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

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Caliper

Rotor

Adapter

Caliper
fixing bolts

Caliper
fixing bolts

Adapter
fixing bolts

Adapter
fixing bolts

■ Brake pad replacement

Maintenance

Note: The M595 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.

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.

1. Remove the brake lever fixing bolt as shown in the illustration.

2. Insert a thin object such as a 2 mm Allen key into the bevelled hole on the

hose side of the brake lever to push out the pin and release the clamp band
lock. Then remove the brake lever.

2. Clean the pistons and surrounding area.

3. Remove the reservoir tank cover while

referring to the step (1) in "Adding
mineral oil".

For international-standard mounts, attach adapters to calipers for post-type mounts.
(Separate front and rear adapters are available.)

1. Loosen the caliper fixing bolts so that the caliper can move sideways, and then install the

adapter to the frame.

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 ● Post mounting type

4. Push the piston back in as far as it will

go, while being careful not to twist it.
(Note that some oil may overflow from
the reservoir tank at this time.)

5. Install the new brake pads, and then

install the pad spacers (red).
After this, bend open the split pin.

6. Depress the brake lever several times to check that the operation becomes stiff.

7. 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".

8. After checking the oil level, replace the reservoir tank cover.

9. Return the brake lever to its original position.

■ 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, and remove the reservoir tank cover.

2. Push the piston back in straight, without bending it. Note that some oil may overflow

from the reservoir tank at this time.

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 spacers, install the wheel, and then check that there is no interference

between rotor and the calipers. If they are touching, adjust using shims.

6. After checking the oil level, replace the reservoir tank cover.

■ 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.

■ Removal of the brake lever

Be sure to read the service instructions for the “Adding mineral oil
and bleeding air” in conjunction with these service instructions.

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.

■ 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-RT53 / RT62)

SM-RT53 (160mm)
SM-RT53M (180mm)
SM-RT53L (203mm)

SM-RT62 (160mm)
SM-RT62M (180mm)
SM-RT62L (203mm)

Rotating
direction of
wheel

Front left Rear left Rear right Front right

Fig. 2Fig. 1

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

Reservoir tank cover

Cable supporter

Brake hose fixing bolt

Bleed nipple

TL-LR15

Allen key 4 mm

Allen key 5 mm

Adapter (post type) fixing bolt Allen key 5 mm

Radio pliers

Phillips screwdriver #1

Phillips screwdriver #2

Socket wrench 8 mm

Socket wrench 7 mm

Tool

Tightening torque:

40 - 50 N·m {350 - 435 in. lbs.}

■ Installation of the brake lever (BL-M595)

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.)
* Refer to the procedure for removing the brake

lever when opening the clamp band.

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

Installation

■ Installation of the hose

< For right lever >

Refer to the Service Instructions for the SM-BH59 brake hose (SI-8H20) 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.

BL-M595

BR-M595

Reach
adjustment bolt

■ Reach adjustment

Tighten the reach adjustment bolt (clockwise direction) to make the reach narrower,
and loosen it (counterclockwise direction) to make the reach wider.

< For left lever >

Spacer for bleeding

(yellow)

Brake pads

Split pin

Either a cap method or a wire ring method can be used to stop the bolts from turning.
Use whichever method is suitable for the front fork and frame.

< Front > < Rear >

Caps

Caps

Caps

Post type

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.

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 >

Cap method

Wire ring method

< Rear >

Wire

< Front >

Wire

Clamp band

Brake pads

Piston

Pad spacer (red)

Split pin

Split pin

SI-8G40A-002-00

The following tools are required in order to remove this product.

Usage location

Brake lever fixing bolt

Releasing the clamp band lock

4 mm Allen key

Thin rod such as 2 mm Allen key

Tool

Clamp band

■ 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 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.

• 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, 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 reservoir tank
cover and then try again. (Note that some oil may overflow from the reservoir
tank at this time.)

• 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.

• Do not remove the pistons when disassembling the calipers.

• If the rotor is worn, cracked or warped, it should be replaced.

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

• For maximum performance we highly recommend Shimano lubricants and

maintenance products.