Shimano Alfine BR-S500 Service-instructies

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Shimano Alfine BR-S500 Service-instructies

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.

• 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 pad thicknesses are 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 to get into the brake system, otherwise vapor

lock may occur. Be particularly careful when removing the cover of the reservoir tank.

• 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 S500 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 brake operation is sluggish when the lever is depressed >

Set the brake lever so that it is parallel to the ground, and then 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".)

• 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.

• 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.

• The S500 disc brakes are designed for optimum performance when used in

combination with the BR-S500 (calipers), BL-S500 (brake lever), SM-RT62 (rotor) and

Shimano pad unit.

• Obtain and read the service instructions carefully prior to installing the parts. Loose,

worn, or damaged parts may cause injury to the rider.

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.

CAUTION

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.

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.

Technical Service Instructions

SI-8EC0A

Disc Brake System

In order to realize the best performance, we recommend that the following

combination be used.

Caliper

BR-S500

Cable Supporter

SM-HANG

Brake Lever

BL-S500

Mineral Oil

SM-DB-OIL

Rotor

SM-RT62

Brake pad

Resin Pads

M07-S

unit

Hose

SM-BH59

I Installation of the hose

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.

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

• 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.

Adding mineral oil and bleeding air

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

normal use.

• 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 installation ring

TL-LR15

Brake lever fixing bolt

Allen key 5 mm

Caliper fixing bolt / Adapter fixing bolts

Allen key 5 mm

Brake pad fixing shaft

Radio pliers

Brake hose fixing bolt

8 mm wrench

Reservoir tank cover

Phillips screwdriver #1

Cable supporter

Phillips screwdriver #2

Bleed nipple

Socket wrench 7 mm

I 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

Fig. 1

Fig. 2

I Installation of the rotor

(SM-RT62)

Rotor

installation ring

Tightening torque:

TL-LR15

40 N·m {350 in. lbs.}

I Installation of the brake lever (BL-S500)

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.)

Brake lever Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

< For left lever >

With the brake lever depressed, open and close the bleed

nipple 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 bleed nipple again.

With the pad spacers still attached to

Brake lever should

the calipers, place the bicycle into a

be parallel to ground

bicycle stand or similar as shown in

the illustration. Set the brake lever so

that it is parallel to the ground, and

then remove the reservoir tank cover.

Fill the reservoir tank with oil and then replace the reservoir tank cover. Fill the reservoir tank to

overflowing with oil while replacing the cover to ensure that no air bubbles remain inside the

reservoir tank. In addition, be careful not to get any oil on parts such as the rotor and brake pads.

Reservoir tank

Hose

Calipers

Return the brake lever to its original position.

Socket wrench

(7mm)

Tube

Note:

Do not use brake fluid fillers, as they can cause small bubbles of air to form, and such

bubbles can cause severe drops in braking performance.

Set a 7mm socket wrench in place,

attach a bag to the tube, and then

I Installation of the calipers (BR-S500) and securing the hose

place the tube onto the bleed nipple

Bleed nipple

as shown in the illustration.

• Remove the pad spacer A (yellow), and then set the wheel

which has the rotor onto the frame.

• Install the brake pads.

Bag

After this, bend open the

split pin.

Loosen the bleed nipple by 1/8th of a turn to open it, and then pour oil into

the reservoir tank. Gently operate the brake lever while doing this to help

prime the system with the oil.

When the oil goes into the hose, the oil level

in the reservoir tank will drop, so be sure to

For international-standard mounts, attach adapters to calipers for post-type mounts.

continue adding oil to maintain the oil level

(Separate front and rear adapters are available.)

so that air is not drawn in through the port.

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

adapter to the frame.

Depress the brake lever so that the rotor is being clamped by the pads, and then tighten the

caliper fixing bolts.

G International standard mounting type

< Front >

Adapter

fixing bolts

If oil periodically comes out from the bleed

nipple, tighten the bleed nipple for a while.

If the brake lever is then operated, air bubbles in

Rotor

the system will rise up through the port into the

reservoir tank. Once the bubbles stop appearing,

depress the brake lever as far as it will go. The

< Rear >

normal condition is for the lever to be stiff at this

point.

Adapter

fixing bolts

Lever operation

Loose

Slightly stiff

Stiff

Either a cap method or a wire ring method can be used to stop the bolts from turning.

If the lever isn't stiff, adjust by the following procedure.

Use whichever method is suitable for the front fork and frame.

Cap method

< Front >

When the lever is depressed once more, bubbles will rise

up and be released into the reservoir tank. It can be useful

to shake the hose gently or shift the position of the calipers

at this time.

Wire ring method

< Front >

Becomes stiff

For C-shaped guides and the

usual type of cable stoppers,

use the special Shimano

cable supporter (sold

Bleed nipple

separately) to secure as

shown in the illustration.

Tightening torque:

4 - 6 N·m {35 - 53 in. lbs.}

Operate the brake lever several times and check whether

the brakes operate normally or not. Also check that there are no oil leaks visible.

I Brake pad replacement

Tightening torque:

0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}

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,

replace the brake pads.

Brake pads

Pad spacer A (yellow)

Split pin

I Adjustment when the pistons are not operating correctly

G Post mounting type

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

Provisionally install the caliper to the

pistons by the following procedure.

frame (so that the caliper can move

sideways), depress the brake lever so that

Adapter

the rotor is being clamped by the pads,

and then tighten the caliper fixing bolts.

< Front >

Caliper

I Mineral oil replacement

Caliper fixing

It is recommended that you replace the oil inside the reservoir tank if it becomes severely

bolts

discolored.

Caliper fixing

bolts

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.

Tightening torque:

Dispose of the waste oil according to proper country and/or state disposal regulations.

6 - 8 N·m {53 - 69 in. lbs.}

Tightening torque:

Please note: specifications are subject to change for improvement without notice. (English)

6 - 8 N·m {53 - 69 in. lbs.}

Caps

< Rear >

Post type

Caps

< Rear >

Wire

< C-shaped guide >

< Usual type of cable stopper >

Tightening torque:

0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}

Maintenance

Note:

The S500 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.

Brake pads

Remove the wheel from the frame, and remove the

brake pads as shown in the illustration.

Split pin

Clean the pistons and surrounding area.

Set the brake lever so that it is parallel to the ground,

and then remove the reservoir tank cover.

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.)

Piston

Install the new brake pads, and then

install the pad spacers B (red). After

this, bend open the split pin.

Depress the brake lever several times

to check that the operation becomes

stiff.

Check that the rotor and the brake

Split pin

pads do not touch each other, and then

Pad spacer B (red)

check the oil level (adding more oil if

required). After doing this, replace the

reservoir tank cover.

Remove the wheel and the brake pads.

Clean the pistons and surrounding area, set the brake lever so that it is parallel to the

ground, and remove the reservoir tank cover.

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

from the reservoir tank at this time.

Install the brake pads and the pad spacers B (red).

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.

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".

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

Return the brake lever to its original position.

This service instruction explains how to use

and maintain the Shimano bicycle parts

which have been used on your new bicycle.

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003

For any questions regarding your bicycle or

other matters which are not related to

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222

Shimano parts, please contact the place of

purchase or the bicycle manufacturer.

3-77 Oimatsu-cho Sakai-ku, Sakai, Osaka 590-8577, Japan