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Disc Brake System In the case of carbon handlebars, it may be
necessary to lower the tightening torque in
order to prevent damage to the handlebar.
Please consult the bicycle or handlebar manufacturer regarding the appropriate
level of tightening torque for carbon handlebars.
General Safety Information
Wire
Bolt
For post type (BR-M966)
In order to realize the best performance, we recommend that the following combination
be used.
Technical Service Instructions
SI-8CM0F
Rotating
direction of
wheel
Fig. 1
Fig. 2
Front right
Rear left Rear right
Front left
Resin Pads
Metal Pads
Installation
Caliper
Brake Lever
Rotor
Hose
BR-M965 / BR-M966
ST-M965
SM-RT96
SM-BH96
Cable Supporter
Mineral Oil
Brake pad
unit
SM-HANG
SM-DB-OIL
M07
M06
The following tools are needed to assemble this product.
Tool
TL-LR15
Allen key 4 mm
Allen key 5 mm
Allen key 5 mm
Flat-tipped screwdriver
Phillips screwdriver #1
Phillips screwdriver #2
Allen key 3 mm
Socket wrench 7 mm
Usage location
Rotor installation ring
Brake lever fixing bolt
Caliper fixing bolt
Adapter (post type) fixing bolt
Brake pad fixing shaft
Reservoir tank cover
Cable supporter
Brake hose fixing bolt
Bleed nipple
Calipers
Frame
mounting boss
Rotor
Shim
(0.5mm, 0.2mm)
Adding mineral oil and bleeding air
1.
With the pad spacers
F
A (yellow) still attached to the calipers, place the
bicycle into a bicycle stand or similar as shown in the illustration so that the
reservoir tank is parallel to the ground.
Tank should be parallel
to the ground
3.
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.
2.
Set a 7mm socket wrench in place, attach a bag to the tube, and then place
the tube onto the bleed nipple as shown in the illustration.
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
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 normal condition is for the lever to be stiff at
this point.
If the lever isn't stiff, adjust by the following procedure.
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.
Becomes stiff
5.
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.
Tightening torque:
0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}
6.
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.
7.
Return the brake lever to its original position.
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.
Installation of the calipers (BR-M965)
and securing the hose.
4.
When the oil goes into the hose, the oil level in
the reservoir tank will drop, so be sure to
continue adding oil to maintain the oil level so
that air is not drawn in through the port.
Tightening torque:
4 - 6 N·m {35 - 53 in. lbs.}
Calipers
Hose
0.2 mm
0.5 mm
While wearing protective gloves, apply
a force to the calipers to turn it in a
counterclockwise direction. While
doing this, tighten the fixing bolts.
Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
Remove the pad spacer
F
A (yellow), and then set the wheel
which has the rotor onto the frame.
Install the brake pads.
Start with two 0.5 mm thick shims, and use the 0.2
mm shims for fine tuning. tighten the calipers, and
check that the calipers and the rotor do not
interfere with each other. Next, the caliper fixing
bolts do not contact the rotor.
Lever operation
Loose
Slightly stiff
Stiff
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.
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.
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
M965 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.
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.
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
M07 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 M06 pads.
Handling the mineral oil
Use safety glasses when handling, and avoid contact with eyes. Contact with eyes may resul