Shimano_XTR_M975_usermanual_bleedprocedure Shimano XTR M975 Usermanual Bleedprocedure

User Manual: Shimano_XTR_M975_usermanual_bleedprocedure

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Oil bottle

Bleed nipple

1. Place the reservoir tank so that it is parallel to the ground,

and then remove the reservoir tank cover.

(Refer to step 1 in "Adding oil and bleeding air at the

reservoir tank")

2. Attach a 7 mm socket wrench, and fill the syringe with oil

and connect a hose to the bleed nipple. Then loosen the

bleed nipple by 1/8 of a turn to open it. Push the plunger of

the syringe to add oil. The oil will start coming out from the

reservoir tank. Continue adding oil until there is no more air

mixed in with the oil that is coming out. (If using the Shimano bleeding tool, be sure to read the

service instructions for the Shimano bleeding tool.)

3. Once air stops coming out, temporarily close the bleed nipple. (If the Shimano bleeding tool has

been installed to the brake lever at this time, remove the Shimano bleeding tool.)

4. Connect the oil bottle to the bleed nipple, and then loosen the bleed nipple. After a little while, the

oil and air will flow naturally from the bleed nipple into the tube of the oil bottle. In this way it will be

possible to easily extract the greater part of the air remaining inside the brake system.

It may help to shake the hose gently or to tap the reservoir tank or caliper gently with a screwdriver

or move the position of the caliper at this time.

Do not continually squeeze and release the lever at this point.

If this is not observed, air bubbles may remain mixed in with the oil inside

the caliper, and it will take longer to bleed the air. (If the lever is

continually squeezed and released, drain out all of the oil and then add oil

again.)

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.

9. 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.

10. Return the brake lever to its original position.

6. Once air stops coming out from the bleed nipple, temporarily tighten the bleed nipple.

7. 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.

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

Please note: specifications are subject to change for improvement without notice. (English) © Mar. 2007 by Shimano Inc. XBC IZM Printed in Japan.

Hose

Diaphragm

Diaphragm

Base of reservoir tank

Diaphragm

Reservoir tank

Reservoir tank

Calipers

Lever operation

Loose Slightly stiff Stiff

1. With the spacer for bleeding (yellow) still attached to the calipers, place the bicycle into a bicycle

stand or similar as shown in the illustration.

Set so that the brake lever is

parallel to the ground, and then

remove the reservoir tank cover.

Tu r n the lever unit so that the top of the reser vo ir ta nk is parallel t o the

ground, and then remove the reservoir tank cover.

Note : When reassembling, set the

diaphragm so that it is aligned at the

same angle as the base of the

reservoir tank.

< BL-M975/M775 >

< ST-M975/M775 >

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.

4. Oil will come out periodically from the bleed nipple about every 5 minutes.

5. After a little while, the oil and air will flow naturally from the bleed nipple into the tube. In this way it

will be possible to easily extract the greater part of the air remaining inside the brake system.

It may help to shake the hose gently or to tap the reservoir tank or caliper gently with a screwdriver

or move the position of the caliper at this time.

8. 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.

Brake lever

should be parallel

to ground

Socket wrench

(7mm)

Tub e

Bleed nipple

Bag

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.

Tub e

Bleed nipple

Bag

Reservoir tank

Te c h n i c a l Ser vice I n s t r uctions SI-0037A-001

Adding mineral oil and bleeding air

■Adding oil and bleeding air at the reservoir tank

■Adding oil and bleeding air at the caliper using a syringe

(including Shimano bleeding kit)

Tightening torque:

0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}

Tightening torque:

4 - 6 N·m {35 - 53 in. lbs.}

The oil level in the reservoir

tank will drop at this time, so

be sure to keep adding oil to

maintain the oil level so that

air is not drawn in through

the port (so that air does not

enter through the port).

5. Carry out steps 6 to 10 in "Adding oil and bleeding air at the reservoir tank".

The oil level in the reservoir

tank will drop at this time, so

be sure to keep adding oil to

maintain the oil level so that

air is not drawn in through

the port (so that air does not

enter through the port).

DESCRIPTION

SHIMANO

CODE NO.

ITEM

NO.

*

0808-2612A

Lid Unit

Lid

Diaphragm

Lever Axle Fixing Bolt

Lever Axle

Lever Unit

Lever Member

Adjust Boss & Boss Spacer

Clamp Bolt (M8 x 16) & Washer

1

2

3

4

5

6

7

8

9

Y-8U0

Y-8U0

Y-8U0

Y-8SZ

Y-8U0

Y-8U0

Y-8U0

Y-8U0

Y-6AU

98010

98080

24000

07000

98020

98030

98040

98050

98090

A: Same parts.

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

Absence of mark indicates non-interchangeability.

INTERCHANGE-

ABILITY

A

A A

ST-M966

ST-M975

For Left Hand

For Right Hand

1

2

3

1

2

3

4

4

5

5

6

78

6

78

9

9

For Disc Brake

BL-M975

XTR Brake Lever

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 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.

•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

M975 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.

•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.

•M07Ti 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 M06Ti 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: +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. 2009 by Shimano Inc. XBC IZM Printed in Japan.

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.

■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 calipers (BR-M975)

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.

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.

While wearing protective gloves, apply

a force to the calipers to turn it in a

counterclockwise direction. While

doing this, tighten the fixing bolts.

■Installation of the rotor

(SM-RT97)

SM-RT97L (203mm)

SM-RT97M (180mm)

SM-RT97 (160mm)

SM-RT97SS (140mm)

* The RT97SS (140 mm) rotor is

for rear use only.

* For the HB-M975, the

right side of the front

wheel can be a radial

spoke type.

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

Flat-tipped screwdriver

Phillips screwdriver #1

Phillips screwdriver #2

8 mm wrench

Socket wrench 7 mm

Tool

Tightening torque:

40 - 50 N·m {350 - 435 in. lbs.}

Te chn ic al Ser v i ce I n str uct io ns SI-8E50C-004

Disc Brake System

(For Cross-Country)

Caliper

Brake Lever

Rotor

Hose

BR-M975

ST-M975 / BL-M975

SM-RT97

SM-BH59

Cable Supporter

Mineral Oil

Brake pad unit Resin Pads

Metal Pads

SM-HANG

SM-DB-OIL

M07Ti

M06Ti

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

combination be used.

■Installation of the brake lever

< ST-M975 >

Secure the brake lever as shown in the

illustration.

< BL-M975 >

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.)

■Installation of the hose

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.}

Brake lever Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

< For left lever >

< For right lever >

ST-M975

BL-M975

For post type (BR-M975P)

0.2 mm 0.5 mm

If bolt 1tries to loosen (turn in the counterclockwise direction), force is applied

via the wire to turn bolt 2in the tightening direction (clockwise). However, bolt

2cannot turn any further in the tightening direction.

Accordingly, this prevents bolt 1from turning in the loosening direction

because it is also connected via the wire.

If either one of the bolts tries to loosen, this causes a force to be applied to the

other bolt to turn it in the tightening direction. In other words, this system

prevents the bolts from loosening.

Shim

Brake pads

Bolt 1

Bolt 2

Spacer for bleeding

Shim

(0.5mm, 0.2mm)

Frame

mounting boss

Rotor

Wire

Wire

Bolt

Calipers

Tightening torque:

0.2 - 0.4 N·m {1.8 - 3.5 in. lbs.}

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Secure the two bolts with a length of wire as shown

in the illustration in order to prevent the bolts from

coming loose.

Rotor fixing

lock ring

TL-LR15

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.}

Tightening torque:

0.2 - 0.4 N·m {1.8 - 3.5 in. lbs.}

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

■Brake pad replacement

Maintenance

Note: The M975 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.

2. Clean the pistons and surrounding area.

3. Remove the reservoir tank cover while referring to the

step (1) in "Adding mineral oil".

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). Make

sure that you do not forget to install the

snap rings at this time also.

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

7. Check that the rotor and the brake pads do not touch each other, and then check the oil

level (adding more oil if required). After doing this, replace the reservoir tank cover.

■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.

Be sure to read the service instructions for the “Adding mineral oil and

bleeding air” in conjunction with these service instructions.

Brake pads

Pad spacer (red)

Snap ring

Snap ring

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.

Piston

Installation

SI-8E50C-004-00

■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 and

140 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.