DAHON ALFINE DISC BRAKE SYSTEM - TECHNICAL Service Instructions
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Type: Service instructions for DAHON ALFINE DISC BRAKE SYSTEM - TECHNICAL
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Download DAHON ALFINE DISC BRAKE SYSTEM - TECHNICAL Service instructions
1
General Safety Information
• 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.
• 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 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.
■ 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 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.
■ 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.)
■ Installation of the calipers (BR-S500) and securing the hose
• Remove the pad spacer A (yellow), and then set the wheel
which has the rotor onto the frame.
• Install the brake pads.
After this, bend open the
split pin.
■ Brake pad replacement
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.
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.
Caliper fixing
bolts
Caliper fixing
bolts
■ Installation of the rotor
(SM-RT62)
Rotating
direction of
wheel
Front left Rear left Rear right Front right
Fig. 2Fig. 1
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.
• Parts are not guaranteed against natural wear or deterioration resulting from
normal use.
• For maximum performance we highly recommend Shimano lubricants and
maintenance products.
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.
WARNING
CAUTION
Installation
Adding mineral oil and bleeding air
Maintenance
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.
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.
< 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".)
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.
Technical Service Instructions SI-8EC0A
Disc Brake System
4 1
Caliper
Brake Lever
Rotor
Hose
BR-S500
BL-S500
SM-RT62
SM-BH59
Cable Supporter
Mineral Oil
Brake pad
unit
Resin Pads
SM-HANG
SM-DB-OIL
M07-S
In order to realize the best performance, we recommend that the following
combination be used.
The following tools are needed to assemble this product.
Usage location
Rotor installation ring
Brake lever fixing bolt
Caliper fixing bolt / Adapter fixing bolts
Brake hose fixing bolt
Reservoir tank cover
Cable supporter
Bleed nipple
TL-LR15
Allen key 5 mm
Allen key 5 mm
Brake pad fixing shaft Radio pliers
8 mm wrench
Phillips screwdriver #1
Phillips screwdriver #2
Socket wrench 7 mm
Tool
Rotor
installation ring
TL-LR15
Hose
Bleed nipple
Reservoir tank
Calipers
Socket wrench
(7mm)
Tube
Bleed nipple
Bag
Tightening torque:
40 N·m {350 in. lbs.}
Lever operation
Loose Slightly stiff Stiff
Brake lever Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
< For left lever >
< For left lever >
1. With the pad spacers still attached to
the calipers, place the bicycle into a
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.
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.
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.
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.
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. Set the brake lever so that it is parallel to the ground,
and then remove the reservoir tank cover.
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 B (red). After
this, bend open the split pin.
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, set the brake lever so that it is parallel to the
ground, 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 B (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 the rotor and the caliper. If they are touching, adjust while referring to
"Installation of the caliper".
6. After checking the oil level, replace the reservoir tank cover.
7. Return the brake lever to its original position.
■ 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.
Please note: specifications are subject to change for improvement without notice. (English)
© May 2006 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.
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.
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.
7. Return the brake lever to its original position.
● International standard mounting type
< Front >
< Front >
< Rear >
● Post mounting type
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.
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. 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.
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.
Brake lever should
be parallel to ground
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
Tightening torque:
4 - 6 N·m {35 - 53 in. lbs.}
Tightening torque:
0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}
Tightening torque:
0.3 - 0.5 N·m {2.7 - 4.4 in. lbs.}
Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
Tightening torque:
6 - 8 N·m {53 - 69 in. lbs.}
Cap method
Wire ring method
< C-shaped guide > < Usual type of cable stopper >
< Front >
Post type
< Rear >
< Rear >
Caps
Wire
Caps
Caps
Pad spacer A (yellow)
Adapter
Caliper
Brake pads
Brake pads
Piston
Pad spacer B (red)
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, Osaka 590-8577, Japan
Rotor
< Front >
Wire
Split pin
Split pin
Split pin
Adapter
fixing bolts
Adapter
fixing bolts