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Shimano BR-C501, Service Manual

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Shimano BR-C501 Service Manual Download Page 8

Disc Brake Line-up

BR-M965
ST-M965
SM-RT96
SM-BH96

XC Competition

M755-DH

For Downhill 203mm 
Roter and adapter

BR-M755
BL-M756
SM-RT75
SM-BH62

MTB All-around

BR-M555
BL-M556
SM-RT61
SM-BH62

BR-M525
BL-M525
SM-RT61
SM-BH59

MTB All-around

BR-M515-LA    SM-RT61

MTB Sport / Recreational

BR-M475    SM-RT61

BR-C901
BL-C901
SM-RT61
SM-BH61/60

Premium Comfort Disc Brakes for Utility / Recreational

BR-C601
BL-C600
SM-RT61

BR-C501
SM-RT61
ST-C503
SM-PM50

SM-PM50

Note : Hydraliuc disc brake hoses SM-BH96 / SM-BH62 /

SM-BH61 / SM-BH59 are cuttable

7

Shimano Disc Brake Featur

es

Summary of Contents for BR-C501

Page 1: ...77 Fax 65 6 6632504 This publication is printed on recycled paper Specifications are subject to change for improvement without notice MA8CMEC Dec 2002 Shimano Inc 1202 Printed in Japan XBC IZM UCI official neutral technical support Shimano recommends that helmets be worn at all times when riding bicycles When participating in the sports depicted in this brochure Shimano recommends that you use the...

Page 2: ...For best performance SHIMANO Disc Brake Systems Service manual vol 1 ...

Page 3: ...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 charac...

Page 4: ...t 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 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 th...

Page 5: ...ment Shimano genuine mineral oil brake pads rotors 12 13 Notes on installation 13 14 Replacement of the brake lever unit 14 Technical Notes Disc brake dimensions 15 16 Hub dimensions for Shimano disc brake 17 Dimensions for XTR Disc Rotor Hub 17 Combination Chart Hydraulic Disc 18 Brake Hose 19 Combination Chart Mechanical Disc 20 Power Modulator SM PM50 20 Brake Pad Interchangeability 21 Performa...

Page 6: ...ions Parts list Combination Chart P 18 Combination Chart P 20 Adjustable reach lever P 8 Brake lever Interchangeability P 20 Mount dimensions P 15 Brake Pad P 21 23 Preventing loosening of the bolts P 9 39 Installation of the rotor P 38 Installation of the hose P 19 33 Hose material length P 18 Mount dimensions P 15 Brake Pad P 21 Installation of shims P 9 28 Preventing loosening of the bolts P 9 ...

Page 7: ...n priorities As our testing confirmed the highest priority is not Power One of the most important things that a disc brake needs for severe off road conditions is a highly modulated feeling of control The brake must be able to provide a balance of speed control as well as strong stopping power when quick deceleration or stops are needed Our engineer s development and effort is in creating and impr...

Page 8: ... RT61 SM BH62 BR M525 BL M525 SM RT61 SM BH59 MTB All around BR M515 LA SM RT61 MTB Sport Recreational BR M475 SM RT61 BR C901 BL C901 SM RT61 SM BH61 60 Premium Comfort Disc Brakes for Utility Recreational BR C601 BL C600 SM RT61 BR C501 SM RT61 ST C503 SM PM50 SM PM50 Note Hydraliuc disc brake hoses SM BH96 SM BH62 SM BH61 SM BH59 are cuttable 7 Shimano Disc Brake Features ...

Page 9: ...spacer BR M965 966 Adjustable reach lever Center lock mounting system New shape shim for easy adjust Disc brake with power modulator 0 2mm 0 5mm TL LR15 Becomes wider Becomes narrower 4 finger Brake Lever SM PM50 Power Modulator Brake Caliper Rotor rotor lockring hub spline ...

Page 10: ...of the rotor Adapter for 203mm rotor SM RT75 DH SM RT75 61 SM RT96 for Manitou M965 M755 M555 M525 M515 M966 Y 8B2 98110 Y 8B2 98100 Y 8B2 98210 Y 8B2 98120 for Boxxer fork for International standard International standard Rear 0 2 mm 0 5 mm O rings NEW 0 5mm 0 9mm Preventing loosening of the caliper fixing bolts M755 M555 M525 M515 M475 C901 C601 C501 M965 M755 DH Wire Bolt Guide to brake pad rep...

Page 11: ...h hydraulic type systems which is not required for cable type systems is the prevention of vapor lock When the brakes are used the calipers and rotors become hot The heat from the calipers is transferred to the hydraulic oil which also becomes hot This heating of the oil can cause any water or air bubbles in the oil to expand which can cause sudden changes in the operating feel of the brake lever ...

Page 12: ...the reservoir tank Vapor lock may occur if the brakes are applied continuously To relieve this condition momentarily release the lever If vapor lock occurs stop riding the bicycle immediately The cause of vapor lock is usually water mixed in with the oil so replace the oil with Shimano genuine mineral oil If vapor lock occurs burn in period Disc brakes have a burn in period during which the rotors...

Page 13: ...es For some installations it will be necessary to mount a Shimano adapter for post type frame and fork bosses If an adaptor needs to be installed consult the place of purchase for further details Combining with other manufacturers products The Shimano disc brakes are designed for optimum performance when used in combination with the calipers brake lever rotor brake hose cable and the Shimano pad u...

Page 14: ...e snap rings or cotter pins when replacing the brake pads Brake pads If the rotors are bent or severely damaged they should be replaced Rotors Notes on installation I During installation or maintenance do not touch the rotor while it is turning otherwise injury may result I When connecting the hose apply Shimano genuine mineral oil to the O ring to help preserve the O ring from deterioration I The...

Page 15: ...wire to secure the caliper fixing bolt in order to prevent the bolt from loosening I If using shims to provisionally secure the calipers during installation be sure to only tighten the bolts to the specified torque The caliper holding force will be sufficient even if all of the supplied shims are used to eliminate any interference between the pads and the rotor I When removing the diaphragm inside...

Page 16: ...ont fork dimensions ø6 2 0 1 ø6 2 0 1 R87 3 0 1 R49 7 0 1 5 1 0 1 25 max 4 0 1 1 0 7 F F C A A G G D D B B C Dimension Cap type Wiring type Cap type Wiring type BR M965 BR M755 BR M555 BR M525 BR M515 BR C601 BR M475 BR C501 BR M965 BR M755 BR M555 BR M525 BR M515 BR C601 BR M475 BR C501 6mm 6mm 6mm 8mm 8mm A min 60 60 60 60 60 30 45 65 45 B min D max C min F min H min G max 12mm 8mm 8mm 45 50 45 ...

Page 17: ...Part C E C C G B B D D H A A Part D Dimension 6mm 6mm 6mm 8mm 8mm A min 60 60 60 60 60 30 45 90 45 B min D max C min F min H min G max 8mm 8mm 8mm 45 10 45 60 45 6 0mm 6 5mm 1 3mm 4mm 1mm 4mm Part C Dimension 6mm 6mm 6mm 8mm 8mm A min 60 60 30 60 60 60 45 45 B min D max C min H min 18mm 10mm 8mm 8mm 6 0mm 6 5mm 1 3mm 4mm 1mm 4mm Part D Cap type Wiring type BR M965 BR M755 BR M555 BR M525 BR M515 B...

Page 18: ...e the same as Hayes disc brake standard A B ø44 0 1 60 A Front Dimension B Dimension Rear 10 5 0 1 M755 15 1 16 7 M756 M525 M475 C501 15 3 16 9 15 25 0 1 A Front Dimension Rear 10 5 0 1 15 25 0 1 ø32 9 ø 1 6 0 ø52 8 9 1 75 A PCD ø44 ø38 8 Hub dimensions for Shimano disc brake Dimensions for XTR Disc Rotor Hub Technical Notes ...

Page 19: ...mpatible brake lever caliper 44mm 160mm 203mm For BR M755 DH for Manitou suspension Only for front side Not available for 2000 Manitou Mars CL Lock ring type mount 170mm 160mm 160mm Outside Diameter PCD mm Deore XT Deore Deore XT BR M555 M SM BH60 61 BL M555 BR M555 SM BH62 BL M556 International standard International standard Post mount Post mount International standard International standard XTR...

Page 20: ...t Banjo A Banjo nut Hose Olive O ring O ring Connector insert Banjo Hose Banjo sleeve Banjo bolt O ring SM BH96 Cutable ST M965 BR M965 M966 SM BH62 Cutable At brake lever end At caliper end SM BH61 Cutable SM BH59 Cutable Hose Caliper Banjo Banjo bolt O ring While pushing the brake hose tighten the banjo nut While pushing the brake hose tighten the connecting bolt While pushing the brake hose tig...

Page 21: ... good Good No good No good No good 4 finger No good No good No good Good 2 finger Good Good Good BR M515 LA BR C601 BR C501 BR M475 4 finger w modulator Caliper Mount type Brake Lever Roter PAD BR M515 LA International standard V brake BL 1 5 2 5finger BR M515 LA M Post mount only front V brake BL 1 5 2 5finger BR C601 International standard International standard V brake BL 4finger w modulator BR...

Page 22: ...ke pads in combination with the BR M515 BR M515 LA brake system If M08 brake pads are used the brake arm and caliper will touch before the pad wear indicator is noticed and a noise indicating that the pads need to be replaced is heard and this will result in a gradual reduction in braking performance until ultimately the brakes stop working C01 Easy controllable metal pad good for trekking use cab...

Page 23: ... Free ride Touring Recommended use XC Free ride Touring metal resin metal metal resin resin 1 2 0 3 4 5 Modulation Stopping power Weight Resists abrasion Wet Fade Noise Brake BR M755 DH metal resin Pad M03 Metal M04 Resin 5 4 4 4 4 4 4 Modulation Stopping power Resists abrasion Fade Noise Wet Weight 1 2 0 3 4 5 Modulation Stopping power Weight Resists abrasion Wet Fade Noise Brake BR M755 DH metal...

Page 24: ...esin Pad M02 Resin 5 3 3 3 5 3 5 Modulation Stopping power Resists abrasion Fade Noise Wet Weight Recommended use XC Free ride Touring Recommended use XC Free ride Touring Recommended use XC Free ride Touring metal resin metal metal resin resin 1 2 0 3 4 5 Modulation Stopping power Weight Resists abrasion Wet Fade Noise Brake BR M525 resin resin Pad M08 Resin 5 3 3 3 5 3 5 Modulation Stopping powe...

Page 25: ... 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 Maintenance nipple 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 Torx wrench 25 Flat tipped screwdriver Allen key 5 mm Allen...

Page 26: ... 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 25 Use a flat tipped screwdriver or similar tool to bend the edges of the tightening plate over the heads of the bolts as shown in Fig 3 Fig 2 Fig 3 While wearing gloves apply a force to th...

Page 27: ...o Hose O rings Banjo Hose O rings Banjo Tightening torque 5 7 N m 44 60 in lbs Tightening torque 5 7 N m 44 60 in lbs O rings BL M755 M555 BL M756 M556 ST M965 BL M525 BL M755 M555 BL M756 M556 At caliper end At caliper end Check that the hose is positioned as shown in the illustration Check that the O rings are positioned in the grooves at both the top and bottom of the banjo and then secure the ...

Page 28: ...htly stiff Stiff Lever operation Hose Calipers Reservoir tank Socket wrench 8mm Bleed nipple Tube Adding brake fluid and bleeding air 1 With the pad spacers 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 2 Set a 8mm socket wrench in place attach a bag to the tube and then place the t...

Page 29: ... Spacer 2mm 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...

Page 30: ... Separate front and rear adapters are available Rotor Calipers Frame mounting boss Shim 0 5mm 0 2mm BR M555 C901 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 BR M525 Frame Rotor C...

Page 31: ...e illustration Front Caps Caps Installation of the SHIMANO adapter and caliper Installation of the adapters for SM RT75 DH 203 mm rotors For front For rear Adapter Front fork Seat stay Adapter Post type Rear Front Caliper fixing bolts 20 mm Caliper fixing bolts 24 5 mm Adapter fixing bolts 20 mm Tightening torque 6 8 N m 53 69 in lbs Tightening torque 6 8 N m 53 69 in lbs Tightening torque 6 8 N m...

Page 32: ...f 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 C shaped guide Usual type of cable stopper Tightening torque 0 3 0 5 N m 2 7 4 4 in lbs Maintenance Note Disc brake system is designed so that as the brake pads become worn the pistons gradually move outward to automatic...

Page 33: ...o 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 pistons back in straight without bending them Note that some oil may overflow from the reservoir tank at this time 3 Install...

Page 34: ...leaks from the hose or the system Do not reuse the olive piece or the connector insert when reinstalling A damaged or reused olive or the connector insert may not provide secure hose connection possibly causing the hose to disconnect from the calipers or brake lever If the hose becomes disconnected there is the danger that the brakes may suddenly stop working WARNING When cutting the hose handle t...

Page 35: ...ome disconnected or fluid leaks may occur Hose 4mm Olive Vise TL BH61 Connector insert Connector insert Hose Caliper end Note The banjo should face at an angle of 90 to the calipers Banjo nut Banjo sold separately 3 After checking that the olive is positioned as shown in the illustration apply grease to the thread of the banjo nut and then tighten the banjo nut While pushing the brake hose tighten...

Page 36: ... In order to check that the end of the hose is fitted securely into the base of the hose mount of the brake lever make a mark on the hose beforehand as shown in the illustration As a guide the length of hose inside the mount should be approximately 14 mm measured from the cut end of the hose Apply grease to the outside of the olive Olive Grease 4 After checking that the olive is positioned as show...

Page 37: ...e hose is not touching the base of banjo A the hose may become disconnected or fluid leaks may occur Make sure that the banjo faces in the correct direction at this time Vise TL BH61 Banjo A brake lever end Note The banjo should face at an angle of 90 to the calipers of 90 to the calipers Direction of insertion Cut end Olive Banjo nut sold separately Hose 4 Slide the olive into banjo A until banjo...

Page 38: ...e to the TL BH61 as shown in the illustration and secure the TL BH61 in a vise Then use a hammer or similar tool to knock the connector insert in firmly until the base of the connector insert touches the end of the hose If the end of the hose is not touching the base of the connector insert the hose may become disconnected or fluid leaks may occur Hose 4mm Olive Vise TL BH61 Connector insert Conne...

Page 39: ...or Hub Rotor fixing bolts T25 torx Tightening torque 2 4 N m 18 35 in lbs Use a flat tipped screwdriver or similar tool to bend the edges of the tightening plate over the heads of the bolts as shown in Fig 3 Fig 2 Fig 3 Tightening plate While wearing gloves apply a force to the rotor to turn it in a clockwise direction as shown in Fig 2 While doing this tighten the rotor fixing bolts in the order ...

Page 40: ...by two clicks and then remove the spacer Tightening torque 6 8 N m 53 69 in lbs Spacer TL BR51 2 clicks Cable adjusting bolt Cable fixing bolt Inner cable 6 Securing the cable Pass the inner cable through the cable adjusting bolt and then tighten the cable fixing bolt 7 Depress the brake lever about 10 times until it touches the grip and check that there are no problems with any components and als...

Page 41: ...ting screw B side Tighten the pad adjusting screw to adjust A side Turn the cable adjusting bolt at the brake lever or the caliper body to adjust Adjust so that clearances A and B are both 0 2 0 4 mm If the brake pads are worn down to a thickness of 0 5 mm 0 9 mm replace the brake pads Replacing the brake pads 3 Install the new brake pads After this bend open the split pin Tighten the pad adjustin...

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