Shimano SM-BH96 Operating instructions

Technical Service Instructions SI-8H30C
SM-BH96 Brake Hose
General Safety Information
WARNING
• After installing SM-BH96 hose to the brake unit, adding brake fluid and
bleeding air bubbles, depress the lever again several times to check
that the brakes are operating normally and there are no fluid 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.
• Cut the hose so that the cut end is perpendicular to the length of the
hose. If the hose is cut at an angle, fluid leaks may result.
• 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.
• Obtain and read the service instructions carefully prior to installing the
parts. Loose, worn, or damaged parts may cause serious 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.
• When cutting the hose, handle the knife carefully so as not to cause
injury.
• Be careful to avoid injury from the olive.
Note
• Parts are not guaranteed against natural wear or deterioration
resulting from normal use.
• Read these Service Instructions together with the Service Instructions
for the BR-M965 / M966.
• For maximum performance we highly recommend Shimano lubricants
and maintenance products.
CAUTION
Connector insert
Cut end
Olive
Banjo nut
Hose
90 degrees
SM-BH96
Series
Brake Hose
Caliper
Brake Lever
Mineral Oil
BR-M965 /M966
ST-M965
SM-DB-OIL
In order to realize the best performance, we
recommend that the following combination be used.
XTR
t

Installation
* Make sure that you handle the utility
knife safely and correctly in accordance
with the instructions which are provided
with the utility knife.
1. Use a utility knife or similar tool
to cut the hose.
2. < At brake lever end >
Pass the hose through the banjo nut and the olive as shown
in the illustration.
Cut end
Olive
Banjo nut
Hose
Direction of insertion
Apply grease to the
outside of the olive.
Olive
Grease
3. Use an object such as a needle to smooth the inside of the cut end of the
hose, and then install the connector insert. Attach the hose 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.
Banjo nut
4. 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
the banjo nut.
Tightening torque:
5 - 7 N·m {44 - 60 in. lbs.}
Hose
4mm
Olive
Vise
TL-BH61
Connector insert
Connector
insert
Hose
Olive 5mm
Hose Connector insert
Caliper end
Note : The banjo should face at
an angle of 90° to the
calipers.

Please note: specifications are subject to change for improvement without notice. (English)
© Apr. 2003 by Shimano Inc. XBC IZM Printed in Japan
One Holland, Irvine, California 92618, U.S.A. Phone: [phone]
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: [phone]
3-77 Oimatsu-cho, Sakai, Osaka 590-8577, Japan
5. < Installation of the hose >
Check that the O-rings are positioned in the grooves at both the top and
bottom of the banjo, and then secure the banjo to the brake lever and
calipers as shown in the illustration. Make sure that the O-rings do not
protrude from the grooves at this time. The O-ring has grease applied.
At brake lever end At caliper end
Tightening torque:
5 - 7 N·m {44 - 60 in. lbs.}
Hose
Hose
Banjo
Banjo
O-rings
O-rings
t