Routine Maintenance - Brakes
Shimano BR-M375 Caliper
Disc Brake Caliper
Your Fat Woody is equipped with a pair of Shimano BR-M375 Disc Brake Calipers. These calipers will require routine adjustment on a regular basis for optimal performance..
The most frequent routine maintenance adjustment is tightening the brake cable. This is needed when the brake lever pulls all the way to the grip with little braking force. It's very quick and easy, and takes only a minute or two.
The second type adjustment (less frequent) is installing/adjusting the caliper position on the disc rotor and brake pad clearance. If you hear the disc rotor hitting/rubbing the brake pads at a certain point of the wheel's rotation (vs. hearing rubbing for the complete rotation), this adjustment/alignment might be required.
⚠️ Caution - Disc brakes have a burn-in period, and the braking force will gradually increase as the burning 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.
Adjusting the Brake Cable
Brake cable needs adjustment when lever comes too far back.
This procedure is pretty straight forward and easy to perform.
If your brake lever is coming too far back before it actually applies the braking force, you need to tighten the brake cable by performing a brake cable adjustment.
This adjustment is typically required because the brake cable pulled/slipped through the cable clamp, probably by pulling a little too hard on the lever. That's normal operation and it is easily re-adjusted.
The procedure is the same for both front and rear brakes.
Tool Required: 10mm Wrench
⚠️ Important Note: Adjusting the brake cable works well when the caliper is properly positioned with respect to the disc rotor. If the caliper is not properly positioned, the caliper will need to be adjusted before adjusting the brake cable tension. Follow the caliper adjustments section further below.
Check the brake lever to ensure that there are no problems with any components, and also that the rotors and the pads do not interfere with each other when the wheel is rotated.
The brake should engage about a third to half way back.
If you prefer, you can use a couple spacers between the brake pads and the disc rotor. The most innovative tool to use as a spacer is an old plastic credit card or a thicker business card.
Cut it into a couple smaller pieces and insert a piece on each side of the disc rotor. Rotate the adjustment arm to clamp the spacers and then tighten the cable clamping bolt.
Remove the plastic spacers and you're properly adjusted.
Lastly, small precise brake cable adjustments can be made both on the caliper and the brake lever cable adjusting bolts - thumb and forefinger tightening. No tools required for that adjustment, but it is limited.
Installing/Adjusting the Brake Calipers
Adjusting the brake caliper is done whenever the caliper is installed for the first time, or if the caliper fixing bolts are loosened.
Caliper Adjustment Washer Kit
Your Fat Woody e-cruiser has been provided with a high quality titanium caliper adjustment kit. This kit allows the caliper to be precisely adjusted for optimal alignment with the rotor disc.
1. Install the caliper to the aluminum caliper adapter using the adjustment washers and caliper fixing bolts provided. You will be using a thread-lock adhesive, but we'll apply that after the adjustment is properly set. In the event you need to pull it back apart, the adhesive won't get on your components.
2. Install the wheel. The caliper can only be installed after the bicycle wheel / brake rotor is mounted.
3. Loosen the caliper fixing bolts. This allows the caliper to move laterally (left/right) on the adapter bracket while fitting it over the disc rotor and attaching it to the frame.
4. Install the caliper clamp bolts (with lock washers) and tighten. The titanium caliper fixing bolts should still be loose and the caliper will move about a little bit.
4. Install the caliper clamp bolts (with lock washers). The titanium caliper fixing bolts should still be loose and the caliper will move about a little bit. Apply pressure to the adapter in the counterclockwise direction while tightening the caliper clamp bolts.
Securing the Brake Cable
1. Pass the brake cable through the cable adjusting bolt, and then under the loosened cable clamp. Leave the brake arm in the idle position and gently tighten the cable clamping bolt. You don't need to torque it at this point.
The brake caliper fixing bolts should still be loose at this point, and the caliper should be free to move about slightly.
On the inboard side of the brake caliper is a pad adjusting screw that moves the inboard brake pad in/out.
2. Using a 5mm allen key, loosen the pad adjusting screw all the way out (counterclockwise) till it stops and then tighten 4-5 clicks (clockwise).
3. Loosen the cable clamping bolt and rotate the brake adjustment arm until tight. Pull any slack out of the brake cable and tighten the cable clamping bolt.
4. While depressing the brake lever, set the calipers to the required position and then tighten the two caliper fixing bolts alternately by small amounts each time.
5. Loosen the cable clamping bolt to release the tension on the brake caliper.
6. Loosen the pad adjusting screw by two or three clicks.
The inboard pad is stationary and does not move when the brake caliper is operated. Only the outboard pad moves.
⚠️ The goal here is to adjust the inboard pad out just far enough that it does not touch the disc rotor while the wheel turns freely.
7. Adjust the brake cable tension by loosening the cable clamping bolt and rotating the brake adjustment arm until tight. Before tightening the cable clamping bolt, back off the adjustment arm just enough that the outboard brake pad doesn't rub the disc rotor while the wheel spins freely.
8. Check the brake lever to ensure that there are no problems with any components, and also that the rotors and the pads do not interfere with each other when the wheel is rotated.
The brake should engage about a third to half way back.
9. The last and final step is putting some thread lock adhesive on the caliper fixing bolts.
⚠️ At this point, don't loosen both caliper fixing bolts at the same time. Make sure that both are tight.
Loosen only one of the caliper fixing bolts and carefully remove it. Apply a small drop of thread lock adhesive (doesn't take much) to the threads and re-insert the bolt. Tighten/torque as necessary.
Repeat the procedure for the second bolt.