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Related Manuals for Shimano DEORE Series
Summary of Contents for Shimano DEORE Series
- Page 1 DM-MBDBR01-00 (English) Dealer's Manual ROAD Trekking City Touring/ URBAN SPORT E-BIKE Comfort Bike HYDRAULIC DISC BRAKE DEORE BR-M6100 BR-M6120 BL-M6100 Non-Series BR-MT410 BL-M4100...
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Page 2: Table Of Contents
Replacing the brake pads ..............36 SHIMANO genuine mineral oil replacement ........39 • Draining the mineral oil ......................39 • Adding SHIMANO genuine mineral oil and bleeding air ............ 42 Replacing the brake hose ..............52 • Checking and cutting the hose length .................. 52 •... -
Page 3: Important Notice
• All manuals and technical documents are accessible online at https://si.shimano.com. • For consumers who do not have easy access to the internet, please contact a SHIMANO distributor or any of the SHIMANO offices to obtain a hardcopy of the User's Manual. -
Page 4: To Ensure Safety
• Be sure to follow the instructions provided in the manuals when installing the product. It is recommended to use SHIMANO genuine parts only. If parts such as bolts and nuts become loose or damaged, the bicycle may suddenly fall over, which may cause serious injury. - Page 5 TO ENSURE SAFETY • Check the thickness of the brake pads and do not use them if they have a thickness of 0.5 mm or less. Doing so may prevent the brakes from operating and result in serious injury. 2 mm 0.5 mm •...
- Page 6 Doing so may prevent the brakes from operating and result in serious injury. • Do not use oil other than SHIMANO genuine mineral oil. Doing so may prevent the brakes from operating and result in serious injury.
- Page 7 CAUTION Be sure to also inform users of the following: „ Cautions on SHIMANO genuine mineral oil • In the event of eye contact, flush with fresh water and seek medical assistance immediately. Contact with skin may cause a rash and discomfort.
- Page 8 • Do not drink. May cause vomiting or diarrhea. • Keep out of reach of children. • Do not cut, let near heat, weld or pressurize the SHIMANO genuine mineral oil container. Doing so may cause an explosion or fire.
- Page 9 • Products are not guaranteed against natural wear and deterioration from normal use and aging. • For maximum performance we highly recommend SHIMANO lubricants and maintenance products. For installation to the bicycle, and maintenance: • The 203 mm and 180 mm disc brake rotors have a larger diameter than the 160 mm disc brake rotor for cross-country bicycles, and so the warping of these disc brake rotors is greater.
- Page 10 TO ENSURE SAFETY • If the brake lever is depressed without the pad spacers installed, the pistons will protrude further than is normal. Use a flat-shaped tool to push back the brake pad, while being careful not to damage the surface of the brake pads. (If the brake pads are not installed, use a flat-shaped tool to 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 bleed screws and then try again.
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Page 11: List Of Tools To Be Used
LIST OF TOOLS TO BE USED LIST OF TOOLS TO BE USED The following tools are needed for installation/removal, adjustment, and maintenance purposes. Tool 2 mm hexagon wrench 2.5 mm hexagon wrench 3 mm hexagon wrench 4 mm hexagon wrench 5 mm hexagon wrench 8 mm spanner 7 mm box wrench... -
Page 12: Installation/Removal
INSTALLATION/REMOVAL Installing the brake lever INSTALLATION/REMOVAL Installing the brake lever For the installation method when installing with an I-SPEC EV type shifting lever, refer to the dealer's manual of the shifting lever being used. When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque with the carbon frame or handlebar manufacturer. - Page 13 INSTALLATION/REMOVAL Installing the brake lever Attach the brake lever to the handlebar. Secure the lever using the mounting bolt. Mounting bolt 4 - 6 N·m When installing the brake lever in combination with a standard type shifting lever, install the brake lever so that the position of the shifting lever band is within the range shown in the figure.
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Page 14: Installing The Disc Brake Rotor
INSTALLATION/REMOVAL Installing the disc brake rotor Installing the disc brake rotor Check that the spokes are laced as shown in the figure. Radial lacing cannot be used. Front left Rear left Rear right Front right Set the disc brake rotor on the hub, and then secure it with the disc brake rotor lock ring. -
Page 15: Removing The Disc Brake Rotor
INSTALLATION/REMOVAL Removing the disc brake rotor Removing the disc brake rotor Perform the removal of the disc brake rotor in the reverse order from the installation procedure. Installing the brake caliper Post mount type Install the wheel with an attached disc brake rotor onto the frame. Remove the bleed spacer (yellow). - Page 16 INSTALLATION/REMOVAL Installing the brake caliper Set the brake pad presser spring in the brake pads. Since there are fins on the front and rear of the finned pads, set the pads as shown in the figure. When a brake pad has markings, take note of the left (L) and right (R) markings to set it. Brake pad presser spring Finned pads Install the brake pads.
- Page 17 INSTALLATION/REMOVAL Installing the brake caliper Temporarily install the caliper on the frame without fully tightening the fixing bolts so that the caliper can still move horizontally. If it is necessary to install a mount adapter, temporarily install the adapter after setting it on the caliper.
- Page 18 INSTALLATION/REMOVAL Installing the brake caliper Depress the brake lever so that the disc brake rotor is held between the pads, and then tighten the caliper fixing bolts. If the brake hose is not already installed in the caliper, install the brake hose and then perform the step.
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Page 19: International-Standard Mount Type
INSTALLATION/REMOVAL Installing the brake caliper International-standard mount type NOTICE • For international-standard mounts, a dedicated adapter is required. Install the wheel with an attached disc brake rotor onto the frame. Remove the bleed spacer (yellow). (1) Close the tip of the split pin. (2) Remove the split pin. - Page 20 INSTALLATION/REMOVAL Installing the brake caliper Install the brake pads. (1) Set the brake pads in the caliper. (2) Insert the split pin. (3) Open the tip of the split pin. Brake pads Split pin...
- Page 21 INSTALLATION/REMOVAL Installing the brake caliper Temporarily install the caliper on the adapter, and then install it onto the frame. Tighten with the adapter fixing bolts. * Leave enough slack so that the caliper can still move horizontally. Rear Front (Temporary) 6 - 8 N·m Caliper fixing bolts Adapter fixing bolts...
- Page 22 INSTALLATION/REMOVAL Installing the brake caliper Depress the brake lever so that the disc brake rotor is held between the pads, and then tighten the caliper fixing bolts. If the brake hose is not already installed in the caliper, install the brake hose and then perform the step.
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Page 23: Installing The Brake Hose
INSTALLATION/REMOVAL Installing the brake hose NOTICE • Use the supplied snap rings. Other models of snap rings cannot be installed. Installing the brake hose Overview of the easy hose joint system Brake caliper Hose cap Brake hose connection port Lever stopper Brake lever... -
Page 24: Checking The Length Of The Hose
INSTALLATION/REMOVAL Installing the brake hose Checking the length of the hose Route the brake hose into the final installation position. Do not remove the hose caps from the ends of the brake hoses. NOTICE • This figure is only for explanatory purposes. For details on how to route the brake hoses, consult the manufacturer of the bicycle or refer to the bicycle's manual. - Page 25 INSTALLATION/REMOVAL Installing the brake hose Check the appropriate length of the brake hose. Secure the brake lever in the position used when riding. Check the mark on the brake hose with the edge of the brake lever connecting bolt. * If the hose is at the appropriate length, it is not necessary to cut the hose. Proceed to “Connecting the hose”...
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Page 26: Cutting The Hose
Use care when cutting the hose, as oil may leak when the hose is cut. NOTICE • Make sure to also refer to the manual for SHIMANO original tool TL-BH62. • Do not move the lever indicated in the figure before disassembling SHIMANO original tool TL-BH62. - Page 27 INSTALLATION/REMOVAL Installing the brake hose Add a cut mark. Add a cut mark 18 mm towards the end of the hose from the witness mark. * When not using an easy hose joint system, add a cut mark 11 mm towards the end of the hose from the witness mark.
- Page 28 INSTALLATION/REMOVAL Installing the brake hose Place the brake hose in tool TL-BH62. When inserting the brake hose, make sure that the cut mark is parallel with the groove in the tool. Groove Cut mark Check the cut location and secure the brake hose in place.
- Page 29 INSTALLATION/REMOVAL Installing the brake hose Check that the hose is secure, and then install the hose cutter. Hose cutter Press the hose cutter as shown in the figure to cut the brake hose. Remove the hose cutter and check that the cut end is even. 90°...
- Page 30 NOTICE • When connecting with an easy hose joint system, a specialized connector insert (BL-M6100: SHIMANO CODE No.: Y8JA98020/color: silver, BL-M4100: SHIMANO CODE No.: Y8H298040/color: gold) must be used. Use of any connector insert other than the specified one may lead to oil leakage and other malfunctions.
- Page 31 INSTALLATION/REMOVAL Installing the brake hose Depress the lever on tool TL-BH62 to install the connector insert in the brake hose. Check that the connector insert is installed correctly. Remove the brake hose from tool TL-BH62.
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Page 32: Connecting The Hose
INSTALLATION/REMOVAL Installing the brake hose Connecting the hose Remove the hose cap. If the brake hose was cut, it is not necessary to remove the hose cap. Pass the hose cover over the brake hose. Hose cover Secure the brake lever with a tool such as a vise. Secure the hose connection port so that it is facing upward. - Page 33 INSTALLATION/REMOVAL Installing the brake hose Insert the brake hose in the brake hose connection port. The lever comes with a pre-installed olive. When inserting the hose, ensure it does not snag on the olive. Insert the hose up to the witness mark added beforehand on the surface of the hose is covered.
- Page 34 Operate the brake lever several times and check that the brake pads grip the disc brake rotor and that the lever becomes stiff. If the lever does not become stiff, refer to “Adding SHIMANO genuine mineral oil and bleeding air” and bleed the air from the system.
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Page 35: Adjustment
ADJUSTMENT Adjusting the reach ADJUSTMENT Adjusting the reach Turn the adjustment bolt to adjust the reach. Tightening the adjustment bolt (clockwise) widens the distance between the initial position of the brake lever and the handlebar, while loosening bolt (counterclockwise) narrows it. BL-M4100 BL-M6100 Reach adjustment... -
Page 36: Maintenance
MAINTENANCE Replacing the brake pads MAINTENANCE Replacing the brake pads Replace the brake pads in the following circumstances. • When oil adheres to the brake pads • When the brake pads are worn down to a thickness of 0.5 mm •... - Page 37 MAINTENANCE Replacing the brake pads Push the pistons straight back as far as they will go. This brake system is designed to automatically adjust the clearance between the disc brake rotor and the brake pads by the pistons gradually protruding in relation to the wear of the brake pads.
- Page 38 MAINTENANCE Replacing the brake pads Install the brake pads. (1) Set the brake pads in the caliper. (2) Insert the split pin. (3) Open the tip of the split pin. (4) Install the pad spacer (red). Brake pads Split pin Pad spacer (red) Depress the brake lever a few times and make sure that the lever operation becomes stiff.
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Page 39: Shimano Genuine Mineral Oil Replacement
MAINTENANCE SHIMANO genuine mineral oil replacement SHIMANO genuine mineral oil replacement It is recommended to change your oil when the oil in the reservoir tank becomes noticeably discolored. Draining the mineral oil Follow local county and/or state codes for disposal of used oil. - Page 40 MAINTENANCE SHIMANO genuine mineral oil replacement Remove the bleed screw and O-ring. Bleed screw O-ring Install a bag and tube on the bleed boss/bleed nipple. BR-M6100/BR-MT410 (1) Place a 3 mm hexagon wrench in the position shown in the figure.
- Page 41 MAINTENANCE SHIMANO genuine mineral oil replacement BR-M6120 (1) Place a 7 mm box wrench in the position shown in the figure. (2) Connect the tube with bag attached to the bleed nipple. Bleed nipple Loosen the bleed screw/bleed nipple. The oil will begin to drain. Operating the brake lever while the oil drains will allow the oil to drain more easily.
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Page 42: Adding Shimano Genuine Mineral Oil And Bleeding Air
SHIMANO genuine mineral oil replacement Adding SHIMANO genuine mineral oil and bleeding air When adding oil, use only SHIMANO genuine mineral oil. When bleeding the air out of the caliper, you will need the SM-DISC (oil funnel and oil stopper). - Page 43 MAINTENANCE SHIMANO genuine mineral oil replacement Remove the bleed screw and O-ring, and then insert the oil funnel. Do not insert the oil stopper. Bleed screw Oil funnel O-ring Add the oil through the bleed boss/bleed nipple. Do not depress and release the lever repeatedly. Doing so will lengthen the amount of time needed to bleed the air as it will cause air bubbles to remain inside the brake caliper, even if no bubbles appear.
- Page 44 MAINTENANCE SHIMANO genuine mineral oil replacement BR-M6100/BR-MT410 (1) Place a 3 mm hexagon wrench in the position shown in the figure. (2) Remove the bleed boss cap, fill the syringe with oil, and then connect the tube to the bleed boss.
- Page 45 MAINTENANCE SHIMANO genuine mineral oil replacement Once there are no more air bubbles mixed in with the oil, temporarily tighten the bleed screw/bleed nipple. BR-M6120 BR-M6100/BR-MT410 Bleed nipple Bleed screw Bleed boss Bleed the air. Most of the air bubbles remaining inside the brake system can be bled by performing the following operation.
- Page 46 MAINTENANCE SHIMANO genuine mineral oil replacement BR-M6120 (1) Place a 7 mm box wrench in the position shown in the figure. (2) Connect the tube with bag attached to the bleed nipple. (3) Loosen the bleed nipple. (4) After a little while, the oil and air bubbles will flow naturally from the bleed nipple into the tube.
- Page 47 MAINTENANCE SHIMANO genuine mineral oil replacement While bleeding the air, maintain the oil level by adding additional oil. As the oil level in the funnel drops, add additional oil to maintain an oil level that keeps air from being sucked into the reservoir tank.
- Page 48 MAINTENANCE SHIMANO genuine mineral oil replacement With the brake lever depressed, loosen and tighten the bleed screw/ bleed nipple in rapid succession. Loosen and tighten for approximately 0.5 seconds each time to release any air bubbles inside the caliper. BR-M6120...
- Page 49 MAINTENANCE SHIMANO genuine mineral oil replacement Operate the brake lever. Air bubbles in the system will rise up through the port into the oil funnel. Continue operating the brake lever until no more bubbles appear. Check that the lever has become stiff.
- Page 50 MAINTENANCE SHIMANO genuine mineral oil replacement Tilt the brake lever downwards 30° from the ground and conduct step Check that there are no remaining air bubbles. 30° Set the brake lever so that it is parallel to the ground. Plug the oil funnel with the oil stopper.
- Page 51 MAINTENANCE SHIMANO genuine mineral oil replacement Tighten with a bleed screw to which an O-ring has been attached. Tighten until oil flows out to make sure that no air bubbles remain inside the reservoir tank. Do not operate the brake lever. If operated, there is a risk of air bubbles entering the cylinder.
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Page 52: Replacing The Brake Hose
MAINTENANCE Replacing the brake hose Replacing the brake hose After replacing the brake hose, refer to “SHIMANO genuine mineral oil replacement” to inject the mineral oil and bleed the air from the system. Checking and cutting the hose length Route the brake hose into the final installation position. -
Page 53: Assembly To The Brake Lever
MAINTENANCE Replacing the brake hose Assembly to the brake lever Pass the cover, connecting bolt, and olive over the brake hose in the order shown below. Olive Cover Connecting bolt Brake hose Check that the olive is in the position shown in the figure, and then apply Premium Grease to the threads of the connecting bolt and outer surface of the olive. - Page 54 MAINTENANCE Replacing the brake hose Tighten the connecting bolt while pushing on the brake hose. After tightening, install the cover. 5 - 7 N·m Connecting bolt Install the cover. Cover...
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Page 55: Assembly To The Brake Caliper
MAINTENANCE Replacing the brake hose Assembly to the brake caliper `Straight type Pass the connecting bolt and olive over the brake hose in the order shown below. Connecting bolt Olive Brake hose Check that the olive is in the position shown in the figure, and then apply Premium Grease to the threads of the connecting bolt and outer surface of the olive. - Page 56 MAINTENANCE Replacing the brake hose Install the brake hose in the caliper. Insert the hose up to the witness mark added beforehand on the surface of the hose is covered. Witness mark Connecting bolt NOTICE • Do not let the brake hose become twisted when installing it. When the caliper and brake lever are not installed on the bicycle, there is no twist in the hose if the caliper and brake lever are in the positions shown in the figure below.
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Page 57: Caliper Piston Maintenance
MAINTENANCE Caliper piston maintenance Caliper piston maintenance The caliper includes pistons. Adjust the pistons with the following procedure if these pistons do not operate properly, if they protrude unevenly, or if the brake pads remain in contact with the disc brake rotor. Remove the wheel from the frame. - Page 58 MAINTENANCE Caliper piston maintenance Install the brake pads. (1) Set the brake pads in the caliper. (2) Insert the split pin. (3) Open the tip of the split pin. (4) Install the pad spacer (red). Brake pads Split pin Pad spacer (red) Operate the brake lever through its full range of travel and depress it several more times so that the pistons move to their initial positions.
- Page 59 Please note: specifications are subject to change for improvement without notice. (English) © Dec. 2019 by SHIMANO INC. ITP...
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