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Summary of Contents for Shimano BR-M9100
- Page 1 DM-MADBR01-04 (English) Dealer's Manual ROAD Trekking City Touring/ URBAN SPORT E-BIKE Comfort Bike HYDRAULIC DISC BRAKE BR-M9100 BR-M9110 BR-M9120 BL-M9100 BL-M9120 RT-MT900 DEORE XT BR-M8100 BR-M8110 BR-M8120 BL-M8100 RT-MT800 BR-M7100 BR-M7110 BR-M7120 BL-M7100...
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Page 2: Table Of Contents
Adjusting the free stroke ..............44 Adjusting the reach ................45 MAINTENANCE ................46 Replacing the brake pads ..............46 SHIMANO genuine mineral oil replacement ........49 • Draining the mineral oil ......................49 • Adding SHIMANO genuine mineral oil and bleeding air ............ 51... - Page 3 Replacing the brake hose ..............59 • Checking the hose length and cutting the hose ..............59 • Assembly to the brake lever ....................60 • Assembly to the brake caliper ....................61 Caliper piston maintenance ..............64 Designated small parts for magnesium components ......66...
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Page 4: 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 5: To Ensure Safety
• Be sure to follow the instructions provided in the manuals when installing the product. It is recommended that you use SHIMANO genuine parts. If parts such as bolts and nuts become loose or damaged, the bicycle may suddenly fall over, which may cause serious injury. - Page 6 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 7 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 8 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 eyes may result in irritation.
- Page 9 • 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 10 • 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 11 TO ENSURE SAFETY • Do not remove the pistons when disassembling and cleaning the calipers. • If the disc brake rotor is worn, cracked or warped, it should be replaced. • BL-M9100 is a magnesium component. Corrosion starts when these components come into contact with parts made of other types of metals, such as steel hardware.
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Page 12: 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 13: 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 14 INSTALLATION/REMOVAL Installing the brake lever Attach the brake lever to the handlebar. Secure the lever using the mounting screw. Mounting screw 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 15: 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 16: Removing The Disc Brake Rotor
Post mount type Install the wheel with an attached disc brake rotor onto the frame. Remove the bleed spacer (yellow). (1) Remove the retaining clip. (2) Remove the pad axle. (3) Remove the bleed spacer (yellow). Bleed spacer (yellow) (BR-M9100/BR-M9120) (BR-M8100/BR-M8120/ BR-M7100/BR-M7120) - Page 17 Brake pad presser spring Finned pads Install the brake pads. (1) Set the brake pads in the caliper. (2) Insert the pad axle. (3) Install the retaining clip. Brake pads Retaining clip 0.2 - 0.4 N·m (BR-M9100/BR-M9120) 2 - 4 N·m (BR-M8100/BR-M8120/ BR-M7100/BR-M7120)
- Page 18 If it is necessary to install a mount adapter, temporarily install the adapter after setting it on the caliper. Set the adapter so that the mark is facing up. Without mount adapter (Temporary) (BR-M9100/BR-M9120) (Temporary) (BR-M8100/BR-M8120/ BR-M7100/BR-M7120) Caliper fixing screws...
- Page 19 If the brake hose is not already installed in the caliper, install the brake hose and then perform the step. 6 - 8 N·m (BR-M9100/BR-M9120) 6 - 8 N·m (BR-M8100/BR-M8120/ BR-M7100/BR-M7120) Caliper fixing screws...
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Page 20: International-Standard Mount Type
(1) Remove the retaining clip. (2) Remove the pad axle. (3) Remove the bleed spacer (yellow). Bleed spacer (yellow) (BR-M9100/BR-M9120) (BR-M8100/BR-M8120/ BR-M7100/BR-M7120) 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. - Page 21 Installing the brake caliper Install the brake pads. (1) Set the brake pads in the caliper. (2) Insert the pad axle. (3) Install the retaining clip. Brake pads Retaining clip 0.2 - 0.4 N·m (BR-M9100/BR-M9120) 2 - 4 N·m (BR-M8100/BR-M8120/ BR-M7100/BR-M7120)
- Page 22 Temporarily install the caliper on the adapter, and then install it onto the frame. Tighten with the adapter fixing screws. * Leave enough slack so that the caliper can still move horizontally. Front Rear 6 - 8 N·m (Temporary) (BR-M9100/BR-M9120) (BR-M9100/BR-M9120) 6 - 8 N·m (Temporary) (BR-M8100/BR-M8120/ (BR-M8100/BR-M8120/ BR-M7100/BR-M7120) BR-M7100/BR-M7120) Caliper fixing screws...
- Page 23 Front Rear 6 - 8 N·m (BR-M9100/BR-M9120) 6 - 8 N·m 6 - 8 N·m (BR-M9100 / BR-M9120) (BR-M8100/BR-M8120/ BR-M7100/BR-M7120) 6 - 8 N·m Caliper fixing screws (BR-M8100 / BR-M8120 / BR-M7100 / BR-M7120) Caliper fixing screws Secure the caliper fixing screw.
- Page 24 INSTALLATION/REMOVAL Installing the brake caliper NOTICE • Use the supplied snap ring for BR-M8100/BR- M8120/BR-M7100/BR-M7120. Other models of snap rings cannot be installed. TECH TIPS • If screw [1] loosens (turns counterclockwise), force is screw [1] applied via the wire to turn screw [2] in the tightening direction (clockwise).
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Page 25: Installing The Brake Caliper (Flat Mount Type)
INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) Installing the brake caliper (flat mount type) Installing the brake pads Remove the bleed spacer (yellow). (1) Remove the retaining clip. (2) Remove the pad axle. (3) Remove the bleed spacer (yellow). Bleed spacer (yellow) (BR-M9110) (BR-M8110/BR-M7110) -
Page 26: Installing To The Frame
INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) Install the brake pads. (1) Set the brake pads in the caliper. (2) Insert the pad axle. (3) Install the retaining clip. Brake pads Retaining clip 0.2 - 0.4 N·m (BR-M9110) 2 - 4 N·m (BR-M8110/BR-M7110) Installing to the frame Install to the frame the caliper with attached brake pads. - Page 27 INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) `For rear 140 mm disc brake rotor Insert the brake caliper mounting screw C into the frame mount area. Make sure that the length of the protruding section of the brake caliper mounting screw C is 13 mm.
- Page 28 INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) NOTICE • When using a screw length selector, make sure the tip of the brake caliper mounting screw C is within the range A. Brake caliper mounting screw C Screw length selector •...
- Page 29 INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) Temporarily install the brake caliper to the frame so that the brake caliper can still move horizontally. (Temporary) Brake caliper mounting screw C Depress the brake lever so that the disc brake rotor is held between the pads, and then tighten the caliper mounting screw C.
- Page 30 INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) Install the screw fixing pin. Check that the screw fixing pin is fully inserted all the way to the back. Screw fixing pin ` For rear 160 mm and rear 180 mm disc brake rotors Check the length of the brake caliper mounting screw C.
- Page 31 INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) NOTICE • Pay attention to the marking on the mount bracket when attaching it. Temporarily install the mount bracket to the frame so that it can move left and right. Temporarily install it using the brake caliper mounting screw C that has an attached washer.
- Page 32 INSTALLATION/REMOVAL Installing the brake caliper (flat mount type) Depress the brake lever so that the disc brake rotor is held between the pads, and then tighten the caliper mounting screw C that has an attached washer. 6 - 8 N·m Brake caliper mounting screw C Install the retaining clip.
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Page 33: Installing The Brake Hose
INSTALLATION/REMOVAL Installing the brake hose Installing the brake hose Overview of the easy hose joint system Brake caliper Hose cap Brake hose connection port Brake lever Lever stopper 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. - Page 34 INSTALLATION/REMOVAL Installing the brake hose Check the appropriate length of the brake hose. Secure the brake lever in the position used when riding. (Since BL-M9100 cannot be secured on the handlebars unless the lever stopper is removed, place the lever in the position assumed to be used when riding, and then perform a check.) Check the mark on the brake hose with the edge of the brake lever connecting screw.
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Page 35: 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 36 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 37 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 38 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 39 NOTICE • When connecting with an easy hose joint system, a specialized connector insert (SHIMANO CODE No.: Y8JA98020/color: silver) must be used. Use of any connector insert other than the specified one may lead to oil leakage and other malfunctions.
- Page 40 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 41: 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 42 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 hose up to the witness mark on the outer hose casing. Cover with a clean rag while conducting this procedure as some of the internal oil may leak.
- Page 43 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 44: Adjustment
ADJUSTMENT Adjusting the free stroke ADJUSTMENT Adjusting the free stroke Adjust the range of travel of the brake lever until the brake pad and disc brake rotor come into contact. The initial position of the brake lever changes when performing the free stroke adjustment. -
Page 45: Adjusting The Reach
ADJUSTMENT Adjusting the reach Adjusting the reach Turn the reach adjustment screw or reach adjustment knob to adjust. Tightening the reach adjustment screw or reach adjustment knob (clockwise) widens the distance between the initial position of the brake lever and the handlebar, while loosening it (counterclockwise) narrows it. -
Page 46: Maintenance
Remove the wheel from the frame. Remove the brake pads. (1) Remove the retaining clip. (2) Remove the pad axle. (3) Remove the brake pads from the caliper. Brake pads Retaining clip (BR-M9100/BR-M9110/BR-M9120) (BR-M8100/BR-M8110/BR-M8120/ BR-M7100/BR-M7110/BR-M7120) Clean the pistons and the surrounding area. - Page 47 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 48 (4) Install the pad spacer (red). Brake pads Retaining clip Pad spacer (red) 0.2 - 0.4 N·m (BR-M9100/BR-M9110/BR-M9120) 2 - 4 N·m (BR-M8100/BR-M8110/BR-M8120/ BR-M7100/BR-M7110/BR-M7120) Depress the brake lever a few times and make sure that the lever operation becomes stiff.
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Page 49: 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 50 MAINTENANCE SHIMANO genuine mineral oil replacement Remove the bleed screw and O-ring. Bleed screw O-rings Install a bag and tube on the bleed nipple. (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.
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Page 51: Adding Shimano Genuine Mineral Oil And Bleeding Air
Bleed nipple 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). Position the bicycle as shown in the figure. - Page 52 MAINTENANCE SHIMANO genuine mineral oil replacement Set the brake lever so that it is parallel to the ground. Remove the bleed screw and O-ring, and then insert the oil funnel. Do not insert the oil stopper. Bleed screw Oil funnel O-rings Add the oil through the bleed nipple.
- Page 53 MAINTENANCE SHIMANO genuine mineral oil replacement (4) Push the piston of the syringe to add the oil. (5) Oil will start to come out from the oil funnel. Continue adding the oil until there are no more air bubbles in the oil that is coming out.
- Page 54 MAINTENANCE SHIMANO genuine mineral oil replacement (4) After a little while, the oil and air bubbles will flow naturally from the bleed nipple into the tube. Bleed nipple bubbles TECH TIPS • It may help to gently shake the hose or lightly tap the reservoir tank or caliper with a non-marring screwdriver handle.
- Page 55 MAINTENANCE SHIMANO genuine mineral oil replacement Once no more air bubbles come out from the bleed nipple, temporarily tighten the bleed nipple. Bleed nipple With the brake lever depressed, loosen and tighten the bleed nipple in rapid succession. Loosen and tighten for approximately 0.5 seconds each time to release any air bubbles inside the caliper.
- Page 56 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 57 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 58 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 59: Replacing The Brake Hose
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 the hose length and cutting the hose Route the brake hose into the final installation position. -
Page 60: Assembly To The Brake Lever
MAINTENANCE Replacing the brake hose Assembly to the brake lever Pass the cover, connecting screw, and olive over the brake hose in the order shown below. Olive Cover Connecting screw 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 screw and outer surface of the olive. -
Page 61: Assembly To The Brake Caliper
MAINTENANCE Replacing the brake hose Tighten the connecting screw while pushing on the brake hose. After tightening, install the cover. 5 - 7 N·m Connecting screw Install the cover. Cover Assembly to the brake caliper `Straight type Pass the connecting screw and olive over the brake hose in the order shown below. - Page 62 MAINTENANCE Replacing the 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 screw and outer surface of the olive. Premium Grease 2 mm Brake hose Connecting screw Connector insert Witness mark...
- Page 63 MAINTENANCE Replacing the brake hose Tighten the connecting screw while pushing on the brake hose. 5 - 7 N·m Connecting screw ` Banjo type Install the brake hose on the caliper as shown in the figure. Banjo O-rings 8 - 10 N·m (BR-M9120/BR-M8120/ BR-M7120) 4 - 6 N·m...
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Page 64: Caliper Piston Maintenance
(1) Remove the retaining clip. (2) Remove the pad axle. (3) Remove the brake pads from the caliper. (3) Brake pads Retaining clip (BR-M9100/BR-M9110/BR-M9120) (BR-M8100/BR-M8110/BR-M8120/ BR-M7100/BR-M7110/BR-M7120) Clean the pistons and the surrounding area. Push the pistons straight back as far as they will go. - Page 65 (4) Install the pad spacer (red). Brake pads Retaining clip Pad spacer (red) 0.2 - 0.4 N·m (BR-M9100/BR-M9110/BR-M9120) 2 - 4 N·m (BR-M8100/BR-M8110/BR-M8120/ BR-M7100/BR-M7110/BR-M7120) 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.
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Page 66: Designated Small Parts For Magnesium Components
MAINTENANCE Designated small parts for magnesium components Designated small parts for magnesium components The BL-M9100 is made of magnesium. Use small parts designated for use with magnesium components as shown in the following figure. If parts other than those designated for use with magnesium components are used, the rusting process will accelerate. - Page 67 Please note: specifications are subject to change for improvement without notice. (English) © Dec. 2019 by SHIMANO INC. ITP...
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