Shimano DEORE Series User manual

(English)
Dealer's Manual
ROAD MTB Trekking
City Touring/
Comfort Bike URBAN SPORT E-BIKE
HYDRAULIC DISC BRAKE
DEORE
BR-M6100
BR-M6120
BL-M6100
Non-Series
BR-MT410
BL-M4100
DM-MBDBR01-00

2
CONTENTS
CONTENTS .................................................................................2
IMPORTANT NOTICE ..................................................................3
TO ENSURE SAFETY...................................................................4
LIST OF TOOLS TO BE USED ....................................................11
INSTALLATION/REMOVAL .......................................................12
Installing the brake lever.....................................................................12
Installing the disc brake rotor .............................................................14
Removing the disc brake rotor............................................................15
Installing the brake caliper..................................................................15
• Post mount type ..................................................................................................................... 15
• International-standard mount type ...................................................................................... 19
Installing the brake hose.....................................................................23
• Overview of the easy hose joint system................................................................................ 23
• Checking the length of the hose........................................................................................... 24
• Cutting the hose..................................................................................................................... 26
• Connecting the hose .............................................................................................................. 32
ADJUSTMENT ..........................................................................35
Adjusting the reach..............................................................................35
MAINTENANCE........................................................................36
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
• Assembly to the brake lever .................................................................................................. 53
• Assembly to the brake caliper ............................................................................................... 55
Caliper piston maintenance.................................................................57

3
IMPORTANT NOTICE
IMPORTANT NOTICE
• This dealer's manual is intended primarily for use by professional bicycle mechanics.
Users who are not professionally trained for bicycle assembly should not attempt to
install the components themselves using the dealer's manuals.
If any part of the information on the manual is unclear to you, do not proceed with the
installation. Instead, contact your place of purchase or a distributor for assistance.
•Make sure to read all manuals included with the product.
•Do not disassemble or modify the product other than as stated in the information
contained in this dealer's manual.
•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.
•Please observe the appropriate rules and regulations of the country, state or region in
which you conduct your business as a dealer.
For safety, be sure to read this dealer's manual thoroughly before use, and
follow it for correct use.
The following instructions must be observed at all times in order to prevent personal injury
and physical damage to equipment and surroundings.
The instructions are classified according to the degree of danger or damage which may occur
if the product is used incorrectly.
DANGER Failure to follow the instructions will result in death or serious
injury.
WARNING Failure to follow the instructions could result in death or
serious injury.
CAUTION Failure to follow the instructions could cause personal injury or
physical damage to equipment and surroundings.

4
TO ENSURE SAFETY
TO ENSURE SAFETY
WARNING
• 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.
•Wear approved eye protection while performing maintenance tasks such as
replacing components.
Be sure to also inform users of the following:
•Because each bicycle may handle slightly differently depending on the model, be sure to
learn the proper braking technique (including brake lever pressure and bicycle control
characteristics) and operation of your bicycle. Improper use of your bicycle's brake system
may result in a loss of control or a fall, which could lead to severe injury.
•Make sure that you completely understand the braking characteristics before using the
brakes. The 203 mm and 180 mm disc brake rotors provide a higher braking force than
the 160 mm disc brake rotors. If you ride the bicycle without sufficiently familiarizing
yourself with the characteristics of this brake, brake operations may cause a fall and
result in an accident that could lead to serious injury or even death.
•Please use extra caution to keep your fingers away from the rotating disc brake rotor.
The disc brake rotor is sharp enough to inflict severe injury to your fingers if caught
within the openings of moving rotor.
•Do not touch the calipers and disc brake rotor while riding or immediately after
dismounting from the bicycle. The calipers and disc brake rotor will become hot when
the brakes are operated, so you may get burned if you touch them.
•Be careful not to allow any oil or grease to get onto the disc brake rotor and brake pads.
Riding the bicycle with oil or grease on the disc brake rotor and brake pads may prevent
the brakes from operating and result in serious injury due to a fall or collision.

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
•Do not use the disc brake rotor if it is cracked or deformed. The disc brake rotor may
break, and result in serious injury due to a fall.
•Do not use the disc brake rotor if its thickness is 1.5 mm or less. Also do not use it if the
aluminum surface becomes visible. The disc brake rotor may break, and result in serious
injury due to a fall.
•Do not continuously apply the brakes. Doing so may cause a sudden increase in the brake
lever stroke and prevent the brakes from operating and result in serious injury.
•Do not use the brakes with fluid leaking. Doing so may prevent the brakes from
operating and result in serious injury.
•Do not apply the front brake too strongly. If you do so, the front wheel may lock and the
bicycle may fall forward, and serious injury may result.
•Because the required braking distance will be longer during wet weather, reduce your
speed and apply the brakes early and gently. You may fall or collide and be seriously
injured.
•A wet road surface may cause tires to skid; therefore, to avoid this, reduce your speed
and apply the brakes early and gently. If the tires skid, you may fall and be seriously
injured.
•If the quick release lever is on the same side as the disc brake rotor, confirm that it does
not interfere with the disc brake rotor. Otherwise, the bicycle may fall forward, and
serious injury may result.
For installation to the bicycle, and maintenance:
•Please make sure to keep your fingers away from the rotating disc brake rotor during
installation or maintenance of the wheel. The disc brake rotor is sharp enough to inflict
severe injury to your fingers if caught within the openings of moving rotor.

6
TO ENSURE SAFETY
•Do not use the disc brake rotor if it is cracked or warped. The disc brake rotor may break,
and result in serious injury due to a fall.
•Do not use the disc brake rotor if its thickness is 1.5 mm or less. Also do not use it if the
aluminum surface becomes visible. The disc brake rotor may break, and result in serious
injury due to a fall.
•The calipers and disc brake rotor will become hot when the brakes are operated; do not
touch them while riding or immediately after dismounting from the bicycle. Otherwise,
you may get burned.
•Be careful not to allow any oil or grease to get onto the disc brake rotor and brake pads.
Riding the bicycle in that state may prevent the brakes from operating and result in
serious injury due to a fall or collision.
•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.
•Do not use oil other than SHIMANO genuine mineral oil. Doing so may prevent the
brakes from operating and result in serious injury.
•Be sure to use only oil from a freshly-opened container. Doing so may prevent the brakes
from operating and result in serious injury.
•Do not let water or air bubbles to get into the brake system. Doing so may prevent the
brakes from operating and result in serious injury.
•Do not use with a tandem bicycle. Doing so may prevent the brakes from operating and
result in serious injury due to a fall or collision.
Brake hose
•Refer to the table below, and do not use an incorrect connector insert. Doing so may
prevent the brakes from operating and result in serious injury.
Brake hose Connector insert
Length Color
SM-BH90 11.2 mm Silver
SM-BH59/80 13.2 mm Gold
YM-BH81 13.2 mm Silver

7
TO ENSURE SAFETY
•Do not reuse the olive piece or the connector insert when reinstalling. Doing so may
prevent the brakes from operating and result in serious injury due to a fall.
Cut end
Connecting bolt
Brake hose
Olive
Connector
insert
When using TL-BH62
•Cut the brake hose so that the cut end is perpendicular to the length of the hose. If the
brake hose is cut at an angle, fluid leaks may result.
90°
•Read the TL-BH62 manual carefully, and keep it in a safe place for later reference.
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.
•In the event of skin contact, wash well with soap and water. Contact with skin may cause
a rash and discomfort.
•Cover nose and mouth with a respirator type mask and use in a well ventilated area.
Inhalation of mineral oil mist or vapors may cause nausea. If mineral oil mist or vapor is
inhaled, go immediately to an area with fresh air. Cover up with a blanket. Stay warm
and stable and seek professional medical advice.

8
TO ENSURE SAFETY
Burn-in period
•Disc brakes have a burn-in period, and the braking force will gradually increase as the
burn-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 disc brake rotor are replaced.
For installation to the bicycle, and maintenance:
•When using the SHIMANO original tool (TL-FC36) to remove and install the disc brake
rotor mounting ring, wear gloves and be careful not to touch the outside of the disc
brake rotor with your hands. Failure to do so may result in cuts to your hands.
Handling SHIMANO genuine mineral oil
•Use safety glasses when handling, and avoid contact with eyes. In the event of eye
contact, flush with fresh water and seek medical assistance immediately. Contact with
skin may cause a rash and discomfort.
•Use gloves when handling. In the event of skin contact, wash well with soap and water.
Contact with skin may cause a rash and discomfort.
•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.
•Disposal of Used Oil: Follow local county and/or state codes for disposal. Use caution
when preparing the oil for disposal.
•Directions: Keep the container sealed to prevent foreign objects and moisture from
getting inside, and store it in a cool, dark area away from direct sunlight or heat. Keep
from heat or flame, Petroleum Class III, Danger level III
Brake hose
•When cutting the brake hose, handle the knife carefully so as not to cause injury.
•Be careful to avoid injury from the olive.
When using TL-BH62
•When cutting the hose, handle the knife carefully so as not to cause injury.
•Be careful to avoid pinching your fingers between the lever and the tool during
operations.
•When replacing the knife blade, handle the knife carefully so as not to cause injury.

9
TO ENSURE SAFETY
•If mineral oil adheres to the brake hose, use isopropyl alcohol to clean the hose and
remove the oil.
•Keep the tool and the blades out of reach of children.
•Use isopropyl alcohol or a dry cloth when cleaning brake hoses and cleaning and
maintaining tools. Do not use commercially available brake cleaners. Doing so may cause
damage to plastic parts.
NOTICE
Be sure to also inform users of the following:
•When the bicycle wheel has been removed, it is recommended that pad spacers are
installed. Do not depress the brake lever while the wheel is removed. If the brake lever is
depressed without the pad spacers installed, the pistons will protrude further than
normal. If that happens, consult a place of purchase.
•Use soapy water and a dry cloth when cleaning and carrying out maintenance of the
brake system. Do not use commercially available brake cleaners or silencing agents. Such
substances can cause damage to parts such as seals.
•In the case of carbon levers, wash them with a soft cloth using a neutral detergent.
Otherwise, the material may be damaged and lose strength.
•Avoid leaving the carbon levers in areas of high temperature. Also keep them well away
from fire.
•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. As a result, they may interfere with the performance of the brake pads.
•If the brake caliper mounting boss and the dropout are not parallel, the disc brake rotor
and caliper may touch.
•When the bicycle wheel has been removed, it is recommended that pad spacers are
installed. The pad spacers will prevent the piston from coming out if the brake lever is
depressed while the wheel is removed.

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. (Note that some oil may overflow from the reservoir tank at
this time.)
•Use isopropyl alcohol, soapy water or a dry cloth when cleaning and carrying out
maintenance of the brake system. Do not use commercially available brake cleaners or
silencing agents. Such substances can cause damage to parts such as seals.
•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.
The actual product may differ from the illustration because this manual is
intended mainly to explain the procedures for using the product.

11
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
Adjustable wrench
TL-BH62
TL-FC36
TL-LR15
Micrometer

12
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. This will prevent damage to the
frame/handlebar due to over-torquing or inadequate securing of the components.
1. Open the clamp band of the brake lever.
(1) Loosen the mounting bolt.
(2) Press the recessed area of the clamp band with a tool such as a 2 mm hexagon wrench
to disengage the safety latch.
(1)
(2)
Mounting bolt
2. Pull a snap spring to the clamp band side as shown in the figure.
Mounting bolt
Snap spring

13
INSTALLATION/REMOVAL
Installing the brake lever
3. Attach the brake lever to the handlebar.
Secure the lever using the mounting bolt.
Mounting bolt
4 - 6 N·m
Shifting lever band
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. After the shifting lever is installed, install
the brake lever while checking its position.

14
INSTALLATION/REMOVAL
Installing the disc brake rotor
Installing the disc brake rotor
1. Check that the spokes are laced as shown in the figure.
Radial lacing cannot be used.
Front left Rear left Rear right Front right
2. Set the disc brake rotor on the hub, and then secure it with the disc
brake rotor lock ring.
Secure with TL-LR15 and an adjustable wrench or TL-FC36.
Disc brake rotor lock ring
Lock ring tightening tool
40 N·m
Internal spline type External spline type
Disc brake rotor lock ring
Lock ring tightening tool TL-LR15 and adjustable wrench TL-FC36

15
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
1. Install the wheel with an attached disc brake rotor onto the frame.
2. Remove the bleed spacer (yellow).
(1) Close the tip of the split pin.
(2) Remove the split pin.
(3) Remove the bleed spacer (yellow).
Bleed spacer (yellow)
(1)
(2)
(3)
Split pin

16
INSTALLATION/REMOVAL
Installing the brake caliper
3. 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
4. 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
(1)
(3)
(2)
Split pin

17
INSTALLATION/REMOVAL
Installing the brake caliper
5. 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. Set the adapter so that the mark is facing up.
Without mount adapter
(Temporary)
Caliper fixing bolts
With mount adapter
Mount adapter
Caliper fixing bolt (long)
Caliper fixing bolt (short)
(Temporary)
Mark

18
INSTALLATION/REMOVAL
Installing the brake caliper
6. 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.
6 - 8 N·m
Caliper fixing bolts
7. Secure the caliper fixing bolt.
In order to prevent the bolt from loosening, install a snap ring on the head of the bolt.
Snap ring
NOTICE
•Use the supplied snap rings. Other models of
snap rings cannot be installed.

19
INSTALLATION/REMOVAL
Installing the brake caliper
International-standard mount type
NOTICE
•For international-standard mounts, a dedicated adapter is required.
1. Install the wheel with an attached disc brake rotor onto the frame.
2. Remove the bleed spacer (yellow).
(1) Close the tip of the split pin.
(2) Remove the split pin.
(3) Remove the bleed spacer (yellow).
Bleed spacer (yellow)
(1)
(2)
(3)
Split pin
3. 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

20
INSTALLATION/REMOVAL
Installing the brake caliper
4. 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
(1)
(3)
(2)
Split pin