DM-BR0005-11

(English)

Dealer's Manual
ROAD

MTB

Trekking

City Touring/
Comfort Bike

URBAN SPORT

E-BIKE

Hydraulic Disc Brake

XTR

ZEE

DEORE XT (Trekking)

BR-M9000
BR-M9020
BR-M987

BR-M640

BL-T785-B

BL-M640
BL-M640-B

DEORE LX (Trekking)

BL-M9000
BL-M9020
BL-M988-B
BL-M987

DEORE
BR-M615

BL-T675
BL-T675-B

BL-M615

DEORE (Trekking)

SAINT

ALIVIO

BR-T615

BR-M820

BR-M4050

BL-T615

BL-M820
BL-M820-B

SHIMANO

Mount adapter

BR-M447
BR-M395

SM-MA-F180P/P2

DEORE XT
BR-M8000
BR-M785
BL-M8000
BL-M785-B

SLX
BR-M675
BL-M675
BL-M675-B

BL-M506
BL-M425
BL-M396
BL-M395

BR-T675

CONTENTS
IMPORTANT NOTICE.............................................................................................. 3
TO ENSURE SAFETY................................................................................................ 4
LIST OF TOOLS TO BE USED................................................................................. 11
INSTALLATION...................................................................................................... 13
Disc brake mount adapter (for 180mm disc brake rotors).......................................................................13
Disc brake rotor adapter.............................................................................................................................14
Brake hose...................................................................................................................................................17

MAINTENANCE..................................................................................................... 20
Adding Shimano genuine mineral oil and bleeding air...........................................................................20
Replacing the brake hose...........................................................................................................................26
Replacing the brake pads...........................................................................................................................33
Designated parts for magnesium products...............................................................................................35

IMPORTANT NOTICE

IMPORTANT NOTICE
This dealers 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 dealers 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 local
bicycle dealer for their assistance.
Make sure to read all instruction manuals included with the product.
Do not disassemble or modify the product other than as stated in the information contained in this dealers manual.
All dealers manuals and instruction manuals can be viewed on-line on our website (http://si.shimano.com).
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 dealers 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.

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 genuine Shimano parts only. If parts such as bolts and nuts become loose or damaged, the bicycle may suddenly fall over,
which may cause serious injury.
In addition, if adjustments are not carried out correctly, problems may occur, and the bicycle may suddenly fall over, which may cause serious injury.

Be sure to wear safety glasses or goggles to protect your eyes while performing maintenance tasks such as replacing parts.

After reading the dealer's manual thoroughly, keep it in a safe place for later reference.

Be sure to also inform users of the following:

SAINT/ZEE
Downhill bicycle riding and freeriding are inherently dangerous activities. There is a risk of being involved in an accident that can result in a
serious injury or even death. It is strongly recommended that riders wear protective head and body gear and perform thorough safety checks of
their bicycles before riding. Please remember that you are riding at your own risk and that you have to consider your experience and your skills
very carefully.
The brake system is designed for downhill bicycle riding and freeriding, and its braking performance is much higher than for other brakes. Riders
must become accustomed to the higher performance of this brake in a controlled environment before riding the bicycle as described above. If you
do not familiarize yourself with the performance level of this brake, you may be involved in an accident that could result in serious injury or even
death.
Furthermore, the settings of the brakes makes them unsuitable for riding on city streets. If riding the bicycle on streets is unavoidable, take
extreme care while doing so.
The 203mm and 180mm disc brake rotors provide a higher braking force than the 160mm disc brake rotors. Make sure that you completely understand
the braking characteristics before using the brakes.
Each bicycle may handle slightly differently depending on the model.
Therefore, 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. For proper operation,
consult a professional bicycle dealer or the bicycle's owner's manual. It is also important to practice riding and braking, etc.
Please make sure 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 in the openings of the disc brake rotor while it is moving.

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. Otherwise the brakes may not work correctly.
If any oil or grease does get on the brake pads, you should consult a dealer or an agency. Otherwise the brakes may not work correctly.

TO ENSURE SAFETY

If noise occurs during brake operation, the brake pads may have been worn down to the usable limit. Check that brake
system temperature has cooled down sufficiently, check the thickness of the brake pad. If the thickness is 0.5mm or
less, the brake pad needs to be replaced with a new one. Consult a dealer or an agency.

2mm

0.5mm

If the disc brake rotor is cracked or deformed, immediately stop using the brakes and consult a dealer or an agency.
If the disc brake rotor becomes worn down to a thickness of 1.5mm or less, or if the aluminum surface appears, immediately stop using the brakes and
consult a dealer or an agency. The disc brake rotor may break, and you may fall off the bicycle.
Vapor lock may occur if the brakes are applied continuously. To solve this problem, momentarily release the lever.
Vapor lock occurs when the oil inside the brake system becomes heated, which causes the water or air bubbles inside the brake system to expand.
This can then result in a sudden increase in the brake lever stroke.
The disc brake is not designed to work when the bicycle is upside down. If the bicycle is turned upside down or on its side, the brake may not work
correctly, and a serious accident could occur. Before riding the bicycle, be sure to operate the brake lever a few times to check that the brakes operate
normally. If the brakes do not operate normally, stop using the brakes and consult a dealer or an agency.
If you feel no resistance when depressing the brake lever, immediately stop using the brakes and consult a dealer or an agency.
If fluid leaks occur, immediately stop using the brakes and consult a dealer or an agency.
If the front brake is applied too strongly, the wheel may lock and the bicycle may fall forward, and serious injury may result.
Always make sure that the front and rear brakes are working correctly before riding the bicycle.
The required braking distance will be longer during wet weather. Reduce your speed and apply the brakes early and gently.
If the road surface is wet, the tires will skid more easily. If the tires skid, you may fall off the bicycle. Reduce your speed and apply the brakes early and
gently.
Because of the characteristics of the carbon fiber material, the lever should never be altered. Otherwise, the lever may break preventing braking
operation.
Check before riding that there is no damage such as carbon peeling or cracking. If there is any damage, stop using the bicycle and consult a dealer or
an agency. Otherwise, the lever may break preventing braking operation.

TO ENSURE SAFETY

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 in the openings of the disc brake
rotor while it is moving.
If the disc brake rotor is worn, cracked or warped, it should be replaced.
If the disc brake rotor becomes worn down to a thickness of 1.5mm or the aluminum surface becomes visible, be sure to replace the disc brake rotor
with a new one.
Check that the brake components have cooled down sufficiently before attempting to adjust the brakes.
Use only Shimano genuine mineral oil. If other types of oil are used, it may cause problems with brake operation, and cause the system to be unusable.
Be sure to use only oil from a freshly-opened container, and do not re-use oil which has been drained from the bleed nipple.
Old or reused oil may contain water, which could cause vapor lock in the brake system.
Be careful not to let water or air bubbles to get into the brake system. Otherwise, vapor lock may occur. Be particularly careful when removing the
cover of the reservoir tank.
If cutting the brake hose in order to adjust the length of the hose, or when changing over the brake hose from left to right or vice versa, be sure to
bleed the air from the hose according to steps given in Adding Shimano genuine mineral oil and bleeding air.
When turning the bicycle upside down or on its side, the brake system may have some air bubbles inside the reservoir tank which are still there when
the bleed screw is closed, or which accumulate in various parts of the brake system when it is used for long periods. This disc brake system is not
designed to work with the bicycle upside down. If the bicycle is turned upside down or on its side, the air bubbles inside the reservoir tank may move
in the direction of the calipers. If the bicycle is ridden in this condition, there is danger that the brakes may not operate and a serious accident may
occur. If the bicycle has been turned upside down or on its side, be sure to operate the brake lever a few times to check that the brakes operate
normally before riding the bicycle. If the brakes do not operate normally, adjust them according to the following procedure.

If brake does not seem to work (feels sluggish) when the lever is depressed
Set the brake lever so that it is parallel to the ground, and then gently depress the brake lever several times and wait for the bubbles to return to
the reservoir tank. It is recommended that you then remove the reservoir tank cover and fill the reservoir tank with mineral oil until no bubbles
remain.
If the brakes are still sluggish, bleed the air from the brake system. (Refer to "Adding Shimano genuine mineral oil and bleeding air".)
If the quick release lever on the hub is on the same side as the disc brake rotor, they may interfere with each other, which is dangerous, so check that
they do not.
Shimano disc brake systems are not compatible with tandem bicycles. Because tandem bicycles are heavier, the stress on the brake system increases
during brake operation. If hydraulic disc brakes are used with tandem bicycles, the oil temperature will become too high and vapor locks or ruptures
in the brake hoses may occur, causing the brakes to fail.

TO ENSURE SAFETY

SM-RTAD05

Disc brake rotor adapter

Disc brake rotors with diameters of up to 203mm can be installed. If disc brake rotors with a larger diameter than this are installed, the braking force
may damage the main unit.

Brake

hose
After installing the brake hose to the brake unit, adding Shimano genuine mineral oil 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.
The connector insert is for this brake hose only. Use an appropriate connector insert according to the following table. Use of a connector insert
incompatible with the brake hose may cause fluid leaks.
Model No.
SM-BH90
SM-BH59/80
YM-BH81

Length
11.2mm
13.2mm
13.2mm

Color
Silver
Gold
Silver

Do not reuse the olive piece or the connector insert when reinstalling. A damaged or reused olive, or connector insert, may not provide a secure brake
hose connection, possibly causing the brake hose to disconnect from the calipers or brake lever.
If the brake hose becomes disconnected, there is danger that the brakes may suddenly stop working.
Connecting bolt

Brake hose

Cut end

Olive

Connector insert

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

TO ENSURE SAFETY

CAUTION
Be sure to also inform users of the following:
Cautions

on Shimano genuine mineral oil

Contact with eyes may result in irritation. In the event of contact with eye, wash with water and seek medical attention immediately.
Contact with skin may cause a rash and discomfort. In the event of contact with skin, wash well with soap and water.
Inhalation of Shimano genuine mineral oil mist or vapors may cause nausea. Cover nose and mouth with a respirator type mask and use in a well
ventilated area. If Shimano genuine mineral oil mist or vapor is inhaled, cover up with a blanket and go immediately to an area with fresh air. Stay
warm and calm, and seek professional medical advice.

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 fixing ring, be careful not to touch the outside of the disc
brake rotor with your hands. Wear gloves to protect your hands from getting cut.

Handling

Shimano genuine mineral oil

Contact with eyes may result in irritation. Use safety glasses when handling, and avoid contact with eyes.
In the event of contact with eye, wash with water and seek medical attention immediately.
Contact with skin may cause a rash and discomfort. Use gloves when handling.
In the event of contact with skin, wash well with soap and water.
Do not drink. May cause vomiting or diarrhea.
Keep out of reach of children.
Do not cut, let near heat, weld or pressurize the oil container, as this may cause 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

When

cleaning with a compressor

If disassembling the caliper body to clean the internal parts using a compressor, note that moisture from the compressed air may remain on the caliper
components.
Let the caliper components dry sufficiently before reassembling the calipers.

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.

TO ENSURE SAFETY

NOTE
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
dealer.
Use soapy water and a dry cloth when cleaning and carrying out maintenance of the brake system. Do not use commercially available brake cleansers
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 break down and be damaged.
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.

SAINT/ZEE

This product is not warranted against damage resulting from improper use, such as jumping while riding or if the bicycle falls over, except if such
malfunctions are caused by manufacturing methods.

For Installation to the Bicycle, and Maintenance:

The 203mm and 180mm disc brake rotors have a larger diameter than the 160mm disc brake rotor for cross-country bicycles, and so the flexing of
these disc brake rotors is greater. As a result, they will interfere with the brake pads.
If the brake caliper mounting boss and the fork end 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.
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 pads, while being careful not to damage the surfaces 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 cleansers or silencing agents. Such substances can cause damage to parts such as seals.
Do not remove the pistons when disassembling the calipers.
If the disc brake rotor is worn, cracked or warped, it should be replaced.
The caliper of BR-M9000/BR-M987 and the master cylinder of BL-M9000/BL-M987 are made of magnesium. Corrosion starts when these components
come into contact with parts made of other types of metals, such as iron bolts. In the contact area, water residue, sweat, rain and other moisture
particles may create a potential reaction. This forms an electrochemical cell, resulting in an electrochemical reaction. To prevent this problem, each
part is treated with a special-purpose surface treatment. Use appropriate parts to prevent the progression of rusting. For more details, refer to
"Designated parts for magnesium products" in "MAINTENANCE".

SM-RTAD05

Disc brake rotor adapter

When using this disc brake rotor adapter to install disc brake rotors, the structure of the adapter means that there will be more play than normal in
the disc brake rotor. Because of this, the disc brake rotor may interfere with the brake pads. Furthermore, it may also interfere with the calipers in the
radial direction (upward).
This product cannot be used with the 6-bolt disc brake rotor that is installed with an aluminum adapter (SM-RT86/RT76).

The actual product may differ from the illustration because this manual is intended mainly to explain the procedures for using
the product.

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, adjustment, and maintenance purposes.
Tool

Tool

Tool

3mm hexagon wrench

8mm spanner

Hexalobular[#15]

4mm hexagon wrench

Utility knife

TL-BH61

5mm hexagon wrench

Slotted screwdriver (nominal diameter:

0.84)

TL-FC36

11

INSTALLATION

INSTALLATION
Disc brake mount adapter (for 180mm disc brake rotors)

INSTALLATION
* Refer to the Disc Brake section of General Operations for how to install the brake caliper, brake lever, and disc brake rotor.

Disc brake mount adapter (for 180mm disc brake rotors)

SM-MA-F180P/P2
(y) Long

Place the adapter onto the brake caliper, and then install the adapter to the frame.

(z) Short
(A) Mount adapter
(B) 5mm hexagon wrench

(A)

BR-M9000/M9020/M987:
4mm hexagon wrench

(y)
(B)

Tightening torque

6 - 8 Nm
(z)

NOTE
Be sure to attach the caps when attaching the
brake caliper fixing bolts.

(B)

13

INSTALLATION
Disc brake rotor adapter

Disc brake rotor adapter

SM-RTAD05

(A)
(C)

(B)

This product is an adapter used for

installing 6 bolt type disc brake
rotors to center lock system hubs/
wheels.

(D)

(E)

Place the disc brake rotor adapter

on to the hub.

To be continued on next page

14

(A) Disc brake rotor

(B) Washer
(C) Disc brake rotor adapter
(D) Disc brake rotor fixing bolt
(E) Disc brake rotor fixing lock ring

INSTALLATION
Disc brake rotor adapter

Place the disc brake rotor on to

the hub, and then temporarily fix
it in place by tightening the disc
brake rotor fixing bolts.

(z) Hexalobular[#15]
(A) Disc brake rotor
(B) Disc brake rotor fixing bolt

(A)

2
(B)
(z)

Wear gloves and turn the disc

brake rotor clockwise with some
force.

4
2

Fit the washer.

To be continued on next page

2 - 4 Nm

Then, tighten the disc brake rotor

fixing bolts in the order shown in
the illustration.

3
6

Tightening torque

(A)

15

(A) Washer

INSTALLATION
Disc brake rotor adapter

Tighten the disc brake rotor fixing

lock ring.

(A)

(A) Disc brake rotor fixing lock ring

(B) TL-FC36
Tightening torque

40 Nm

5
(B)

16

INSTALLATION
Brake hose

Brake hose
For information on installing the brake hose, refer to the brake section of General Operations.
Make sure that the calipers and levers are in the positions shown in the illustrations.
XTR/DEORE XT

(A)

(B)

(A) Brake caliper

(B) Brake lever
NOTE
The installation position of the brake hose
differs depending on the model.

Do not let the brake hose become twisted

when installing it.

SAINT/ZEE

(A)

(B)

SLX

(A)

(B)

DEORE LX (Trekking)/DEORE (Trekking)/M395

(A)

(B)

17

INSTALLATION
Brake hose

Overview of the easy hose joint system

For information on how to install and replace the brake hose, refer to the brake section of General Operations.

(A) Brake caliper

(B) Hose cap
(C) Seal plug
(D) Hose connection port
(E) Brake lever
(F) Stopper

(B)

(C)
(A)
(F)

(D)

(E)

18

MAINTENANCE

MAINTENANCE
Adding Shimano genuine mineral oil and bleeding air

MAINTENANCE
This section describes specification differences between products that are not included in the disc brake section of General Operations.

Adding Shimano genuine mineral oil and bleeding air

BR-M447/BR-M4050/BR-M395
When removing air from the brake caliper, a funnel is needed.

TECH TIPS
Shimano genuine mineral oil replacement
It is recommended to replace the oil inside the reservoir tank if it becomes severely discolored.
Attach a tube with a bag to the bleed nipple, and then open the bleed nipple to drain out the oil. The brake lever can be operated at this time to help the oil drain
out. After this, add oil while referring to the section "Adding Shimano genuine mineral oil and bleeding air".
Use only Shimano genuine mineral oil.
Dispose of the waste oil according to proper country and/or state disposal regulations.

Set the brake lever so that it is in

riding position at a 45 angle from
the ground.

(z)

(z) 45

(A) Bleed screw

(B) Oil funnel

Remove the upper bleed screw, and set the oil funnel.

(A)

To be continued on next page

(B)

20

MAINTENANCE
Adding Shimano genuine mineral oil and bleeding air

(z)
(A)
(B)
(C)
(D)

(E)

Remove the bleed nipple cap of the

caliper, fill the syringe with oil, and
connect the tube to the bleed nipple.
Use a 3mm hexagon wrench to loosen
the bleed screw by 1/8th of a turn to
open it.
When the plunger of the syringe is
pushed to add oil, oil will start coming
out through the oil funnel.
Continue adding oil until there are no
more air bubbles mixed in with the oil
that is coming out.

(z) 1/8th of a turn

Once there are no more air bubbles mixed in with the oil, temporarily close the bleed nipple.
Remove the syringe while covering the end of the syringe tube with a waste cloth to prevent
oil from spattering.

To be continued on next page

21

(A) 3mm hexagon wrench

(B) Bleed screw
(C) Bleed nipple cap
(D) Bleed nipple
(E) Brake hose from syringe
NOTE
Secure the brake caliper in a vise to prevent
the tube from being accidentally
disconnected.
Do not depress and release the lever
repeatedly.
Oil without air bubbles may come out as a
result of such operation, but air bubbles may
remain in the oil inside the brake caliper, and
it will take longer to bleed the air. (If you
have depressed and released the lever
repeatedly, drain out all of the oil and then
add oil again.)

MAINTENANCE
Adding Shimano genuine mineral oil and bleeding air

(A)

Secure the tube and bag with rubber

bands, set a 3mm hexagon wrench as
shown in the illustration, and connect
the tube to the bleed nipple.

(A) 3mm hexagon wrench

(B) Bag

Loosen the bleed screw.

(A) Bleed screw

(B) Air bubbles
(C) 3mm hexagon wrench

5
(B)

(A)

After a little while, the oil and air

bubbles will flow naturally from the
bleed nipple into the tube.

(C)
(B)

To be continued on next page

This way it will be possible to easily

extract the greater part of the air
bubbles remaining inside the brake
system.

22

TECH TIPS
It may be effective to shake the brake hose
gently, tap the reservoir tank or brake calipers
gently with a screwdriver, or move the
position of the calipers at this time.

MAINTENANCE
Adding Shimano genuine mineral oil and bleeding air

The level of liquid inside the oil funnel drops at this time, so keep filling the funnel with oil
to maintain the level of liquid so that air is not drawn in.

Once no more air bubbles come from the bleed nipple, temporarily close the bleed screw.

With the brake lever depressed, open

and close the bleed screw in rapid
succession (for approximately 0.5 seconds
each time) to release any air bubbles
which may be in the brake calipers.
Repeat this procedure about 2 to 3
times.

(A)

To be continued on next page

Then tighten the bleed screw again.

(B)

23

(A) 3mm hexagon wrench

(B) Bleed screw
Tightening torque

4 - 6 Nm

MAINTENANCE
Adding Shimano genuine mineral oil and bleeding air

If the brake lever is then operated, air bubbles in the system will rise up through the port
into the oil funnel.

(x) Loose

Once the bubbles stop appearing, depress the brake lever as far as it will go.

(z) Stiff

(y) Slightly stiff

Under normal conditions, lever action should feel stiff at this point.

NOTE
If the lever does not become stiff, repeat the
procedures from step 5.

10
Lever operation

(x)

[1]
(z)

11

(z)

(y)

[2]
(z)

Set the lever unit to the horizontal

position as shown in the illustration and
tilt it 30 degrees in direction [1]; then
carry out step 10 to check that there is
no air remaining.

(z) 30

Next, tilt the lever unit 30 degrees in

direction [2], and carry out step 10 again
to check that there is no air remaining.
If any air bubbles appear, repeat the
above procedure until they stop
appearing.

Plug the oil funnel with the oil

stopper so that the O-ring
mounted side is facing downward.

(A)

12

To be continued on next page

(B)

24

(A) Oil stopper

(B) O-ring

MAINTENANCE
Adding Shimano genuine mineral oil and bleeding air

13

Remove the oil funnel while it is

still plugged with the oil stopper
and then tighten the bleed screw
while letting oil flow out to make
sure no air bubbles remain inside
the reservoir tank.
At this point, use a waste cloth to
prevent oil from flowing out to
the surrounding areas.

Wipe away any oil that has

overflowed.

14

15

Finally, after removing the bleeding spacer and installing the pads and the pad
spacer, depress the brake lever several times to check that the brake lever is
operating normally and there are no fluid leaks from the brake hose or the
system.

25

Tightening torque

0.5 - 1 Nm
NOTE
Do not operate the brake lever. If operated,
there is a risk of air bubbles entering the
cylinder.

MAINTENANCE
Replacing the brake hose

Replacing the brake hose

Brake lever side
NOTE
If there is a marking as shown in the illustration, refer to the section "Replacing the brake hose (easy hose joint
system)" in General Operations.

Mark

(z)

Use a utility knife or other cutting

tool to cut the brake hose.

(z) 90

NOTE
Use the utility knife safely and correctly in
accordance with its instruction manual.

TECH TIPS

If you are using TL-BH62, refer to the manual

accompanying the product.

(A)

(A)

(z)

In order to check that the ends of

the brake hose are fitted securely
into the base of the brake hose
mounts of the brake calipers and
brake lever, make marks on the
brake hose beforehand as shown
in the illustration. (As a guide, the
length of brake hose inside the
mount should be approximately
11mm, measured from the cut end
of the brake hose.)

(z) Approx. 11mm

To be continued on next page

26

(A) Mark

MAINTENANCE
Replacing the brake hose

(B)

(w)

Pass the brake hose through the

connecting bolt and olive.

(C)
(x)

(w) Direction of insertion

(x) Cut end
(y) Grease the outside of the
olive.

(z) Attach the cover to the

(A)

connecting bolt for the

brake lever.

(y)
(C)
(D)

(A) Brake hose

(B) Connecting bolt
(C) Olive
(D) Premium grease
(E) Cover

(E)

(z)

(B)

Use a tapered tool to smooth out

the inside of the cut end of the
brake hose, and mount the
connector insert.

(A) (A)

(B)
(C)
(D)

(z)

(E)

Attach the brake hose to the

TL-BH61 as shown in the
illustration, secure the TL-BH61 in
a vise, and 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 brake hose.

(A) Connector insert

(B) Brake hose
(C) Olive
(D) TL-BH61
(E) Vise

If the end of the brake hose is not

touching the base of the
connector insert, the brake hose
may become disconnected or fluid
leaks may occur.

(z) 1mm

(z)

After checking that the olive is

positioned as shown in the
illustration, apply premium grease
to the threads of the connecting
bolt.

(z) 2mm
(A)

To be continued on next page

(B)

(C)

27

(A) Brake hose

(B) Olive
(C) Connector insert

MAINTENANCE
Replacing the brake hose

(B)

(C)

Attach the brake hose to the brake

lever as shown in the illustration.

(A) Connecting bolt

(B) Olive
(C) Brake lever

While pushing the brake hose,

tighten the connecting bolt.

(A) 8mm spanner

(B) Connecting bolt

6
(A)

Tightening torque

(A)

5 - 7 Nm

(B)

28

MAINTENANCE
Replacing the brake hose

Caliper side
Mount the connecting bolt, the olive, and the connector insert by following the same procedure as for the brake lever.
Use an 8mm spanner to secure the connecting bolt.
Use a utility knife or other cutting
tool to cut the brake hose.

(z)

(z) 90

NOTE
Use the utility knife safely and correctly in
accordance with its instruction manual.

TECH TIPS

If you are using TL-BH62, refer to the manual

accompanying the product.

(A)

In order to check that the ends of

the brake hose are fitted securely
into the base of the brake hose
mounts of the brake calipers and
brake lever, make marks on the
brake hose beforehand as shown
in the illustration. (As a guide, the
length of brake hose inside the
mount should be approximately
14mm, measured from the cut end
of the brake hose.)

(A)

(z)

(A) Mark

(z) Approx. 14mm

(x)

(B)

Pass the brake hose through the

connecting bolt and olive.

(C)
(y)

3
(A)

(y) Cut end

(z) Grease the outside of the olive.
(A) Brake hose
(B) Connecting bolt
(C) Olive
(D) Premium grease

(z)
(C)
(D)

To be continued on next page

(x) Direction of insertion

29

MAINTENANCE
Replacing the brake hose

Use a tapered tool to smooth out

the inside of the cut end of the
brake hose, and mount the
connector insert.

(B)

(A)

(A)

(B)
(C)
(D)

(z)

(E)

Attach the brake hose to the

TL-BH61 as shown in the
illustration, secure the TL-BH61 in
a vise, and 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 brake hose.

(A) Connector insert

(B) Brake hose
(C) Olive
(D) TL-BH61
(E) Vise

If the end of the brake hose is not

touching the base of the
connector insert, the brake hose
may become disconnected or fluid
leaks may occur.

(z) 4mm

(z)

After checking that the olive is

positioned as shown in the
illustration, apply premium grease
to the threads of the connecting
bolt.

(A) Brake hose

(B) Olive
(C) Connector insert

(z) 5mm
(A)

(B)

(C)

Attach the brake hose to the brake

calipers as shown in the
illustration.

(B)

(A) Connecting bolt

(B) Olive
(C) Brake caliper
NOTE

(A)

Do not let the brake hose become twisted

when installing it.
Make sure that the calipers and brake levers
are in the positions shown in the illustrations.

(C)

To be continued on next page

30

MAINTENANCE
Replacing the brake hose

While pushing the brake hose, tighten the connecting bolt.

(A) 8mm spanner

(B) Connecting bolt

BR-T675/BR-T675-B

(A)
Tightening torque

5 - 7 Nm

(B)

(A) 8mm spanner

(B) Olive
(C) Connecting bolt
(D) Caliper

BR-M395/BR-M615

(A) (B)

Tightening torque

5 - 7 Nm

(C)

(D)

31

MAINTENANCE
Replacing the brake hose

Banjo type
(A) Brake hose
(B) Banjo
(C) O-ring
(D) 3mm hexagon wrench/4mm

XTR/DEORE XT

(A)

hexagon wrench

(B)
Tightening torque

5 - 7 Nm
(C)

8 - 10 Nm

(D)

(A) Brake hose

(B) Banjo
(C) O-ring
(D) 3mm hexagon wrench

SAINT/ZEE

(A)

Tightening torque

4 - 6 Nm
(B)

(C)
(D)

(A) Brake hose

(B) Banjo
(C) O-ring
(D) 3mm hexagon wrench/4mm

SLX

(A)

hexagon wrench

(B)
Tightening torque

5 - 7 Nm
(C)

8 - 10 Nm

(D)

32

MAINTENANCE
Replacing the brake pads

Replacing the brake pads

BR-M9000/M9020/M987/M820/

Brake pad

M8000/M785

BR-M675/M640/M615

BR-M447/M4050/M395/T675

Pad position (from top)

Pad axle

Pad pin

When replacing the brake pad from the top (when pushing back the piston), refer to Replacement of the brake pads in the Maintenance section of
General Operations.

When replacing the brake pads from the bottom (BR-M447/M4050/M395/T675/T675B)

NOTE
This brake system is designed to automatically adjust the clearance between the disc brake rotor and the brake pads by the piston gradually protruding according
to the wear of the brake pads; therefore, when you replace the brake pads, you need to push back the piston.

If oil adheres to the brake pads, if the brake pads are worn down to a thickness of 0.5mm, or if the brake pad presser springs are interfering with the disc brake
rotor, replace the brake pads.

Remove the wheel from the frame,

and remove the brake pads as
shown in the illustration.

(A) Split pin

(B) Brake pad

Use a flat-shaped tool to push the

pistons straight back in as far as
they will go, while being careful
not to twist the pistons.

(A) Piston

(A)

(B)

Clean the pistons and surrounding area.

3
(A)

To be continued on next page

Do not push the pistons with a

sharp tool. The pistons may be
damaged.

33

NOTE
Note that there is a risk of oil overflowing
from the reservoir tank.

MAINTENANCE
Replacing the brake pads

Install the new brake pads, and

then install the pad spacers (red).

(A) Split pin

(B) Pad spacer (red)

After this, bend open the split pin.

(A)

4
(B)

Depress the brake lever several times to check that the operation becomes
stiff.

Remove the pad spacers.

Install the wheel, and then check that there is no interference between the
disc brake rotor and brake pads.

After checking the oil level, close the reservoir tank cover.

Return the brake lever to its original position.

34

NOTE
If they touch, adjust while referring to the
section "INSTALLATION (HYDRAULIC DISC
BRAKES)" in General Operations.

MAINTENANCE
Designated parts for magnesium products

Designated parts for magnesium products

NOTE
Do not use any parts other than those listed below with BR-M9000, BR-M987 or BL-M9000, BL-M987, which are made of magnesium. Otherwise the rusting process will
accelerate.

BR-M987
(A) Bleed screw
(B) Lever axle
(C) Clamp bolt

(A)
(B)

(C)

SM-BH90-SBM/BR-M987
(A) Banjo bolt
(B) Brake hose (Banjo)
(C) Bleed nipple
(D) Fixing bolt
(E) Pad axle

(C)

(D)

(B)

(A)

(E)

35

MAINTENANCE
Designated parts for magnesium products

For customers who use this product with SM-MA90-F180P/P

When using BR-M987 with SM-MA90-F180P/P, be sure to use a surface-treated (silver) R washer.

(A) R washer
(A)

NOTE
Do not use non-surface-treated (gray) R
washers.
S-part No. ISMMA90F180PP
(SM-MA90-F180P/P) and S-part No.
ESMMAF180PP2 (SM-MA-F180P/P2) are
non-surface-treated (gray) R washers. Do not
use them.
(R washers S-part No. ISMMA90F180PPC and
Shimano code No. Y8LF12000 (SM-MA90F180P/P) are surface-treated (silver) and
therefore usable.)

SM-MA90-F180P/P
SM-MA-F180P/P2

S-part#

Surface-treatment for R washers

Usage

ISMMA90F180PPC

Silver

OK

ISMMA90F180PP

Gray

Not OK

ESMMAF180PP2

Gray

Not OK

DESCRIPTION

Surface-treatment for R washers

Usage

R-Washer A

Silver

OK

Service parts (R washer)

ITEM No.
28

SHIMANO CODE
No.
Y8LF12000

36

Please note: specifications are subject to change for improvement without notice. (English)
Jul. 2016 by Shimano Inc. HTR