Shimano BL-M4100 Dealer'S Manual Download Page 26 | Manualshive

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26

INSTALLATION/REMOVAL

Installing the brake hose

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.

1.

Determine the appropriate length and add a witness mark on the

brake hose.

Add the mark so it is aligned with the edge of the connecting bolt.

Witness mark

Connecting bolt

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Summary of Contents for BL-M4100

Page 1: ...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...

Page 2: ...g 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 Replacin...

Page 3: ...asy 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 coun...

Page 4: ...ics 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...

Page 5: ...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...

Page 6: ...hickness 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...

Page 7: ...r 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 immediate...

Page 8: ...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 child...

Page 9: ...uch 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...

Page 10: ...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 ma...

Page 11: ...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...

Page 12: ...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...

Page 13: ...olt 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...

Page 14: ...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 ro...

Page 15: ...r 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 yello...

Page 16: ...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 Instal...

Page 17: ...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 Wit...

Page 18: ...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 preven...

Page 19: ...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 b...

Page 20: ...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...

Page 21: ...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 Adapter fixing bolts Front Adapter Caliper fixin...

Page 22: ...bolts If the brake hose is not already installed in the caliper install the brake hose and then perform the step Caliper fixing bolts Front 6 8 N m Rear Caliper fixing bolts 6 8 N m 7 Secure the calip...

Page 23: ...he 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 Brake hose connection por...

Page 24: ...ute 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...

Page 25: ...e lever connecting bolt If the hose is at the appropriate length it is not necessary to cut the hose Proceed to Connecting the hose in Installing the brake hose If the hose needs to be shortened proce...

Page 26: ...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 1 Determine the appropriate le...

Page 27: ...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 18 mm Cut mark Witness mark 3 Prepare tool TL BH62 for the c...

Page 28: ...ing the brake hose 4 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 5 Check the cut location and...

Page 29: ...ing the brake hose 6 Check that the hose is secure and then install the hose cutter Hose cutter 7 Press the hose cutter as shown in the figure to cut the brake hose 8 Remove the hose cutter and check...

Page 30: ...is correctly positioned inside the opening of the brake hose Press block Connector insert 1 2 NOTICE When connecting with an easy hose joint system a specialized connector insert BL M6100 SHIMANO COD...

Page 31: ...EMOVAL Installing the brake hose 10 Depress the lever on tool TL BH62 to install the connector insert in the brake hose Check that the connector insert is installed correctly 11 Remove the brake hose...

Page 32: ...was cut it is not necessary to remove the hose cap 2 Pass the hose cover over the brake hose Hose cover 3 Secure the brake lever with a tool such as a vise Secure the hose connection port so that it...

Page 33: ...en 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 Cover with a clean rag while conducting this pr...

Page 34: ...lever BL M6100 Lever stopper Brake lever BL M4100 9 Check that the pad spacer is installed on the caliper and that the disc brake rotor is between the two sides of the caliper 10 Operate the brake le...

Page 35: ...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 counterclockwis...

Page 36: ...ds When the brake pads are worn down to a thickness of 0 5 mm When the brake pad presser spring is interfering with the disc brake rotor 1 Remove the wheel from the frame 2 Remove the brake pads 1 Clo...

Page 37: ...ake pads are replaced the pistons need to be pushed back into position Use a flat shaped tool to push the pistons back while being careful not to twist them Do not push the pistons with a sharp tool D...

Page 38: ...pin 7 Depress the brake lever a few times and make sure that the lever operation becomes stiff 8 Remove the pad spacer and install the wheel 9 Check that the disc brake rotor does not interfere with t...

Page 39: ...the reservoir tank becomes noticeably discolored Draining the mineral oil Follow local county and or state codes for disposal of used oil 1 Position the bicycle as shown in the figure Install a bleed...

Page 40: ...screw and O ring O ring Bleed screw 4 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 2 Remove the bleed boss...

Page 41: ...shown in the figure 2 Connect the tube with bag attached to the bleed nipple Bleed nipple 5 Loosen the bleed screw bleed nipple The oil will begin to drain Operating the brake lever while the oil drai...

Page 42: ...SHIMANO genuine mineral oil When bleeding the air out of the caliper you will need the SM DISC oil funnel and oil stopper 1 Position the bicycle as shown in the figure Install a bleed spacer yellow t...

Page 43: ...w Oil funnel 4 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 bu...

Page 44: ...ding the oil until there are no more air bubbles in the oil that is coming out Bleed boss Bleed screw BR M6120 1 Place a 7 mm box wrench in the position shown in the figure 2 Fill a syringe with oil t...

Page 45: ...6 Bleed the air Most of the air bubbles remaining inside the brake system can be bled by performing the following operation BR M6100 BR MT410 1 Place a 3 mm hexagon wrench in the position shown in th...

Page 46: ...d 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 Bleed nipple Air bubbles TECH TIPS It may help to...

Page 47: ...nal 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 8 Once no more air bubbles come from the bleed boss bl...

Page 48: ...n rapid succession Loosen and tighten for approximately 0 5 seconds each time to release any air bubbles inside the caliper Bleed screw BR M6100 BR MT410 BR M6120 Bleed nipple 10 Repeat step 9 two to...

Page 49: ...nto the oil funnel Continue operating the brake lever until no more bubbles appear 12 Check that the lever has become stiff If the lever does not become stiff repeat the procedures from step 6 Stiff S...

Page 50: ...Check that there are no remaining air bubbles 30 15 Set the brake lever so that it is parallel to the ground 16 Plug the oil funnel with the oil stopper Make sure that the side of the oil stopper with...

Page 51: ...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 bubbl...

Page 52: ...r from the system Checking and cutting the hose length 1 Route the brake hose into the final installation position 2 After determining the appropriate length add a witness mark on the brake hose as sh...

Page 53: ...ck 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 Connector insert Brake hose Witness mark Pre...

Page 54: ...54 MAINTENANCE Replacing the brake hose 4 Tighten the connecting bolt while pushing on the brake hose After tightening install the cover Connecting bolt 5 7 N m 5 Install the cover Cover...

Page 55: ...ve over the brake hose in the order shown below Olive Connecting bolt Brake hose 2 Check that the olive is in the position shown in the figure and then apply Premium Grease to the threads of the conne...

Page 56: ...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...

Page 57: ...c brake rotor 1 Remove the wheel from the frame 2 Remove the brake pads 1 Close the tip of the split pin 2 Remove the split pin 3 Remove the brake pads from the caliper 3 Brake pads 1 2 Split pin 3 Cl...

Page 58: ...er red 4 Brake pads 1 3 2 Split pin 6 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 7 Remove the pad sp...

Page 59: ...Please note specifications are subject to change for improvement without notice English Dec 2019 by SHIMANO INC ITP...

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