Shimano BL-4600 User Manual

TIAGRA Brake Lever

BL-4600

ITEM

NO.

1

Y8VB98010

Cable Adjusting Bolt & Nut A
2 Y6BX87000 Reach Adjusting Bolt (M4x 10.3) A
3

Y8U806000

Clamp Bolt (M6x 14.8) A

A: Same parts. Mar.-2011-3141
B: Parts are usable, but differ in materirals, appearance, finish, size, etc.

©

Shimano Inc.

A

Absence of mark indicates non-interchangeability.

Specifications are subject to change without notice.

INTERCHANGEABILITY

SHIMANO

CODE NO.

DESCRIPTION

S

L

-

I

M

6

0

S

T

-

T

4

0

0

-

B

L

B

L

-

M

7

7

1

Installation of the brake lever

1. Installation to the handlebar
<ST-4600 / 4603>

Secure the assembly with the installation nut on the outside of
the bracket. Pull the bracket cover back and use a 5 mm Allen
key to ti ghten the bolt.

<BL-4600 / R780>

Use a 4 mm Allen key to install.

<BL-4600 / R780>

5.6 mm

7.5 mm

Initial condition:
4º

4º

8º

14 mm

22 mm

<BL-4600 / R780>

•Mode switching

Bracket cover

5 mm Allen key

Installation nut

General Safety Information

WARNING

•Improper use of your bicycle's brake system may result in a loss of control or
an accident, which could lead to a severe injury.Because each bicycle may
handle differently, be sure to learn the proper braking technique (including
brake lever pressure and bicycle control characteristics) for your bicycle.
Consult your bicycle dealer and the bicycle's owners manual, and practice
your ridi ng and bra king techniq ue.

•The BL-4600/BL-R780 brake levers are equipped with a mode switching
mechanism to make them compatible with V-BRAKE brakes, caliper brakes,
cantilever brakes and roller brakes.

If the incorrect mode is selected it may cause either excessive or
insufficient braking force to occur, which could result in dangerous
accidents. Be sure to select the mode in accordance with the
instructions given in the mode switching table.

•If the front brake is applied too strongly, the wheel may lock and the bicycle
may fall forward, and serious injury may result.

•Use the ST-4600/4603, BL-4600/R780 with the BR-4600.Do not use the BR­4600 in combination with previous STI levers for road riding or with the BL­R770/BL-R550 brake levers for flat handlebars, otherwise the braking
performance provided will be much too strong.

•Securely tighten the caliper brake mounting nuts to the specified tightening
torque.

·Use lock nuts with nylon inserts (self-locking nuts) for nut-type brakes.

·For sunken nut type brakes, use sunken nuts of the appropriate length
which can be turned six times or more; when re-installing, apply sealant
(locking adhesive) to the nut threads.

If the nuts become loose and the brakes fall off, they may get caught up in
the bicycle and the bicycle may fall over. Particularly if this happens with the
front wheel, the bicycle may be thrown forward and serious injury could
result.

• Brakes designed for use as rear brakes should not be used as front brakes.

• Obtain and read the service instructions carefully prior to installing the
parts. Loose, worn or damaged parts may cause the bicycle to fall over and
serious injury may occur as a result. We strongly recommend only using
genuine Shimano replacement parts.

•Be careful not to allow any oil or grease to get onto the brake shoes.If any
oil or grease do get on the shoes, you should replace the shoes, otherwise
the brakes may not work correctly.

•Check the brake cable for rust and fraying, and replace the cable
immediately if any such problems are found. If this is not done, the brakes
may not work correctly.

•Always make sure that the front and rear brakes are working correctly before
you ride the bicycl e.

•The required braking distance will be longer during wet weather.Reduce
your spee d and apply the brakes early an d gently.

•If the road surface is wet, the tires will skid more easily.If the tires skid, you
may fall off the bicycle. To avoid this, reduce your speed and apply the
brakes early and gently.

•Read the Service Instructions for the Brake Systems carefully before use.

•Read these Technical Service Instructions carefully, and keep them in a safe
place for later reference.

Note

•If using SHIMANO's road brake shoes in combination with ceramic rims, the
brake shoes will wear more quickly than normal.

•If the brake shoes have worn down until the grooves are no longer visible,
they should be replaced.

•Different brake shoes have their own characteristics.Ask the place of
purchase for details when purchasing the brake shoes.

•Parts are not guaranteed against natural wear or deterioration resulting from
normal use.

•For maximum performance we highly recommend Shimano lubricants and
maintenance products.

•For any questions regarding methods of handling or maintenance, please
contact the place of purchase.

– To avoid serious injuries:

When installing the components to carbon frame/handle bar
surfaces, verify with the manufacturer of the carbon frame/parts
for the ir reco mmendati on on t ightenin g torqu e in or der to
prevent over tightening that can cause damage to the carbon
material and/or under tightening that can cause lack of fixing
strength for the components.

Series

TIAGRA

In order to realize the best performance, we recommend
that the following combination be used.

One Holland, Irvine, California 92618, U.S.A. Phone: [phone]

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: [phone]

3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan

* Service Instructions in fur ther languages are available at :

http://techdocs.shimano.com

Please note: specifications are subject to change for improvement without notice. (English)
© Mar.2011 by Shimano Inc. XBC IZM Printed in Malaysia.

Brake lever

ST-4600 / ST-4603, BL-4600 / BL-R780

Caliper Brake

BR-4600

Brake cable

2. Installation of the brake cable
<ST-4600 / 4603>

Tilt the lever in (as when shifting) to make it easier to pass the
cable through the cable hook.

Pass t he in ner c able t hrough as s hown i n the illus tratio n, an d
then set the inner cable drum into the cable hook.

Tightening torque:

6 – 8 N·m {52 – 69 in. lbs.}

Cable hook

Cable hook

Inner cable drum

Inner cable drum

Outer casing

Outer casing

SI-8JY0A-002-00

Outer casing

Tape

Note:

The BR-4600 allows the angle of contact between the shoe
and the rim (toe-in) to be adjusted. Adjusting the toe-in
makes it possible to obtain smoother braking operation.

Note:

Cut the cable at the length at which it is not pulled tight
when the handlebar is turned all the way to the left and
right.

6. Check

Depress the brake lever about 10 times as far as the grip and
check that everything is operating correctly and that the shoe
clearance is correct before using the brakes.

3. Cable connection

Set the quick release lever to the closed position; then adjust
the shoe clearance (as shown in the illustration below) and
secure the cable.

•To increase the lever
stroke

Remove the pad spacer (A)
and install the bump rubber.

•To decrease the lever
stroke

Insert pad spacer (B) as far as
it will go and so that the
projections fit into the holes in
pad spacer (A).

* Apply a small amount of grease to the projections when installing

the pad spacer and the bump rubber.

4. Centering of the brake shoe

Make a minor adjustment by using the centering adjustment
screw.

Depress about
10 times

Depress about
10 times

2. Brake shoe setting position

After adjusting the brake shoe position so that the shoe surface
and the rim surface are as shown in the illustration, tighten the
shoe fixing bolt.

3. Lever stroke adjustment
<ST-4600 / 4603>

Shoe fixing bolt

Centering adjustment
screw

4 mm Allen key

Quick release lever

Installation of the brake

1. Installation of the brake itself

Compress the arch‚ and set while the shoe is in firm contact
with the rim.

5 mm Allen key

Tem p or a r i ly s e cu r e th e o ut e r ca s i ng t o th e h a nd l e ba r ( by u s in g
tape or similar material).

Then wrap the handlebar with handlebar tape.

Open

Closed

5. Readjustment of the shoe clearance

Tur n th e c ab l e a d j u st m e nt b o lt t o r e a dj u s t t h e sh o e cl e a ra n c e.

Cable adjustment bolt

Direction of
rim rotation

Direction of
rim rotation

1 mm or more

Pad spacer (A)

Pad spac er (A )

Pad spac er (A )

Pad spac er (B )

Bump rubber

Pad spacers (A) + (B)

Toe -i n

0.5 mm

Tightening torque:

5 – 7 N·m {43 – 61 in. lbs.}

Tightening torque:

8 – 10 N·m {69 – 87 in. lbs.}

Cable bolt tightening torque:

6 – 8 N·m {52 – 69 in. lbs.}

The usual position during
installation is when the head
of the centering adjustment
screw is as shown in the
illustration.

3 mm Allen key

2 mm Allen key

<ST-4600 / 4603>

<BL-4600 / R780>

Use a handlebar grip with a
maximum outer diameter of
32 mm.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

4 mm Allen key

Note: The front lever cannot be tilted

to the inside until lever

b

F

is

pushed once or twice.

Lever b

F

Pull

Tilt

Inner cable drum

Cable hook

C/R position

BR-4600

Caliper Brake

Tec h n ic a l Se r v i ce I n st r u ct i o ns SI-8JY0A-002

V

V

C

C

R

R

Mode position Applicable brake

The V indicates the mode
position for compatibility with
V-BRA KE b rak es.

•V-BRAKE brakes

V position

R

V

V

C

C

R

The C indicates the mode
position for compatibility with
caliper brakes and cantilever
brakes.
The R indicates the mode
position for compatibility with
roller brakes.

•Caliper brakes

•Cantilever brakes

•Roller brakes

C/R position