Page 1
(English)
DM-UABR001-06
Dealer's Manual
ROAD MTB Trekking
City Touring/
Comfort Bike
METREA
ST-U5060
BR-U5000
BR-RS785
BL-U5010
BL-U5000
SM-RT500-SS
URBAN SPORT E-BIKE
Hydraulic Disc Brake/
DUAL CONTROL LEVER
Non-series
BR-UR300
BL-MT200
BL-MT201
Page 2
CONTENTS
IMPORTANT NOTICE .............................................................................................. 3
TO ENSURE SAFETY ............................................................................................... 4
LIST OF TOOLS TO BE USED ................................................................................ 10
INSTALLATION ..................................................................................................... 12
Names of parts ...........................................................................................................................................12
Installation of the brake hose (easy hose joint system) ........................................................................... 13
Installation of the brake hose ...................................................................................................................18
Installation to the handlebar ....................................................................................................................23
Adding Shimano genuine mineral oil and bleeding air ..........................................................................27
Installation of the disc brake rotor ...........................................................................................................44
Installation of brake calipers .....................................................................................................................45
Preventing loosening of frame fixing bolts .............................................................................................. 57
Installing the shifting cable .......................................................................................................................58
ADJUSTMENT ...................................................................................................... 64
Reach adjustment ....................................................................................................................................... 64
MAINTENANCE .................................................................................................... 66
Replacing Shimano genuine mineral oil ................................................................................................... 66
Replacement of brake pads ....................................................................................................................... 67
Replacing the cover .................................................................................................................................... 71
Pulling out a disconnected inner end (shifting cable) .............................................................................72
Replacement of the SL cable guide ........................................................................................................... 73
2
Page 3
IMPORTANT NOTICE
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.
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 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 dealer’s manual.
•
All dealer’s manuals and instruction manuals can be viewed on-line on our website (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.
3
Page 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 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:
Brake
•
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.
•
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 0.5
mm or less, the brake pad needs to be replaced with a new one. Consult a dealer or an agency.
•
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 1.5 mm 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; therefore, please refrain from doing this.
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.
2 mm 0.5 mm
4
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TO ENSURE SAFETY
SM-RT500-SS
•
This disc brake rotor is designed for recreational use.
If sudden braking is repeated while the disc brake rotors are hot, the brakes will generate noise, and there will be a reduction in braking force.
If you sense that braking force has reduced, immediately stop riding and reduce the temperature of the disc brake rotors.
•
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.
•
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.
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 1.5 mm or so that 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 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 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, any air bubbles inside the reservoir tank may move
in the direction of the calipers and if the bicycle is ridden in this condition, there is a danger that the brakes may not operate and a serious accident
could 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, and 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 bleed section of 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.
If the brakes still operate sluggishly, bleed the air from the brake system (refer to "Adding Shimano genuine mineral oil and bleeding air").
5
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TO ENSURE SAFETY
•
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.
•
When installing the brake caliper using bolt fixing pins, be sure to use mounting bolts of the
appropriate length.
If not, the bolt fixing pins may not be securely fastened, and the bolts may fall out.
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.
Bolt fixing pin
Model No. Length Color
SM-BH59-JK-SS 13.2 mm Gold
•
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.
Brake hose Olive Connector
•
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.
Cut endConnecting bolt
insert
90°
6
Page 7
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 vapor is inhaled, go immediately to an area with fresh air and cover up with a blanket. 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.
For Installation to the Bicycle, and Maintenance:
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; therefore, 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.
7
Page 8
TO ENSURE SAFETY
NOTICE
Be sure to also inform users of the following:
•
Be sure to keep turning the crank during gear shifting.
•
Handle the product carefully, and avoid subjecting it to any strong shocks.
•
Do not use thinners or similar substances to clean the products. Such substances may damage the surfaces.
•
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 places where high temperatures are present. Also keep them well away from fire.
•
If gear shifting operations do not feel smooth, wash the derailleur and lubricate all moving parts.
•
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 cleaners
or silencing agents, as they can cause damage to parts such as seals.
•
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:
•
Use a brake hose/outer casing which still has some length to spare even when the handlebars are turned all the way to both sides. Furthermore, check
that the shifting lever does not touch the bicycle frame when the handlebars are turned all the way.
•
Use an OT-SP sealed outer casing and cable guide for smooth operation.
•
Grease the inner cable and the inside of the outer casing before use to ensure that they slide properly. Do not let dust adhere to the inner cable. If the
grease on the inner cable is wiped off, the application of SIS SP41 grease (Y04180000) is recommended.
•
A special grease is used for the gear shifting cable. Do not use premium grease or other types of grease, otherwise they may cause deterioration in
gear shifting performance.
•
If gear shifting adjustments cannot be carried out, check that the rear fork ends are aligned. Check whether the cable is lubricated and clean, and if
the outer casing is too long or short.
•
Do not remove the lever unit.
Disc brake
•
If the brake caliper mounting boss and the fork end are not of standard dimensions, 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-tipped screwdriver or
similar 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 cleaners 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 actual product may differ from the illustration because this manual is intended mainly to explain the procedures for using
the product.
8
Page 9
LIST OF TOOLS TO BE USED
Page 10
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
1.5 mm hexagon wrench 8 mm spanner TL-LR15
2 mm hexagon wrench 10 mm spanner TL-BH61
2.5 mm hexagon wrench 7 mm socket wrench TL-CT12
3 mm hexagon wrench Screwdriver[#1]
4 mm hexagon wrench
5 mm hexagon wrench Utility knife Needle-nose pliers
Slotted screwdriver
(nominal dia. 0.8 × 4)
SM-DISC
(Oil funnel and oil stopper)
BL-U5000 funnel adapter
10
Page 11
INSTALLATION
Page 12
INSTALLATION
Names of parts
INSTALLATION
Names of parts
Model No.
(B)
(A)
(z)
(A)
BL-U5000/MT200/MT201
(B)
BL-U5010
ST-U5060
(C)
BR-U5000/RS785/UR300
SM-RT500-SS/RT10-S
SM-BH59-JK-SS
(z)
For flat handlebars
(C)
TECH TIPS
This manual covers the disc brake system.
For the specifications of individual
components, refer to the following
website.
(https://productinfo.shimano.com/#/spec/)
12
Page 13
INSTALLATION
Installation of the brake hose (easy hose joint system)
Installation of the brake hose (easy hose joint system)
ST-U5060/BL-U5010
(B)(A)
(C)
(A)
Dual control lever or Brake lever
(B)
Joint sleeve
(C)
Lever stopper
(D)
Hose cap
(E)
Brake caliper
Route the brake hose through the holes in the built-in frame and the handlebar.
1
Remove the hose cap.
2
Secure the joint component in a vise or
other similar device.
Face the hose connection port upward as
shown in the illustration.
3
(E)(D)
4
To be continued on next page
Remove the seal plug.
Cover the seal plug with a waste cloth as
the oil applied to the seal plug may leak.
13
Page 14
INSTALLATION
Installation of the brake hose (easy hose joint system)
5
6
(A)
(B)
Insert the brake hose on the brake
caliper side into the joint component.
It comes with a built-in olive. Insert it
while making sure that it will not get
snagged on the olive.
Check that the brake hose is inserted up
to the line printed on the hose.
Tighten the connecting bolt with two 8
mm spanners.
TECH TIPS
Use a waste cloth when inserting the brake
hose as some oil inside may leak.
(A)
Connecting bolt
(B)
8 mm spanner
Tightening torque
5 - 7 N·m
7
(A)
Wipe away any oil and make sure that
the O-rings are attached as in the
illustration.
(A)
O-ring
14
Page 15
INSTALLATION
Installation of the brake hose (easy hose joint system)
BL-U5000/MT200/MT201
(A)
(C)
(F)
(B)
(A)
Hose cap
(B)
Brake caliper
(C)
Seal plug
(D)
Hose connection port
(E)
Brake lever
(F)
Stopper
(D)
Pass the brake hose through each hole in the built-in frame.
(E)
1
Remove the hose cap.
2
Secure the brake lever in a vise or
another similar device.
Face the hose connection port upward
when securing the brake lever.
3
To be continued on next page
15
Page 16
INSTALLATION
Installation of the brake hose (easy hose joint system)
4
5
6
(A)
(A)
Remove the seal plug.
Cover the seal plug with a waste cloth as
the oil applied to the seal plug may leak.
Pass the brake hose through the hose
cover.
Insert the brake hose into the joint
component.
It comes with a built-in olive.
Insert it while making sure that it will
not get snagged on the olive.
(A)
Seal plug
(A)
Hose cover
TECH TIPS
Use a waste cloth when inserting the brake
hose as some oil inside may leak.
7
(A)
Check that the brake hose is inserted up
to the line printed on the hose.
Tighten the connecting bolt with an 8
mm spanner.
(A)
8 mm spanner
Tightening torque
5 - 7 N·m
To be continued on next page
16
Page 17
INSTALLATION
Installation of the brake hose (easy hose joint system)
8
Clean any oil residue and attach the hose
cover.
9
(A)
Remove the brake lever stopper.
(A)
Lever stopper
NOTICE
After removing the lever stopper, check that
the pad spacer is installed on the caliper side
or that the caliper is installed to the bicycle
and the disc brake rotor is between the two
sides of the caliper, before depressing the
lever.
After installation to the bicycle, make sure to
check that the lever stopper is removed.
TECH TIPS
Move and pull on the lever stopper to remove
it while being careful not to depress the lever.
17
Page 18
INSTALLATION
Installation of the brake hose
Installation of the brake hose
1
2
(z)
(z)
Use a utility knife or other cutting tool
to cut the brake hose.
(z)
90°
Put a mark on the brake hose
beforehand as shown in the illustration
so that you can check if the ends of the
brake hose are secured to the hose
mounts of the brake caliper and the dual
control lever/brake lever.
(As a guide, the length of the portion of
the brake hose that is inside the mount
is approximately 11 mm.)
NOTICE
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.
3
(A) (B) (C) (D)
(y)
(z)
(E) (C)
(z)
11 mm
Pass the brake hose through the
connecting bolt and olive.
(y)
Direction of insertion
(z)
Grease the outside of the olive.
(A)
Brake hose
(B)
Connecting bolt
(C)
Olive
(D)
Cut end
(E)
Grease
NOTICE
When installing to a built-in type frame, make
sure to first pass the lever end of the brake
hose through the caliper end of the frame.
To be continued on next page
18
Page 19
INSTALLATION
(D)
Installation of the brake hose
4
5
Use a tapered tool to smooth out the
inside of the cut end of the brake hose,
and mount the connector insert.
Connect the brake hose to TL-BH61 and
secure TL-BH61 in a vise.
Then, hammer down the connector
insert until the connector insert mount
comes into contact with the end of the
brake hose.
(z)
SM-BH59-JK-SS: 1 mm
After checking that the olive is
positioned as shown in the illustration,
grease the threads of the connecting
bolt.
(z)
2 mm
(B)
(A)
(z)
(A)
(B)
(C)
(E)
(z)
(A) (B) (C)
Model No. Length Color
SM-BH59-JK-SS 13.2 mm Gold
(A)
Connector insert
(B)
Brake hose
(C)
Olive
(D)
TL-BH61
(E)
Vise
NOTICE
If the end of the brake hose is not in contact
with the connector insert mount, the brake
hose may be disconnected or cause fluid leaks.
(A)
Brake hose
(B)
Olive
(C)
Connector insert
NOTICE
Use the dedicated connector insert supplied
with SM-BH59-JK-SS.
Use of any connector insert other than the
one supplied may produce a loose assembly,
leading to oil leaks or other problems.
To be continued on next page
19
Page 20
INSTALLATION
(B)
Installation of the brake hose
ST-U5060/BL-U5010, BR-U5000
6
(A)
BL-U5000, BR-U5000/RS785
BL-MT200/MT201, BR-UR300
(A)
(y)
(z)
(A)
Make sure that the brake hose is not
twisted.
Make sure that the brake calipers and
dual control levers/brake levers are in the
positions shown in the illustrations.
(y)
Left lever
(z)
Right lever
(A)
Brake caliper
ST-U5060/BL-U5010
7
ST-U5060/BL-U5010
8
(A)
(A)
(B)
(z)
Pass the brake hose through the
handlebar.
(z)
60 mm
Attach an O-ring to the brake hose.
(A)
(B)
(A)
(B)
Handlebar
Brake hose
O-ring
Brake hose
To be continued on next page
20
Page 21
INSTALLATION
Installation of the brake hose
ST-U5060/BL-U5010
(A)
(B)
(C)
9
BL-U5000/MT200/MT201
(A)
Secure the dual control lever/brake lever
to the handlebar or in a vise and insert
the brake hose straight.
Tighten the connecting bolt with a
spanner while pushing the brake hose.
ST-U5060/BL-U5010
Keep the joint sleeve held in place with a
spanner when carrying out the
procedure.
(A)
8 mm spanner
(B)
Connecting bolt
(C)
Joint sleeve
Tightening torque
5 - 7 N·m
NOTICE
At this point, make sure the brake hose is
straight when pushing.
10
(A) (B)
(B)
Attach the O-rings to the connecting
bolt.
(A)
Connecting bolt
(B)
O-ring
21
Page 22
INSTALLATION
Installation of the brake hose
End of the brake hose on the brake caliper side
Attach the connector insert to the brake hose.
BR-U5000/UR300
1
BR-RS785
(A) (B) (C) (D)
(A)
Brake hose
(B)
Connecting bolt
(C)
Olive
(D)
Connector insert
Tightening torque
5 - 7 N·m
(A) (B) (C) (D)
While pushing the brake hose, tighten the connecting bolt.
2
22
Page 23
INSTALLATION
(A)
Installation to the handlebar
Installation to the handlebar
ST-U5060/BL-U5010
1
2
(A)
(B)
Remove the 2 mounting bolts and then
remove the upper cover.
Loosen the clamp bolt with a 10 mm
spanner.
(A)
Cover
(B)
Mounting bolt
(A)
Clamp bolt
TECH TIPS
The clamp bolt is loose at the time of
purchase so this step is unnecessary when first
installing.
3
(A)
To be continued on next page
Insert the handlebar into the lever body.
23
(A)
Handlebar
Page 24
INSTALLATION
(B)
Installation to the handlebar
4
5
(A)
(B)
(A)
Remove the mounting bolt on the
underside and then remove the band
cover.
Check that the handlebar has been
inserted as far as it will go by peering
through the band cover mounting hole.
(A)
Band cover
(B)
Mounting bolt
(A)
Dual control lever or Brake lever
(B)
Handlebar
6
(A)
Tighten the clamp bolt.
(A)
Clamp bolt
Tightening torque
4 - 6 N·m
To be continued on next page
24
Page 25
INSTALLATION
Installation to the handlebar
7
(A)
(y)
(z)
(B)
Attach the upper cover and the
2 mounting bolts.
Engage the catch on the band cover and
secure in place with the mounting bolt.
(y)
Catch (main body side)
(z)
Catch (band cover side)
(A)
Cover
(B)
Mounting bolt
Tightening torque
0.15 - 0.25 N·m
Tightening torque
0.15 - 0.25 N·m
8
25
Page 26
INSTALLATION
(A)
Installation to the handlebar
BL-U5000/MT200/MT201
Secure the brake lever as shown in the
illustration.
(A)
BL-U5000:
4 mm hexagon wrench
BL-MT200/MT201:
5 mm hexagon wrench
BL-U5000
Tightening torque
6 - 8 N·m
BL-MT200/MT201
Tightening torque
4 - 6 N·m
NOTICE
Check that the brake lever does not interfere
with the shifting lever during operation.
Some types might require the shifting lever to
be installed first, due to the position of the
shifting lever fixing bolts.
For open clamp band type
[2]
(D) (B) (z)
Use a 2 mm hexagon wrench to open the
(C)(A)
clamp band of the brake lever as shown
in the illustration.
(z)
Push
(A)
Clamp band
(B)
2 mm hexagon wrench
(C)
Lock release hole
(D)
Spacer
NOTICE
•
When installing the brake lever, be sure to
use a spacer.
[1]
•
The spacer should only be removed when
combining with an I-Spec II type shifting
lever. For information on the combining
procedure, refer to the dealer's manual for
the "RAPIDFIRE Plus 11-speed shifting
lever".
26
Page 27
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
Adding Shimano genuine mineral oil and bleeding air
With the bleed spacer (yellow) attached to the brake caliper, place the bicycle in the work stand as
shown in the illustration.
(A)
(B)
ST-U5060/BL-U5010, BR-U5000
Mount the bleed spacer (yellow).
(A)
Brake hose
(B)
Brake caliper
NOTICE
When bleeding the brake caliper, you need
SM-DISC (oil funnel and oil stopper).
(A)
Pad axle
(B)
Bleed spacer
1
2
(A)
Tightening torque
0.1 - 0.3 N·m
(B)(A)
Remove the 2 mounting bolts and then
remove the upper cover.
(B)
(A)
Cover
(B)
Mounting bolt
To be continued on next page
27
Page 28
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
3
(A)
(B)
(A)
(B)
Remove the bleed screw and O-ring.
Attach the BL-U5000 funnel adapter to
the oil funnel.
(A)
Bleed screw
(B)
O-ring
TECH TIPS
Be careful not to drop the bleed screw or
O-ring.
(A)
Oil funnel
(TL-BT03/TL-BT03-S)
(B)
BL-U5000 funnel adapter
4
5
(A)
Mount the oil funnel.
(A)
Oil funnel
(TL-BT03/TL-BT03-S)
Secure the brake caliper in a vise while bleeding.
6
To be continued on next page
28
Page 29
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
7
(A)
(B)
Set a 7 mm socket wrench in place.
Fill the syringe with sufficient oil,
connect the syringe tube to the bleed
nipple, and fasten it with the tube
holder so that the tube will not be
disconnected.
Loosen the bleed nipple by a 1/8 of a
turn to open it.
Push the piston of the syringe to add oil.
(A)
Bleed nipple
(B)
Tube holder
NOTICE
Secure the brake caliper in a vise to prevent
the tube from being accidentally
disconnected.
(A)
Bleed nipple
(B)
Tube holder
(C)
7 mm socket wrench
8
(C)
(A)
(B)
The oil then starts coming out from the
oil funnel.
Continue adding oil until there are no
more air bubbles mixed in with the oil
that is coming out.
NOTICE
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.)
To be continued on next page
29
Page 30
INSTALLATION
)A( )B(
Adding Shimano genuine mineral oil and bleeding air
9
10
Once there are no more air bubbles in
the oil in the funnel, angle the handles
downward until the boundary between
the band cover and bracket is
perpendicular to the ground.
Push the piston of the syringe again to
add oil, and once there are no more air
bubbles in the oil in the funnel, angle
the handles up to their previous position
and 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.
(A)
(B)
Bracket
Band cover
11
(A)
(B)
Tie the supplied tube and bag with
rubber bands.
Set a 7 mm socket wrench as shown in
the illustration, and connect the tube to
the bleed nipple.
(A)
7 mm socket wrench
(B)
Bag
To be continued on next page
30
Page 31
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
12
(A)
(B)
Loosen the bleed nipple.
At this point, make sure that the tube is
secured to the bleed nipple.
After a little while, the oil and air
bubbles will flow naturally from the
bleed nipple into the tube.
This way it will be possible to easily
extract the greater part of the air
bubbles remaining inside the brake
system.
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.
(A)
7 mm socket wrench
(B)
Air bubbles
TECH TIPS
It may be effective to shake the brake hose
gently, tap the lever bracket or brake calipers
gently with a screwdriver, or move the
position of the calipers at this time.
13
To be continued on next page
31
Page 32
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
14
(A)
(B)
Once no more air bubbles come from the
bleed nipple, temporarily close the bleed
nipple.
With the brake lever depressed, open
and close the bleed nipple 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)
7 mm socket wrench
(B)
Bleed nipple
Tightening torque
4 - 7 N·m
15
Then tighten the bleed nipple.
To be continued on next page
32
Page 33
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
Lever operation
If the brake lever is then operated, air
bubbles in the system will rise up
through the port into the oil funnel.
Once the bubbles stop appearing,
depress the brake lever as far as it will
go.
Under normal conditions, lever action
should feel stiff at this point.
(x)
Loose
(y)
Slightly stiff
(z)
Stiff
16
(x)
(y)
(z)
To be continued on next page
33
Page 34
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
17
(A)
(B)
(A)
Plug the oil funnel with the oil stopper
so that the O-ring mounted side is facing
downward.
Remove the oil funnel together with the
BL-U5000 funnel adapter while it is still
plugged with the oil stopper, and then
attach the O-ring to the bleed screw and
tighten it while letting oil flow out to
make sure that there are no air bubbles
remaining inside the reservoir tank.
(A)
(B)
(A)
Oil stopper
O-ring
O-ring
Tightening torque
0.5 - 1 N·m
18
19
At this point, use a waste cloth to
prevent oil from flowing out to the
surrounding areas.
Wipe away any oil which may have
leaked out.
NOTICE
Do not operate the brake lever. If operated,
there is a risk of air bubbles entering the
cylinder.
34
Page 35
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
BL-U5000, BR-U5000/RS785 BL-MT200/MT201, BR-UR300
BR-U5000
BR-RS785
Mount the bleed spacer (yellow).
(A)
Pad axle
(B)
Bleed spacer
(C)
Split pin
Tightening torque
0.1 - 0.3 N·m
(B)(A)
1
(B)(A)
BR-UR300
(C)
(C)
(B)
To be continued on next page
35
Page 36
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
Set the brake lever so that it is in riding
position at 45° to the horizontal.
2
3
(z)
(B)
(C)
(A)
(z)
45°
Remove the bleed screw and O-ring.
(A)
BL-U5000:
2.5 mm hexagon wrench
BL-MT200/MT201:
2 mm hexagon wrench
(B)
Bleed screw
(C)
O-ring
TECH TIPS
4
(A)
(B)
Attach the BL-U5000 funnel adapter to
the oil funnel.
*The funnel adapter does not need to be
installed for BL-MT200/MT201.
Be careful not to drop the bleed screw or
O-ring.
(A)
Oil funnel
(TL-BT03/TL-BT03-S)
(B)
BL-U5000 funnel adapter
To be continued on next page
36
Page 37
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
(A)
5
Secure the brake caliper in a vise while bleeding.
6
BR-U5000/UR300
(A)
(B)
Mount the oil funnel.
Set a 7 mm socket wrench in place, fill
the syringe with oil, connect a tube to
the bleed nipple, and then loosen the
bleed nipple by 1/8 of a turn to open it.
Push the piston of the syringe to add oil.
The oil will start coming out from the oil
funnel.
Continue adding oil until there are no
more air bubbles in the oil that is coming
out.
(A)
Oil funnel
(TL-BT03/TL-BT03-S)
(A)
Bleed nipple
(B)
7 mm socket wrench
7
BR-RS785
(A)
(B)
(D)
(C)
Fill the syringe with sufficient oil.
Attach the adapter provided with this
product or Shimano original tool to the
end of the tube, connect the tube to the
bleed boss, and fasten it with the tube
holder so that the tube will not be
disconnected.
Loosen the bleed screw by 1/8 of a turn
to open it.
Push the piston of the syringe to add oil.
The oil then starts coming out from the
oil funnel.
Continue adding oil until there are no
more air bubbles mixed in with the oil
that is coming out.
(A)
Bleed screw
(B)
Bleed boss
(C)
Tube holder
(D)
Adapter
To be continued on next page
37
Page 38
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
Once there are no more air bubbles mixed in with the oil, temporarily close the bleed nipple.
8
BR-U5000/UR300
(A)
Set a 7 mm socket wrench in place as
shown in the illustration, and then
attach the bag to the tube.
NOTICE
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.)
(A)
7 mm socket wrench
(B)
Bag
9
BR-RS785
(B)
(B)
(A)
Tie the supplied tube and bag with
rubber bands, set a 3 mm hexagon
wrench as shown in the illustration, and
connect the tube to the bleed boss.
(A)
3 mm hexagon wrench
(B)
Bag
To be continued on next page
38
Page 39
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
10
BR-U5000/UR300
BR-RS785
(B)
(A)
(z)
Connect the tube to the bleed nipple
and loosen the bleed nipple.
After a little while, the oil and air
bubbles will flow naturally from the
bleed nipple into the tube.
This way it will be possible to easily
extract the greater part of the air
bubbles remaining inside the brake
system.
(z)
Air bubbles
Loosen the bleed screw.
At this point, make sure that the tube is
secured to the bleed boss.
(A)
7 mm socket wrench
(B)
Bag
TECH TIPS
It may help to shake the hose gently or to tap
the reservoir tank or caliper gently with a
screwdriver or move the position of the
caliper at this time.
(z)
After a little while, the oil and air
bubbles will flow naturally from the
bleed boss into the tube.
In this way it will be possible to easily
extract the greater part of the air
bubbles remaining inside the brake
system.
(z)
Air bubbles
To be continued on next page
39
Page 40
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
11
The level of liquid inside the funnel will
drop at this time, so keep filling the
funnel with oil to maintain the level of
liquid so that air is not drawn in (air does
not get inside).
12
BR-U5000/UR300
BR-RS785
(A)
(B)
(A)
(B)
Once no more air bubbles come from the
bleed nipple, temporarily close the bleed
nipple.
Once no more air bubbles come from the
bleed boss, temporarily close the bleed
screw.
(A)
Bleed nipple
(B)
7 mm socket wrench
(A)
Bleed screw
(B)
Bleed boss
To be continued on next page
40
Page 41
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
13
BR-U5000/UR300
BR-RS785
(A)
With the brake lever depressed, open
and close the bleed nipple in rapid
succession (for approximately 0.5 seconds
each time) to release any air bubbles
which may be in the calipers.
Repeat this procedure about 2 to 3
times.
Then tighten the bleed nipple.
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.
(A)
7 mm socket wrench
Tightening torque
Tightening torque
4 - 6 N·m
4 - 7 N·m
Repeat this procedure about 2 to 3
times.
Then tighten the bleed screw again.
To be continued on next page
41
Page 42
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
14
Lever operation
(x)
(y)
If the brake lever is then operated, air
bubbles in the system will rise up
through the port into the oil funnel.
Once the bubbles stop appearing,
depress the brake lever as far as it will
go.
It is normal for the lever to be stiff at this
point.
(x)
Loose
(y)
Slightly stiff
(z)
Stiff
NOTICE
If the lever does not become stiff, repeat the
procedures from step 9.
15
(z)
[1]
(z)
(z)
[2]
Set the lever unit to the horizontal
position as shown in the illustration and
tilt it in the direction of [1] by 30°, and
then carry out step 9 to check that there
is no air remaining.
Next, tilt the lever unit 30° in the
direction of [2], and carry out step 9
again to check that there is no air
remaining.
If any air bubbles appear, repeat the
above procedure until they stop
appearing.
(z)
30°
To be continued on next page
42
Page 43
INSTALLATION
Adding Shimano genuine mineral oil and bleeding air
16
(A)
(B)
Plug the oil funnel with the oil stopper
so that the side with the O-ring attached
is facing downward.
Remove the oil funnel together with the
BL-U5000 funnel adapter while it is still
plugged with the oil stopper, and then
attach the O-ring to the bleed screw and
tighten it while letting oil flow out to
make sure that there are no air bubbles
remaining inside the reservoir tank.
(A)
Oil stopper
(B)
O-ring
(A)
O-ring
BL-MT200/MT201
Tightening torque
0.5 - 1 N·m
17
18
(A)
BL-U5000
Tightening torque
0.5 - 1 N·m
NOTICE
Do not operate the brake lever. If operated,
there is a risk of air bubbles entering the
cylinder.
Wipe away any oil that has overflowed.
43
Page 44
INSTALLATION
Installation of the disc brake rotor
Installation of the disc brake rotor
Center lock type
(A)
Disc brake rotor fixing lock ring
(B)
TL-LR15
(A) (B)
Tightening torque
40 - 50 N·m
44
Page 45
INSTALLATION
Installation of brake calipers
Installation of brake calipers
Installing the brake pads
BR-U5000
(A) (B)
BR-RS785
Remove the bleed spacer (yellow).
(A)
Slotted screwdriver
(nominal dia. 0.8 × 4)
(B)
Bleed spacer
(C)
Needle-nose pliers
1
(A) (B)
BR-UR300
(C)
(B)
To be continued on next page
45
Page 46
INSTALLATION
Installation of brake calipers
2
(A)
Set the pad fixing spring as shown in the
illustration. (The spring for BR-RS785 has
markings on the left side (L) and the
right side (R).)
(A)
Pad fixing spring
To be continued on next page
46
Page 47
INSTALLATION
Installation of brake calipers
BR-U5000
BR-RS785
(C)
(A)
(A)
(B)
(B)
Install the new brake pads and bolts.
Make sure to use a snap retainer at this
time.
Install the pads as shown in the
illustration.
(A)
Brake pads
(B)
Snap retainer
(C)
Pad axle
(D)
Split pin
Tightening torque
0.1 - 0.3 N·m
NOTICE
BR-RS785
When using a pad with fins, take note of the
left (L) and right (R) markings to set it.
3
(C)
BR-UR300
(D)
(D)
(A)
47
Page 48
INSTALLATION
Installation of brake calipers
Checking the length of brake caliper mounting bolts C (BR-U5000/UR300)
Same for both 140 mm and 160 mm
(z)
(A)
Insert brake caliper mounting bolts C
into the frame mount area, and check
that the length of the protruding
portion of each brake caliper mounting
bolt C is 13 mm.
(z)
13 mm
(A)
Brake caliper mounting bolt C
NOTICE
•
When using a bolt length selector, check
whether the tip of the brake caliper
mounting bolt C is within the range [X].
Brake caliper
mounting bolt C
[X]
•
Do not use a washer when checking the
length of brake caliper mounting bolt C.
•
The length of brake caliper mounting bolts
C to be used vary depending on the
thickness of the frame.
Use brake caliper mounting bolts C that are
appropriate for the thickness of the frame.
Bolt length
selector
[A]
[A]
Thickness
of frame
10 mm 23 mm
15 mm 28 mm
20 mm 33 mm
25 mm 38 mm
30 mm 43 mm
35 mm 48 mm
[B]
Length of
brake caliper
mounting bolt C
[B]
Y-part
Y8N208000
Y8N208050
Y8N208010
Y8N208020
Y8N208030
Y8N208040
48
Page 49
INSTALLATION
Installation of brake calipers
Converter fixing bolt length confirmation (BR-RS785)
Same for both 140 mm and 160 mm
(z)
(A)
Insert the converter fixing bolts into the
frame mount area, and make sure that
the lengths of the protruding sections of
the bolts are 6.8mm.
(z)
6.8 mm
(A)
Converter fixing bolts
NOTICE
•
When using a bolt length selector, make
sure the tip of the converter fixing bolt is
within the range
Converter
fixing bolts
•
Do not use a washer when checking the
length of the converter fixing bolt.
•
The length of the converter fixing bolts
used varies depending on thickness of the
frame.
Use converter fixing bolts that are suitable
for the thickness of the frame.
[X].
Bolt length
selector
[X]
[A]
[A]
Frame
thickness
10 mm 16.8 mm
15 mm 21.8 mm
20 mm 26.8 mm
25 mm 31.8 mm
30 mm 36.8 mm
35 mm 41.8 mm
[B]
Converter fixing
bolt length
[B]
Y-part
Y81743100
Y81743150
Y81743200
Y81743250
Y81743300
Y81743350
49
Page 50
INSTALLATION
(A)
Installation of brake calipers
Installation to the frame (BR-U5000/UR300)
When using a mount bracket
(140 mm disc brake rotor (BR-U5000))
1
(A)
(B) (C)
Attach the mount bracket to the brake
caliper.
Install the bolt fixing pin.
Check that the bolt fixing pin is fully
inserted all the way to the back.
(A)
Bolt fixing pin
(B)
Brake caliper mounting bolt B
(C)
Mount bracket
Tightening torque
6 - 8 N·m
NOTICE
Pay attention to the marking on the mount
bracket when attaching it.
2
Attach the mount bracket to the frame
provisionally.
Depress the brake lever, and tighten the
brake caliper mounting bolts A while the
brake pads are pressed against the disc
brake rotor.
(A)
Brake caliper mounting bolt A
Tightening torque
6 - 8 N·m
To be continued on next page
50
Page 51
INSTALLATION
Installation of brake calipers
3
(A)
Install the snap ring.
(A)
Snap ring
NOTICE
Positions for attaching snap rings are different
for 140 mm and 160 mm. (Illustration shows
140 mm)
Snap ring
51
Page 52
INSTALLATION
(A)
Installation of brake calipers
When using a mount bracket
(160 mm disc brake rotor (BR-U5000))
1
(A)
(B) (C)
Attach the mount bracket to the brake
caliper.
Install the bolt fixing pin.
Check that the bolt fixing pin is fully
inserted all the way to the back.
(A)
Bolt fixing pin
(B)
Brake caliper mounting bolt B
(C)
Mount bracket
Tightening torque
6 - 8 N·m
NOTICE
Pay attention to the marking on the mount
bracket when attaching it.
2
Attach the mount bracket to the frame
provisionally.
Depress the brake lever, and tighten the
brake caliper mounting bolts A while the
brake pads are pressed against the disc
brake rotor.
(A)
Brake caliper mounting bolt A
Tightening torque
6 - 8 N·m
To be continued on next page
52
Page 53
INSTALLATION
Installation of brake calipers
3
(A)
When using a brake caliper mounting bolt A
(160 mm disc brake rotor (BR-UR300))
(A)
Install the snap ring.
Depress the brake lever, and tighten the
brake caliper mounting bolts A while the
brake pads are pressed against the disc
brake rotor.
(A)
Snap ring
NOTICE
Positions for attaching snap rings are different
for 140 mm and 160 mm. (Illustration shows
160 mm)
Snap ring
(A)
Brake caliper mounting bolt A
Tightening torque
1
2
(A)
Install the snap ring.
(A)
6 - 8 N·m
Snap ring
53
Page 54
INSTALLATION
Installation of brake calipers
When using a brake caliper mounting bolt C
(140 mm disc brake rotor (BR-U5000)/160 mm disc brake rotor (BR-UR300))
Attach the brake caliper to the frame.
Install the bolt fixing pin.
(A)
(B)
When using a brake caliper mounting bolt C
(160 mm disc brake rotor (BR-UR5000))
(A)
Attach the mount bracket to the brake
caliper.
Install the bolt fixing pin.
(A)
Bolt fixing pin
(B)
Brake caliper mounting bolt C
Tightening torque
6 - 8 N·m
(A)
Bolt fixing pin
(B)
Mount bracket
(C)
Brake caliper mounting bolt B
1
Tightening torque
6 - 8 N·m
NOTICE
(B)
Pay attention to the marking on the mount
bracket when attaching it.
(C)
To be continued on next page
54
Page 55
INSTALLATION
Installation of brake calipers
2
3
(B)
(C)
(B)
(A)
Use brake caliper fixing bolt C and a
washer to secure the mount bracket to
the frame.
Install the snap retainer.
(A)
Mount bracket
(B)
Washers
(C)
Brake caliper mounting bolt C
Tightening torque
6 - 8 N·m
(A)
Snap Retainer
(A)
55
Page 56
INSTALLATION
Installation of brake calipers
Installation to the frame (BR-RS785)
Front/Rear
(C)
(A)
(D)
(B)
(C)
Temporarily install the brake caliper to
the frame.
Depress the brake lever, and tighten the
brake caliper fixing bolts while pressing
the brake pads against the disc brake
rotor.
(A)
Disc brake rotor
(B)
Brake caliper
(C)
Brake caliper fixing bolts
(D)
Mount bracket
Tightening torque
6 - 8 N·m
TECH TIPS
Make sure that the brake caliper can move
sideways before installing it.
NOTICE
Be sure to attach snap rings when attaching
the brake caliper fixing bolts.
(C)
56
Page 57
INSTALLATION
Preventing loosening of frame fixing bolts
Preventing loosening of frame fixing bolts
The snap ring method, the fixing pin insertion method, or the wiring method can be used to prevent loosening of the bolts.
Choose whichever method is suitable for the model, front fork and frame.
Fixing pin insertion method
Front Rear
Snap ring method
Front Rear
(A)
(A)
(A)
(A)
Bolt fixing pin
(A)
Snap ring
(z)
Post type
(z)
Wiring method
(A)
(A)
Front Rear
(A)
(A)
(A)
Wire
57
Page 58
INSTALLATION
Installing the shifting cable
Installing the shifting cable
Cable used
Designated inner cable
Ø1.2 mm
Opposite side
Normal outer cap installation position
(A)
Normal outer cap/
SP41 outer casing
Ø4 mm
(A)
SP41
NOTICE
Do not let dust adhere on the inner cable.
(A)
Normal outer cap
(B)
Sealed outer cap (resin type)
(B)(B)
58
Page 59
INSTALLATION
Installing the shifting cable
Cutting the outer casing
1
2
(B)
SP41
SP41
(z)
(B)
(A)
(A)
(y)
Use the cable cutter (TL-CT12) or an
equivalent tool to cut the side opposite
of the inscription.
After cutting, expand the tip of the liner
(Ø2.2 mm or more) with TL-CT12 or
another narrow tool.
(y)
Remove normal outer cap
(z)
Arrange the cut end into a perfect
circle
(A)
Normal outer cap
(B)
TL-CT12
NOTICE
•
Use a cable which still has some length to
spare even when the handlebars are turned
all the way to both sides.
•
Be careful not to injure your hand with the
TL-CT12 needle section.
(A)
TL-CT12
(B)
TL-CT12 needle
3
SP41
(A)
(B)
Insert the outer casing until it is in close
contact with the seating surface of the
normal outer cap.
(A)
Normal outer cap
(B)
Outer casing
59
Page 60
INSTALLATION
(B)
Installing the shifting cable
Passing through the shifting inner cable
The illustration is of the rear lever.
1
2
(A)
(A)
(B)
Operate the release lever 10 or more
times and set the lever to the top
position.
Remove the 2 mounting bolts and then
remove the upper cover.
(A)
Release lever
(A)
Cover
(B)
Mounting bolt
3
(A)
Remove the mounting bolt on the
underside and then remove the band
cover.
(A)
Band cover
(B)
Mounting bolt
To be continued on next page
60
Page 61
INSTALLATION
Installing the shifting cable
4
5
Insert the inner cable vertically from
above.
Insert the cable in such a manner that
the inner end is attached to the unit.
NOTICE
Insert the cable while being careful not to
damage the coating.
6
Attach the upper cover.
7
(B)
(A)
Put the inner cable through as shown in
illustration.
Temporarily secure the outer casing to
the handlebar (by using tape or a similar
material).
(A)
Normal outer cap
Tightening torque
(A)
Tape
(B)
Outer casing
0.15 - 0.25 N·m
8
(A)
To be continued on next page
61
Page 62
INSTALLATION
Installing the shifting cable
9
(y)
(z)
Engage the catch on the band cover and
secure in place with the mounting bolt.
(y)
Catch (main body side)
(z)
Catch (band cover side)
Tightening torque
0.15 - 0.25 N·m
62
Page 63
ADJUSTMENT
Page 64
ADJUSTMENT
Reach adjustment
ADJUSTMENT
Reach adjustment
ST-U5060/BL-U5010
(A)
(B)
BL-U5000/MT200/MT201
Turn the reach adjustment screw to
position the lever unit.
Insert a 1.5 mm hexagon wrench into the
end of the ST and turn it.
(A)
1.5 mm hexagon wrench
(B)
Reach adjustment screw
NOTICE
Make sure that braking operates properly
after the adjustment.
TECH TIPS
Clockwise: Decreases the lever stroke
Counterclockwise: Increases the lever stroke
(A)
Turn the reach adjustment screw to
position the lever unit.
(A)
Reach adjustment screw
TECH TIPS
Clockwise: Increases the lever stroke
Counterclockwise: Decreases the lever stroke
64
Page 65
MAINTENANCE
Page 66
MAINTENANCE
Replacing Shimano genuine mineral oil
MAINTENANCE
Replacing Shimano genuine mineral oil
It is recommended that you 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 dual control lever/brake lever can be operated
at this time to help the oil drain out. After draining the oil, pour in fresh brake oil in accordance with the "Adding Shimano genuine mineral oil and
bleeding air" section. Use only Shimano genuine mineral oil.
Dispose of the waste oil according to proper country and/or state disposal regulations.
66
Page 67
MAINTENANCE
Replacement of brake pads
Replacement of brake pads
BR-U5000
BR-RS785
(A)
(A)
(B)
(B)
Remove the wheel from the frame, and
remove the brake pads as shown in the
illustration.
(A)
Brake pads
(B)
Snap retainer
NOTICE
•
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 0.5 mm, or if the brake pad presser
springs are interfering with the disc brake
rotor, replace the brake pads.
•
BR-U5000/BR-RS785/BR-UR300 brake pads
are not compatible.
Use a compatible brake pad when
replacing.
•
When using a pad with fins, take note of
the left (L) and right (R) markings to set it.
1
BR-UR300
(A)
To be continued on next page
67
Page 68
MAINTENANCE
Replacement of brake pads
Clean the pistons and surrounding area.
2
3
4
(A)
(A)
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.
Do not push the pistons with a sharp
tool.
The pistons may be damaged.
Set the pad fixing spring as shown in the
illustration. (The spring for BR-RS785 has
markings on the left side (L) and the
right side (R).)
(A)
Piston
(A)
Pad fixing spring
To be continued on next page
68
Page 69
MAINTENANCE
(E)
Replacement of brake pads
Install the new brake pads, the bolt, and the pad spacer (red).
Make sure to use a snap retainer at this time.
BR-U5000
(C)
(D)
BR-UR300
BR-RS785
(A)
(B)
(C)
(A)
(B)
(D)
(A)
Brake pads
(B)
Snap retainer
(C)
Pad axle
(D)
Pad spacer (red)
(E)
Split pin
Tightening torque
0.1 - 0.3 N·m
5
(E)
(A)
(D)
To be continued on next page
69
Page 70
MAINTENANCE
Replacement of brake pads
Depress the brake lever several times to check that the operation becomes stiff.
6
Remove the pad spacer, install the wheel, and then check that there is no interference
between the disc brake rotor and caliper.
7
If they are touching, adjust in accordance with the section "Installation of brake calipers".
70
Page 71
MAINTENANCE
(B)
(A)
Replacing the cover
Replacing the cover
Replacing the band cover
1
Remove the main body from the
handlebar.
2
Remove the mounting bolt and then
remove the band cover.
(A)
Band cover
(B)
Mounting bolt
NOTICE
Note the
markings
R: for right
L: for left
•
The markings are engraved inside the band
cover.
•
Replace the band cover with the dual
control lever/brake lever and brake hose
removed from the bicycle, as shown in the
illustration, or, alternatively, perform the
replacement by removing the brake caliper
from the frame and passing the band cover
from the caliper side.
•
Perform bleeding after removing the brake
hose.
TECH TIPS
The tabs on the band cover each fit a slot in
the bracket body.
71
Page 72
MAINTENANCE
Pulling out a disconnected inner end (shifting cable)
Pulling out a disconnected inner end (shifting cable)
If it is hard to pull out the inner end, follow the procedure below.
1
2
(A) (B)
Remove the 2 mounting bolts and then
remove the upper cover.
Pull out the inner end on the cable hook
of the winding body.
(A)
Cover
(B)
Mounting bolt
TECH TIPS
Should the inner cable break, it is
recommended that you also replace the cable
guide together with the inner cable in order
to maintain smooth shifting.
Re-attach the cover and then tighten the screws.
3
Tightening torque
0.15 - 0.25 N·m
72
Page 73
MAINTENANCE
Replacement of the SL cable guide
Replacement of the SL cable guide
Remove the lever from the handle.
1
Use a pointed tool to pry out the SL
cable guide.
2
3
Push in the new cable guide with hands.
73
Page 74
Please note: specifications are subject to change for improvement without notice. (English)
© Feb. 2022 by SHIMANO INC. ITP
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