Shimano BR-M416, BR-M416-A Service Instructions

Installation

■ Wheel spoke lacing

Check that the spokes have been laced as shown in the illustration.
A radial assembly cannot be used.

Lace the spokes as shown in Figure 1 below for the left side of the front wheel
(the side where the rotor is installed), and the left and right sides of the rear
wheel, and as shown in Figure 2 below for the right side of the front wheel.

■ Installation of the rotor
<SM-RT51>

Install the rotor and the rotor tightening
plate to the hub, and then install and
tighten the bolts as shown in Fig. 1.

■ Installation of the brake lever

Use a 5 mm Allen key to install.

■ Installing the calipers

While wearing gloves, apply a force to the
rotor to turn it in a clockwise direction as
shown in Fig. 2. While doing this, tighten
the rotor fixing bolts in the order shown in
the illustration.

Use a flat-tipped screwdriver or similar tool to bend the edges of the tightening
plate over the heads of the bolts as shown in Fig. 3.

Rotating
direction of
wheel

Front left Rear left Rear right Front right

Fig. 1 Fig. 2

Fig. 1

Tightening plate

Rotor

Hub

Rotor fixing bolts
(#T25 torx)

* TORX is a registered
trademark of Camcar LLC.

Tightening torque:

2 - 4 N·m {18 - 35 in. lbs.}

Fig. 2 Fig. 3

Tightening plate

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

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

1. Install the bicycle wheel. Loosen the

caliper fixing bolts, and then install
the calipers to the frame so that the
calipers work at the left and right.

Caliper clamp bolt

Caliper fixing bolts

2. While wearing protective gloves, apply pressure to the adapter in the

counterclockwise direction while tightening the caliper clamp bolt.

1. Pass the inner cable through the

cable adjusting bolt, and then
tighten the cable fixing bolt.

4. Depress the brake lever about

10 times until it touches the grip,
and check that there are no
problems with any components,
and also that the rotors and the
pads do not interfere with each
other when the wheel is rotated.

5. Turn the cable adjusting bolt to take up any slack in the cable.

Caliper clamp bolt

Adapter

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Cable adjusting
bolt

Cable fixing bolt

Inner cable

Depress
about
10 times

Secure the three bolts with a cap as shown in the illustration in order to
prevent the bolts from coming loose.

Caps

< Front > < Rear >

■ For post type

Caps

■ Adjusting when the pads are worn

Use the cable adjusting bolts at the brake lever and the caliper body and also the
pad adjusting screws to adjust the clearance for pads which are worn. The pads
can still be used as long as the thickness of the pad lining is 0.5 mm or more.

• When making the adjustment when the pad is worn, use both the cable adjusting
bolt and the pad adjusting screw. If only the cable adjusting bolt is used, it will not
be possible to use the pad down to the standard replacement thickness of 0.5
mm. Moreover, the pad and rotor may interfere with each other even when the
brakes are not being operated.

If the brake pads are worn down to a thickness of 0.5 mm, replace the brake pads.

Adjust so that clearances A and B are both 0.2 -- 0.4 mm.

Pad adjusting screw Cable adjusting bolt

Pad adjusting screw

< B side >

Tighten the pad adjusting screw
to adjust.

< A side >

Turn the cable adjusting bolt at
the brake lever or the caliper
body to adjust.

Replacing the brake pads

1. Remove the bicycle wheel from the frame, and then remove the brake pads as

shown in the illustration.

2. Loosen the pad adjusting screw

and turn the cable adjusting bolts at
the brake lever and caliper body
clockwise to loosen them.

3. Install the new brake pads. After this,

bend open the split pin. Tighten the
pad adjusting screw so that the
clearance between the brake pad and
the rotor is 0.2--0.4 mm.

Brake pad

Cable adjusting bolt

Pad adjusting screw

Split pin

Split pin

Caliper

Brake Lever

Rotor

Brake cable

BR-M416 / BR-M416-A

ST-M410 / ST-M405 / ST-M360 / BL-M421

SM-RT53 / SM-RT51

Brake pad unit (Resin pads)

B01S

Technical Service Instructions SI-8EA0D-003

Disc Brake System

(For Cross-Country)

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

4. After checking that the brake pad and

the rotor are not touching each other,
check that there are no problems when
the brake lever is depressed.

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 further languages are available at :

http://techdocs.shimano.com

Please note: specifications are subject to change for improvement without notice.(English)
© Nov.2009 by Shimano Inc. XBC IZM Printed in Malaysia.

This service instruction explains how to use and maintain the Shimano bicycle parts
which have been used on your new bicycle.
For any questions regarding your bicycle or other matters which are not related to
Shimano parts, please contact the place of purchase or the bicycle manufacturer.

General Safety Information

WARNING

• Please use extra caution to keep your fingers away from the rotating
disc brake rotor during installing or servicing the wheel. The rotor is
sharp enough to inflict severe injury to your fingers if caught within the
openings of moving rotor.

• Adjust the inner cable so that the protruding length is less than 20 mm
(3/4 inch). If the protruding length is any longer, the end of the inner
cable may become stuck in the rotor, which could cause the wheel to
lock and the bicycle could fall forward causing serious injuries.

• The calipers and rotor will become hot when the brakes are operated,
so do not touch them while riding or immediately after dismounting
from the bicycle, otherwise you may get burned. Check that the brake
components have cooled down sufficiently before attempting to adjust
the brakes.

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

• Before riding the bicycle, check that the pad thicknesses are 0.5 mm or
more.

• If noise occurs when the brakes are operated, it may indicate that the
brake pads have worn down to their usage limit. After checking that the
brake system has cooled down sufficiently, check the brake pad
thicknesses.
Replace the brake pads if the pad wear indicators are visible.

• Be careful not to allow any oil or grease to get onto the rotor and brake
pads, otherwise the brakes may not work correctly.

• If any oil or grease do get on the pads, you should replace the pads. If
any oil or grease gets on the rotor, you should clean the rotor. If this is not
done, 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.

• 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. To avoid this, reduce your speed and apply the brakes early and gently.

• If the quick release lever is on the same side as the rotor, there is the danger that it may
interfere with the rotor, so check that it does not interfere.

• It is important to completely understand the operation of your bicycle's brake system.
Improper use of your bicycle's brake system may result in a loss of control or an
accident, which could lead to severe injury. Because each bicycle may handle differently,
be sure to learn the proper braking technique (including brake lever pressure and bicycle
control characteristics) and operation of your bicycle. This can be done by consulting
your professional bicycle dealer and the bicycle's owners manual, and by practicing your
riding and braking technique.

• The

M416

disc brakes are designed for optimum performance when used in combination

with the BR-

M416/M416-A

(calipers), ST-M410/M405/M360/BL-M421 (brake
lever), SM-RT53/51 (rotor) and Shimano pad unit (B01S).The brake lever
used should be a two-finger lever for V-brakes, such as the ST-M410/M405/
M360/BL-M421.
If using in combination with 4-finger levers such as the ST-T300/T400, the
braking force will be higher. Accordingly, under some conditions such as
certain riding positions or overall weight, the bicycle may fall over and injury may result if
proper care is not taken.

• 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.

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

• 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 rotor are replaced.

Note

• The SM-RT53 rotor should be used together with resin pads. If it is used with metal
pads, the pads will wear out very rapidly.

• If the brake caliper mounting boss and the dropout are not parallel, the rotor and caliper
may touch.

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

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

Pad wear
indicators

CAUTION

Less than
20mm

<SM-RT53>

Rotor installation ring

TL-LR15

Tightening torque:

40 N·m {350 in. lbs.}

Cable adjusting bolt

■ Securing the cable

Rotor

2. While depressing the brake lever, set the calipers to the required position and

then tighten the caliper fixing bolts.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

3. Loosen the pad adjustment screw by

two clicks.

Pads

Pad adjusting screw

SI-8EA0D-003-00