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(English)
Dealer's Manual
ROAD GRAVEL MTB
E-BIKE LIFESTYLE GENERAL
DM-7JL0A-02
Non Series
BS-AU301
BS-AS300
BS-SS300
BS-AP301
BS-EW302
BS-EW305
Anti-lock Braking
System (ABS)
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Contents
IMPORTANT NOTICE........................................................................................ 3
TO ENSURE SAFETY......................................................................................... 4
List of tools to be used................................................................................... 9
Installation/removal ..................................................................................... 10
SHIMANO STEPS battery management systems and compatibility ................10
Overall wiring diagram......................................................................................10
Installing the brake lever...................................................................................11
Installing the brake caliper and wheel speed sensor.......................................11
Connecting the brake hose ...............................................................................15
Wiring .................................................................................................................23
Installing the ABS main unit..............................................................................30
Maintenance.................................................................................................. 37
Replacing the brake hose ..................................................................................37
Bleeding air from the ABS main unit................................................................38
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IMPORTANT NOTICE
IMPORTANT NOTICE
ABS maintenance requires certification by SHIMANO.
For details on how to obtain certification, contact SHIMANO.
Components and tools for repair (SM-PCEBS and ABS service software) are only sold to certified dealers.
Configuration via the ABS service software is required to operate the ABS normally. When the installation
procedure is complete according to the instructions in this manual, refer to “ ABS Service Software Dealer's
Manual ” to perform configuration.
This manual is for the following target readers:
Dealers certified by SHIMANO
In addition to the ABS user's manual, please read the user's manual and dealer's manual for the connected
brake lever and brake caliper.
Do not disassemble or modify the product other than as stated in the information contained in this manual
and the dealer's manual for each component.
Related manuals and technical documents are accessible online at 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.
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
CAUTION
Failure to follow the instructions could result in death or serious injury.
Failure to follow the instructions could cause personal injury or physical damage to equipment and
surroundings.
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TO ENSURE SAFETY
TO ENSURE SAFETY
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TO ENSURE SAFETY
Be sure to follow the instructions provided in the manuals when installing the product.
Only use SHIMANO genuine parts. If a component or replacement part is incorrectly assembled or adjusted, it
can lead to component failure and cause the rider to lose control and crash.
Wear approved eye protection while performing maintenance tasks such as replacing components.
Be sure to also inform users of the following:
Do not disassemble or modify the product. This may cause the product to not operate correctly, and you may
suddenly fall and be seriously injured.
Operate the brake carefully, without overestimating the operation of this product. This product does not
guarantee that the bicycle will be protected from an accidental fall. Improper brake control may result in a
loss of control even if this product is installed in the brake system, which could lead to serious injury due to a
fall or collision.
When replacing parts such as the ABS, front brake, and front wheel, make sure to use the same products that
came with the bicycle at the time of purchase. The ABS is configured to operate correctly with the parts that
come with the bicycle at the time of purchase. Operation is not guaranteed if parts with different
specifications are used.
Do not perform repair or maintenance work yourself. The repair or maintenance work of this product must be
performed by an authorized ABS maintenance dealer.
For installation to the bicycle and maintenance
Do not use oil other than SHIMANO genuine mineral oil. Doing so may prevent the brakes from operating and
result in serious injury due to a fall or collision.
Use only mineral oil from a container that has been stored in a clean and sealed state. Doing otherwise may
prevent the brakes from operating and result in serious injury due to a fall or collision.
Do not let water or air bubbles get into the brake system. Doing so may prevent the brakes from operating
and result in serious injury due to a fall or collision.
Be sure to remove the battery and charging cable before wiring or attaching parts to the bicycle. Failure to do
so may cause an electric shock.
Do not allow the connectors to get wet. Do not high-pressure wash. If these are not observed, problems with
operation may occur. When IP67 or higher waterproof performance is required, treat the connectors as
follows:
Cover the connector with a cover
Install a heat-shrinkable tube
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TO ENSURE SAFETY
Be sure to also inform users of the following:
Receive maintenance at an authorized ABS maintenance dealer once a year to maintain the proper operation
of this product.
When an error occurs in the bicycle, make sure to check the situation. Stop using the bicycle until the error has
been resolved. This product shares the power of the bicycle with SHIMANO STEPS components. If the system
stops because an error occurs in SHIMANO STEPS components, the operation of this product also stops. The
general method for responding to an error/warning is to turn the power OFF then ON again, or to turn the
power OFF, remove the battery, reinstall the battery, then turn the power ON again. If the situation does not
improve after doing so, stop using the bicycle and swiftly contact your place of purchase or a distributor for
assistance.
For installation to the bicycle and maintenance
Install the ABS compatible cycle computer in a position where it can always be seen while riding. The ABS does
not operate while a warning is indicated. The brake still functions when the ABS does not operate.
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TO ENSURE SAFETY
For installation to the bicycle and maintenance
Observe the following instructions to ensure that the ABS operates normally:
Install the ABS main unit to the specified position on the frame. Operation is not guaranteed if the ABS
main unit is installed in another position or installed with a method other than that specified in this
manual.
The ABS main unit must be completely secured to the bicycle to maintain a stable installation position
throughout the life of the bicycle. After installation, confirm there are no gaps or looseness.
Insert the connectors used for wiring the ABS in firmly until the green and red colored parts cannot be
seen.
The connector used for the ABS wiring must be connected with a certain orientation according to the pins
and protrusion on the inner side. Connect the connector with the orientation of the pins and protrusion
aligned as indicated in the schematic diagram below. Forcibly connecting the connector without aligning
the orientation of the pins and protrusion may damage the pins and protrusion on the inner side of the
connector.
Be sure to also inform users of the following:
Do not clean the bicycle with a high-pressure wash. If water gets into any of the components, operating
problems or rusting may result.
Handle the components carefully, and avoid subjecting them to strong shock.
Do not use the thinners or harsh solvents to clean the products. Such solvents may damage the surface.
Contact an authorized dealer for updates of the component software.
Perform the following operations to enable ABS:
Turn the power of the bicycle ON.(1)
Confirm that the ABS icon is displayed on the cycle computer.(2)
Depress the brake lever for the front once before riding.(3)
Ride the bicycle at a speed of 6 km/h or higher and check whether the ABS icon has disappeared on the
(4)
cycle computer.
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TO ENSURE SAFETY
Bicycles with an ABS retain a certain level of battery power to operate the ABS even when the assist function
stops due to a low battery level, but you should charge the battery as soon as possible.
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.
The actual product may differ from the illustration because this manual is
intended mainly to explain the procedures for using the product.
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List of tools to be used
List of tools to be used
The following tools are needed for installation/removal, adjustment, and maintenance purposes.
Tool
2.5 mm hexagon wrench
4 mm hexagon wrench
8 mm spanner
10 mm spanner
Adjustable wrench
TL-BH62
TL-FC36
Hexalobular [#25]
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Location of terminals
Battery (terminal) Battery mount (terminal)
Installation/removal
SHIMANO STEPS battery management systems and compatibility
Installation/removal
SHIMANO STEPS battery management systems and
compatibility
There are two generations of the SHIMANO STEPS battery management system: first generation and second
generation (Gen.2).
This manual only describes products compatible with Gen.2.
With some exceptions, first-generation and Gen.2 components are not compatible with each other. For details,
refer to the compatibility information on the SHIMANO product website (
https://productinfo.shimano.com/#/com ).
The Gen.2 battery and compatible battery mount are marked “Gen.2” as indicated in the figure.
Example: BT-EN805 and compatible battery mount
Overall wiring diagram
Check the SHIMANO product website for details on the compatibility between ABS component and drive unit.
https://productinfo.shimano.com/#/com
The brake hose is connected as indicated below, which differs from a regular brake system:
Between brake lever and ABS main unit
Between ABS main unit and brake caliper
Select the ABS main unit mounting parts depending on the method for installing the ABS main unit to the
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Cable A BS-EW302
CAN conversion cable
Second-generation
(Gen.2) battery
BS-AU301
BS-SS300
Cable B
BS-AP301
Cable C
Installation/removal
Installing the brake lever
frame (internal/external).
The connection method for the ABS main unit differs according to the drive unit and battery to connect. Refer
to the dealer's manual of your drive unit when connecting the cables to the drive unit.
Installing the brake lever
For details on installing the brake lever, refer to the dealer's manual for the brake lever.
Temporarily install the brake lever to the handlebar.1.
Check the length of the brake hose.
2.
Refer to “ Checking the length of the hose ”.
Remove the brake lever from the handlebar and connect the brake hose.
3.
Refer to “ Connecting the brake hose ”.
Install the brake lever to the desired position on the handlebar.4.
Installing the brake caliper and wheel speed sensor
For models: BS-SS300-C (CENTER LOCK type), BS-SS300-S (6-bolt type)
Refer to the dealer's manual for the brake caliper and disc brake rotor.
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ABS-dedicated lock
ring
40 N·m
Rivets (six locations)
Installation/removal
Installing the brake caliper and wheel speed sensor
Install the phonic wheel to the front wheel.
1.
Tighten the phonic wheel together with the disc brake rotor when installing it.
CENTER LOCK type
Be sure to use the lock ring described as ABS-dedicated for installing the CENTER LOCK-type phonic
wheel. The thread of a regular lock ring is not long enough. Therefore, the lock ring cannot be
tightened sufficiently, which can cause it to fall off or damage the thread on the hub side.
The ABS-dedicated lock ring is included with the BS-SS300-C.
The dedicated ABS lock ring is installed so that the lock ring washer cannot be easily removed.
For some models of disc brake rotor, the rivets interfere with the phonic wheel. In this case, align
the six holes of the phonic wheel with the rivets.
6-bolt type
Wear gloves and turn the disc brake rotor clockwise with some force. While doing this, tighten the fixing
screws in the order shown in the figure.
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2 - 4 N·m
Fixing screw x 6
Marking
Installation/removal
Installing the brake caliper and wheel speed sensor
Install the phonic wheel so that the side with the model name marking is facing outward.
Install a phonic wheel that matches the types of the front fork disc brake mount. The types for
compatible disc brake mounts can be confirmed by the markings as shown below.
Marking Types for disc brake mounts Supported disc brake rotor
P160 MOUNT ONLY 160 mm direct mount Ø180 mm / Ø203 mm
P180 MOUNT ONLY 180 mm direct mount Ø203 mm
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Wheel speed sensor
Mark
Caliper mounting screw (long)
Mount adapter for wheel speed sensor
(Temporary)
Caliper mounting screw (short)
Installation/removal
Installing the brake caliper and wheel speed sensor
Temporarily install the brake caliper and mount adapter for wheel speed sensor to the front fork.
2.
Some models are secured with a total of four screws; two mount adapter mounting screws, and two
caliper mounting screws. Also refer to the mount adapter dealer's manual when installing the
mount adapter.
Adjust the installation position of and secure the brake caliper and wheel speed sensor after “ Connecting
3.
the brake hose ” is complete.
Refer to the manual for the brake caliper for details on the method for securing the brake caliper and the
tightening torque.
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Brake caliper
Brake lever
Lever stopper
Brake hose connection port
Brake hose connection
port
ABS main unit
Mark
Mark
Inner cover
Hose cover (for ABS main unit)
0.8 - 1.2 mm
1.5 N·m
Phonic wheel
Installation/removal
Connecting the brake hose
Adjust the gap between the wheel speed sensor and phonic wheel to be within 0.8 and 1.2 mm, then secure
4.
the wheel speed sensor.
Connecting the brake hose
Overview of the easy hose joint system
The configuration of the ABS easy hose joint system is shown in the figure.
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Brake hose of brake caliper
Brake hose of ABS main unit
Installation/removal
Connecting the brake hose
The inner cover is included with the ABS main unit. When connecting the brake hoses, make sure to
pass them through the holes of the inner cover.
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Installation/removal
Connecting the brake hose
Checking the length of the hose
Route the brake hose into the final installation position.
1.
Example of external ABS main unit installation
To temporarily install the ABS main unit to the frame to check the length of the brake hoses, refer to “
Installing the ABS main unit ”.
This figure is only for explanatory purposes. For details on how to route the brake hoses, consult
the manufacturer of the bicycle or refer to the frame's manual.
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Mark
Flare nut
Brake hose of ABS
main unit
Mark
Brake hose of brake caliper
Flare nut
Flare nut
Extender
Seal plug
Housing
Resin part
Installation/removal
Connecting the brake hose
Check the appropriate length of the brake hose.
2.
Secure the brake lever to the ride position and check the length of the brake hose. Use a brake hose which
still has some length to spare even when the handlebars are turned all the way to both sides. Check the mark
on the brake hose with the edge of the brake lever flare nut.
If the hose is at the appropriate length, connect the brake hose.
To shorten the hose, refer to the dealer's manual for the brake lever or brake caliper to cut the hose. Use
care when cutting the hose, as oil may leak when the hose is cut. If you cut the hose, make sure to insert a
connector insert into the tip of the hose.
If the hose length is insufficient, refer to “ Replacing the brake hose ”.
Connecting the brake hose
Secure the metal housing part of the ABS main unit with a vise or adjustable wrench when handling
the seal plug, extender, and flare nut. Excessive force on the resin part may damage the ABS main unit.
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Inner cover
Hose cover (for ABS main unit)
Inner cover
Hose cover (for ABS main unit)
Installation/removal
Connecting the brake hose
Route the brake hose of the brake caliper up to the ABS main unit.
1.
Refer to “ Checking the length of the hose ” as necessary to check the length of the brake hose.
Make sure to pass the brake hose through the inner cover and hose cover (for ABS main unit).
Example of internal ABS main unit installation
Example of external ABS main unit installation
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Seal plug
Extender
Flare nut
4 - 6 N·m
Housing
Installation/removal
Connecting the brake hose
Remove the extender from the ABS main unit.
2.
Face the hose connection port upward when working.
With the seal plug attached, remove the extender with the flare nut secured as shown in the figure so that it
will not turn.
* Use a clean rag to keep oil from dripping off the extender.
Connect the brake hose to the ABS main unit.
3.
Secure the metal housing part with a vise or adjustable wrench when working.
The ABS main unit comes with a pre-installed olive. When inserting the hose, ensure it does not snag on
the olive.
Insert hose up to the witness mark on the outer hose casing. If you cut the hose, insert it in firmly as far as
it will go, as the witness mark will no longer be there.
Cover with a clean rag while conducting this procedure as some of the internal oil may leak.
Wipe away any spilled oil with a clean rag.
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Hose cover
Connector insert
Installation/removal
Connecting the brake hose
Route the brake hose that was connected to the ABS main unit from the start up to the brake lever.
4.
Check the length of the brake hose as necessary.
Make sure to pass the brake hose through the inner cover and hose cover (for ABS main unit).
Example of internal ABS main unit brake hose routing
Example of external ABS main unit brake hose routing
Pass the hose cover over.
5.
If you cut the hose, make sure to install a connector insert into the tip of the hose.
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Seal plug
5 - 7 N·m
Flare nut
Installation/removal
Connecting the brake hose
Remove the seal plug from the brake lever.
6.
Set the hose connection port of the brake lever so that it is facing upward. Secure it by adjusting the angle of
the handlebar, or other means.
* Use a clean rag to keep oil from dripping off the seal plug.
Connect the brake hose to the brake lever.
7.
The brake lever comes with a pre-installed olive. When inserting the hose, ensure it does not snag on the
olive.
Insert hose up to the witness mark on the outer hose casing. If you cut the hose, insert it in firmly as far as
it will go.
Cover with a clean rag while conducting this procedure as some of the internal oil may leak.
Wipe off any residual oil and install the hose cover.8.
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Lever stopper
Installation/removal
Wiring
Remove the lever stopper from the brake lever.
9.
The shape, location, and method for removing the lever stopper differ according to the brake lever. Check
the dealer's manual for the brake lever.
Pull out the lever stopper by means of short back and forth movements while taking care not to depress
the brake lever.
Check that the brake pads are installed in the brake caliper, and that the wheel is properly installed with the
10.
disc brake rotor between the brake pads.
Operate the brake lever several times and check that the brake pads grip the disc brake rotor and that the
11.
lever becomes stiff.
If the brake lever does not become stiff, refer to “ Bleeding air from the ABS main unit ” and bleed the air
from the system. Also refer to the dealer's manual for the brake lever or brake caliper for instructions on
bleeding air.
Wiring
This section describes wiring using an example of internal ABS main unit installation. The connection method for
the cables is the same for both the internal type and external type. For details on routing the cables to the
frame, refer to the manual for the frame.
To secure the main unit to the frame first, refer to “ Installing the ABS main unit ”.
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Cable C
CAN conversion cable (included with
BS-AU301)
To CAN port of drive unit
Installation/removal
Wiring
Connect cable C to the drive unit.
1.
Refer to the dealer's manual of the drive unit when connecting the CAN conversion cable to the
drive unit.
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Cable A
BS-EW302
Installation/removal
Wiring
Connect cable A to the wheel speed sensor.
2.
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Power cord of battery mount
Power plug
Power port
Installation/removal
Wiring
Connect the power cord of the battery mount to the power split cable.
3.
Confirm that the power plug and power port are facing each other and insert straight into the
power port along the fitting axle. Inserting the power plug at an angle or while changing the
direction it is facing may cause the pin of the power port to become deformed or bent.
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Insulator
Installation/removal
Wiring
Insert the insulator from the drive unit side of the frame.
4.
This is an example of how to store the power split cable in the bottom of the seat tube. Ensure the insulator
is inserted against the inner wall of the seat tube.
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Power cord of battery mount
Power port of drive unit
Installation/removal
Wiring
Store the power split cable in the frame.
5.
To store the power split cable in the seat tube, a seat tube diameter of Ø26 mm or more is required.
Note the following when storing the power split cable in the seat tube:
When installing the bottle cage fixing screws, make sure that you do not damage the power
split cable with the fixing screws.
Set the length of the seat post so that it will not touch the power split cable even when
adjusted to its lowest position.
Retain the bottom of the insulator to fill the gap between the split cable and the drive unit. If the
weight of the power split cable is directly applied to itself, disconnection or damage may be caused.
Refer to the “SHIMANO STEPS Dealer's Manual” for information on connecting the power cord to
the drive unit.
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Cable B
Power split cable
Installation/removal
Wiring
Connect cable B to the power split cable.
6.
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Inner cover
Hose cover (for ABS main unit)
Installation/removal
Installing the ABS main unit
After connecting the brake hose and wiring the cables, install the inner cover and hose cover to the ABS
7.
main unit. Insert them in firmly as far as they will go.
When installing the inner cover, be careful not to interfere with or apply excessive force to the
brake hose or wiring.
Installing the ABS main unit
It is necessary to rotate or shake the ABS main unit when bleeding air from the system. Ensure that,
when bleeding air, the ABS main unit is not installed to the frame. Refer to the dealer's manual for the
brake lever and brake caliper you are using for details on the method for bleeding air. Also refer to “
Bleeding air from the ABS main unit ” in this manual.
Internal type
For models: BS-AS300-I, BS-AU301, BS-AP301
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Fixing screw x 2
Front
Bracket
3 - 4 N·m
Installation/removal
Installing the ABS main unit
Install the bracket to the specified position of the frame opening.
1.
Install it in the orientation shown in the figure. Refer to the manual for the frame for the specified
installation position.
If the above tightening torque (3 - 4 N·m) exceeds that specified in the manual for the frame, use
the tightening torque specified by the frame manufacturer.
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Protrusion
ABS main unit
Front
Bracket
Installation/removal
Installing the ABS main unit
Install the ABS main unit to the bracket.
2.
When the protrusion on the rear of the ABS main unit engages with the bracket, the protrusions on both
sides also engage with the bracket.
Do not forcibly push in the ABS main unit. Doing so may deform the bracket.
Confirm that the ABS main unit is securely inside the bracket and that there is no excess play. After
installation, be sure to check that the protrusion on the rear of the ABS main unit fits into the
bracket, as indicated in the figure.
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Front
Bracket
Cover stay
Fixing screw x 2
3 - 4 N·m
Installation/removal
Installing the ABS main unit
External type
For models: BS-AS300-O, BS-AU301, BS-AP301
Tighten the bracket and cover stay together at the specified position of the frame.
1.
If the above tightening torque (3 - 4 N·m) exceeds that specified in the manual for the frame, use
the tightening torque specified by the frame manufacturer.
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Snap ring
Installation/removal
Installing the ABS main unit
Install the snap ring to the fixing screw.
2.
Fit the snap ring into the spline around the screw head.
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Hose cover
Inner cover
Installation/removal
Installing the ABS main unit
Install the ABS main unit to the bracket.
3.
Refer to step 2 of “Internal type”.
Do not forcibly push in the ABS main unit. Doing so may deform the bracket.
Confirm that the ABS main unit is securely inside the bracket and that there is no excess play. After
installation, be sure to check that the protrusion on the rear of the ABS main unit fits into the
bracket, as indicated in the figure.
Pull the wires from the ABS main unit out from the base in the position indicated in the figure.
Confirm that the inner cover and hose cover are securely installed to the ABS main unit.
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Outer cover
Installation/removal
Installing the ABS main unit
Install the outer cover to the ABS main unit.
4.
Fit the outer cover onto the cover stay from the brake hose side, while taking care not to pinch the brake
hose or wires. Check that the outer cover is securely engaged with the cover stay.
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Flare nut
Brake hose
Olive
Hose cover
Hose cover (for ABS main
unit)
Connector insert
Maintenance
Replacing the brake hose
Maintenance
Replacing the brake hose
With the ABS, a connector insert, olive, and flare nut are required on the ABS main unit side in addition to the
brake lever side, as indicated in the figure.
To replace the brake hose, refer to the dealer's manual for the brake lever or brake caliper.
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90° or less
90° or less90° or less
Maintenance
Bleeding air from the ABS main unit
Once the brake hose has been replaced, it is required to inject mineral oil and bleed the air from the
system. Temporarily remove the ABS main unit from the frame when bleeding air. Refer to the dealer's
manual for the brake lever and brake caliper you are using for details on the method for bleeding air.
Also refer to “ Bleeding air from the ABS main unit ” in this manual.
Bleeding air from the ABS main unit
Bleeding air can be performed with the same method as for a regular hydraulic brake system. Shake or tilt the
ABS main unit as indicated in the figure when bleeding air.
After bleeding air, check that the ABS operates normally with the [ ABS Check-up ] in the ABS service
software. Refer to the “ ABS Service Software Dealer's Manual ” for details.
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One Holl and, Irvine, California 92 618, U.S.A. Ph one: +1-949-9 51-5003
High Tec h Campus 92, 5656 AG Eindho ven, The Neth erlands Phone : +31-402-6122 22
3-77 Oim atsu-cho, Sak ai-ku, Sakai City, Osaka 59 0-8577, Japan
Please note: specifications are subject to change for improvement without notice. (English)
© Jul. 2023 by SHIMANO INC. ITP
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