Shimano BR-M545 Service Instructions

Browse online or download pdf Service Instructions for Bicycle Accessories Shimano BR-M545. Shimano BR-M545 1 pages. Disc brake system (for cross-country)

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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.

• 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.

• Check that the quick release lever is on the right side (the opposite side to the rotor). 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 M545 disc brakes are designed for optimum performance when used in combination

with the BR-M545 (calipers), ST-M410 (brake lever), SM-RT61, SM-RT62 (rotor) and

Shimano pad unit (M06). The brake lever used should be a two-finger lever for V-brakes,

such as the ST-M410.

If using in combination with 4-finger levers such as the BL-T400/ST-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 injury to the rider.

We strongly recommend only using genuine Shimano replacement parts.

We strongly recommend that only genuine Shimano replacement parts be used.

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

later reference.

CAUTION

• 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

• 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.

Technical Service Instructions

Disc Brake System

(For Cross-Country)

In order to realize the best performance, we recommend that the following

combination be used.

Caliper

BR-M545

Brake Lever

ST-M410

Rotor

SM-RT61, SM-RT62

Brake pad unit (Metal Pads)

Brake cable

Installation

I 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.

Rotating

Front left

direction of

wheel

Less than

20mm

I Installation of the rotor

<SM-RT61>

Install the rotor and the rotor tightening plate to the hub, and then install and

tighten the bolts as shown in Fig. 1.

Fig. 1

Hub

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.

Fig. 2

<SM-RT62>

SI-8EB0A

I Installation of the brake lever

Use a 5 mm Allen key to install.

Use a handlebar grip with a maximum

outer diameter of 32 mm.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

M06

I Installing the calipers

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.

Rear left Rear right

Front right

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

counterclockwise direction while tightening the caliper clamp bolt.

Fig. 1

Fig. 2

Tightening plate

Rotor

3. Securing the cable

Place the inner cable as shown in

Rotor fixing bolts (#T25 torx)

the illustration, and then tighten

the cable fixing bolt.

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

2 - 4 N·m {18 - 35 in. lbs.}

Fig. 3

Tightening plate

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.}

Loosen the pad adjustment screw by

two clicks.

Rotor

installation ring

TL-LR15

Tightening torque:

40 N·m {350 in. lbs.}

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.

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

Secure the three bolts with a cap as shown in the illustration in order to

Caliper clamp bolt

prevent the bolts from coming loose.

Caliper fixing bolts

I Adjusting when the pads are worn

Use a 3 mm Allen key to tighten the pad adjustment screw on the calipers so that

clearances (A) and (B) are both 0.2 – 0.4 mm.

Caliper clamp bolt

Tightening torque:

6 - 8 N·m {53 - 69 in. lbs.}

Adapter

Replacing the brake pads

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

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

shown in the illustration.

Inner cable

Cable fixing bolt

3 mm Allen key

Loosen the pad adjusting screw

and turn the cable adjusting bolts at

the brake lever clockwise to loosen

them.

Pads

Install the new brake pads. Be careful

not to forget to install the snap ring at

this time.

2 - 4 N·m {18 - 35 in. lbs.}

Tighten the pad adjusting screw so that

Pad adjusting screw

the clearance between the brake pad

and the rotor is 0.2 – 0.4 mm.

After checking that the brake pad and

Rotor

the rotor are not touching each other,

check that there are no problems when

the brake lever is depressed.

Depress

about

10 times

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.

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222

Please note: specifications are subject to change for improvement without notice. (English)

Cable adjusting bolt

I For post type

< Front >

< Rear >

Caps

Pad adjusting screw

(0.2 – 0.4 mm)

Snap ring

Brake pad

Pad adjusting screw

Tightening torque:

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