Shimano BL-MT200/BR-MT200 Hydraulic Disc Brake Set Instruction Manual

1. Introduction

This manual provides essential instructions for the proper installation, operation, and maintenance of your Shimano BL-MT200 Hydraulic Disc Brake Lever and BR-MT200 Disc Brake Caliper set. Please read this manual thoroughly before use to ensure safe and correct handling of the product. Keep this manual for future reference.

2. Safety Information

WARNING: Failure to follow these instructions could result in serious injury or death.

• Always wear appropriate safety gear, including gloves and eye protection, during installation and maintenance.
• Ensure all components are securely fastened according to torque specifications. Loose components can lead to loss of control.
• Brakes are pre-bled. Do not attempt to disassemble the hydraulic system unless you are a qualified bicycle mechanic. Improper handling of hydraulic fluid can cause system failure.
• Regularly inspect brake pads for wear and replace them when necessary. Worn pads reduce braking performance.
• Ensure brake levers operate smoothly and return to their original position. Any stiffness or unusual feel should be investigated.
• Do not use rotors that are not compatible with resin pads if your brake set includes resin pads.
• Consult a professional bicycle mechanic if you are unsure about any installation or maintenance procedures.

3. Package Contents

Your Shimano Hydraulic Disc Brake Set package includes the following components:

• BL-MT200 Hydraulic Disc Brake Lever (Left)
• BR-MT200 Disc Brake Caliper (Front)
• Hydraulic Hose (SM-BH59-SS, 1000 mm, Black) - Pre-bled and connected to lever and caliper.
• Resin Brake Pads (W/O FIN) - Pre-installed in caliper.
• Installation Hardware (Bolts, Olive, Insert Pin, Hose Guide)

Note: A brake rotor is not included with this set and must be purchased separately if needed.

Image 3.1: Shimano BL-MT200 Hydraulic Disc Brake Lever. This image shows the black brake lever with the hydraulic hose attached.

Image 3.2: Shimano BR-MT200 Disc Brake Caliper. This image displays the black disc brake caliper with the hydraulic hose connected.

Image 3.3: Alternative view of the Shimano BR-MT200 Disc Brake Caliper, showing different angles of the component.

Image 3.4: Installation hardware including an olive, insert pin, mounting bolts, and a hose guide. These small parts are crucial for securing the hydraulic line and mounting the caliper.

Image 3.5: Yellow brake pad spacers. These are typically used to prevent the brake pads from closing when the wheel or rotor is removed, protecting the hydraulic system.

4. Setup and Installation

This brake set comes pre-bled and assembled. Installation primarily involves mounting the lever to the handlebar and the caliper to the fork, then routing the hydraulic hose.

4.1 Mounting the Brake Lever

1. Position the BL-MT200 brake lever on the left side of your handlebar.
2. Adjust the lever angle for comfortable reach and operation.
3. Secure the lever clamp bolt. Refer to your bicycle's manufacturer specifications or a reliable torque guide for the correct torque value. Overtightening can damage the handlebar or lever.

4.2 Mounting the Brake Caliper

1. Attach the BR-MT200 caliper to the front fork's post mount using the provided mounting bolts.
2. Ensure the caliper is correctly aligned over your disc rotor. The rotor should pass freely through the center of the brake pads without rubbing.
3. Tighten the caliper mounting bolts. Consult torque specifications for your fork and caliper.
4. After initial tightening, squeeze the brake lever several times to center the caliper. Then, while holding the lever, fully tighten the mounting bolts.

4.3 Routing the Hydraulic Hose

1. Route the hydraulic hose along your bicycle frame, securing it with appropriate clips or zip ties. Ensure the hose does not interfere with steering, suspension, or other moving parts.
2. Avoid sharp bends or kinks in the hose, as this can impede fluid flow and reduce braking performance.
3. The hose length is 1000 mm. If shortening is required, this procedure involves cutting the hose, installing a new olive and insert pin, and potentially re-bleeding the system. This should only be performed by an experienced mechanic.

5. Operating Instructions

5.1 Initial Brake Check

Before your first ride, perform the following checks:

• Squeeze the brake lever firmly. It should feel solid and not spongy. If it feels spongy, the system may require bleeding (see Troubleshooting).
• Spin the wheel to ensure the rotor does not rub against the brake pads. Adjust caliper alignment if rubbing occurs.
• Test the brakes at a low speed in a safe, open area before riding at higher speeds or on challenging terrain.

5.2 Brake Lever Adjustment

The BL-MT200 lever typically features a reach adjustment screw to customize the distance from the handlebar to the lever blade. Adjust this screw to achieve a comfortable and effective lever position for your hand size and riding style.

5.3 Bedding-in New Brake Pads

New brake pads and rotors require a "bedding-in" process to achieve optimal braking performance. This involves gradually heating the pads and rotor to transfer pad material onto the rotor surface.

1. Find a safe, flat area with no traffic.
2. Accelerate to a moderate speed (e.g., 15-20 mph).
3. Apply the brakes firmly but gradually, slowing down to walking speed. Do not come to a complete stop.
4. Repeat this process approximately 20-30 times.
5. Allow the brakes to cool down completely.

After bedding-in, your brakes will offer improved power and modulation.

6. Maintenance

Regular maintenance ensures the longevity and performance of your Shimano disc brake set.

6.1 Cleaning

• Clean the brake calipers and rotors regularly with a clean cloth and isopropyl alcohol or a dedicated disc brake cleaner.
• Avoid using lubricants or oil-based cleaners near brake components, as this can contaminate pads and rotors, leading to reduced braking power.

6.2 Brake Pad Inspection and Replacement

• Inspect brake pads for wear regularly. Replace pads when the pad material is less than 0.5 mm thick or if they show signs of uneven wear or contamination.
• To replace pads, remove the wheel, then remove the pad retaining pin or clip from the caliper. The old pads can then be pulled out. Install new pads, ensuring they are correctly seated, and re-insert the retaining pin.
• Always use genuine Shimano replacement pads for optimal performance and safety.

6.3 Hydraulic Fluid Check and Bleeding

• Shimano hydraulic brakes use mineral oil. Do not use DOT fluid.
• If the brake lever feels spongy or braking power decreases significantly, the hydraulic system may need to be bled to remove air bubbles. This is a technical procedure that requires specific tools and knowledge. It is recommended to have this performed by a qualified bicycle mechanic.

7. Troubleshooting

8. Specifications

• Model Numbers: BL-MT200 (Lever), BR-MT200 (Caliper)
• Shimano Model Number: EMT200KLFPRA100
• Brake Type: Hydraulic Disc Brake
• Brake Lever Use: Left
• Brake Caliper Type: Post Mount
• Hydraulic Fluid Type: Mineral Oil
• Pad Compound: Resin (W/O FIN)
• Hydraulic Hose Length: 1000 mm (SM-BH59-SS)
• Color: Black
• Material (Lever Handle): Aluminum
• Material (Caliper Pads): Resin
• Weight: Approximately 0.28 Kilograms (for the set, as per product data)
• UPC: 689228881488

9. Warranty and Support

For warranty information, please refer to the official SHIMANO website or contact your authorized SHIMANO dealer. SHIMANO products are designed for durability and performance, and proper installation and maintenance are key to their longevity.

For technical support or service, please contact your local SHIMANO service center or visit the official SHIMANO website for a list of authorized dealers and service providers. Visit the SHIMANO Store on Amazon for more products and information.