TO ENSURE SAFETY
For Installation to the Bicycle, and Maintenance:
11
NOTE
Be sure to attach dummy plugs to any unused terminals.
e, check that the 
shi
Electric wires / Electric wire covers
f at the same time when removing the electric wire 
f, replace it with a new one. When removing the electric wire 
cover, do not peel it off too.
-SD50-I). 
Disc brake
he piston from 
coming out if the brake lever is depressed while the wheel is removed.
tipped screwdriver or 
are not installed, use a 
If it is difthe 
reservoir tank at this time.)
mmercially-available 
Do not remove the pistons when disassembling the calipers.
Dual control lever
The actual product may dif
the product.
Notes when reinstalling and replacing components
ettings.
eck the operation.
If the component configuration changes or mal
ficiently 
available.
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INSTALLATION
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13
INSTALLATION
INSTALLATION
This dealer’s manual describes how to install road disc brakes.
List of tools to be used
The following tools are needed to assemble this product.
Component
Usage location
Tool
Disc brake rotor
Disc brake rotor mounting bolt
#T15
#T15 torx
Disc brake rotor fixing lock ring
TL-LR15
TL-LR15
Dual control lever
Clamp nut
5 mm Allen key
Connecting bolt
8mm
8 mm spanner
Name plate
#2 Screw driver
Switch unit
#T5
#T5 torx
Nameplate fixing screw
Slotted screwdriver (nominal dia. 0.5 x 3)
Free stroke adjustment screw
#1 Phillips screwdriver
Reach adjustment screw
Slotted screwdriver (nominal dia. 0.7 x 3)
Lever fixing bolt
1
.
5
1.5 mm Allen key
Bleed screw
2.5 mm Allen key
Brake caliper
Brake hose
Utility knife
Connector insert
TL-BH61
TL-BH61
Banjo
4
4 mm Allen key
Bleed nipple tube
7mm
7 mm socket wrench
Pad axle
Slotted screwdriver (nominal dia. 0.7 x 3)
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INSTALLATION
Wheel spoke assembly
To be continued on next page
14
„
Wheel spoke assembly
Direction of wheel rotation
Front right
Fig.2
Front left t Rear left t Rear right
Fig.1
CAUTION
Check that the spokes have been laced as 
shown in the illustration.
A radial assembly cannot be used.
Refer to Fig. 1 for the spoke patterns of the 
left side of the front wheel (disc brake rotor 
mounted side) and both sides of the rear 
wheel. Refer to Fig. 2 for the spoke pattern of 
the right side of the front wheel.
„
Installation of the disc brake rotor
Center lock type
(A)
(B)
TL-LR15
(A) 
Disc brake rotor fixing lock ring
(B) 
TL-LR15
TL-LR15
Tightening torque:
40.0 - 50.0 N·m  
{350 - 437 in. lbs.}
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INSTALLATION
Installation of the disc brake rotor
15
6-bolt mounting type (with lock washers)
1
Install the disc brake rotor and rotor lock 
washers to the hub and tighten the 
bolts.
(A)
(B)
#T15
(A) 
Lock washer
(B) 
Disc brake rotor mounting bolt
CAUTION
Install the lock washers so that the side 
labeled "TOP" faces toward you.
Do not reuse old lock washers.  
Use new lock washers when installing a disc 
brake rotor.
Use the dedicated disc brake rotor 
mounting bolts for installation.
#T15
Tightening torque:
2.0 - 4.0 N·m  
{17 - 35 in. lbs.}
2
Wear gloves and turn the disc brake 
rotor clockwise with some force. Then, 
tighten the disc brake rotor mounting 
bolts in the order shown in the 
illustration.
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INSTALLATION
Installation of the dual control lever
16
„
Installation of the dual control lever
1
Unhook both the right and left tabs of 
the bracket cover and open up the 
bracket cover as shown in the 
illustration.
2
Install the dual control lever to the 
handlebar and tighten the clamp nut 
with an Allen key.
(A)
(A) 
Clamp nut
CAUTION
With a carbon handle, even the 
recommended tightening torque may 
cause damage to the handle or insufficient 
fixation of the handle. For the appropriate 
torque value, consult with the 
manufacturer of the completed bicycle or 
the manufacturer of the handle.
The clamp band, clamp nut, and clamp bolt 
of ST-R785 have no compatibility with 
other products. Do not use components 
that are used in other products together.
Tightening torque:
6.0 - 8.0 N·m  
{52 - 70 in. lbs.}
INSTALLATION
Installation of the brake hose
To be continued on next page
17
„
Installation of the brake hose
1
Use a cutter knife or other cutting tool 
to cut the brake hose.
90 degrees
CAUTION
Use the cutter knife safely and correctly in 
accordance with its instruction manual.
If you are using TL-BH62, refer to the manual 
accompanying the product.
2
i
dual control lever.  
approximately 11 to 14 mm.)
14mm
3
illustration.
Model No.
Length
Color
(A)
(B)
(C)
SM-BH59-SB: 2 mm
SM-BH59-SB
13.2 mm
Gold
OK
Not OK
(A) 
Olive
(B) 
Brake hose
(C) 
Connector insert
CAUTION
Use the dedicated connector insert supplied 
with SM-BH59-SB.
INSTALLATION
Installation of the brake hose
To be continued on next page
18
4
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. If the end of the 
brake hose is not in contact with the 
connector insert mount, the brake hose 
may be disconnected or cause fl uid leaks.
(D)
(F)
(H)
(G)
(E)
(E)
(D)
SM-BH59-SB: 1 mm 
TL-BH61
(D) 
Brake hose
(E) 
Connector insert
(F) 
Olive
(G) 
TL-BH61
(H) 
Vise
5
Pass the brake hose through the 
connecting bolt and olive.
(J)
(K)
(L)
(I)
Direction of insertion
(K)
(L)
Grease the outside of the olive.
(K)
(M)
(I) 
Brake hose
(J) 
Cut end
(K) 
Olive
(L) 
Connecting bolt
(M) 
Grease
CAUTION
For installation to the built-in type frame, fi rst 
connect to the frame caliper the end of the 
brake hose to which the banjo is not 
attached.
INSTALLATION
Installation of the brake hose
To be continued on next page
19
6
Make sure that the brake hose is not twisted.
illustrations.
(N)
(O)
8mm
(O) 
Connecting bolt
8mm
Tightening torque:
5.0 - 7.0 N·m  
{44 - 61 in. lbs.}
8
Temporarily secure the brake hose to the 
handlebar (by using tape or similar 
material).
(Q)
(P)
(P) 
Brake hose
(Q) 
Tape
INSTALLATION
Installation of the brake hose
20
End of the brake hose on the brake caliper side
in the grooves.
(R) 
Brake hose
(S) 
Banjo
(T) 
O-rings
The O-rings are greased.
4
Tightening torque:
8.0 - 10.0 N·m 
{70 - 87 in. lbs.}
4
(R)
(S)
(T)
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