[ Toysfun Cycling ] shimano deore brake lever disassemble jam faulty spoilt problem 

Small grub screw under a tiny rubber cap in the centre of the back of the brake lever pivot, undo this, it's tight and push the pin through.

Hi, thank you for your advice, the screw only available with model m675, xt, maybe slx but not on normal deore model like m615.

@@asotnes My BL-MT 501 has this screw

ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-oc3B53z-5EI.html

U can use wat ever method as long as make sure air completely let out.

@@asotnes i meant to take them apart all the way to the reservoir, instead of using a funnel

The spongy I suppose u mean, brake feels soft n not solid. Mostly oil insufficient n air inside the brake. The brake need bleeding. The clicking sound I not sure. Try check first if the clicks r from the lever or caliper counld help alot.

True!

HI, u need to grind the pin that hold the lever. from bottom side of the lever, need to do it carefully make sure that u dont over grind, shimano really not design it to be remove so u have to think of some solution after u grind. if u dont mind finding some other screw+nut as replace to the pin, u need to save some material of the pin that u grind and be able to relock the pin again in it position. I use to make a hole in center of the pin and tap a screw thread hold back the pin, later on i decide to just drill a small hole on the pin and tied with a wire.

By using mini grinder such as dremel I grind the lever pin side facing down slowly until it reach a point where top and bottom pin can be seperate, remember not to over grind bcoz i so u will not able to relock it back again. 2 way of grind 1) ginding side of pin only leaving center as pole, aftere that make a small hole at center of pin and lock position using a wayar pierce tru the hole of pin that we made. this way we could open the pin again anytime in future 2) griding whole pin shorter until reach the point where seperation of top and bottom pin is posible , after work or service, using hammer hit on end pin until expend thus holding the bottom pin in position.This method may result the next time u open the pin may not able to relock it back securely again. I suing the first method.

If at the side of the lever have screw， just remove the screw n push out. If don't have screw, u need to grind the bottom side of the pole 1-2mm then punch out.

Hi, please read the comment and reply below

ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-oc3B53z-5EI.html

HI, not that difficult if u own a mini grinder n abit of hand work. sory that i didnt have a chance to make a video of how I grind. But if the jamming pump of your lever is not that heavy, u can try this another method without open up the lever. I have done this method before without opening the lever. 1) remove everything from top cap 2) using heavy soap water deep in the lever n works the pump in n out 3) after cleaning thoroughly n rinse out the water 4) put in mineral oil n works the pump again 5) until the jamming pump go away 6) reinstall everything n re bleed I also use a ultrasonic to help with soap water in cleaning the old oil n dirt

Toysfun JBmoon what kind of problem do you encounter with your m615 brakes?

Amoladora eléctrica, debajo del clavo. Desbaste abierto. Retire de abajo hacia arriba.

ya, by carefully grind with dremel mini grinder, have to b careful not to ovr grind as later we have to reinstall back

@@asotnes - Thanks for Reply so what holds the pin in place NOW ? GLUE !!!

i drill a very small hole (about 1mm) at near the end of the pin and pierce tru a wire n the wire hold bottom sleeve from coming out.

the pin material they use is kind of soft, the drilling is kind of easy

ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-oc3B53z-5EI.html

hi, i m not sure where if there s any selling, some site or ebay do sale the whole lever.

@@asotnes thanks for taking the time to show this as it has helped me with my Shimano lever problem .A great help indeed.Martin

hi sory dont realy know wats the name

Lever blade guide

has anyone learned whats it called; i need to know as well

Any questions pls leave a comment, I will try to answer n help. This video was taken very long time ago, I was.not knowing wat ppl want to see at that time.

Spring lock I guess. If u loose it can be replace try hardware shop or try Savage from junk parts or just modify using a washer of it size

what really jamming the piston was over long period of time using without changing the oil , the very tiny rubber from the seal cameoff and accumulate n stuck at the surface of the tube

@@asotnes thanks for reply , i try to soak it in ultrasonic cleaner and blow it out with compressed air !!! make a new video of the assembled lever and how the grinding of the Pin looks after assembly

ultrasonic wont work, i try before. need stronger chemical. need to take good care of the seal, if the seal defect, the lever will no longer worth

I blow Compressed Air inside and bleed brake now working OK

U have to grind the bottom of the pivot pin in order to release the pin. Remember to grind carefully n not over grind otherwise the pin won't b able to relock again, unless u can replace with screw n nut.

ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-oc3B53z-5EI.html

hi, after google, shimano doesnot provide a name of the part, from other source they name the part piston and the seal as piston seals