山地车刹车手柄更换指南

Shimano Brake Lever Replacement

2023-06-21 23:38:06

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Summary

This is a simple and effective fix for broken shimano levers of all types.

The Lever is made from two aluminium plates which sandwich the original lever adjuster. The 3D printed centre is then clipped over these, providing an ergonomic and customisable brake lever.

As per my profile I am an keen on providing high performance replacement parts, using my engineering background.

I have used this lever for the past 6 months, I have ridden loads (at least 500 miles) including trips to Bike Park Wales, Forest of Dean etc. I have also had more crashes than I would like to admit but the lever is still in great condition with no issues. I have not had to replace any parts since fitting it.

I wanted to create a 3D printed lever replacement as I have broken several shimano ones in the past. However, I was concerned about their strength and reliability over time. I also wanted to re-use the reach adjustment that is normally replaced along with the lever (Rather Wastefully) even if it is undamaged. This lever is also ambidextrous and can be used on either a RHS or LHS body.

This lever is as strong as a shimano one due to it's use of 2 aluminium sheet arms . The 3D printed part of the lever only acts as a cover that transmits pressure into the arms. As the arms are not directly connected the lever tolerates shear forces without deforming and is resilant during crashes. When pulled the lever is very stuff and stable, equal to the original.

The metal lever arms are made from 1.5mm thick aluminium sheet. This was laser cut for me at a university but can be sent to a company such as sendcutsend or equivalent. I had several made at once for any future replacements.

I am happy to film an installation video if anyone is interested

note that this was designed and tested on a Shimano SLX M7100 Lever, all of this generation use the same design so I believe this can be fitted to all current models from XTR to MT200 - however the space between the metal arms may vary and the depth between the slots in the print may need to be adjusted to account for this.

Print Settings

Printer brand:
Creality
Printer:
Ender 3
Rafts:
Yes
Supports:
Yes
Resolution:
Very Fine
Infill:
Solid
Notes:
Just printed mine in standard PLA, on very fine settings with solid infill.

Place the part with the lever facing upwards, use supports but ensure they are not within the channels for the metal pieces.

Post-Printing

Installation

Instillation follows the standard shimano process, but that the small lever spring is slightly harder than normal to install.

Fit the metal lever arms to the adjuster, fit to the lever with the spring in place, the push the pivot pin through. Finally tighten the adjuster grub screw to secure the lever in place.

*This may be easier to do with the 3D printed cover already installed to hold the arms in place on the adjuster.

To install the plastic cover on the arms, simply place the rounded end of the arm firmly into the end of the slot on the plastic cover. then pivot the cover on this point using moderate pressure until the cover clips over the arms. The cover should have some movement but should it should not be possible to easily remove - with the clips fully engaged.

The lever due to it's construction tends to have more lateral movement than the original, this is due to tolerances in the two lever arms and 3D print but the strength and feel in use is not effected.