E-Bike Brake Sensor for Shimano Lever BL-M445

This model allows you to mount the brake sensors required for e-bike conversion kits e.g. the Bafang e-bike retrofit kits to a Shimano brake lever. Without this, you would have to use double-sided tape and there is not a good place to mount it.

This particular one is designed for the Shimano BL-M445 / BR-M447 hydraulic levers. There is a left and right side for each component so print them all if you have sensors on both sides.

It will accommodate 11mm x 6.5 mm sensor and 10mm magnets that typically ship with the Bafang BBS02 BBSHD kits.

Advantages:

1.  Securely mounts both the sensor and the magnet
2. Magnet is protected from the elements
3. The design allows to easily adjust the position of the sensor with respect to the magnet.
4. Does not require any glue - held together with zip ties and screws.

Assembly:

Lever (magnet) Mounts

1.  Place the 10x3 mm magnet inside the bottom part of the lever mount
2.  Place the bottom lever mount underneath the brake lever (make sure the magnet faces away from the bike - if it doesn't you've messed up the right and left sides).
3. Insert 4X M2 nuts in the top hexagons of the lever mount
4. Screw the two halves of the lever mount together using 4X M2x16 flat head bolts

Sensor Mounts

1. Tap 5mm treads into the top hole of the sensor mount
2. Slide the sensor into the opening of the mount
3. Partially screw in a 5mm bolt into the threaded hole
4. Run a zip tie (~4mm width) through the bottom slots of the sensor mounts and attach to the hydraulic fluid reservoir (make sure the orientiation matches the photos above)
5. Make sure the groove of the sensor mount goes into the corresponding slot in the brake reservoir
6.  Tighten the zip tie to hold it in place

Adjustment

1. Slide the sensor back and forth until the brake sensor works properly.
2. Once you've decided on the final position, you can tighten the 5mm bolt to hold the sensor in place - WARNING - DO NOT OVER TIGHTEN this bolt. It takes very little force to hold the sensor in place. Over tightening can damage the sensor.
3. If you need to adjust it in the field, you should be able to loosen the 5mm bolt by hand and adjust the sensor.

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