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How to install your Bafang Hydraulic Disc Brake Sensors

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  • Sebz
    started a topic How to install your Bafang Hydraulic Disc Brake Sensors

    How to install your Bafang Hydraulic Disc Brake Sensors

    Were is the best place to mount the sensor and magnet on your hydraulics brake levers and how to do it on the first try?

    Link to the Bafang sensors

    There are way too many models to show you all, but I taken the 3 most popular ones:
    1. The new Shimano series have a very similar lever. Shimano Deore (M615 and M506), the Shimano SLX (M675 M7000), the Shimano XT (M8000 and M785), the Shimano XTR (M90XX), The Shimano ZEE (M640) and the Shimano Saint (M820)
    2. The Shimano M355 (same as M396 and Acera)
    3. The Avid series (Elixir, CODES, BDx and juicy) Sram is now the new brand but the lever mechanism is similar.
    Missing from that list are the Hopes brakes, but from this post, you can probably figure out a way to mount them. Same goes for non-hydraulic brakes!


    This is what you receive: a magnet and sensor with double sided tape on it : Click image for larger version

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    This sensor is a simple piece of hardware, there are no moving parts in it, it's just a reed switch (or hall sensor) potted in the plastic case. Basically when the magnet is close to the sensor the circuit is open and the controller lets power pass through the motor. Then when you pull the magnet further away from the sensor, the switch closes the circuit and send voltage to the controller then it instantly cuts the power to the motor.


    For the installation procedure, I used the Shimano SLX version, but it's the same for all the lever, look down on the thread to your model to give you an idea were to start.

    Also, the distance between the sensor and magnet shown in these photos is not the real one and it depends on the sensor and magnets, some will need to be closer together!

    Sorry for my used sensor, I had to remove the glue around the magnet to do this post.
    Click image for larger version

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    So before you epoxy everything in place and next figure out that it's not working properly, follow the next steps:

    Clean the lever and base with alcohol to remove any trace of oils and dirt.

    You want it to be sensible, to actually stop the motor before your callipers start to bite hard, but not too sensible that vibrations and just finger resting on the lever triggers the sensor.
    I suggest to use a bike stand or find a way to lift the back wheel so it can spin freely while you work on the levers.

    Plug on sensor in the yellow plug on your main harness. turn on the LCD.

    Place the magnet at the most logical place on the lever (Again look down to other model to give you an idea)

    If your don't have steel in the lever, use gum, tape, anything temporary to test the magnet. Click image for larger version

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    What I do it use a clamp to set the desired level of lever action I want (like this next picture). place the sensor at the appropriate place closer to the magnet (do not remove the tape yet), give a little throttle and move the sensor away from the magnet till the motor stops. Remove the plastic and stick the sensor at the exact place the motor stopped. next remove the clamp (or whatever you used) to let go the lever.

    Test again with a little throttle, actuate the lever, the motor will stop exactly were you wanted.

    If it satisfies your needs, you can fix it permanently. I ride in wild trails and get hit by branches all the time, so I used good quality hot glue around the sensor and on the magnet, epoxy glue can be used too at your own risks! But I do not recommend to drill a hole in your lever and screw the magnet in place. Yes there is a hole in the magnet but it's really fragile and will crack with minimal pressure... better to use epoxy then it you tell want it solid! If you cracke the magnet, get some on eBay, look for neodymium magnets (do not use cheap black fridge ceramic magnet, it won't work)

    Repeat for the other side, unplug the battery, plug the brake sensor....follow the steps!


    Now the other models:

    The Shimano M355 can be mounted 2 ways,


    Front mount (Best), like the Shimano SLX. The double sided tape won't hold it enough, not enough contact surface, you will need use hot glue (or epoxy) Click image for larger version

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    Click image for larger version

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    Underside installation, cleaner but harder to set properly. The double sided tape won't hold it enough, not enough contact surface, you will need use hot glue (or epoxy) Click image for larger version

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    Last edited by Sebz; 12-07-2016, 10:41 AM.

  • tijoeruci
    replied
    So, I did something a bit funky with some KYDEX sheets. As you can see in the photo, it's not pretty, but it was my first attempt. Basically, it's plastic that when heated will form to the shape you want when cooled. I cut it to the shape I thought I wanted and took a few tries to wrap the plastic around the magnet. My second try was much better and used no epoxy. I would cut up an old cotton tshirt into strips and wrap and tie as tight as I could while heating with a gun. I recommend another set of hands. I also recommend using a flat head screw driver to force down edges or push corners of the plastic into areas so that it grabs on to the brake lever. I know it's not pretty, but with a bit more patience and help, it could be quite good for those with no 3D printer. It took about 5 tries of testing on road before I settled to a point where it was consistent.

    The only reason the magnet is suspended instead of the obvious choice of maybe using the magnet on the brake lever, is because when I did that, it expanded the range of the magnet, this making it very difficult to find a spot for the sensor. Although, I think swapping their positions should work better for most. KYDEX is fun stuff, I'm sure I'll find more uses for it later.

    Link to the KYDEX I used. https://www.amazon.com/gp/product/B077S5N6TP

    Leave a comment:


  • Jamie Gleeson
    commented on 's reply
    I have exactly the same promax dechiper brakes and have the same problem. It would help 2 people if there are any ideas to fix?

  • Ckwasnik
    replied
    Just got the entire bbshd kit installed and everything works great except for the brake sensors. I can't seem to figure out a good way to mount them because my disk brakes travel such little distance when using them. Any ideas or suggestions are greatly appreciated!

    Leave a comment:


  • JPLabs
    replied
    Love it! Way to make that printer earn it's bench space!!

    Leave a comment:


  • kalahari
    replied
    I have a 3d printer, so I decided to make some lever arms to hold the magnets. This gave me a better place to mount the switch, and more travel for the magnet when the lever is pulled. I decided to use zip ties over epoxy, in case I want to change/adjust it in the future.
    Switch and magnet mounting Magnet arm mounting

    Leave a comment:


  • BCBeaver
    replied
    My kit came with the magnetic sensor but I also have a set of levers with a switch built in that were sent in error as part of a different kit. I've got cable brakes so I want to use them because the crappy ancient levers on the bike don't work well with the sensors (and they're crap). My levers are 2 wire, the magnetic sensors are 3 wire. What is the third wire for?

    Leave a comment:


  • AZguy
    replied
    I used 3M VRB tape (extremely strong) and put the sensors on the underside of my SRAM Guide RS brakes and you can't even see the sensors or wires and they work just fine. Took some fussing to get it right but once done.... well it's done!

    I've seen some other brakes that are darn near impossible to get the same results but on mine it's a very nice clean solution...

    Leave a comment:


  • lukasra
    replied
    I have to admit that I really hate this glue/epoxy solution! Its unreliable for me and it looks bad.
    Does anyone know a brake where these sensors are integrated?
    I assume the Magura MT5e has integrated Higo switches but cannot see for sure.

    Thank you!

    Leave a comment:


  • squirrelpie0
    replied
    After several months and nearly 10000 km on BBSO2B on TT Rover, It has been great. Started having intermittent power cut off. Noted brake signal was coming on on display, and noted 'flicking' brake level restored power. Then magnet epoxied to the handle fell off and of course problem was found. 2nd miracle was finding magnet on trail. Taping it in position would not give me consistent power on. Noted shiny coating was peeling off/ gone from some of the magnet. Taped magnet right onto sensor and power on problem solved, but of course no power off which I like for shifting.
    Question: Is it the magnet weakness causing issue or sensitivity of switch that is problem? It was not proximity of magnet to switch as that had not moved since installation. Do the switches or magnets get weak?
    Advice please

    Solved.... I think. After running with old magnet taped to sensor and no problem, I salvage a magnet from the guts of an old hard drive. Taped it to the handle for a temporary fix and according to the brake indicator lamp on the display it is working properly.. I will take it for a test run tomorrow before epoxy it in place. But looks fine w adequate apply of brake handle before indicator turns on.
    Last edited by squirrelpie0; 02-19-2018, 11:16 AM. Reason: Figured it out

    Leave a comment:


  • Petal
    replied
    I modded the mechanical bafang breaksensors with hall sensors instead. Way smaller then the original hall sensors from bafang!

    Link for foto collage: https://imgur.com/a/595wB




    Leave a comment:


  • JPLabs
    commented on 's reply
    I really like the Bafang sensors. Cheap, easy to retrofit, and perfectly reliable in my experience. You must be setting them up differently than I do. Or have a wiring glitch, perhaps.

    I set the magnet very close to the sensor. Too far, and it won't work consistently. Even if too far, I never got an error, though.

  • bikermiker
    replied
    I hate the Bafang sensors with a passion, they just don't function correctly, don't buy them is my advice. I have shimano 315"s which are really good and cost effective, I only want hydraulic fluid brakes because I go pretty fast and can not afford a brake failure so wire brakes are to risky. ,You have to position sensors and magnet very carefully for them to function at all and it's down to a 1/2 millimeter difference as the whether they work without a "out range fault" which stops the engine from turning on, I have tried all of the above positions and have had to change position of the magnets with temperature change due to weather which aren't that extreme in mild Australia, there are times when for no reason I can find that they just cut the motor because of the fault and now I have had to disconnect one of them permanently, the luna seller in Australia blames my installation and refuses to deal with a refund. Waste of money. I have ordered a complete "installed already" set of factory installed shimano 365"s from passion bikes via aliexpress which will be fitted tomorrow and I'll post to let you know how they work, it only cost me $100 AUD delivered to my door - includes everything but disc's.
    Attached Files
    Last edited by bikermiker; 09-18-2017, 04:24 PM.

    Leave a comment:


  • Dead President
    replied
    Ordered the sensors. Will take pictures and post next weekend after i get it working.

    Leave a comment:


  • JPLabs
    commented on 's reply
    I looked that up - you are right, a bit different. I see why you are asking...

    This one, right?

    https://www.hayesdiscbrake.com/wp-co...comp-white.jpg

    Looks like the front of the lever still moves away from the housing with actuation. Is that right?

    If so, then one way would be to make a small wedge to space the sensor out, so it can end next to a magnet on the lever.
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