Shimano Direct Mount Rear Brake Repair and Mods Tutorial Guide How To DIY

This is a guide showing how to fix modify and service a Shimano Ultegra BR6810-R rear brake. There are lots of basic installation videos here on YT, but no one shows how to service or repair a non-working unit. This should work on any of the Ultegra or Dura Ace rear brakes with the same bolt/bearing arrangement including the BR8010-R and BR9010-R.
Note: I advise replacement of all defective parts as per the manufacturer's instructions. However, if you do not have these parts available, this is only an example of what I did and how that has worked out for me so far. If you choose to do something like this, you do so entirely at your own risk.
TIMELINE:
00:10 DAY 1 (bad - LA/SA)
xx:xx Long Arm disassembled b4 filming
00:30 Short Arm disassembly
03:10 Full Assembly Order Layout
03:30 MOD Double Spring
03:55 LA clean and assembled (off camera)
04:14 SA clean and assembly
05:39 DAY 2 (bad - LA/SA)
06:18 TOOL FABRICATION
08:07 MOD SA + grease
09:52 LA clean + grease
10:48 DAY 3 (bad - LA)
11:29 LA disassembly
12:00 LA cut out liner material
14:10 MOD LA assembly
15:37 DAY 4 (bad - LA)
16:46 LA disassembly
17:40 LA MOD assembly + grease
18:08 SA MOD disassembly
19:55 LA bore measurements
21:14 Full ~realtime assembly LA/SA
27:02 DAY 5 (good)
27:48 MOD short spring (watch 29:13 too)
29:04 DAY 6 (good)
29:37 Brake on the bike
30:14 CB90 Warning
30:41 MEASUREMENTS
Relevant Shimano PDF Doc "DM-BR0003-09:"
si.shimano.com/pdfs/dm/DM-BR0...
If the link is broken, search the web for "DM-BR0003-09-ENG."
Ride Safe!

[@UpcycleElectronics]

TIMELINE:
00:10 DAY 1 (bad - LA/SA)
xx:xx Long Arm disassembled b4 filming
00:30 Short Arm disassembly
03:10 Full Assembly Order Layout
03:30 MOD Double Spring
03:55 LA clean and assembled (off camera)
04:14 SA clean and assembly
05:39 DAY 2 (bad - LA/SA)
06:18 TOOL FABRICATION
08:07 MOD SA + grease
09:52 LA clean + grease
10:48 DAY 3 (bad - LA)
11:29 LA disassembly
12:00 LA cut out liner material
14:10 MOD LA assembly
15:37 DAY 4 (bad - LA)
16:46 LA disassembly
17:40 LA MOD assembly + grease
18:08 SA MOD disassembly
19:55 LA bore measurements
21:14 Full ~realtime assembly LA/SA
27:02 DAY 5 (good)
27:48 MOD short spring (watch 29:13 too)
29:04 DAY 6 (good)
29:37 Brake on the bike
30:14 CB90 Warning
30:41 MEASUREMENTS

[@electronic7979]

Nice

[@UpcycleElectronics]

UPDATE -1
November 7th
This marks 1 month since day 7 in this video. I've had 4 days off the bike since October 7th, including today. So it has been around 700 miles in 28 days. Last night it wasn't raining hard, but enough to wet the bottoms of my socks in the last few miles despite toe covers.
The brake is starting to feel a little bit stiffer at the lever, but still works without getting stuck at all. I mean, normally when these brakes start to fail the caliper arms will stick in place. This makes some slack in the cable that you can feel at the lever. I haven't felt anything like that. It just feels a little stiffer and slightly gritty when actuating the brake hard.
I have not removed it or made any attempts to service it since the video. After the rain ride, and a day of sitting (today), I plan to take it apart and maybe regrease it tomorrow. I'm in Southern California, riding in places where saltwater corrosion can be an issue, and this was the first rain in around 6 months, so the cleaning is nothing extraordinary. I still haven't felt the need to source a replacement, or make any changes. Let those actions and observations speak for themselves.

[@winningismyhobby]

you're genius