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Shimano Ultegra Di2 ST-R8150-L Brake Level Dealer's Manual PDF
Summary of Content for Shimano Ultegra Di2 ST-R8150-L Brake Level Dealer's Manual PDF
(English) DM-RACBR10-01
Dealer's Manual
ROAD MTB Trekking
City Touring/ Comfort Bike
URBAN SPORT E-BIKE
Dual Pivot Caliper Brake/Dual Control Lever (Di2)
DURA-ACE BR-R9200
BR-R9210-F
BR-R9210-RS
DURA-ACE Di2 ST-R9250
ULTEGRA Di2 ST-R8150
ULTEGRA BR-R8100
BR-R8110-F
BR-R8110-RS
SHIMANO BR-RS811-R
SHIMANO ROAD Di2 SW-RS801
Non Series BR-R9210
BR-R8110
SW-RS801-E
SW-RS801-S
SW-RS801-T
Contents
IMPORTANT NOTICE........................................................................................ 3
TO ENSURE SAFETY......................................................................................... 4
List of tools to be used................................................................................. 10
Installation/removal ..................................................................................... 11 Installing the dual control levers ......................................................................11
Installing the brake cable ..................................................................................16
Installing the SM-CB90.......................................................................................21
Installing satellite shifters..................................................................................22
Installing the brake calipers ..............................................................................32
Brake shoe setting position...............................................................................38
Securing the BC-9000 cable ...............................................................................39
Adjustment.................................................................................................... 43 Arch spring tension adjustment........................................................................43
Readjustment of shoe clearance (when brake shoes are worn) .....................46
Adjusting the reach ...........................................................................................47
Maintenance.................................................................................................. 49 Replacing the cartridge shoe ............................................................................50
Brake shoe characteristics..................................................................................51
Replacing the bracket cover..............................................................................53
2
IMPORTANT NOTICE
For safety, be sure to read this dealer's manual thoroughly before use, and
follow it for correct use.
The following instructions must be observed at all times in order to prevent personal injury and physical damage to
equipment and surroundings.
The instructions are classified according to the degree of danger or damage which may occur if the product is used
incorrectly.
DANGER Failure to follow the instructions will result in death or serious injury.
WARNING Failure to follow the instructions could result in death or serious injury.
CAUTION Failure to follow the instructions could cause personal injury or physical damage to equipment and
surroundings.
This dealer's manual is intended primarily for use by professional bicycle mechanics.
Users who are not professionally trained for bicycle assembly should not attempt to install the components
themselves using the dealer's manuals.
If any part of the information on the manual is unclear to you, do not proceed with the installation. Instead,
contact your place of purchase or a distributor for assistance.
Make sure to read all manuals included with each product.
Do not disassemble or modify the product other than as stated in the information contained in this dealer's
manual.
All manuals and technical documents are accessible online at https://si.shimano.com .
For consumers who do not have easy access to the internet, please contact a SHIMANO distributor or any of
the SHIMANO offices to obtain a hardcopy of the user's manual.
Please observe the appropriate rules and regulations of the country, state or region in which you conduct your
business as a dealer.
IMPORTANT NOTICE
3
TO ENSURE SAFETY
TO ENSURE SAFETY
4
Be sure to also inform users of the following:
For installation to the bicycle and maintenance
Be sure to follow the instructions provided in the manuals when installing the product.
Only use SHIMANO genuine parts. If a component or replacement part is incorrectly assembled or adjusted, it
can lead to component failure and cause the rider to lose control and crash.
Wear approved eye protection while performing maintenance tasks such as replacing components.
Because each bicycle may handle slightly differently depending on the model, be sure to learn the proper
braking technique (including brake lever pressure and bicycle control characteristics) and operation of your
bicycle. Improper use of your bicycle's brake system may result in a loss of control, which could lead to serious
injury due to a fall or collision.
Do not apply the front brake too strongly. If you do so, the front wheel may lock and the bicycle may fall
forward, and serious injury may result.
Because the required braking distance will be longer during wet weather, reduce your speed and apply the
brakes early and gently. You may fall or collide and be seriously injured.
A wet road surface may cause tires to lose traction; therefore, to avoid this, reduce your speed and apply the
brakes early and gently. If the tires lose traction, it may result in serious injury due to a fall or collision.
Do not allow any oil or grease to get onto the brake shoes. Riding the bicycle with oil or grease on the brake
shoes may prevent the brakes from operating and result in serious injury due to a fall or collision.
Do not use the brake cable if it has any rust, fraying, or cracks. Otherwise, the brakes may not work correctly.
Dual control lever
Do not throw or subject this product to strong shocks. If this is not observed, bursting, overheating or
problems with operation may occur.
When operating the shift switch, be careful not to allow your fingers to be caught in the derailleur. The motor
in the derailleur is powerful enough to be operated without stopping until the shifting position is reached,
and may cause serious injury if your fingers interfere with the shifting motion.
Use the brake and dual control levers or brake lever in the combinations specified in the following table. Do
not use the combinations with the NO indication in the table. This will excessively increase the braking
force, which could cause you to lose control of the bicycle, fall, and be seriously injured. (Refer to the dealer's
manual for each model for details on the dual control levers and brake levers indicated in the table.)
TO ENSURE SAFETY
5
Caliper brake Combinations Dual control lever Brake lever
BR-R9200
BR-R9210
BR-R8100
BR-R8110
BR-RS811-R
OK ST-R9250
ST-R9100
ST-R9150
ST-R9160
ST-R8150
ST-R8050
ST-R8000
ST-R7000
ST-9070
ST-9071
ST-9001
ST-9000
ST-6870
ST-6871
ST-6800
ST-6770
ST-6700
ST-5800
ST-5700
ST-4700
ST-4600
ST-R3000
ST-3500
ST-2400
ST-R460
ST-R353
ST-R350
BL-4700
BL-4600
BL-R3000
BL-3500
BL-R2000
BL-R780
BL-2400
BL-TT79
NO Dual control levers not
included above
Brake levers not included
above
The cable adjustment nut and quick release lever are not provided with the BR-RS811-R; be sure to use the
SM-CB90 (cable adjuster). When the brake shoes are worn down, it becomes impossible to adjust the shoe
clearance by hand. Also confirm that the SM-CB90 is in the Close position before riding the bicycle.
Securely tighten the caliper brake fixing nuts to the specified tightening torque. If the nuts become loose and
the brakes fall off, they may get caught up in the bicycle and the bicycle may fall over. In particular, if this
happens with the front wheel, you may be thrown forward and seriously injured.
Use lock nuts with nylon inserts (self-locking nuts) for nut-type brakes.
For sunken nut-type brakes, use sunken nuts of the appropriate length which can be threaded onto the fixing
screw for at least five full turns. When re-assembling, apply a threadlocker to the nut threads.
Brakes designed for use as rear brakes should not be used as front brakes. Also, brakes designed for use as
front brakes should not be used as rear brakes.
Make sure to use the dedicated brake shoe for the shoe holder of the BR-R9210-F / R8110-F / RS811-R. The
conventional brake shoes have different fixing positions preventing the fixing screw from being tightened,
TO ENSURE SAFETY
6
BR-R9210-F / BR-R8110-F
BR-R9210-RS / BR-R8110-RS
Shoe holder
BC-9000 (polymer coating brake cable) has low frictional resistance; therefore, be sure to observe the following
instructions. If not observed, the holding force of the brake cable will not be sufficient causing the brake cable to
slacken, a loss of brake control and possibly severe injury.
which will cause the brake shoe to come off and disable braking.
Dedicated brake shoes:
R55C4 / R55C4 (for carbon rim) / R55C4-A (for carbon rim) / R55CT4
Do not install the shoe and shoe holder on the wrong side. There are two different types of shoe and shoe
holder for the left and right respectively. Take note of the correct directions and screw hole positions for
inserting the shoes.
BR-R9210-RS / BR-R8110-RS
BR-R9210-RS / BR-R8110-RS is designed for use as a rear brake and should not be used as a front brake. BR-
R9210-F / BR-R8110-F (front brake) and BR-R9210-RS / BR-R8110-RS use different shoe holders and internal
parts.
BC-9000
Make sure to use it in combination with a brake in the BR-R9210 / BR-R8110 / BR-RS811-R series.
Use the designated Cable Grease (Y04180000) for BC-9000.
When the inner cable is passed through the outer casing, be sure to wipe the inner cable fixing section with a
cloth before fixing the inner cable. Grease may adhere to the inner cable fixing section and prevent sufficient
holding force.
TO ENSURE SAFETY
7
Be sure to also inform users of the following:
For installation to the bicycle and maintenance
In the case of carbon levers, wash them with a soft cloth using a neutral detergent. Otherwise, the material
may be damaged and lose strength.
Avoid leaving the carbon levers in areas of high temperature. Also keep them well away from fire.
When combined with a ceramic rim, SHIMANO road brake shoes wear down more quickly.
If the brake shoes have worn down until the grooves are no longer visible, consult your place of purchase or a
distributor.
Different brake shoes have their own characteristics. Ask the place of purchase or a distributor for details
when purchasing the brake shoes.
Be sure to keep rotating the crank arm during gear shifting operations.
Be careful not to get water into the E-TUBE ports and the satellite shifter connection port.
The components are designed to be fully waterproofed to withstand wet weather riding conditions; however,
do not deliberately place them into water.
Do not clean the bicycle in a high-pressure wash. If water gets into any of the components, operating
problems or rusting may result.
Contact the place of purchase for updates of the component software. The most up-to-date information is
available on the SHIMANO website.
Be sure to attach dummy plugs to any unused E-TUBE ports and the satellite shifter connection port. If water
gets into any of the components, operating problems or rusting may result.
The electric wire has small waterproof connectors, so do not repeatedly connect and disconnect it too often.
Doing so may impair the waterproofing.
Products are not guaranteed against natural wear and deterioration from normal use and aging.
For maximum performance we highly recommend SHIMANO lubricants and maintenance products.
Use an outer casing/electric wire which still has some length to spare even when the handlebars are turned all
the way to either side. Furthermore, check that the dual control levers do not touch the bicycle frame when
the handlebars are turned all the way.
Use the parts indicated in the exploded view of the dual control levers when you replace the clamp band,
clamp screw, or clamp nut.
Even with the recommended tightening torque, there is a possibility that the carbon handlebars may become
damaged and insufficiently tightened. Confirm the appropriate torque value with the bicycle manufacturer or
the handlebar manufacturer.
TO ENSURE SAFETY
8
The actual product may differ from the illustration because this manual is
intended mainly to explain the procedures for using the product.
Dual control lever
Dummy plugs are installed at the time of shipment from the factory. Do not remove them except when
necessary.
When routing the electric wires, take care to ensure that they do not interfere with the brake levers.
Satellite shifter
When connecting electric wires, make sure that foreign matter does not get inside the plug or satellite shifter
connection port. A connection with foreign matter present may result in a malfunction.
If the plug is exposed during storage, transportation, or maintenance work, and there is a possibility of
foreign matter getting inside, protect the plug with masking tape or a similar material.
If you do not feel a click when connecting an electric wire, check that there is no foreign matter inside the
plug or satellite shifter connection port. If foreign matter is present, use a blower to remove it. If the problem
persists, replace the satellite shifter with a new one.
TO ENSURE SAFETY
9
List of tools to be used The following tools are needed for installation, adjustment, and maintenance purposes.
Tool
2 mm hexagon wrench
4 mm hexagon wrench
5 mm hexagon wrench
Slotted screwdriver
Blade width at tip: 4.0 - 5.0 mm
Blade thickness at tip: 0.5 - 0.6 mm
TL-CT12
TL-EW300
Utility knife
Cutters
List of tools to be used
10
Installation/removal Installing the dual control levers
Turn over the bracket cover from the front side.
Gently turn over the ends of the bracket cover with both hands and slowly push them down.
Forcibly pulling the bracket cover may damage it because of its material properties.
1.
Loosen the clamp screw and pass the clamp band over the handlebar.
Clamp screw
Clamp band
2.
Installation/removal
Installing the dual control levers
11
Temporarily install the lever to the handlebar.
Temporarily install the lever so that it cannot move.
Clamp screw (Temporary)
Use the parts indicated in the exploded view of the dual control levers when you replace the clamp
band, clamp screw, or clamp nut.
3.
Return the turned bracket cover to its original position and turn it over from the back side.4.
Installation/removal
Installing the dual control levers
12
Lift up the port junction.
Port junction
Bracket cover
When removing/inserting dummy plugs or electric wires, be sure the port junction is firmly
supported by hand or by the bracket body. Otherwise you may cause damage to the inner
connecting wires of the dual control levers.
5.
Installation/removal
Installing the dual control levers
13
Connect the electric wire. If required, first remove the dummy plug of the E-TUBE port.
Be sure to push it in firmly with the TL-EW300 until you feel a click.
For instructions on using the TL-EW300, refer to the ROAD Di2 Series General Guide .
E-TUBE port 2
Dummy plug Electric wire
It is possible for the electric wires to become disconnected accidentally while riding or winding the
handlebar tape. By allowing sufficient wire length, accidental disconnection can be prevented after
winding the handlebar tape.
Ensure that the electric wire to connect to the dual control levers has extra length to make it easier
to remove and insert when performing maintenance.
PC linkage devices can be connected to the E-TUBE port when performing maintenance. However,
leave the dummy plug attached to the unused E-TUBE port when a PC linkage device is not in use.
6.
After installing and connecting brake hose and electric wire, check the connections.7.
Installation/removal
Installing the dual control levers
14
Secure the dual control levers to the handlebar.
6 - 8 Nm Clamp screw
8.
Installation/removal
Installing the dual control levers
15
Installing the brake cable Outer casing comes internally pre-lubricated with an appropriate grease.
Cable to be used
BC-9000 inner cable BC-9000 outer casing
1.6 mm 5 mm
BC-1051 inner cable SLR outer casing
1.6 mm 5 mm
When an inner cable is passed through the outer casing, be sure to wipe the fixing section of the inner
cable which will be secured by the clamp screw before securing the cable. Residual grease in the area of
the clamp screw may prevent sufficient holding force.
When feeding the BC-9000 inner cable through the shift lever or caliper brake, try to minimize the
contact between the cable and the components. If the coating of the cable gets abraded during
installation, it may develop a fuzzy appearance, although this will not affect performance.
Installation/removal
Installing the brake cable
16
Cutting the outer casing
Cut the outer casing using a cable cutter (TL-CT12).
Cut the outer casing so that the coil does not tip over inward.
Cut the outer casing so it still has some length to spare even when the handlebars are turned all the
way to either side.
1.
Spread out the tip of the liner using a thin tool such as a TL-CT12 needle.
Arrange the cut end into a perfect circle.
TL-CT12 needle
Be careful not to hurt your hands with the TL-CT12 needle.
2.
Installation/removal
Installing the brake cable
17
Install the outer cap with tongue.
Insert the outer casing until it closely contacts with the seating surface of the outer cap with tongue.
BR-R9200 / R9210-RS BR-R8100 / R8110-RS
BR-RS811-R
When inserting the outer casing, take care to ensure that the tip of the outer cap with tongue is
not damaged.
When using the BC-1051 inner cable, use a regular outer cap rather than an outer cap with tongue.
3.
Installation/removal
Installing the brake cable
18
Installing the brake cable
Depress the brake lever and insert the brake cable.
Pass the brake cable through the outer casing and install it to the lever as shown in the figure.
Outer casing
Inner end
Cable hook
Make sure that the inner end is firmly fit into the cable hook.
Cable hook
Inner end
1.
Installation/removal
Installing the brake cable
19
Temporarily secure the outer casing to the handlebar (by using tape or a similar material).
Tape
Outer casing
2.
Installation/removal
Installing the brake cable
20
Installing the SM-CB90
Installation
The cable adjustment nut and quick release lever are not provided with the BR-RS811-R; be sure to use
the SM-CB90 (cable adjuster). When the brake shoes are worn down, it becomes impossible to adjust
the shoe clearance by hand. Also confirm that the SM-CB90 is in the Close position before riding the
bicycle.
Be sure to install the SM-CB90 so that it does not contact the frame when the handlebars are turned.
Install the SM-CB90.
Inner cable
Self-locking nut
(1)
(3)
Open
Close
Outer casing on the brake caliper side
Outer casing on the brake lever side
Quick release lever
(2) (4)
Pass the inner cable through the SM-CB90 and install it to the outer casing on the brake lever side.(1)
Move the quick release lever to the Open position.(2)
Install the outer casing on the brake caliper side to the SM-CB90.(3)
Move the quick release lever to the Close position.(4)
Ensure the orientation of the SM-CB90 is the same as is illustrated in the figure.
1.
Installation/removal
Installing the SM-CB90
21
Installing satellite shifters This section describes how to add a satellite shifter.
SW-RS801-T
Routing map
Satellite shifter
Dual control lever (left)
Dual control lever (right)
Connection method
Set the band on the shift unit.
Shift unit
Band
1.
Installation/removal
Installing satellite shifters
22
Place the rubber sheet on the installation position and set the satellite shifter on top of it.
Satellite shifter
Rubber sheet
Handlebar
2.
Secure the satellite shifter to the handlebar with a zip tie.
Wind the zip tie aligned with the groove on the band.
Zip tie
Groove
Satellite shifter
3.
Installation/removal
Installing satellite shifters
23
Cut the remaining part of the zip tie using cutters, etc.
Zip tie
4.
Installation/removal
Installing satellite shifters
24
SW-RS801-E / SW-RS801-S
Routing map
SW-RS801-E
Connect the electric wire of the satellite shifter to the satellite shifter connection port of the dual control
levers.
There is an alignment tab on the plug of the electric wire, which should be aligned with the shape of the
satellite shifter connection port.
Be sure to push it in firmly with the TL-EW300 until you feel a click.
For instructions on using the TL-EW300, refer to the ROAD Di2 Series General Guide .
Electric wire of satellite shifter
Satellite shifter connection port
When passing an electric wire through the frame, handlebar, or other parts, protect the plug with
masking tape or a similar material to prevent foreign matter from getting inside.
If there is length to spare in the electric wire of the satellite shifter, retaining it on the dual control
lever side will make it easier to remove and insert wiring when performing maintenance.
5.
Installation/removal
Installing satellite shifters
25
Dual control lever (left)
Dual control lever (right)
Satellite shifter
SW-RS801-S
Satellite shifter
Dual control lever (left)
Dual control lever (right)
Installation/removal
Installing satellite shifters
26
Connection method
Use a utility knife or a similar tool to cut the handlebar tape to the length of 80 mm.
Make sure that you handle the utility knife safely and correctly in accordance with the instructions
which are provided with the utility knife.
1.
Make a hole in the cut handlebar tape for the button of the satellite shifter to pass through (13 mm x 9
mm).
9 mm
13 mm
80 mm
2.
Set the band on the shift unit.
Shift unit
Band
3.
Installation/removal
Installing satellite shifters
27
Affix double-sided tape to the satellite shifter.
Double-sided tape
Affixing position
4.
Connect the electric wire of the satellite shifter to the satellite shifter connection port of the dual control
levers.
There is an alignment tab on the plug of the electric wire, which should be aligned with the shape of the
satellite shifter connection port.
Be sure to push it in firmly with the TL-EW300 until you feel a click.
For instructions on using the TL-EW300, refer to the ROAD Di2 Series General Guide .
Electric wire of satellite shifter
Satellite shifter connection port
When passing an electric wire through the frame, handlebar, or other parts, protect the plug with
masking tape or a similar material to prevent foreign matter from getting inside.
5.
Installation/removal
Installing satellite shifters
28
Mark the installation position, and affix the satellite shifter to the handlebar using double-sided tape.
SW-RS801-E
Double-sided tape
SW-RS801-S
Double-sided tape
The adhesive force weakens if there is any dirt, water or oil on the surface where the double-sided
tape is applied.
6.
Installation/removal
Installing satellite shifters
29
Align the cut hole in the handlebar tape with the button.
SW-RS801-E
SW-RS801-S
7.
Installation/removal
Installing satellite shifters
30
Troubleshooting
Check the following information if you have a problem.
Wind on the handlebar tape.
Wind the handlebar tape on securely so that the satellite shifter does not move.
SW-RS801-E
SW-RS801-S
In order to protect the electric wire, use handlebar tape to secure the wire. Do not secure the wire
with the zip tie or the bracket for the cycle computer.
The illustration shows an example of how to wind the handlebar tape.
8.
Installation/removal
Installing satellite shifters
31
If the problem is not covered below or cannot be solved with the indicated method, contact a distributor.
Symptoms Causes / possibilities Remedies
Click cannot be felt when connecting an
electric wire.
Cannot fully connect a wire.
Is there foreign matter inside the plug or
satellite shifter connection port?
Check that there is no foreign matter
inside the plug or satellite shifter
connection port. If foreign matter is
present, use a blower to remove it. If the
problem persists, replace the satellite
shifter with a new one.
Installing the brake calipers
Recommended tire size/rim outer width/brake shoe
Recommended tire size
The recommended tire sizes for installation are as follows.
Caliper brake Tire width Outer diameter of tire
BR-R9200
BR-R9210
BR-R8100
BR-R8110
BR-RS811-R
28 mm or less 684 mm or less
Outer diameter of tire
Recommended rim outer width/brake shoes
The recommended rim outer width and brake shoes for installation are as follows.
Installation/removal
Installing the brake calipers
32
Caliper brake Rim Rim outer width Brake shoe
BR-R9200
BR-R9210
BR-R8100
BR-R8110
BR-RS811-R
Aluminum rim 20.8 - 24 mm WH-R9100-C60-CL R55C4
R55CT4 WH-R9100-C40-CL
WH-R9100-C24-CL
WH-9000-C50-CL
WH-9000-C35-CL
WH-9000-C24-CL
WH-9000-C24-TL
Carbon rim 20.8 - 24 mm WH-9000-C75-TU R55C4 (for carbon rim)
WH-9000-C50-TU
WH-9000-C35-TU
WH-9000-C24-TU
28 mm WH-R9100-C60-TU R55C4-A (for carbon
rim) WH-R9100-C40-TU
WH-R9200-C36-TU
WH-R9200-C50-TU
WH-R9200-C60-HR-TU
Brakes designed for use as rear brakes should not be used as front brakes. Also, brakes designed for use
as front brakes should not be used as rear brakes.
Installation/removal
Installing the brake calipers
33
Installing the brake caliper (BR-R9200 / BR-R8100)
Use brake shoes that are appropriate for the rim type and rim outer width.
BR-R9210 / BR-R8110 / BR-RS811-R
Do not remove the assembly tool until installation is finished. Otherwise the brake caliper may be
scratched.
Assembly tool
Install the brake caliper to the frame.
Depress the arch of the brake caliper and push the brake shoes firmly against the rim.
8 - 10 Nm
1.
Installation/removal
Installing the brake calipers
34
Installing the brake caliper (BR-R9210 / BR-R8110)
Installing the front brake caliper
Check that the centering adjustment screw is in the standard position.
With the standard position, the centering adjustment screw protrudes as shown in the figure. If the
centering adjustment screw is not in the standard position, turn it for adjustment.
Centering adjustment screw
3 mm
2.
Temporarily install the brake caliper to the frame base.
Install it together with the assembly tool.
0.5 Nm Assembly tool
Brake fixing screw
1.
Installation/removal
Installing the brake calipers
35
Installing the rear brake caliper (BR-R9210-RS / BR-R8110-RS)
Remove the wire portion of the assembly tool pulling in the direction of (1), then remove the plastic spacer
portion of the assembly tool in the direction of (2).
(2)
(1)
2.
Secure the brake caliper to the frame base.
Brake fixing screw
5 - 7 Nm
3.
Remove the protection sheet.4.
Temporarily install the brake caliper to the frame base.
Install it together with the assembly tool.
0.5 NmAssembly tool
Brake fixing screw
1.
Installation/removal
Installing the brake calipers
36
Installing the brake caliper (BR-RS811-R)
Remove the wire portion of the assembly tool pulling in the direction of (1), then remove the plastic spacer
portion of the assembly tool in the direction of (2).
(1)
(2)
2.
Secure the brake caliper to the frame base.
5 - 7 Nm Brake fixing screw
3.
Remove the protection sheet.4.
Temporarily install the brake caliper to the frame base.
Install it together with the assembly tool.
Brake fixing screw
0.5 Nm
1.
Installation/removal
Installing the brake calipers
37
Brake shoe setting position The contact angle (toe-in) of the brake shoe against the rim can be adjusted. Setting toe-in enables smooth
braking operation.
Pull out the assembly tool in the direction of the arrow.
Assembly tool
2.
Secure the brake caliper to the frame base.
Brake fixing screw
5 - 7 Nm
3.
Remove the protection sheet.4.
Installation/removal
Brake shoe setting position
38
Securing the BC-9000 cable
Install the brake shoe to the rim surface as shown in the figure.
Direction of rim rotation
Toe-in 0.5 mm 5 - 7 Nm Shoe mounting screw
1 mm or more
Use brake shoes that are appropriate for the rim type and rim outer width. For details, refer to the
Recommended tire size/rim outer width/brake shoe section.
1.
When an inner cable is passed through the outer casing, be sure to wipe the fixing section of the inner
cable before securing the cable. Residual grease in the area of the clamp screw may prevent sufficient
holding force.
When feeding the BC-9000 inner cable through the shift lever or caliper brake, try to minimize the
contact between the cable and the components. If the coating of the cable gets abraded during
installation, it may develop a fuzzy appearance, although this will not affect performance.
Installation/removal
Securing the BC-9000 cable
39
Move the quick release lever to the Close position.
Quick release lever
BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-R8100 / BR-R8110-F / BR-R8110-RS
BR-RS811-R
Quick release lever Open
Close
1.
Wipe off any grease or other lubricants on the inner cable fixing section.2.
Secure the inner cable.
Turn the centering adjustment screw to adjust the shoe clearance to be the same on the left and right (1.5 - 2
mm).
Centering adjustment screwCentering adjustment screw
Shoe clearance Shoe clearance
BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-R8100 / BR-R8110-F / BR-R8110-RS
BR-RS811-R
6 - 8 Nm
6 - 8 Nm
3.
Installation/removal
Securing the BC-9000 cable
40
Cable outer stopper position and appropriate outer casing length (BR-RS811-R)
When caliper brake is open
When the caliper brake is in its resting position, ensure the edge of the outer casing is at least 15 mm from the
smallest chainring. (A 15 mm)
Cut off any excess inner cable.
Install the inner end cap.
4.
After depressing the brake lever several times, there may be a change in the shoe clearance. If necessary,
adjust the shoe clearance again to be the same on the left and right (1.5 - 2 mm).
Adjust the shoe clearance to be the same on the left and right (1.5 - 2 mm).
BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-R8100 / BR-R8110-F / BR-R8110-RS
BR-RS811-R
Shoe clearance
Shoe clearance
Cable adjustment nut
Self-locking nut
5.
Depress the brake lever until it touches the grip about ten times to re-check shoe clearance and each
component for any abnormalities.
6.
Installation/removal
Securing the BC-9000 cable
41
Non -d
riv e
sid e
Cable outer stopper
Smallest chainring
Drive side
Driv e s
id e
BB center
When caliper brake is fully closed
When the caliper is fully closed without a rear wheel, the brake outer casing should be long enough to reach
from the cable outer stopper to the caliper.
Cable outer stopper
Installation/removal
Securing the BC-9000 cable
42
Adjustment Arch spring tension adjustment
BR-RS811-R
If the brake lever is not returning smoothly, you may need to adjust the fixing position of the spring.
Perform this task with the brake caliper removed from the frame.
When using assembly tool
The Assembly Tool (Y8L398040) can aid in reinstallation of the brake caliper after repositioning the spring.
Remove the brake caliper from the frame.1.
Reposition the spring.
Securely attach the spring to the spring attachment pin.
Default setting
(Factory condition) Spring force increase
Spring attachment pin
Spring attachment pin
2.
Adjustment
Arch spring tension adjustment
43
Install the assembly tool to the brake caliper.
Assembly tool
3.
Temporarily install the brake caliper to the frame base.
Install it together with the assembly tool.
Brake fixing screw
0.5 Nm
4.
Pull out the assembly tool in the direction of the arrow.
Assembly tool
5.
Adjustment
Arch spring tension adjustment
44
When not using assembly tool
Secure the brake caliper.
Brake fixing screw
5 - 7 Nm
6.
Remove the brake caliper from the frame.1.
Reposition the spring.
Securely attach the spring to the spring attachment pin.
Default setting
(Factory condition) Spring force increase
Spring attachment pin
Spring attachment pin
2.
Adjustment
Arch spring tension adjustment
45
Readjustment of shoe clearance (when brake shoes are worn) If the clearance with the rim widens due to wear in the brake shoe, readjust the shoe clearance.
Temporarily install the brake caliper to the frame base.
Brake fixing screw
C-arm Y-arm
Half-tighten the Y-arm onto the frame.(1)
Tighten the C-arm onto the frame.(2)
3.
Secure the brake caliper.
Brake fixing screw
5 - 7 Nm
4.
Adjustment
Readjustment of shoe clearance (when brake shoes are worn)
46
Adjusting the reach
Turn the cable adjustment nut/self-locking nut to readjust the shoe clearance.
Adjust the shoe clearance to be the same on the left and right (1.5 - 2 mm).
BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-R8100 / BR-R8110-F / BR-R8110-RS
BR-RS811-R
Shoe clearance
Shoe clearance
Cable adjustment nut Self-locking nut
When the grooves of brake shoe are worn away, replace the brake shoe.
1.
Turn over the bracket cover from the front side.1.
Adjustment
Adjusting the reach
47
Turn the reach adjustment screw to adjust the reach.
Tightening the reach adjustment screw (clockwise) narrows the distance between the initial position of the
brake lever and the handlebar, while loosening the screw (counterclockwise) widens it.
Reach adjustment screw
(1)
(1)
(2) (2)
Use a slotted screwdriver with a blade width of 4.0 - 5.0 mm and blade thickness of 0.5 - 0.6 mm at
the tip.
Make sure that braking operates properly after the adjustment.
2.
Adjustment
Adjusting the reach
48
Maintenance
Maintenance
49
Replacing the cartridge shoe
BR-R9200 / BR-R9210-RS / BR-R8100 / BR-R8110-RS
BR-R9210-F / BR-R8110-F / BR-RS811-R
Remove the fixing screw.
Fixing screw
1.
Remove the shoe by sliding it along the groove of the shoe holder.
Shoe
2.
Slide the new shoes into the grooves on the shoe holders to secure them.
There are two different types of shoe and shoe holder for the left and right respectively. Take note of the
correct directions and screw hole positions for inserting the shoes.
For left (same for front and rear)
For right (same for front and rear)
ShoeShoe
Shoe holder
Shoe holder
Shoe insertion direction
Fixing screw
1 - 1.5 Nm
3.
Remove the fixing screw.
Fixing screw
1.
Maintenance
Replacing the cartridge shoe
50
Brake shoe characteristics The specifications of the brake shoes are subject to change for product improvement.
Remove the shoe by sliding it along the groove of the shoe holder.
Shoe
2.
Slide the new shoes into the grooves on the shoe holders to secure them.
There are two different types of shoe and shoe holder for the left and right respectively. Take note of the
correct directions and screw hole positions for inserting the shoes.
For left For right
ShoeShoe
Shoe holder
Shoe holder
Shoe insertion direction
Front
Fixing screw
1 - 1.5 Nm
Make sure to use the dedicated brake shoe for the shoe holder of the BR-R9210-F / BR-R8110-F / BR-
RS811-R. Other models of brake shoes have different fixing positions preventing the fixing screw
from being tightened, which will cause the brake shoe to come off and disable braking.
Dedicated brake shoes:
R55C4 / R55C4 (for carbon rim) / R55C4-A (for carbon rim) / R55CT4
3.
Maintenance
Brake shoe characteristics
51
Model No. R55C4 R55C4 for carbon rim R55C4-A for carbon rim
Brake shoe shape
Cartridge type X X X
Recommended rim Aluminum Carbon Carbon
Characteristi
cs
DRY Power
WET Power
Silence
Anti-fading
Durability (on-road)
Durability (muddy conditions)
Anti-rim attack
Maintenance
Brake shoe characteristics
52
Model No. R55C3 R55C+1 R55CT4
Brake shoe shape
R 5
5 C
3 R
FO RW
A RD
R 5
5 C
3 R
FO RW
A RD
Cartridge type X X X
Recommended rim Aluminum Aluminum Aluminum
Characteristi
cs
DRY Power
WET Power
Silence
Anti-fading
Durability (on-road)
Durability (muddy conditions)
Anti-rim attack
Replacing the bracket cover Remove the brake cables and electric wires from the dual control levers.1.
Remove the dual control levers from the handlebar.2.
Maintenance
Replacing the bracket cover
53
Remove the bracket cover.
Bracket cover
3.
Install a new bracket cover.
Insert the protrusions on the bracket cover into the recesses in the bracket body when fitting on the bracket
cover.
The inside of the bracket cover has a marking indicating the left side or right side.
Bracket cover
It is easier to perform installation if isopropyl alcohol is applied to the inside of the bracket cover.
4.
Maintenance
Replacing the bracket cover
54
Reinstall the dual control levers.
Install the dual control levers to the handlebar.(1)
Install the electric wires and brake cables to the dual control levers.(2)
5.
Maintenance
Replacing the bracket cover
55
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003
High Tech Campus 92, 5656 AG Eindhoven, The Netherlands Phone: +31-402-612222
3-77 Oimatsu-cho, Sakai-ku, Sakai City, Osaka 590-8577, Japan
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