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Shimano GRX Di2 FD-RX815-F Front Derailleur Dealer's Manual PDF
Summary of Content for Shimano GRX Di2 FD-RX815-F Front Derailleur Dealer's Manual PDF
(English) DM-RX815-02
Dealer's Manual
ROAD MTB Trekking
City Touring/ Comfort Bike
URBAN SPORT E-BIKE
RX815 Series GRX Di2 ST-RX815
FD-RX815
RD-RX815
RD-RX817
DURA-ACE Di2 SW-R9150
EW-RS910
SM-BA01
Non Series SM-EW90-A
SM-EW90-B
SHIMANO Di2 EW-WU111
EW-SD50
EW-SD50-I
EW-JC130
SM-EWC2
SM-JC40
SM-JC41
SM-BTR1
BT-DN110
BT-DN110-A
BM-DN100
SM-BCR1
SM-BCR2
SM-BCC1
Contents
IMPORTANT NOTICE........................................................................................ 4
TO ENSURE SAFETY......................................................................................... 5
List of tools to be used................................................................................. 24
Installation/removal ..................................................................................... 26 Overall wiring diagram (external battery types) .............................................26
Overall wiring diagram (built-in battery types) ...............................................31
Wiring diagram around the cockpit .................................................................34
Handling electric wires ......................................................................................36
Temporarily installing the dual control levers..................................................41
Installing the satellite switch.............................................................................45
Installing junction [A] ........................................................................................49
Installing the wireless unit ................................................................................57
Temporarily installing the front derailleur.......................................................58
Installing the rear derailleur .............................................................................62
Installing the external battery ..........................................................................66
Installing junction [B].........................................................................................73
Installing the built-in type battery....................................................................78
Checking connections ........................................................................................80
Securing the front derailleur.............................................................................82
Installing the disc brake rotor ...........................................................................85
Installing the brake calipers ..............................................................................85
Installing the brake hose ...................................................................................86
Securing the dual control levers .......................................................................94
How to operate............................................................................................. 96 Gear position control.........................................................................................96
Adjustment.................................................................................................... 98 Installing the chain ............................................................................................98
Checking the chain length ................................................................................98
2
Adjusting the rear derailleur...........................................................................100
Adjusting the front derailleur.........................................................................106
Adjusting the dual control levers....................................................................112
Charging the battery .................................................................................. 115 External type ....................................................................................................115
Built-in type......................................................................................................116
Connection and communication with devices.......................................... 120 E-TUBE PROJECT...............................................................................................120
Wireless function .............................................................................................121
Items configurable in E-TUBE PROJECT ..........................................................122
Shift mode setting (synchronized shift)..........................................................122
Maintenance................................................................................................ 125 Replacing the brake pads ................................................................................125
SHIMANO genuine mineral oil replacement..................................................125
Replacing the brake hose ................................................................................141
Caliper piston maintenance ............................................................................146
Replacing the bracket cover............................................................................146
Replacing the pulleys.......................................................................................148
Applying grease to the chain stabilizer..........................................................148
Adjusting friction .............................................................................................151
Replacement of the plate and the plate tension spring ...............................155
3
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.
The Bluetooth word mark and logos are registered trademarks owned by the Bluetooth SIG, Inc. and any use
of such marks by SHIMANO INC. is under license.
Other trademarks and trade names are those of their respective owners.
ANT and ANT+ are trademarks or registered trademarks of ANT Wireless.
IMPORTANT NOTICE
4
TO ENSURE SAFETY
TO ENSURE SAFETY
5
Be sure to also inform users of the following:
Be sure to observe the following instructions in order to avoid burns or other injury from fluid leakage,
overheating, fire, or explosion.
Be sure to observe the following instructions in order to avoid burns or other injury from fluid leakage,
overheating, fire, or explosion.
Lithium-ion battery
Use the designated battery charger to charge the battery. If any non-specified items are used, fire,
overheating or leakage may occur.
Do not heat the battery or expose it to flames. If this is not observed, combustion or bursting of the battery
may occur.
Do not deform, modify, disassemble, or apply solder directly to the battery. Do not use or leave the battery in
places which may exceed 60C in temperature, such as places which are exposed to direct sunlight, inside
vehicles on hot days or near stoves. If this is not observed, leakages, overheating or bursting may cause fire,
burns, or other injuries.
Do not connect the (+) and (-) terminals with metallic objects. Do not carry or store the battery together with
metallic objects such as necklaces or hairpins. If this is not observed, short-circuits, overheating, burns or other
injury may occur.
If any liquid leaking from the battery gets into the eyes, immediately wash the affected area with clean water
without rubbing the eyes, then seek medical attention. If this is not done, blindness may occur.
Battery charger/battery charger cord
Do not get the battery charger wet and do not touch or hold it while it is wet or with wet hands. If this is not
observed, problems with operation or electric shocks may occur.
Do not use the battery charger when it is covered with a cloth or other material. Doing otherwise may cause
the heat to build up and the case may become deformed, or fire, ignition, or overheating may occur.
Do not disassemble or modify the battery charger. If this is not observed, electric shocks or injury may occur.
Use the battery charger at the specified power supply voltage only. If a power supply voltage other than that
specified is used, fire, destruction, smoke, overheating, electric shocks or burns may occur.
Do not touch the metallic parts of the device or the power plug on the AC adapter or other parts if there is a
lightning storm. If lightning strikes, electric shocks may occur.
SM-BCR2: Battery charger for SM-BTR2/BT-DN110/BT-DN110-A
Use an AC adapter with a USB port that has a voltage of 5.0 V DC and a current equal to or higher than 1.0 A
TO ENSURE SAFETY
6
DC. If one with a current lower than 1.0 A is used, the AC adapter may heat up, potentially causing a fire,
smoke, overheating, destruction, electric shock, or burns.
TO ENSURE SAFETY
7
Be sure to also inform users of the following:
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.
This dealer's manual is for use with the SHIMANO GRX RX815 series (electronic gear shifting system) only.
For information on products not explained in this manual, search for the model on our website (
https://si.shimano.com ).
Clean the chain with an appropriate chain cleaner regularly. Intervals between maintenance depend on the
use and riding circumstances.
Never use alkali-based or acid-based solvents such as rust cleaners. If those solvents are used the chain might
break and cause serious injury.
Check that the wheels are fastened securely before riding the bicycle. Otherwise, you may fall and be seriously
injured.
Check the chain for any damage (deformation or cracking), skipping, or other abnormalities such as
unintended gear shifting. If any problems are found, consult your place of purchase or a distributor. The chain
may break, and you may fall.
Be careful not to let the hemming of your clothes get caught in the chain while riding. Otherwise, you may
fall off the bicycle.
Lithium-ion battery
Do not place the battery into fresh water or sea water, and do not allow the battery terminals to get wet. If
this is not observed, fire, bursting, ignition, or overheating may occur.
Do not use the battery if it has any noticeable scratches or other external damage. If this is not observed,
bursting, overheating or problems with operation may occur.
Do not throw or subject the battery to strong shock. If this is not observed, bursting, overheating or problems
with operation may occur.
Do not use the battery if leakages, discoloration, deformation or any other abnormalities occur. If this is not
observed, bursting, overheating or problems with operation may occur.
If any leaked fluid gets on your skin or clothes, wash it off immediately with clean water. The leaked fluid may
damage your skin.
Do not use the battery outside its operating temperature ranges. If the battery is used or stored in
temperatures which are outside these ranges, fire, injury or problems with operation may occur. The
TO ENSURE SAFETY
8
SM-BTR1: Lithium-ion battery (external type)
SM-BTR2/BT-DN110/BT-DN110-A: Lithium-ion battery (built-in type)
SM-BCR1: Battery charger for SM-BTR1
SM-BCR2: Battery charger for SM-BTR2/BT-DN110/BT-DN110-A
operating temperature ranges are given below:
During discharge: -10C - 50C(1)
During charging: 0C - 45C(2)
If the battery does not become fully charged within the charging time, stop charging. If this is not observed,
fire, bursting, ignition, or overheating may occur.
If the battery does not become fully charged after 4 hours of charging, stop charging. If this is not observed,
fire, bursting, ignition, or overheating may occur.
Battery charger/battery charger cord
Hold the power plug when connecting or disconnecting from the electrical outlet. Failure to do so may cause
a fire or electric shock.
If the following symptoms are observed, stop using the device and contact your place of purchase. A fire or
electric shock may be caused.
If the power plug is smoking or generating heat.
There may be a bad connection inside the power plug.
Do not overload the electrical outlet with appliances beyond its rated capacity, and use only a 100 V - 240 V
AC electrical outlet. If the electrical outlet is overloaded by connecting too many appliances using adapters,
overheating resulting in fire may occur.
Do not damage the power cord or power plug. (Do not damage, modify, forcibly bend, twist or pull it, put it
near hot objects, place heavy objects on it or bundle it tightly together.) If it is used while damaged, fire,
electric shocks or short-circuits may occur.
Do not use the battery charger with commercially-available electrical transformers designed for overseas use
(travel converters). They may damage the battery charger.
Always be sure to insert the power plug as far as it will go. If this is not observed, fire may occur.
Do not use any USB cable other than the USB cable which is supplied with the PC linkage device. This may
cause a charging error, fire, or failure to connect to PC due to overheating.
Do not connect the battery charger to PC when it is on standby. This may cause a PC failure depending on its
specifications.
*
*
TO ENSURE SAFETY
9
When connecting or disconnecting the USB cable or the charging cable, be sure to hold the cable by the plug.
Failure to do so may cause a fire or electric shock.
If the following symptoms are observed, stop using the device and contact your place of purchase. A fire or
electric shock may be caused.
If the power plug is smoking or generating heat.
There may be a bad connection inside the power plug.
If it thunders while charging with an AC adapter with a USB port, do not touch the device, bicycle, or the AC
adapter. If lightning strikes, electric shocks may occur.
Use an AC adapter with a USB port that has a voltage of 5.0 V DC and a current equal to or higher than 1.0 A
DC. If one with a current lower than 1.0 A DC is used, a charging error may occur or the AC adapter may heat
up, leading to a fire.
Do not use a USB hub when connecting the cable to a computer USB port. This may cause a charging error or
fire due to overheating.
Be careful not to damage the charging cable. (Do not damage, modify, forcibly bend, twist or pull it, put it
near hot objects, place heavy objects on it or bundle it tightly together.) If it is used while damaged, fire,
electric shocks or short-circuits may occur.
Brake
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, you may fall and be seriously injured.
Hydraulic disc brake
Please use extra caution to keep your fingers away from the rotating disc brake rotor. The disc brake rotor is
sharp enough to inflict severe injury to your fingers if caught within the openings of moving rotor.
*
*
TO ENSURE SAFETY
10
0.5 mm2 mm
For installation to the bicycle and maintenance
Do not touch the calipers or disc brake rotor while riding or immediately after dismounting from the bicycle.
The calipers and disc brake rotor will become hot when the brakes are operated, so you may get burned if you
touch them.
Do not allow any oil or grease to get onto the disc brake rotor and brake pads. Riding the bicycle with oil or
grease on the disc brake rotor and brake pads may prevent the brakes from operating and result in serious
injury due to a fall or collision.
Check the thickness of the brake pads and do not use them if they have a thickness of 0.5 mm or less. Doing so
may prevent the brakes from operating and result in serious injury due to a fall or collision.
Do not use the disc brake rotor if it is cracked or deformed. The disc brake rotor may break, and result in
serious injury due to a fall.
Do not use the disc brake rotor if its thickness is 1.5 mm or less. Also do not use it if the aluminum surface
becomes visible. The disc brake rotor may break, and result in serious injury due to a fall.
Do not continuously apply the brakes. Doing so may cause a sudden increase in the brake lever stroke,
preventing the brakes from operating and resulting in serious injury due to a fall or collision.
Do not use the brakes with fluid leaking. Doing so may prevent the brakes from operating and result in
serious injury due to a fall or collision.
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.
Hydraulic disc brake
Please make sure to keep your fingers away from the rotating disc brake rotor during installation or
maintenance of the wheel. The disc brake rotor is sharp enough to inflict severe injury to your fingers if
caught within the openings of moving rotor.
TO ENSURE SAFETY
11
Screw fixing pin
Do not use the disc brake rotor if it is cracked or warped. The disc brake rotor may break, and result in serious
injury due to a fall.
Do not use the disc brake rotor if its thickness is 1.5 mm or less. Also do not use it if the aluminum surface
becomes visible. The disc brake rotor may break, and result in serious injury due to a fall. Replace the disc
brake rotor with a new one.
The calipers and disc brake rotor will become hot when the brakes are operated; do not touch them while
riding or immediately after dismounting from the bicycle. Otherwise, you may get burned.
Do not use oil other than SHIMANO genuine mineral oil. Doing so may prevent the brakes from operating and
result in serious injury due to a fall or collision.
Use only mineral oil from a container that has been stored in a clean and sealed state. Doing so may prevent
the brakes from operating and result in serious injury due to a fall or collision.
Do not let water or air bubbles get into the brake system. Doing so may prevent the brakes from operating
and result in serious injury due to a fall or collision.
If the quick release lever is on the same side as the disc brake rotor, confirm that it does not interfere with the
disc brake rotor. Otherwise, the bicycle may fall forward, and serious injury may result.
Do not use with a tandem bicycle. Doing so may prevent the brakes from operating and result in serious injury
due to a fall or collision.
When installing the brake caliper using screw fixing pins, be sure to use fixing screws of the appropriate
length.
If not, the screw fixing pins may not be securely fastened, and the screws may fall out.
Brake hose
The connector insert is for this brake hose only. Use an appropriate connector insert according to the
following table. Use of a connector insert incompatible with the brake hose may cause fluid leaks.
Model number Length Color
SM-BH90-JK-SSR 11.2 mm Silver
Do not reuse the olive piece or the connector insert when reinstalling. Doing so may prevent the brakes from
operating and result in serious injury due to a fall.
TO ENSURE SAFETY
12
EW-RS910 (Built-in bar end type)
Cut end
Flare nut
Brake hose
Olive
Connector insert
Cut the brake hose so that the cut end is perpendicular to the length of the hose. If the brake hose is cut at an
angle, fluid leaks may result.
90
Points to note about the handlebars
Handlebar inner diameter: 20.5 - 21.5 mm
Handlebar outer diameter: 23.8 - 24.2 mm
TO ENSURE SAFETY
13
Be sure to also inform users of the following:
SM-BTR1: Lithium-ion battery (external type)
SM-BTR2/BT-DN110/BT-DN110-A: Lithium-ion battery (built-in type)
SM-BCR1: Battery charger for SM-BTR1
SM-BCR2: Battery charger for SM-BTR2/BT-DN110/BT-DN110-A
Cautions on SHIMANO genuine mineral oil
Bed-in period
For installation to the bicycle and maintenance
Lithium-ion battery
Store the product in a safe place out of the reach of infants and pets.
When you do not use the battery for a long period, remove and charge the battery before storage.
When you do not use the battery for a long period, charge the battery before storage.
Battery charger/battery charger cord
Disconnect the power plug from the electrical outlet when performing maintenance.
Disconnect the USB cable or the charging cable when performing maintenance.
Hydraulic disc brake
Use appropriate eye protection when handling, and avoid contact with eyes. In the event of eye contact, flush
with fresh water and seek medical assistance immediately. Contact with eyes may result in irritation.
Use gloves when handling. In the event of skin contact, wash well with soapy water. Contact with skin may
cause a rash and discomfort.
Cover nose and mouth with a respirator type mask and use in a well ventilated area. Inhalation of mineral oil
mist or vapors may cause nausea. If mineral oil mist or vapor is inhaled, go immediately to an area with fresh
air. Cover up with a blanket. Stay warm and stable and seek professional medical advice.
Disc brakes have a bed-in period, and the braking force will gradually increase as the bed-in period progresses.
Accidents or falls may occur due to losing control of the bicycle, possibly resulting in serious injury. The same
thing will happen when the brake pads or disc brake rotor are replaced.
Hydraulic disc brake
TO ENSURE SAFETY
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Handling SHIMANO genuine mineral oil
Brake hose
Do not drink. May cause vomiting or diarrhea.
Keep out of reach of children.
Do not cut, let near heat, weld or pressurize the SHIMANO genuine mineral oil container. Doing so may cause
an explosion or fire.
Disposal of used oil: Follow local county and/or state codes for disposal.
Directions: Keep the container sealed to prevent foreign objects and moisture from getting inside, and store it
in a cool, dark area away from direct sunlight or heat. Keep from heat or flame
For cleaning brake hoses exposed to mineral oil, or cleaning and maintaining tools, use isopropyl alcohol or a
dry cloth. Do not use commercially available brake cleaners. Doing so may cause damage to plastic parts.
When cutting the brake hose, handle the knife carefully so as not to cause injury.
Be careful to avoid injury from the olive.
TO ENSURE SAFETY
15
Be sure to also inform users of the following:
Be sure to rotate the crank arm when carrying out any operations which are related to gear shifting.
The connectors are small and waterproof, so do not connect and disconnect electric wires except when
necessary. Doing so may impair the waterproofing.
Be careful not to get water into the E-TUBE ports.
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 with a high-pressure washer. If water gets into any of the components, operating
problems or rusting may result.
Be sure to keep rotating the crank arm during gear shifting operations.
Handle the components carefully, and avoid subjecting them to strong shock.
Do not use the thinners or harsh solvents to clean the products. Such substances may damage the surface.
If gear shifting operation does not feel smooth, consult the place of purchase for assistance.
Keep away from magnetic objects. If this is not observed, problems with operation may occur.
When installing a product that uses a magnet, make sure the magnet is set in the specified location before
installing the product.
Contact the place of purchase for updates of the component software. The most up-to-date information is
available on the SHIMANO website.
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.
Lithium-ion battery
Lithium-ion batteries are recyclable, valuable resources.
For information on used batteries, contact the place of purchase or a distributor.
Charging can be carried out at any time regardless of the battery level. Always be sure to use the special
battery charger to charge the battery until it is fully recharged.
The battery is not fully charged at the time of purchase. Before riding, be sure to fully charge the battery.
When the battery is completely depleted, charge it as soon as possible. If you leave the battery without
charging it, it will cause the battery to deteriorate.
The battery is an exhaustible item. The battery will gradually lose its capacity to charging after repeated use. If
the length of time that the battery can be used becomes extremely short, it has probably reached the end of
its life, and so you will need to purchase a new battery.
The life of the battery will vary depending on factors such as the storage method, the usage conditions, the
TO ENSURE SAFETY
16
SM-BTR1: Lithium-ion battery (external type)
SM-BTR2/BT-DN110/BT-DN110-A: Lithium-ion battery (built-in type)
surrounding environment and the characteristics of the individual battery pack.
If storing the battery away for a long period, remove it when the battery level is 50% or higher or when the
green indicator is illuminating in order to prolong its useful life. It is recommended that you charge the
battery every six months.
If the storage temperature is too high, the performance of the battery is reduced, and its useable time will be
shorter. When you use the battery after a long storage period, store the battery indoors where the battery
will not be exposed to direct sunlight or rain.
If the ambient temperature is too low, the battery's usable time will be shorter.
When storing the battery away, remove the battery from the bicycle and install the terminal cover first.
The charging time is approximately 1.5 hours. (Note that the actual time will vary depending on the remaining
battery charge.)
If the battery feels difficult to insert or remove, apply specified grease (Premium Grease) to the part that
touches the O-ring at the side.
After removing the battery from the bicycle for storage, install a dummy plug to each port.
The charging time of an AC adapter with a USB port is about 1.5 hours, and that of computer USB port type
about 3 hours. (Note that the actual time will vary depending on the amount of charge remaining in the
battery. Depending on the specifications of the AC adapter, recharging via the AC adapter may require as
much time (about 3 hours) as recharging via PC.)
Battery charger/battery charger cord
Use this instrument under the direction of a safety supervisor or the direction for use. Do not allow anyone
(including children) with reduced physical, sensual, or mental capacity, or those without experience or
knowledge, to use the product.
Do not allow children to play near the product.
Disposal information for countries outside the European Union
This symbol is only valid within the European Union.
Contact the place of purchase or a distributor for advice on disposing.
Charge the battery indoors to avoid exposure to rain or wind.
Do not use outdoors or in environments with high humidity.
Do not place the battery charger on dusty floors when using it.
Place the battery charger on a stable surface such as a table when using it.
TO ENSURE SAFETY
17
SM-BCR2: Battery charger/PC linkage device for SM-BTR2/BT-DN110/BT-DN110-A
Do not place any objects on top of the battery charger or its cable.
Do not bundle the cables.
Do not hold the battery charger by the cables when carrying it.
Do not apply excessive tension to the cables.
Do not wash the battery charger or wipe it using detergents.
Connect the PC linkage device directly to the USB port on a PC, without using an intermediate device such as a
USB hub.
Do not ride the bicycle while the PC linkage device and cable are still connected to it.
Do not connect two or more of the same units to the same connection point. If this is not done, the units may
not operate correctly.
Do not connect or disconnect units again while unit recognition is in progress or after recognition is complete.
If this is not done, the units may not operate correctly.
Check the procedures which are given in the user's manual for the E-TUBE PROJECT when connecting and
disconnecting units.
The tightness of the PC link cable will tend to drop after repeated connections and disconnections. If this
happens, replace the cable.
Do not connect two or more PC linkage devices at the same time. If two or more PC linkage device units are
connected, they will not operate correctly. In addition, the PC may need to be restarted if operating errors
occur.
PC linkage devices cannot be used while the battery charger is connected.
Rear derailleur
If gear shifting operation does not feel smooth, consult the place of purchase for assistance.
If you feel the chain or other drivetrain components skipping, consult the place of purchase for assistance.
If the pulleys of the derailleur develop excess play or noise, consult the place of purchase for assistance.
The gears should be periodically washed with a neutral detergent. In addition, cleaning the chain with neutral
detergent and lubricating it can be an effective way of extending the life of the gears and the chain.
Hydraulic disc brake
When the bicycle wheel has been removed, it is recommended that pad spacers are installed. Do not depress
the brake lever while the wheel is removed. If the brake lever is depressed without the pad spacers installed,
the pistons will protrude further than normal. If that happens, consult a place of purchase.
When conducting maintenance, do not use commercially available brake cleaners or silencing agents, as they
TO ENSURE SAFETY
18
For installation to the bicycle and maintenance
can cause damage to parts such as the seals.
Wireless unit
If using EW-WU111, use it together as a set with one of the following units.
External type: BM-DN100, built-in type: BT-DN110/BT-DN110-A
The connectors are small and waterproof, so do not connect and disconnect electric wires except when
necessary. Doing so may impair the waterproofing.
Be careful not to get water into the E-TUBE ports.
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 with a high-pressure washer. If water gets into any of the components, operating
problems or rusting may result.
Handle the components carefully, and avoid subjecting them to strong shock.
As shown in the figure, install the product so that it does not reach the side of the bicycle body.
Otherwise, it could be damaged if the bicycle tips over and it is pinched between the frame and curb.
Do not use the thinners or harsh solvents to clean the products. Such substances may damage the surface.
Do not leave the product in an area exposed to strong sunlight for an extended period of time.
Do not disassemble the product as it cannot be reassembled.
When cleaning the product, use a cloth moistened with a diluted neutral detergent.
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.
Be sure to use SHIMANO original tool TL-EW02 to remove the electric wires.
Contact SHIMANO INC. for information regarding the shipment of the battery charger to South Korea and
Malaysia.
Use a brake hose/outer casing 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
TO ENSURE SAFETY
19
the handlebars are turned all the way.
The clamp band, clamp bolt and clamp nut are not compatible with other products. Be sure to always use the
clamp band, clamp bolt and clamp nut which is specific to each product.
Electric wires/electric wire covers
Secure the electric wires with a zip tie so that they do not interfere with the chainrings, sprockets or tires.
The strength of the adhesive is fairly weak to prevent the paint on the frame from being peeled off at when
removing the electric wire cover, such as when replacing the electric wires. If the electric wire cover is peeled
off, replace it with a new one. When removing the electric wire cover, do not peel it off too vigorously. If so,
the paint on the frame will peel off, too.
Do not remove the wire holders which are attached to the built-in type electric wires (EW-SD50-I). The wire
holders prevent the electric wires from moving inside the frame.
When installing to the bicycle, do not forcibly bend the electric wire plug. It may result in a poor connection.
Rear derailleur
Be sure to adjust the high limit screw and the low limit screw according to the instructions given in the
adjustment section.
If these are not adjusted, the chain may become clamped between the spokes and the largest sprocket and
the wheel may lock, or the chain may slip onto the small sprocket.
Periodically clean the shifting unit and lubricate all moving parts (mechanism and pulleys).
If gear shifting adjustments cannot be carried out, check the degree of parallelism of the dropout.
The guide pulley and tension pulley have an arrow on one side to indicate the direction of rotation. When
installing the pulleys, install so that the surfaces with arrows are on the inner side when looking from the
outer side of the shifting unit.
Hydraulic disc brake
If the brake caliper mounting boss and the dropout are not of standard dimensions, the disc brake rotor and
caliper may touch.
When the bicycle wheel has been removed, it is recommended that pad spacers are installed. The pad spacers
will prevent the piston from coming out if the brake lever is depressed while the wheel is removed.
If the brake lever is depressed without the pad spacers installed, the pistons will protrude further than normal.
Use a slotted screwdriver or other tool to push open the brake pads, while being careful not to damage the
surfaces of the brake pads. (If the brake pads are not installed, use a flat-shaped tool to push the pistons
straight back in, while being careful not to damage them.)
If it is difficult to push the brake pads or pistons back, remove the bleed screws and try again. (Note that some
oil may overflow from the reservoir tank at this time.)
TO ENSURE SAFETY
20
The actual product may differ from the illustration because this manual is
intended mainly to explain the procedures for using the product. For installation to the bicycle
Be sure to also inform users of the following:
In the case of using SM-BTR1
Use isopropyl alcohol, soapy water or a dry cloth when cleaning and carrying out maintenance of the brake
system. Do not use commercially available brake cleaners or silencing agents. Such substances can cause
damage to parts such as seals.
If the disc brake rotor is worn, cracked or warped, it should be replaced.
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.
Notes on reinstalling and replacing components
When the product is reinstalled or replaced, it is automatically recognized by the system to allow operation
according to the settings.
If the system does not operate after reassembly and replacement, follow the system power reset procedure
below to check the operation.
If the component configuration changes or malfunction is observed, use the E-TUBE PROJECT software to
update the firmware of each component to the latest version and perform a check again. Also make sure that
the E-TUBE PROJECT software is the latest version. If the software is not the latest version, the component
compatibility or the product functions may not be available.
About used batteries
Lithium-ion batteries are recyclable, valuable resources.
For information on used batteries, contact the place of purchase or a distributor.
About system power reset
When the system fails to operate, it may be recovered by resetting the system power.
After the battery is removed, about one minute is usually required for the system power to reset.
Remove the battery from the battery mount. After about one minute, install the battery.
TO ENSURE SAFETY
21
If using SM-BTR2/BT-DN110/BT-DN110-A
About compatibility with E-TUBE
Disconnect the plug from SM-BTR2/BT-DN110/BT-DN110-A. After about one minute, insert the plug.
Connection and communication with PC
PC linkage devices can be used to connect a PC to the bicycle (system or components), and E-TUBE PROJECT
can be used to carry out tasks such as customizing single components or the whole system and updating their
firmware.
If your versions of E-TUBE PROJECT software and firmware for each component are not up to date, there
could be problems operating the bicycle. Check the software version and update it to the latest one.
PC linkage device E-TUBE PROJECT Firmware
SM-BMR2/SM-BTR2
SM-PCE1/SM-BCR2 Version 3.4.0 or later
Version 3.0.0 or later
BT-DN110/BT-DN110-A/BM-
DN100
Version 4.0.0 or later
Connection and communication with smartphone or tablet
E-TUBE PROJECT for smartphones/tablets can be used to carry out tasks such as updating firmware and
customizing single components or the whole system, after connecting the bicycle (system or components) to a
smartphone or tablet via Bluetooth LE.
E-TUBE PROJECT: Application for smartphones/tablets
Firmware: Software inside each component
Disconnect the Bluetooth LE connection when not using E-TUBE PROJECT for smartphones/tablets.
Using a wireless unit without disconnecting the Bluetooth LE connection could increase battery consumption.
Check the following website for information on compatibility with each unit and functional limitations.
( https://bike.shimano.com/e-tube/project/compatibility.html#guide_list )
About the multi-shifting function
Connecting this system to E-TUBE PROJECT and switching [Multi shift] to [ON] will allow you to continuously
shift gears while the shift switch is held down. When modifying this setting, carefully read Items
configurable in E-TUBE PROJECT in this dealer's manual.
Gear-shifting interval
[Gear-shifting interval] can be set to one of five levels as a multi-shifting function setting in E-TUBE PROJECT:
[Very fast], [Fast], [Normal], [Slow], or [Very slow] (Default: [Normal]).
TO ENSURE SAFETY
22
A faster [Gear-shifting interval] setting will result in faster gear shifting. The rider can quickly adjust the
traveling speed and the speed at which the crankset turns (cadence below) in response to changes in riding
conditions.
However, if a gear shifting operation is performed at an insufficient cadence when the system is set to a fast
gear-shifting interval, the chain may be unable to follow the movement of the rear derailleur, resulting in the
following problems:
The chain may slip over the tip of the cassette sprocket teeth
The cassette sprocket may deform
The chain may break
Fully understand the features of the gear-shifting interval, then set the gear-shifting interval according to the
riding conditions, such as the terrain and the riding style of the rider.
Gear-shifting interval Benefits Drawbacks
Fast setting
Slow setting
Quick multi-shifting is possible
The rider can quickly adjust the cadence or
traveling speed in response to changes in the
riding conditions
A high cadence is required when gear shifting
Unintended over-shifting occurs easily
Gear shifting can be performed reliably Gear shifting takes some time
TO ENSURE SAFETY
23
List of tools to be used The following tools are needed for installation, adjustment, and maintenance purposes.
Junction [A]
Tool
TL-EW02
2 mm hexagon wrench
Junction [B]
Tool
TL-EW02
3 mm hexagon wrench
Wireless unit
Tool
TL-EW02
Battery, battery mount
Tool
TL-EW02
2 mm hexagon wrench
2.5 mm hexagon wrench
3 mm hexagon wrench
Internal snap ring pliers (1.8 mm)
Dual control lever, satellite switch
List of tools to be used
24
Tool
TL-EW02
SM-DISC
TL-BH62
TL-BT03 / TL-BT03-S
Funnel adapter
2 mm hexagon wrench
2.5 mm hexagon wrench
5 mm hexagon wrench
7 mm box wrench
8 mm spanner
Front derailleur
Tool
TL-EW02
2 mm hexagon wrench
5 mm hexagon wrench
Rear derailleur
Tool
TL-EW02
2 mm hexagon wrench
3 mm hexagon wrench
4 mm hexagon wrench
5 mm hexagon wrench
Cross head screwdriver [#2]
Hexalobular [#30]
5.5 mm spanner
List of tools to be used
25
Installation/removal Overall wiring diagram (external battery types) When routing wires through the inside of the frame, be sure to do so before installing each component. The
wiring diagram for using an external battery is shown below.
Wiring example for installing junction [B] on the outside
In this wiring example, junction [B] is located on the lower side of the frame. In many cases, most of the wiring
will be external.
When using junction [A] on the outside
Use an external type junction [A]. In this wiring example, all electric wires are external.
(A) (B)
(C) (H)
(I)
(J)
(G) (D)
(E)
(F)
Wiring component parts
(A) Battery mount: SM-BMR2 / BM-DN100 (B) Lithium-ion battery (external type): SM-BTR1
(C) Junction [A]: SM-EW90-A / SM-EW90-B (D) Junction [B]: SM-JC40
Electric wire (EW-SD50)
When passing the wires through the inside of the frame, especially when pulling junction [B] into the
frame, it is necessary to finish wiring and check the connection before installing the bottom bracket.
This is particularly important when you use a press-fit bottom bracket.
Installation/removal
Overall wiring diagram (external battery types)
26
(E) From battery mount to junction [B] (E) + (F) 900 mm
(E) + (G) 1,100 mm (F) From front derailleur to junction [B]
(G) From rear derailleur to junction [B]
(H) From dual control lever to junction [A] (H), (I) 500 mm
(I) From dual control lever to junction [A]
(J) From junction [A] to junction [B] (J) 1,400 mm
When using junction [A] on the inside
Use a built-in type junction [A]. In this wiring example, some of the wiring will be inside the handlebar.
The wireless unit can be used to send the current gear position and other information to an external device.
Built-in frame type
Built-in bar end type
(A) (B)
(C)
(D) (E) (F)
(G)
(H)
(I)
(C)
(J)
(E) (F)
Wiring component parts
(A) Battery mount: SM-BMR2 / BM-DN100 (B) Lithium-ion battery (external type): SM-BTR1
(C) Junction [A]: EW-RS910 (Built-in bar end type /
built-in frame type)
(D) Junction [B]: SM-JC40
(E) Wireless unit: EW-WU111 (F) Branch type junction: EW-JC130
Electric wire (EW-SD50 / EW-SD50-I)
Installation/removal
Overall wiring diagram (external battery types)
27
(G) From battery mount to junction [B] (G) + (H) 900 mm
(G) + (I) 1,100 mm (H) From front derailleur to junction [B]
(I) From rear derailleur to junction [B]
(J) From wireless unit to junction [B] (J) 1,400 mm
About the branch type junction (EW-JC130)
Three types of EW-JC130 are available.
L1 L3
L2
L1 (mm) L2 (mm) L3 (mm)
EW-JC130-SS 350 50 250
EW-JC130-SM 350 50 450
EW-JC130-MM 550 50 550
Wiring example for installing junction [B] on the inside
In this wiring example, most of the wires are routed through the inside of the frame by installing junction [B]
inside the frame.
When using junction [A] on the outside
Use an external type junction [A]. This wiring example shows a configuration where most of the wiring (except
for around the battery and cockpit) is inside the frame.
If using EW-WU111, use it in combination with BT-DN110, BT-DN110-A or BM-DN100.
Refer to the dealer's manual for EW-WU101 ( https://si.shimano.com/dm/RBWU001/ ) for information on
wiring when using EW-WU101 as the wireless unit.
Installation/removal
Overall wiring diagram (external battery types)
28
(A) (B)
(D) (E)
(F)
(G)
(H)
(I)
(J)
(C)
Wiring component parts
(A) Battery mount: SM-BMR2 / BM-DN100 (B) Lithium-ion battery (external type): SM-BTR1
(C) Junction [A]: SM-EW90-A / SM-EW90-B (D) Junction [B]: SM-JC41
Electric wire (EW-SD50 / EW-SD50-I)
(E) From built-in type battery to junction [B] (E) + (F) 1,500 mm
(E) + (G) 1,700 mm (F) From front derailleur to junction [B]
(G) From rear derailleur to junction [B]
(H) From dual control lever to junction [A] (H), (I) 500 mm
(I) From dual control lever to junction [A]
(J) From junction [A] to junction [B] (J) 1,400 mm
When using junction [A] on the inside
Use a built-in type junction [A]. This wiring example shows a configuration where most of the wiring (except for
around the battery and cockpit) is inside the frame. The wireless unit can be used to send the current gear
position and other information to an external device.
Installation/removal
Overall wiring diagram (external battery types)
29
Built-in frame type
Built-in bar end type
(A) (B)
(C)
(D) (E) (F)(G)
(H)
(I)
(C)
(J)
(E) (F)
Wiring component parts
(A) Battery mount: SM-BMR2 / BM-DN100 (B) Lithium-ion battery (external type): SM-BTR1
(C) Junction [A]: EW-RS910 (Built-in bar end type /
built-in frame type)
(D) Junction [B]: SM-JC41
(E) Wireless unit: EW-WU111 (F) Branch type junction: EW-JC130
Electric wire (EW-SD50-I)
(G) From battery mount to junction [B] (G) + (H) 1,500 mm
(G) + (I) 1,700 mm (H) From front derailleur to junction [B]
(I) From rear derailleur to junction [B]
(J) From wireless unit to junction [B] (J) 1,400 mm
For EW-JC130, refer to About the branch type junction (EW-JC130) .
If using EW-WU111, use it in combination with BT-DN110, BT-DN110-A or BM-DN100.
Refer to the dealer's manual for EW-WU101 ( https://si.shimano.com/dm/RBWU001/ ) for information on
wiring when using EW-WU101 as the wireless unit.
Installation/removal
Overall wiring diagram (external battery types)
30
Overall wiring diagram (built-in battery types) When routing wires through the inside of the frame, be sure to do so before installing each component. The
wiring diagram for using a built-in type battery is shown below.
Wiring example for installing junction [A] on the outside
Use an external type junction [A]. In this wiring example, most of the wires excluding the wires around the
cockpit are routed through the inside of the frame.
(A) (B)
(H) (D)
(G)
(I)
(C)
(E)
(F)
Wiring component parts
(A) Lithium-ion battery (built-in type): BT-DN110 / BT-
DN110-A
(B) Junction [A]: SM-EW90-A / SM-EW90-B
(C) Junction [B]: SM-JC41
Electric wire (EW-SD50 / EW-SD50-I)
When passing the wires through the inside of the frame, especially when pulling junction [B] into the
frame, it is necessary to finish wiring and check the connection before installing the bottom bracket.
This is particularly important when you use a press-fit bottom bracket.
Installation/removal
Overall wiring diagram (built-in battery types)
31
(D) From built-in type battery to junction [B] (D) + (E) 1,500 mm
(D) + (F) 1,700 mm (E) From front derailleur to junction [B]
(F) From rear derailleur to junction [B]
(G) From dual control lever to junction [A] (G), (H) 500 mm
(H) From dual control lever to junction [A]
(I) From junction [A] to junction [B] (I) 1,400 mm
Wiring example for installing junction [A] on the inside
Use a built-in type junction [A]. In this wiring example, as many wires as possible as well as the battery are routed
through the inside of the frame. The wireless unit can be used to send the current gear position and other
information to an external device.
Built-in frame type
Built-in bar end type
(A)
(C)
(D)
(D) (E)
(G)
(H)
(B)
(I)
(E)
(F)
(B)
Wiring component parts
(A) Lithium-ion battery (built-in type): BT-DN110 / BT-
DN110-A
(B) Junction [A]: EW-RS910 (Built-in bar end type /
built-in frame type)
(C) Junction [B]: SM-JC41 (D) Wireless unit: EW-WU111
(E) Branch type junction: EW-JC130
Electric wire (EW-SD50-I)
Installation/removal
Overall wiring diagram (built-in battery types)
32
(F) From built-in type battery to junction [B] (F) + (G) 1,500 mm
(F) + (H) 1,700 mm (G) From front derailleur to junction [B]
(H) From rear derailleur to junction [B]
(I) From wireless unit to junction [B] (I) 1,400 mm
For EW-JC130, refer to About the branch type junction (EW-JC130) .
If using EW-WU111, use it in combination with BT-DN110, BT-DN110-A or BM-DN100.
Refer to the dealer's manual for EW-WU101 ( https://si.shimano.com/dm/RBWU001/ ) for information on
wiring when using EW-WU101 as the wireless unit.
Installation/removal
Overall wiring diagram (built-in battery types)
33
Wiring diagram around the cockpit
Wiring example for installing junction [A] on the outside
E-TUBE port 2
E-TUBE port 2
E-TUBE port 3Satellite switch
SW-R9150
Satellite switch SW-R9150
Junction [A]
Dual control lever Dual control lever
E-TUBE port 5
Junction [A] Junction [B]
ST-RX815-L ST-RX815-R
SM-EW90-A
SM-EW90-B EW-JC40/EW-JC41
Installation/removal
Wiring diagram around the cockpit
34
Wiring example for installing junction [A] inside the handlebar
E-TUBE port 2
E-TUBE port 2
E-TUBE port 2
SW-R9150 Satellite switch
40 mm or more
Dual control lever
To junction [B]
Wireless unit EW-WU111
Branch type junction
Junction [A] EW-RS910
ST-RX815-L Dual control lever
ST-RX815-R
EW-JC130
Installation/removal
Wiring diagram around the cockpit
35
Wiring example for installing junction [A] inside the frame
Dual control lever Dual control lever
Installed inside the frame and to junction [A] (EW-RS910)
Wireless unit EW-WU111
Branch type junction
SW-R9150 Satellite switch
E-TUBE port 2
E-TUBE port 2
ST-RX815-L ST-RX815-R
EW-JC130
Handling electric wires Be sure to use the SHIMANO original tool to remove and insert electric wires.
Connecting the electric wire
Connect the electric wire to the E-TUBE port.
When connecting and disconnecting electric wires, do not forcibly bend the plug part. It may result in a
poor connection.
Installation/removal
Handling electric wires
36
Set the plug part of the electric wire to the SHIMANO original tool.
If there is an alignment tab on the plug part of the electric wire, set it aligned with the groove on the
SHIMANO original tool.
Without alignment tab on plug With alignment tab on plug
1.
Insert the plug part on the electric wire into the E-TUBE port.
Push it straight in until you feel it click into place.
E-TUBE port
Plug part
2.
Installation/removal
Handling electric wires
37
Disconnecting the electric wire
Insertion direction of the electric wires for internal use
Electric wires for internal use come with wire holders to prevent the electric wires from moving inside the frame.
When passing an electric wire for internal use through the frame, insert in the direction shown in the figure.
Wire holder Frame wiring hole
Finishing for external wiring
When wiring the electric wire outside the frame, use an electric wire cover.
Remove the electric wire.
(2)(1)
(A)
Insert the SHIMANO original tool into the groove on the plug part of the electric wire.(1)
Disconnect the electric wire from the E-TUBE port.
* As shown in the figure, use part (A) of the SHIMANO original tool as a fulcrum and move it like a
lever, then disconnect it. If there is limited space to insert the tool, lift the SHIMANO original tool
straight up and disconnect the electric wire.
(2)
Do not repeatedly connect and disconnect the electric wire too often. The connector may become
worn or deformed, and affect the waterproof function or connection function.
1.
Installation/removal
Handling electric wires
38
Finishing for internal wiring
When routing the electric wire inside the frame, install a grommet to the wiring hole of the frame for protective
purposes after passing the electric wire through the frame.
Install each component and connect the electric wire.
Refer to each section in this chapter for details. Perform the procedure with the electric wire temporarily
secured to the frame using tape with low adhesion, etc.
1.
After installing and connecting all the components, perform the procedures in Checking connections .2.
Remove the temporary tape, and affix the electric wire cover to the locations on the frame.
Affix the electric wire cover after peeling off the film from the back side.
Example of affixing to the lower side of the down tube (wiring to the junction [B])
Example of affixing to the seat tube (wiring to the front derailleur)
Example of affixing to the chainstay (wiring to the rear derailleur)
Electric wire cover
Electric wire cover
Electric wire cover
Electric wire
Front
Front
Front
Electric wire
Electric wire
To ensure adhesion, before affixing the electric wire cover, wipe off the grease on the frame with
isopropyl alcohol or a cleaner.
3.
Installation/removal
Handling electric wires
39
Example of installing to the chainstay (wiring to the rear derailleur)
Example of installing to the seat tube (wiring to the front derailleur)
There are two types of grommets as shown in the figure. Use the correct one according to the shape of
the wiring hole.
SM-GM01
Circular wiring hole
SM-GM02
Elliptical wiring hole
Install each component and connect the electric wire.
Refer to each section in this chapter for details. Pass the electric wire through the inside of the frame as
indicated in the wiring diagram, and connect each component.
1.
After installing and connecting all the components, perform the procedures in Checking connections .2.
Open the grommet from the center, and place it over the electric wire in the appropriate position.
Perform the procedure after determining the length of the electric wire to expose from the frame in
advance.
Installation example to the down tube
Junction [A] side
3.
Installation/removal
Handling electric wires
40
Temporarily installing the dual control levers Temporarily install the dual control lever. You will need to check the connections and install the brake hose
before proceeding to Securing the dual control levers .
ST-RX815
Install the grommet.
(1) (2)
Insert the grommet so that it hooks onto the wiring hole of the frame.(1)
Push in the grommet with your finger.(2)
If the grommet is difficult to insert, spray it with isopropyl alcohol to aid installation.
4.
Turn over the bracket cover from the back side.
Gently turn over the ends of the bracket cover with both hands and slowly push them down.
Clamp bolt
Forcibly pulling it may cause damage to the bracket cover because of its material properties.
1.
Installation/removal
Temporarily installing the dual control levers
41
Loosen the clamp bolt and pass the clamp band over the handlebar.
The clamp bolt is found on top of the lever bracket when the bracket cover is turned over.
Clamp band
Clamp bolt
Be sure to loosen the clamp bolt sufficiently. Otherwise the handlebar may be damaged when
passing the clamp band over the drop handlebar.
2.
Installation/removal
Temporarily installing the dual control levers
42
Temporarily install the lever to the handlebar.
Temporarily install the lever so that it cannot move.
Clamp bolt
(Temporary)
The clamp band, clamp bolt and clamp nut are not compatible with other products. Be sure to
always use the clamp band, clamp bolt and clamp nut which is specific to each product.
3.
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 lever.
4.
Installation/removal
Temporarily installing the dual control levers
43
Connect the electric wire. If required, first remove the dummy plug.
Be sure to push it in firmly until you feel a click.
E-TUBE port 2
Dummy plug Electric wire
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.
The remaining E-TUBE port can be used to connect a satellite switch (next section) or connect a PC
linkage device when performing maintenance. Leave the dummy plug attached to the unused E-
TUBE port.
5.
Installation/removal
Temporarily installing the dual control levers
44
Installing the satellite switch This section describes how to add a satellite switch.
Installation/removal
Installing the satellite switch
45
SW-R9150
Routing map
A routing example of the satellite switch is shown below.
Dual control lever (left)
Satellite switch (left)
Satellite switch (right)
Dual control lever (right)
Two types of adapters for installing the satellite switch to the handlebar are included in the product.
Select the adapter according to the cross-section of the handlebar.
Handlebar
Adapter
Handlebar
Adapter
Installation/removal
Installing the satellite switch
46
Connection method
Set the satellite switch to the adapter.
Electric wire for satellite switch
Adapter
Satellite switch
Marking
Marking
Check the marks (R/L) on the satellite switch and the adapter.(1)
Set the satellite switch to the adapter.(2)
1.
Installation/removal
Installing the satellite switch
47
Secure the satellite switch and adapter to the handlebar with a zip tie.
Zip tie
Adapter
Satellite switch
Electric wire for satellite switch
(1) (2)
Pass the zip tie through.(1)
Check that the zip tie has been passed through correctly, and tighten the zip tie.(2)
When tightening the zip tie, take care not to also tighten the electric wire. Failure to do so will
cause operation failure.
2.
Perform post-processing of the zip tie.
(1) (2) Zip tie
Clamp part
Cut the remaining part of the zip tie using cutters, etc.(1)
Rotate the zip tie, and insert the clamp part into the hole of the adapter.(2)
3.
Installation/removal
Installing the satellite switch
48
Installing junction [A]
External type
Install external type junction [A] to the bottom of the stem. A band and mounting bracket to use for installation
is included.
Connect the electric wire of the satellite switch to the E-TUBE port of the dual control lever.
Be sure to push it in firmly until you feel a click.
Electric wire for satellite switch
If there is length to spare in the electric wire of the satellite switch, retaining it on the dual control
lever side will make it easier to remove and insert wiring when performing maintenance.
4.
Check the electric wire that will be connected to junction [A].
The figure is an example of placing the electric wire inside the frame.
To junction [A]
Electric wire
To junction [B]
1.
Installation/removal
Installing junction [A]
49
Install the band and mounting bracket to the stem.
Band
Stem
Front
Mounting bracket
Set the mounting bracket on the band.(1)
Adjust the length of the band according to the thickness of the stem, hook it on the mounting bracket
and wind it. Pull the mounting bracket with your hand so that it does not become displaced, and install
it securely.
(2)
2.
Slide junction [A] into the rail section of the mounting bracket to install it.
Junction [A]
3.
Installation/removal
Installing junction [A]
50
Removal
Built-in bar end type
When installing a built-in bar end type junction [A], use a compatible handlebar.
Connect the electric wire to the E-TUBE port of junction [A].
Check the wiring diagram, and connect the electric wire to the E-TUBE port of junction [A]. Be sure to push it
in firmly until you feel a click.
E-TUBE port E-TUBE port
Junction [A] Junction [A]
Electric wire
(SM-EW90-A) (SM-EW90-B)
4.
Remove the electric wire connected to junction [A].1.
Remove junction [A].
Slide junction [A] to remove it while gently pushing the release lever of the mounting bracket.
Release lever
Do not push the release lever strongly. Doing so may cause the release lever to break.
2.
Installation/removal
Installing junction [A]
51
Prepare the wires.
Electric wire
Wire holder
Handlebar
(1) (2)
Pass the electric wires through the wiring hole in the handlebar and pull them out from the bar end.(1)
Attach the wire holder to the electric wires.(2)
1.
Connect the electric wire to the E-TUBE port of junction [A].
Be sure to push it in firmly until you feel a click.
E-TUBE port
Junction [A]
2.
Insert junction [A] into the handlebar using a gentle twisting motion.
Insert junction [A] fully and securely ensuring the wire holder does not become crooked in the handlebar.
Wire holder
Do not tap junction [A] with a hammer or similar tool when inserting it. Disassembling them may
result in malfunctions.
Perform the following steps after Checking connections . Double check the connections to
junction [A] before proceeding to the next step.
3.
Installation/removal
Installing junction [A]
52
Attach the handlebar holder to the bar end.
(1)
(2)
Handlebar holder top
Handlebar holder bottom
Handlebar holder top
Handlebar holder bottom
Peel the film on the back and attach the handlebar holder top to the handlebar.(1)
In the same manner, attach the handlebar holder bottom. Combine the handlebar holder top and
handlebar holder bottom by hooking the handlebar holder bottom into the groove in the handlebar
holder top as shown in the figure, then attach it.
(2)
After attaching the handlebar holders, hold them down with your finger for approximately 1 minute.(3)
If the adhesive force of the double-sided tape on the handlebar holders has weakened, cut some
commercially-available double-sided tape as shown in the figure and replace them.
15 mm
10 mm
4.
Installation/removal
Installing junction [A]
53
Temporarily secure the electric wires to the handlebar.
Electric wire
Tape
Adjust the length of the electric wires by tucking any excess length into the handlebar, etc.(1)
Temporarily secure the electric wires to the handlebar using tape or a similar material.(2)
If there is length to spare in the electric wire, retaining it inside the handlebar will make it easier to
remove and insert wiring when performing maintenance.
5.
Attach the end cap and handlebar holder to the bar end on the opposite side.
End cap
Handlebar Handlebar holder
End cap (1) (2)
Insert the end cap into the bar end without junction [A] installed.(1)
Refer to step 4 to attach the handlebar holder.(2)
6.
Installation/removal
Installing junction [A]
54
Temporarily secure the dummy wires to the handlebar as necessary.
Route and temporarily secure the dummy wires in the same manner as the electric wires.
Tape
Dummy wire
Dummy wire
Dummy wires are attached to give the handlebar end not fitted with junction [A] the same
thickness of the electric wires so that the rider does not feel the difference between the left and
right handlebar grips. Route and temporarily secure the dummy wires in the same manner as the
electric wires.
7.
Wrap the handlebar with the handlebar tape.
Finally, wrap the handlebar with the handlebar tape, after installing the hydraulic brake system.
For information on wrapping the handlebar with the handlebar tape, refer to the instruction
manual included with the handlebar tape. SHIMANO recommends the following method for
wrapping the handlebar with the handlebar tape.
Handlebar holder
Handlebar tape
(1) (2)
Cut off the end of the handlebar tape diagonally.(1)
Wrap the handlebar with the handlebar tape over the handlebar holders.(2)
8.
Installation/removal
Installing junction [A]
55
Built-in frame type
Connect the electric wire to junction [A].
Be sure to push it in firmly until you feel a click.
Electric wire
Frame
Junction [A] (1) (2)
E-TUBE port
1.
Install junction [A] to the frame.
0.26 - 0.4 Nm
(1)
(2)
Fixing screw
Junction [A]
Holder plate
Insert junction [A] into the frame.(1)
Install the holder plate.(2)
When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque
with the carbon frame or handlebar manufacturer. This will prevent damage to the frame/
handlebar due to over-torquing or inadequate securing of the components.
2.
Installation/removal
Installing junction [A]
56
Installing the wireless unit This section describes how to install EW-WU111. When using EW-WU101, refer to the dealer's manual for EW-
WU101 ( https://si.shimano.com/dm/RBWU001/ ).
Position the wireless unit so that it is not on the side of the bicycle. Otherwise, it could be damaged if
the bicycle tips over and it is pinched between the frame and curb.
Connect the electric wire to the wireless unit.
Perform the subsequent steps after installing the brake hose.
Electric wire (to junction [B])
Electric wire (to junction [A])
Wireless unit
Check the electric wire that will be connected to the wireless unit.(1)
Connect the electric wire to the E-TUBE port of the wireless unit.
* Be sure to push it in firmly until you feel a click.
(2)
1.
Secure the electric wire and brake hose with clips.
Clip
Brake hose
2.
Installation/removal
Installing the wireless unit
57
Temporarily installing the front derailleur The recommended installation order for the front derailleur varies depending on whether the wiring is inside or
outside the frame.
When there is a mounting boss on the seat tube
Be sure to install the support plate to prevent the frame from being damaged by pressure from the support
screw.
If the wiring is inside the frame, temporarily install the front derailleur as described here, check all
connections (including with other components), then proceed to Securing the front derailleur .
If the wiring is outside the frame, refer to the information here as well as the information in Securing the
front derailleur , then complete installing the front derailleur.
Check the installation location.
Check where the support screw makes contact with the seat tube when adjusting the front derailleur support
screw.
1.
Installation/removal
Temporarily installing the front derailleur
58
When there is no mounting boss on the seat tube
When there is no mounting boss on the seat tube, use a band adapter (SM-AD91).
Temporarily install the front derailleur.
Fixing screw
(Temporary)
Support screw
Adhesive
Support plate
(2)
(3)
Support plate(1)
Peel the film off the back of the support plate, then attach it to the seat tube.
* Avoid positioning the adhesive on the support plate between the contact point of the support screw
and the frame.
(1)
Temporarily install the front derailleur.(2)
Tighten the support screw until it touches the support plate.(3)
2.
Install the band adapter to the front derailleur.
Fixing screw
Band adapter
5 - 7 Nm
1.
Installation/removal
Temporarily installing the front derailleur
59
Tighten the support screw until it touches the band adapter.
Band adapter
Support screw
2.
Temporarily install the front derailleur to the seat tube.
Seat tube adapter (for 28.6)
Clamp screw
Seat tube
(Temporary)
Remove the clamp screw, and expand the clamp band of the band adapter.(1)
Set the clamp band to the frame, and reinstall the clamp screw.
* Use a seat tube adapter (for 28.6) according to the size of the seat tube.
(2)
3.
Installation/removal
Temporarily installing the front derailleur
60
Connecting the electric wire
Connect the electric wires.
Electric wire E-TUBE port
Plug cover
(1) (2)
Install the electric wire to the plug cover.(1)
Connect the electric wire with the plug cover to the E-TUBE port of the front derailleur.
* Be sure to push it in firmly until you feel a click.
(2)
When removing the electric wire of the front derailleur, insert the SHIMANO original tool into the
two holes of the plug cover.
Plug cover
Electric wire
1.
Installation/removal
Temporarily installing the front derailleur
61
Installing the rear derailleur
Standard type
Set the switch lever in the OFF position.
Switch lever
1.
Installation/removal
Installing the rear derailleur
62
Secure the rear derailleur.
Be careful not to insert the rear derailleur fixing screw in the derailleur hanger at an angle.
In addition, be sure to install the rear derailleur so that the stopper plate contacts the B-tension stop, with no
gap in between.
Stopper plate
Rear derailleur fixing screw
Stopper plate
B-tension stop
8 - 10 Nm
Periodically check to make sure that there is no gap between the B-tension stop and the stopper
plate. If there is a gap between these two parts, problems with gear shifting performance may
occur.
2.
Installation/removal
Installing the rear derailleur
63
Direct mount type
Set the switch lever in the OFF position.
Switch lever
1.
Remove the bracket axle plate.
B-axle 2
Bracket axle plate
2.
Installation/removal
Installing the rear derailleur
64
Connecting the electric wire
Install the rear derailleur.
8 - 10 Nm
Derailleur hanger(1)
B-axle 2(2)
Insert the derailleur hanger into the installation part for direct mount of the rear derailleur.(1)
Install the rear derailleur with the B-axle 2.(2)
3.
Connect the electric wires.
Be sure to push it in firmly until you feel a click.
Example when the wiring is built into the frame
E-TUBE port(2)
Electric wire(1)
1.
Installation/removal
Installing the rear derailleur
65
Installing the external battery This section describes how to install the battery near the bottle cage on the down tube. Depending on the
frame, the way the battery is installed may differ. For details, contact the manufacturer of the frame.
Install the built-in type battery after installing the internal type junction [B]. Refer to Installing the built-in type
battery .
When the wiring to the battery is external
Temporarily install the battery mount.
Short type
Use the fixing screw included with the battery mount.
Bottle cage
Fixing screw
(Temporary)
Battery mount
Long type (temporarily installing the front of the battery mount)
Tighten it together with the bottle cage using the fixing screw included with the frame.
Bottle cage
Fixing screw
(Temporary)
Battery mount
1.
Installation/removal
Installing the external battery
66
Adjust the position of the battery mount and bottle cage so there is enough space to attach and remove the
battery.
The figure shows the short type, but performs the same position adjustment for the long type.
Attach and remove the battery to check the space.
108 mm
2.
Installation/removal
Installing the external battery
67
Secure the battery mount.
Short type
This completes the installation process for the short type.
Bottle cage
Battery mount
1.2 - 1.5 Nm Fixing screw
Long type (securing the front of the battery mount)
Refer to the owner's manual for the bottle cage for details on the tightening torques.
For the long type, also perform the following procedure.
Bottle cage
Fixing screw
Battery mount
When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque
with the carbon frame or handlebar manufacturer. This will prevent damage to the frame/
handlebar due to over-torquing or inadequate securing of the components.
3.
Installation/removal
Installing the external battery
68
Secure the rear of the battery mount.
For the long type, secure the rear of the battery mount.
When using a zip tie
Zip tie
When there is a mounting boss on the frame
If there is a mounting boss on the frame, the rear of the battery mount can be secured to the frame with a
fixing screw.
Fixing screw
Mounting boss
1.2 - 1.5 Nm
When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque
with the carbon frame or handlebar manufacturer. This will prevent damage to the frame/
handlebar due to over-torquing or inadequate securing of the components.
4.
Installation/removal
Installing the external battery
69
When the wiring to the battery is built into the frame
If the frame wiring hole is between the installation holes of the bottle cage, you can use an electric wire cover
for the battery mount.
Connect the electric wire to the E-TUBE port of the battery mount.
Be sure to push it in firmly until you feel a click.
Electric wire
E-TUBE port
5.
Installation/removal
Installing the external battery
70
Set the electric wire to the electric wire cover.
(2) (3)
(1) Electric wire
Electric wire cover
Battery mount
To junction [B]
To junction [B]
Check the electric wire that will be connected to the battery.(1)
Set the electric wire to the groove of the electric wire cover.(2)
Install the electric wire cover to the battery mount.(3)
1.
Connect the electric wire to the E-TUBE port of the battery mount.
Refer to step 5 of When the wiring to the battery is external.
2.
Installation/removal
Installing the external battery
71
Installation of the bottle cage adapter
If the bottle cage or bottle which is installed to the seat tube interferes with the external battery, move the
position of the bottle cage upwards within a range of 32 mm - 50 mm using the bottle cage adapter.
Secure the front of the battery mount together with the included spacer.
Tighten them together when installing the bottle cage. Refer to the owner's manual for the bottle cage for
details on the tightening torques.
Spacer
Fixing screw
When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque
with the carbon frame or handlebar manufacturer. This will prevent damage to the frame/
handlebar due to over-torquing or inadequate securing of the components.
3.
Secure the rear of the battery mount.
Refer to step 4 of When the wiring to the battery is external.
4.
Installation/removal
Installing the external battery
72
Installing junction [B] When installing junction [B], connect the electric wires first, then install on the frame.
External type junction [B]
Install external type junction [B] to the bottom of the bottom bracket shell. If a cable guide is attached to the
bottom of the bottom bracket shell, remove it in advance.
Install the bottle cage adapter.
(1) (2)
3 Nm Fixing screw
Long (15 mm)
Long (15 mm)
Short (10 mm)
Short (10 mm)
Spacer
Fixing screw
Use the longer fixing screw to install the bottle cage adapter.
* If it interferes with the mounting boss for the front derailleur, use the included spacer.
(1)
Use the short fixing screw to install the bottle cage.
* Refer to the owner's manual for the bottle cage for details on the tightening torques.
(2)
When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque
with the carbon frame or handlebar manufacturer. This will prevent damage to the frame/
handlebar due to over-torquing or inadequate securing of the components.
1.
Installation/removal
Installing junction [B]
73
Check the electric wire that will be connected to junction [B].
Connect the electric wires indicated below to junction [B].
Electric wire between junction [B] and junction [A] (or wireless unit)
Electric wire between junction [B] and the battery
Electric wire between junction [B] and the front derailleur
Electric wire between junction [B] and the rear derailleur
1.
Connect the electric wires to the E-TUBE port on junction [B].
Be sure to push it in firmly until you feel a click.
Top (frame side)
Electric wire
E-TUBE port 4
FrontRear
2.
Adjust the excess length of the electric wire.
Wind any excess length of the electric wire to the grooves on the top of junction [B] as indicated in the
figure, to adjust the length.
Example of adjusting the length of the electric wire to the rear side
Example of adjusting the length of the electric wire to the front side
3.
Installation/removal
Installing junction [B]
74
Internal type junction [B]
Install junction [B] to the frame.
Fixing screw
Junction [B]
4.
The inner wall of the bottom bracket shell is threaded. Be careful not to damage the electric wires.
Check the electric wire that will be connected to junction [B].
Pull out the following electric wires from the bottom bracket shell.
Electric wire
When the battery is an external type
Bottom bracket shell
Electric wire
When the battery is a built-in type
Electric wire between junction [B] and junction [A] (or wireless unit)
Electric wire between junction [B] and the battery
Electric wire between junction [B] and the front derailleur
Electric wire between junction [B] and the rear derailleur
1.
Installation/removal
Installing junction [B]
75
Connect the electric wires to the E-TUBE port on junction [B].
Be sure to push it in firmly until you feel a click.
Electric wire
E-TUBE port 4
2.
Installation/removal
Installing junction [B]
76
Pull the seat tube side and chainstay side electric wires into the frame.
When the battery is an external type
Electric wire for rear derailleur
Electric wire for front derailleur
Seat tube
Chainstay
When the battery is a built-in type
Electric wire for rear derailleur
Electric wire for battery
Seat tube
Chainstay
Electric wire for front derailleur
3.
Installation/removal
Installing junction [B]
77
Installing the built-in type battery This section describes how to install the battery inside the seat post. Depending on the frame, the way the
battery is installed may differ. For details, contact the manufacturer of the frame. Refer to Installing the
external battery when installing the external battery.
Pull in junction [B] toward the down tube side.
When the battery is an external type
Electric wire for junction [A]
Electric wire for battery mount
Down tube
(1) (2)
When the battery is a built-in type
Electric wire for junction [A]
Down tube
(1) (2)
Pull in the electric wire on the down tube side.(1)
Store junction [B] inside the down tube and arrange the wires so that only the seat tube side and
chainstay side electric wires are visible inside the bottom bracket shell.
(2)
Pull in the electric wire on the down tube side.(1)
Store junction [B] inside the down tube and arrange the wires so that only the seat tube side and
chainstay side electric wires are visible inside the bottom bracket shell.
(2)
4.
Installation/removal
Installing the built-in type battery
78
Prepare a seat post compatible with Di2 (SM-BTR2/BT-DN110/BT-DN110-A). If you have any questions,
consult the manufacturer of the seat post.
Insert the battery into the seat post.
Seat post
Battery spacer
Battery
Battery adapter
(1) (2)
Insert the battery spacer into the seat post.(1)
Insert the battery into the seat post.(2)
1.
Installation/removal
Installing the built-in type battery
79
Checking connections After connecting the electric wires to all of the components, check the operation.
Secure the battery with the internal snap ring.
A
Part A cross section Wave washer
Washer
Internal snap ring
Use internal snap ring pliers (1.8 mm) to mount the internal snap ring.
2.
Connect the electric wire to the battery.
Be sure to push it in firmly until you feel a click.
(2)
(1)
E-TUBE port
Electric wire
3.
Insert the seat post into the frame.4.
Installation/removal
Checking connections
80
Check the connection for each component.
When there is a problem with a component connection:
Return to the installation procedure for each component, and check the electric wire connections.
Refer to the user's manual of the dual control lever to operate the shift switch and confirm the
operation of the derailleurs.
(1)
Refer to the user's manual of the junction [A] to check the operation of the LED, etc.(2)
If a wireless unit is connected, refer to E-TUBE PROJECT to check whether you can connect to the
tablet version of E-TUBE PROJECT.
(3)
1.
When checking of the connections is complete, temporarily remove the battery.
Refer to Installing the external battery .
Make sure to remove the battery when performing a procedure at a position near the front
derailleur, such as installation and removal of the crankset and front derailleur, chain installation,
and length adjustment. If the front derailleur is accidentally triggered while performing a
maintenance procedure, your fingers could get caught in the front derailleur and be injured.
2.
Installation/removal
Checking connections
81
Securing the front derailleur
Preparations
Securing the front derailleur
Before starting the work, check that the procedures in Temporarily installing the front derailleur have been
completed.
Install the bottom bracket and crankset to the frame.
Refer to the dealer's manual for the bottom bracket and crankset .
If the front derailleur interferes with the installation of the crankset, temporarily remove it to aid the
installation process.
Make sure the electric wires exposed in the bottom bracket shell pass around the inner cover of the
bottom bracket.
Installation example to the thread type bottom bracket
Electric wire
Inner cover
If using a frame which does not have enough space between the inner wall of the bottom bracket
shell and the inner cover to route the electric wires, use an inner cover which is sold separately.
1.
Installation/removal
Securing the front derailleur
82
Adjust the installation height.
Adjust so that there is a clearance of 1 - 3 mm between the outer plate and the tip of the teeth of the largest
chainring.
1 - 3 mm
Outer plate
Largest chainring
1.
Installation/removal
Securing the front derailleur
83
Adjust the installation angle and secure the front derailleur.
(1) 0.5 - 1 mm (1) 0.5 - 1 mm
Fixing screw
With mounting boss (direct mount) Without mounting boss (use band adapter)
Outer plate Outer plate
Largest chainring
Largest chainring
5 - 7 Nm
5 - 7 Nm (2)
Clamp screw(2)
Perform adjustment so that the flat surface of the outer plate is in a position directly above the largest
chainring and that the rear edge of the outer plate is inwards by 0.5 - 1 mm compared to the front
edge.
(1)
Secure the front derailleur with a fixing screw or clamp screw.(2)
When installing parts onto a carbon frame/handlebar, confirm the recommended tightening torque
with the carbon frame or handlebar manufacturer. This will prevent damage to the frame/
handlebar due to over-torquing or inadequate securing of the components.
2.
Installation/removal
Securing the front derailleur
84
Installing the disc brake rotor Refer to the dealer's manual for the wheels to install and remove the disc brake rotor.
Installing the brake calipers Refer to the dealer's manual for the brake caliper to install and remove the brake caliper.
Readjust the position of the outer plate.
Adjust the support screw so that the flat surface of the outer plate is aligned with the surface of the largest
chainring. Make sure that the support screw is in contact with the support plate or the band adapter.
Support screw With mounting boss (direct mount)
Without mounting boss (use band adapter)
Check the adjustment position by pressing a hexagon wrench or other tool to the flat portion of
the largest chainring.
3.
Installation/removal
Installing the disc brake rotor
85
Installing the brake hose
Overview of the easy hose joint system
Brake caliper
Dual control lever
Flare nut
Lever stopper
Checking the length of the hose
Route the brake hose into the final installation position.
This figure is only for explanatory purposes. For details on how to route the brake hoses, consult
the manufacturer of the bicycle or refer to the bicycle's manual.
1.
Installation/removal
Installing the brake hose
86
Cutting the hose
Use care when cutting the hose, as oil may leak when the hose is cut.
Check the appropriate length of the brake hose.
Secure the lever in the position used when riding.
Check the mark on the brake hose with the edge of the brake lever flare nut.
Flare nut
Mark
Appropriate length
Seal plug
If the hose is at the appropriate length, proceed to Connecting the hose .
If the hose needs to be shortened, proceed to Cutting the hose .
If the hose length is insufficient, replace it with a hose that has an appropriate length.
2.
Determine the appropriate length and add a witness mark on the brake hose.
Add the witness mark so it is aligned with the edge of the flare nut.
Flare nut
Witness mark
1.
Add a cut mark.
Mark the hose at a position 21 mm from the witness mark towards the end of the hose.
21 mm
Cut mark Witness mark
2.
*
*
*
Installation/removal
Installing the brake hose
87
Prepare tool TL-BH62 for the cutting of the brake hose.
Do not move the lever indicated in the figure before disassembling SHIMANO original tool TL-BH62.
Hose cutter
Main body
Press block
(1)
(2) (3) (4)
Lever
Make sure to also refer to the manual for SHIMANO original tool TL-BH62.
3.
Place the brake hose in the TL-BH62.
When inserting the brake hose, make sure that the cut mark is parallel with the indicator groove in the tool.
Groove
Cut mark
4.
Installation/removal
Installing the brake hose
88
Check the cut location and secure the brake hose in place.5.
Check that the hose is secure, then install the hose cutter.
Hose cutter
6.
Press the hose cutter as shown in the figure to cut the brake hose.7.
Installation/removal
Installing the brake hose
89
Remove the hose cutter and check that the cut end is even.
9090
8.
Install the connector insert in the press block, then set the press block in the TL-BH62.
Make sure that the tip of the connector insert is correctly positioned inside the opening of the brake hose.
Press block
Connector insert(1) (2)
When connecting with an easy hose joint system, a specialized Connector Insert (Y8JA98020/color:
silver) must be used. Use of any connector insert other than the specified one may lead to oil
leakage and other malfunctions.
9.
Installation/removal
Installing the brake hose
90
Depress the lever on the TL-BH62 to install the connector insert in the brake hose.
Check that the connector insert is installed correctly.
10.
Remove the brake hose from the TL-BH62.11.
Installation/removal
Installing the brake hose
91
Connecting the hose
Secure the lever with the hose connector facing up by changing the angle of the handlebar, etc.
To install the handlebar, adjust the angle of the bracket by tilting the bracket outward from the
handlebar so that you can turn the spanner. At that time, be careful not to damage the handlebar
and other parts.
Handlebar
1.
Remove the seal plug.
Use a clean rag to keep oil from dripping off the seal plug.
Seal plug
2.
Installation/removal
Installing the brake hose
92
Insert the brake hose in the brake hose connection port.
The lever comes with a pre-installed olive. When inserting the hose, ensure it does not snag on the olive.
Insert hose up to the witness mark on the outer hose casing.
Cover with a clean rag while conducting this procedure as some of the internal oil may leak.
3.
Tighten the flare nut with flange.
Tighten the flare nut while pushing the brake hose in.
Flare nut with flange
5 - 6 Nm
Make sure to fully insert the brake hose and tighten the flare nut. Otherwise, oil leaks or
insufficient braking force may occur.
4.
Wipe away any excess oil.5.
Installation/removal
Installing the brake hose
93
Securing the dual control levers When connection of the brake hose is complete, secure the dual control levers in the appropriate position.
Remove the lever stopper.
Pull out the lever stopper by means of short back and forth movements. Take care to not depress the lever.
Lever stopper
6.
Check that the pad spacer is installed on the caliper and that the disc brake rotor is between the two sides
of the caliper.
7.
Operate the brake lever several times and check that the brake pads grip the disc brake rotor and that the
lever becomes stiff.
If the lever does not become stiff, refer to Adding mineral oil and bleeding air and bleed the air from the
system.
8.
Secure the dual control levers to the handlebar.
Clamp bolt
6 - 8 Nm
1.
Installation/removal
Securing the dual control levers
94
The installation procedure is complete after finishing the wiring, etc.
For information on finishing the wiring, refer to Finishing for external wiring or Finishing for internal
wiring .
Also, the method for wrapping the handlebar tape is listed at the end of Built-in bar end type .
2.
Installation/removal
Securing the dual control levers
95
How to operate Gear position control [Gear position control] in this system is set to [Yes] by default. Therefore, if you try to shift into gear positions
that would lower the chain tension, shift switches may shift differently from the basic operations.
The figure below shows the gear positions that would lower the chain tension and the shifting operations
performed when you shift into those gears.
Points to remember when shifting the front derailleur
When you shift the front into the smallest chainring, shifting is controlled as follows.
Gear position control (during front gear shifting)
Gear position in the rear When the front is shifted into the smallest chainring
Smallest or 2nd smallest sprocket
Sprockets other than the smallest two The front gear shifts to the smallest chainring (normal
operation).
Intended operation on front
Rear gear shifting operation
The front derailleur does not shift.
Instead, the rear derailleur is shifted down through 2 gears.
How to operate
Gear position control
96
Points to remember when shifting the rear derailleur
When shifting the rear to the smallest sprocket, the following gear shifting control is performed.
Gear position control (during rear gear shifting)
Gear position in the front When the rear is shifted toward the smallest sprocket
Smallest chainring Does not shift to the smallest two sprockets.
State of front
Rear range where gear shifting is not possible
[Gear position control] can be disabled in E-TUBE PROJECT. However, it may not be possible to disable
this, depending on the combination between the product and tooth combination.
If you use combinations of front and rear derailleurs besides those recommended, the number of gears
affected by the gear position control may become larger. In this case, the number of gears that can be
shifted freely becomes smaller.
How to operate
Gear position control
97
Adjustment Installing the chain Refer to the dealer's manual for the chain ( https://si.shimano.com/dm/CN0001/ ) to find instructions on installing/
removing the chain.
Checking the chain length Set the chain on the largest sprocket and the largest chainring.
Largest sprocket
Chain
Largest chainring
1.
Adjustment
Installing the chain
98
Check the length of the chain.
Add 4 - 6 links to set the length of the chain as shown in the figure.
If the inner links and outer links match when mounting the chain
Add 4 or 6 links to set the length.
When setting the chain length with 4 links added, if you are concerned about turbulence in the drivetrain
components when the chain is on the largest sprocket and largest chainring, set the chain length with 6 links
added.
Inner link
+4 links or +6 links
Outer link
If the inner links match together and the outer links match together
Add 5 links to set the length.
+5 links
2.
Adjustment
Checking the chain length
99
Adjusting the rear derailleur
Adjusting the B-screw
The rear derailleur plate assembly is equipped with a pin or plate that prevents chain derailment.
When passing the chain through the rear derailleur, pass it through the main body of the rear
derailleur from the side of the chain derailment prevention plate as shown in the figure.
If the chain is not passed through the correct position, damage may be caused to the chain or the
rear derailleur.
Chain derailment prevention plate
RD-RX815
RD-RX817
Chain derailment prevention plate
Chain derailment prevention plate
Chain derailment prevention plate
Install the battery.
Refer to Installing the external battery .
1.
Adjustment
Adjusting the rear derailleur
100
Shift the chain to the smallest chainring and the largest sprocket.
Turn the crank arm in reverse.
Smallest chainring
Largest sprocket
2.
Adjust the B-screw.
Smallest sprocketLargest sprocket
*B-screw
(1) (2)B-screw* B-screw*
Bring the guide pulley as close to the largest sprocket as possible without any turbulence between the
pulley and sprocket.
(1)
Set the chain on the largest chainring and smallest sprocket. Then check that there is no turbulence
between the chain and small sprocket.
* If the frame interferes with the rear derailleur, adjust by turning the B-screw until they do not
interfere.
(2)
3.
Adjustment
Adjusting the rear derailleur
101
Gear shifting adjustment in adjustment mode
Shift the rear derailleur to the 5th gear position from the largest sprocket.
Guide pulley
Largest sprocket
1.
Switch the gear shifting system to adjustment mode.
Press and hold the button on junction [A] until the LED linked to the button lights up red.
For external type
LED linked to the button
LED linked to the button
Button
Button
For built-in bar end or built-in frame types
The button operation may differ depending on the connected battery. Refer to the user's manual
for junction [A] for details.
If you keep pressing the button after the LED linked to the button lights up red, RD protection reset
will begin. Refer to the user's manual for the rear derailleur (Di2) for details. If you accidentally
started RD protection reset, press the button again to switch back to normal mode and start over.
2.
Adjustment
Adjusting the rear derailleur
102
Press shift switch [X] while turning the crank, and move the guide pulley toward the largest sprocket.
Move it to the position where the chain makes contact with the fourth gear and a subtle noise is heard.
Shift switch [X]
The derailleur can move 16 steps inward and 16 steps outward from the initial position, for a total
of 33 positions.
In adjustment mode, the guide pulley will overrun slightly, then move back in an exaggerated
manner so that you can check the adjustment direction. When checking the positions of the guide
pulley and the gear, perform the check when the rear derailleur has come to a stop.
3.
Press shift switch [Y] five times while turning the crank, and move the guide pulley five steps toward the
smallest sprocket.
This position will serve as the target for adjustment.
Shift switch [Y]
4.
Adjustment
Adjusting the rear derailleur
103
Adjusting the low / high limits
Switch the gear shifting system back to normal mode.
Press the button on junction [A] and check that the LED linked to the button is turned off.
For external type
LED linked to the button
LED linked to the button
Button
Button
For built-in bar end or built-in frame types
5.
Shift to each gear and check that no noise is generated at any sprocket position.
If fine adjustment is needed, switch back to adjustment mode and readjust the rear derailleur.
6.
The following issues may occur if the low / high limits are not properly adjusted:
Gears do not shift to the smallest sprocket or largest sprocket. Even if the gears are shifted, the
gear may shift back by 1 gear after approximately 5 seconds.
Noise does not stop.
The battery level drops quickly because an undue load is being placed on the motor.
The motor may be damaged due to overload (irreparable).
Adjustment
Adjusting the rear derailleur
104
Adjust the low limit.
Low limit screw
Low limit stopper
Shift the rear derailleur to the largest sprocket.(1)
Tighten the low limit screw until it just touches the low limit stopper.(2)
1.
Adjustment
Adjusting the rear derailleur
105
Adjusting the front derailleur
Checking screw positions
The high limit screw and the support screw are close to each other. Make sure that you are adjusting the correct
screw.
Adjust the high limit.
High limit screw
High limit stopper
Over-stroke allowance
Shift the rear derailleur to the smallest sprocket.(1)
Tighten the high limit screw until it just touches the high limit stopper.(2)
Turn the high limit screw counterclockwise one turn from position (2) so that an over-stroke allowance
can be maintained.
(3)
When shifting from larger sprockets into smaller sprocket, the rear derailleur briefly moves past the
target position towards the outside of the bicycle. This distance is referred to as the over-stroke
allowance. The derailleur then moves back and settles in the target position.
2.
Adjustment
Adjusting the front derailleur
106
Support screw
High limit screw
Adjusting the high limit
Set the chain on the largest chainring and the smallest sprocket.
Largest chainring
Smallest sprocket
1.
Adjust the clearance between the chain and outer plate.
Adjust the clearance to 0.5 - 1 mm.
Outer plate
High limit screw
High limit screw
Chain
0.5 - 1 mm
2.
Adjustment
Adjusting the front derailleur
107
Adjusting the low limit in adjustment mode
Shift the chain to the smallest chainring and the largest sprocket.
Smallest chainring
Largest sprocket
1.
Switch the gear shifting system to adjustment mode.
Press and hold the button on junction [A] until the LED linked to the button lights up red.
For external type
LED linked to the button
LED linked to the button
Button
Button
For built-in bar end or built-in frame types
The button operation may differ depending on the connected battery. Refer to the user's manual
for junction [A] for details.
If you keep pressing the button after the LED linked to the button lights up red, RD protection reset
will begin. Refer to the user's manual for the rear derailleur (Di2) for details. If you accidentally
started RD protection reset, press the button again to switch back to normal mode and start over.
2.
Adjustment
Adjusting the front derailleur
108
Adjust the clearance between the chain and inner plate.
Adjust the clearance to 0 - 0.5 mm.
Inner plate Chain
Shift switch [X]
Shift switch [X]
Shift switch [Y]
Shift switch [Y]
0 - 0.5 mm
The derailleur can move 18 steps inward and 18 steps outward from the initial position, for a total
of 37 positions.
In adjustment mode, the chain guide will overrun slightly then move back in an exaggerated
manner so that you can check the adjustment direction. When checking the positions of the chain
guide and the chain, perform the check when the front derailleur has come to a stop.
3.
Switch the gear shifting system back to normal mode.
Press the button on junction [A] and check that the LED linked to the button is turned off.
For external type
LED linked to the button
LED linked to the button
Button
Button
For built-in bar end or built-in frame types
4.
Shift the front derailleur and the rear derailleur to all gears to make sure that the chain does not contact the
inner or outer plates.
If fine adjustment is needed, switch back to adjustment mode and readjust the front derailleur.
5.
Adjustment
Adjusting the front derailleur
109
Adjusting the high limit in adjustment mode
Set the chain on the largest chainring and the largest sprocket.
Largest chainring
Largest sprocket
1.
Switch the gear shifting system to adjustment mode.
Press and hold the button on junction [A] until the LED linked to the button lights up red.
For external type
LED linked to the button
LED linked to the button
Button
Button
For built-in bar end or built-in frame types
The button operation may differ depending on the connected battery. Refer to the user's manual
for junction [A] for details.
If you keep pressing the button after the LED linked to the button lights up red, RD protection reset
will begin. Refer to the user's manual for the rear derailleur (Di2) for details. If you accidentally
started RD protection reset, press the button again to switch back to normal mode and start over.
2.
Adjustment
Adjusting the front derailleur
110
Adjust the clearance between the chain and inner plate.
Adjust the clearance to 0 - 0.5 mm.
0 - 0.5 mmShift switch [X]
Shift switch [X]
Shift switch [Y]
Shift switch [Y]
The derailleur can move 12 steps inward and 12 steps outward from the initial position, for a total
of 25 positions.
In adjustment mode, the chain guide will overrun slightly then move back in an exaggerated
manner so that you can check the adjustment direction. When checking the positions of the chain
guide and the chain, perform the check when the front derailleur has come to a stop.
3.
Switch the gear shifting system back to normal mode.
Press the button on junction [A] and check that the LED linked to the button is turned off.
For external type
LED linked to the button
LED linked to the button
Button
Button
For built-in bar end or built-in frame types
4.
Shift the front derailleur and the rear derailleur to all gears to make sure that the chain does not contact the
inner or outer plates.
If fine adjustment is needed, switch back to adjustment mode and readjust the front derailleur.
5.
Adjustment
Adjusting the front derailleur
111
Adjusting the dual control levers
Adjusting the reach
Adjust the reach of the lever.
Adjusting the free stroke
Adjust the range (gap) of travel of the lever until the brake pad and disc brake rotor come into contact. The left-
hand lever is used as an example for this explanation. The free stroke adjustment screw is outside of the bracket
body.
Adjust the position of the lever body.
Bracket cover
Lever body
Reach adjustment screw
(2)
(1)
Turn over the bracket cover from the front side.(1)
Adjust the position of the lever body using the reach adjustment screw.(2)
Make sure that braking operates properly after the adjustment.
1.
Adjustment
Adjusting the dual control levers
112
The initial position of the brake lever changes when performing the free stroke adjustment. Therefore,
also perform reach adjustment.
Adjustment
Adjusting the dual control levers
113
Adjust the free stroke.
Lever initial position
Clockwise Counterclockwise
Lever position where the brake pad contacts the disc brake rotor
Free stroke adjustment screw
(2)
Bracket cover(1)
Turn over the bracket cover from the front side.(1)
Adjust the stroke of the lever with the free stroke adjustment screw.(2)
Stop loosening the free stroke adjustment screw when the stroke stops increasing. Loosening it
excessively may cause the free stroke adjustment screw to fall out.
Do not forcibly tighten the free stroke adjustment screw. Otherwise, the free stroke adjustment
screw may be damaged.
Do not remove the washer from the free stroke adjustment screw.
Position the free stroke adjustment screw so that it does not interfere with the bracket cover.
1.
Adjustment
Adjusting the dual control levers
114
Charging the battery External type Remove the external type battery (SM-BTR1) from the bicycle and charge it.
It can be charged in approximately 1.5 hours. The charging time differs according to the battery level.
Make sure to charge the external type battery (SM-BTR1) using the dedicated battery charger (SM-
BCR1).
If the terminals of the battery and battery charger are modified or damaged, problems with operation
will occur. Be very careful when handling them.
Terminal
Battery charger (SM-BCR1) Battery (SM-BTR1)
Terminal
Refer to the user's manual of the battery and battery charger, and be careful of the operating
temperature and storage temperature when handling them.
Connect the power cord to the battery charger.
Insert the power cord in firmly as far as it will go.
Battery charger (SM-BCR1)
Power cord (sold separately)
1.
Connect the plug of the power cord to the electrical outlet.2.
Charging the battery
External type
115
Built-in type Built-in type batteries (SM-BTR2/BT-DN110/BT-DN110-A) can be charged while mounted on the bicycle. The
charging time is as follows. The charging time differs according to the battery level.
When charging by connecting to a PC Approximately 3 hours
When charging with an AC adapter with a USB port Approximately 1.5 hours * 1
* 1 Depending on the specifications of the AC adapter, recharging via the AC adapter may require as much time
(approximately 3 hours) as recharging via PC.
Installing the battery to the battery charger.
Insert the battery in firmly as far as it will go.
Charging begins when the charge indicator lights up. When the charge indicator turns off, charging is
complete.
Charge indicator On: Charging
Off: Charging complete
If the ERROR indicator lights up, remove the battery from the battery charger, and remove the
power cord from the electrical outlet. Then repeat the charging procedure from step 1 . If charging
is still not possible, the ambient temperature may be too low or too high, or there may be a
problem with the battery.
ERROR indicator
Flashing: Charging error
When charging is complete, make sure to remove the power cord from the electrical outlet.
3.
Charging the battery
Built-in type
116
Always use the designated battery charger (SM-BCR2) when charging built-in type batteries (SM-BTR2/
BT-DN110/BT-DN110-A).
Wipe off any dirt or water on junction [A] or the charging port on the system information display
before charging. Failure to do so may cause damage.
Refer to the user's manual of the battery and battery charger, and be careful of the operating
temperature and storage temperature when handling them.
Do not connect two or more SM-BCR2 units to a PC at the same time.
When charging by connecting to a PC, E-TUBE PROJECT cannot be used while charging.
Prepare the battery charger.
Connect the micro USB plug on the USB cable to the battery charger.
* Insert it in firmly as far as it will go.
(1)
Connect the USB plug on the USB cable to a PC or an AC adapter with a USB port.
* When using an AC adapter with a USB port, plug the AC adapter into an electrical outlet.
Battery charger (SM-BCR2)
Micro USB plug(1)
USB cable (included with battery charger)
USB plug(2)
To an AC adapter with a PC or USB
(2)
1.
Charging the battery
Built-in type
117
Insert the plug for product connection into the charging port on junction [A].
The position of the charging port differs depending on which junction [A] is used. Insert the plug for product
connection in firmly as far as it will go.
Charging begins when the charge indicator lights up. When charging is complete, the charge indicator will
turn off.
Plug for product connection
Charging port
Charge indicator
On: Charging
Off: Charging complete
2.
Charging the battery
Built-in type
118
If the ERROR indicator blinks, the ambient temperature during charging may be outside the
operating temperature range. If the ambient temperature is within the specified range, there is a
problem with the battery or the connected product.
ERROR indicator
Flashing: Charging error
If the charge indicator blinks, the following conditions may have caused a charging problem. If the
following conditions are not found, there is a problem with the battery or the connected product.
Charge indicator
Flashing: Charging error
The current capacity of your AC adapter with a USB port is lower than 1.0 A DC.
A USB hub is connected to SM-BCR2.
If the charge indicator does not light up or goes out soon, the battery may be fully charged. Check
the remaining battery level. If the battery is low or dead, contact your distributor.
Once charging is complete, always remove the USB cable from the AC adapter or PC.
Charging the battery
Built-in type
119
Connection and communication with devices E-TUBE PROJECT Connecting the bicycle to a device allows you to update the settings and firmware, and more.
E-TUBE PROJECT is needed to configure the settings and update firmware.
Download E-TUBE PROJECT from the support website ( https://bike.shimano.com/e-tube/project.html ).
For information on how to install E-TUBE PROJECT, check the support website.
System requirements
PC linkage device E-TUBE PROJECT Firmware
SM-BMR2/SM-BTR2 SM-PCE1/SM-PCE02/SM-BCR2 Version 3.4.2 or later Version 3.0.0 or later
BT-DN110/BT-DN110-A/BM-
DN100
Version 4.0.0 or later
The SM-PCE1, SM-PCE02 or SM-BCR2 can be used to connect the entire bicycle to a PC. To connect
individual components, the SM-PCE1 or SM-PCE02 must be used.
When using the SM-PCE1 / SM-PCE02 to connect to the entire bicycle, an SM-JC40 / JC41 and EW-SD50
wire are required if there are no unused E-TUBE ports available.
Firmware is subject to change without notice.
If your versions of E-TUBE PROJECT software and firmware for each component are not up to date,
there could be problems operating the bicycle. Check the version and update them to the latest ones.
Connection and communication with devices
E-TUBE PROJECT
120
Wireless function
Compatible cycle computers
A D-FLY compatible cycle computer is required to establish communication between the wireless unit and the
cycle computer. The types of information displayed on the cycle computer vary by product. For details, refer to
the owner's manual for the cycle computer.
Function
You can check the latest functions by using E-TUBE PROJECT to update the software.
ANT connection
The wireless unit transmits the following three types of information to cycle computers or receivers via ANT
connection:
The types of information displayed on the receiving side differ depending on the product. Refer to the owner's
manual for your cycle computer or receiver.
Bluetooth LE connection
E-TUBE PROJECT for smartphones/tablets may be used if a Bluetooth LE connection is established with a
smartphone/tablet.
Gear position information (front and rear)
Di2 battery level information
Adjustment mode information
Connection and communication with devices
Wireless function
121
Items configurable in E-TUBE PROJECT Display settings Display time setting Sets the time until the display turns off when the display
monitor is left unattended.
Switch function setting Modify the shift switch function settings.
Shift mode setting Modify the shift mode (synchronized shift) settings.
Multi shift mode setting Multi-shifting mode ON/OFF Select whether or not to use multi-shifting.
Gear-shifting interval Sets the gear-shifting interval for multi-shifting.
Gear number limit Sets the limit on the number of gears shifted when the
shift switch is pressed and held.
Shift mode setting (synchronized shift) The shift mode can be registered in E-TUBE PROJECT to maintain the ideal front and rear gear positions by
synchronizing the shifting between the front and rear derailleurs.
Semi-synchronized shift
The rear derailleur automatically shifts gears in synchronization with front derailleur gear shifting. The rear
derailleur can be set to automatically shift from 0 to 4 gears. 2 gear positions is the default. The setting for the
number of gears shifted varies depending on the combination of the number of teeth on the chainring and
sprocket.
When shifting from the largest chainring to the smallest chainring
The rear derailleur shifts from 0 to 4 gears outward. 2 gear positions is the default.
Up to two shift modes can be registered in E-TUBE PROJECT. For the setting procedure, refer to the user's
manual for E-TUBE PROJECT.
The shift mode can be switched by using the button on junction [A]. Consult the user's manual for junction [A]
for the details of this operation.
Connection and communication with devices
Items configurable in E-TUBE PROJECT
122
Front shifting functionality
Rear synchronization shift
When shifting from the smallest chainring to the largest chainring
The rear derailleur shifts from 0 to 4 gears inward. 2 gear positions is the default.
Front shifting functionality
Rear synchronization shift
Synchronized shift
The front derailleur automatically shifts gears in synchronization with rear derailleur gear shifting. The switching
gear position for synchronized shift is configured as shown in the figure by default.
Connection and communication with devices
Shift mode setting (synchronized shift)
123
Gear position (cassette sprocket)
Largest sprocket (low)
Smallest sprocket (top)
Smallest chainring (inner) Largest chainring (outer)
1
2
3
4
5
6
7
8
9
10
11
: Shifting up : Shifting down : Combination with unused gear
The figure shows the following operations following rear gear shifting.
Shifting up: When the front is on the smallest chainring and the rear is shifted up to 7th gear, the following
operation is performed.
The front automatically switches to the largest chainring.
The rear also automatically switches to 5th gear.
Shifting down: When the front is on the largest chainring and the rear is shifted down to 2nd gear, the
following operation is performed.
The front automatically switches to the smallest chainring.
The rear also automatically switches to 4th gear.
Connection and communication with devices
Shift mode setting (synchronized shift)
124
Maintenance Replacing the brake pads Refer to the dealer's manual for the brake caliper and replace the brake pads in the following situations:
SHIMANO genuine mineral oil replacement It is recommended to change your oil when the oil in the reservoir tank becomes noticeably discolored.
Draining the mineral oil
When oil adheres to the brake pads
When the brake pads are worn down to a thickness of 0.5 mm
When the brake pad presser spring is interfering with the disc brake rotor
Note the following cautions when handling SHIMANO genuine mineral oil:
Do not drink. May cause vomiting or diarrhea.
Keep out of reach of children.
Do not cut, let near heat, weld or pressurize the SHIMANO genuine mineral oil container. Doing
so may cause an explosion or fire.
Disposal of used oil: Follow local county and/or state codes for disposal.
Directions: Keep the container sealed to prevent foreign objects and moisture from getting
inside, and store it in a cool, dark area away from direct sunlight or heat. Keep from heat or
flame
For cleaning brake hoses exposed to mineral oil, or cleaning and maintaining tools, use isopropyl
alcohol or a dry cloth. Do not use commercially available brake cleaners. Doing so may cause
damage to plastic parts.
Maintenance
Replacing the brake pads
125
When changing the lever installation angle, be careful not to apply excessive force to the brake hose or
electric wire. Doing so may cause damage or disconnection.
Position the bicycle as shown in the figure.
Install a bleed spacer (yellow) to the caliper and secure the bicycle with a stand, etc.
Brake caliper
Brake hose
Brake caliper
1.
Turn over the bracket cover from the back side.
Turn it over until the bleed screw is exposed.
Bracket cover Bleed screw
2.
Maintenance
SHIMANO genuine mineral oil replacement
126
Set the lever in a position where the top surface of the bleed screw is parallel with the ground.3.
Remove the bleed screw and O-ring.
Bleed screw
O-ring
Be careful not to lose the bleed screw or O-ring.
Be careful not to dirty or damage the O-ring.
4.
Maintenance
SHIMANO genuine mineral oil replacement
127
Adding mineral oil and bleeding air
Use only SHIMANO genuine mineral oil.
Install a bag and tube on the bleed nipple.
Bleed nipple
Place a 7 mm box wrench in the position shown in the figure.(1)
Connect the tube with bag attached to the bleed nipple.(2)
5.
Loosen the bleed nipple.
The oil will begin to drain. Operating the brake lever while the oil drains will allow the oil to drain more
quickly.
Bleed nipple
6.
When bleeding air out of the caliper, you will need the SM-DISC (oil funnel and oil stopper).
When changing the lever installation angle, be careful not to apply excessive force to the brake hose or
electric wire. Doing so may cause damage or disconnection.
Maintenance
SHIMANO genuine mineral oil replacement
128
Position the bicycle as shown in the figure.
Install a bleed spacer (yellow) to the caliper and secure the bicycle with a stand, etc.
Brake caliper
Brake hose
Brake caliper
1.
Turn over the bracket cover from the back side.
Turn it over until the bleed screw is exposed.
Bracket cover Bleed screw
2.
Maintenance
SHIMANO genuine mineral oil replacement
129
Set the lever in a position where the top surface of the bleed screw is parallel with the ground.3.
Remove the bleed screw and O-ring, and set the oil funnel.
Attach the funnel adapter to the oil funnel.
Oil funnel
Funnel adapter
Be careful not to lose the bleed screw or O-ring.
4.
Maintenance
SHIMANO genuine mineral oil replacement
130
Set the lever in the position where the bracket is at 45, as shown in the figure.
Perform adjustment by changing the angle of the handlebar, etc.
45
5.
Maintenance
SHIMANO genuine mineral oil replacement
131
Inject oil from the brake caliper side.
Do not depress and release the lever repeatedly. Doing so will lengthen the amount of time needed to bleed
the air as it will cause air bubbles to remain inside the brake caliper, even if no bubbles appear. (If the lever
was depressed and released repeatedly, drain out all of the oil then add the oil again.)
Bleed nipple
Tube holder
Place a 7 mm box wrench in the position shown in the figure.(1)
Fill a syringe with oil, then connect the tube to the bleed nipple.
* Fix the tube with a tube holder so that it does not come loose.
(2)
Loosen the bleed nipple by 1/8 of a turn.(3)
Push the piston of the syringe to add the oil.(4)
Oil will start to come out from the oil funnel. Continue adding the oil until there are no more air
bubbles in the oil that is coming out.
(5)
If possible, secure the brake caliper body to prevent the tube from being accidentally disconnected.
6.
Maintenance
SHIMANO genuine mineral oil replacement
132
Once there are no more air bubbles mixed in with the oil, set the lever in a position where the label on the
bracket (highlighted in the figure) is parallel with the ground, as shown in the figure.
Perform adjustment by changing the angle of the handlebar, etc.
7.
Fill the oil funnel with oil until there are no more air bubbles mixed in with the oil, and temporarily close
the bleed nipple.
8.
Remove the syringe.
Cover the end of the syringe with a clean rag to prevent spilling any oil.
9.
Maintenance
SHIMANO genuine mineral oil replacement
133
Bleed the air.
Most of the air bubbles remaining inside the brake system can be bled by performing the following
operation:
Bleed nipple
(1) (2) (3) (4) (5)
Place a 7 mm box wrench in the position shown in the figure.(1)
Connect the tube with bag attached to the bleed nipple.(2)
Loosen the bleed nipple.(3)
After a little while, the oil and air bubbles will flow naturally from the bleed nipple into the tube.(4)
As the oil level drops in the funnel, add oil to maintain the oil level and prevent air from getting into
the system.
(5)
It may help to gently shake the hose or lightly tap the lever bracket or caliper with a non-marring
screwdriver handle. Changing the caliper position may also improve results.
10.
Maintenance
SHIMANO genuine mineral oil replacement
134
Once no more air bubbles come out from the bleed nipple, temporarily tighten the bleed nipple.
Bleed nipple
11.
With the lever depressed, loosen and tighten the bleed nipple in rapid succession.
Loosen and tighten for approximately 0.5 seconds each time to release any air bubbles inside the caliper.
Bleed nipple
12.
Repeat step 12 two to three times, then tighten the bleed nipple.
Bleed nipple
13.
Maintenance
SHIMANO genuine mineral oil replacement
135
Set the lever in the position where the bracket is at 45, as shown in the figure.
Perform adjustment by changing the angle of the handlebar, etc.
45
14.
Operate the lever.
Slowly repeat until no more air bubbles appear.
15.
Maintenance
SHIMANO genuine mineral oil replacement
136
Set the lever in a position where the label on the bracket (highlighted in the figure) is parallel with the
ground, as shown in the figure.
Perform adjustment by changing the angle of the handlebar, etc.
16.
Operate the lever.
Air bubbles in the system rise up through the port into the oil funnel. Slowly repeat until no more air
bubbles appear.
17.
Maintenance
SHIMANO genuine mineral oil replacement
137
Operate the brake lever several times and check that the brake pads grip the disc brake rotor and that the
lever becomes stiff.
If the lever does not become stiff, repeat the procedures from step 10 .
Loose Slightly stiff Stiff
18.
Set the lever in a position where the top surface of the bleed screw is parallel with the ground.
Perform adjustment by changing the angle of the handlebar, etc.
19.
Maintenance
SHIMANO genuine mineral oil replacement
138
Plug the oil funnel with the oil stopper.
Make sure that the side of the oil stopper with the O-ring attached is facing downward.
Oil stopper
O-ring
20.
Remove the oil funnel.
Remove it while it is still plugged by the oil stopper.
Tuck a clean rag between the bracket cover and oil port to prevent any excess oil from seeping under the
bracket cover.
21.
Maintenance
SHIMANO genuine mineral oil replacement
139
Tighten with a bleed screw to which an O-ring has been attached.
Tighten with a bleed screw until oil flows out to make sure that no air bubbles remain inside the reservoir
tank.
Do not operate the brake lever. If operated, there is a risk of air bubbles entering the cylinder.
Bleed screw
0.5 - 0.7 Nm
Bleed screw
O-ring
22.
Wipe away any oil that has overflowed.23.
Maintenance
SHIMANO genuine mineral oil replacement
140
Replacing the brake hose After replacing the brake hose, refer to SHIMANO genuine mineral oil replacement to inject the mineral oil
and bleed the air from the system.
Checking the hose length and cutting the hose
Route the brake hose into the final installation position.
This figure is only for explanatory purposes. For details on how to route the brake hoses, consult
the manufacturer of the bicycle or refer to the bicycle's manual.
1.
After determining the appropriate length, add a witness mark on the brake hose as shown in the figure.
Add marks to both the lever side and caliper side of the hose.
Flare nut Witness mark
Lever side Caliper side
Witness mark
2.
Cut the brake hose.
Refer to Cutting the hose in Installing the brake hose.
3.
Maintenance
Replacing the brake hose
141
Assembly to the brake lever
Pass the flare nut with flange and olive over the brake hose.
Olive
Brake hose
Flare nut with flange
1.
After checking that the olive is positioned as shown in the figure, apply SHIMANO Premium Grease as
shown in the figure.
Connector insert
Olive
Witness mark
Apply SHIMANO Premium Grease
Flare nut with flange
2 mmBrake hose
2.
Install the brake hose in the lever.
Secure the lever to the handlebar or in a vise and insert the brake hose straight.
Insert the hose up to the witness mark on the outer hose casing.
3.
Maintenance
Replacing the brake hose
142
Assembly to the brake caliper
Tighten the flare nut with flange to the lever while pushing the brake hose.
Make sure the brake hose is straight when pushing.
Flare nut with flange
5 - 6 Nm
To install the handlebar, adjust the angle of the bracket by tilting the bracket outward from the
handlebar so that you can turn the spanner. At that time, be careful not to damage the handlebar
and other parts.
4.
Temporarily attach the brake hose to the handlebar using tape, etc.5.
Pass the flare nut and olive over the brake hose in the order shown below.
Olive
Flare nut
Brake hose
1.
Maintenance
Replacing the brake hose
143
After checking that the olive is positioned as shown in the figure, apply SHIMANO Premium Grease as
shown in the figure.
Olive
Connector insertWitness mark
Apply SHIMANO Premium Grease
Flare nut
2 mm Brake hose
2.
Maintenance
Replacing the brake hose
144
Install the brake hose in the caliper.
Insert the hose until the witness marks added beforehand on the surface of the hose are covered.
Do not let the brake hose become twisted when installing it.
When the caliper and brake lever are not installed on the bicycle, there should be no twist in the
hose if the caliper and brake lever are in the positions shown in the figure below.
Left-hand lever
Right-hand lever
3.
Maintenance
Replacing the brake hose
145
Caliper piston maintenance The caliper mechanism includes two pistons. If these pistons do not operate properly or if they protrude
unevenly, or if the brake pads remain in contact with the disc brake rotor, refer to the dealer's manual for the
brake caliper to adjust the pistons.
Replacing the bracket cover
Tighten the flare nut while pushing on the brake hose.
5 - 7 Nm
Flare nut
4.
Remove the brake hose and electric wire from the lever.
Be careful so that oil does not spill from the lever or removed brake hose.
1.
Remove the lever from the handlebar.2.
Remove the bracket cover.
Bracket cover
3.
Maintenance
Caliper piston maintenance
146
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 mark indicating the left side or right side.
Bracket cover
Protrusion (inside bracket cover)
It is easier to perform installation if isopropyl alcohol is applied to the inside of the bracket cover.
4.
Return the lever to its original position.
Install the lever to the handlebar.(1)
Install the electric wire and brake hose to the lever.(2)
A new olive and connector insert is required to reinstall the brake hose.
Make sure to perform the procedure in Adding mineral oil and bleeding air .
5.
Maintenance
Replacing the bracket cover
147
Replacing the pulleys
Applying grease to the chain stabilizer If there is a noticeable change in friction in the chain stabilizer assembly, or if it starts to make noise, you may
need to add grease to the chain stabilizer.
Replace the guide pulley/tension pulley.
Install the pulleys so the side with the arrow marking is facing the bicycle.
2.5 - 5 Nm
2.5 - 5 Nm Guide pulley
Tension pulley
1.
Set the switch lever in the OFF position.
Switch lever
1.
Maintenance
Replacing the pulleys
148
Remove the plate unit cover.
Plate unit cover screw
Plate unit cover
2.
Remove the chain stabilizer and cam unit.
Chain stabilizer
Cam unit
3.
Disassemble the chain stabilizer as shown in the figure.
Chain stabilizer
Cam unit
Roller clutch
Remove the cam unit.(1)
Remove the roller clutch from the chain stabilizer.(2)
4.
Maintenance
Applying grease to the chain stabilizer
149
Apply grease to the circumference of the roller clutch.
SHADOW RD+ Grease number: Y04121000 (50 g)
NEXUS Grease number: Y04120800 (100 g)
Roller clutch
Be careful not to get grease inside the roller clutch. Otherwise, the clutch could stick, slip, or
otherwise malfunction.
5.
Install the removed parts to their original position.
Install it in the reverse order from the removal procedure.
For installing the chain stabilizer and cam unit, refer to step 5 in Installation in Replacement of the
plate and the plate tension spring.
For installing the plate unit cover, refer to step 6 in Adjusting friction.
6.
Maintenance
Applying grease to the chain stabilizer
150
Adjusting friction The level of friction can be adjusted as desired. Furthermore, the friction can also be adjusted when it changes
during use.
RD-RX815
Set the switch lever in the OFF position.
Switch lever
1.
Remove the plate unit cover.
Plate unit cover screw
Plate unit cover
2.
Maintenance
Adjusting friction
151
Adjust the friction.
Friction adjustment screw
IncreaseDecrease
RD-RX815
3.
Check the friction torque.
Switch lever
ON Cam unit(1)
3.1 - 5 Nm
Chain stabilizer(2)
Use your finger to hold the cam unit securely in place, then set the switch lever to the ON position.(1)
Insert a 4 mm hexagon wrench into the chain stabilizer and check the friction torque.(2)
If adjusting the friction once more, be sure to set the switch lever to the OFF position while pressing
the cam unit with your finger before making the adjustment.
4.
Maintenance
Adjusting friction
152
RD-RX817
The friction can be adjusted for RD-RX817 without removing the plate unit cover.
Set the switch lever in the OFF position.
Set the switch lever to the OFF position while pressing the cam unit with your finger. At that time, make sure
that the cam unit is in contact with the bottom of the plate unit.
OFF
Do not install the plate unit cover if the plate unit is not fully seated against the switch base. This
may result in insufficient sealing, which can lead to corrosion and malfunction of the chain
stabilizer assembly.
5.
Install the plate unit cover.
Plate unit cover screw
Plate unit cover
1 - 1.5 Nm
6.
Maintenance
Adjusting friction
153
Set the switch lever in the ON position.1.
Open the plate unit rubber cap.
The plate unit rubber cap can be opened by hand.
Plate unit rubber cap
The plate unit rubber cap can be completely removed. However, be careful not to lose it. If the cap
comes off when riding the bicycle, problems with operation will occur.
2.
Adjust the friction.
Friction adjustment screw
IncreaseDecrease
3.
Maintenance
Adjusting friction
154
Replacement of the plate and the plate tension spring
Removal
Before starting the work, shift the gear of the rear derailleur to the largest sprocket.
Check the friction torque.
Use the hexalobular hole on the left plate to check the friction torque.
Left plate
2.5 - 4 Nm
4.
Install the plate unit rubber cap as shown in the figure.
Plate unit rubber cap
5.
Maintenance
Replacement of the plate and the plate tension spring
155
Set the switch lever in the OFF position.
Switch lever
ON
OFF
If operating the switch lever while the plate unit cover is removed, hold the cam unit down with
your finger. Failure to follow these instructions may cause the cam unit to slide out.
1.
Remove the plate stopper pin.
Plate stopper pin
1 Nm
2.
Turn the plate to loosen the plate tension spring.
Plate
3.
Maintenance
Replacement of the plate and the plate tension spring
156
Remove the plate unit cover.
Plate unit cover screw
Plate unit cover
4.
Remove the chain stabilizer and cam unit.
Chain stabilizer
Cam unit
5.
Maintenance
Replacement of the plate and the plate tension spring
157
Installation
When removing it, reverse the procedure.
Remove the plate axle.
Plate axle
6.
Apply the dedicated grease to the plate axle.
Grease application area Grease number: Premium Grease (Y04110000)
Plate axle
Do not apply grease outside of the application area indicated above. If grease is applied here, it will
get inside the roller clutch and friction will be lost.
1.
Maintenance
Replacement of the plate and the plate tension spring
158
Insert the plate axle, then fit the tip of the plate tension spring in the hole of the plate.
RD-RX815
Plate
8 - 10 Nm
Plate tension spring
Plate axle
RD-RX817
Plate
8 - 10 Nm
Plate tension spring
Plate axle
2.
Maintenance
Replacement of the plate and the plate tension spring
159
Check that the switch lever is in the OFF position.
If the switch lever is in the ON position, be sure to set it to the OFF position.
Switch lever
ON
OFF
3.
Set the chain stabilizer into the cam unit as shown in the figure.
Check that the cam lobe of the cam unit is in the position shown in the figure.
Cam unit
Chain stabilizer
Cam lobe
Cam lobe
4.
Maintenance
Replacement of the plate and the plate tension spring
160
Install the cam unit and chain stabilizer.
Pay attention to the positioning of the cam lobe of the cam unit.
Cam lobe
When installing, it helps to move the plate back and forth while pushing on the cam unit and chain
stabilizer.
Plate
If there is resistance when moving the switch lever to the ON position, the components are installed
correctly. If there is no resistance, check the position of the cam lobe of the cam unit and reinstall
the components.
Switch lever
5.
Maintenance
Replacement of the plate and the plate tension spring
161
Install the plate unit cover gasket.
Check that it is installed along the groove in the plate unit.
Plate unit cover gasket
6.
Install the plate unit cover.
1 - 1.5 Nm Plate unit cover screw
Plate unit cover
7.
Turn the plate to tighten the plate tension spring.
Plate
8.
Maintenance
Replacement of the plate and the plate tension spring
162
Related manuals for Shimano GRX Di2 FD-RX815-F Front Derailleur Dealer's Manual
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