Contents

Shimano GRX RD-RX400 Rear Derailleur Dealer's Manual PDF

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Summary of Content for Shimano GRX RD-RX400 Rear Derailleur Dealer's Manual PDF

(English)

Dealer's Manual ROAD MTB Trekking

City Touring/ Comfort Bike

URBAN SPORT E-BIKE

Rear Derailleur

GRX RD-RX810 RD-RX812 RD-RX400

DM-GARD001-02

2

Contents Contents ...................................................................................2

IMPORTANT NOTICE ..................................................................3

TO ENSURE SAFETY ...................................................................4

List of tools to be used ............................................................6

Installation/removal ................................................................7

Installing the rear derailleur ..................................................................7 Standard type ........................................................................................................................... 7

Direct mount type .................................................................................................................... 9

Adjustment .............................................................................11

Adjusting the stroke on the high limit ...............................................11

Installing the chain ...............................................................................11

Checking the chain length ...................................................................11

Connection and securing of the inner cable ......................................14 Outer casing length ................................................................................................................ 14

Connection and securing of the inner cable ........................................................................ 16

Adjusting the stroke on the low limit ................................................18

Adjusting the B-screw ..........................................................................19

SIS adjustment ......................................................................................20

Maintenance ...........................................................................22

Replacing the pulleys ...........................................................................22

Applying grease to the chain stabilizer ..............................................23

Adjusting friction .................................................................................24

Replacement of the plate and the plate tension spring ...................28 Removal .................................................................................................................................. 28

Installation .............................................................................................................................. 31

3

IMPORTANT NOTICE

IMPORTANT NOTICE 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 the 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.

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.

4

TO ENSURE SAFETY

TO ENSURE SAFETY WARNING

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.

Be sure to also inform users of the following:

Clean the chain and QUICK-LINK 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 or QUICK-LINK might break and cause serious injury.

Check the chain for any damage (deformation or cracking), skipping, or other abnormalities such as unintended gear shifting. The chain may break, and you may fall. If any problems are found, consult your place of purchase or a distributor.

When using TL-CT12:

Be careful not to get injured by the blade or needle while working.

Be careful not to get your fingers pinched by the tool while working.

Keep the tool out of the reach of small children.

NOTICE

Be sure to also inform users of the following:

For SHADOW RD+, be sure to check that the plate unit cover and the plate unit rubber cap are installed before riding the bicycle.

If gear shifting operation does not feel smooth, consult the place of purchase for assistance.

The gears should be periodically washed with a neutral detergent then lubricated. In addition, cleaning the chain and QUICK-LINK with a neutral detergent and lubricating them can be an effective way of extending the life of the chain and QUICK-LINK.

Products are not guaranteed against natural wear and deterioration from normal use and aging.

5

TO ENSURE SAFETY

For maximum performance we highly recommend SHIMANO lubricants and maintenance products.

For installation to the bicycle, and maintenance:

Depending on the shape of the frame, the rear derailleur may interfere with the chainstay. Use the B-screw to adjust so that the rear derailleur does not interfere with the chainstay.

Grease with SIS SP41 grease (Y04180000) the inner cable and the sliding portions of the outer casing before use to ensure that they slide properly. Do not let dust adhere to the inner cable.

To ensure smooth operation, use OT-RS900 outer casing for rear derailleur and a cable guide.

Use an 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 shifting lever does not touch the bicycle frame when the handlebars are turned all the way.

The end of the outer casing which has the sealed outer cap (aluminum type) should be on the shifting unit side. Refer to the ST-RX810 dealer's manual for details.

Shifting unit side

Sealed outer cap (aluminum type)

Cap with long tongue

If gear shifting adjustments cannot be carried out, check the alignment of the dropout and check if the cable is lubricated or if the outer casing is too long or too short.

Periodically clean the shifting unit and lubricate all moving parts (mechanism and pulleys).

If you hear abnormal noise as a result of excess play in a pulley, you should replace the pulley.

The actual product may differ from the illustration because this manual is intended mainly to explain the procedures for using the product.

6

List of tools to be used

List of tools to be used The following tools are needed for installation/removal, adjustment, and maintenance purposes.

Tool

2 mm hexagon wrench

3 mm hexagon wrench

4 mm hexagon wrench

5 mm hexagon wrench

5.5 mm spanner

Cross head screwdriver [#2]

TL-CT12

7

Installation/removal

Installing the rear derailleur

Installation/removal Installing the rear derailleur

TECH TIPS

The rear derailleur will not gear shift properly if the derailleur hanger is not straight. Use TL-RD11 to check whether the derailleur hanger is straight or not.

Standard type

1. Set the switch lever in the OFF position.

Switch lever

ON

OFF

8

Installation/removal

Installing the rear derailleur

2. Tighten the rear derailleur fixing screw.

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 xing screw

Stopper plate

B-tension stop

8 - 10 Nm

NOTICE

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.

9

Installation/removal

Installing the rear derailleur

Direct mount type

1. Set the switch lever in the OFF position.

Switch lever

ON

OFF

2. Remove the bracket axle plate.

RD-RX810/RD-RX812 RD-RX400

3. Install the rear derailleur.

(1) Insert the derailleur hanger into the installation part for direct mount of the rear derailleur.

10

Installation/removal

Installing the rear derailleur

(2) Install the rear derailleur with the B-axle2.

Derailleur hanger(1)

B-axle2(2)

8 - 10 Nm

11

Adjustment

Adjusting the stroke on the high limit

Adjustment Adjusting the stroke on the high limit

1. Adjust by turning the high limit screw.

Adjust so that the center of the guide pulley is aligned with the outer face of the smallest sprocket when viewed from the rear side.

High limit screw

Smallest sprocket

Guide pulley

High limit screw*

RD-RX400 RD-RX810/ RD-RX812

*

Installing the chain Refer to the dealer's manual for the chain to find instructions on installing/removing the chain.

Checking the chain length

1. Mount the chain on the largest sprocket and the largest chainring.

Largest sprocket Chain

Largest chainring

12

Adjustment

Checking the chain length

2. 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

13

Adjustment

Checking the chain length

NOTICE

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-RX810

RD-RX812/RD-RX400

Chain derailment prevention plate

Chain derailment prevention plate

Chain derailment prevention plate

14

Adjustment

Connection and securing of the inner cable

Connection and securing of the inner cable

Outer casing length

1. Loosen the B-screw to the position shown in the figure.

Make sure that the stopper plate touches the bracket body without leaving a gap.

B-screw

Bracket body

Stopper plate

2. Determine the length of the outer casing.

Fit a sealed outer cap to the end of the outer casing. Align the end of the outer cap to the bottom edge of the outer casing holder on the rear derailleur.

Make sure to leave enough slack in the outer casing.

Outer casing Outer casing holder

Sealed outer cap (aluminum type)

NOTICE

Make sure to use OT-RS900 for the outer casing.

15

Adjustment

Connection and securing of the inner cable

3. Cut off any excess outer casing with the cable cutter.

Cut the end of the outer casing that is opposite to the marking.

Outer cap with tongue

4. Remove the outer cap with tongue from the cut outer casing.

5. Spread out the tip of the liner using a thin tool such as a TL-CT12 needle.

Arrange the cut end into a perfect circle.

TL-CT12 needle

NOTICE

Be careful not to hurt your hands with the TL-CT12 needle.

16

Adjustment

Connection and securing of the inner cable

6. Install the cap with long tongue to the end.

The end of the outer casing which has the sealed outer cap (aluminum type) should be on the shifting unit side.

Route the inner cable through the outer casing.

Sealed outer cap

Cap with long tongue

OT-RS900

(aluminum type)

Connection and securing of the inner cable

1. Set the shifting lever in its initial position.

Operate the release lever 10 times or more.

2. Secure the inner cable to the rear derailleur.

There is no cover with tongue for RD-RX400.

Inner cable Cover with tongue

NOTICE

When replacing the inner cable for RD-RX810/RD-RX812, it is recommended to replace the cover with tongue.

Cables with a polymer coating may develop a fuzzy appearance or texture through natural wear when used. However, if the cables are installed with care according to the procedures outlined in this manual, this is strictly cosmetic and performance will not be affected where the inner cables are housed by outer casing.

17

Adjustment

Connection and securing of the inner cable

3. Remove the initial slack from the inner cable.

Hold the rear derailleur so that it won't move under load from the shift cable. Operate the shifting lever several times in order to tension the shift cable assembly and fully seat all the shift cable components.

4. Re-secure the inner cable to the rear derailleur.

While pulling the inner cable, be sure that it is securely in the cable fixing groove.

6 - 7 Nm

Inner cable

5. Cut the inner cable so that the protruding length is approximately 30 mm.

Install the inner end cap.

Inner end cap

30 mm

18

Adjustment

Adjusting the stroke on the low limit

NOTICE

Check that the inner cable does not interfere with the spokes of the wheel.

Do not allow the wheel to turn while carrying out this step.

Adjusting the stroke on the low limit

1. Adjust by turning the low limit screw.

Adjust so that the center of the guide pulley is aligned with the center of the largest sprocket.

Largest sprocket

Guide pulley

Low limit screw *

Low limit screw*

RD-RX810/ RD-RX400

RD-RX812

19

Adjustment

Adjusting the B-screw

Adjusting the B-screw

1. 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.

Bring the guide pulley as close to the largest sprocket as possible without any turbulence between the pulley and sprocket.

B-screw *

Smallest sprocket

Largest sprocket

B-screw*

20

Adjustment

SIS adjustment

3. Check that the chain has running clearance when it is in the smallest rear sprocket.

If the chainstay and rear derailleur interfere, adjust by turning the B-screw until they do not interfere.

If there is some slack in the chain, adjust the B-screw to remove the slack from the chain.

SIS adjustment

1. Set the switch lever in the OFF position.

Switch lever

ON

OFF

2. Operate the shifting lever once to shift to the 2nd sprocket counting from the smallest sprocket.

3. Shift to the 2nd from the smallest sprocket. If using a 2x system, also shift to the largest chainring.

4. Turn the cable adjustment barrel counterclockwise to add cable tension until you can hear noise from the chain rubbing the 3rd smallest sprocket.

Cable adjustment barrel

21

Adjustment

SIS adjustment

5. Turn the cable adjustment barrel clockwise to reduce cable tension until no noise is heard from the chain rubbing the sprocket.

Cable adjustment barrel

6. Return the shifting lever to its original position (the position of the 2nd sprocket counting from the smallest sprocket, with your finger released from the shifting lever), then turn the crank.

NOTICE

If it is touching the 3rd sprocket counting from the smallest sprocket and making noise, turn the cable adjustment barrel clockwise slightly to tighten it just enough until the noise stops.

7. Operate the shifting lever to change gears while turning the crank, and check that no noise occurs in any of the gear positions.

TECH TIPS

The rear derailleur will not gear shift properly if the derailleur hanger is not straight. Use TL-RD11 to check whether the derailleur hanger is straight or not.

8. Set the switch lever in the ON position and check that the gear shifting is smooth, consistent, and that there is no noise in any of the gear positions while riding the bicycle.

If gear shifting from the largest sprocket becomes slow with the switch lever in the ON position, adjust the guide pulley slightly further away by turning the B-screw.

22

Maintenance

Replacing the pulleys

Maintenance Replacing the pulleys

1. Replace the guide pulley and tension pulley.

Check the arrow direction on the pulley when installing it.

For RD-RX400, the pulley can be installed in any direction.

2.5 - 5 Nm

2.5 - 5 Nm

Guide pulley RD-RX810/RD-RX812 RD-RX400

RD-RX810/RD-RX812 RD-RX400 Tension pulley

2.5 - 5 Nm

2.5 - 5 Nm

Guide pulley

Tension pulley

NOTICE

The pulley for RD-RX810/RD-RX812 has an arrow on it to indicate the direction of rotation. Install so that the guide pulley moves clockwise and the tension pulley moves counterclockwise when viewed from the inner side of the shifting unit.

23

Maintenance

Applying grease to the chain stabilizer

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.

* When assembling, reverse the procedure.

1. Set the switch lever in the OFF position.

Switch lever

ON

OFF

2. Remove the plate unit cover.

Plate unit cover

3. Remove the chain stabilizer and cam unit together.

Chain stabilizer

24

Maintenance

Adjusting friction

4. Apply the dedicated grease to the outer diameter of the roller clutch.

SHADOW RD+ Grease number: Y04121000 (50 g)

NEXUS Grease number: Y04120800 (100 g)

Roller clutch

NOTICE

Be careful not to get grease inside the roller clutch. Otherwise, the clutch could stick, slip, or otherwise malfunction.

Adjusting friction The level of friction can be adjusted as desired. Furthermore, the friction can also be adjusted when it changes during use.

1. Set the switch lever in the OFF position.

Switch lever

ON

OFF

25

Maintenance

Adjusting friction

2. Use a 2 mm hexagon wrench to remove the plate unit cover.

Plate unit cover

3. Turn the friction adjustment screw to adjust the friction.

Friction adjustment screw

IncreaseDecrease

RD-RX810

Friction adjustment screw

IncreaseDecrease

RD-RX812/RD-RX400

26

Maintenance

Adjusting friction

4. Check the friction torque.

Use your finger to hold the cam unit securely in place, then set the switch lever to the ON position.

Insert a 4 mm hexagon wrench into the chain stabilizer and check the friction torque.

2.6 - 4.2 Nm 3 - 4.9 Nm

(RD-RX812) (RD-RX810/RD-RX400)

Cam unit

Chain stabilizer

Switch lever ON

NOTICE

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.

5. 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

27

Maintenance

Adjusting friction

NOTICE

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.

6. Install the plate unit cover.

1 - 1.5 Nm

Plate unit cover

28

Maintenance

Replacement of the plate and the plate tension spring

Replacement of the plate and the plate tension spring

Removal

1. Set the switch lever in the OFF position.

Switch lever

ON

OFF

NOTICE

If operating the switch lever while the plate unit cover is removed, hold the cam unit down with your finger so that it does not slide out.

2. Remove the plate stopper pin with a cross head screwdriver.

Plate stopper pin

29

Maintenance

Replacement of the plate and the plate tension spring

NOTICE

Hold the plate and rear derailleur body firmly when working, as there is spring tension applied to the plate.

3. Turn the plate to loosen the plate tension spring.

As shown in the figure, squeeze the outer casing holder and cable attachment portion together to move the link and turn the plate.

Outer casing holder

Cable attachment portion

Link

4. Remove the plate unit cover screws.

Plate unit cover screw

30

Maintenance

Replacement of the plate and the plate tension spring

5. Remove the plate unit cover.

Plate unit cover

6. Remove the chain stabilizer and cam unit.

Cam unit

Chain stabilizer

7. Remove the plate axle.

Plate axle

31

Maintenance

Replacement of the plate and the plate tension spring

Installation

Perform the installation in the reverse order from the removal procedure.

1. Apply the dedicated grease to the plate axle.

Grease application area Grease number: Premium Grease (Y04110000)

Plate axle

NOTICE

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.

2. Insert the plate axle, then fit the tip of the plate tension spring in the hole of the plate.

RD-RX810

Plate

8 - 10 Nm

Plate tension spring

Plate axle

32

Maintenance

Replacement of the plate and the plate tension spring

RD-RX812

Plate tension spring

Plate axle

8 - 10 Nm

Plate

RD-RX400

Plate tension spring

Plate axle

Plate

8 - 10 Nm

3. 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

33

Maintenance

Replacement of the plate and the plate tension spring

4. 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

NOTICE

Ensure the cam unit is installed with the cam lobe in the correct position. Do not install it in the position shown in this figure.

Cam lobe

34

Maintenance

Replacement of the plate and the plate tension spring

5. Install the cam unit and chain stabilizer.

Pay attention to the positioning of the cam lobe of the cam unit.

35

Maintenance

Replacement of the plate and the plate tension spring

TECH TIPS

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 then reinstall the components.

Switch lever

6. Install the plate unit cover gasket.

Check that it is installed along the groove in the plate unit.

Plate unit cover gasket

36

Maintenance

Replacement of the plate and the plate tension spring

7. Install the plate unit cover screws.

Plate unit cover screw

1 - 1.5 Nm

8. Twist the plate, install the plate stopper pin.

Plate

Plate stopper pin

1 Nm

NOTICE

Hold the plate and rear derailleur body firmly when working, as there is spring tension applied to the plate.

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