Shimano Ultegra ST-6870 Dealer's Manual
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Shimano Ultegra ST-6870 Dealer's Manual

Ultegra 6870 series
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(English)
DM-UL0001-00
Dealer's Manual
6870 Series
ST-6870
ST-6871
FD-6870
RD-6870
SW-R610
SW-9071
SW-R671
SM-EW90
EW-SD50
SM-EWC2
SM-JC40
SM-JC41
SM-BTR1
SM-BTR2
SM-BMR1
SM-BMR2
SM-BA01
SM-BCR1
SM-BCR2
SM-BCC1

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Summary of Contents for Shimano Ultegra ST-6870

  • Page 1 (English) DM-UL0001-00 Dealer's Manual 6870 Series ST-6870 ST-6871 FD-6870 RD-6870 SW-R610 SW-9071 SW-R671 SM-EW90 EW-SD50 SM-EWC2 SM-JC40 SM-JC41 SM-BTR1 SM-BTR2 SM-BMR1 SM-BMR2 SM-BA01 SM-BCR1 SM-BCR2 SM-BCC1...

  • Page 2: Table Of Contents

    CONTENTS IMPORTANT NOTICE ....................4 TO ENSURE SAFETY ....................5 Introduction ..............................5 Lithium ion battery ............................6 Battery charger / Battery charger cord .......................8 Brake ................................10 Rear derailleur ............................10 For Installation to the Bicycle, and Maintenance: ..................10 Be sure to also inform users of the following: ..................12 INSTALLATION .....................
  • Page 3 CONNECTION OF THE ELECTRIC WIRES ............. 39 Connection of the Junction (A) .........................39 Connection of the Junction (B) .........................40 Connection to the Dual control lever .......................45 Routing junction (B) and the electric wires inside the frame ..............47 Assembly of the bottom bracket shell ......................48 Installation of the grommets ........................48 Checking connections ..........................49 Disconnection of the electric wires ......................50...

  • Page 4: Important Notice

    • Do not disassemble or modify the product other than as stated in the information contained in this dealer’s manual. • All dealer’s manuals and instruction manuals can be viewed on-line on our website (http://si.shimano.com). • Please observe the appropriate rules and regulations of the country, state or region in which you conduct your business as a dealer.

  • Page 5: To Ensure Safety

    • When installing components, be sure to follow the instructions that are given in the instruction manuals. It is recommended that you use only genuine Shimano parts. If parts such as bolts and nuts become loose or damaged, the bicycle may suddenly fall over, which may cause serious injury.

  • Page 6: Lithium Ion Battery

    TO ENSURE SAFETY Lithium ion battery „ Lithium ion battery DANGER Be sure to also inform users of the following: Be sure to observe the following in order to avoid burns or other injury from fluid leakages, overheating, fire or explosions. •...
  • Page 7 TO ENSURE SAFETY Lithium ion battery CAUTION Be sure to also inform users of the following: • Store the battery in a safe place away from the reach of infants and pets. SM-BTR1: Lithium ion battery (external type) • When you do not use the battery for a long period, remove and charge the battery before storage. SM-BTR2: Lithium ion battery (built-in type) •...

  • Page 8: Battery Charger / Battery Charger Cord

    TO ENSURE SAFETY Battery charger / Battery charger cord „ Battery charger / Battery charger cord DANGER Be sure to also inform users of the following: Be sure to observe the following in order to avoid burns or other injury from fluid leakages, overheating, fire or explosions. •...
  • Page 9 Disposal information for countries outside the European Union This symbol is only valid within the European Union. Contact the place of purchase or your nearest Shimano agent for advice on disposing. • Charge the battery in indoor places to avoid exposure to rain or wind.

  • Page 10: Brake

    TO ENSURE SAFETY Brake „ Brake WARNING • It is important to completely understand the operation of your bicycle's brake system. Improper use of your bicycle's brake system may result in a loss of control or a fall, which could lead to severe injury. Because each bicycle may handle differently, be sure to learn the proper braking technique (including brake lever pressure and bicycle control characteristics) and operation of your bicycle.

  • Page 11: Rear Derailleur

    • The motors of the motor unit cannot be repaired. • Contact Shimano for information regarding the shipment of the battery charger to South Korea and Malaysia. • Use an electric wire which still has some length to spare even when the handlebars are turned all the way to both sides. Furthermore, check that the shifting lever does not touch the bicycle frame when the handlebars are turned all the way.

  • Page 12: Be Sure To Also Inform Users Of The Following

    TO ENSURE SAFETY Be sure to also inform users of the following: „ Be sure to also inform users of the following: NOTE Be sure to also inform users of the following: About used batteries • Lithium ion batteries are recyclable, valuable resources. For information on used batteries, contact the place of purchase or a bicycle dealer.
  • Page 13 INSTALLATION...

  • Page 14: Installation

    INSTALLATION INSTALLATION This Dealers manual provided a ULTEGRA 6870 series only (electric transmission system). For other products refer Dealer's Manual of 6800 series. List of tools to be used The following tools are required to assemble the product. Component Where to use Tool Clamp nut 5 mm Allen key...

  • Page 15: Electric Wire Wiring Diagram (Overall Conceptual Diagram)

    INSTALLATION Electric wire wiring diagram (overall conceptual diagram) „ Electric wire wiring diagram (overall conceptual diagram) Lithium ion battery (external type) SM-BTR1 External type (SM-JC40) SM-BTR1 SM-BMR2 Lithium ion battery Battery mount (external type) EW-SD50 Electric wire SM-EW90-A/B Junction (A) SM-JC40 Junction (B) Built-in type (SM-JC41)
  • Page 16 INSTALLATION Electric wire wiring diagram (overall conceptual diagram) Lithium ion battery (built-in type) SM-BTR2 Built-in type (SM-JC41) SM-BTR2 Lithium ion battery (built-in type) SM-EW90-A/B Junction (A) SM-JC41 Junction (B) EW-SD50-I Electric wire...

  • Page 17: Electric Wire Wiring Diagram (Junction (A) Side)

    INSTALLATION Electric wire wiring diagram (junction (A) side) „ Electric wire wiring diagram (junction (A) side) 3 port Drop handle type ST-6870 ST-6870 E-tube port ×2 Port for remote Port for remote sprinter shifter sprinter shifter SM-EW90-A E-tube connector Connector for remote sprinter...
  • Page 18 INSTALLATION Electric wire wiring diagram (junction (A) side) 5 port Clip-on bar type SW-R671 SW-9071 option option ST-6870 ST-6870 E-tube E-tube Port for remote port ×2 port ×2 Port for remote sprinter shifter sprinter shifter SM-EW90-B E-tube connector SW-R610 SM-EW90-B...

  • Page 19: Installation Of The Dual Control Lever And Brake Cable

    • The clamp band, clamp bolt, and clamp nut of ST-6870 have no compatibility with other products. Do not use components that are used in other products together. Tightening torque: 6.0 - 8.0 N·m...
  • Page 20 INSTALLATION Installation of the dual control lever and brake cable Move the lever in the direction of brake Outer casing operation and put the brake cable Cable hook through. CAUTION Inner end Make sure that the inner end is firmly seated in the cable hook.

  • Page 21: Tightening Torque

    INSTALLATION Installation of the dual control lever and brake cable ST-6871 Pass the outer casing through the handlebar. Adjust the length of the outer casing so that it will fit securely into the outer casing holder when the brake lever is installed. Install the brake lever to the handlebar Handlebar by using an Allen key to turn it...

  • Page 22: Installation Of The Front Derailleur

    INSTALLATION Installation of the front derailleur „ Installation of the front derailleur Check if the front derailleur mounting frame is a brazed-on type or band type. When installing to a brazed-on type frame Mount the backup plate to the seat Tape tube.
  • Page 23 INSTALLATION Installation of the front derailleur Adjust so that there is a clearance of 1 Chain guide outer plate Clearance: 1 - 3 mm – 3 mm between the chain guide outer plate and the largest chainring. Use a Allen key to secure the chain guide Chain guide outer plate so that the flat part of the Front chainwheel...

  • Page 24: Installation Of The Rear Derailleur

    INSTALLATION Installation of the rear derailleur „ Installation of the rear derailleur Dropout tab B-tension adjustment bolt CAUTION Install the rear derailleur to the frame. When installing the rear derailleur, make sure that the B-tension adjustment bolt does not touch the dropout tab and cause it to bend. Tightening torque: 8.0 - 10.0 N·m {70 - 87 in.

  • Page 25: Installation Of The Shifting Switch

    INSTALLATION Installation of the shifting switch „ Installation of the shifting switch SW-R610 (Sprinter Switch) Routing Map ST-6870(R) ST-6870(L) SW-R610 Determine the length of the handlebar tape in accordance with the length of the cutout tool as shown in the Make sure that you handle the utility knife illustration.
  • Page 26 INSTALLATION Installation of the shifting switch Align the cut holes in the handlebar tape with the switches. CAUTION Wind the handlebar tape. At this time, be sure to overlap the tape In order to protect the cable, use handlebar below the switches. tape to secure the cable.
  • Page 27 Installation of the shifting switch SW-R671 (Shifting switch for aero bar) Routing Map Junction (A) SW-R671 ST-6870 Remove the cover fi xing bolt (M4) with Cover fi xing bolt an Allen key. Cover fi xing nut Remove the bracket cover from the end Bracket cover of the bracket.
  • Page 28 INSTALLATION Installation of the shifting switch Place the bracket onto the end of the Pull-up bolt aero bar. Adjust the direction of the Aero bar switch operation surface at this time. Use an Allen key to turn the pull-up bolt counterclockwise to tighten it in order to CAUTION install the bracket to the aero bar.
  • Page 29 Installation of the shifting switch SW-9071 (Shifting switch for aero bar) Routing Map Junction (A) SW-9071 ST-6870 Remove two cover fi xing bolts (M2.6) Cover fi xing bolt with an Allen key. Cover fi xing nut Remove the bracket cover from the end Bracket cover of the bracket.
  • Page 30 INSTALLATION Installation of the shifting switch Place the bracket onto the end of the Pull-up bolt aero bar. Adjust the direction of the Aero bar switch operation surface at this time. Use an Allen key to turn the pull-up bolt counterclockwise to tighten it in order to CAUTION install the bracket to the aero bar.
  • Page 31 SM-EW90 ST-6870(R) Shifting switch Dummy plug Electric wire CAUTION The illustration shows an example for ST-6870/ SW-R610. • This varies depending on the combination of the dual control lever and the gear-shifting switch. For details, refer to the electric cable wiring diagram (junction (A)).

  • Page 32: Installation Of The Junction (A)

    INSTALLATION Installation of the junction (A) „ Installation of the junction (A) Attach to the stem using the band and Band hook included with SM-EW90. Stem Hook Hook the band on the hook and wind it around the stem. Pull on and secure the band. Slide SM-EW90 into the rail section of SM-EW90 Junction (A) the hook to install it.

  • Page 33: Installation Of The Junction (B)

    INSTALLATION Installation of the junction (B) „ Installation of the junction (B) If a wire guide is mounted on the frame, Wire guide remove it. Attach junction (B) using the wire guide Junction (B) mounting hole. (Finished image) „ Installation of the battery In the case of an external battery (SM-BTR1) Installation of the battery mount Tightening torque:...
  • Page 34 INSTALLATION Installation of the battery Leave a space of 108 mm or more at the end of the battery mount. Check that the battery can be inserted and removed while the bottle cage is installed. Tighten the bolt of the bottle cage to Zip tie secure the battery mount.
  • Page 35 INSTALLATION Installation of the battery Installation of the battery cable cover Set the electric wire for the battery mount into the groove in the electric wire cover for the battery mount. Place the accessory spacers in between Spacers the battery mount and the frame and then secure them by tightening the bolts.
  • Page 36 INSTALLATION Installation of the battery Installation of the bottle cage adapter Spacers • If the bottle cage which is installed to the seat tube interferes with the battery, move the position of the bottle cage upward. The installation position for the bottle cage can be moved upward by a minimum of 32 mm and a maximum of 50 mm from the original installation position.
  • Page 37 INSTALLATION Installation of the battery In the case of a built-in battery (SM-BTR2) Installation of the Lithium ion battery (built-in type) Bond seat post collar to inside of seat Seat post post. Insert internal battery into the collar Seat post collar from the bottom of seat post.
  • Page 38 CONNECTION OF THE ELECTRIC WIRES...

  • Page 39: Connection Of The Electric Wires

    • The electric wire can be wound around the handle when the bar tape is wrapped. • Wire SM-EW90 with a sufficient margin to allow the positioning of ST-6870 and the full turning of the handle. 5 port ST-6870 SM-JC40/41 Junction (B) E-tube port ×5...

  • Page 40: Installation Of Electric Wires

    CONNECTION OF THE ELECTRIC WIRES Connection of the Junction (B) Installation of the electric wires Set so that the projection on the connector is aligned with the groove on the narrow end. TL-EW02 Plug CAUTION Use the special tool for installation and removal of the electric wire.
  • Page 41 CONNECTION OF THE ELECTRIC WIRES Connection of the Junction (B) Connect the electric wires to the front derailleur, the rear derailleur and the battery mount. Front derailleur Rear derailleur Battery mount TL-EW02 FD-6870 has a cable holder on the back side. After connection, attach the cable as shown in the illustration.
  • Page 42 CONNECTION OF THE ELECTRIC WIRES Connection of the Junction (B) Wind any excess length of electric wire inside junction (B) to adjust the length. Example of adjusting junction (B) length CAUTION Install the electric wire cover to the frame. To ensure adhesion, before installing the electric wire cover, wipe off the grease on the frame with alcohol or a cleaner.
  • Page 43 CONNECTION OF THE ELECTRIC WIRES Connection of the Junction (B) Built-in type (SM-JC41) Bottom bracket shell Electric wire for rear derailleur Electric wire for front derailleur Electric wire for junction (A) In the case of an external battery (SM-BTR1) In the case of a built-in battery (SM-BTR2) Electric wire for battery mount Electric wire for battery mount To be continued on next page...
  • Page 44 CONNECTION OF THE ELECTRIC WIRES Connection of the Junction (B) First pass the electric wires for junction Wire holder (A), the battery mount, the front derailleur and the rear derailleur through the holes in the frame into the bottom bracket shell. The electric wires for built-in use can be inserted only in one direction.

  • Page 45: Connection To The Dual Control Lever

    CONNECTION OF THE ELECTRIC WIRES Connection to the Dual control lever „ Connection to the Dual control lever < ST-6870 > Open up the bracket cover and lift up Bracket cover the connector cover. Connector cover Use the TL-EW02 to connect the...
  • Page 46 CONNECTION OF THE ELECTRIC WIRES Connection to the Dual control lever < SW-R671/SW-9071/ST-6871 > SW-R671 For the following models, attach to the electric cable (the type that comes out from a component) junction (A) of the product. SW-R671/SW-9071/ST-6871 SW-9071 ST-6871 <...

  • Page 47: Routing Junction (B) And The Electric Wires Inside The Frame

    CONNECTION OF THE ELECTRIC WIRES Routing junction (B) and the electric wires inside the frame „ Routing junction (B) and the electric wires inside the frame Pass the electric wires for the front Rear derailleur derailleur and the rear derailleur Front derailleur through the seat tube and chainstay respectively.

  • Page 48: Assembly Of The Bottom Bracket Shell

    CONNECTION OF THE ELECTRIC WIRES Assembly of the bottom bracket shell „ Assembly of the bottom bracket shell Make sure that the electric wires for the Inner cover front derailleur and the rear derailleur Adapter pass over the top of the inner cover. Install the inner cover to the bottom Inner cover bracket adapter.

  • Page 49: Checking Connections

    CONNECTION OF THE ELECTRIC WIRES Checking connections Push the tops to fit them into place. There are two types of grommets. Choose one according to the shape of the hole in the frame. Circle: SM-GM01 Ellipse: SM-GM02 Rear derailleur Front derailleur „...

  • Page 50: Disconnection Of The Electric Wires

    If you forcibly remove the electric wire, you may damage the wire. Remove the electric wire from the cable Cable holder holder. If the electric wire is diffi cult to remove, remove the rear wheel. „ Removing other parts RD-6870 ST-6870 SM-JC40 SM-JC41...
  • Page 51 ADJUSTMENT...

  • Page 52: Adjustment

    ADJUSTMENT Adjustment of the rear derailleur ADJUSTMENT „ Adjustment of the rear derailleur Install the battery. Adjust the B-tension adjustment bolt. Largest chainring Mount the chain on the smallest Smallest chainring chainring and the largest sprocket, and Guide pulley turn the crank arm backward. B-tension adjustment bolt Then turn the B-tension adjustment bolt to adjust the guide pulley as close to the...
  • Page 53 ADJUSTMENT Adjustment of the rear derailleur If shifting switch (X) is pressed once Shifting switch while the initial setting condition is active, the guide pulley will move one step toward the inside. If shifting switch (Y) is pressed once, the guide pulley will move one step toward the outside.
  • Page 54 ADJUSTMENT Adjustment of the rear derailleur Next, operate shifting switch (Y) 4 times to move the guide pulley toward the outside by 4 steps to the target position. 4 steps 4 times Press the button at junction (A) until the Junction (A) red LED turns off in order to switch from rear derailleur adjustment mode to gear...

  • Page 55: Adjustment Of The Front Derailleur

    ADJUSTMENT Adjustment of the front derailleur Adjustment of the top-side stopper bolt Adjust the stopper bolt with an Allen Top-side stopper adjustment key. bolt Shift the rear derailleur to the smallest sprocket, and then tighten the top-side stopper adjustment bolt until it touches the stopper at the position where the rear derailleur finally stopped.
  • Page 56 ADJUSTMENT Adjustment of the front derailleur Use an Allen key to turn the low adjustment bolt. Adjust so that there is a clearance of 0 - 0.5 mm between the chain and the chain guide inner plate. 0 - 0.5 mm Top adjustment Set the chain onto the largest chainring Smallest sprocket...
  • Page 57 ADJUSTMENT Adjustment of the front derailleur Top position electrical adjustment Set the rear derailleur to the largest Largest sprocket sprocket. Largest chainring Press the button at the junction (A) until LED window for button the red LED illuminates in order to Junction (A) switch to adjustment mode.
  • Page 58 ADJUSTMENT Adjustment of the front derailleur CAUTION Adjust the gap between the chain and the front derailleur to 0 - 0.5 mm. Move the front derailleur and the rear derailleur to all gear positions, and check that the chain guide does not touch the chain. 0 - 0.5 mm Press the button at junction (A) until the Junction (A)

  • Page 59: Lever Stroke Adjustment

    ADJUSTMENT Lever stroke adjustment „ Lever stroke adjustment < ST-6870 > CAUTION Make sure that the braking operates after the adjustment. Clockwise: The grip width becomes narrower Counterclockwise: The grip width becomes wider < ST-6871 > Clockwise: The grip width becomes narrower...
  • Page 60 CHARGING THE BATTERY...

  • Page 61: Charging The Battery

    (Insert into the connector. * Insert as far as it will go.) Charger cord < Sold separately > This charger is a special charger for use in charging Shimano lithium ion batteries (SM-BTR1). Special battery (SM-BTR1) Electrical contacts (If these are modified or damaged, problems with operation will occur.
  • Page 62 (Connect to the junction (A) or the charging connector of the information display.) • This charger is a special charger for use in charging Shimano lithium ion batteries (SM-BTR2). • If water collects in the connector of the product side, wipe the water and then connect the plug to the connector.

  • Page 63: Charging Method

    CHARGING THE BATTERY Charging method „ Charging method External (SM-BCR1 / SM-BTR1) Insert the power plug of the battery charger into an electrical outlet. Insert the battery (SM-BTR1) into the battery charger (SM-BCR1) as far as it will The charging time is approximately 1.5 hours.
  • Page 64 CHARGING THE BATTERY Charging method Built-in (SM-BCR2 / SM-BTR2) Example of connection for charging Charging port The position of the charging port differs depending on the product. To an AC adapter with a USB port or PC Connect the battery to the junction (A) or information display. You can charge the battery by using the AC adapter with a USB port or connecting the battery charger to a PC USB port.

  • Page 65: Troubleshooting For Charging Error

    CHARGING THE BATTERY Troubleshooting for charging error „ Troubleshooting for charging error External (SM-BCR1 / SM-BTR1) Remove the battery from the battery charger, disconnect the power plug of the battery charger from the electrical outlet, and then repeat the charging operation.
  • Page 66 MAINTENANCE...

  • Page 67: Maintenance

    MAINTENANCE Installation of the bracket cover MAINTENANCE „ Installation of the bracket cover CAUTION Always replace the bracket cover with the lever removed from the bicycle as shown in the illustration. Note the markings The tabs on the bracket cover each fit to R: for right a matching slot on the bracket.

  • Page 68: Disassembly Of The Bracket Unit And Lever Unit

    MAINTENANCE Disassembly of the bracket unit and lever unit „ Disassembly of the bracket unit and lever unit Use the special tool which is sold Y6RT68000 Direction for removing separately to remove the E-ring. (Special E-ring removal tool) the E-ring Align part of the special tool with the removal direction of the E-ring.
  • Page 69 MAINTENANCE Disassembly of the bracket unit and lever unit Remove the two switch unit fixing Switch unit fixing screws screws, and then remove the switches (#T5 TORX®) and the switch springs. The bracket unit TORX is a registered trademark of Camcar LLC.

  • Page 70: Assembly Of The Switch Unit

    MAINTENANCE Assembly of the switch unit „ Assembly of the switch unit Check that the buttons are attached to Switch springs the springs, and then place the switch Apply grease springs into the holes in the switch unit Premium grease setting plate.

  • Page 71: Assembly Of The Bracket Unit And Lever Unit

    MAINTENANCE Assembly of the bracket unit and lever unit Tightening torque: Make a gap between the switch unit and 0.18 N·m the switch unit setting plate and check that the end of the rubber on the switch {1.6 in. lbs.} unit is on the button.

  • Page 72: Replacing The Pulley

    MAINTENANCE Replacing the pulley Y6RT68000 Use part of the special tool to install (Special E-ring removal tool) the E-ring. CAUTION Do not use the removed E-ring again. Operate the shifting switches (X / Y) and check that they turn on, and check that the lever operates smoothly.

  • Page 73: How To Install The B Axle

    MAINTENANCE How to install the B axle „ How to install the B axle Removing the B axle Remove the B axle stop ring using a B axle stop ring slotted screwdriver. CAUTION Be careful when removing the B axle stop ring.
  • Page 74 MAINTENANCE How to install the B axle Temporarily assemble the B tension B tension spring spring, B body seal ring, stopper plate Stopper plate and B axle to the B body. Hold the stopper plate with pliers and turn it counterclockwise. Push in the stopper plate, turning it.
  • Page 75 Please note: specifications are subject to change for improvement without notice. (English) © Jul. 2013 by Shimano Inc. HTR...

This manual is also suitable for:

Ultegra st-6871Ultegra fd-6870Ultegra rd-6870Ultegra sw-r610Ultegra sw-9071Ultegra sw-r671 ... Show all

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