Shimano GRX RX 815 Series Dealer's Manual
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Shimano GRX RX 815 Series Dealer's Manual

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(English)
ROAD
City Touring/
Comfort Bike
SHIMANO GRX
ST-RX815
FD-RX815
RD-RX815
RD-RX817
SHIMANO
SW-R9150
SM-EW90-A
SM-EW90-B
EW-RS910
EW-WU111
EW-SD50
EW-SD50-I
EW-JC130
MTB
URBAN SPORT
RX815 series
SM-EWC2
SM-JC40
SM-JC41
SM-BTR1
BT-DN110
BT-DN110-A
BM-DN100
SM-BA01
SM-BCR1
SM-BCR2
SM-BCC1
Dealer's Manual
Trekking
E-BIKE
DM-RX815-00

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  • Page 1 DM-RX815-00 (English) Dealer’s Manual ROAD Trekking City Touring/ URBAN SPORT E-BIKE Comfort Bike RX815 series SHIMANO GRX ST-RX815 SM-EWC2 SM-JC40 FD-RX815 SM-JC41 RD-RX815 RD-RX817 SM-BTR1 BT-DN110 BT-DN110-A SHIMANO BM-DN100 SW-R9150 SM-EW90-A SM-BA01 SM-EW90-B SM-BCR1 EW-RS910 SM-BCR2 SM-BCC1 EW-WU111 EW-SD50 EW-SD50-I...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS .................2 IMPORTANT NOTICE ..............6 TO ENSURE SAFETY ..............7 LIST OF TOOLS TO BE USED ............26 INSTALLATION/REMOVAL ............29 OVERALL WIRING DIAGRAM (external battery specifications) ..29 • Wiring example for installing junction [B] on the outside ..........29 • Wiring example for installing junction [B] on the inside ............. 32 OVERALL WIRING DIAGRAM (built-in battery specifications) ..
  • Page 3 Temporarily installing the front derailleur .........65 • When there is a mounting boss on the seat tube ..............65 • When there is no mounting boss on the seat tube .............. 66 • Connecting the electric wire ....................69 Installing the rear derailleur ..............71 •...
  • Page 4 Shift mode setting (synchronized shift) ...........140 • Semi-synchronized shift ....................... 140 • Synchronized shift ........................ 142 MAINTENANCE ..............143 Replacing the brake pads ..............143 SHIMANO genuine mineral oil replacement ........143 • Draining the mineral oil ....................... 143 • Adding mineral oil and bleeding air ................... 148...
  • Page 5 Replacing the brake hose ..............164 • Checking and cutting the hose length ................164 • Installing the brake hose (lever side) .................. 165 • Installing the brake hose (caliper side) ................168 Adjustment when the pistons are not operating correctly ....170 Replacing the bracket cover ..............170 Replacing the pulleys .................172 Applying grease to the chain stabilizer ..........173...

  • Page 6: Important Notice

    • All owner's manuals and dealer's manuals can be viewed on-line on our website (http:// 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.

  • Page 7: To Ensure Safety

    TO ENSURE SAFETY TO ENSURE SAFETY DANGER Be sure to also inform users of the following: „ Lithium-ion battery Be sure to observe the following instructions in order to avoid burns or other injury from fluid leakage, overheating, fire, or explosion. •...
  • Page 8 • Be sure to follow the instructions provided in the owner's manuals when installing the product. It is recommended to use SHIMANO genuine parts only. If parts such as bolts and nuts become loose or damaged, or if adjustments are not carried out correctly, the bicycle may suddenly fall over, which may cause serious injury.
  • Page 9 TO ENSURE SAFETY „ About the multi-shifting function • Connecting this system to E-TUBE PROJECT and switching [Multi shift mode setting] to [ON] will allow you to continuously shift gears while the shifting switch is held down. When modifying this setting, carefully read "Items configurable in E-TUBE PROJECT" in this dealer's manual.
  • Page 10 TO ENSURE SAFETY • 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.
  • Page 11 TO ENSURE SAFETY SM-BCR2: Battery charger for SM-BTR2/BT-DN110/BT-DN110-A • 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.
  • Page 12 TO ENSURE SAFETY • If the road surface is wet, the tires will skid more easily. If the tires skid, you may fall off the bicycle; therefore, to avoid this, reduce your speed and apply the brakes early and gently. „...
  • Page 13 • Check that the brake system has cooled down sufficiently before attempting brake system maintenance. • Use only SHIMANO genuine mineral oil. If other types of oil are used, it may cause problems with brake operation, and cause vapor lock or the brake system to be unusable •...
  • Page 14 „ Brake hose • After installing the brake hose to the brake unit, adding SHIMANO genuine mineral oil and bleeding air bubbles, depress the brake lever several times to check that the brakes...
  • Page 15 TO ENSURE SAFETY • 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...
  • Page 16 • Contact with skin may cause a rash and discomfort. In the event of contact with skin, wash well with soap and water. • Inhalation of SHIMANO genuine mineral oil mist or vapors may cause nausea. Cover your nose and mouth with a respirator type mask and use in a well-ventilated area. If SHIMANO genuine mineral oil vapor is inhaled, go immediately to an area with fresh air and cover up with a blanket.
  • Page 17 TO ENSURE SAFETY • Do not drink. May cause vomiting or diarrhea. • Keep out of reach of children. • Do not cut, let near heat, weld or pressurize the mineral oil container, as this may cause explosion or fire. •...
  • Page 18 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.
  • Page 19 TO ENSURE SAFETY SM-BTR1: Lithium-ion battery (external type) • 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.) •...
  • Page 20 TO ENSURE SAFETY SM-BCR2: Battery charger/PC linkage device for SM-BTR2/BT-DN110/BT-DN110-A • 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. •...
  • Page 21 SHIMANO website. For installation to the bicycle, and maintenance: • 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.
  • Page 22 TO ENSURE SAFETY • The motor unit cannot be disassembled and repaired. • Contact SHIMANO 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.
  • Page 23 TO ENSURE SAFETY „ 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.
  • Page 24 TO ENSURE SAFETY 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 distributor. „ About system power reset •...
  • Page 25 • 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. About compatibility with E-TUBE • Check the following website for information on compatibility with each unit and functional limitations. (http://e-tubeproject.shimano.com/guide/#guide_list)

  • Page 26: List Of Tools To Be Used

    LIST OF TOOLS TO BE USED 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...
  • Page 27 LIST OF TOOLS TO BE USED Dual control lever, shifting switch Tool TL-EW02 SM-DISC TL-BH62 2 mm hexagon wrench 2.5 mm hexagon wrench 5 mm hexagon wrench 7 mm socket wrench 8 mm spanner Front derailleur Tool TL-EW02 2 mm hexagon wrench 5 mm hexagon wrench...
  • Page 28 LIST OF TOOLS TO BE USED Rear derailleur Tool TL-EW02 2 mm hexagon wrench 3 mm hexagon wrench 4 mm hexagon wrench 5 mm hexagon wrench Screwdriver [#2] Hexalobular [#30] 5.5 mm spanner...

  • Page 29: Installation/Removal

    INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (external battery specifications) INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (external battery specifications) 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. NOTICE •...
  • Page 30 INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (external battery specifications) Electric wire (EW-SD50) From battery mount to junction [B] (E) + (F) ≤ 900 mm From front derailleur to junction [B] (E) + (G) ≤ 1,100 mm From rear derailleur to junction [B] From dual control lever to junction [A] (H), (I) ≤...
  • Page 31 INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (external battery specifications) Electric wire (EW-SD50/EW-SD50-I) From battery mount to junction [B] (G) + (H) ≤ 900 mm From front derailleur to junction [B] (G) + (I) ≤ 1,100 mm From rear derailleur to junction [B] From wireless unit to junction [B] (J) ≤...

  • Page 32: Wiring Example For Installing Junction [B] On The Inside

    INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (external battery specifications) 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].
  • Page 33 INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (external battery specifications) ` 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.

  • Page 34: Overall Wiring Diagram (Built-In Battery Specifications)

    INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (built-in battery specifications) TECH TIPS • Refer to "About the branch type junction (EW-JC130)" for information on 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 for information on wiring when using EW-WU101 as the wireless unit.

  • Page 35: Wiring Example For Installing Junction [A] On The Inside

    INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (built-in battery specifications) Wiring component parts Lithium-ion battery (built-in type): Junction [A]: SM-EW90-A/SM-EW90-B BT-DN110/BT-DN110-A Junction [B]: SM-JC41 Electric wire (EW-SD50/EW-SD50-I) From built-in battery to junction [B] (D) + (E) ≤ 1,500 mm From front derailleur to junction [B] (D) + (F) ≤...
  • Page 36 INSTALLATION/REMOVAL OVERALL WIRING DIAGRAM (built-in battery specifications) Wiring component parts Lithium-ion battery (built-in type): Junction [A]: SM-EW90-A/SM-EW90-B BT-DN110/BT-DN110-A Junction [B]: SM-JC41 Wireless unit: EW-WU111 Branch type junction: EW-JC130 Electric wire (EW-SD50-I) From built-in battery to junction [B] (F) + (G) ≤ 1,500 mm From front derailleur to junction [B] (F) + (H) ≤...

  • Page 37: Wiring Diagram Around The Cockpit

    INSTALLATION/REMOVAL Wiring diagram around the cockpit Wiring diagram around the cockpit Wiring example for installing junction [A] on the outside Dual control lever ST-RX815-L Dual control lever ST-RX815-R E-TUBE E-TUBE port ×2 port ×2 E-TUBE port ×3 Junction [A] SM-EW90-A Shifting switch Shifting switch SW-R9150...

  • Page 38: Wiring Example For Installing Junction [A] Inside The Handlebar

    INSTALLATION/REMOVAL Wiring diagram around the cockpit Wiring example for installing junction [A] inside the handlebar Dual control lever ST-RX815-L Dual control lever ST-RX815-R E-TUBE E-TUBE port ×2 port ×2 Shifting switch SW-R9150 E-TUBE port ×2 40 mm or more Junction [A] EW-RS910 Branch type junction Wireless unit...

  • Page 39: Wiring Example For Installing Junction [A] Inside The Frame

    INSTALLATION/REMOVAL Wiring diagram around the cockpit Wiring example for installing junction [A] inside the frame Dual control lever ST-RX815-L Dual control lever ST-RX815-R E-TUBE E-TUBE port ×2 port ×2 Shifting switch SW-R9150 Branch type junction EW-JC130 Wireless unit EW-WU111 Installed inside the frame and to junction [A] (EW-RS910)

  • Page 40: Handling Electric Wires

    INSTALLATION/REMOVAL Handling electric wires Handling electric wires Be sure to use the SHIMANO original tool to remove and insert electric wires. NOTICE • When connecting and disconnecting electric wires, do not forcibly bend the plug part. It may result in a poor connection.

  • Page 41: Disconnecting The Electric Wire

    (2) Disconnect the electric wire from the E-TUBE port. * As shown in the figure, use part (A) of the SHIMANO original tool as an axle and move it like a lever, and then disconnect it. If there is limited space to insert the tool,...

  • Page 42: Insertion Direction Of The Electric Wires For Built-In Use

    INSTALLATION/REMOVAL Handling electric wires NOTICE • Do not repeatedly connect and disconnect the electric wire too often. The connector may become worn or deformed, and affect the waterproof performance or connection performance. Insertion direction of the electric wires for built-in use Electric wires for built-in use come with wire holders to prevent the electric wires from moving inside the frame.
  • Page 43 INSTALLATION/REMOVAL Handling electric wires 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 release liner from the back side. Installation example to the lower side of the down tube (wiring to junction [B]) Electric wire cover Electric wire...

  • Page 44: Finishing For Internal Wiring

    INSTALLATION/REMOVAL Handling electric wires Finishing for internal wiring When wiring 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. Installation example to the chainstay Installation example to the seat tube (wiring to the rear derailleur) (wiring to the front derailleur)
  • Page 45 INSTALLATION/REMOVAL Handling electric wires 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 Install the grommet.

  • Page 46: Temporarily Installing The Dual Control Lever

    INSTALLATION/REMOVAL Temporarily installing the dual control lever Temporarily installing the dual control lever 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 lever". ST-RX815 Turn over the bracket cover from the back side.
  • Page 47 INSTALLATION/REMOVAL Temporarily installing the dual control lever Loosen the clamp bolt, and pass the clamp band through the handlebar. The clamp bolt is on top of a bracket which has had its bracket cover turned over. Clamp bolt Clamp band NOTICE •...
  • Page 48 INSTALLATION/REMOVAL Temporarily installing the dual control lever Temporarily install the lever to the handlebar. Temporarily install the lever so that it cannot move. Clamp bolt (temporary) NOTICE • The clamp band, clamp bolt, and clamp nut are not compatible with other products.
  • Page 49 INSTALLATION/REMOVAL Temporarily installing the dual control lever Lift up the connector cover. Bracket cover Connector cover Remove the dummy plug, and connect the electric wire. Be sure to push it in firmly until you feel a click. E-TUBE port ×2 Dummy plug Electric wire...

  • Page 50: Installing The Shifting Switches

    INSTALLATION/REMOVAL Installing the shifting switches TECH TIPS • Ensure that the electric wire to connect to the dual control lever 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 shifting switch (next section) or connect a PC linkage device for maintenance.
  • Page 51 INSTALLATION/REMOVAL Installing the shifting switches TECH TIPS • Two types of adapters for connecting the shifting switches to the handlebar are included in the product. Select the adapter according to the cross-section of the handlebar. Handlebar Handlebar Adapter Adapter ` Connection method Set the shifting switch to the adapter.
  • Page 52 INSTALLATION/REMOVAL Installing the shifting switches Secure the shifting switch and adapter to the handlebar with a zip tie. (1) Pass the zip tie through. (2) Check that the zip tie has been passed through correctly, and tighten the zip tie. Zip tie Shifting switch Adapter...
  • Page 53 INSTALLATION/REMOVAL Installing the shifting switches Perform post-processing of the zip tie. (1) Cut the remaining part of the zip tie using nippers, etc. (2) Rotate the zip tie, and insert the clamp part into the hole of the adapter. Zip tie Clamp part Connect the electric wire of the shifting switch to the E-TUBE port of the dual control lever.

  • Page 54: Installing Junction [A]

    INSTALLATION/REMOVAL Installing junction [A] TECH TIPS • If there is length to spare in the electric wire of the shifting switch, retaining it on the dual control lever side will make it easier to remove and insert wiring when performing maintenance. Installing junction [A] External type Install external type junction [A] to the bottom of the stem.
  • Page 55 INSTALLATION/REMOVAL Installing junction [A] Install the band and hook to the stem. (1) Set the hook on the band. (2) Adjust the length of the band according to the thickness of the stem, hook it on the hook and wind it. Pull the hook with your hand so that it does not become displaced, and install it securely.
  • Page 56 INSTALLATION/REMOVAL Installing junction [A] 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. Junction [A] Junction [A] (SM-EW90-A)

  • Page 57: Built-In Bar End Type

    INSTALLATION/REMOVAL Installing junction [A] Built-in bar end type When installing a built-in bar end type junction [A], use a compatible handlebar. Prepare the wires. (1) Pass the electric wires through the wiring hole in the handlebar and pull them out from the bar end.
  • Page 58 INSTALLATION/REMOVAL Installing junction [A] 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 NOTICE • Do not tap junction [A] with a hammer or similar tool when inserting it. Doing so may cause damage.
  • Page 59 INSTALLATION/REMOVAL Installing junction [A] TECH TIPS • If the adhesive force of the double-sided tape on the handle holders has weakened, cut some commercially-available double-sided tape as shown in the figure below and replace them. 15 mm 10 mm Temporarily secure the electric wires to the handlebar. (1) Adjust the length of the electric wires by tucking any excess length into the handlebar etc.
  • Page 60 INSTALLATION/REMOVAL Installing junction [A] Attach the end cap and handle holder to the bar end on the opposite side. (1) Insert the end cap into the bar end without junction [A] installed. (2) Refer to Step 4 to attach the handle holder. End cap Handle holder Handlebar...
  • Page 61 INSTALLATION/REMOVAL Installing junction [A] Wrap the handlebar with the handlebar tape. Finally, wrap the handlebar with the handlebar tape, after installing the hydraulic brake system. (1) Cut off the end of the handlebar tape diagonally. (2) Wrap the handlebar with the handlebar tape over the handle holders. Handle holder Handlebar tape...

  • Page 62: Built-In Frame Type

    INSTALLATION/REMOVAL Installing junction [A] Built-in frame type When installing junction [A] of a built-in frame type, prepare a compatible frame. Connect the electric wire to junction [A]. (1) Check the electric wire that will be connected to junction [A]. (2) Connect the electric wire to the E-TUBE port of junction [A]. * Be sure to push it in firmly until you feel a click.

  • Page 63: Installing The Wireless Unit

    INSTALLATION/REMOVAL Installing the wireless unit Install junction [A] to the frame. (1) Insert junction [A] into the frame. (2) Install the holder plate. Holder plate Mounting bolt 0.26 - 0.4 N·m Junction [A] NOTICE • When installing parts on a carbon frame/handlebars, confirm the recommended tightening torque with the carbon frame or part manufacturer in order to prevent damage to the carbon material due to overtightening or inadequate securing of the components due to insufficient tightening torque.
  • Page 64 INSTALLATION/REMOVAL Installing the wireless unit Connect the electric wire to the wireless unit. (1) Check the electric wire that will be connected to the wireless unit. (2) 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. Perform the subsequent steps after installing the brake hose.

  • Page 65: Temporarily Installing The Front Derailleur

    INSTALLATION/REMOVAL Temporarily installing the front derailleur 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. • If the wiring is inside the frame, temporarily install the front derailleur as described here, check all connections (including with other components), and then proceed to "Securing the front derailleur".

  • Page 66: When There Is No Mounting Boss On The Seat Tube

    INSTALLATION/REMOVAL Temporarily installing the front derailleur Temporarily install the front derailleur. (1) Peel the release liner on the back, and then attach the backup plate to the seat tube. * Avoid positioning the tape that attaches the backup plate to the seat tube in the location where the support bolt directly touches the frame.
  • Page 67 INSTALLATION/REMOVAL Temporarily installing the front derailleur Install the band adapter to the front derailleur. (1) Refer to Step 2 of "When there is a mounting boss on the frame" to attach the backup plate to the band adapter. (2) Install the band adapter to the front derailleur. Band adapter Mounting bolt 5 - 7 N·m...
  • Page 68 INSTALLATION/REMOVAL Temporarily installing the front derailleur Temporarily install the front derailleur to the seat tube. (1) Remove the clamp bolt, and expand the clamp band of the band adapter. (2) Set the clamp band to the frame, and reinstall the clamp bolt. * Use a seat tube adapter (for Ø28.6) according to the size of the seat tube.

  • Page 69: Connecting The Electric Wire

    INSTALLATION/REMOVAL Temporarily installing the front derailleur Connecting the electric wire Check the electric wire that will be connected to the front derailleur. Electric wire To junction [B] Connect the electric wire. (1) Install the electric wire to the plug cover. (2) Connect the electric wire with the plug cover to the E-TUBE port of the front derailleur.
  • Page 70 INSTALLATION/REMOVAL Temporarily installing the front derailleur TECH TIPS • 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...

  • Page 71: Installing The Rear Derailleur

    INSTALLATION/REMOVAL Installing the rear derailleur Installing the rear derailleur Standard type Set the switch lever in the OFF position. Switch lever...
  • Page 72 INSTALLATION/REMOVAL Installing the rear derailleur Secure the rear derailleur. Be careful not to insert the rear derailleur mounting bolt in the derailleur hanger at an angle. In addition, be sure to install the rear derailleur so that the stopper plate tab contacts the B-tension stop, with no gap in between.

  • Page 73: Direct Mount Type

    INSTALLATION/REMOVAL Installing the rear derailleur Direct mount type Set the switch lever in the OFF position. Switch lever Remove the bracket axle. Bracket axle...
  • Page 74 INSTALLATION/REMOVAL Installing the rear derailleur Install the rear derailleur. (1) Insert the derailleur hanger into the installation part for direct mount of the rear derailleur. (2) Install the rear derailleur with the bracket axle. Derailleur hanger Bracket axle...

  • Page 75: Connecting The Electric Wire

    INSTALLATION/REMOVAL Installing the rear derailleur Connecting the electric wire Connect the electric wire. (1) Check the electric wire that will be connected to the rear derailleur. (2) Connect the electric wire to the E-TUBE port of the rear derailleur. * Be sure to push it in firmly until you feel a click. Example when the wiring is built into the frame Electric wire E-TUBE port...

  • Page 76: Installing The Battery

    INSTALLATION/REMOVAL Installing the battery Installing the battery 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 a manufacturer of completed bicycles.
  • Page 77 INSTALLATION/REMOVAL Installing the battery Long type (temporarily installing the front of the battery mount) Tighten it together with the bottle cage using the mounting bolt included with the frame. Mounting bolt (temporary) Bottle cage Battery mount Adjust the position of the battery mount and bottle cage so there is enough space to attach and remove the battery.
  • Page 78 INSTALLATION/REMOVAL Installing the battery Secure the battery mount. Short type This completes the installation process for the short type. Bottle cage Mounting bolt 1.2 - 1.5 N·m Battery mount 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.
  • Page 79 INSTALLATION/REMOVAL Installing the battery 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 mounting bolt too.
  • Page 80 INSTALLATION/REMOVAL Installing the battery 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. E-TUBE port Electric wire...
  • Page 81 INSTALLATION/REMOVAL Installing the battery ` 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. Set the electric wire to the electric wire cover.
  • Page 82 INSTALLATION/REMOVAL Installing the battery 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. Mounting bolt Spacer NOTICE •...
  • Page 83 INSTALLATION/REMOVAL Installing the battery ` 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.

  • Page 84: Installing The Built-In Battery

    INSTALLATION/REMOVAL Installing the battery Installing the built-in battery This section describes how to place the battery inside the seat post. Depending on the frame, the way the battery is installed may differ. For details, contact a manufacturer of completed bicycles. TECH TIPS •...
  • Page 85 INSTALLATION/REMOVAL Installing the battery Secure the battery with a snap ring. Wave washer Part A cross section Washers Snap ring TECH TIPS • Use snap ring pliers with a claw diameter of 2 mm or less to mount the snap ring.
  • Page 86 INSTALLATION/REMOVAL Installing the battery Connect the electric wire to the battery. (1) Check the electric wire that will be connected to the battery. (2) Connect the electric wire to the E-TUBE port of the battery. * Be sure to push it in firmly until you feel a click. E-TUBE port Electric wire...

  • Page 87: Installing Junction [B]

    INSTALLATION/REMOVAL Installing junction [B] Insert the seat post. Insert the seat post while pulling out the electric wire from the bottom bracket shell. Seat post Bottom bracket shell Installing junction [B] When installing junction [B], connect the electric wires first, then install on the frame. External type Install external type junction [B] to the bottom of the bottom bracket shell.
  • Page 88 INSTALLATION/REMOVAL Installing junction [B] 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 Top (frame side) E-TUBE port ×4 Rear (rear side) Front (front side) Adjust the excess length of the electric wire.
  • Page 89 INSTALLATION/REMOVAL Installing junction [B] Install junction [B] to the frame. Mounting bolt Junction [B]...

  • Page 90: Built-In Type

    INSTALLATION/REMOVAL Installing junction [B] Built-in type NOTICE • 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. •...
  • Page 91 INSTALLATION/REMOVAL Installing junction [B] Connect the electric wires to the E-TUBE port on junction [B]. Be sure to push it in firmly until you feel a click. E-TUBE port ×4 Electric wire Pull the seat tube side and chainstay side electric wires into the frame. When the battery is an external type Electric wire for front Seat tube...
  • Page 92 INSTALLATION/REMOVAL Installing junction [B] When the battery is a built-in type Seat tube Electric wire for battery Electric wire for front derailleur Electric wire for rear derailleur Chainstay Pull in junction [B] toward the down tube side. When the battery is an external type (1) Pull in the electric wire on the down tube side.

  • Page 93: Checking Connections

    INSTALLATION/REMOVAL Checking connections When the battery is a built-in type (1) Pull in the electric wire on the down tube side. (2) 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. Down tube Electric wire for junction [A] Checking connections...

  • Page 94: Securing The Front Derailleur

    INSTALLATION/REMOVAL Securing the front derailleur When checking of the connections is complete, temporarily remove the battery. Refer to "Installing the battery". CAUTION • Make sure to remove the battery when performing procedures in a position near the front derailleur, such as installing or removing the front chainwheel and front derailleur, or installing the chain and adjusting its length.
  • Page 95 INSTALLATION/REMOVAL Securing the front derailleur NOTICE • Make sure that the electric wire exposed in the bottom bracket shell passes over the top of the inner cover of the bottom bracket. Installation example to the thread type bottom bracket Electric wire Inner cover •...

  • Page 96: Securing The Front Derailleur

    INSTALLATION/REMOVAL Securing the front derailleur Securing the front derailleur Before starting the work, check that the procedures in "Temporarily installing the front derailleur" have been completed. Adjust the installation height. Adjust so that there is a clearance of 1 - 3 mm between the chain guide outer plate and the tip of the teeth of the largest chainring.
  • Page 97 INSTALLATION/REMOVAL Securing the front derailleur Adjust the installation angle and secure the front derailleur. (1) Perform adjustment so that the flat surface of the chain guide outer plate is in a position directly above the largest chainring and that the rear edge of the chain guide is inwards by 0.5 to 1 mm compared to the front edge.
  • Page 98 INSTALLATION/REMOVAL Securing the front derailleur Readjust the position of the chain guide. Adjust the support bolt so that the flat portion of the chain guide outer plate is aligned with the surface of the largest chainring. Make sure that the support bolt is in contact with the backup plate.

  • Page 99: Installing The Disc Brake Rotor

    INSTALLATION/REMOVAL Installing the disc brake rotor 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 caliper Refer to the dealer's manual for the brake caliper to install and remove the brake caliper. Installing the brake hose Overview of the easy hose joint system Dual control lever...

  • Page 100: Checking The Length Of The Hose

    INSTALLATION/REMOVAL Installing the brake hose Checking the length of the hose Route the brake hose into the final installation position. NOTICE • This illustration 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 owner's manual.

  • Page 101: Cutting The Hose

    INSTALLATION/REMOVAL Installing the brake hose Check the appropriate length of the brake hose. Secure the lever in the position used when riding. Check the appropriate length of the brake hose by aligning the mark added beforehand on the brake hose with the edge of the lever connecting bolt. * If the hose is at the appropriate length, proceed to "Connecting the hose".
  • Page 102 Mark the hose at a position 21 mm from the check mark towards the end of the hose. 21 mm Cut mark Check mark Prepare the SHIMANO original tool TL-BH62. Disassemble the tool as shown in the figure. Main body Hose cutter...
  • Page 103 INSTALLATION/REMOVAL Installing the brake hose NOTICE • Make sure to also refer to the owner's manual for SHIMANO original tool TL- BH62. • Do not move the lever indicated in the figure before disassembling SHIMANO original tool TL-BH62. Place the brake hose in SHIMANO original tool TL-BH62.
  • Page 104 INSTALLATION/REMOVAL Installing the brake hose NOTICE • When inserting the brake hose, make sure that the cut mark is parallel with the groove in the tool. Cut mark Groove Check the cut location and secure the brake hose in place.
  • Page 105 INSTALLATION/REMOVAL Installing the brake hose Check that the hose is secure, and then install the hose cutter. Hose cutter Press the hose cutter as shown in the figure to cut the brake hose. Remove the hose cutter and check that the cut end is even. 90°...
  • Page 106 Installing the brake hose Install the connector insert in the press block, and then set the press block in SHIMANO original tool TL-BH62. Make sure that the tip of the connector insert is correctly positioned inside the opening of the brake hose.

  • Page 107: Connecting The Hose

    INSTALLATION/REMOVAL Installing the brake hose Depress the lever on SHIMANO original tool TL-BH62 to install the connector insert in the brake hose. Check that the connector insert is installed correctly. Remove the brake hose from SHIMANO original tool TL-BH62. Connecting the hose Remove the hose cap.
  • Page 108 INSTALLATION/REMOVAL Installing the brake hose Fix the lever with the hose connector facing up by changing the angle of the handle, etc. NOTICE • When attaching to the handlebar, adjust the angle of the bracket by tilting the bracket from the handlebar so that you can turn the spanner. When doing so, take care not to damage the handle, etc.
  • Page 109 INSTALLATION/REMOVAL Installing the brake hose Remove the seal plug. Cover the seal plug with a waste cloth while conducting this procedure as oil that has adhered to the seal plug may leak. Seal plug Insert the brake hose in the brake hose connection port. It comes with a built-in olive.
  • Page 110 INSTALLATION/REMOVAL Installing the brake hose Tighten the connecting bolt with flange. Tighten the bolt while pushing the brake hose in. Connecting bolt with flange 5 - 6 N·m NOTICE • Make sure to insert the brake hose and tighten the connecting bolt. Otherwise, oil leaks or insufficient braking force may occur.
  • Page 111 INSTALLATION/REMOVAL Installing the brake hose 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 NOTICE • After removing the lever stopper, check that the pad spacer is installed on the caliper side and that the caliper is installed on the bicycle with the disc brake rotor between both sides of the caliper before depressing the lever.

  • Page 112: Securing The Dual Control Lever

    INSTALLATION/REMOVAL Securing the dual control lever Securing the dual control lever When connection of the brake hose is complete, secure the dual control lever in the appropriate position. Secure the dual control lever to the handlebar. Clamp bolt 6 - 8 N·m The installation procedure is complete after finishing the wiring, etc.

  • Page 113: How To Operate

    HOW TO OPERATE Gear position control HOW TO OPERATE Gear position control [Gear position control] in this system is set to [Set] by default. Therefore, if you try to shift into gear positions that would lower the chain tension, shifting switches may shift differently from the basic operations.

  • Page 114: Points To Remember During Rear Gear Shifting

    HOW TO OPERATE Gear position control TECH TIPS • [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.

  • Page 115: Adjustment

    ADJUSTMENT Installing the chain ADJUSTMENT Installing the chain Refer to the dealer's manual for the chain to install/remove the chain. Checking the chain length Set the chain on the largest sprocket and the largest chainring. Largest sprocket Chain Largest chainring Check the length of the chain.
  • Page 116 ADJUSTMENT Checking the chain length NOTICE • The rear derailleur plate assembly is equipped with a pin or plate that prevents the chain from derailing. 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.

  • Page 117: Adjusting The Rear Derailleur

    ADJUSTMENT Adjusting the rear derailleur Adjusting the rear derailleur Adjusting the end adjustment screw Install the battery. Refer to "Installing the battery". Set the chain on the smallest chainring and the largest sprocket. Turn the crank arm in reverse. Smallest chainring Largest sprocket...
  • Page 118 ADJUSTMENT Adjusting the rear derailleur Adjust the end adjustment screw. Bring the guide pulley close to the gear to a position where the chain does not jam. End adjustment screw Largest sprocket Smallest sprocket End adjustment screw Check that the chain does not jam even at the smallest sprocket. If there is some slack in the chain, adjust the end adjustment screw to remove the slack from the chain.

  • Page 119: Gear Shifting Adjustment In Adjustment Mode

    ADJUSTMENT Adjusting the rear derailleur Gear shifting adjustment in adjustment mode Shift the rear derailleur to the 5th gear position from the largest sprocket. Largest sprocket Guide pulley 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 For built-in bar end or built-in frame type LED linked to the button...
  • Page 120 ADJUSTMENT Adjusting the rear derailleur 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 4th gear and a subtle noise is heard. Shifting switch [X] TECH TIPS •...

  • Page 121: Adjusting The Stopper Bolt

    ADJUSTMENT Adjusting the rear derailleur 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 For built-in bar end or built-in frame type LED linked to the button Button Button...
  • Page 122 ADJUSTMENT Adjusting the rear derailleur Adjust the low-side stopper bolt. (1) Shift the rear derailleur to the largest sprocket. (2) Then, tighten the low-side stopper bolt until it just touches the low-side stopper. Low-side stopper Low-side stopper bolt Adjust the top-side stopper bolt. (1) Shift the rear derailleur to the smallest sprocket.

  • Page 123: Adjusting The Front Derailleur

    ADJUSTMENT Adjusting the front derailleur TECH TIPS Over-stroke • By shifting from the largest sprocket to the smallest sprocket, the rear derailleur moves past the top position toward the outside by the over-stroke allowance and then moves back. Adjusting the front derailleur Checking bolt positions The top adjustment bolt and the support bolt are close to each other.

  • Page 124: Adjusting The Top Side

    ADJUSTMENT Adjusting the front derailleur Adjusting the top side Set the chain on the largest chainring and the smallest sprocket. Turn the crank arm in reverse. Largest chainring Smallest sprocket Adjust the clearance between the chain and chain guide outer plate. Adjust the clearance to 0.5 - 1 mm.

  • Page 125: Adjusting The Lowest Position In Adjustment Mode

    ADJUSTMENT Adjusting the front derailleur Adjusting the lowest position in adjustment mode Set the chain on the smallest chainring and the largest sprocket. Turn the crank arm in reverse. Smallest chainring Largest sprocket 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.
  • Page 126 ADJUSTMENT Adjusting the front derailleur Adjust the clearance between the chain and chain guide inner plate. Adjust the clearance to 0 - 0.5 mm. Shifting switch [Y] Shifting switch [X] Chain guide inner plate Chain Shifting switch [X] Shifting switch [Y] 0 - 0.5 mm TECH TIPS •...

  • Page 127: Adjusting The Top Position In Adjustment Mode

    ADJUSTMENT Adjusting the front derailleur Shift the front derailleur and the rear derailleur to all gears to make sure that the chain does not contact the chain guide. If fine adjustment is needed, switch back to adjustment mode and readjust the front derailleur.
  • Page 128 ADJUSTMENT Adjusting the front derailleur NOTICE • 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.
  • Page 129 ADJUSTMENT Adjusting the front derailleur 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 For built-in bar end or built-in frame type LED linked to the button Button Button...

  • Page 130: Adjusting The Dual Control Lever

    ADJUSTMENT Adjusting the dual control lever Adjusting the dual control lever Adjusting the reach Adjust the reach of the lever. Adjust the position of the lever body. (1) Turn over the bracket cover from the front side. (2) Adjust the position of the lever body using the reach adjustment screw. Bracket cover Reach adjustment screw Lever body...

  • Page 131: Adjusting The Free Stroke

    ADJUSTMENT Adjusting the dual control 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. TECH TIPS • Perform reach adjustment if the initial position of the lever changes when performing the free stroke adjustment.
  • Page 132 ADJUSTMENT Adjusting the dual control lever NOTICE • Stop loosening the free stroke adjustment screw when the gap 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.

  • Page 133: Charging The Battery

    CHARGING THE BATTERY External type Charging the battery External type Remove the external type battery (SM-BTR1) from the bicycle and then charge it. It can be charged in approximately 1.5 hours. The charging time differs according to the battery level. NOTICE •...

  • Page 134: Built-In Type

    CHARGING THE BATTERY Built-in type Installing the battery to the battery charger. Insert it in firmly as far as it will go. Charging starts and the charge indicator lights up. When the charge indicator turns off, charging is complete. Charge indicator On: Charging Off: Charging complete NOTICE...
  • Page 135 CHARGING THE BATTERY Built-in type NOTICE • 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. •...
  • Page 136 CHARGING THE BATTERY Built-in type Connect the plug for product connection on the battery charger to the charging port on the product. The position of the charging port differs depending on the product. Insert it in firmly as far as it will go. Charging starts and the charge indicator lights up.
  • Page 137 CHARGING THE BATTERY Built-in type NOTICE • 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.

  • Page 138: Connection And Communication With Devices

    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 our support website (http://e-tubeproject.shimano.com). For information on how to install E-TUBE PROJECT, check the support website.

  • Page 139: About Wireless Functions

    CONNECTION About wireless functions About wireless functions 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. Functions You can check the latest functions by using E-TUBE PROJECT to update the software.

  • Page 140: Shift Mode Setting (Synchronized Shift)

    CONNECTION Shift mode setting (synchronized shift) Shift mode setting (synchronized shift) The [Shift mode setting] can be registered in E-TUBE PROJECT to maintain the ideal front and rear gear positions synchronized with front derailleur and rear derailleur gear shifting. • Up to two shift mode settings can be registered in E-TUBE PROJECT. Refer to the help manual for E-TUBE PROJECT for information on how to configure this.
  • Page 141 CONNECTION Shift mode setting (synchronized 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 movements in conjunction...

  • Page 142: Synchronized Shift

    CONNECTION Shift mode setting (synchronized shift) Synchronized shift The front derailleur automatically shifts gears in synchronization with rear derailleur gear shifting. The numbers of switch gears for synchronized shift are configured by default as shown in the figure below. Gear position (cassette sprocket) Smallest chainring (inner) Largest chainring (outer) Largest sprocket (low)

  • Page 143: Maintenance

    • 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 SHIMANO genuine mineral oil replacement It is recommended to change your oil when the oil in the reservoir tank becomes noticeably discolored.
  • Page 144 MAINTENANCE SHIMANO genuine mineral oil replacement 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 hose Brake caliper Brake caliper...
  • Page 145 MAINTENANCE SHIMANO genuine mineral oil replacement Turn over the bracket cover from the back side. Turn it over until the bleed screw is exposed. Bleed screw Bracket cover Set the lever in a position where the top surface of the bleed screw is...
  • Page 146 MAINTENANCE SHIMANO genuine mineral oil replacement Remove the bleed screw and O-ring. Bleed screw O-ring NOTICE • Be careful not to lose the bleed screw or O-ring. • Be careful not to dirty or damage the O-ring.
  • Page 147 MAINTENANCE SHIMANO genuine mineral oil replacement Install a bag and tube on the bleed nipple. (1) Place a 7 mm socket wrench in the position shown in the figure. (2) Connect the bag and attached tube to the bleed nipple.

  • Page 148: Adding Mineral Oil And Bleeding Air

    MAINTENANCE SHIMANO genuine mineral oil replacement Adding mineral oil and bleeding air Use only SHIMANO genuine mineral oil. NOTICE • 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.
  • Page 149 MAINTENANCE SHIMANO genuine mineral oil replacement Turn over the bracket cover from the back side. Turn it over until the bleed screw is exposed. Bleed screw Bracket cover Set the lever in a position where the top surface of the bleed screw is...
  • Page 150 MAINTENANCE SHIMANO genuine mineral oil replacement Remove the bleed screw and O-ring, and set the oil funnel. Attach the funnel adapter to the oil funnel. Oil funnel Funnel adapter NOTICE • Be careful not to lose the bleed screw or O-ring.
  • Page 151 MAINTENANCE SHIMANO genuine mineral oil replacement 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 handle, etc. 45°...
  • Page 152 MAINTENANCE SHIMANO genuine mineral oil replacement Inject oil from the brake caliper side. (1) Place a 7 mm socket wrench in the position shown in the figure. (2) Fill a syringe with oil, and then connect the tube to the bleed nipple.
  • Page 153 MAINTENANCE SHIMANO genuine mineral oil replacement NOTICE • Secure the brake caliper main body in a clip to prevent the tube from being disconnected accidentally. • Do not operate the lever repeatedly while injecting oil. 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 within the oil funnel.
  • Page 154 MAINTENANCE SHIMANO genuine mineral oil replacement Once there are no more air bubbles mixed in with the oil, set the lever in a position where the bracket surface indicated in the figure is parallel with the ground. Perform adjustment by changing the angle of the handle, etc.
  • Page 155 MAINTENANCE SHIMANO genuine mineral oil replacement Bleed the air. Most of the air bubbles remaining inside the brake system can be bled by performing the following operation. (1) Place a 7 mm socket wrench in the position shown in the figure.
  • Page 156 MAINTENANCE SHIMANO genuine mineral oil replacement Once no more air bubbles come out from the bleed nipple, temporarily tighten the bleed nipple. Bleed nipple 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.
  • Page 157 MAINTENANCE SHIMANO genuine mineral oil replacement Repeat step 12 two to three times, and then tighten the bleed nipple. Bleed nipple 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 handle, etc.
  • Page 158 MAINTENANCE SHIMANO genuine mineral oil replacement Operate the lever. Slowly repeat until no more air bubbles appear. Set the lever in a position where the bracket surface indicated in the figure is parallel with the ground. Perform adjustment by changing the angle of the handle, etc.
  • Page 159 MAINTENANCE SHIMANO genuine mineral oil replacement 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. Check that the lever has become stiff. Loose Slightly stiff...
  • Page 160 MAINTENANCE SHIMANO genuine mineral oil replacement 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 handle, etc.
  • Page 161 MAINTENANCE SHIMANO genuine mineral oil replacement 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...
  • Page 162 MAINTENANCE SHIMANO genuine mineral oil replacement Remove the oil funnel. Remove the oil funnel while it is still plugged by the oil stopper.
  • Page 163 MAINTENANCE SHIMANO genuine mineral oil replacement 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. Bleed screw Bleed screw 0.5 - 0.7 N·m...

  • Page 164: Replacing The Brake Hose

    Wipe away any oil that has overflowed. Replacing the brake hose After replacing the brake hose, refer to "SHIMANO genuine mineral oil replacement" to replace the mineral oil and bleed the air from the system. Checking and cutting the hose length...

  • Page 165: Installing The Brake Hose (Lever Side)

    MAINTENANCE Replacing the brake hose NOTICE • This illustration 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 owner's manual. Determine the appropriate length of the brake hose and add a check mark on the brake hose.
  • Page 166 MAINTENANCE Replacing the brake hose After checking that the olive is positioned as shown in the figure, apply grease as shown in the figure. Grease Brake hose 2 mm Check mark Olive Connecting bolt with flange Connector insert Install the brake hose in the lever. Secure the lever to the handlebar or in a vise and insert the brake hose straight.
  • Page 167 MAINTENANCE Replacing the brake hose Tighten the connecting bolt with flange while pushing on the brake hose. Make sure the brake hose is straight when pushing. Connecting bolt with flange 5 - 6 N·m NOTICE • When attaching to the handlebar, adjust the angle of the bracket by tilting the bracket from the handlebar so that you can turn the spanner.

  • Page 168: Installing The Brake Hose (Caliper Side)

    MAINTENANCE Replacing the brake hose Installing the brake hose (caliper side) Pass the connecting bolt and olive over the brake hose. Connecting bolt Olive Brake hose After checking that the olive is positioned as shown in the figure, apply grease as shown in the figure. Grease Brake hose 2 mm...
  • Page 169 MAINTENANCE Replacing the brake hose NOTICE • Do not let the brake hose become twisted when installing it. Make sure that the calipers and levers are in the positions shown in the figures. Left hand lever Right hand lever Tighten the connecting bolt while pushing on the brake hose. Connecting bolt 5 - 7 N·m...

  • Page 170: Adjustment When The Pistons Are Not Operating Correctly

    MAINTENANCE Adjustment when the pistons are not operating correctly Adjustment when the pistons are not operating correctly 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.
  • Page 171 MAINTENANCE Replacing the bracket cover Install a new bracket cover. Insert the protrusions on the bracket cover into the hollows in the bracket body when fitting on the bracket cover. Protrusion (inside bracket cover) Bracket cover TECH TIPS • The inside of the bracket cover has a mark indicating the left side or right side. •...

  • Page 172: Replacing The Pulleys

    MAINTENANCE Replacing the pulleys Return the lever to its original position. (1) Install the lever to the handlebar. (2) Install the electric wire and brake hose to the lever. NOTICE • A new olive is required to reinstall the brake hose. •...

  • Page 173: Applying Grease To The Chain Stabilizer

    MAINTENANCE Applying grease to the chain stabilizer TECH TIPS • The arrow on the pulley indicates the rotation direction when the bicycle travels forward. Tension pulley Guide pulley Applying grease to the chain stabilizer If the friction changes or noise is generated, the grease may have become discolored or insufficient.
  • Page 174 MAINTENANCE Applying grease to the chain stabilizer Remove the plate unit cover. Plate unit cover mounting bolt Plate unit cover Remove the chain stabilizer. Remove the cam unit together. Cam unit Chain stabilizer...
  • Page 175 MAINTENANCE Applying grease to the chain stabilizer Disassemble the chain stabilizer as shown in the figure below. (1) Remove the cam unit. (2) Remove the roller clutch from the chain stabilizer. Roller clutch Chain stabilizer Cam unit Apply grease to the circumference of the roller clutch. New grease number: Y04121000 (50 g) Grease number:...

  • Page 176: Adjusting Friction

    MAINTENANCE Adjusting friction 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...
  • Page 177 MAINTENANCE Adjusting friction Use a 2 mm hexagon wrench to remove the plate unit cover. Plate unit cover mounting bolt Plate unit cover Adjust the friction. RD-RX815 Friction adjustment bolt Decrease Increase...
  • Page 178 MAINTENANCE Adjusting friction Check the friction torque. (1) While pressing the cam unit with your finger, set the switch lever to the ON position. (2) Insert a 4 mm hexagon wrench into the chain stabilizer, and check the friction torque. Switch lever Cam unit Chain stabilizer...
  • Page 179 MAINTENANCE Adjusting friction NOTICE • Do not install the plate unit cover with a gap between the switch base and the bottom of the plate unit. It may not seal sufficiently, which will cause the inner mechanism to rust, potentially resulting in the adhesion of the plate. Install the plate unit cover.

  • Page 180: Rd-Rx817

    MAINTENANCE Adjusting friction RD-RX817 The friction can be adjusted for RD-RX817 without removing the plate unit cover. Set the switch lever in the ON position. Open the plate unit cap. The plate unit cap can be opened by hand. Plate unit cap NOTICE •...
  • Page 181 MAINTENANCE Adjusting friction Adjust the friction. Friction adjustment bolt Decrease Increase Check the friction torque. Use the hexalobular hole on the left plate to check the friction torque. Left plate 2.5 - 4 N·m...
  • Page 182 MAINTENANCE Adjusting friction Close the plate unit cap as it was before. Plate unit cap...

  • Page 183: Replacement Of The Plate And The Plate Tension Spring

    MAINTENANCE Replacement of the plate and the plate tension spring 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. Set the switch lever in the OFF position. Switch lever NOTICE •...
  • Page 184 MAINTENANCE Replacement of the plate and the plate tension spring Remove the plate stopper pin. Plate stopper pin Turn the plate to loosen the plate tension spring. Plate...
  • Page 185 MAINTENANCE Replacement of the plate and the plate tension spring Remove the plate unit cover. Plate unit cover mounting bolt Plate unit cover Remove the cam unit and chain stabilizer. Chain stabilizer Cam unit...

  • Page 186: Installation

    MAINTENANCE Replacement of the plate and the plate tension spring Remove the plate axle. Plate axle Installation Carry out the removal procedure in reverse. Apply grease to the plate axle. Plate axle Grease application area Grease number: premium grease (Y04110000)
  • Page 187 MAINTENANCE Replacement of the plate and the plate tension spring 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. Insert the plate axle, and then fit the tip of the plate tension spring in the hole of the plate.
  • Page 188 MAINTENANCE Replacement of the plate and the plate tension spring 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 Set the chain stabilizer into the cam unit as shown in the figure.
  • Page 189 MAINTENANCE Replacement of the plate and the plate tension spring Install the cam unit and chain stabilizer. Pay attention to the positioning of the convex section of the cam unit TECH TIPS • When installing, it helps to move the Plate plate while holding down the cam unit and chain stabilizer.
  • Page 190 MAINTENANCE Replacement of the plate and the plate tension spring Install the plate unit cover gasket. Check that it is installed along the groove in the plate unit. Plate unit cover gasket Install the plate unit cover bolts. Plate unit cover mounting bolt 1 - 1.5 N·m Plate unit cover...
  • Page 191 MAINTENANCE Replacement of the plate and the plate tension spring Turn the plate to tighten the plate tension spring. Tighten the plate tension spring so that it is not loose, and then insert the plate. Plate Install the plate stopper pin. Plate stopper pin...
  • Page 192 Please note: specifications are subject to change for improvement without notice. (English) © Mar. 2019 by SHIMANO INC. ITP...

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