Shimano Non Series Dealer's Manual
  1. Manuals
  2. Brands
  3. Shimano Manuals
  4. Controller
  5. Non Series
  6. Dealer's manual

Shimano Non Series Dealer's Manual

Dual pivot caliper brake / dual control lever (di2)
Hide thumbs Also See for Non Series:
Table of Contents

Advertisement

Quick Links

(English)
ROAD
City Touring/
Comfort Bike
Dual Pivot Caliper Brake /
Dual Control Lever (Di2)
DURA-ACE
ST-R9250
BR-R9200
BR-R9210
ULTEGRA
ST-R8150
BR-R8100
BR-R8110
Non-Series
BR-RS811-R
SW-RS801-S
SW-RS801-T
MTB
URBAN SPORT
DM-RACBR10-00
Dealer's Manual
Trekking
E-BIKE

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Non Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Shimano Non Series

Summary of Contents for Shimano Non Series

  • Page 1 DM-RACBR10-00 (English) Dealer's Manual ROAD Trekking City Touring/ URBAN SPORT E-BIKE Comfort Bike Dual Pivot Caliper Brake / Dual Control Lever (Di2) DURA-ACE ST-R9250 BR-R9200 BR-R9210 ULTEGRA ST-R8150 BR-R8100 BR-R8110 Non-Series BR-RS811-R SW-RS801-S SW-RS801-T...

  • Page 2: Table Of Contents

    Contents Contents ...................2 IMPORTANT NOTICE ..............4 TO ENSURE SAFETY ..............5 List of tools to be used ............10 Installation/removal ..............11 Installing the dual control lever ............11 Installing the brake cable ..............15 • Cable to be used ........................16 • Cutting the outer casing ......................16 •...
  • Page 3 Maintenance ................51 Replacing the cartridge shoe ...............51 • BR-R9200 / BR-R9210-RS / BR-R8100 / BR-R8110-RS .............. 51 • BR-R9210-F / BR-R8110-F / BR-RS811-R .................. 52 Brake shoe characteristics ..............53 Replacing the bracket cover ..............54...

  • Page 4: Important Notice

    • 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.

  • Page 5: To Ensure Safety

    • 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.
  • Page 6 TO ENSURE SAFETY For installation to the bicycle and maintenance • Use the brake and dual control levers or brake lever in the combinations specified in the following table. Do not use the combinations with the “NO” indication in the table. This will excessively increase the braking force, which could cause you to lose control of the bicycle, fall, and be seriously injured.
  • Page 7 TO ENSURE SAFETY • Securely tighten the caliper brake fixing nuts to the specified tightening torque. If the nuts become loose and the brakes fall off, they may get caught up in the bicycle and the bicycle may fall over. In particular, if this happens with the front wheel, you may be thrown forward and seriously injured.
  • Page 8 • Avoid leaving the carbon levers in areas of high temperature. Also keep them well away from fire. • When combined with a ceramic rim, SHIMANO road brake shoes wear down more quickly. • If the brake shoes have worn down until the grooves are no longer visible, consult your place of purchase or a distributor.
  • Page 9 TO ENSURE SAFETY • For maximum performance we highly recommend SHIMANO lubricants and maintenance products. For installation to the bicycle and maintenance • Use an outer casing / electric wire which still has some length to spare even when the handlebars are turned all the way to either side.

  • Page 10: 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. Tool 2 mm hexagon wrench 4 mm hexagon wrench 5 mm hexagon wrench Slotted screwdriver Blade width at tip: 4.0 - 5.0 mm Blade thickness at tip: 0.5 - 0.6 mm TL-CT12 TL-EW300...

  • Page 11: Installation/Removal

    Installation/removal Installing the dual control lever Installation/removal Installing the dual control lever Turn over the bracket cover from the front side. Gently turn over the ends of the bracket cover with both hands and slowly push them down. NOTICE • Forcibly pulling it may cause damage to the bracket cover because of its material properties.
  • Page 12 Installation/removal Installing the dual control lever Temporarily install the lever to the handlebar. Temporarily install the lever so that it cannot move. Clamp screw (Temporary) NOTICE • Use the parts indicated in the part breakdown of the dual control levers when you replace the clamp band, clamp screw, or clamp nut.
  • Page 13 Installation/removal Installing the dual control lever Lift up the port junction. Bracket cover Port junction NOTICE • When removing / inserting dummy plugs or electric wires, be sure the port junction is firmly supported by hand or by the bracket body. Otherwise you may cause damage to the inner connecting wires of the dual control lever.
  • Page 14 Installation/removal Installing the dual control lever Connect the electric wire. If required, first remove the dummy plug of the E-TUBE port. Be sure to push it in firmly with the TL-EW300 until you feel a click. For instructions on using the TL-EW300, refer to the ROAD Di2 Dealer's Manual General Guide.

  • Page 15: Installing The Brake Cable

    Installation/removal Installing the brake cable TECH TIPS • PC linkage devices can be connected to the E-TUBE port when performing maintenance. However, leave the dummy plug attached to the unused E-TUBE port when a PC linkage device is not in use. Wire, connect, and check the connection of the outer casing and electric wire.

  • Page 16: Cable To Be Used

    Installation/removal Installing the brake cable NOTICE • Be careful not to let the BC-9000 inner cable come into contact with the shifting lever or the metallic part (adjustment section) of the caliper brake. If the coating of the cable gets abraded during installation, it may develop a fuzzy appearance, although this will not affect performance.
  • Page 17 Installation/removal Installing the brake cable 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 CAUTION • Be careful not to hurt your hands with the TL-CT12 needle. Install the outer cap with tongue.

  • Page 18: Installing The Brake Cable

    Installation/removal Installing the brake cable NOTICE • When inserting the outer casing, take care to ensure that the tip of the outer cap with tongue is not damaged. • When using the BC-1051 inner cable, use a regular outer cap rather than an outer cap with tongue.

  • Page 19: Installing The Sm-Cb90

    Installation/removal Installing the SM-CB90 NOTICE • Make sure that the inner end is firmly fit into the cable hook. Inner end Cable hook Temporarily secure the outer casing to the handlebar (by using tape or a similar material). Tape Outer casing Installing the SM-CB90 WARNING •...

  • Page 20: Installation

    Installation/removal Installing satellite shifters Installation Install the SM-CB90. (1) Pass the inner cable through the SM-CB90 and install it to the outer casing on the brake lever side. (2) Move the quick release lever to the “Open” position. (3) Install the outer casing on the brake caliper side to the SM-CB90. (4) Move the quick release lever to the “Close”...

  • Page 21: Sw-Rs801-T

    Installation/removal Installing satellite shifters SW-RS801-T `Routing map Dual control lever (left) Dual control lever (right) Satellite shifter `Connection method Set the band on the shift unit. Band Shift unit...
  • Page 22 Installation/removal Installing satellite shifters Place the rubber sheet on the installation position and set the satellite shifter on top of it. Satellite shifter Rubber sheet Handlebar...
  • Page 23 Installation/removal Installing satellite shifters Secure the satellite shifter to the handlebar with a zip tie. Wind the zip tie aligned with the groove on the band. Groove Satellite shifter Zip tie Cut the remaining part of the zip tie using cutters, etc. Zip tie...
  • Page 24 Installation/removal Installing satellite shifters Connect the electric wire of the satellite shifter to the satellite shifter connection port of the dual control levers. There is an alignment tab on the plug of the electric wire, which should be aligned with the shape of the satellite shifter connection port.

  • Page 25: Sw-Rs801-S

    Installation/removal Installing satellite shifters SW-RS801-S `Routing map Dual control lever (right) Dual control lever (left) Satellite shifter ` Connection method Use a utility knife or a similar tool to cut the handlebar tape to the length of 80 mm. NOTICE •...
  • Page 26 Installation/removal Installing satellite shifters Make a hole in the cut handlebar tape for the button of the satellite shifter to pass through (13 mm x 9 mm). 80 mm 13 mm 9 mm Set the band on the shift unit. Shift unit Band Affix double-sided tape to the satellite shifter.
  • Page 27 Installation/removal Installing satellite shifters Connect the electric wire of the satellite shifter to the satellite shifter connection port of the dual control levers. There is an alignment tab on the plug of the electric wire, which should be aligned with the shape of the satellite shifter connection port.
  • Page 28 Installation/removal Installing satellite shifters Mark the installation position, and affix the satellite shifter to the handlebar using double-sided tape. Double-sided tape NOTICE • The adhesive force weakens if there is any dirt, water or oil on the surface where the double-sided tape is applied. Align the cut hole in the handlebar tape with the button.

  • Page 29: Troubleshooting

    Installation/removal Installing satellite shifters Wind on the handlebar tape. Wind the handlebar tape on securely so that the satellite shifter does not move. NOTICE • In order to protect the electric wire, use handlebar tape to secure the wire. Do not secure the wire with the zip tie or the bracket for the cycle computer.

  • Page 30: Installing The Brake Caliper

    Installation/removal Installing the brake caliper Installing the brake caliper Recommended tire size / rim outer width / brake shoe `Recommended tire size The recommended tire sizes for installation are as follows. Caliper brake Tire width Outer diameter of tire BR-R9200 BR-R9210 BR-R8100 28 mm or less...
  • Page 31 Installation/removal Installing the brake caliper Caliper brake Rim outer width Brake shoe WH-R9100-C60-CL WH-R9100-C40-CL WH-R9100-C24-CL R55C4 Aluminum rim 20.8 - 24 mm WH-9000-C50-CL R55CT4 WH-9000-C35-CL WH-9000-C24-CL WH-9000-C24-TL BR-R9200 WH-9000-C75-TU BR-R9210 BR-R8100 WH-9000-C50-TU R55C4 (for carbon 20.8 - 24 mm BR-R8110 rim) WH-9000-C35-TU BR-RS811-R...

  • Page 32: Installing The Brake Caliper (Br-R9200 / Br-R8100)

    Installation/removal Installing the brake caliper NOTICE • Use brake shoes that are appropriate for the rim type and rim outer width. • BR-R9210 / BR-R8110 / BR-RS811-R Do not remove the assembly tool until installation is finished. Otherwise the brake caliper may be scratched.

  • Page 33: Installing The Brake Caliper (Br-R9210 / Br-R8110)

    Installation/removal Installing the brake caliper Check that the centering adjustment screw is in the standard position. With the standard position, the centering adjustment screw protrudes as shown in the figure. If the centering adjustment screw is not in the standard position, turn it for adjustment.
  • Page 34 Installation/removal Installing the brake caliper Remove the wire portion of the assembly tool pulling in the direction of (1), then remove the plastic spacer portion of the assembly tool in the direction of (2). Secure the brake caliper to the frame base. 5 - 7 N·m Brake fixing screw...
  • Page 35 Installation/removal Installing the brake caliper Remove the protection sheet. ` Installing the rear brake caliper (BR-R9210-RS / BR- R8110-RS) Temporarily install the brake caliper to the frame base. Install it together with the assembly tool. Assembly tool 0.5 N·m Brake fixing screw Remove the wire portion of the assembly tool pulling in the direction of (1), then remove the plastic spacer portion of the assembly tool in the direction of (2).

  • Page 36: Installing The Brake Caliper (Br-Rs811-R)

    Installation/removal Installing the brake caliper Secure the brake caliper to the frame base. 5 - 7 N·m Brake fixing screw Remove the protection sheet. Installing the brake caliper (BR-RS811-R) Temporarily install the brake caliper to the frame base. Install it together with the assembly tool. 0.5 N·m Brake fixing screw...

  • Page 37: Brake Shoe Setting Position

    Installation/removal Brake shoe setting position Pull out the assembly tool in the direction of the arrow. Assembly tool Secure the brake caliper to the frame base. 5 - 7 N·m Brake fixing screw Remove the protection sheet. Brake shoe setting position The contact angle (toe-in) of the brake shoe against the rim can be adjusted.

  • Page 38: Securing The Bc-9000 Cable

    Installation/removal Securing the BC-9000 cable Install the brake shoe to the rim surface as shown in the figure. Direction of rim rotation 1 mm or more 5 - 7 N·m Toe-in 0.5 mm Shoe fixing screw NOTICE • Use brake shoes that are appropriate for the rim type and rim outer width. For details, refer to the “Recommended tire size / rim outer width / brake shoe”...
  • Page 39 Installation/removal Securing the BC-9000 cable Move the quick release lever to the “Close” position. BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-RS811-R BR-R8100 / BR-R8110-F / BR-R8110-RS Quick release lever Open Close Quick release lever Wipe off any grease or other lubricants on the inner cable fixing section.
  • Page 40 Installation/removal Securing the BC-9000 cable Secure the inner cable. Turn the centering adjustment screw to adjust the shoe clearance to be the same on the left and right (1.5 - 2 mm). BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-RS811-R BR-R8100 / BR-R8110-F / BR-R8110-RS Centering adjustment screw Centering adjustment screw 6 - 8 N·m...
  • Page 41 Installation/removal Securing the BC-9000 cable After depressing the brake lever several times, there may be a change in the shoe clearance. If necessary, adjust the shoe clearance again to be the same on the left and right (1.5 - 2 mm). Adjust the shoe clearance to be the same on the left and right (1.5 - 2 mm).

  • Page 42: Cable Outer Stopper Position And Appropriate Outer Casing Length (Br-Rs811-R)

    Installation/removal Securing the BC-9000 cable Cable outer stopper position and appropriate outer casing length (BR-RS811-R) `When caliper brake is open When the caliper brake is in its resting position, ensure the edge of the outer casing is at least 15 mm from the smallest chainring. (A ≥ 15 mm) BB center Drive side Smallest chainring...
  • Page 43 Installation/removal Securing the BC-9000 cable ` When caliper brake is fully closed When the caliper is fully closed without a rear wheel, the brake outer casing should be long enough to reach from the cable outer stopper to the caliper. Cable outer stopper...

  • Page 44: Adjustment

    Adjustment Arch spring tension adjustment Adjustment Arch spring tension adjustment BR-RS811-R If the brake lever is not returning smoothly, you may need to adjust the fixing position of the spring. Perform this task with the brake caliper removed from the frame. `When using assembly tool The Assembly Tool (Y8L398040) can aid in reinstallation of the brake caliper after repositioning the spring.
  • Page 45 Adjustment Arch spring tension adjustment Install the assembly tool to the brake caliper. Assembly tool Temporarily install the brake caliper to the frame base. Install it together with the assembly tool. 0.5 N·m Brake fixing screw...
  • Page 46 Adjustment Arch spring tension adjustment Pull out the assembly tool in the direction of the arrow. Assembly tool Secure the brake caliper. 5 - 7 N·m Brake fixing screw ` When not using assembly tool Remove the brake caliper from the frame.
  • Page 47 Adjustment Arch spring tension adjustment Reposition the spring. Securely attach the spring to the spring attachment pin. Default setting (Factory condition) Spring force increase Spring attachment Spring attachment Temporarily install the brake caliper to the frame base. (1) Half-tighten the Y-arm onto the frame. (2) Tighten the C-arm onto the frame.

  • Page 48: Readjustment Of Shoe Clearance (When Brake Shoes Are Worn)

    Adjustment Readjustment of shoe clearance (when brake shoes are worn) Secure the brake caliper. 5 - 7 N·m Brake fixing screw Readjustment of shoe clearance (when brake shoes are worn) If the clearance with the rim widens due to wear in the brake shoe, readjust the shoe clearance.

  • Page 49: Adjusting The Reach

    Adjustment Adjusting the reach Turn the cable adjustment nut / self-locking nut to readjust the shoe clearance. Adjust the shoe clearance to be the same on the left and right (1.5 - 2 mm). BR-R9200 / BR-R9210-F / BR-R9210-RS / BR-RS811-R BR-R8100 / BR-R8110-F / BR-R8110-RS Cable adjustment nut...
  • Page 50 Adjustment Adjusting the reach Turn the reach adjustment screw to adjust the reach. Tightening the reach adjustment screw (clockwise) narrows the distance between the initial position of the brake lever and the handlebar, while loosening the screw (counterclockwise) widens it. Reach adjustment screw NOTICE •...

  • Page 51: Maintenance

    Maintenance Replacing the cartridge shoe Maintenance Replacing the cartridge shoe BR-R9200 / BR-R9210-RS / BR-R8100 / BR-R8110-RS Remove the fixing screw. Fixing screw Remove the shoe by sliding it along the groove of the shoe holder. Shoe Slide the new shoes into the grooves on the shoe holders to secure them.

  • Page 52: Br-R9210-F / Br-R8110-F / Br-Rs811-R

    Maintenance Replacing the cartridge shoe BR-R9210-F / BR-R8110-F / BR-RS811-R Remove the fixing screw. Fixing screw Remove the shoe by sliding it along the groove of the shoe holder. Shoe Slide the new shoes into the grooves on the shoe holders to secure them.

  • Page 53: Brake Shoe Characteristics

    Maintenance Brake shoe characteristics WARNING • Make sure to use the dedicated brake shoe for the shoe holder of the BR-R9210-F / BR-R8110-F / BR-RS811-R. Other models of brake shoes have different fixing positions preventing the fixing screw from being tightened, which will cause the brake shoe to come off and disable braking.

  • Page 54: Replacing The Bracket Cover

    Maintenance Replacing the bracket cover Model No. R55C3 R55C+1 R55CT4 Cartridge type Recommended rim Aluminum Aluminum Aluminum DRY Power WET Power Silence Anti-fading Characteristics Durability (on-road) Durability (muddy conditions) Anti-rim attack Replacing the bracket cover Remove the brake cable and electric wire from the dual control lever. Remove the dual control levers from the handlebar.
  • Page 55 Maintenance Replacing the bracket cover Install a new bracket cover. Insert the protrusions on the bracket cover into the recesses in the bracket body when fitting on the bracket cover. The inside of the bracket cover has a mark indicating the left side or right side. Bracket cover TECH TIPS •...
  • Page 56 Please note: specifications are subject to change for improvement without notice. (English) © Mar. 2021 by SHIMANO INC. ITP...

This manual is also suitable for:

Dura-aceUltegraSt-r9250Br-r9200Br-r9210St-r8150 ... Show all

Table of Contents

Save PDF