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Dura-Ace Manual

The document provides detailed service instructions and safety information for the installation and adjustment of Shimano bicycle components, specifically the DURA-ACE series. It emphasizes the importance of using genuine parts, proper adjustments, and maintenance to prevent accidents and ensure optimal performance. Key warnings include the necessity of removing the battery during installation and ensuring correct alignment of components to avoid serious injury.

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jonperez08
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0% found this document useful (0 votes)
70 views18 pages

Dura-Ace Manual

The document provides detailed service instructions and safety information for the installation and adjustment of Shimano bicycle components, specifically the DURA-ACE series. It emphasizes the importance of using genuine parts, proper adjustments, and maintenance to prevent accidents and ensure optimal performance. Key warnings include the necessity of removing the battery during installation and ensuring correct alignment of components to avoid serious injury.

Uploaded by

jonperez08
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 18

SERVICE INSTRUCTIONS

EINBAUANLEITUNG
INSTRUCTIONS DE MONTAGE
General Safety Information

English
WARNING Note
• When the shifting switch is operated, the motor • RD-7970: Be sure to adjust the top
which drives the front derailleur will operate adjustment bolt and the low adjustment
without stopping at the shifting lever position. bolt by following the procedures in the
Always be sure to remove the battery before Service Instructions. If these bolts are not
carrying out installation and adjustment, adjusted, the chain may become clamped
otherwise your fingers may become stuck. between the spokes and the large
• Obtain and read the service instructions carefully sprocket and the wheel may lock, or the
prior to installing the parts. Loose, worn or chain may slip onto the small sprocket.
damaged parts may cause the bicycle to fall over • Use a soft cloth to clean the carbon fiber
and serious injury may occur as a result. We levers, and be sure to moisten the cloth
strongly recommend only using genuine Shimano with neutral detergent before using it,
replacement parts. otherwise the lever material may become
• Obtain and read the service instructions carefully damaged and lose its strength.
prior to installing the parts. If adjustments are not • Avoid leaving the carbon fiber levers in
carried out correctly, the chain may come off and places where high temperatures are
this may cause you to fall off the bicycle which present. Also keep them well away from
could result in serious injury. fire.
• Use the BR-7900 with the ST-7970. Do not use the • Operation of the levers related to gear
BR-7900 in combination with previous STI levers for shifting should be made only when the
road riding or with the BL-R770/ BL-R550 brake front chainwheel is turning.
levers for flat handlebars, otherwise the braking • Always be sure to use the TL-EW01
performance provided will be much too strong. special tool to remove the cable.
• Because of the characteristics of the carbon fiber • Be careful not to let water get into the
material, you must never modify the levers, terminal.
otherwise the lever may break and the brakes may • Parts are not guaranteed against natural
no longer work as a result. wear or deterioration resulting from
• Before riding the bicycle, check that there is no normal use.
damage such as carbon fiber peeling or cracking. If • For maximum performance we highly
there is any damage, replace with a new part recommend Shimano lubricants and
immediately without trying to repair the damage, maintenance products.
otherwise the lever may break and the brakes may • For any questions regarding methods of
no longer work as a result. installation, adjustment, maintenance or
• Read these Technical Service Instructions carefully, operation, please contact a professional
and keep them in a safe place for later reference. bicycle dealer.

In order to realize the best performance, we recommend that the following combination
be used.
Series DURA-ACE
Dual control lever ST-7970
Electric cable EW-7970
Battery / Battery charger SM-BTR1 / SM-BCR1
Gears 20
Front derailleur FD-7970
Front chainwheel FC-7900
Rear derailleur RD-7970
Freehub FH-7900
Cassette sprocket CS-7900 (Except for 11-28T)
Chain CN-7900
Caliper brake BR-7900

3
SI-5X20A-001-00
General Safety Information Technical Service Instructions SI-5X20A-001 Chain length
WARNING Note:
• In order to obtain good gear shifting performance, the CN-7900 has a forward side and a RD-7970 In order to obtain good gear shifting performance, the CN-
reverse side, and the sides are marked so that the CN-7900 will face the correct way when 7900 has a forward side and a reverse side, and the sides are
installed. The proper design performance will be obtained when the CN-7900 is installed so 00 marked so that the CN-7900 will face the correct way when
that it faces the correct way. If it is installed so that it faces the opposite way, the chain may installed.
come off and the bicycle may fall over and serious injury may occur as a result. Rear derailleur
• Use neutral detergent to clean the chain. Do not use alkali-based or acid based detergent such as Forward
rust cleaners as it may result in damage and/or failure of the chain. (outer side)
• For a narrow-type chain, connect using a QUICK-LINK (SM-CN79) or a reinforced connecting pin. If
In order to realize the best performance, we recommend The side with the mark shown in the illustration is the forward side
using a QUICK-LINK, follow the procedure given in the QUICK-LINK Service Instructions. (outer side).
• If connecting pins other than reinforced connecting pins are used, or if a reinforced connecting pin
that the following combination be used.
or tool which is not suitable for the type of chain is used, sufficient connection force may not be Series DURA-ACE Reverse
obtained, which could cause the chain to break or fall off. (inner side)
Dual control lever ST-7970
Reinforced Gears 10
Chain Chain tool
connecting pin
Electric cable EW-7970 / SM-EW79A Smallest Largest
sprocket chainring
10-speed super narrow chain TL-CN32 Battery SM-BTR1
such as with groove (2) TL-CN23
CN-7900 Rear derailleur RD-7970
TL-CN27
Type SS Chain
Guide pulley
• Make sure that the connecting pin is aligned with the outer link Freehub FH-7900
Tension pulley 90°
surface from the side that the pin is inserted. It should feel Cassette sprocket CS-7900 (Except for 11-28T)
smooth and flush when you run your finger over it. The pin will Right angle to the ground
protrude slightly on the backside after the break off pin is Chain CN-7900
removed.
• If it is necessary to adjust the length of the chain due to a change in Reinforced Connecting Pin
the number of sprocket teeth, make the cut at some other place than
the place where the chain has been joined using a reinforced Specifications Protection function
connecting pin. The chain will be damaged if it is cut at a place
where it has been joined with a reinforced connecting pin. Type SS If the bicycle receives a strong impact, the protection function
Link Pin Link Pin
• Check that the tension of the chain is correct and that the chain is operates and the connection between the motor and the link is
Total capacity 32 teeth or less momentarily severed so that the rear derailleur will no longer operate.
not damaged. If the tension is too weak or the chain is damaged, the chain should be replaced. If this
is not done, the chain may break and cause serious injury. Largest sprocket 27 T This is done in order to protect the system at times such as if the
• Obtain and read the service instructions carefully prior to installing the parts. Loose, worn or bicycle falls over. If this happens, press the button on junction (A) of
Smallest sprocket 11 T
damaged parts may cause the bicycle to fall over and serious injury may occur as a result. We the SM-EW79A for 5 seconds or more. This will restore the
strongly recommend only using genuine Shimano replacement parts. Front chainwheel tooth difference 16 teeth or less
connection between the motor and the link and clear the protection
• Obtain and read the service instructions carefully prior to installing the parts. If adjustments are function for the rear derailleur. Operate the shifting switches to check
not carried out correctly, the chain may come off and this may cause you to fall off the bicycle which that the connection has been restored.
could result in serious injury.
• Read these Technical Service Instructions carefully, and keep them in a safe place for later reference.
Refer to the Service Instructions for the electric cable (EW-7970 /
Note SM-EW79A) when connecting and routing the electric cable.
Junction (A)
• Be sure to adjust the top adjustment bolt and the low adjustment bolt by following the
procedures in the Service Instructions. If these bolts are not adjusted, the chain may become Installation of the rear derailleur
clamped between the spokes and the largest sprocket and the wheel may lock, or the chain may Button
slip onto the smallest sprocket. When installing the rear derailleur, make sure that the B-tension Illuminates (red)

• If the amount of looseness in the links is so great that adjustment is not possible, you should replace adjustment bolt does not touch the fork of the dropout and cause it to
the derailleur. bend.
• Periodically clean the derailleur and lubricate all moving parts and pulleys.
• If gear shifting adjustment cannot be carried out, check the degree of parallelism at the rear end of Fork of dropout
the bicycle. B-tension adjustment bolt
• If you hear abnormal noise as a result of looseness in a pulley, you should replace the pulley.
• The tension pulley has a mark which indicates the direction of rotation. The side with the arrow is the
front side.
• Always be sure to use the TL-EW01 special tool to remove the cable. Protection clear
Button held down Illuminates (red) Flashes (red)
operation
• Be careful not to let water get into the terminal.
• Parts are not guaranteed against natural wear or deterioration resulting from normal use.
• For maximum performance we highly recommend Shimano lubricants and maintenance products. Approx. 5-second period
Protection
• For any questions regarding methods of installation, adjustment, maintenance or operation, please cleared
contact a professional bicycle dealer.
* Guide pulley / tension pulley 5 mm Allen key
tightening torque:
2.5 - 3 N·m {22 - 27 in. lbs.}

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003 Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222 3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan
Bracket tightening torque: * Refer to the Service instructions for the ST-7970 for details on
8 - 10 N·m {70 - 86 in. lbs.} stroke adjustment.
Please note: specifications are subject to change for improvement without notice. (English) © Dec. 2008 by Shimano Inc. XBC SZK Printed in Japan.
SI-5LF0A-001-00
General Safety Information In order to realize the best performance, we recommend that the * Protectors with a curved adhesion surface
following combination be used. and a flat adhesion surface exist as shown in
the illustration, so use whichever type
WARNING Series DURA-ACE matches the shape of the frame.
Dual control lever ST-7970 Duct tape
• When the shifting switch is operated, the motor which drives the front
derailleur will operate without stopping at the shifting lever position. Always Electric cable EW-7970 / SM-EW79A
be sure to remove the battery before carrying out installation and adjustment, Battery SM-BTR1 1. Adjust so that there is a clearance of
otherwise your fingers may become stuck. 1 – 3 mm between the chain guide
• Obtain and read the service instructions carefully prior to installing the parts. Gears 20
outer plate and the large chainring. Clearance 1 – 3 mm
Loose, worn or damaged parts may cause the bicycle to fall over and serious Front derailleur FD-7970
injury may occur as a result. We strongly recommend only using genuine
Shimano replacement parts. Front chainwheel FC-7900
Tightening torque:
• Obtain and read the service instructions carefully prior to installing the parts. Rear derailleur RD-7970 5 - 7 N·m {43 - 60 in. lbs.}
If adjustments are not carried out correctly, the chain may come off and this may Freehub FH-7900
cause you to fall off the bicycle which could result in serious injury.
• ÅE Use the CN-7900 chain in combination with the FC-7900. If a 10-speed chain Cassette sprocket CS-7900 (Except for 11-28T)
such as the CN-7801 or CN-6600 is used, the chain may come off and the Chain CN-7900 Chain guide outer plate
bicycle may suddenly fall over, and serious injury may result.
• Be careful not to let the cuffs of your clothes get caught in the chain while riding,
otherwise you may fall off the bicycle.
• Read these Technical Service Instructions carefully, and keep them in a safe Specifications
place for later reference.
Brazed on
Type Band type
Note type
• If gear shifting operations cannot be carried out smoothly, clean the derailleur Model number FD-7970-F FD-7970-L FD-7970-M FD-7970-S 2. Use a 5 mm Allen key to secure the
and lubricate all moving parts. chain guide outer plate so that the
• If the amount of looseness in the links is so great that adjustment is not possible, Band adapter (Front derailleur SM-AD79L SM-AD79M SM-AD79MS flat part of the plate is directly above

you should replace the derailleur. installation band diameter) (34.9 mm) (31.8 mm) (28.6 mm) the large chainring and so that the
• Always be sure to use the TL-EW01 special tool to remove the cable. rear edge of the chain guide within
• Be careful not to let water get into the terminal. Top gear teeth 50 - 56 T
0.5 – 1.0 mm from the front edge of
• Parts are not guaranteed against natural wear or deterioration resulting from normal Front chainwheel tooth the chain guide.
16 teeth or less
use. difference Front chainwheel (large chainring)
• For maximum performance we highly recommend Shimano lubricants and Chainstay angle (C) 61˚ - 66˚
maintenance products.
• For any questions regarding methods of installation, adjustment, maintenance or Chain line 43.5 mm
operation, please contact a professional bicycle dealer.

Refer to the Service Instructions for the electric cable (EW-7970 / SM- Chain guide 0.5 – 1 mm
EW79A) when connecting and routing the electric cable.

Installation of the front derailleur


If installing the front derailleur to a brazed-on type frame, a protector must be
attached to the seat tube. Always be sure to install the protector in order to 3. Use a 2 mm Allen key to turn the
prevent damage to the frame from the pressure applied by the support bolt of support bolt in order to adjust the
the front derailleur. position of the front derailleur so that
the flat part of the chain guide outer
■ Installation of the protector plate is directly above and parallel to
Check the position where the support bolt directly touches the frame when the large chainring.
the support bolt of the front derailleur is being adjusted, and attach the
Technical Service Instructions SI-5LF0A-001 protector in that position. In addition, avoid positioning the duct tape that
attaches the protector to the seat tube in the location where the support bolt
directly touches the frame.

FD-7970 Band adapter

00

Front derailleur
When installing the components to carbon frame/handle bar surfaces, verify
with the manufacturer of the carbon frame/parts for their recommendation on
tightening torque in order to prevent over tightening that can cause damage to
the carbon material and/or under tightening that can cause lack of fixing
Protector
strength for the components.
Support bolt

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003

* If using a band adapter (SM-AD79L/M/S), the protector and washer are not
Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222 3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan
required. Use the SM-AD79 in combination with the FD-7970. The SM- * Refer to the Service Instructions for the ST-7970 for details on the
Please note: specifications are subject to change for improvement without notice. (English)
© Dec. 2008 by Shimano Inc. XBC SZK Printed in Japan.
AD11/15 cannot be installed. adjustment method for the front derailleur.
SI-7DT0A-001-00
Technical Service Instructions SI-7DT0A-001 Use the accessory cable ties to secure junction (A) to the outer casing of the brake cable.
In addition, set the connector of junction (A) onto the outer casing of the rear brake cable
as shown in the illustration.

SM-EW79A
00

Electric Cables

Note
• Always be sure to use the TL-EW01 special tool to remove the cable.
• Be careful not to let water get into the terminal.

■ Components
• Junction A
• Connectors : 3 places
(Right lever/left lever/junction) Use the TL-EW01 special tool to connect to the ST-7970. Set
so that the projection on the connector is aligned with the
groove on the narrow end.

Junction A

Accessories Options (sold separately)


• Cable ties x2 SM-EWC1-L (black)
SM-EWC1-W (white)
SM-SWC1-G (gray) Open up the bracket cover and lift up the connector
cover. Connect the connector to the terminal at the
lever end so that the projection on the connector is
■ Routing Map aligned with the groove in the connector cover. Be
Names and locations of each part sure to push them together until they connect with a
click. Either the top or bottom terminal can be used.
Junction A

Left lever

Front derailleur Bottle cage

Groove in the connector cover

Right lever The remaining terminal can be used for an additional shifting
switch. If not using an additional shifting switch, be sure to attach
a dummy plug to the unused terminal using the TL-EW01.
Battery bracket

Junction B
Rear derailleur

• When routing the electric cable to junction (A), allow enough looseness in Dummy plug
the cable so that the ST-7970 installation position can be adjusted and so
that the handlebars can be turned fully to the left and right. When routing
the electric cable to junction (A), the cable can be laid underneath the • Install the battery in order to check the connections. Operate the shifting switch and
handlebar tape when it is wound onto the handlebars. check that the front derailleur and rear derailleur both operate.
• Refer ST-7970 service instructions for button indicator operations. • Be sure to operate shifting switch (X) for the left lever once or more to set the front
derailleur to the large chainring position for greater ease when installing the chain. After
this, be sure to remove the battery.
• In addition, use the wide end of the TL-EW01 special tool when disconnecting the
Connection of the electric cables connectors. If you pull too firmly on the connectors, problems with operation may occur.
Insert the special tool so that the flat side is facing toward the derailleur, and then tilt it
Insert the connector coming from junction (A) into the connector coming so as to pull out the connector. When disconnecting the connector at the lever end,
from junction (B) so that the triangular marks (d) on the connectors are insert the special tool so that the flat side is facing toward the lever. When disconnecting
aligned with each other. Push the connectors together until they connect the connector of junction (A), insert the special tool so that the flat side is facing toward
with a click. Because of the waterproof structure of the connectors, they do junction (A).
not fit together rigidly. Be sure to push them together until they connect
with a click.

Connector from EW-7970


junction (B)

Connector from SM-EW79A junction (A)

One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003 Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222 3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan

Please note: specifications are subject to change for improvement without notice. (English) © Dec. 2008 by Shimano Inc. XBC SZK Printed in Japan.
with a click. Because of the waterproof structure of the connectors, they do
00 not fit together rigidly. Be sure to push them together until they connect
with a click.
ables (External Specifications)
Connector from EW-7970
junction (B)

to the frame so that they will not caught by the tire or


ile pedaling.
use the TL-EW01 special tool to remove the cable.
et water get into the terminal.
Connector from SM-EW79A junction (A)

Once the electric cable has been


laces (Front derailleur/rear derailleur/junction) routed, secure junction (B) to the
bottom of the bottom bracket shell
with a bolt (length 10.5 mm or 15
ength : 3 types (770/830/890 mm)
mm).

Leave a space of 108 mm or more at the end of the battery bracket.


Check that the battery can be inserted and removed while the bottle cage Connect the electric cable connectors to the terminals of the derailleurs.
is installed. Insert the connectors so that the triangular marks (d) on the connectors
and the derailleur terminals are aligned with each other.
Because of the waterproof structure of the connectors and terminals, they Next, install the cable cover to the
do not fit together rigidly. Be sure to push them together until they connect frame. In order to make sure that the
with a click. cable cover is securely installed,
clean the frame with alcohol or some
other cleaning agent to remove any
For rear derailleur grease or other substances before
installing the cable cover. Place the
cable cover over the electric cable,
Junction cable and then attach the cable cover to the
tion B frame.

) length : 2 types <Battery installation and removal>


5/DT) Open the clamp, and then install the battery so that it follows the groove in
D/FD) the battery bracket. Close the clamp until it clicks into place.
m, L=15 mm
For front derailleur

tions of each part

Junction A

Left lever

<Removal of the connectors>


Bottle cage

Right lever Open the clamp, pull out the battery slightly, and then press the button to
fully remove the battery.

Battery bracket

Junction B Routing of the electric cables


erailleur

Provisionally attach the electric cables to the frame with tape.

• When routing the electric cable to


the rear derailleur, be sure to install
it to the bottom of the chainstay to
avoid any interference between the
a 92618, U.S.A. Phone: +1-949-951-5003 cable and the chain.
Gear shifting operation
Rear shifting switch operation
< Shifting switch (X) > < Shifting switch (Y) >
The chain moves from a small sprocket to a larger The chain moves from a large sprocket to a smaller
sprocket each time the switch is operated. sprocket each time the switch is operated.

Shifting switch (X) Shifting switch (Y)

The checker (SM-EC79) can be used to shift up and shift down shifting switches (X) and (Y).

* For details on the shifting switch selection method, refer to the Service Instructions for the checker.

Front shifting switch operation


< Shifting switch (X) > < Shifting switch (Y) >
The chain moves from the small chainring to the The chain moves from the large chainring to the
large chainring. small chainring.

Shifting switch (X) Shifting switch (Y)

If the chain falls off on the inside, keep pressing


shifting switch (X) to move the front derailleur to
the outermost position in order to reset the chain.

4
Installation
Installation to the handlebars
Bracket cover
Wind the bracket cover from the front, and then use
a 5 mm Allen key to tighten the mounting nut in
5 mm Allen key
order to secure the bracket cover.

When installing the components to carbon


frame/handle bar surfaces, verify with the
manufacturer of the carbon frame/parts for their
recommendation on tightening torque in order to
prevent over tightening that can cause damage to
the carbon material and/or under tightening that can
cause lack of fixing strength for the components.
Tightening torque:
6 - 8 N·m {52 - 69 in. lbs.}

Installation of the brake cables


Cables used
• Inner cable (PTFE inner cable) •••••• 1.6 mm dia.
Outer casing

• SLR outer casing ••••••••••••••••••• 5 mm dia. Cable hook

Use cables which are long enough so that they still have
some slack even when the handlebars are turned as far as
they will go to the left and to the right. Inner end cap

1. Gently pull the brake lever.

2. Pass the inner cable through from


directly in front, set the inner
cable end into the cable hook,
and then install the outer casing
from the opposite side.
The lever stroke can be smoothly
adjusted using the bolt on the top
of the bracket unit. Check the
lever operation while adjusting.

* Refer to the Service Instructions for the electric cables (EW-7970/SM-EW79A) when connecting and routing
the electric cables.

5
Adjustment
Adjustment of the rear derailleur (RD-7970)
1. Install the battery.

2. Shift the rear derailleur to the 5th sprocket position.


Press the button at the junction
(A) of the SM-EW79A until the
red LED illuminates in order to Janction (A)
switch to rear derailleur
adjustment mode.
Note that if you keep pressing
the button after the red LED
has illuminated, protection
Button
recovery operation will begin.
illuminates red

* Refer to the Service Instructions for the rear derailleur for details
on the protection function.

3. If shifting switch (X) is pressed once, 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.
The guide pulley can move 12 steps inward and 12 steps outward
from the initial position, for a total of 25 positions.

When adjusting, the guide pulley will overrun slightly and then move back in an exaggerated movement so
that you can check the adjustment direction.
When checking the positions of the guide pulley and the sprocket, check at the position where the guide
pulley finally stops.

6
4. While turning the crank arm, operate shifting switch (X) to move
the guide pulley toward the inside until the chain touches the 4th
sprocket and makes a slight noise.

Next, operate shifting switch (Y) 4 times to move the guide pulley
toward the outside by 4 steps to the target position.

4 times

4 steps

Press the button at junction (A) until the red LED turns
off in order to switch from rear derailleur adjustment
mode to gear shifting mode.
Shift to each gear and check that no noise is generated
at any gear position.
If fine adjustment is needed, switch back to adjustment
mode and readjust the rear derailleur.
Button

Turned off

7
5. Next, carry out the adjustments for the low
adjustment bolt and top adjustment bolt.

< Low adjustment >


Shift the rear derailleur to the largest sprocket,
and then tighten the low adjustment bolt until it
touches the stopper.

2 mm Allen key

Low adjustment bolt

< Top adjustment >


2 mm Allen key
Shift the rear derailleur to the smallest sprocket,
and then tighten the top adjustment bolt until it
touches the stopper at the position where the rear
derailleur finally stopped.
From this position, turn the top adjustment bolt
counterclockwise one turn so that an over.

Top adjustment bolt

By shifting from the largest sprocket to the


smallest sprocket, the rear derailleur will
move toward the outside by the over-stroke
allowance and then move back.

8
Adjustment

6. B-tension adjustment bolt adjustment Largest sprocket Smallest sprocket


Set the chain onto the small chainring and the
largest sprocket, and then turn the crank arm
backward.
Turn the B-tension adjustment bolt to adjust so
that the guide pulley moves close to the sprocket
without obstructing the chain.
Next, set the chain onto the smallest sprocket and
check in the same way that the guide pulley does
not obstruct the chain.

Guide pulley

B-tension
adjustment bolt

Adjustment of the front derailleur (FD-7970)

WARNING Support bolt


When the shifting switch is operated, the motor
which drives the front derailleur will operate without Top adjustment bolt
stopping at the shifting lever position.
Always be sure to remove the battery before carrying
out installation and adjustment, otherwise your
fingers may become stuck.
Low adjustment bolt
Note:
The low adjustment bolt, the top adjustment bolt and the
support bolt are close to each other. Make sure that you
are using the correct bolt for adjustment.

< Low adjustment >


Set the chain onto the small chainring and the largest
sprocket.
Use a 2 mm Allen key to turn the low adjustment bolt
to adjust so that there is a clearance of 0.5 - 1 mm
between the chain and the chain guide inner plate.

0.5 – 1 mm

9
Adjustment

< Top adjustment >


Next, set the chain onto the large chainring and the
smallest sprocket.
Use a 2 mm Allen key to turn the top adjustment bolt
to adjust so that there is a clearance of 0.5 - 1 mm
between the chain and the chain guide outer plate.
Move the front derailleur and the rear derailleur to all
gear positions, and check that the chain guide does not
touch the chain.

0.5 – 1 mm

Other lever operation functions


< Battery charge indicator >
Press and hold either shifting switch for 0.5 seconds or more.
You can check the amount of battery charge remaining using the
battery indicator on top of junction (A).

Battery indicator

100 % Illuminates green (for 2 seconds)

50 % Flashes green (5 times)

25 % Illuminates red (for 2 seconds)

0% Flashes red (5 times)

* When the battery charge is low, first the front derailleur will stop operating, and then the rear derailleur will
stop operating. When the battery is fully spent, the derailleurs will stop at the positions where they were last
shifted to. If the battery indicator is illuminated red, it is recommended that you recharge the battery as
soon as possible.

10
Maintenance
* The illustrations show the right-side lever.

Disassembly of the bracket unit and lever unit


1. Use a 2 mm Allen key to remove the lever shaft fixing
screw at the bottom of the bracket unit.

Lever shaft fixing screw

2. Tap an Allen key or similar tool with a plastic mallet to Lever shaft
push out the lever shaft.

Return spring
3. Remove the return spring.

11
4. Remove the two switch unit fixing screws, and then remove the
switches and the switch springs. The bracket unit and the lever unit
can then be disassembled.

Switch unit fixing screws


(#T5 TORX® *)

* TORX is a registered trademark


of Camcar LLC.

Assembly of the switch unit


1. Check that the buttons are attached to the springs, and then place
the switch springs into the holes in the switch lever setting plate.

DURA-ACE grease
Switch springs (Y-04110000)
Apply grease

2. Place the switch unit against the mounting surface of the switch
unit setting plate.

12
Maintenance

3. Press the switch unit by hand so that the switch springs go into the
grooves in the buttons, and then push the shifting switches (X and Y)
in as far as they will go.

Switch unit

Shifting switches (X and Y)

4. Make a gap between the switch unit and the


switch unit setting plate and check that the end of
the rubber on the switch unit is on the button.

5. Return the switch unit to the setting position for


the switch unit setting plate, and while pressing it
by hand, operate the shifting switches (X and Y)
once more and check that the switches turn on.
Install the switch using the switch unit fixing
screws.

Tightening torque:
0.18 N·m {1.5 in. lbs.}

13
Maintenance

Assembly of the bracket unit and lever unit


1. Assemble the bracket unit and the lever unit, attach the return
spring, and then press-fit the lever shaft so that it is facing in
the correct direction. Then tighten the lever shaft fixing screw
to secure the lever shaft.

Apply grease
DURA-ACE grease
(Y-04110000)

Note:
Tighten the lever shaft fixing
screw so that it is flush with
the bracket as shown in the
illustration.

* Operate the shifting switches (X and Y) and check that they turn on, and check that the lever operates
smoothly.

14
One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003

Industrieweg 24, 8071 CT Nunspeet, The Netherlands Phone: +31-341-272222

3-77 Oimatsu-cho, Sakai-ku, Sakai-shi, Osaka 590-8577, Japan

Please note: specifications are subject to change for improvement without notice.
© Nov. 2008 by Shimano Inc. XBC IZM Printed in Japan

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