Introduction
This manual provides detailed instructions for the proper installation, operation, and maintenance of your Shimano Dura-Ace BC-9000 Polymer-Coated Brake Cable Set. Designed for road cycling and cyclocross, these cables feature a polymer coating for reduced friction and enhanced braking performance. Adhering to these instructions will ensure optimal function and longevity of your brake system.
Safety Information
WARNING: Improper installation or maintenance of bicycle brake components can lead to serious injury or death. If you are unsure about any part of the installation process, consult a professional bicycle mechanic. Always wear appropriate safety gear when working on your bicycle.
- Ensure all components are clean and free from debris before installation.
- Do not re-use frayed or damaged cables or housing.
- Verify proper brake function and lever feel before riding.
- Regularly inspect brake cables and housing for wear and damage.
Package Contents
An image showing the various components of the Shimano Dura-Ace BC-9000 brake cable set, including the polymer-coated inner cables, outer housing, ferrules, and end caps.
Your Shimano Dura-Ace BC-9000 Polymer-Coated Brake Cable Set typically includes:
- Front and Rear Polymer-Coated Inner Brake Cables (Stainless Steel)
- Front and Rear BC-9000 Brake Cable Housing
- Ferrules
- Cable End Caps
Setup and Installation
This brake cable set is compatible with Dura-Ace 9000/9010, Ultegra 6800/6810, and Cyclocross BR-CX70 brake systems. Follow these general steps for installation:
- Remove Old Cables and Housing: Carefully remove existing brake cables and housing from your bicycle.
- Measure and Cut Housing: Measure the new brake housing to the appropriate length, ensuring smooth routing without sharp bends. Use a sharp cable cutter to achieve clean cuts.
- Install Ferrules: Place the appropriate ferrules onto the ends of the cut housing.
- Route Housing: Route the new brake housing through the frame and handlebar guides.
- Insert Inner Cable: Carefully insert the polymer-coated inner brake cable through the brake lever and into the housing. Important: The polymer coating is delicate. Avoid bending or forcing the cable, as this can damage the coating and impair performance.
- Secure Cable: Route the cable through the brake caliper mechanism. Secure the cable at the fixing bolt, ensuring it is properly tensioned.
- Pre-stretch Cable: Apply firm pressure to the brake lever several times to pre-stretch the cable. Due to the low-friction polymer material, some initial slippage at the cable fixing bolt may occur. Re-tension and re-secure the cable after pre-stretching.
- Trim Excess Cable: Trim any excess inner cable, leaving sufficient length for future adjustments. Install a cable end cap.
- Adjust Brakes: Adjust the brake calipers and lever reach for optimal braking performance and comfort.
Operation
After installation, test the brakes thoroughly before riding. The polymer-coated cables are designed to provide lighter and quicker brake operation. Ensure that the brake levers return smoothly and that the brake calipers engage and release effectively. The pre-lubed inner cable with special polymer-compatible grease contributes to this smooth operation.
Maintenance
Regular maintenance is crucial for the performance and safety of your brake system:
- Inspection: Periodically inspect the brake cables and housing for signs of wear, fraying, kinks, or damage. Pay close attention to areas where the cable enters and exits the housing.
- Cleaning: Keep the brake levers, calipers, and cable routing areas clean. Avoid using harsh chemicals that could damage the polymer coating or housing material.
- Replacement: Replace cables and housing immediately if any damage is observed. The polymer coating, if damaged, can affect performance. It is not recommended to re-use cables once the polymer coating has stripped or frayed, as this can clog the housing and reduce braking efficiency.
- Lubrication: The cables are pre-lubed. Avoid applying additional lubricants unless specifically recommended by Shimano for polymer-coated cables, as incompatible lubricants can degrade the polymer.
Troubleshooting
| Issue | Possible Cause | Solution |
|---|---|---|
| Brake lever feels spongy or has excessive travel. | Cable stretch (initial), improper cable tension, worn brake pads. | Re-tension cable after pre-stretching. Adjust cable tension at the brake caliper. Inspect and replace brake pads if worn. |
| Brakes do not release fully or drag. | Cable housing too short or kinked, damaged polymer coating, dirty calipers. | Check housing length and routing. Replace damaged cables/housing. Clean brake calipers. |
| Friction or resistance when pulling brake lever. | Damaged polymer coating on inner cable, contaminated housing, improper cable routing. | Inspect inner cable for fraying or damage; replace if necessary. Check housing for debris or kinks. Ensure smooth cable routing. |
| Cable slippage at fixing bolt after initial use. | Characteristic of low-friction polymer coating during initial break-in. | This is normal. Perform cable pre-stretching and re-tighten the fixing bolt securely. Repeat if necessary. |
Specifications
- Model: BC-9000
- Brand: SHIMANO
- Cable Material: Stainless Steel with Polymer Coating
- Compatible Components: Dura-Ace 9000/9010, Ultegra 6800/6810, Cyclocross BR-CX70
- Recommended Use: Road Cycling, Cyclocross
- Color: Black
- Item Weight: Approximately 9.6 ounces (for the set)
- Nominal Wall Thickness (Housing): 0.8 millimeters
- Outside Diameter (Housing): 1.6 millimeters
- Item Length (Cable): 200 centimeters (approximate, typically includes front and rear lengths)
Warranty and Support
For warranty information and technical support, please refer to the official Shimano website or contact your authorized Shimano dealer. Keep your proof of purchase for any warranty claims. Shimano provides comprehensive support for its products to ensure customer satisfaction.
Official Shimano Website: bike.shimano.com
