Shimano ROAD Di2 Series General Guide - Dealer's Manual

Important Notice

This dealer's manual is intended for professional bicycle mechanics. Users without professional training should not attempt installation using these manuals. If any information is unclear, contact your place of purchase or a distributor. Always read all included manuals. Do not disassemble or modify the product beyond the information provided. Manuals and technical documents are available online at si.shimano.com. Bluetooth® word mark and logos are registered trademarks of Bluetooth SIG, Inc., used under license by SHIMANO INC. ANT and ANT+ are trademarks of ANT Wireless.

For safety, read this manual thoroughly before use and follow instructions for correct operation.

The following instructions must be observed to prevent personal injury and damage. Instructions are classified by the degree of danger or damage:

• DANGER: Failure to follow instructions results in death or serious injury.
• WARNING: Failure to follow instructions could result in death or serious injury.
• CAUTION: Failure to follow instructions could cause personal injury or physical damage to equipment and surroundings.

To Ensure Safety

Follow all instructions provided in the manuals during installation. Use only SHIMANO genuine parts. Incorrect assembly or adjustment can lead to component failure and accidents. Wear approved eye protection during maintenance.

Inform users of the following:

• Clean the chain and QUICK-LINK with an appropriate cleaner. Avoid alkali- or acid-based solvents.
• Ensure wheels are securely fastened before riding. Incorrect use of axle release levers can cause wheels to detach.
• Check the chain for damage, skipping, or abnormalities. Consult a distributor if issues are found, as chain breakage can occur.
• Be careful not to let clothing get caught in the chain while riding.
• When operating the shift switch, be cautious of fingers getting caught in the derailleur, as the motor is powerful.

Additional user information:

• Connect/disconnect electric wires only when necessary, as it may impair waterproofing.
• Prevent water from entering E-TUBE ports.
• Components are waterproof for wet weather but should not be submerged.
• Avoid high-pressure washing. Water ingress can cause operating problems or rust.
• Rotate the crank arm during gear shifting operations.
• Handle components carefully and avoid strong shocks.
• Use a cloth moistened with diluted neutral detergent for cleaning; avoid thinners or harsh solvents.
• If gear shifting is not smooth, consult the place of purchase.
• Keep away from magnetic objects, as this can cause operational problems.
• When installing products with magnets, ensure the magnet is in the specified location.
• Contact the place of purchase for component software updates; the latest information is on the SHIMANO website.
• Products are not guaranteed against natural wear and aging.
• For maximum performance, use SHIMANO lubricants and maintenance products.

For installation and maintenance:

• Attach dummy plugs to unused E-TUBE ports.
• Use SHIMANO original tools TL-EW02 / TL-EW300 for removing/installing electric wires.
• Contact SHIMANO INC. for battery charger shipment information to South Korea and Malaysia.
• Ensure brake hose/outer casing has sufficient length for handlebar turning. Check that dual control levers do not touch the frame.
• Use specific clamp bands, screws, and nuts for each product.

Electric wire:

• Secure electric wires with zip ties to prevent interference with gears or tires.
• Do not remove wire holders attached to internal electric wires (EW-SD50-I / EW-SD300-I).
• Do not forcibly bend electric wire plugs during installation to avoid poor connections.
• Ensure no foreign matter enters plugs or E-TUBE ports during connection; this can cause malfunctions.
• Protect exposed plugs with masking tape during storage, transportation, or maintenance.
• If a click is not felt when connecting, check for foreign matter in the plug or port. Use a blower to remove it; replace the wire if the problem persists.

The actual product may differ from illustrations; this manual primarily explains usage procedures.

Notes on reinstalling and replacing components:

• Reinstalled or replaced products are automatically recognized.
• If component configuration changes or malfunctions occur, use E-TUBE PROJECT to update firmware to the latest version and recheck. Ensure E-TUBE PROJECT is also updated.

Connection and communication with PC:

• PC linkage devices and E-TUBE PROJECT Professional can be used for component customization and firmware updates.
• Ensure E-TUBE PROJECT Professional and component firmware are up-to-date to avoid operational issues.

Connection and communication with smartphone or tablet:

• E-TUBE PROJECT Cyclist can update firmware and customize components/systems via Bluetooth® LE.
• Disconnect Bluetooth LE when not using E-TUBE PROJECT Cyclist to conserve battery.

Compatibility with E-TUBE PROJECT:

• Check compatibility and limitations at https://bike.shimano.com/e-tube/project.html.

About This Manual

This manual is the ROAD Di2 Dealer's Manual General Guide, detailing wiring diagrams and installation workflows. For individual component handling, refer to specific dealer manuals. Dealer manuals are available at si.shimano.com.

Booklet Structure

The ROAD Di2 series manuals are divided into several booklets. The latest versions are available on the SHIMANO website (si.shimano.com).

Workflow Overview

A recommended workflow is outlined below:

Preparation / Confirmation

• Checking wiring: Refer to 'Overall wiring diagram' and 'Wiring diagram around the cockpit'.
• Pairing: Refer to 'Rear Derailleur Dealer's Manual' (wired) or 'E-TUBE PROJECT User's Manual'/'E-TUBE PROJECT Professional'/'E-TUBE PROJECT Cyclist' (wireless).
• Checking before securing: Refer to 'Checking connections'.
• Handling electric wires: Refer to 'Electric wires'.

Installation

• Installing dual control levers: Refer to Hydraulic Disc Brake / Dual Control Lever (Di2) Dealer's Manual or Dual Pivot Caliper Brake / Dual Control Lever (Di2) Dealer's Manual.
• Installing satellite shifters: Refer to the same manuals as dual control levers.
• Temporarily installing front derailleur: Refer to Front Derailleur Dealer's Manual (FD-R9250/FD-R8150, FD-R7150).
• Installing rear derailleur: Refer to Rear Derailleur Dealer's Manual.
• Installing battery: Refer to ROAD Di2 Battery and Parts Dealer's Manual.
• Installing bottom bracket and cranks: Refer to Crankset Dealer's Manual.
• Securing front derailleur: Refer to Front Derailleur Dealer's Manual (FD-R9250/FD-R8150, FD-R7150).
• Installing brake calipers: Refer to Hydraulic Disc Brake / Dual Control Lever (Di2) Dealer's Manual or Dual Pivot Caliper Brake / Dual Control Lever (Di2) Dealer's Manual.
• Securing dual control levers: Refer to the same manuals as brake calipers.
• Confirming chain length / installing chain: Refer to Rear Derailleur Dealer's Manual, Chain Dealer's Manual.

Adjustment

• Adjusting rear derailleur: Refer to Rear Derailleur Dealer's Manual.
• Adjusting front derailleur: Refer to Front Derailleur Dealer's Manual (FD-R9250/FD-R8150, FD-R7150).
• Adjusting dual control levers: Refer to Hydraulic Disc Brake / Dual Control Lever (Di2) Dealer's Manual or Dual Pivot Caliper Brake / Dual Control Lever Dealer's Manual.

Connection and communication with devices

• Connection and communication with devices: Refer to Rear Derailleur Dealer's Manual.

Maintenance

• Maintenance: Refer to dealer's manuals for individual components.

List of Tools to be Used

The following tools are required for installation, adjustment, and maintenance:

Installation / Removal

Introduction

Di2 systems with wireless gear shifting differ from existing Di2 systems by not requiring a conventional junction [A] or separate wireless unit. Wireless gear shifting may be possible without handlebar-to-frame wiring depending on the model. The BT-DN300 has three E-TUBE ports. The rear derailleur supports battery charging, wireless connection with dual control levers and external devices (Bluetooth® LE or ANT), and a function button for shift modes and adjustment.

Overall Wiring Diagram

Route wires through the frame before installing components. Models ST-R9270, ST-R8170, and ST-R7170 can connect wirelessly to derailleurs; other dual control levers or satellite shifters require wired connections.

NOTICE:

• Complete wiring and check connections before installing the bottom bracket, especially with press-fit types.
• Ensure an electric wire is connected to the center E-TUBE port for normal operation.
• Attach dummy plugs to any unused E-TUBE ports; the product will not operate normally without them.

Example wiring for wireless gear shifting:

This diagram illustrates wireless pairing between dual control levers and the rear derailleur. Refer to the E-TUBE PROJECT user's manual for pairing procedures.

Diagram Description: A bicycle diagram showing wireless gear shifting. The BT-DN300 unit is mounted on the frame. Wireless signals are shown connecting the BT-DN300 to the rear derailleur and to the dual control levers at the handlebars. Wire (A) connects the battery to the front derailleur, and wire (B) connects the battery to the rear derailleur. Specified wire lengths are (A) ≤ 1,500 mm and (B) ≤ 1,700 mm.

TECH TIPS:

• The rear derailleur connects to external devices similarly to previous wireless units. Refer to the Rear Derailleur Dealer's Manual for details.

Example wiring for wired gear shifting:

This setup uses junction [B] (EW-JC304) to connect shifters and the rear derailleur via electric wires routed internally.

Diagram Description (Page 14): A bicycle diagram showing wired gear shifting. The BT-DN300 unit is shown. Wire (A) connects the battery to the front derailleur, and wire (B) connects the battery to the rear derailleur. Specified wire lengths are (A) ≤ 1,500 mm and (B) ≤ 1,700 mm.

Diagram Description (Page 15): A bicycle diagram showing wired gear shifting with junction [B] (EW-JC304). Wire (A) connects the battery to the front derailleur, wire (B) connects the battery to the rear derailleur, wire (C) connects the battery to junction [B], and wire (D) connects the dual control levers to junction [B]. Specified wire lengths are (A) ≤ 1,500 mm, (B) ≤ 1,700 mm, and (C) + (D) ≤ 2,200 mm.

Wiring Diagram Around the Cockpit

The ST-R7170 lacks an E-TUBE port for gear shifting or satellite shifters and is intended for wireless gear shifting.

Example wiring for wireless gear shifting:

Diagram Description: Two handlebar setups are shown. Each features dual control levers (ST-R9270/ST-R8170) with a port for satellite shifters and an E-TUBE port (for SD300). SW-RS801-S and SW-RS801-T satellite shifters are connected via plugs.

Example wiring for wired gear shifting (1):

Diagram Description: Two handlebar setups are shown, each with dual control levers (ST-R9270/ST-R9250, ST-R8170/ST-R8150) featuring E-TUBE ports (for SD300) x 2. A junction box (EW-JC304) is shown connected to the battery. SW-RS801-S and SW-RS801-T satellite shifters are connected via plugs. An E-TUBE plug (EW-SD300-I) and satellite shifter plug are also depicted.

Example wiring for wired gear shifting (2):

Diagram Description: Two handlebar setups are shown, each with dual control levers (ST-R9250/ST-R8150) featuring E-TUBE ports (for SD300) x 2. A junction box (EW-JC304) is shown connected to the battery. SW-RS801-S and SW-RS801-T satellite shifters are connected via plugs. An E-TUBE plug (EW-SD300-I) and satellite shifter plug are also depicted.

Wiring diagram for time trial / triathlon handlebar type:

This diagram shows wiring for dual control levers and battery using electric wires. Refer to the E-TUBE compatibility table for compatible time trial/triathlon components.

NOTICE: The cockpit area uses EW-SD50-I electric wire only. Do not connect junction [A] or a wireless unit.

Diagram Description: A diagram shows a handlebar setup with ST-R9160, ST-R9180, ST-R8060 dual control levers and SW-R9160 satellite shifters. Connections are made via EW-JC130 and SM-JC41 junctions, leading to the battery. Electric wires EW-SD300-I, EW-SD50-I, and EW-AD305 are shown.

Wiring diagram around the battery:

Diagram Description: A bicycle diagram illustrating wire routing for wireless gear shifting, showing connections from the battery to other components.

Pairing

Wireless gear shifting requires pairing the dual control levers with the rear derailleur. Pairing is necessary after reinstalling or replacing these components. Pairing can be done via wired or wireless connection. Refer to the E-TUBE PROJECT user's manual for wireless pairing and the rear derailleur dealer's manual for wired pairing.

Connection and Communication with Devices

Connecting the bicycle to a device allows for settings and firmware updates. Refer to the Rear Derailleur Dealer's Manual for details.

Maintenance

Refer to the dealer's manuals for individual components for periodic maintenance information.

Electric Wires

Use SHIMANO original tools for removing and inserting electric wires. Two types of electric wire are available: EW-SD300-I and EW-SD50-I. Supported wires vary by component model. Check SHIMANO's product website for specifications.

Supported Products

NOTICE:

• Do not forcibly bend the plug part when connecting/disconnecting wires; it may cause poor connection.
• SHIMANO original tools and accessories differ for EW-SD300-I and EW-SD50-I; use compatible products.
• EW-CL300-S has a groove for differentiation from EW-CL300-M.

Conversion Adapter:

A conversion adapter (EW-AD305) is needed to connect EW-SD50-I to a component with an E-TUBE port for EW-SD300-I.

Diagram Description: Shows a conversion adapter (EW-AD305) connecting an electric wire (EW-SD300-I) to an electric wire (EW-SD50-I).

Connecting / Disconnecting the Electric Wires

Use SHIMANO original tools for connecting and disconnecting electric wires. Avoid bending the plug part.

Connecting the electric wire (EW-SD300-I):

1. Set the electric wire plug to the TL-EW300. Align the plug's alignment tab with the E-TUBE port's shape if present.
2. Insert the plug straight into the E-TUBE port until it clicks.

Diagram Description: Illustrates setting the plug to TL-EW300 with and without an alignment tab, and inserting the plug into the E-TUBE port. A TECH TIP suggests using TL-EW300 for installation.

Disconnecting the electric wire (EW-SD300-I):

1. Disconnect the electric wire: Insert TL-EW300 into the plug groove and use it as a lever to disconnect.

Diagram Description: Shows steps (1) and (2) for disconnecting the wire using TL-EW300. A TECH TIP notes using TL-EW300 for disconnection in tight spaces.

Connecting the electric wire (EW-SD50-I):

1. Set the electric wire plug to the TL-EW02. Align the plug's alignment tab with the tool's groove if present.
2. Insert the plug straight into the E-TUBE port until it clicks.

Diagram Description: Illustrates setting the plug to TL-EW02 with and without an alignment tab, and inserting the plug into the E-TUBE port.

Disconnecting the electric wire (EW-SD50-I):

1. Disconnect the electric wire: Insert TL-EW02 into the plug groove and use it as a lever to disconnect.

Diagram Description: Shows steps (1) and (2) for disconnecting the wire using TL-EW02. A NOTICE warns against frequent connect/disconnect cycles that can deform the connector.

Insertion direction of the electric wires for internal use:

Electric wires for internal use have wire holders to prevent movement within the frame. Insert wires in the direction shown in the figure.

Diagram Description: Shows wire insertion into a frame wiring hole with a wire holder.

NOTICE: Protect plugs with masking tape or similar material when passing wires through the frame or handlebars to prevent foreign matter entry.

TECH TIPS: Insert wire holders in the indicated direction for easier removal.

Finishing for internal wiring:

Install a grommet to the frame's wiring hole for protection after routing wires internally.

Diagram Description: Examples of installing grommets to a chainstay (for rear derailleur) and seat tube (for front derailleur). Another diagram shows two types of grommets (GM300-S for circular, GM300-M for elliptical wiring holes).

1. Install components and connect electric wires according to wiring diagrams. Refer to individual component dealer manuals.
2. After installation and connection, perform 'Checking connections'.

Checking Connections

After connecting all electric wires, check component operation.

1. Check connection for each component:
   • Refer to the dual control lever user's manual (UM-0MX0A / UM-0RM0A) to operate the shift switch and confirm derailleur operation.
   • Refer to the rear derailleur user's manual for LED display and operation checks.
   • Connect to E-TUBE PROJECT and verify each component is displayed. Refer to E-TUBE PROJECT user's manuals for details.
2. If a component connection issue occurs, return to the installation procedure, check wire connections, and pairing.
3. After checking connections, disconnect electric wires from the battery and components.

WARNING: Disconnect electric wires from the battery and components before performing procedures near the front derailleur (e.g., crankset/front derailleur installation/removal, chain length adjustment). Accidental front derailleur activation can cause injury.

Troubleshooting

When a Problem Occurs

Consult the following information for troubleshooting. If a problem is not listed or cannot be solved, contact a distributor.