The Shimano Ultegra ST‑R8160 TT is a high-performance, dual-control brake lever system designed for time trial and triathlon bikes. Engineered to deliver precise braking and Di2 shifting integration, this component requires methodical attention for optimal function. Whether you’re performing a basic inspection or a complete service, understanding the specifics of the ST‑R8160 TT ensures consistent braking power and long-term reliability.
Tools Required
- 4mm and 5mm hex keys
- Torque wrench (preset or adjustable)
- Shimano hydraulic mineral oil
- Shimano Bleed Kit (including funnel and stopper)
- Clean rags and isopropyl alcohol
- Bleed block or pad spacer
- Flat-head screwdriver (for pad inspection)
- Digital caliper (optional for rotor and pad thickness)
Component Overview and Functionality
The Ultegra ST‑R8160 TT levers are tailored for aero [paid link] bar mounting, providing hydraulic disc brake actuation and Di2 electronic shifting. These levers route internally and pair with the BR-R8170 calipers. Key features include a short lever throw, enhanced grip ergonomics, and dual control capabilities for both braking and Di2 electronic shifting.
Installation Guidelines
Proper installation of the ST‑R8160 TT brake set is essential for safety and performance. Begin by securing the lever body into the aero extensions, ensuring alignment and firm clamping without over-torquing. Shimano recommends a torque specification of 5–6 Nm for lever fixing bolts.
Connect the hydraulic line, ensuring a clean cut and precise insertion of the barb and olive. Insert the hose into the lever, torquing the compression nut to 5–7 Nm. If installing Di2 shifters simultaneously, carefully route the e-tube wires through designated internal paths to avoid cross-interference with brake hoses.
Finally, mount the calipers to the frame’s flat-mount interface using the correct hardware length. Always use thread-lock compound and torque bolts to 6–8 Nm as per Shimano’s specifications.
Adjustment Procedures
Brake lever reach is adjustable via a 2mm hex screw located beneath the lever body. This lets riders customize the lever pull to suit individual hand sizes and preferences. It’s critical to adjust both levers evenly to ensure symmetrical brake feel.
Caliper centering should be performed after wheel and rotor installation. Loosen the caliper bolts, squeeze the brake lever to center the caliper over the rotor, then torque the bolts evenly. Rotor rub should be checked post-adjustment; slight realignment may be necessary.
Routine Maintenance Schedule
Regular maintenance ensures consistent braking performance and prolongs component life. Perform a visual inspection of pads and rotors monthly. Pads should be replaced when the compound thickness reaches 0.5 mm. Rotors must maintain a minimum thickness of 1.5 mm.
Hydraulic fluid should be flushed annually or after heavy use. Contaminated or dark mineral oil is a clear indicator of required servicing. Always use Shimano-branded mineral oil for system compatibility.
Cable housing and hose integrity should be checked for kinks or abrasions, particularly where they enter the lever body. Replace damaged hoses immediately.
Brake Bleeding Process
Shimano’s funnel bleeding method simplifies hydraulic maintenance. Begin by securing the bike on a stand with the levers horizontal. Remove the bleed port screw and install the funnel with a stopper inserted.
Fill the funnel with Shimano mineral oil [paid link] and slowly pump the brake lever. Remove the stopper and allow air bubbles to escape. When bubbles cease, reinsert the stopper, remove the funnel, and replace the bleed screw. Wipe all surfaces clean.
Bleeding the caliper end may be required in case of major system overhaul or air intrusion. In such cases, follow the two-way bleed method using the bleed block and syringe system included in Shimano’s professional bleed kit.
Troubleshooting Common Issues
Spongy lever feel is often due to trapped air or inadequate bleeding. Repeat the funnel bleed and ensure no bubbles remain in the lever reservoir.
Pad rub typically indicates caliper misalignment or rotor warping. Check rotor trueness with a gauge or eyeball method, and re-center calipers as needed.
Lever rattle or inconsistent engagement can result from worn pivot bushings or contamination. Clean the lever pivot with isopropyl alcohol and inspect internal spring tension.
Customizing Performance
Riders can fine-tune braking responsiveness by adjusting lever throw and pad contact point. Pairing the ST‑R8160 TT with 140mm rotors can reduce rotational mass, while 160mm rotors offer greater heat dissipation.
For superior heat management, consider upgrading to Ice-Tech Freeza rotors. These rotors provide consistent stopping power during prolonged descents or intense competition conditions.
Component Compatibility
The ST‑R8160 TT levers are fully compatible with Shimano’s 12-speed Di2 systems and are designed to work seamlessly with BR-R8170 hydraulic disc brake calipers. Use only Shimano’s hydraulic hoses (SM-BH90) to maintain consistent pressure and fluid integrity.
Mixing with older 11-speed or non-series calipers may result in degraded performance and is not recommended. Ensure firmware is up to date using Shimano’s E-Tube Project software to enable full Di2 functionality.
Comparison with Similar Models
Compared to the higher-tier Dura-Ace ST-R9180 TT, the Ultegra ST‑R8160 TT offers nearly identical performance at a lower cost, albeit with a minor weight penalty due to alloy vs. carbon construction.
Versus mechanical options such as the Shimano 105 ST-R7025, the ST‑R8160 TT provides superior modulation, reduced hand fatigue, and Di2 integration—ideal for serious time trialists and triathletes prioritizing efficiency and control.
Conclusion
Servicing the Shimano Ultegra ST‑R8160 TT brake sets at home is entirely feasible with the right tools, patience, and understanding of the system’s hydraulic and electronic intricacies. Routine maintenance, correct installation, and periodic adjustments ensure this performance-focused component continues to deliver race-ready results.