The Shimano Ultegra ST‑R8160 TT is a high-performance dual control lever designed specifically for time trial and triathlon bikes. Engineered to deliver seamless integration with Shimano’s Di2 electronic drivetrain and hydraulic disc brakes, it offers precise braking control and aerodynamic efficiency. This guide provides a comprehensive, step-by-step approach to installing, adjusting, maintaining, and optimizing the ST‑R8160 TT brake levers to achieve peak performance and reliability.
Tools Required
- 4mm and 5mm hex keys
- Torque wrench (Nm calibrated)
- Shimano hydraulic brake bleed kit
- Isopropyl alcohol and lint-free cloth
- Shimano Mineral Oil [paid link]
- Internal cable routing tool (if applicable)
- Digital caliper (for pad wear check)
- Clean syringe and hose for fluid fill
Installation Instructions
Proper installation of the ST‑R8160 TT levers ensures optimal hydraulic performance and integration with electronic shifting systems. Begin by verifying compatibility with the frame and handlebar setup.
Handlebar and Lever Mounting
Mount the ST‑R8160 TT levers into the designated aero [paid link] extensions using the included wedge and clamp system. Ensure that each lever sits flush without gaps to prevent play. Tighten the mounting bolts to Shimano’s specified torque of 6–8 Nm to avoid damage to carbon extensions.
Hydraulic Hose Connection
Connect the hydraulic hose using Shimano’s recommended compression fittings and barbed inserts. Slide the hose into the lever body and use a torque wrench to secure the connection to 5–6 Nm. Check for any potential kinks or sharp bends in the hose routing.
Di2 Junction and Wiring
Connect the lever’s Di2 shifter wires to the appropriate junction box (typically EW-RS910 or EW-JC130). Use heat shrink tubing to secure and protect wires running inside the handlebar. Confirm routing paths do not interfere with shifting or braking.
Brake Adjustment Procedures
Once installed, fine-tuning the braking system ensures consistent lever feel and stopping power under high-speed conditions.
Lever Reach Adjustment
Use the small set screw beneath each lever blade to adjust reach. This fine-tuning allows you to set the lever distance relative to hand size and aero bar length, improving ergonomics and control. Make incremental adjustments to avoid over-tightening.
Pad Contact Point
Although the ST‑R8160 does not have an external pad contact adjustment, pad feel can be modulated by carefully setting rotor-to-pad clearance during caliper installation. Align the caliper over the rotor with both mounting bolts loosened, squeeze the brake lever, then torque bolts to 6–8 Nm while holding pressure.
Hydraulic Pressure Modulation
If lever feel is too firm or spongy, assess hydraulic fluid levels and presence of air. Shimano’s Servo Wave technology automatically modulates braking force, but bleeding the system can restore original responsiveness if degraded.
Maintenance Guidelines
Routine maintenance preserves performance and extends the lifespan of both the lever unit and hydraulic system.
Brake Bleeding
Bleed the brakes every 6–12 months or if you detect inconsistent lever response. Use only Shimano mineral oil and the official bleed kit to prevent contamination or damage to seals. Always perform a full bleed if you change the hose length.
Pad and Rotor Inspection
Inspect brake pads for wear monthly. Replace them when thickness is less than 0.9mm. Use a digital caliper for accurate readings. Clean rotors with isopropyl alcohol to remove grime and ensure optimal friction contact.
Lever Body Cleaning
Wipe down the lever body with a lint-free cloth to remove sweat and debris. Avoid harsh solvents, as these can compromise electronic seals or fade the finish. Check Di2 connection points for corrosion or loose pins.
Troubleshooting Common Issues
Proper diagnosis helps correct issues before they affect riding safety or performance.
Soft Lever Feel
Typically caused by air in the hydraulic line or a slow leak at the connection point. Inspect the junction, perform a pressure bleed, and check for loose fittings.
Inconsistent Braking
May result from contaminated brake pads or rotors. Use sandpaper to lightly roughen pads and clean rotors thoroughly. If contamination is severe, replace the pads entirely.
Unresponsive Shifting
Since the ST‑R8160 also integrates Di2 shifting, confirm electronic wire integrity. Check for damaged E-Tube wires or loose connections within the junction box. Run the Shimano E-Tube Project app to diagnose firmware or component failures.
Customization and Performance Optimization
Maximizing the performance of the ST‑R8160 TT involves tuning setup for specific disciplines and rider preferences.
Aero Bar Integration
Route all cables internally for the cleanest aerodynamic profile. This also reduces drag and minimizes interference from wind or debris. Ensure the hose exit points align with your bike’s internal routing ports.
Lever Blade Modulation
Although the blade shape is optimized for aero use, riders can customize hoods or grip tape texture to enhance grip. Apply silicone or anti-slip surfaces to increase lever control in wet conditions.
Rotor Size Adjustment
Opt for 140mm rotors for weight savings in flat TT courses or 160mm rotors if descending or high-load braking is expected. Always match rotor size with caliper and frame mount compatibility.
Comparison with Similar Models
While the ST‑R8160 TT is a premium mid-tier time trial component, it stands between the Dura-Ace ST-R9180 and 105 R7120 in terms of features and pricing.
Versus ST-R9180 Dura-Ace TT
- The R9180 offers marginal weight savings and faster Di2 actuation, but uses the same mineral oil system and bleed procedure.
- ST‑R8160 provides nearly identical braking performance at a lower cost.
Versus 105 R7120
- The 105 lacks Di2 integration in current TT formats and has less precise lever modulation.
- Ultegra is better suited for competitive time triallists seeking high efficiency and customization.
Compatibility Overview
Understanding drivetrain and hydraulic compatibility ensures smooth integration with your existing setup.
Hydraulic System
Fully compatible with Shimano flat-mount hydraulic disc calipers such as BR-R8170 or BR-R9170. Uses Shimano SM-BH90 hoses.
Di2 Integration
Requires a 12-speed Di2 setup using the R8100 or R9200 series. Not backward compatible with 11-speed Di2 systems. Junction box EW-RS910 or EW-JC304 is recommended for cockpit integration.
Handlebar and Extension Fit
Designed for standard 22.2mm aero bar extensions. Check for internal routing channels and sufficient depth to accommodate hose and wire length.
Conclusion
The Shimano Ultegra ST‑R8160 TT brake lever is a purpose-built solution for time trial and triathlon cyclists seeking precision braking, electronic shifting, and streamlined integration. With correct installation, meticulous maintenance, and strategic customization, this component delivers performance that rivals top-tier setups without excessive complexity or cost. Following this guide will ensure optimal setup and long-term functionality on the road or racecourse.