The Shimano Ultegra ST‑R8160 TT brake sets are purpose-built for time trial and triathlon performance, delivering precise braking and integrated shifting capabilities in a compact form factor. Designed to be compatible with Shimano’s 12-speed Di2 system, this model features some of the most advanced technologies seen in road bike components. This guide will cover installation, adjustment, maintenance, and all technical aspects of the ST‑R8160 to help riders and mechanics get the most from this high-performance component.
Tools Required
- 4 mm and 5 mm hex keys
- Torque wrench with 4–6 Nm range
- Shimano Di2 E-Tube cable tool
- Cable routing guide or internal routing kit (for integrated frames)
- Isopropyl alcohol and clean cloth
- Shimano mineral oil [paid link] (for brake system maintenance)
- Bleed kit compatible with Shimano disc brakes
Installation of the Ultegra ST‑R8160 TT Brake Sets
The ST‑R8160 integrates seamlessly with modern aerodynamic TT cockpit designs. Each lever is a dual-control unit, allowing electronic shifting and hydraulic braking in a minimalist shape.
Begin by ensuring that your handlebar extensions are compatible with the 22.2 mm clamp diameter. Slide the levers into place and tighten the clamp bolts evenly to the recommended 5–6 Nm torque. For internal cable routing setups, guide the E-Tube wires through the handlebar before finalizing clamp placement. Connect the Di2 wires to the designated ports, following Shimano’s wiring configuration for the 12-speed Di2 platform.
Brake hoses should be pre-cut to the appropriate length based on your handlebar and frame geometry. Connect them to the calipers and levers, ensuring all connections are torqued per Shimano’s specifications. Bleeding the system is mandatory after installation to ensure consistent brake performance.
Adjustment for Optimal Performance
Precise adjustment is essential for maximizing the braking and shifting efficiency of the ST‑R8160. Lever reach can be adjusted via the hidden screw behind the lever pivot, using a 2 mm hex key. This feature allows riders with smaller hands or specific ergonomic preferences to fine-tune lever positioning.
Brake caliper alignment is critical. Once the levers are installed and hoses connected, center the calipers by loosening the mounting bolts, applying brake pressure, and re-tightening while holding the lever. This ensures even pad contact and prevents rotor rub.
For Di2 shifting responsiveness, ensure the levers are updated to the latest firmware via Shimano’s E-Tube Project app. Use the app to customize button assignments and multi-shift settings for optimized shifting flow.
Maintenance and Cleaning
Routine maintenance extends the lifespan of your ST‑R8160 levers. Clean the levers and surrounding cockpit area regularly with a damp cloth and mild detergent. Avoid aggressive solvents that may damage the housing or electronics.
Brake fluid should be inspected every six months, especially in high-use or hot climates. Shimano mineral oil is the only approved fluid for these systems. During bleeding, always use the specified bleed blocks to prevent piston misalignment.
Inspect the lever pivots for smooth return action. If any stiffness is detected, apply a light, non-corrosive lubricant to the pivot points and test the action. Shifter function should also be tested regularly to ensure electronic communication is uninterrupted.
Troubleshooting Common Set-Up Issues
A frequent issue post-installation is inconsistent brake feel or lever travel. This is typically caused by air in the hydraulic lines. Re-bleeding the system, while carefully following Shimano’s protocol, usually resolves this.
Another issue involves Di2 button misfires or non-response. These are often linked to loose E-Tube connections or outdated firmware. Check all wire junctions, and verify that firmware is current using the E-Tube Project software.
In some cases, brake pad rub may persist after caliper centering. Ensure the rotor is true and that the pad springs are seated correctly. If noise continues, lightly sand the brake pads and clean the rotor with isopropyl alcohol.
Customization and Rider Optimization
The ST‑R8160 allows for functional customization via Shimano’s E-Tube app. Riders can tailor shifting speed, button response, and assign functions such as rear derailleur trim or front derailleur manual shift.
For TT specialists, positioning is key. Adjust lever rotation angle and clamp location on the extensions for ideal wrist alignment. This minimizes fatigue and enhances control during braking zones.
High-performance riders may opt for lightweight hoses or integrate the system with an aero [paid link] cockpit harness for reduced drag. However, all customization should adhere to Shimano’s recommended configurations to preserve safety and performance.
Compatibility with Other Drivetrain Components
The Ultegra ST‑R8160 is designed to operate within Shimano’s 12-speed Di2 ecosystem. It pairs optimally with the Ultegra RD-R8150 rear derailleur and FD-R8150 front derailleur, as well as the BR-R8170 flat-mount disc brake calipers.
It is not compatible with mechanical drivetrains or 11-speed Di2 components due to differences in protocol and wiring architecture. Ensure all E-Tube wires and junctions used are from Shimano’s EW-SD300 series to maintain system integrity.
Cranksets from both the Ultegra and Dura-Ace 12-speed lines are fully compatible, provided the Di2 derailleurs are correctly tuned for chainline and gear range. The ST‑R8160 supports full and semi-synchro shift modes when used with compatible derailleurs.
Model Comparison: Ultegra ST‑R8160 vs Dura-Ace ST-R9180
When compared to the Dura-Ace ST-R9180, the ST‑R8160 offers a more accessible price point while retaining nearly all core functionalities. Both models feature Di2 shifting and hydraulic disc braking, with identical E-Tube architecture and firmware support.
The primary differences lie in material construction and weight. Dura-Ace levers use lighter, stiffer carbon fiber materials, whereas Ultegra opts for composite and aluminum blends. This results in a modest weight difference without sacrificing stiffness.
Performance-wise, shifting and braking response is virtually identical in lab tests. However, riders seeking the absolute lightest configuration may still favor the Dura-Ace model.
FAQs About Shimano Ultegra ST‑R8160 TT Brake Sets
1. Can the ST‑R8160 levers be used with rim brakes?
No, they are designed exclusively for hydraulic disc brake systems and are incompatible with rim brakes.
2. Are these levers suitable for triathlon use?
Yes, they are optimized for time trial and triathlon handlebars with 22.2 mm extensions.
3. Can I use the ST‑R8160 with an 11-speed Di2 drivetrain?
No, the 12-speed Di2 system uses a different wiring protocol (EW-SD300), which is not backward compatible with 11-speed components.
4. Is firmware updating mandatory for these levers?
While not mandatory, regular firmware updates via E-Tube Project improve performance and compatibility with newer Di2 features.
5. How do I adjust the lever reach?
Use a 2 mm hex key to access the reach adjustment screw behind the pivot point, then fine-tune for your preferred reach.
6. What is the recommended bleed interval?
Shimano suggests bleeding the hydraulic brake system every 6–12 months, depending on usage intensity and environmental conditions.