The Shimano Ultegra ST‑R8160 TT brake set is a high-performance, dual-control lever system tailored for time trial and triathlon setups. While primarily designed for speed disciplines, its integration with hydraulic disc brakes, compact ergonomics, and seamless Di2 shifting have attracted the attention of gravel riders seeking performance, precision, and reliability over rough terrain. This guide provides a technical deep dive into its installation, adjustment, maintenance, troubleshooting, and customization to help you get the most out of this elite component.
Tools Required
- 4mm and 5mm hex wrenches
- Shimano Hydraulic Mineral Oil
- Shimano bleed kit (e.g., TL-BT03-S or TL-BT05)
- Di2 E-Tube Project app or SM-PCE02 for firmware updates
- Torque wrench with Nm scale
- Internal cable routing kit (optional for frame types)
Installation of the Ultegra ST‑R8160 TT
Proper installation ensures reliable operation on rugged gravel paths. Begin by confirming the frame’s internal routing compatibility and brake caliper mounting standards.
Lever Installation
Install each ST‑R8160 TT lever onto the aero [paid link] base bar extensions. The clamp diameter fits standard 22.2 mm extensions. Use a torque wrench to tighten the clamp bolts to Shimano’s recommended torque specification (6–8 Nm).
Hydraulic Brake Line Connection
Route the hydraulic hoses from the lever ports to the calipers. Shimano recommends using BH90 hoses. Trim the hoses to the required length, insert the olive and barb, then connect to the lever using a 5mm wrench. Torque the compression nut to 5–7 Nm. Bleed the system to remove any air using Shimano’s one-way bleed process.
Di2 Wiring
Connect the ST‑R8160 levers to the Di2 system using EW-SD300 wires. Route internally if possible to maintain a clean setup. Confirm that each shifter is securely connected to the central junction box, typically the EW-RS910 or EW-JC304, depending on your setup.
Adjustment for Performance and Fit
Precise setup maximizes control and minimizes fatigue over long gravel rides.
Lever Reach Adjustment
The reach of the ST‑R8160 TT is adjustable via a small hex bolt inside the lever body. Adjust to suit hand size and riding style. A shorter reach can help improve modulation on bumpy descents.
Pad Contact Adjustment
Although the levers themselves don’t offer pad contact tuning, you can fine-tune brake feel through the caliper piston setup or by adjusting rotor size (140 mm vs. 160 mm).
Shifting Calibration
Using the E-Tube Project app, assign functions to each Di2 button (e.g., left for front derailleur, right for rear) and set multi-shift preferences. Check firmware updates to ensure compatibility with the rest of your drivetrain.
Routine Maintenance Procedures
Maintaining peak braking and shifting performance is essential, especially in gritty gravel conditions.
Brake System
Inspect pads and rotors regularly. Gravel riding introduces more contaminants that can accelerate wear. Replace pads when thickness is below 0.9 mm. Clean rotors with isopropyl alcohol and re-bleed the system annually or if lever feel becomes spongy.
Di2 Components
Check wire connections every few months and clean the junction ports. Use the E-Tube app to monitor battery status and diagnose communication issues. Always store the bike with a partially charged battery to prolong longevity.
Troubleshooting Common Issues
Even a high-end component like the ST‑R8160 TT can encounter performance hiccups. Here’s how to resolve them effectively.
Soft Lever Feel
Usually due to air in the brake lines. Re-bleed the system thoroughly, ensuring no micro-bubbles remain. Use a vacuum tool if necessary for complete fluid fill.
Intermittent Shifting
Loose Di2 connectors or damaged wires are the typical causes. Use the SM-PCE02 diagnostic tool or E-Tube Project to test continuity and replace cables if errors persist.
Brake Pad Rubbing
Check caliper alignment and ensure that rotors are true. Gravel riding can deform rotors over time. Use a rotor truing tool to correct minor warping.
Customization and Optimization for Gravel Riding
Gravel riders benefit from component tuning that balances comfort with aggressive control.
Lever Ergonomics
Add gel handlebar tape to your aero extensions to enhance grip. Consider modifying the reach to reduce wrist strain during long hours in the aero position.
Rotor Size Upgrades
For heavier riders or steep descents, upgrading to 160 mm rotors improves heat dissipation and braking consistency. Ensure your frame and caliper adapter support this size.
Integration with Other Accessories
The levers can interface with remote satellite shifters via auxiliary ports. This is useful for adding shift buttons to different hand positions, especially in variable gravel terrains.
Compatibility with Other Drivetrain Components
The Ultegra ST‑R8160 TT levers are designed for Di2 12-speed systems and are fully compatible with other Shimano 12-speed Di2 components from Ultegra and Dura-Ace series.
Front and Rear Derailleurs
Use the RD-R8150 rear derailleur and FD-R8150 front derailleur for seamless electronic shifting. These levers do not support mechanical drivetrains.
Brakes
Only compatible with Shimano flat-mount hydraulic disc calipers, such as BR-R8170. Avoid mixing with post-mount or third-party calipers, as modulation and safety may be compromised.
Comparison with Similar Models
Comparing the ST‑R8160 TT with other TT levers helps riders make informed decisions.
vs. Dura-Ace ST-R9180
The Dura-Ace version offers lighter weight and slightly more refined ergonomics. However, performance differences are marginal for gravel use. The Ultegra ST‑R8160 TT provides nearly identical functionality at a lower cost.
vs. SRAM eTap AXS Blips and Clics
While SRAM’s wireless system offers easier installation, Shimano’s levers provide a more tactile lever feel and hydraulic modulation, which is preferred by many gravel riders.
FAQs
1. Can the Ultegra ST‑R8160 TT levers be used on drop bars?
No, they are specifically designed for TT or aero bar extensions and are not suitable for traditional drop bar setups.
2. Are these levers compatible with mechanical derailleurs?
No, the ST‑R8160 TT is Di2-only and cannot operate mechanical derailleurs.
3. How often should the hydraulic system be bled?
Bleed the system every 12–18 months or after any signs of air intrusion or fluid contamination.
4. Can I install these levers on a 1x drivetrain setup?
Yes, simply disable the front derailleur function in the E-Tube app. The right shifter will control the rear derailleur alone.
5. What type of bar does the clamp fit?
They are designed for 22.2 mm diameter aero bar extensions.
6. Do they support sprint shifters or satellite buttons?
Yes, auxiliary ports allow for the installation of additional Di2 shifters for multiple hand positions.
Conclusion
The Shimano Ultegra ST‑R8160 TT brake set stands out as a reliable and high-performing option for gravel riders seeking aerodynamic gains without compromising control. With robust hydraulic braking, intuitive Di2 integration, and adjustable ergonomics, it meets the demands of riders tackling mixed terrain. Its compatibility with Shimano’s 12-speed ecosystem and adaptability for gravel-specific customizations make it a worthy addition to any performance-focused build.