How to Install, Adjust, and Maintain the Shimano BR-6800 Brakes

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The Shimano BR-6800 [paid link] brakes, part of the Ultegra series, offer exceptional stopping power, modulation, and reliability. Designed for road cycling enthusiasts, these brakes provide a high-performance braking system with dual-pivot calipers for better control. Proper installation, adjustment, and maintenance are essential to ensuring peak braking performance.

In this guide, we’ll cover everything you need to know about installing, adjusting, and maintaining the Shimano BR-6800 [paid link] brakes to keep your bike stopping smoothly and safely.

Tools Required

Before starting the installation, make sure you have the following tools:

  • 5mm Allen wrench [paid link]
  • Torque wrench [paid link] (for precise bolt tightening)
  • Cable cutter
  • Phillips-head screwdriver
  • Ruler or caliper (for pad alignment)
  • Isopropyl alcohol and clean cloth (for cleaning)

Installing Shimano BR-6800 Brakes

Step 1: Mounting the Brake Calipers

  1. Position the BR-6800 [paid link] brake calipers onto the frame or fork’s mounting hole.
  2. Insert the center bolt through the hole and hand-tighten the nut on the backside.
  3. Use a 5mm Allen wrench [paid link] to tighten the caliper bolt, ensuring the brake is centered over the wheel.
  4. Check that the calipers move smoothly when squeezed.

Step 2: Installing the Brake Cables

  1. Route the brake cable through the brake lever and housing.
  2. Feed the cable into the caliper’s pinch bolt and pull it taut.
  3. Tighten the cable pinch bolt using a 5mm Allen wrench [paid link] to secure the cable in place.
  4. Squeeze the brake lever to ensure the calipers engage properly.

Step 3: Setting Brake Pad Alignment

  1. Loosen the brake pad fixing bolt using a 5mm Allen wrench.
  2. Adjust the brake pads so they make full contact with the braking surface of the rim.
  3. Ensure there is a slight toe-in (front of the pad touches the rim first) to prevent squealing.
  4. Tighten the bolt securely and repeat for the other side.

Adjusting Shimano BR-6800 Brakes

Centering the Brake Calipers

  1. Check if the brake pads make even contact with the rim.
  2. If one side moves more than the other, adjust the small centering screw on the caliper using a Phillips-head screwdriver.
  3. Turn the screw clockwise to move the caliper toward the opposite side.
  4. Squeeze the brake lever and release it multiple times to ensure even movement.

Setting the Correct Cable Tension

  1. If the lever feels too soft, loosen the pinch bolt slightly and pull the cable tighter.
  2. If the lever feels too stiff, release a bit of cable tension.
  3. Fine-tune using the barrel adjuster on the brake lever or caliper.

Brake Pad Clearance Adjustment

  1. Ensure the brake pads do not rub against the rim when the brakes are released.
  2. Adjust the clearance using the barrel adjuster by turning it clockwise to reduce tension or counterclockwise to increase it.

Maintaining Shimano BR-6800 Brakes

Cleaning the Brake Pads and Rim Surface

  1. Use isopropyl alcohol and a clean cloth to wipe down the brake pads.
  2. Clean the rim braking surface to remove dirt, grease, or debris.
  3. Check for embedded metal shards in the brake pads and remove them with a pick.

Lubricating the Brake Pivot Points

  1. Apply a drop of light lubricant (such as Shimano’s special grease) to the pivot points.
  2. Work the brake levers several times to distribute the lubricant.
  3. Wipe away excess grease to prevent dirt buildup.

Inspecting for Wear and Replacing Components

  • Brake Pads: Replace when the grooves are no longer visible or the pad is less than 1mm thick.
  • Cables and Housing: Check for fraying or rust and replace as needed.
  • Calipers: Inspect for corrosion or stiffness in movement.

Troubleshooting Common Shimano BR-6800 Brake Issues

1. Brake Lever Feels Spongy

Cause: Loose cable tension or contaminated brake pads.
Fix: Tighten the cable, clean or replace the brake pads.

2. Brakes Squeal When Applied

Cause: Dirty rim surface or improper brake pad toe-in.
Fix: Clean the rim and adjust the pads for slight toe-in.

3. Brake Pads Drag on the Rim

Cause: Misaligned caliper or cable tension issue.
Fix: Center the calipers and adjust the barrel adjuster.

Optimizing Shimano BR-6800 Brakes for Maximum Performance

  1. Upgrade Brake Pads: Using high-quality brake pads like Shimano R55C4 improves stopping power.
  2. Use a Lighter Cable Housing: Reducing friction with high-end cables enhances responsiveness.
  3. Pair with a Compatible Brake Lever: Shimano Ultegra ST-6800 [paid link] levers work best with these calipers.
  4. Fine-Tune Pad Contact: Adjusting toe-in and pad angle prevents unwanted noise and enhances modulation.

Conclusion

The Shimano BR-6800 brakes offer outstanding braking performance when properly installed, adjusted, and maintained. Regular cleaning, correct pad alignment, and periodic inspections will ensure they deliver consistent stopping power. By following the steps outlined in this guide, you can optimize your braking performance and ride with confidence.