Know-How, Workshop - August 20, 2016

How to fit Shimano XT and XTR Di2 : plug and play shifting

Shimano XTR Di2 has already proven itself in our long term review, and now the technology has filtered down to the more affordable XT, we are likely to see it on more and more bikes. But how easy is it to fit? Do you need an electronics degree from Oxford and the patience of a saint? Let’s find out.

The new Shimano Deore XT Di2 drivetrain brings electronic shifting to a more affordable price point. — The new Shimano Deore XT Di2 drivetrain brings electronic shifting to a more affordable price point but how easy is it to fit?

What tools do I need to fit Shimano Di2

After a quick tutorial from Shimano, we found that Shimano Di2 is incredibly easy to fit. The hardest part of the whole process is working out the best cable routing. Most bikes sold now have internal cable routing ports allowing cables to be carried neatly through the frame. We’re not going to lie here, if you’ve ever tried fitting internal cabling you will know it can drive you madder than a bag of cats, so if you’re a budding home mechanic we would highly recommend the Park Tools IR-1 cable installation tool. It is not essential to own an IR-1 but you fit a lot of cables it will help your hairline. To fit Di2 you will need:

Allen Key Set
Shimano Di2 Installation tool TL-EW01 (provided with drivetrain)
Park Tools IR-1 (optional)

Fitting Shimano Di2 is very simple, and requires few tools.

Important note

Every Di2 installation will be different depending on the drivetrain chosen and your frames internal routing – this walk-through is intended to show how simple the plug and play system is to install. We chose to fit an internal battery to our Cube Stereo test bike, but any internal, or even external routing will work. If in doubt your local bike shop or Shimano dealer will be able to advise, but this guide aims to show that installing Di2 is a very easy task for an enthusiastic amateur bike mechanic.

What is plug and play

The beauty of the Shimano system is its plug and play setup. Each component (such as the shifters, rear and front mechs) are connected to the main System Information Display Unit using purpose built Di2 cables. Each cable has a weather sealed connector on the end and is installed simply with a TL-EW01 tool. To make internal routing easy, cables can be joined inside the frame (at a suitable location depending on your frame) using easy to use connector blocks, no wiring knowledge is needed you just need to plug everything in. Once everything is joined up the system is clever enough to find out where everything is. Plug and play – simple!

Connector blocks allow cables to be easily joined inside the frame.

Step 1: Finding a home for the Di2 battery.

The original Di2 batteries were chunky and a little ugly, but the latest SM-BTR2 can be mounted internally to really clean up the look of your drivetrain. Some creativity may be required to find a suitable location for the SM-BTR2, and we found the best spot was wrapped in foam inside the bike’s seat tube, located by the bottom bracket. Housing the battery internally helps to keep it protected from the elements.

We located the battery inside the bikes seat tube, protecting it from the rain and mud. NOTE we inverted the battery when we installed it so the cable exited from the bottom down towards a connector block hidden inside the bottom bracket.

Step 2: Making a connection.

Once a suitable location has been identified, we attach one Di2 cable to the battery using the TL-EW01 installation tool and run it to where we have chosen to house the main connector block above the bottom bracket, pressing home the cable until an audible “click” is heard. The heart of Di2 is its ‘plug and play’ installation, all the wires are simply passed through a connector block and the system is smart enough to know where everything is, but more on that later.

Step 3: Installing the Di2 rear derailleur.

To install the rear derailleur simply choose where your main junction box will be located (we chose just above the bottom bracket), then run a cable back from the junction box using your frames natural cable routing to the rear mech mounting point. Once the cable is installed simply attach the rear mech using the proper torque settings and connect the cable using the TL-EW01 tool, being sure to press until a distinct click is heard.

The rear mech cable is installed through the rear swing arm with a Park IR-1 tool, the other end of the cable is routed towards the battery.

Once the cable is ready, the XT Di2 Rear Mech is fitted into place.

The cable is pushed into place using the TL-EW01 tool until an audible click is heard.

Step 4: Installing a Di2 front derailleur

If you are still using a 2x drivetrain – and indeed the Synchro shift of XT Di2 makes this more desirable – the process is the same as the rear mech. Simply route the cable through the frame using the internal routing and then attach the front mech using the manufacturer instructions to ensure the front mech is at the correct height. Simply install the cable using the TL-EW01 tool again ensuring that at audible “click” is heard.

Fit the front mech using the correct torque settings.

Ensure the cage is at the correct height, new mechs have a sticker fitted to guide you.

Carefully install the cable to ensure that a click is heard

Step 5: Installing the Di2 Shifter

In this installation, we are using the PRO Tharsis bar and stem which allows the Di2 cables to be hidden inside the bar for a full stealth look. The first step is to install the shifter cable into the bar. Once installed, the shifter simply slides onto bars and is fixed in place with the unit fixing bolt. The shifting paddles can then be adjusted to the riders preference. NOTE: Ensure a loop of cable is left before mounting to provide protection in a crash (see image).

The PRO Tharsis Bar allows the cables to be run internally for a full stealth install.

Simply slide on the shifters and position them to rider preference.

Run a loop of cable around the mount as shown and connect with the TL-EW01 tool.

Step 6: Putting it all together

To put it all together the next step is to connect all the parts. Simply connect the battery, rear mech and front mech cables to a junction box hidden inside the frame (we chose just above the bottom bracket), it does not matter what order you connect the wires to the junction box as the System Information Display Unit will figure it all out. Then take a final new cable from the remaining port of the junction box and run it up to the handlebars using the bikes internal routing.

This junction box can be hidden inside the downtube or seat tube, wherever works best on your frame. In our case we had a cable coming from the rear mech, one from the front mech and one looped back up into the seat tube to the battery. One cable then exited the last port and was routed up the downtube to the handlebars to connect to the System Information Display Unit.

Step 7: Fitting the Di2 System Information Display Unit

At the bars, we should now have a cable from the shifter and single main cable from the junction box connecting the battery/front mech/rear mech. The final step is to install the System Information Display Unit. The unit comes with a clamp band for both 31.8 mm ad 35 mm handlebars, simply choose the required band and fix the unit into position. Once in position simply plug in the front and rear shifter cables and the single cable from the battery connector block using the TL-EW01 tool.

You should now have a cable coming from each of the front and rear shifters and a cable coming from the battery/mech connector block. — You should now have a cable coming from the shifter and a cable coming from the battery/mech connector block.

Affix the System Information Display Unit to the bars.

Connect the three cables using the proper TL-EW01 tool, ensuring a click is heard.

The system will power up and is now live.

Step 8: Setting up the Di2 system.

Setting up Shimano Di2 used to require the use of a laptop to run the Shimano E-Tube software but soon (early Autumn 2016) the drivetrain will be able to be customized from your smartphone or tablet using the new Shimano App. We will bring a full How-To on setting up the Di2 drivetrain very soon.

The XT and XTR Di2 drivetrains will be able to be customised from a smartphone or tablet using the new Shimano E-Tube App.

We were impressed how easy it is to install Shimano’s Di2 drivetrain. Every installation will be slightly different, but if you are confident installing conventional internal cables and a mechanical drivetrain, you will have no trouble at all installing Di2.

Now you know how easy it is to install the Di2 system. Don’t miss our Shimano XT Di2 review and our Shimano XTR Di2 long-term review.

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