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Remote RL Service Procedures

Caution!

When you're washing your bicycle, be sure to keep any high pressure spray away from the Remote RL fork topcap mechanism. As a basic rule of thumb, never use a pressure washer.
Directly spraying the Remote RL topcap mechanism will result in the loss of internal mechanism lubrication, which will cause poor performance of the Remote Lockout.
Directly spraying the Remote RL topcap mechanism will also likely result with fine grit dirt deposits entering the topcap mechanism, probably resulting in poor performance as well.

If your Remote RL actuator internal cam mechanism is beginning to stick, see Relubricating the Remote RL Actuator Internal Mechanism.

If you need to service the Remote RL actuator inner control cable only, see Replacing the Remote RL Actuator Control Cable and Housing.

Click the linked kit part numbers in the table below, to view tables containing the constituent parts with their numbers and descriptions.

Kit Part #	Kit Description
820-05-054-KIT	Kit: 09 32 Remote RL Topcap Assy
820-00-248-KIT	Kit: 09 Remote Lockout Lever Assy with Cable Housing and Ferrules
820-00-204-KIT	Kit: Cable Holder Assy, 09 Remote RL

Note: Before you proceed with the following service procedures, click the linked graphics below for a thorough overview of the Remote RL assembly and Remote Lockout lever.

Disassemble the Remote RL System

Located in the bottom of the steerer under the fork crown is the cable holder assembly (820-00-204). With a 3 mm Allen key wrench, loosen the fastener holding the assembly in place.
Figure 1: Removing the Cable Holder Assembly
As you avoid pulling on the RL cable, pull the cable holder assembly straight down to remove.
Figure 2: Removing the Cable Holder Assembly
With a 2 mm Allen key wrench, remove the rebound knob (210-03-097).
Figure 3: Removing the Rebound Knob
While removing the five (5) M2 screw fasteners (019-01-005 x 5) that secure the Remote RL assembly to the topcap, press lightly down on the Remote RL stamped cover (210-22-240) with your thumb, to prevent the assembly from popping out. Use a 1.5 mm Allen key wrench to remove these five screws.
Figure 4: Remove the Five M2 Screw Fasteners
Remove the stamped cover (210-22-240) and cover shim (241-01-023) by pulling these together straight upwards.
Figure 5: Stamped Cover and Cover Shim
Loosen the Shimano inner cable set screw (019-01-044) enough with a 1.5 mm Allen key wrench to allow you to pull the cable out of the Remote RL assembly; see Figure 6: Remove the Inner Cable Set Screw.
Figure 6: Remove the Inner Cable Set Screw
Pull upwards on the Remote RL housing (210-22-241) to remove it from the Remote RL topcap (234-04-147).
Turn the Remote RL housing upside down over a clean shop towel and carefully pull out the upper cam (210-22-239).
Note: the two (2) return springs (039-00-124 x2) will come out loose with the upper cam. Take care to perform this step over a clean shop towel.
Remove the return springs from the upper cam, and set these aside on the shop towel.
Figure 7: Upper Cam With Return Springs
Remove the lower cam (210-22-242), two (2) wave springs (039-00-125 x2), plunger (210-22-243), and main spring (039-00-126) from the parts of the Remote RL assembly that are still in the topcap.
Pull and remove the Shimano SIS-SP40 outer cable casing from the inner control cable.
With a pick, pry the inner cable stop out of the Shimano actuation lever, and pull the inner cable all the way out.
Figure 8: Remove the Original Inner Cable
Note: At this time, be sure the barrel adjuster on the Remote RL assembly (820-00-248) is turned all the way clockwise, and that the Shimano lockout lever (210-15-062) is in its unlocked position.

Assemble the Remote RL System

Drop the main spring (039-00-126) into the top counterbore of the topcap.
Figure 9: Topcap Counterbore
With an acid brush, grease the plunger o-ring counterbore in the topcap. Grease the 8 mm ID x 1.5 mm CS o-ring (029-08-084), slide it on the installation bullet and install it onto the gland of the Remote RL plunger (210-22-243).
Place a small dab of grease inside and at the bottom of the Remote RL plunger. This will help provide initial lubrication to the o-ring that is mounted on the rebound rod, as well as provide an overall decrease in friction.
Install the plunger over the rebound rod and push down until the plunger contacts with the main spring (039-00-126). As shown in Figure 10: Push Down on the RL Plunger to Lubricate, push downwards on the Remote RL plunger and release it 3 or 4 times, to ensure full lubrication of the assembly.
Figure 10: Push Down on the RL Plunger to Lubricate
Place grease on both ends of the return springs, (039-00-124, x2).
Place one end of each return spring into the two holes found in the upper cam (210-22-239); see Figure 11: Place Greased Return Springs into Receiving Holes in Upper Cam and Figure 12: Greased Return Springs Placed in Receiving Holes in Upper Cam.
Figure 11: Place Greased Return Springs into Receiving Holes in Upper Cam

Figure 12: Greased Return Springs Placed in Receiving Holes in Upper Cam
With an acid brush, grease the uppermost surface of the upper cam (210-22-239), as well as on the ramped cam surface of the upper cam. Set the upper cam down on a clean shop towel.
Apply a thin layer of grease to the uppermost inner surface of the Remote RL housing (210-22-241), as shown in Figure 13: Inner View of the Upper Housing.
Figure 13: Inner View of the Upper Housing
Invert the Remote RL housing and slide the upper cam (210-22-239) (with return springs installed) in through the opening in the back side of the Remote RL housing. Be sure the ramped cam surface of the upper cam is facing upwards towards you.
Figure 14: Push and Slide the Upper Cam From Under Side of Remote RL Housing
Push and slide the upper cam (210-22-239) until the cable holding area of the upper cam shows through the upper window in the housing; see Figure 15: Push the Upper Cam Through the Back Side of the Remote RL Housing and Figure 16: Upper Cam Viewed Through Remote RL Housing Window.
Figure 15: Push the Upper Cam Through the Back Side of the Remote RL Housing

Figure 16: Upper Cam Viewed Through Remote RL Housing Window
Ensure that the return springs are seated into their small receiving holes in the Remote RL housing by gently pressing on the exposed sections of the springs.
Flip the Remote RL housing upside down to allow access to the inner well of the housing.
Using an acid brush, grease the top cam surface of the lower cam (210-22-242).
Place the lower cam (210-22-242) inside of the Remote RL housing (210-22-241), such that the lower cam ramped surface directly contacts the upper cam's ramped surface. Refer to Figure 17: Remote RL Housing and Lower Cam Alignment:
1. The hole in the lower cam is positioned in proximity to the cable attachment screw.
2. The two flats on the lower cam will align with two flats in the Remote RL housing.
Figure 17: Remote RL Housing and Lower Cam Alignment
With an acid brush, lightly grease, align, and stick the two wave springs (039-00-125) together.
Note: the ends of one wave spring must never directly overlay the ends of the other wave spring. For best results, be sure the ends of each wave spring are set into position staggered at least 90 degrees from one another.
Install the two stacked wave springs centered inside of the Remote RL housing and on the bottom of the lower cam, as shown in Figure 18: Installing the Two Wave Springs.
Figure 18: Installing the Two Wave Springs
Remove the plunger from the topcap.
Figure 19: Removing the Remote RL Plunger from the Topcap
Place the top of the plunger into the bottom of the housing.
Pick up the entire assembly, flip right-side up, and install into the topcap. Push down on the assembly until the housing makes contact with the bottom of the topcap.
Figure 20: Install the Remote RL Assembly into the Topcap
Re-install three (3) of the M2 screws back into the topcap, allowing the Remote RL housing and all parts underneath to be securely held in place. Be sure the Remote RL housing securely settles to the bottom of the topcap, tightening it down lightly.
Figure 21: Loosely Re-install Three M2 Screws

Install the Cable into the Upper Cam

Run the inner cable through the cable outer casing and pull it completely through, until the inner cable stop end and the cable housing fully seat into the Shimano Actuation Lever. Next, ensuring the inner cable is protruding from the Shimano SIS-SP40 outer casing 0.480” ± 0.026”, mark the inner cable with a felt tip ink pen and cut the inner cable with a cable cutting hand tool.
Note: Be sure to use the best hand tool for cable cutting, to ensure a clean, non-frayed cut.

Figure 22: Cut the Exposed Inner Cable End to Specification
Push on the upper cam so that there is a 0.050” gap between the back edge of the upper cam and the opening on top of the Remote RL housing; see Figure 23: Pushed Upper Cam in Remote RL Housing With 0.050" Gap.
Figure 23: Pushed Upper Cam in Remote RL Housing With 0.050" Gap
Note: Be sure the barrel adjuster on the Remote RL assembly (820-00-248) is turned all the way clockwise, and that the Shimano lockout lever (210-15-062) is in its unlocked position.
With the upper cam (210-22-239) being steadily pushed to allow the 0.050” gap (as shown in Figure 23: Pushed Upper Cam in Remote RL Housing With 0.050" Gap), install the control cable through the holes in the Remote RL housing and the upper cam. Also see Figure 24: Installing the Shimano Control Cable and Figure 25: Tightening the Shimano Inner Cable Set Screw.
Figure 24: Installing the Shimano Control Cable
Make sure your Shimano outer cable casing end is seated all the way into the hole in the Remote RL housing, and that the inner cable is cut long enough to pass beyond the cable set screw in the upper cam, to ensure the best set screw attachment.
Figure 25: Tightening the Shimano Inner Cable Set Screw
Tighten the inner cable set screw (019-01-044) to 3 in-lbs.
Allow the upper cam (210-22-239) to return to its starting position.

Ensure Proper Lockout Engagement

On the Remote RL assembly (820-00-248), turn the barrel adjuster out ten (10) clicks.
Push the lockout lever down to its locked-out position.
Measure the gap between the inner window edge of the Remote RL housing to the inner edge of the upper cam (210-22-239); this measurement must be 0.185” ± 0.005” (see Figure 26: Remote RL Housing and Upper Cam Gap Specification). If this measurement is not to specification, adjust the barrel adjuster until it is.
Push the release button to unlock the system.
Figure 26: Remote RL Housing and Upper Cam Gap Specification

Continue Installing the RL System into the Topcap

Remove the three M2 screws loosely securing the Remote RL assembly in the topcap, as instructed in Step 20 of the Assemble the Remote RL System procedure.
Install the shim (241-01-023) over the bottom lip of the Remote RL stamped cover (210-22-240). Install the shim from the bottom of the cover, making sure the opening of the shim is placed underneath the rectangular opening in the cover (see Figure 27: Install Shim Over Bottom Lip of Stamped Remote RL Cover).
Figure 27: Install Shim Over Bottom Lip of Stamped Remote RL Cover
Slip the Remote RL stamped cover (210-22-240) over the Remote RL housing (210-22-241), and push on the cover until the cover is fully seated onto the housing.
Turn the housing so that the left edge of the outer cable casing just contacts the crown, as shown in Figure 28: Remote RL Assembly, Top View.
Figure 28: Remote RL Assembly, Top View
Install five M2 screws (019-01-005) to secure the Remote RL assembly, as shown in Figure 28: Remote RL Assembly, Top View. Tighten the screws down in a counterclockwise sequence, to 0.75 in-lb each. At this point, make sure that the bottom of the socket head contacts the top face of the shim (241-01-023). Continue with the counterclockwise sequence tightening of the screws, until the final torque value of 1.5 in-lb for each screw is attained.
Place the rebound knob (210-03-097) onto the rebound rod. Make sure to align the flats located on the rebound knob to the flats located on the rebound rod.
Apply one drop of purple Loctite 222 to the rebound knob screw (019-01-007) and with a 2 mm Allen key wrench, torque the rebound knob screw to 2.5 in-lb.
Figure 29: Installing the Rebound Knob

Install the Cable Holder Assembly

With the Cable Holder Assembly (820-00-204), hook the steel bracket (026-03-012) around the cable housing located in front of the steerer.
Figure 30: Cable Housing With Cable Holder Assembly
While keeping the cable housing inside of the hook on the steel bracket, place the nut (019-00-005) end of the assembly up into the steerer from the underside of the crown; see Figure 30: Cable Housing With Cable Holder Assembly.
Push the assembly in the steerer until the large washer (241-01-021) contacts the bottom of the steerer.
Position the Cable Holder Assembly so that the cable housing runs parallel with the crown.
While holding the front of the assembly to keep it from turning, tighten the M5 bolt (019-01-043) to 8 in-lb torque.
Figure 31: Securing the Cable Holder Assembly

Install the Shimano Remote Lockout Lever

Figure 32: Shimano Remote Lockout Lever

Note:

Install the Shimano Remote Lockout lever in a position such that it will not interfere with normal braking or gear shifting operations.
Do not use in any setup combination that could cause brake operation to be compromised in any way.
In the case of carbon handlebars, it might be necessary to slightly lessen the tightening torque, to avoid causing any damage to the handlebars. Consult the bicycle or handlebar manufacturer documentation regarding the appropriate level of tightening torque for carbon handlebars.
When operating the derailleur shift lever, be careful not to accidentally push the release lever of the Shimano Remote Lockout lever.

Remove the right-hand grip from the handlebars. Using a handlebar grip with a maximum outer diameter of 36 mm is highly advised, as to allow enough clearance for normal operation of the Shimano Remote Lockout lever.
Slide the Shimano Remote Lockout lever onto the right-hand end of the handlebars, positioning it outside of the brake lever. Reinstall the handlebar grip.
Position the Shimano Remote Lockout lever so that it abuts the innermost edge of the reinstalled handlebar grip, however be sure the grip does not interfere with the normal operation of the lockout release lever.
Figure 33: Shimano LLA Installed on the Handlebar
Gently tighten the clamp bolt with a 3 mm Allen key wrench. At this point you will want the ability to rotate the lever and feel some resistance, but not tighten the screw so tight such that the lever will not budge.
Note: See the third bullet item in the above note concerning carbon handlebars.
Push the actuation lever down into its locked-out position; be sure the actuation lever clicks into position.
Rotate and position the entire Shimano Remote Lockout lever assembly, to ensure the actuation lever in its locked position does not interfere with the normal thumb operation of the gear shifters.
Figure 34: Actuation Lever and Thumb Shifter Clearance
Fully tighten the clamp bolt to 8 in-lbs of torque. Consult the bicycle or handlebar manufacturer documentation regarding the correct level of tightening torque for carbon handlebars.

Ensuring Proper Remote RL Functionality

Push the Shimano actuation lever down to its locked-out position.
Push down vigorously on the handlebars to check whether the fork is completely locked out.
If the fork is not locked out completely, turn the barrel adjuster clockwise (that is, from the standpoint of the rider facing the front of the bike) until the fork completely locks out. If there are more than 6 clicks out, the cable length needs to be readjusted.
Push the release button to unlock the fork, making sure the fork is completely unlocked.