Nebo1ss,
Installing the SC-EM800 definitely a pain in the ass and requires a bit of fiddling work to install. However, you do not have to cut the EW-SD50 wire. Here is my process for installing the SC-EM800, should anybody wish to install it, instead of installing the SC-E7000 display.
Notes:
A) Preserve the short EW-SD50 wire that formerly went from the EW-AD305 adapter to one end of the EW-EN100. Do not cut and remove it. You want to keep this wire and the EW-EN100 in your riding kit. If you take a bad fall and break the SC-EM800 display, your bike will not work. If you have the EW-SD50 wire and EW-EN100 with you, you can quickly bypass the broken display by re-installing the items and get your badass self back on the trail. For those viewing this post, I've attached pictures of the items for reference.
B) You will need to purchase a 150mm length (Shortest length offered by Shimano) EW-SD300 cable to complete the SC-EM800 installation. You will also need the EW-AD305 adapter located inside the downtube, where it meets at the headtube.
C) Below I've detailed how to install the SC-EM800 using the EW-AD305 adapter located inside the downtube which requires removing the front fork. However, if you are not mechanically inclined, or simply don't want to mess around with dropping the fork, there is an alternative method which will require additional purchase or parts. The SC-EM800 color display only accepts EW-SD300 wire inputs. If you buy the items listed below, you can install the SC-EM800 color display on your Rise as a direct plug and play without having to do any mechanical work. One adapter and EW-SD300 wire will convert the EW-SD50 wire coming out of the headtube and the second adapter and EW-SD300 wire will convert the mode selector switch EW-SD-50 wire. Because you will extend the wiring length by approximately 150mm or 5.90 inches, this will leave you with an excess length of wire at the handlebar which will require a bit of creative management.
Buy Two, 150mm EW-SD300 cables
Buy Two, EW-AD305 adapters
EW-SD50 wire (Formerly went from EW-AD305 adapter to EW-EN100)
EW-AD305 (Found inside frame at downtube, near headtube junction)
EW-EN100 Junction Box (Found mounted to the dropper post cable housing on the front of bike)
Installation Process:
1) Place your Rise frame in a bike stand. The dropper post must be free and clear, and not clamped in the bike stand. Take a pencil and mark your dropper post height at the seat post clamp. During the display installation process, you will need to remove the dropper post from the frame. The pencil mark allows you to reinstall the dropper post back to the correct height.
2) Remove the EW-EN100 junction box from the front of the bike.
3) Remove the dropper cable housing and cable from the dropper seat post lever. To do this, you will need to remove the cable crimp at the end of the cable. If the dropper post cable housing is attached to the brake hose housing via zip ties or clamps at the front of the bike, free it up.
4) Note, this part is not required, but makes the installation process easier. Remove the two bolts holding your front brake caliper to the fork. Place a spacer block firmly between the two brake pads on the caliper. This will keep the caliper pistons from being accidentally actuated. Remove the fork brake hose clamp. The clamp screw is small, I like to re-thread it onto the fork to prevent it from becoming lost. Remove your front wheel from the fork.
5) Loosen the stem bolts. Loosen and completely remove the stem top cap. Remove the fork completely from the frame and place it off to the side so it doesn't get damaged. Pay attention to your stem spacers, their sizes, and if they are above or below the stem. A picture taken with your phone helps. You want to reinstall the spacers in the correct orientation when you re-install the fork and stem.
Note: Because the stem bolts have been loosened and the stem top cap has been removed, it is possible for the fork to fall out of the frame when you remove the stem top cap. Normally it will take a slight bit of tapping with your hand or rubber mallet to get the fork steerer tube past the headset bearings. Just in case however, keep a hand on the fork so it doesn't accidentally drop out of the frame and become damaged by hitting the floor.
6) When you remove the fork from the headtube, the upper headset bearing cap and seal will come off. The Rise comes with an Acros Integrated Headset. The upper headset bearing may also come out, but will likely stay in the frame's integrated bearing cup. Remove the upper headset bearing from the frame by grabbing it with your fingers and rock it back and forth until it comes out. Place you headset items off to the side so they don't accidentally get knocked about and lost.
With a rag, clean out the upper integrated bearing cup.
Your lower headset bearing may come off with the fork or remain inside the lower headtube bearing cup. Remove the lower bearing if it remains in the frame. During the re-installation process, you want to inspect your headset bearings and repack with grease if needed.
6) Using a light, shine the light inside the headtube. You will see the dropper cable housing and the EW-SD50 cable. You will notice they are held to the inside wall of the frame headtube by two loops molded into the inside wall of the frame headtube. These loops prevent the EW-SD50 wire and dropper post cable housing from coming into contact with the fork steerer tube and damaging the wire and or housing while riding.
7) The EW-SD50 wire and dropper post cable housing exit the headtube via a small port in the headtube wall. The EW-SD-50 cable's large leads prevent the EW-SD50 cable from being removed from the headtube unless the dropper cable housing has first been moved out of the way. Why Orbea didn't design the left port like the right port side is a design mistake.
8) Begin the process of slowly backing the dropper post cable housing into the headtube and just slightly into the inside of the headtube. Do not push the dropper post cable housing past the small molded retainer loop. This will clear the headtube port so that the EW-SD50 cable can be removed from the EW-AD305 adapter and removed from the bike via the headtube port. The EW-SD300 cable which is attached to the other end of the EW-AD305 adapter can be routed through the cleared headtube port.
To begin the process of pushing the dropper post cable housing into the headtube, you first have to loosen the seat post clamp. Slowly pull upwards on the dropper post. Using your fingers, keep tension on housing and cable at the same time. Do this because you want to prevent the dropper cable from becoming accidentally disconnected from the bottom of the dropper post. If this does occur, simply remove the dropper post and re-connect the cable. Slowly pull the dropper post up until the housing has just cleared the inside of the headtube.
9) Inside the downtube will be a foam wrapped bundle of wires. The exact location of the bundle varies from bike to bike. Mine was at the junction of the downtube and headtube. I've heard of others being tucked farther into the downtube. The foam bundle will have a small zip tie holding the bundle tightly together. Within the bundle will be a few feet of EW-SD300 wire, which runs from the motor to the adapter, EW-AD305 adapter, and the EW-SD50 wire which runs from the adapter to the EW-EN100 junction box.
Slowly pull on the EW-SD50 wire until the foam bundle appears and has been brought up into the headtube. Cut the zip tire and remove it. Note the EW-SD300 and EW-SD50 wires are fragile and can be damaged if haphazardly pulled or pushed on. Orbea provides a Shimano wire removal/installation tool with each bike. If you were wondering what that odd looking thing in the bike packet is, it's the Shimano wiring tool. Use it to safely remove and install wires.
10) With the bundle pulled up into the headtube, remove the EW-SD50 wire from the adapter and completely remove it from the bike. Remove the EW-SD300 wire from the other side of the EW-SD305 adapter. Place the adapter off to the side. It will be needed during the SC-EM800 display installation process. The EW-SD300 wire from the motor has a few feet or extra length or about 60 centimeters for my European friends. As a side note, you guys need to stop this metric nonsense...
Push the EW-SD300 wire through the molded retaining loop located on the inside wall of the headtube and out the head tube port. You want to pull enough wire through so that it will reach the SC-EM800 computer display when it is mounted on the handlebar. You may have some additional length of EW-SD300 wire left over. If you want, you can coil it up, wrap it back in the foam padding, zip tie it, and tuck it back into the downtube for safe keeping.
Begin The Re-Installation Process
11) Hold the dropper post cable housing and cable at the same time with your fingers. Hold both the housing and cable firmly. You want to prevent the housing from sliding away from the bottom of the dropper post. If it does, the cable may become disconnected from the bottom of the dropper post. If this does happen, no biggie, remove the dropper post and re-attach the cable. With tension on the housing and cable, slowly pull on the dropper housing while inserting your dropper post downwards into the seat tube. Feed the dropper housing through the headtube port. If you have accidentally pulled the dropper post housing too far into the headtube and out of the retaining loop, then feed the housing first it through the retaining loop on the inner headtube wall, before inserting it through the head tube port.
12) Insure that the EW-SD300 wire and dropper post cable housing and secure in their retaining loops and not bulging out into the headtube. If they are, they will rub on the fork steerer tube when it is installed. Eventually this may damage the wire, score the steerer tube, or ruin the dropper cable housing.
13) With a rag, clean the lower headtube integrated bearing cup. Apply some grease to the bearing cup. Inspect the lower headset bearing. The bearing should spin smoothly and easily. You should not feel any grinding or bumpiness as you spin the bearing. Grinding/bumpiness indicates a damaged, dirty and or, lack of lubrication bearing. If the bearing is damaged, it will need to be replaced. If the bearing is simply dry or dirty, you can easily clean and repack a headset bearing with grease. Refer to this great YouTube video:
14) Examine the lower headset seal which will be found pressed onto the fork crown for damage. If the rubber seal has been damaged, the lower seal will need to be replaced. If no seal damage is noted, clean the seal with a rag and apply a light coating of grease onto the rubber seal.
15) After inspecting your lower headset bearing, apply a film of grease to the exterior of the bearing. Note that the lower bearing has a chamfered angle on one side the bearing. The chamfered/angled side of the bearing is inserted upwards into the lower integrated frame bearing cup.
16) Inspect your upper headset bearing. Clean the bearing, the headset cap and seal. Apply a coating of grease to the upper integrated bearing cup and upper headset bearing. Apply a light coating of grease to the rubber areas on the upper headset seal and cap.
17) Insert the fork steerer tube into the headset. With the fork steerer tube fully inserted, slide the headset upper seal and upper headset bearing cap onto the steerer tube.
18) Insert your stem spacers in their correct orientation onto the fork steerer tube. Install your stem on the fork steerer tube. Installed the stem top cap and bolt. Lightly tighten the stem clamping screws to keep the stem from twisting and turning.
19) Re-attach the brake hose and clamp to the fork. Re-attach your brake caliper to the fork with the two caliper screws.
20) Remove the spacer block from the brake caliper and Install your front wheel on the fork.
21) Take your bike off the bike stand. Loosen the stem clamping screws. Center your front wheel and stem. Tighten the stem top cap until all play has been removed from the headset. Torque your stem clamp bolts to the correct torque. Tighten your stem top cap. Note: The stem top cap sets headset preload. The stem clamping screws secure the stem to the fork steerer tube. You don't need to crank down tightly on the stem top cap. Here is a YouTube video detailing how to adjust headset play.
22) With everything fully mounted on the bike, loosen the two front brake caliper screws. Apply the front brake while at the same time tightening the two brake caliper screws. This should center the brake caliper over the rotor. If you experience a slight rubbing noise as you spin the front wheel, you will need to loosen the screws and manually adjust the caliper until until it stops rubbing.
23) The SC-EM800 display will come with two clamps, a 35mm clamp and a smaller clamp for smaller diameter bars. Install the correct clamp on the display. Install the SC-EM800 display on your handlebar.
24) Take the EW-SD50 wire lead coming from the mode selector switch and install it into into one side of the EW-AD305 adapter. Take the 150mm length EW-SD300 cable you purchased and install it into the other side of the adapter. Plug the other end of the 150mm long EW-SD300 cable into the SC-EM800 display.
25) Take the EW-SD300 cable coming out of the headtube port and plug it into the SC-EM800 display.
26) Secure the wring to prevent it from getting snagged on a branch and killing your bike.
27) Turn your bike on and check the display for function. Adjust display settings and do any firmware updates as needed.
28) Get out on the trail and ride.
Note: You have several options for running the wiring to and from the SC-EM800 display and mode selector switch. You can use silicone bands to attach the wires to the handlebars. You can use electrical shrink tubing to secure the wiring to the cable housing and run it to the display. You can buy handlebars which are made so that the wiring can run inside the handlebar. Here are examples of using the rubber band and electrical shrink tubing methods:
I hope you have enjoyed this tech article. My fingers are cramping....If you have any questions, shoot me a message and I can help you out.
Wiring is attached to the cable housing with electrical shrink tubing. This method provides a clean look and prevents your cables from flopping around as you ride. As a side note, my buddy has the same color Rise as my bike. I have a SC-E7000 display, he has a SC-EM800 display. Both the EM800 and E7000 are extremely difficult to find in the United States, everything is sold out. He bought his from a vendor in Germany via eBay.
Wires attached to the handlebar with silicone rubber bands purchased off of Amazon. I now have 1,000 miles/1,609 kilometers on my Rise and none of the bands have broken. This method has also worked well.