WORKSHOP ww w. m ag ur a. co m 2004 Deutsch English Français Nederlands Italiano Español printed in germany © MAGURA 2003 All rights reserved www.magura.com service@magura.de Summary 1. Introduction 2. ISafety instructions before the first ride 3. Safety instructions before every ride 4. Transport of the bicycle 5. Warranty 6. Brake installation 7. RAT Brake Booster for Manitou forks 8. Installation FIRM-tech® 9. Shortening and routing the hose 10. maintenance/brake pad change 11. Filling and bleeding 12. Repairs 13. Brake pads 14. Accessories 15. Spare parts exploded view 3 4 4-5 5 5 6-8 9 10 11 13 14 15 16 17 18-19 WARNING: This symbol means possible danger for your health and even life if you do not follow the instructions given respectively if the necessary safety measures are not followed. ATTENTION: This symbol warns you of inappropriate handling that might cause serious damage to the material and/or the environment. NOTE: This symbol gives you additional information about the general handling of the product or gives hints to paragraphs in this manual which have to be read carefully. For your own safety you should not overestimate your technical skills! We advise you to leave the following works in case of any doubts to a professional bike mechanic. 2 www.magura.com service@magura.de 1. Welcome to the Brake People! Congratulations! You have purchased a fully hydraulic MAGURA rim brake proudly ,,Made in Germany". You will be amazed at the awesome braking power and the minimum amount of maintenance that is necessary on our stoppers. Good to know that you are not alone, millions of riders worldwide rely on them and every day our numbers are increasing Brake caliper (slave cylinders) MAGURA HS 33 Brake lever (master cylinder) MAGURA HS 33 On the fully hydraulic MAGURA rim brake systems HS 33 and HS 11 the braking force is transmitted to the braking surface by a mineral oil column. The movement of the lever blade moves a piston, which is integrated in the brake lever (master cylinder). The piston pushes the mineral oil column through the brake hose in the direction of the brake calliper (slave cylinders), where two pistons, on which the brake pads are clipsed, are pushed out. The friction between the brake pads and the rim slows down the bicycle and causes a heating of the rim. Never touch the rim after long braking as this may cause serious burns! You will be pleased to find out that the MAGURA rim brakes offer a superior braking power even with little hand force applied, no matter what the weather conditions should be. Please note, however, that rim brakes are generally not as powerful in the wet in in snowy conditions mainly and that the reaction of the brake will be slightly retarded under these circumstances. Our rim brakes cause a wear of your rims. So do not forget to check regularly your rims! This manual contains important information about the safe installation, operation and maintenance of your MAGURA rim brakes. We urge you to read it carefully, become familiar with its contents and follow our recommendations to help make your new braking experience enjoyable and trouble free. All setup steps will be explained on the HS 33 rim brake. Any differences with the HS 11 model will be clearly mentioned. Although the MAGURA rim brake systems are relatively simple you should not overestimate your technical skills! We therefore advise you to leave the following works to a trained technician of a professional bike shop. In case of any further questions or problems we warmly recommend to visit our website www.magura.com where you will always find the newest and hottest tips about all our products. Stay tuned with the Brake People! Thank you for your confidence in our products, enjoy your ride and your new MAGURA stoppers! Happy trails! 3 Español Italiano Nederlands Français English Deutsch www.magura.com service@magura.de 2. Before the first ride 1. Are you already familiar with hydraulic rim brakes? Our brakes might be much more powerful than the stoppers on which you relied so far. Take your bicycle to a safe area to learn the proper braking technique and operation of your new brakes and your bike. 2. Check that the front brake is still actuated by the lever on the side you are used to braking with. Should this not be the case you will have to train to your new setup otherwise any unintended front wheel braking manoeuvre may cause an accident leading to possible serious injury! If in doubt get a trained technician to swap the hoses. For further hints concerning the swapping of the brake hose see page 11 onwards. 3. While riding in extreme conditions (total weight of bike plus rider over 100kg and/or a gradient of more than 15%) always use both brakes simultaneously to slow your bike down. 4. Do not use a MAGURA rim brake for downhill sport! Any misuse might cause serious accidents with fatal injuries both to yourself and others! 5. Are you familiar with the other components on your bike such as gears, clipless pedals and suspension units? Always practise using your bike in a saffe area to improve your handling abilities before using it on road. Consult the user's manual of your bike to learn more about this. 6. For your own safety always wear a helmet when you ride a bicycle. Make sure as well that you wear suitable clothing and footwear . 3. Before every ride always check carefully the following points: 1. Always make sure that the quick release skewers of your wheels and seat post are correctly mounted and closed. incorrectly installed quick release skewers might cause the fixed items to become loose. Serious accidents with severe injury may result!! 2. Always make sure that the brake lever pressure is o.k. by pulling the lever blade and ensuring that full braking performance is achieved before the lever blade touches the handlebars. In case, of changing pressure points during a ride you might have air in the brake system. See hints about filling and bleeding from on pages 14-16. 3. Always make sure that the brake system does not have any leaks by activating the lever blade, holding it and checking the hose connections and brake lever for eventual leaks. (Also see page 11) 4. Always protect your rims and brake pads from oil and lubricants (e.g. by lubricating your chain). 4 www.magura.com service@magura.de 5. Release your brake lever and check whether your wheel moves freely and without drag. Check eventually whether the wheels are correctly mounted and if the quick release skewers are tightened sufficiently. 6. Are your tires in a good condition, and have they enough air pressure? Test this with your fingers. Lift up your bike and turn the wheels of your bike. An insufficient rotation might be due to damaged tires, broken axles and/or broken spokes. 7. Pick up your bike and let it drop from a moderate height. Listen for any rattling noises. If any are heard check the bearings and all screwed connections. 8. Always follow the instructions given in the owner's manual of your bicycle. Never use your bicycle if any of the points mentioned above relate to your bicycle. Consult a professional bike mechanic if you feel unsure. A faulty bicycle may result in serious accidents with possible fatal injuries of the rider! 4. Transport of the bicycle For a transport in an aircraft you can leave your brake as it is, e.g. you do not have to empty it. Beside of this there are no further activities necessary. Always make sure that the hose is not snapped or damaged during transport! 5. Warranty MAGURA is giving a 5 year leakproof warranty on brake levers (master cylinder) and brake callipers. Watch out for the red info sheet in the middle of this manual! This warranty is void when damage to the brake has occurred from the following: abuse mixing and matching the brake with parts from other manufacturers damage of the exterior finish caused by improper use any attempt to disassemble the whole brake modifications non-factory changes or improper service We expressly point out that a warranty claim is only accepted with a clear proof of purchase (payment receipt of the dealer!) and recommend to register your brake online on magura.com 5 Español Italiano Nederlands Français English Deutsch Contaminating the pads with oil and lubricants will cause a permanent loss of braking power. Clean contaminated rims and pads with isopropyl alcool or with warm dishwater. See further hints about the brake pad change on page 13. www.magura.com service@magura.de 6. Brake Mounting 1. Tools for mounting (+maintenance) Allen key 2*, (3), and 5mm 8mm open end wrench sharp knife (*delivered with the brake) Please insert the allen key completely to avoid damaging the bolts. 5! RE JAH_I_ NT_E __ GARA _ __ 1 1a _ __ _ __ 1c 1d GARA AHRE _ __ J __ _ I NT_ E _ 5 _ __ __ _ 1b ! 5! RE JAH_I_ NE _ T_ ___ GARA _ 1c 1b 3 __ _ ___ 2 6 2 5 7 4 Unpack your MAGURA brake and arrange all parts (The quantities mentioned here refer to after-market sales boxes including a complete brake set) 1. Preassembled brake, filled and bled, ready for mounting (2 pieces) 1a brake lever (or master cylinder) 1b brake cylinder (or slave cylinder) 1c evolution adaptor 1d quick release cantistud U-washers (4 pieces) fitting bolt for evolution adaptor (2 pieces) quick release (or hourglass) bolt (2 pieces) STANDARD brake booster (only HS 33 models, 2 pieces) washer for brake booster (2 pieces) olives (2 pieces) Contents in the sales box may vary, mainly in the US! 2. 3. 4. 5. 6. 7. 6 www.magura.com service@magura.de 3. In some cases (e.g. extremely narrow rims) it might be better to change the adaptors from one side to the other. The MAGURA embossed side (arrow 2) is interchanged with the Evolution embossed side. The quick release (arrow 3) must be mounted on the right side (your are standing in front of the brake and facing it). The quick release lever points up in the closed position. The black elbows (arrow 1) are adjustable and point preferably downwards (for better tire clearance!). They MUST ALWAYS block against the fork or frame. 4. Loosen the bolts (allen key 5mm) slightly to adjust the slave cylinder. Remove the bolts if you have to switch the sides of the evolution adaptor brackets. 5. This is a good time to see how easy it is to change MAGURA brake pads. Simply click them in! 2 1 3 6. Evolution adaptor details. The black elbow can be adjusted with the toothed washers (arrows 1) as long as the fitting bolt (2) is not tightened. The elbow points preferably downwards (for better tyre clearance). The elbows must always block against the fork or frame. The quick release (arrow 3) is held into the evolution adaptor bracket so that it cannot get lost. It is always mounted on the right side (your are standing in front of the brake and facing it). 7. Mount a canti-stud U-washer on both canti-studs, flat side pointing up. Tip: to prevent losing the washers if the wheel is removed, use silicon glue to semi-permanently fix them on the studs. Fit left evolution adaptor side on the canti stud by using the 5mm allen bolt. Black elbow must block against the fork or frame! Position the brake cylinder in the adaptor bracket so that the pads are parallel to the rim. Distance rim/pad 2mm. Do not yet fully tighten the bolts. Partially screw the quick release hourglass bolt (arrow) into the canti-stud (5mm allen key). 7 Español Italiano Nederlands Français English 2. Now a few fundamentals. Please note that the slave cylinders can be adjusted in several positions in the evolution adaptor brackets before the fitting bolts and quick release are tightened (black arrows). Loosen the screws to position the slave cylinders, to either move the whole adaptor up and down (white arrows), or to move them closer to or further away from the rim. The evolution adaptor offers ample adjustment possibilities which are necessary because rim and frame dimensions can vary a lot between different bikes. Deutsch Mount the brake lever onto the handlebar. (Tightening torque 4Nm/34 in.lbs) In the following pictures the wheel is often is often not in place, this is purely to help show the details better. Mounting a MAGURA brake with the wheels in place is much simpler, for this reason, if at all possible, do not remove the wheels. www.magura.com service@magura.de 8.When installing a MAGURA on a suspension fork, some fork boosters may cause clearance problems. The suspension spacers (available as an accessory) move the adaptors forward for better clearance of the black elbows. They are installed instead of the U-washers and come with a 2mm allen set screw to fix them to the canti-studs, thereby eliminating the chance of losing one when the quick release is open. 9. Adjust the black elbow of the right adaptor side accordingly. Mount the right adaptor. Pass the quick release over the quick release screw. Position the brake cylinder in the adaptor bracket so that the pads are paral ...