English - Magura
Contents
1. New brakes and or new rotors or brake pads must always be run in by braking at least 30 times from a speed of 30 km h to achieve the maximum brake power Take your bike to a safe place to run in the brake Never contaminate brake pads with oil or grease this causing permanent loss of brake power Such contaminated pads can no longer be used and should be replaced wWwww magura com the passion people 8 Repairs a s Fl disc brake service kit code 0721 294 Don t panic if the hose snaps With the disc brake service kit and a separately available spare hose see spare parts pages 21 22 this can be repaired easily The Julie is a low pressure system and comes with the same nylon hose that is used on MAGURA rim brakes Do NOT use the reinforced hose of the other disc brakes with Disc Tube label and do NOT mix and match items of different MAGURA disc brakes Any misuse might cause serious accidents 1 Remove the damaged hose from both the brake lever and the calliper Cut off the barbed adapter calliper connection with a sharp knife Slide both the sleeve nut and hose protector on the other side All mentioned parts can be re used Throw away the damaged hose 2 Prepare a new hose the nylon hose of the Julie disc brake is identical with the one of the MAGURA rim brakes Clamp the hose as shown with the help of the two clamping jaws code 0321 239 into a vice Hose has to stick out 1 5 cm as shown Use a nylo2. make this very easy Clean the pads with a dry rag that is free of oil and grease English Never squeeze the lever blade without the brake pads in place and the wheel mounted If this happened by accident push back the pistons with mounted brake pads by using the transport device or a flat blade screwdriver Use only genuine MAGURA brake pads MAGURA cannot guarantee a cor rect function of the brake if you use brake pads from other manufacturers which were not tested Using other pads might cause poor braking and cause serious injury All warranty claims will be void in case of misuse 7 Clean on the occasion of the brake pad change the brake body with a clean rag Make sure that the friction side of the new brake pads points towards the rotor 8 Secure the new pads with the new cotter pin which is delivered with the pads Check the correct fitting of the pads by pulling them 9 Tighten the end of the cotter pin with a screwdriver or pliers Check the correct fitting of the cotter pin by pulling it 10 Check whether the pistons are fully pushed back and whether the pads are flush with the calliper body Push the brake pads back with the transport device or a flat blade screwdriver as described on page Re install the wheel and check for a correctly tightened quick release skewer of the wheel 11 Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm
3. brakes Ufelmiti lm elm 2007 www magura com Italiano the PAssion people ereeride Gustav M Our disc brake range recommended use LLmountain the passion people bc countru Marta SL 180 180 Marta SL 160 160 Marta 180 180 Marta 160 160 Louise 203 203 Louise 180 180 Louise 160 160 Julie Ground contact isn t that important to you There is almost no terrain where a Freerider won t go Tough and stable components are a must have Here they are There are bikers out there for whom uphill is just a means to an end The downhill fun is having absolute priority for them With lots of travel and robust components the Enduros must cope with technically hairy downhills ans bikpark weekends You re an all rounder You love long and sweeping trails up as well as down The optimum mix of light weight and stability is the hall mark of your All Mountain components meant for a broad spectrum of use Julie 180 160 Mile after mile over the dusty trails as well as hard fast tarmac On every ride your bike should be the epitome of uncomplicated and naturally the parts for your Touring adventures shouldn t cost the earth Race orientated means for us the minimum weight that is technically possible Every gram extra weight can be the decisive factor between winning or losing for you the X country mania
4. 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 bicy cle may result in serious accidents with possible fatal injuries of the rider Be careful to check always to check the following points 4 Transport of the bicycle In case of a disc brake equipped bicycle you should always keep in mind the following points Never activate the lever blade without the brake pads in place and the wheels mounted In case this should have happened see page 10 of this manual Never throw away the transport device which has been delivered with the brake Always clip it between the brake pads whenever the wheel is removed e g transport of the bike Always carefully removed wheels Make sure that the rotors are not damaged deformed or contaminated with lubricants If the bike is transported upside down squeeze with mounted wheel or transport device the lever blade before hold pressure and fix the blade in this position with a rubber band or a cable tie During transport in an aircraft you can leave your brake as it is e g you do not have to empty it www magura com the passion people 5 Brake Inst
5. 5 Remove the transport device shortly before installing the wheel and mount the wheel 6 Squeeze now the brake lever hold the pressure and tighten the fitting bolts B Tightening torque 6 Nm 51 in Ibs If you have a Manitou fork proceed exactly in the same way but dismount the quickmount adaptor beforehand 7 However you must use the black 1 mm spacers between fitting eyelets and calli per on a Julie rear brake If necessary you might have to use here as well additional 0 2 mm spacers for a clean and drag free positioning of the calliper because frames are very often not well enough aligned The transport device prevents the brake pads from being pushed out too far by unintended lever squeeze It is impossible then to install the wheel with the rotor So never throw away the transport device Keep it and always clip it between the brake pads when the wheel is removed Install the wheel by positioning the rotor between the brake pads and fixing the wheel in the dropouts Close the quick release of your wheel which you should mount on the opposite side of the brake calliper and tighten it sufficiently As to thru axle hubs or wheels consult the manual of the respective fork manufacturer Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm wWwww magura com the passion people 8 Correctly mounted disc brake wheel In the case of a constantly draggi
6. 7333 962613 fax 49 7333 962617 m haas magura de Belgium Transmission phone 010 244646 fax 010 244777 infogtransmission be Canada MAGURA USA phone 618 3952200 fax 618 3954711 magura magurausa com Denmark Borandia APS phone 47 107172 fax 47 107066 borandiadborandia dk Finland Best Brakes Ky phone 050 591 5863 fax 019 388485 info bestbrakes inet fi MAGURA 2006 All rights reserved Printed in Germany 0689 643 08 2006 Apollo 11 Germany Heinrich Kahn Stra e 24 D 89150 Laichingen info magura bikeparts de WwW magura com France MAGURA Service Center France phone 49 7333 962643 fax 04 98106289 sav_france magura de Great Britain MAGURA Bike Parts UK Ltd phone 01530 837195 fax 01530 811286 service_uk magura de Greece Nikos Maniatopoulos phone 2610 993 045 fax 2610 990 424 amarket idealbikes gr Hong Kong MAGURA ASIA Inc phone 886 4 23283739 fax 886 4 23283734 service magura com tw Hungary Mali Bicycle Technology phone 01 4207563 fax 01 4205321 maligimali hu Ireland Beara Bike Trading phone 064 89134 fax 064 41334 wschmidtqgindigo ie Italy Areab phone 0438 435550 fax 0438 439847 info areab it Hotline Helpdesk phone 09001 648124 41 Cent pro Min fur Anrufe aus dem deutschen Festnetz fax 07333 962651 service magura de Japan MC International phone 06 6536 0901 fax 06 6536 0907 mcinter omxa alpha web ne jp Korea MAGURA ASIA Inc p
7. Postmount mounts Tuning adaptors for bigger rotors are available as well c f page 21 Never mount the brakes with adapters or brackets from other manufacturers All warranty will be void in case of any misuse Use only direct mounting parts from MAGURA or the frame or fork s manufacturer Make sure that the calliper fitting eyelets on your frame or fork are free of any paint powder coating or burrs arrows If this is not the case you should contact your dealer who will be able to clean the surfaces providing an absolutely flat even mounting surface also see page 9 ATTENTION The treatment of suspension lower legs made of magnesium might be dangerous because of corrosion Always follow the safety instructions given by the respective manufacturer Always make sure after having treated the disc brake mounts that these are protected against corrosion by using an appropriate protective paint www magura com the passion people 3 Mounting on forks and frames that meet the International Standard Mount the calliper onto the fork or the frame bolts A Use a 5 mm allen key Tightening torque 6 Nm 51 in Ibs Do not tighten yet the bolts B 4 Mount the rotor with the 6 Torx T25 bolts onto the hub Watch out for the cor rect rotation direction of the rotor laser arrow Use only new original bolts or thread lock if you use old bolts Tighten the bolts in a crossed pattern Tightening torque 4 Nm 34 in Ibs English
8. a 5 mm allen key and turn the brake lever so that the reservoir is positioned horizontal Slightly tighten the clamp screw in that position 2 For filling and bleeding a MAGURA disc brake you will need the disc brake service kit code 0721 294 including all necessary tools 3 Prepare the transparent filler tube by pushing in by hand the M6 barbed fitting Put the other end of the filler tube on the syringe and fill the syringe completely with MAGURA ROYAL BLOOD mineral oil Fill the syringe completely and make sure that there are no air bubbles inside Turn the syringe eventually to push out air bubbles wWwww magura com the passion people 4 Remove the brake pads as described on page 12 and slide the YELLOW trans port device as shown with its THICK END between the calliper pistons Squeeze slight ly the lever blade pump to tighten the transport device Only use the YELLOW trans port device for this procedure the formerly used black one is not suitable for this work 5 Fix the caliper so that the hose connection points upwards It might be neces sary that you have to unscrew the lower caliper fitting bolt and to fix the caliper as shown to ensure this vertical hose position Unscrew bleeding screw with a 3 mm Allen key Screw in the prepared syringe and tighten it with a 8 mm open end spanner Place now a rag which has to be free of oil or lubricants around the reser voir and more important around the brake calliper Ca
9. brakes and new rotors or brake pads must always be run in by braking at least 30 times from a speed of 30 km h to achieve the maximum brake power Take your bike to a safe place to run in the brake English 4 While riding in extreme riding conditions total weight of bike plus rider over 100 kg and or a gradient of more than 15 always use both brakes simultaneously to slow your bike down 5 Use your Julie disc brake according o the user chart on page 2 of this manual Any misuse might cause serious accidents with fatal injuries to yours elf and others 6 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 safe area to improve your handling abilities before using it on the road Consult the user s manual of your bike to learn more about this 7 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 befor
10. all possible combinations If you mount any of our brake systems always make sure that the brakes are in confor mity with the bicycle Disc brake callipers can generate a lot of heat during extreme riding con ditions The resulting heat transfer from the calliper to the fork and or frame can have a negative influence on the mechanical characteristics of both the fork and or the frame Insufficient heat transfer from the brake calliper to the frame and the fork caused by fork and or frame components having low heat transfer characteri stics e g carbon rear triangles can cause the brake to overheat with the pos sibility of a total failure of the brake system This can cause serious personal injury to yourself and or others With respect to product liability we remind all our users that any manufac turer also bike mechanic or end consumer is responsible for the correct function of the complete bicycle in this context Improper combinations and insufficient installation can cause damage and serious accidents 2 Mount the brake lever to the handlebar with a 5 mm allen key If you install your brake lever the first time you ll hear a crack do not worry because of that Tightening torque 4 Nm 34 in lbs The MAGURA Julie disc brake is compatible with frames and forks which meet the international standard IS for disc brake installation By dismounting the Quickmount adaptor the front brake is also compatible with Manitou forks with
11. allation 1 Tools for installation maintenance Allen key 2 3 and 5 transport mounting device sharp knife 8 mm open end wrench flat blade screw driver Torx T25 key Torx T7 key delivered with the brake the bolt heads ok a 00 0 0 Always insert the allen and torx keys completely to avoid damaging English ol ar Unpack your Julie disc brake brake lever master cylinder connected through the brake hose with the brake calliper with transport device IS Postmount with quickmount adaptor ATTENTION remove transport device only shortly before installation of the wheel rotor diameter front 180 mm rear 160 mm fitting bolts for calliper Allen key 5 2 pieces fitting bolts for rotor Torx key T25 6 pieces black 1 mm spacers 2 pieces only necessary for rear brakes olives 2 pieces 10 Torx T25 key 11 Allen key 2 mm specifications modifying and improving this product are subject to change without prior notice wWwww magura com the passion people The brake levers callipers and hoses of the different MAGURA disc brake models are completely different and not compatible Never mix and match parts from the two models Any misuse might cause serious accidents MAGURA manufacture these braking systems according to the valid standards and make many rigorous product tests Because of the large variety of forks and frames available on the market it is impossible for MAGURA to test
12. asing Brake calliper and rotor MAGURA Julie On the fully hydraulic MAGURA disc brake system Julie the braking force is trans mitted 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 pus hes the mineral oil column through the brake hose in the direction of the brake calliper where two pistons on which the brake pads are fixed are pushed out The friction bet ween the brake pads and the rotor slows down the bicycle and causes both the rotor and the brake calliper to heat up Never touch either the rotor or the brake calliper after long braking as this may cause serious burns You will be pleased to find out that the MAGURA Julie disc brakes offer a superior braking power even with little hand force applied no matter what the weather conditions should be Particularly in wet weather conditions disc brakes are much more responsive than rim brakes and transmit their enormous power immediately after activating the brake lever Disc brakes dont t wear your rims down However if they have been mounted incorrect ly they might cause a squealing noise during braking mainly during wet weather conditi ons This manual contains important information about the safe installation operation and maintenance of your MAGURA disc brake We urge you to read it carefully become familiar with its contents and follow our recommendations
13. ause poor braking performance with possible serious accidents As to hints about repairs of the hose see page 14 onwards Brake pads wear control and replacement Brake pad wear The brake pads are subject to wear due to friction bet ween rotor and pads The Julie disc brake features a fully automatic pad wear adjustment Regularly check the thickness of your brake pads and replace them if necessary Control and replacement of the brake pads 1 Squeeze the lever blade with the wheel mounted and hold the pressure 2 Check out whether the finger of the transport device fits in between the ears of the the brake pads On the picture on the left this is NOT the case the pads must be changed 3 Here the finger of the transport device fits between the ears of the brake pads The pads are still o k Remember the lever has to be pulled during this proce dure Use for this a rubber band or a cable tie Replacement of the brake pads 4 Remove the wheel so that you have free access to the brake calliper Push both brake pads back by putting the transport device or a flat blade screwdriver into the gap Move the screwdriver slowly back and forth until both calliper pistons are fully retracted and flush with calliper body Never push back the pistons without the brake pads mounted wWwww magura com the passion people 5 Remove the cotter pin that holds the brake pads 6 Pull out the brake pads Their ears
14. c WWw magura com the passion people Table of Contents Introduction Safety Instructions before the first ride Safety Instructions before every ride Transport of the bicycle Brake installation shortening the hose Maintenance 0O N O OF A W N ES Repairs 9 Bleeding and Filling 10 The disc brake wheel 11 Accessories 12 Warranty 13 Trouble Shooting 14 Spare parts tuning adaptors WARNING ATTENTION the material and or the environment NOTE PPP 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 5 6 7 10 10 11 12 13 14 15 16 17 18 18 19 20 21 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 This symbol warns you of inappropriate handling that might cause serious damage to wWwww magura com the passion people 1 Welcome to the Passion People Brake lever master cylinder MAGURA Julie Congratulations You have purchased a fully hydraulic MAGURA disc brake proud ly 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 incre
15. d AN IN 0721 831 SRI Cl calliper with pads 0721 304 2x n TYPE 4 1 Performance 0721 314 0721 684 2x TYPE 4 2 Endurance 0721 057 2x 6 Nm 51 in lbs 0721 614 10x 0721 858 10x 2 5 Nm 22 in lbs Specifications are subject to change without prior notice i WWw magura com the passion people Adaptors for all Julie models adaptor adaptor 11 adaptor 12 adaptor 14 adaptor 15 Direct mount no adaptor WARNING Always make sure that the fixing bolts are screwed in to a depth of at least rotor diameter installation 180 Int Standard 6 front 160 Int Standard rear 180 Int Standard 6 rear 210 Int Standard 6 front 1 90 Int Standard rear 210 Postmount 6 front 1 80 Postmount 6 front 8 mm This corresponds to around 8 full turns Should this not be the case longer bolts with a minimum hardness of 8 8 should be used and secured using blue Loctite help order code 0 22 425 0 22 426 0 22 453 0 22 454 Specifications are subejct to change without prior notice Visit our website magura com for further information tech tips and free online English MAGURA Bike Parts GmbH amp Co KG MAGURA Partners and Service Centers Worldwide Andorra Esports Jorma phone 376 844133 fax 376 843022 jorma correu andornet ad Australia TMO Sports phone 02 9695 7744 fax 02 9695 7844 service velovita com au Austria MAGURA Austria phone 49
16. e the lever blade touches the handlebars If this is not the case pull the lever blade several times pump until the brake pads touch the rotor Changing pressure points during a ride might be the result of having air in the brake system See hints about filling and bleeding from on pages 15 16 WWw magura com the passion people 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 reservoir cover for eventual leaks Also see page 11 4 Always protect your rotors and brake pads from oil and lubricants e g by lubri cating your chain Avoid detergents and soap on the brake pads Contaminating the pads with oil and lubricants will cause a permanent loss of braking power Such contami nated pads can no longer be used and should be replaced Clean a contaminated rotor with MAGURA disc cleaner dishwater or alcool See further hints about changing the brake pads on pages 12 13 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 relea se skewers are tightened sufficiently Also see page 9 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 rotati on might be due to damaged tires broken axles and or broken spokes
17. fo intercycle com n Amsler amp Co phone 052 6473636 fax 052 6473637 info amsler ch Taiwan MAGURA ASIA Inc phone 04 23283739 fax 04 23283734 service magura com tw USA MAGURA USA phone 6183952200 fax 6183954711 magura magurausa com www magurausa com
18. he rotor or the brake calliper after long braking as this may cause serious burns www magura com the passion people 1 Remove the wheel so that you have free access to the brake caliper Push back both brake pads by putting the transport device or a flat blade screwdriver into the gap Move the screwdriver slowly back and forth until both calliper pistons are fully retracted and flush with calliper body Never push back the pistons without the brake pads mounted Open the brake system only after having fully pushed back the brake pads 2 Loosen the brake lever clamping screw with a 5 mm allen key Turn the brake lever and ensure that the reservoir is horizontal Squeeze slightly the lever blade and slide the 2 mm allen key between brake lever and lever blade English 3 Slide the hose protection Unscrew the sleeve nut on the brake lever with an 8 mm open end wrench and pull the hose out carefully Hold the hose carefully to avoid any loss of oil Do not squeeze the lever blade with the system open 4 Put the hose on a workbench and shorten it with a sharp knife The best tool is the MAGURA cutter code 0321 233 Do not use saws or pliers If your frame is not equipped for routing hydraulic lines you should now mount the hose fitting kit available as separate accessory see magura com for your rear brake according to the instructions that are included in the kit Hold the hose carefully so that it cannot snap away Cut the ho
19. hone 886 4 23106839 fax 4886 4 23283734 service magura com tw Latvia SIA ELKOR STILS phone 371 7070750 fax 371 7070456 sport elkor lv Luxemburg MAGURA Service Center France phone 49 7333 962643 fax 33 4 98106289 sav_france magura de Netherlands MAGURA Nederlands phone 49 7333 962614 fax 49 7333 962617 c uhl magura de Norway Botolfsen phone 022 630610 fax 022 970662 info botolfsen no Portugal LPL Artigos Desportivos phone 021 4835354 fax 021 4835362 lol netcabo pt Singapore MAGURA ASIA Inc phone 886 4 23283739 fax 886 4 23283734 service magura com tw Slowenia Maraton D O O phone 386 0 74990870 fax 386 0 74990872 maraton siol net Slowakia AGF Invest s r o phone 02 62859549 fax 02 62859052 info agfinvest sk South Africa Cycles Africa phone 011 678 1548 fax 011 678 1548 cunning mweb co za Spain n SAT MAGURA Bicisport S lo para reparaciones y servicio phone 93 3404480 fax 93 3404480 n Bicicletas Monty phone 93 6667111 fax 93 6667112 monty monty es n Casa Masferrer phone 93 8463444 fax 93 8465355 cmcenter casamasferrer com n Comet phone 943 331393 fax 943 551407 comet comet es n Representaciones Spinola amp Perez phone 619 702946 fax 93 2317731 c perez spinolaperez com the PAssion people Sweden Jaguarverken AB phone 060 669800 fax 060 669809 info jaguarverken se Switzerland n Intercycle phone 041 9266511 fax 041 9266355 in
20. inge and screw in the 3mm allen bleeding screw Tightening torque 2 5 Nm 22 in lbs Re position the brake calliper tightening torque 6 Nm 51 in Ibs Re install the brake pads and the wheel English Always pull the lever blade several times pump until the brake pads touch the rotor Always check for correct installation by activating the lever blade and checking for eventual leaks Never contaminate brake pads with oil or grease this causing permanent loss of brake power Contaminated pads are definitely dead and must be repla ced A contaminated rotor can be cleaned with MAGURA Disc cleaner dishwa ter or alcohol 10 The disc brake wheel The XC disc brake wheel There already exists enough literature concerning wheels so just a few tips how a well built X country disc brake wheel has to be Use spokes with a diameter of 2 mm arc 1 8 mm which you cross three times No radial lacing with disc brake wheels Head inside spokes arc outside spokes have to be pulled i e these spokes point for ward on the front wheel on the back wheel these spokes point forward on the rotor side and backwards on the drive side All spokes have to be stressed equally and high Never use ultra lightweight quick releases with titanium or aluminum axles for your wheel sets in combination with a disc brake You will not be in a position to realize the necessary tightening torque WWw magura com the passion people 11 Trouble Sh
21. ke callipers if the brake has been registered on magura com 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 WWw magura com the passion people 14 Spare parts 2007 max tightening torques 0720 847 Torx T7 key 0721 770 0721 207 10x 0720 916 20x 0 6 Nm 5 in Ibs 0720 446 10x 0720 927 10x 4 Nm 34 in lbs 0720 405 10x ec Y S18 D 0721 857 2 Finger 2x 0721 318 4 Finger 2x oo gj of ayn _ left 0721 618 ight 0721 617 0720 918 10x is 4 Nm 34 in lbs 0721 187 10x SL rotors ji 210 mm 0721 830 HI 190 mm 0721 649 180 mm 0721 456 160 mm 0721 455 c y gt 0721 204 Torx T25 key up 0721 057 6x 4 Nm 34 in lbs 0720 411 10x ET E SNC SA 4 Nm 34 in lbs Adaptors c f next page ICM CU 6 Nnm 51 in lbs 6 Nm 51 in lbs I
22. n mallet to tap the barbed adapter carefully into the hose The barbed a dapter must be installed as shown Never heat up the hose to install the barbed adapter This might cause the hose to burst with total failure of the complete brake system 3 Correctly installed barbed adapter 4 Tighten the prepared end of the new hose onto the calliper Tightening torque 4 Nm 34 in lbs www magura com the passion people 5 Measure the requested length of the hose you need and shorten the hose accordingly with a sharp knife Slide on the hose protector sleeve nut and a new olive onto the hose Push the hose with the new olive fully into the brake lever and tighten the sleeve nut with an 8 mm open end wrench Tightening torque 4 Nm 34 in lbs After the installation of a new hose you will always have to refill the brake The following chapter 9 describes who the filling has to be done English 9 Filling and bleeding a brake Brake Oil MAGURA disc brakes use as transmission medium low viscosity mineral oil the biodegradable MAGURA ROYAL BLOOD Contrary to DOT brake fluid the MAGURA ROYAL BLOOD does not irritate human skin or strip the paint of your frame Moreover it does not absorb water like DOT and does not have to be changed regularly What sounds unbelievable is a fact you can use your brakes over years without having to touch them except brake pad change 1 Loosen slightly the clamping screw of the brake lever with
23. ng disc brake causing noise your frame could be miss aligned In such a case you should contact your dealer who can care to this with the MAGURA Gnann o mat disc optimizer for a totally even surface of the disc brake mounts These are absolutely necessary for a drag free function of your brake Do not worry when you hear friction between rotor and pads A slight drag is normal on disc brakes with automatic pad wear adjustment during the break in period This drag will disappear after a while The reason for this is that the brake pads find their optimum working position towards the rotor only after a slight wear during the break in period Slight drag might also happen after a brake pad change or in case of an incorrectly installed wheel New brakes and or new rotors or brake pads must always be run in by breaking at least 30 times from a speed of 30 km h to achieve the maximum brake power Take your bike to a safe place to run in the brake Reach adjust is done with a 2 mm Allen key Turning key clockwise lever blade moves away from the handlebar turning counterclockwise blade moves to the handlebar 6 Shorten the hose The Julie is a low pressure system and comes with the same nylon hose that is used on MAGURA rim brakes Do NOT use the reinforced hose of the other disc brakes with Disc Tube imprint and do NOT mix and match items of different MAGURA disc brakes Any misuse might cause serious accidents Never touch either t
24. ooting problem not enough brake power no pressure point Squealing brake contaminated brake pads contaminated rotor wheel cannot be mounted rattling noise and rough deceleration leaking hose or brake reason brake was not run it oil lubricants on rotor and or pads air in the system leaking systems badly aligned frame Paint powder coating on fitting eyelets Wheel g r skewer insuffi ciently tightened Insufficiently tightened wheel spokes carelessness carelessness Lever blade was pulled with removed wheel brake pads worn holder of pads is wearing the rotor accident incorrect installation solution break in the brake page4 clean the rotor with warm dishwater or alcohol replace contaminated brake pads bleeding the brake pagel 5 Correct transport page 5 Check hose connections and hose for leaks replace hose if necessary pages 14 15 align brake calliper with 0 2mm spacers page 9 remove any paint or powder coating and care for an even contact surface without burrs page Increase tightening of q r skewer and mount it on opposite side of calliper check for an evenly spoked wheel with high spoke tension brake pads must be changed clean rotor with MAGURA Disc cleaner dish water or alcohol Push back the brake pads with transport device or a flat blade screwdriver pagel 2 brake pad change page 12 change hose or defective brake lever or calli
25. per page 14 You will find further tips on our website www magura com in the FAQ section or in our online forum Stay tuned www magura com the passion people 12 Accessories MAGURA disc brake service kit code 0721 294 contains everything that you need for bleeding and repairing a brake ATTENTION the kit does NOT include a spare hose MAGURA braided hose for all MAGURA disc brakes easily shortened with a cable cutter 17 00 mm O fitting code 0721 203 90 fitting code 0721 337 p Watch out for the genuine hose with yellow MAGURA marker of c Use only genuine MAGURA brake pads LLI brake pads Performance Type 4 1 code 0721 304 series pad for maximum brake power brake pads Endurance Type 4 2 code 0721 684 series pad for maximum brake power Use only genuine MAGURA accessories Any parts manufactured by other manufacturers like lever blades hoses or brake pads have not been tested and approved by MAGURA and consequently nothing can be said about their short and long term function Never use those parts All warranty and product liability claims will be void in case of misuse Never change the paint the finish or the consistence of your brake This might cause total failure of the whole system with serious consequences for your health 13 Warranty leakproof WARRANTY on levers brake cylinders and calipers MAGURA is giving a 5 year leakproof warranty on brake levers master cylinder and bra
26. re for a clean working environment No dirt or particles may come into the brake system 6 Unscrew the Torx T7 reservoir cover screw and remove the cover with the mem brane sitting below Begin to slowly press the oil contents of the filling syringe through the system until no further air bubbles can be seen 7 Press the MAGURA ROYAL BLOOD oil through the system Use a second syringe to suck any overflowing oil at the reservoir Then pull the filler syringe to suck oil back Repeat procedure 3 4 times and actuate CAREFULLY the lever blade simultaneously Make sure that there is always enough oil in the reservoir when you suck the oil with the filling syringe 8 Use the second syringe to suck any overflowing oil The rag around the brake lever and the calliper prevents overflowing oil from dropping down and contaminating and killing the brake pads Push the complete contents of the filling syringe through the system 9 The reservoir has to be full to the top before replacing the membrane and the cover www magura com the passion people 10 Replace the cover with the membrane onto the reservoir Oil will spill during this procedure therefore do not forget to place a rag around the brake lever Tighten the cover screw until the cover is flush with the reservoir Use only the original Torx T7 bolt Any other screw will lead to leaks damages and failure of the whole system Tightening torque 0 6 Nm 5 in lbs 11 Remove the syr
27. se squarely The sleeve nut can be reused The olive cannot be reused and must be replaced 5 Slide on the sleeve nut and a new olive onto the hose Push the hose with the sleeve nut and the new olive fully into the brake lever and tighten the sleeve nut with an 8 mm open end wrench Tightening torque 4 Nm 34 in lbs 6 Always check for correct installation by pulling on the hose Make sure that the system has no leaks Squeeze the lever blade hold pressure and check hose connections and the reservoir cover for eventual leaks Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm If you cannot realize this bleed the brake see page 15 onwards WWw magura com the passion people 7 Maintenance Brake Oil MAGURA disc brakes use a transmission medium low viscosity mineral oil the biodegradable MAGURA ROYAL BLOOD Contrary to DOT brake fluid the MAGURA ROYAL BLOOD does not irritate human skin or strip the paint of your frame Moreover it does not absorb water like DOT and does not have to be changed regularly What sounds unbelievable is a fact you can use your brakes over years without having to touch them except brake pad change 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 reservoir cover for eventual leaks Consult a trained technician in case of leaks Leaks c
28. to help make your new braking experience enjoyable and trouble free Although the Julie disc brake system Is relatively simple you should not overestimate your technical skills We therefore advise you to leave the follo wing operations to a trained technician of a professional bike shop Should there be any further questions or problems we warmly recommend that you visit our website www magura com where you will always find the newest and hottest tips about all our products On magura com you can also download this manual in a convenient A4 format Stay tuned with the Passion People Thank you for your confidence in our products enjoy your ride and your new MAGURA disc stoppers Happy trails www magura com the passion people 2 Before the first ride 1 Are you already familiar with hydraulic disc brakes Our brakes might be much more powerful than the stoppers on which you relied on 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 fornt brake is still actuated by the lever on the side your are used to braking with Should this not be the case you wil 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 swapping of the brake hose see page 10 onwards 3 New
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