manual - Greenspeed
Contents
1. WORKSHOP 2002 e Deutsch e English E Nederl nds Ge e BEI Italiano Dy Espanol 2 2o TETT Ce ei 2 Rotes Garantiekarten Anforderungsblatt beachten Read red sheet and order warranty card Lisez la feuille rouge et commandez la carte de garantie S C A WWwW magura com service magura de Table of Contents 1 Introduction 3 2 Safety instructions before the first ride 4 3 Safety instructions before every ride 4 5 4 Transport of the bicycle 5 9 Brake installation 6 9 6 Shorten the hose 9 11 7 Maintenance 11 13 8 Repairs 13 15 9 Bleeding and Filling 15 16 10 Trouble Shooting 17 11 he disc brake wheel 18 12 Accessories 19 13 Warranty 19 14 Spare parts exploded view 20 21 WARNING This symbol means possible danger for your health and even life if you do not follow h the instructions given resp if the necessary safety measures are not followed l Baies you of inappropriate handling that might cause heavy damage to e the material and or the environment NOTE This symbol is giving you additional information about the general handling of the product or gives hints to paragraphs of this manual which have to be read carefully e wWww magura com service magura de 1 Welcome to the Brake People Brake lever master cylinder MAGURA Julie Congratulations You have purchased a fully hydraulic MAGURA disc brake proudly2. Torx T25 key 0721 204 Standard 6 holes 0721 001 Coda 4 holes 0721 183 standard hose 0 fitting 1600 mm 0720 826 51 in Ibs 2500 mm 0720 827 51 in Ibs braided hose 0 fitting 1700 mm 0721 203 51 in lbs 10x 0720 931 22 in lbs hubs Pro front silver 0721 146 front black 0721 153 rear silver 0721 147 rear black 0721 154 Comp front silver 0721 148 front black 0721 155 rear silver 0721 149 front 0721 572 Int Standard rear 0721 573 Int Standard 0721 324 2x TYPE 3 1 20x 0720917 0 2 mm spacer rear black 0721 156 2X 0721 057 Fun 51 in lbs front black 0721 355 rear black 0721 357 front Manitou Postmount 74 0721 314 0721 574 0721 324 2x TYPE 3 1 WWW magura com service magura de Z Z ZE mee spare parts 2002 max tightening torques Torx T7 key 0720 847 0721 207 10x 5 in Ibs 10x 0720 927 0721 305 black with 2 finger blade left 0721557 right 0721556 black with 4 finger blade 10x 0721187 left 0721 559 right Geen 34 in Ibs Ss 2x 2 finger Ee alloy silver 0721317 eo 2x 0721214 2x 4 finger alloy silver 0721318 10x 0720405 10x 0720 446 20x 0720 916 Torx screws 0721 05 7 34 in Ibs 6x Torx T25 key 0721 204 front 180mm 6 holesAnt standard 0721 621 4 holes Coda 0721 311 rear 160mm 6 holes nt standard 0721
3. braking mainly in wet weather conditions 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 to help make your new braking experience enjoyable and trouble free All steps will be explained on the Julie model Any differences with the Clara model will be clearly mentioned although the Clara and Julie disc 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 disc stoppers Happy trails wWww magura com service magura de 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 whether you activate the front brake with the brake lever which you are used to braking on the front If ever this is not
4. 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 WWwW magura com service magura de 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 P 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 6Nim 5 in lbs 11 Remove the syringe and screw in the 3mm allen bleeding screw Tightening torque 2 5Nm 22 in Ibs Re position the brake caliper tightening tor que 6Nm 51 in Ibs Re install the brake pads and the wheel Always pull the lever blade several times pump until the brake pads touch the rotor d NW Always check for correct installation by activating the lever blade and Wi 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 warm dishwater 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
5. diameter of 2mm arc 1 8mm 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 I for your wheel sets in combination with a disc brake You will not be in a positi d h on to realize the necessary tightening torque WWwW magura com service magura de 11 Trouble Shooting 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 section Stay tuned bes e reason brake was not run it oil ubricants 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 page15 Check
6. of that Tightening torque 4Nm 34 in lbs The MAGURA disc brakes Clara and Julie are compatible with frames and forks which meet the international standard IS for disc brake installation Only the front brakes are available with a special Postmount caliper 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 MAGU RA or the frame or fork s manufacturer Make sure that the caliper 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 Is able to care for the absolutely necessary even surface with the help of the MAGURA Gnann o mat disc optimizer tool also see page 9 WWwW magura com service magura de 3 Mount the caliper onto the fork or the frame Use a 5mm allen key Tightening torque 6Nm 51 in lbs 4 Only the front brakes are available with a special caliper for the so called Postmount which you find on Manitou suspension forks MAGURA does not offer rear brakes for the Postmount 5 Very often frames are not well aligned to ensure a drag free mounting of the bra kes You may have to use then the 0 2mm spacers which you should install as shown by the arrows between fitting eyelets and brake caliper See also the 3 caliper sketches on page 9 6 If you use a thru axle hub you must use thicker 3mm spacers Thes
7. release skewers might cause the fixed items to get loose Serious falls with heavy bodily injury might be the result 2 Always make sure that the brake lever pressure is ok by pulling the lever blade and ensuring that full braking performance is achieved before 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 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 15 16 wWww magura com TmT service magura de MPSS L h KE 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 Those pads are definitely killed and cannot be saved They have to be replaced Clean a contamina ted rotor with dishwater or alcohol See further hints about the brake pad change on pages 11 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 sufficiently tigh
8. the brake The following chapter 9 describes who the filling has to be done i Install the hose of your Clara as described in chapter 6 9 Filling and bleeding a brake Brake Oil MAGURA disc brakes use as transmission medium low viscosity mineral oil the biodegradable MAGURA BLOOD Contrary to DOT brake liquid the MAGURA 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 bra kes over years without having to touch them except brake pad change 1 Loosen slightly the clamping screw of the brake lever with a 5mm 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 wWww magura com service magura de 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 BLOOD mineral oil Fill the syringe completely and make sure that there are no air bubbles inside urn the syringe eventually to push out air bubbles 4 Remove the brake pads as described on page 12 and slide the YELLOW trans port device as shown with its THICK END betwe
9. the brake caliper 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 posi tion until the lever feel becomes very firm 10 Correctly mounted disc brake wheel The rotor has to run directly under the separation line of the caliper halves see arrow lf ever this is not the case re position the caliper with the 0 2mm spacers gt lt gt SS wrong wrong OK In case of a constantly dragging disc brake causing noise your frame is badly aligned In such a case you should contact your dealer who can care with the MAGURA Gnann o mat disc optimizer for a totally even surface of the disc brake mounts These are abso lutely necessary for a drag free function of your brake Do not worry when you hear friction between rotor and pads A slight drag i AN is normal on disc brakes with automatic pad wear adjustment during the break d AN in period This drag will disappear after a while The reason for this is that the d WA 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
10. 001 4 holes Coda 0721 183 standard hose 2 3m 0321 227 braided hose 0 1700mm 0721 203 10x 0720 411 34 in lbs hubs 10x 0720 931 22 in lbs Pro front silver 0721 146 front black 0721 153 rear silver 0721 147 rear black 0721 154 Comp front silver 0721 148 front black 0721 155 rear silver 0721 149 rear black 0721 156 Fun front black 0721 355 rear black 0721 357 Int Standard front rear same caliper 0721 562 20x 0720 917 0 2mm spacer 10x 0721 313 1mm spacer rearbrake 2x 0721057 51 in lbs rear 0721 563 Manitou Postmount 74 0721314 2x 0721304 TYPE 4 1 2x 0721304 TYPE 4 1 MAGURA Bike Parts GmbH amp Co Heinrich Kahn Stra e 24 D 89150 Laichingen phone 49 0 7333 9626 0 fax 49 0 7333 9626 17 info magura bikeparts de Hotline Helpdesk phone 49 0 7125 153 180 9 12 h 13 16 h CET fax 49 0 7125 153 184 service magura de MAGURA Partners and Service Centers Worldwide Andorra Esports Jorma phone 376 844133 fax 376 843022 jorma correu andornet ad Argentina Freier S r l phone 4442 3108 fax 4442 1756 esteban freier com ar Australia Velo Vita phone 02 9695 7744 fax 02 9695 7844 service velovita com au Austria Funbike phone 0662 6362450 fax 0662 6362455 funbike funbike at Belgium Transmission phone 010 244646 fax 010 244777 transmi euronet be Canada MAGURA USA phone 618 3952200 fa
11. Greece Nikos Maniatopoulos Cycles Africa phone 061 993045 phone 011 678 1548 fax 061 990424 fax 011 678 1548 idealman hol gr cunning mweb co za Hong Kong Spain Bicicletas Mont Chung Yung Cycle hone 93 phone 02670 3639 ax 9 3766 fax 02679 5602 monty mo cycc168 hkstar com Ge SC Hungary Mali Bicycle Technology phone 01 4207563 fax 01 4205321 mali mali hu Ireland Beara Bike Trading hone 943 331393 phone 064 89134 x SCH 591407 fax 064 41334 wschmidt indigo ie Israel Hobby s Ltd SE 619 702946 phone 972 52 42990 fax 93 2317731 fax 972 3 5754529 c perez es inter net yossi hobbys com SE AB Italy Race Ware 9 phone 019 680639 fax 019 680638 UY mail raceware cc Japan MC Internation phone 06 5360901 fax 06 4 907 mcinter n E ne lp Korea Park s MTE phone 0 fax 02 5 parksmth 2N Luxemburg tra 28 Netherlands Ge K o Wi Dw nline New Zealanc Zi Ground Ze KH Norway Poland Transmissi SE fax 003 244 LU 0 23 910 23 Ge Botolfsen phon 022 fax o 2 info C d Bike phone 032 23 fax 032 bikespor phone 03 5478 fa 8388 info EI o
12. Made in Germany You will be enthusiastic about the awesome braking power and the very little maintenance that is necessary on our stop pers Good to know that you are not alone millions of users worldwide rely on them and every day were becoming more Brake caliper and rotor MAGURA Julie On the fully hydraulic MAGURA disc brake systems Julie and Clara 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 caliper where two pistons on which the brake pads are fixed are pushed out The friction between the brake pads and the rotor is slowing down the bicycle and causes a heating of both the rotor and the brake caliper Never touch either the rotor or the brake caliper after long braking as this may cause serious burns You will be pleased to find out that the MAGURA Clara and 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 shortly after activating the brake lever Disc brakes do not cause a wear of your rims In case of insufficient mounting conditi ons they might however cause a squealing noise during
13. a speed of 30km 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 2mm Allen key Turning key clockwise lever blade moves away from the handlebar turning counterclockwise blade moves to the handlebar WWwW magura com service magura de 6 Shorten the hose The brake levers calipers and hoses of Julie and Clara are completely dif ferent and not compatible The Julie is a low pressure system and comes with aN the same nylon hose that is used on MAGURA rim brakes The Clara is a high d WA pressure system and comes with a reinforced hose the MAGURA Disc Tube g h W wearing also this imprint The Disc Tube needs an additional insert for a proper fitting Never mix and match either the hoses or other parts from the two models Any misuse might cause serious accidents Never touch either the rotor or the brake caliper after long braking as this may cause serious burns 1 Remove the wheel so that you have free access to the brake caliper 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 caliper pistons are fully retracted and flush with caliper body NW Never push back the pistons without the brake pads mounted Open the l AS brake system only after having pushed back fully the brake pads 2 Loosen the brake lever clamping screw with a 5mm allen k
14. about their short A W 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 possible heavy bodily injury 13 Warranty MAGURA is giving a 5 years leak proof warranty on brake levers master cylin der and brake calipers Watch out for the red order form of the warranty card in this manual and order your warranty certificate 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 shipping damages or loss purchase of full value insurance is recommended ate nat dg dt L ARA spare parts 2002 max tightening torques 2x 2 Finger 10x 0720 927 alloy silver 0721317 Torx T7 key 0720 847 2x 4 Finger alloy silver 0721318 5 in lbs 10x 0721 207 0720 958 10x 0720 825 20x 0720 916 10x 0720 446 silver with 2 finger blade left 0721567 right 0721566 14 silver with 4 finger blade 10x 0720 405 left 0721 569 10x 0721187 right Ee 10x 0720918 34 in Ibs 2x 0721 214 6x Torx screws 0721 057 34 in lbs
15. ake 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 5cm as shown Use a nylon 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 caliper Tightening torque Julie 4 Nm Clara 6 Nm WWwW magura com service magura de 5 Measure the requested length of the hose you need and shorten the hose accor dingly with a sharp knife Slide on the hose protector 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 8mm open end wrench Tightening torque 4Nm 34 in lbs 6 Fill the brake as described in chapter 9 Prepare a new hose Only Clara needs the reinforced MAGURA Disc Tube wearing also this imprint One end of this hose comes with a pressed fitting which has to be screwed into the caliper as described above Tightening torque 6Nm 51 in lbs NEVER shorten the MAGURA Disc Tube hose at the end with the pressed fitting You could no longer use this hose then After the installation of a new hose you will always have to refill
16. e are either available separately code 0720 829 or come supplied with the MAGURA Gustav M thru axle hub If necessary you might have to use here as well additional 0 2mm spacers for a clean and drag free positioning of the caliper 7 Exception Julie rear caliper Contrary to all other MAGURA disc brakes the front and rear caliper of a MAGURA Julie are identical However you must use the black lmm spacers between fitting eyelets and caliper on a Julie rear brake If necessary you might have to use here as well additional 0 2mm spacers for a clean and drag free posi tioning of the caliper 8 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 4Nm 34 in I bs 9 Remove the transport device shortly before installing the wheel 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 WWwW magura com service magura de 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
17. en the caliper pistons Squeeze slightly 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 connecting bolts of the caliper arrow are positioned horizontally It might be necessary that you have to unscrew the lower caliper fitting bolt and to fix the caliper as shown Unscrew bleeding screw with a 3mm Allen key Screw in the prepared syringe and tighten it by hand Place now a rag which has to be free of oil or lubricants around the reser voir and more important around the brake caliper Care 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 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 caliper prevents overflowing oil from dropping down and
18. ey Turn the brake lever and ensure that the reservoir is horizontal Squeeze slightly the lever blade and slide the 2mm allen key between brake lever and lever blade 3 Slide the hose protection Unscrew the sleeve nut on the brake lever with an 8mm 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 lf your frame is not equipped for routing hydraulic lines you should now mount the hose fitting kit for your rear brake according to the instructions that are included in the kit WWW magura com service magura de Hold the hose carefully so that it cannot snap away Cut the hose squarely The sleeve nut can be re used The olive and the insert only Clara cannot be re used 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 8mm open end wrench Tightening torque 4Nm 34 in lbs 6 Only Clara Press manually a new insert into the hose until it is fully seated Clamp the hose into the groove of the mounting device as shown 7 Only Clara Or clamp the mounting device as shown into a vice and hammer the insert carefully into the hose If your frame is not eq
19. holding it and checking the hose connections and reservoir cover for eventual leaks Consult a trained technician in case of leaks Leaks cause 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 Both the Clara and the Julie disc brake feature 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 Never touch either the rotor or the brake caliper after long braking as this may cause serious burns 1 Remove the wheel so that you have free access to the brake caliper 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 caliper pistons are fully retracted and flush with caliper body Never push back the pistons without the brake pads mounted 2 Remove the cotter pin that holds the brake pads 3 Pull out the brake pads Their ears make this very easy Clean the pads with a dry rag that is free of oil and grease WwWwWw magura com service magura de 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 moun ted brake pads by using the
20. hose connections and hose for leaks replace hose if necessary pages 14 15 align brake caliper with 0 2mm spacers page9 remove any paint or powder coating and care for an even contact surface without burrs page Increase tightening of or skewer and mount it on opposite side of caliper check for an evenly spoked wheel with high spoke tension brake pads must be changed clean rotor with 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 caliper page 14 You will find further tips on our website www magura com in the FAQ WWwW magura com service magura de 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 1 700mm O fitting code 0721 203 90 fitting code 0721 337 Watch out for the genuine hose with yellow MAGURA marker Use only genuine MAGURA brake pads brake pads Clara Type 3 1 left code 0721 324 brake pads Julie Type 4 1 right code 0721 304 Use only genuine MAGURA accessories Any parts manufactured by other JA manufacturers like lever blades hoses or brake pads have not been tested and JTA approved by MAGURA and consequently nothing can be said
21. models Any misuse might cause serious accidents MAGURA manufacturers these braking systems according to the valid standards and based on profound product tests Because of the large variety of forks and frames avai lable on the market it is impossible for MAGURA to test all possible combinations If you mount any of our brake systems always make sure that the brakes are in conformity with the bicycle Disc brake calipers can generate a lot of heat during extreme riding condi tions The resulting heat transfer from the caliper 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 caliper 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 fun ction of the complete bicycle in this context Improper combinations and insuf ficient installation might cause damage and serious accidents 2 Mount the brake lever to the handlebar with a 5mm allen key If you install your brake lever the first time you ll hear a crack do not worry because
22. o empty It WWwW magura com service magura de 5 Brake Installation 1 Tools for installation maintenance Allen key 2 3 and 5 transport mounting device Sharp knife 8mm open end wrench flat blade screw driver Torx T25 key Torx T7 key delivered with the brake Always insert the allen and torx keys completely to avoid damaging the bolt heads Unpack your Clara or Julie disc brake brake lever master cylinder connected through the brake hose with the brake caliper with transport device shown is International Standard version ATTENTION remove YELLOW transport device only shortly before installation of the wheel rotor diameter Clara front and rear 160mm diameter Julie front 180mm rear 160mm fitting bolts for caliper Allen key 5 2 pieces fitting bolts for rotor Torx key T25 6 pieces 0 2mm spacers 8 pieces black 1mm spacers 2 pieces only necessary for Julie rear brakes 10 hose inserts 2 pieces only necessary for Clara 11 olives 2 pieces 12 Torx T25 key 13 Allen key 2 not shown hose fitting kit for rear brake comes with all rear brakes l 2 3 GAR LO CON OD specifications modifying and improving this product are subject to change without prior notice WWwW magura com service magura de ae The brake levers calipers and hoses of Julie and Clara are completely dif SIX ferent and not compatible Never mix and match parts from the two
23. tened Also see page 9 6 Are your tires in a good condition and are they sufficiently pressurized 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 7 Pick up your bike and let it drop from a moderate height Be careful in case of any rattling noise 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 ever a proper function of the points mentioned above is not guaranteed Consult a professional bike mechanic if you feel unsu re A faulty bicycle might cause serious accidents with possible fatal injuries of the rider 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 moun ted 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 Do not transport the bike upside down For a transport in an aircraft you can leave your brake as it is e g you do not have t
24. the case you will have to train your new setup because any unintended braking might cause an accident with possible heavy bodily injury Change the hose connection by a trained technician in case of any doubts Further hints concerning the swapping of the brake hose see page 10 onwards 3 New brakes and new rotors or brake pads must always be run in by breaking at least 30 times from a speed of 30km h to achieve the maximum brake power Take your bike to a safe place to run in the brake 4 In case of extreme riding conditions total weight of bike plus rider over 100kg and or a gradient of more than 15 always use both brakes simultaneously to brake your bike down 5 Do not use the Clara and Julie disc brake for downhill sport or on tandems Any misuse might cause heavy accidents with fatal injuries for you and others 6 Are you familiar with the other components on your bike such as shifting clipless pedals and suspension units Always train the perfect handling of your bike in a safe area before using it in the public traffic 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 your clothing and footwear are suitable 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
25. transport device or a flat blade screwdriver 4 Minimum thickness of a brake pad including the holder is 2 5mm Use only genuine MAGURA brake pads Tip check the pad wear with the groove of the YELLOW transport device Pad does NOT fit to the groove picture o k Pad does fit to the groove change the pads Use only genuine MAGURA brake pads MAGURA cannot guarantee a correct 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 heavy bodily injury All warranty claims will be void in case of misuse 5 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 6 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 7 Tighten the end of the cotter pin with a screwdriver or pliers Check the cor rect fitting of the cotter pin by pulling it 8 Check whether the pistons are fully pushed back and whether the pads are flush with the caliper 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 tighte ned quick release skewer of the wheel 9 Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes
26. uipped for routing hydraulic lines you should now mount the hose fitting kit for your rear brake according to the instruc tions that are included in the kit 8 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 8mm open end wrench Tightening torque 4Nm 34 in Ibs Remove now the 2mm allen key slided between brake lever and lever blade 9 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 wWww magura com service magura de 7 Maintenance Brake Oil MAGURA disc brakes use a transmission medium low viscosity mineral oil the biodegradable MAGURA Blood Contrary to DOT brake liquid the MAGURA 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 unbelie vable 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
27. very firm New brakes and or new rotors or brake pads must always be run in by braking at least 30 times from a speed of 30km 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 Contaminated pads are definitely dead and must be replaced wWww magura com service magura de 8 Repairs 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 brake levers calipers and hoses of Julie and Clara are completely dif ferent and not compatible The Julie is a low pressure system and comes with the same nylon hose that is used on MAGURA rim brakes The Clara is a high pressure system and comes with a reinforced hose the MAGURA Disc Tube wearing also this imprint The Disc Tube needs an additional insert for a proper fitting Never mix and match either the hoses or other parts from the two models Any misuse might cause serious accidents 1 Remove the damaged hose from both the brake lever and the caliper Cut off the barbed adapter caliper 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 br
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