JULIE 09 E St
Contents
1. WORKSHOP 2009 JULI THE PASSION PEOPLE Our disc brake range recommended use Gustav M Marta SL Magnesium 203 203 Marta SL Magnesium 180 180 Marta SL Magnesium 160 160 Marta SL 203 203 Marta SL 180 180 Marta SL 160 160 Marta 203 203 Marta 180 180 Marta 160 160 Louise 203 203 Louise 180 180 Louise 160 160 Julie HP 203 203 Julie HP 180 180 Julie HP 160 160 Ground contact isn t that important to you There is almost no terrain where a Freerider won t go Tough and stable components are amust have Here they are LA O FREERIDE Gustav M There are bikers out therefor whom uphill is just a means to an end The downhill fun is having absolute priority for them With lots of travel and robust compo nents the Enduros must cope with technically hairy downhills and bike park weekends exe ENDURO You re an all roun der You love long and sweeping trails up as well as down The optimummix of light weight and Stability is the hall mark of your All Mountain compo nents meant for abroad spectrum of use BA lt one ALL MOUNTAIN Mile after mile over the dusty trails as well ashard fast tar mac On every ride your bike shouldbe the epitome of uncomplicated and naturally the parts for your X country adventures shouldn t cost the earth u one X COUNTRY Race orientated means for us the minimum weight that is techni2. 51 in lbs 4 Install the hose as described in chapter 6 After the installation of a new hose you will always have to refill the brake The following chapter 9 describes how the filling and bleeding has to be done THE PASSION PEOPLE www magura com 9 Filling and bleeding a brake Brake Oil MAGURA disc brakes use as transmission medium low viscosity mine ral 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 regular ly 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 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 English 2 For filling and bleeding a MAGURA disc brake you will need the disc brake service kit 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 4 Remove the brake pads as described on pag
3. Front Thor 0724 131 Direct Mount 203 Postmount 8 Front Wotan Travis etc 180 Postmount 7 Front Thor no adaptor 160 Postmount 6 Front WARNING Always make sure that the fixing bolts are screwed in to a depth of at least 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 Specifications are subejct to change without prior notice Visit our website magura com for further information tech tips and free online help JI MAGURA PARTNERS AND SERVICE CENTERS WORLDWIDE Australia Steve Cramer Products phone 03 95871466 fax 03 95872018 sales stevecramerproducts com au Austria MAGURA Bike Parts Austria phone 49 7333 9626 13 fax 49 7333 9626 17 m haas magura bikeparts de Service f meder magura bikeparts de Belgium Vlaanderen gt Sales MAGURA Bike Parts Benelux phone 49 7333 9626 25 fax 49 7333 9626 17 e vandepol magura bikeparts de MAGURA Tech Support Benelux phone 31 653251836 fax 31 842208241 maguratechsupportbenelux beebikes com Belgium Wallonie Sales MAGURA Bike Parts Benelux phone 49 7333 9626 42 fax 49 7333 9626 17 s revillet magura bikeparts de MAGURA Service Center France phone 49 7333 9626 43 fax 49 7333 9626 17 s revillet magura bikeparts de VM VM VM Brasil Ciclovece World Bikes phone 55 11 3154509 marcelo cicl
4. 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 correct fun ction 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 war ranty 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 fitting screw a new one is delivered with the new pads Tightening torque 1 Nm 9 in Ibs Check the correct fitting of the pads by pul ling them The fitting bolt of the pads has to be correctly installed e g it has to go through the drills of the pad holders and then correctly screwed into the caliper 9 Re install the wheel and check for a correctly tightened quick release skewer of the wheel 10 Squeeze the lever blade several times pump to push the pads to their proper posi tion until the lever feel becomes 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 30 km h to achieve the maximum brake power Take your bike to a safe place to ru
5. 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 4 N 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 MAGURA is giving a 5 year leakproof warranty on brake levers master cylinder and brake callipers if the brake has been registered on magura com Watch out for the red info sheet in the middle of this manual leakproof WARRANTY on levers brake cylinders and calipers 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 JI 14 Spare parts 2009 max tightening torques 0720 847 Torx T7 key 0724 044 10x 0721 207 10x 0 6 Nm e 0724 155 0720 927 10x left 0724 100 right 0724 101 0720 8
6. 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 PEOPLE 3 Mounting on forks and frames that meet the International Standard Mount the calliper onto the fork or the frame bolts Al 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 correct 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 5 Remove the transport device shortly before installing the wheel and mount the wheel 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 6 Squeeze now the brake lever hold the pressure 7 Tighten the fitting bolts B Tightening torque 6 Nm 51 in lbs 8 Mounting on forks with Postmount For Postmount 6 installation in combination with a 160mm rotor Postmount 7 with 180mm rotor or Postmount 8 with a 203mm roto
7. the clock 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 THE PASSION PEOPLE www magura com 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 acci dent 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 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 simulta neously to slow your bike down 5 Use your Julie HP disc brake according o the user chart on page 2 of this manual Any misuse might cause serious accidents with fatal inj
8. 25 10x 0720 916 20x 0721 187 10x 0720 446 10x 0720 405 10x 0724 099 2 finger 2x 1 Ze Le 918 10x 4 Nm bw Ventidisc Centerlock with Lockring 203 mm 0722 572 180 mm 0722 571 160 mm 0722 570 Titanium bolt kits 1x M5x18 0737 812 6x M5x10 0737 813 2x M6x18 0737 811 Ventidisc 6 holes IS 203 mm 0722 569 180 mm 0722 568 160 mm 0722 567 0721 204 Torx key T25 0722 636 hose 250 cm 6 Nm 0721 641 braided hose 250 cm 6 Nm 0721 057 6x 4 Nm SL Rotor 6 holes IS 203 mm 0722 332 180 mm 0721 456 160 mm 0721 455 0722 421 10x SL Rotor Rohloff Speedhub 180 mm 0721 931 160 mm 0721 930 10 x 0720 848 2 5 Nm 0722 530 0722 418 Type 6 1 Performance 0722 419 Type 6 2 Endurance Specifications are subject to change without prior notice 0721 314 THE PASSION PEOPLE www magura com Adaptors for all Julie HP models d Bes N Adaptor Rotor diameter Installation Order code ET es LU Adaptor 5 203 Int Standard 6 Front 0722 321 Adaptor 6 180 Postmount 6 Front 0722 322 Adaptor 7 203 Postmount 6 Front 0722 323 Adaptor 8 203 Rockshox Boxxer 0722 324 Adaptor 9 203 Int Standard Rear 0722 325 Adaptor 10 180 Int Standard Rear 0722 424 Adaptor 11 160 Int Standard 6 Front 0722 425 203 Int Standard 8 Front Fox 40 Adaptor 12 180 Int Standard 6 Front 0722 426 160 Int Standard Rear Adaptor 26 203 Postmount 7
9. cally possible Every gram extra weight can be the decisive factor between win ning or losing for you the racer maniac r O XC RACE Marta SL Magnesium 203 203 Marta SL Magnesium 180 180 Marta SL Magnesium 160 160 Marta SL 203 203 Marta SL 180 180 H Marta SL 160 160 Marta 160 160 Marta 203 203 Marta 180 180 Louise 203 203 Louise 180 180 Louise 160 160 Julie HP 203 203 Julie HP 180 180 Julie HP 160 160 Specifications subject to change without prior notice 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 Repairs SoS ON AO OO FP WO DN Bleeding and Filling 10 The disc brake wheel 11 Accessories 12 Warranty 13 Trouble Shooting 14 Spare parts tuning adaptors WARNING 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 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 care
10. 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 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 replaced A conta minated rotor can be cleaned with MAGURA Disc cleaner dishwater or alcohol JI 11 Trouble Shooting problem reason not enough brake power brake was not run it no pressure point oil lubricants on rotor and or pads air in the system leaking systems Squealing brake badly aligned frame Paint powder coating on fitting eyelets Wheel q r skewer insuffi ciently tightened Insufficiently tightened wheel spokes contaminated brake pads carelessness contaminated rotor carelessness wheel cannot be mounted Lever blade was pulled with removed wheel rattling noise and rough dece brake pads worn holder of solution break in the brake page4 clean the rotor with warm dis hwater or alcohol replace con taminated brake pads bleeding the brake page 15 Correct transport page 5 Check hose connections and hose for leaks replace hose if necessary pages 14 15 ali
11. de Ireland Beara Bike Trading phone 064 89134 fax 064 41334 wschmidt indigo ie Israel Toy House phone 972 26718282 fax 972 26724521 sales pedalim com Italy Areab phone 0438 435550 fax 0438 439847 info areab it Japan MC International phone 06 6536 0901 fax 06 6536 0907 mcinter mx 1 alpha web ne jp Luxemburg gt Sales MAGURA Bike Parts Benelux phone 49 7333 9626 42 fax 49 7333 9626 17 s revillet magura bikeparts de gt MAGURA Service Center France phone 49 7333 9626 43 fax 49 7333 9626 17 s revillet magura bikeparts de Netherlands gt Sales MAGURA Bike Parts Benelux phone 49 7333 9626 25 fax 49 7333 9626 17 e vandepol magura bikeparts de gt MAGURA Tech Support Benelux phone 31 653251836 fax 31 842208241 maguratechsupportbenelux beebikes com New Zealand Pure Sports NZ phone 04 385 1185 chris puresports co nz gen info magura bikeparts de Norway Botolfsen phone 022 630610 fax 022 970662 info botolfsen no Poland Polsport phone 48 34 3660456 fax 48 34 3660456 biuro pol sport com Portugal LPL Artigos Desportivos phone 021 4835354 fax 021 4835362 info lpl com pt Romania DAVID SRL BIKE PARTS SHOP phone 0213356577 fax 023355948 miu_cornel yahoo co Russia Chainpower phone 7 4956850912 fax 7 4953034468 info chainpower ru Singapore MAGURA ASIA Inc phone 886 4 23163388 fax 886 4 2323154030 service magura com tw Slowakia AGF I
12. e 14 and slide the transport device as shown with its THICK END between the caliper pistons Squeeze slightly the lever blade pump to tighten the transport device It is advisable to fix the devi ce with a rubber band on the caliper 5 Fix the Heat Eater fitting of the caliper so that it points UPWARDS IUnscrew now the bleed screw with a 5 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 reservoir and more important around the brake caliper Care for a clean working environment No dirt or particles may come into the brake system JI 6 Remove ONLY the bleed plug of the reservoir with a 2 5mm Allen key that you insert into the plug before turning it slightly The reservoir cover and the membrane underneath remain on the brake lever 7 Put the second syringe of the service kit WITHOUT PLUNGER into the opened drill of the reservoir cover Push oil from the brake caliper upwards until the oil column arrives in the syring on the reservoir You will see air bubbles now 8 Now suck the oil carefully back with the filling syringe on the brake caliper Make sure that there is always enough oil in the reservoir syringe when you suck back the oil with the filling syringe You will see air bubbles again 9 Actuate in addition CAREFULLY the lever blade to chase tiny air bubbles that might hide within the system The job
13. el 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 absolutely necessary for a drag free function of your brake 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 10 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 A A Julie HP 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 the parts from the MAGURA Louise with the ones of our rim brakes or other manufacturers brakes Any misuse might cause serious accidents Never touch either the rotor or the brake calliper after long braking as this may cause serious burns THE PASSION PEOPLE www magura com 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 pist
14. fully JI English 1 Welcome to the Passion People Brake lever master cylinder MAGURA Julie HP Congratulations You have purchased a fully hydraulic MAGURA disc brake proudly Made in Germany You will be amazed at the awesome braking power and the mini mum amount of maintenance that is neces sary on our stoppers Good to know that you are not alone millions of riders world wide rely on them and every day our num bers are increasing Brake calliper and rotor MAGURA Julie HP On the fully hydraulic MAGURA disc brake system Julie HP the braking force is transmit ted 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 where two pistons on which the brake pads are fixed are pushed out The friction between 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 HP 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 thei
15. gn 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 page 12 brake pad change page 12 leration pads is wearing the rotor leaking hose or brake accident incorrect change hose or defective installation brake lever or calliper page 14 we N You will find further tips on our website www magura com in the FAQ W section or in our online forum Stay tuned THE PASSION PEOPLE www magura com 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 Order codes see on page 20 Watch out for the genuine hose with yellow MAGURA marker English Use only genuine MAGURA brake pads brake pads Performance Type 6 1 code 0722 418 series pad for maximum brake power brake pads Endurance Type 6 2 code 0722 419 with optimized longevity Use only genuine MAGURA accessories Any parts manufactured by other manufacturers like
16. is done when no air bubbles can be seen after having follo wed the steps above several times 10 Before you remove the syringe on the reservoir make sure that there is only a small quantity of oil inside Place a rag around the brake lever and the caliper thus pre venting overflowing oil from dropping down and contaminating and killing the brake pads Remove the syringe and close the end that was inserted into the reservoir quickly with your finger Empty the remaining content of the syringe into an container 11 Close the plug on the reservoir cover as shown by pressing it by hand into the drill That s it 12 Remove the filling syringe and screw in the 5mm allen bleed screw Tightening torque 2 5 Nm 22 in lbs Re install the brake pads and the wheel 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 per manent loss of brake power Contaminated pads are definitely killed and MUST be replaced A contaminated rotor can be cleaned with MAGURA brake cleaner warm dishwater or alcohol THE PASSION PEOPLE www magura com 10 The disc brake wheel 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
17. le In case of a disc brake equipped bicycle you should always keep in mind the fol lowing 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 remove 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 THE PASSION PEOPLE www magura com 5 Brake Installation 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 Always insert the allen and torx keys completely to avoid damaging the bolt heads English Unpack your Julie HP disc brake 1 brake lever master cylinder connected through the 2 brake hose with the 3 brake caliper with transport device ATTENTION 4 remove the transport device only shortly before installatio
18. n 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 JULI hp 8 Repairs Disc brake service kit Don t panic if the hose snaps With the disc brake service kit and a separately available Spare hose see spare parts pages 20 21 this can be repaired easily Julie HP is a high pressure systems 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 parts from other manufacturers Any misuse might cause serious accidents 1 Remove the damaged hose from both the brake lever and the caliper 2 Prepare a new hose Use only the reinforced MAGURA Disc Tube wearing also this imprint One end of this hose comes with a pressed fitting with blue loctite threadlock which has to be screwed into the Heat Eater as described above The hose is available with 0 and 90 fittings c f page 20 Tightening torque 6 Nm 51 in lbs Use with all Julie HP models with adjustable Heat Eater hose fitting only the hose that comes with the fitting with blue loctite threadlock arrow NEVER shorten the MAGURA Disc Tube hose at the end with the pressed fitting You could no longer use this hose then 3 Tighten the prepared end of the new hose onto the Heat Eater Tightening torque 6 Nm
19. n of the wheel 3 rotor 6 fitting bolts for rotor Torx T25 6 pieces 7 fitting bolts for caliper Allen key 5 2 pieces 8 adaptor with fitting bolts depending on model 9 hose inserts 2 pieces 10 olives 2 pieces 11 Torx T25 key 12 2mm Allen key specifications modifying and improving this product are subject to change without prior notice JI A A A A THE PASSION www magura com The brake levers and callipers of the different MAGURA disc brake models are completely different and not compatible Never mix and match parts from the 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 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 callipers can generate a lot of heat during extreme riding conditions 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 cau sed by fork and or frame components having low heat transfer characteristics e g carbon rear triangles can cause the brake to overheat with
20. ns that are included in the kit 7 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 JI 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 cause poor bra king performance with possible serious accidents As to hints about repai
21. nvest s r o phone 02 62859549 fax 02 62859052 info agfinvest sk Slowenia Maraton D O O phone 386 74990870 fax 386 74990872 maraton siol net South Africa Cycles Africa phone 011 678 1548 fax 011 678 1548 cunning mweb co za South Corea MBS Corporation phone 82 55 265 9415 fax 82 55 265 9419 kbcco kornet net Spain gt SAT MAGURA Bicisport S lo para reparaciones y servicio phone 93 3404480 fax 93 3404480 gt Bicicletas Monty phone 93 6667111 fax 93 6667112 monty monty es gt Casa Masferrer phone 93 8463444 fax 93 8465355 cmcenter casamasferrer com gt Comet phone 943 331393 fax 943 551407 comet comet es gt Representaciones Spinola amp Perez phone 619 702946 fax 93 2317731 c perez spinolaperez com Sweden Jaguarverken AB phone 060 669800 fax 060 669809 info jaguarverken se Switzerland gt Intercycle phone 41 9266511 fax 41 9266355 info intercycle com gt Amsler amp Co phone 052 6473636 fax 052 6473637 info amsler ch Taiwan MAGURA ASIA Inc phone 886 4 23163388 fax 886 4 23154030 service magura com tw USA MAGURA USA phone 6183952200 fax 6183954711 magura magurausa com www magurausa com 0689679 Printed in Germany MAGURA 2009 All rights reserved
22. ons 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 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 English 4 Put the hose on a workbench and shorten it with a sharp knife The best tool is the MAGURA cutter 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 hose squarely The sleeve nut can be reused The olive cannot be reused and must be replaced 5 Press by hand a new insert into the hose until it is fully seated Clamp the hose into the groove of the mounting device as shown 6 or clamp the mounting device as shown into a vice and hammer the insert careful ly into the hose If your frame is not equipped for routing hydraulic lines you should now mount the hose fitting kit for your rear brake according to the instructio
23. ovece com br Canada Orange Sport Supply Inc phone 604 990 5110 fax 604 990 5884 info orangesportsupply com Czech Republic Pell s phone 420 545242631 fax 420 545242634 magura pells cz Denmark Borandia APS phone 47 107172 fax 47 107066 borandia borandia dk Estonia Hawaii Express phone 06 398508 fax 06 398566 olev hawaii co nz Finland Best Brakes Ky phone 050 591 5863 fax 019 388485 info bestbrakes inet fi France gt MAGURA Bike Parts France phone 49 7333 9626 42 fax 49 7333 9626 17 s revillet magura bikeparts de gt MAGURA Service Center France phone 49 7333 9626 43 fax 49 7333 9626 17 s revillet magura bikeparts de Great Britain gt MAGURA Bike Parts UK Ltd phone 49 7333 9626 29 fax 49 7333 9626 17 d coull magura bikeparts de gt MAGURA Service Center UK phone 01530 837195 fax 01530 811286 service_uk magura de Greece Nikos Maniatopoulos phone 2610 993 045 fax 2610 990 424 aftermarket idealbikes net 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 mali mali hu THE PASSION PEOPLE Deutschland Hotline Helpdesk 41 ct pro Minute tol t glich 09 wWw magura com as MAGURA Bike Parts GmbH Phone 09001 64812 WACO 12 20 15 15 h Co KG Heinrich Ka 4 Fax 07333 96265 hn StraBe 24 D 89150 Laichin 1 Service magura
24. protect your rotors and brake pads from oil and lubricants e g by lubricating 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 contaminated 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 E 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 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 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 noi ses 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 bicy cle Consult a professional bike mechanic if you feel unsure A faulty bicycle 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 bicyc
25. r on the front you do not need an adaptor Mount the caliper DIRECTLY onto the fork with MOUNTED wheel and rotor For a better understanding the mounted wheel is not shown on this picture Do not tighten the caliper bolts yet Squeeze the lever blade and keep the pres sure Tighten now the bolts Tightening torque 6 Nm 51 in lbs Further mounting alter natives cf page 21 of this manual 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 JULI hp 9 Hose routing with the Heat Eater fitting The Heat Eater fitting of the Louise caliper allows a 45 rotation for the optimum hose rou ting without using tools Fix the hose on the fork and or frame after you have found the ideal position the Heat Eater must NOT move during compression of the fork and or frame 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 peri od 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 whe
26. r enormous power immediately after activating the brake lever Disc brakes dont t wear your rims down However if they have been mounted incorrectly they might cause a squealing noise during braking mainly during 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 Please note that the Louise brake is delivered in different versions with different rotor diameters and for different fitting alternatives for which we offer a variety of adaptors The basic installations steps remain however always the same Although the Julie HP disc brake system is relatively simple you should not over estimate your technical skills We therefore advise you to leave the following operati ons to a trained technician of a professional bike shop This manual is part of the product Do not hand over the product to third parties without this manual Technical specs are subject to change without prior notice Should there be any further questions or problems we warmly recommend you to 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 in the forum you get free support around
27. rs 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 between 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 procedure 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 THE PASSION PEOPLE www magura com 5 Remove the cotter the brake pad fitting screw with a 2mm Allen key 6 Pull out the brake pads Their ears make this very easy Clean the pads with a dry rag that is
28. the possibility 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 manufacturer also bike mechanic or end consumer is responsible for the correct function of the complete bicycle in this context Improper combinations and insuffi cient 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 tor que 4 Nm 34 in lbs The MAGURA disc brake Julie HP is compatible with frames and forks which meet the International Standard IS and for Postmount PM mounts Depending on the mounting standard and or rotor size adaptors are used for a proper installation cf table on 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 moun ting 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
29. uries to yourself 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 beco me 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 hand lebars 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 JULI hp 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
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