English
Contents
1. 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 Dismount the caliper from the caliper holder by unscrewing the 3 mm Allen screw and slide off the caliper 2 Push fully back the two pistons by placing large water pump pliers on both sides of the brake pads arrows Use a rag to avoid surface damages of the caliper body Never push back the pistons without the brake pads mounted 3 Remove the brake pad fitting screw with a 2 mm allen key 4 Pull out the brake pads Clean the pads with a dry rag that is free of oil and grease www magura com t the passion people Jj 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 transport device or a flat blade screwdriver 5 Minimum thickness of a brake pad including the holder is 2 5 mm 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 English 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 poor2. 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 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 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 WWw magura com the passion people 6 Shorten the hose Gustav M is a high pressure system and comes with a reinforced hose the MAGURA Disc Tube which will show this label The Disc Tube needs an additio nal insert for a proper fitting Never mix and match either the hoses or other parts from the other MAGURA disc brake 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 Put the transport device between the brake pads and pump with the lever blade until you have a firm feel This squeezes the transport device firmly The brake system should only be opened after having squeezed the trans port device as described above 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 m
3. tightening torques 0720 927 2X 4 Finger 0721 318 2X 2 Finger 0721 317 2x 0721 214 2x standard hose 90 0720 824 2500 mm braided hose 90 0721 337 1700 mm 0721 641 2500 mm 0720 829 10x 3 mm Spacer for thru axle hub 0721 057 6 Nm 0720 828 10x 1 Nm Specifications are subject to change without prior notice 0721 000 10x 0 6 Nm 0720 958 0720 918 10x max 4 Nm left 0721 657 right 0721 658 0720 825 10x 0720 916 20x 0720 446 10x 4 Nm 0720 405 10x 0720 849 10x 6 Nm 0720 424 20x standard hose 0 0720 827 2500 mm 6 Nm braided hose 0 0721 203 1700 mm 6 Nm 51 in lbs 0721 386 2500 mm 6 Nm 51 in lbs 0720 917 0 2 mm spacer 20x 0720 848 10x 6 Nm 51 in Ibs 0721 359 10x 3 Nm 26 in lbs 0721 041 2X heat plugs 0721 043 TYPE 1 1 Performance 0721 018 TYPE 1 2 Endurance 0721 205 Www magura com Tg the passion people JJ caliper holder front int Standard 190 mm rotor 0721 210 Rockshox Boxxer 190 mm rotor 0721 212 caliper holder rear Manitou Postmount 74 6 190 mm rotor 0721 379 int Standard 160 mm rotor 0721 211 int Standard 210 mm rotor 0721 395 int Standard 190 mm rotor 0721 395 Rockshox Boxxer 210 mm rotor 0721 644 Manitou Postmont 74 6 210 mm rotor 0721 645 Marzocchi Monster 21
4. 0 mm rotor 0721 604 Manitou Dorado 210 mm rotor 0721 856 SL Rotoren Fox 40 210 mm rotor 0721 996 frontu T9 mm 0721 649 front 210 mm 0721 830 tz rear 160 mm 0721 455 i rear 190 mm 0721 649 cn 6x 4 Nm 0721 057 Z Torx T25 key 0721 204 LLI 0721 041 2x ee heat plugs caliper with pads BO UG 4 0721 205 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 MAGURA Bike Parts GmbH amp Co KG MAGURA Partners and Service Centers Worldwide Andorra Esports Jorma phone 376 844133 fax 376 843022 jorma pcorreu andornet ad Australia TMO Sports phone 02 9695 7744 fax 02 9695 7844 service velovita com au Austria MAGURA Service Center Austria phone 0662 643703 fax 0662 643802 service_austria magura de Belgium Transmission phone 010 244646 fax 010 244777 infogxtransmission be Canada MAGURA USA phone 618 3952200 fax 618 3954711 magura magurausa com Czech Republic Sport 04 phone 0312 698016 fax 0312 698025 info scottsports cz Denmark Borandia APS phone 47 107172 fax 47 107066 borandiagQborandia dk MAGURA 2005 All rights reserved Printed in Germany 0689 614 06 2005 Apollo 11 Germany Heinrich Kahn Stra e 24 D 89150 Laichingen info magu
5. 6 Nm 51 in lbs 4 The front brake is also available in a version for the Manitou Postmount which you find on Manitou suspension forks All available Gustav M versions on magura com All caliper holders are also available as separate spares c f spare parts list on page 22 5 Very often frames are not well enough aligned to ensure a drag free mounting of the brakes You may then have to use the 0 2mm spacers which you should install as shown by the arrows between fitting eyelets and brake caliper See also the 2 caliper sketches on page 9 6 If you use a thru axle hub you must use thicker 3 mm spacers These 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 additional 0 2 mm spacers for a clean and drag free positioning of the caliper 7 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 lbs 8 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
6. K END between the caliper pistons Squeeze slightly the lever blade pump to tighten the transport device Only use the YELLOW transport device for this procedure the formerly used black one is not suitable for this work 5 Fix the caliper so that the hose connection is at the highest point of the caliper hose has to be positioned vertically It might be necessary that you have to unscrew a caliper holder fitting bolt to realize this properly e g on rearbrakes Unscrew bleeding 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 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 www magura com the passion people 6 Unscrew the Torx T7 reservoir cover screws and remove the cover with the membrane 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
7. Ujela oti lele Www magura com Gus Italiano the passion people e go OL un LLI WWw magura com the passion people Summary Introduction Safety Instructions before the first ride Safety Instructions before every ride Transport of the bicycle Brake Installation Shortening the hose Maintenance Repairs O OO N DO GI A ONB Bleeding and Filling 10 Trouble Shooting 11 The disc brake wheel 12 Accessories 13 Warranty 14 Spare parts exploded view WARNING 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 carefully www magura com PO 4 the passion people Jj 1 Welcome to the Passion People 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 increa
8. aks 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 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 check and 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 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 Marta disc brake features a fully automatic pad wear adjustment Regularly check the thickness of your brake pads and replace them if necessary
9. braking and cause heavy bodily injury All warranty claims will be void in case of misuse 6 Clean on the occasion of the brake pad change the brake body with a clean rag 7 Mount the new brake pads Make sure that the heat plugs are correctly mounted in the pistons picture Clamp the spring separating the pads between the new brake pads position them in the caliper and mount the fitting screw Tightening torque of the fitting screw 1 Nm 9 in Ibs Make sure that the friction side of the new brake pads points towards the rotor Check after installation the correct fitting of the pads by pulling them 8 Slide the caliper onto the caliper holder and tighten the 3mm allen screw Tightening torque of the fitting screw 3 Nm 26 in lbs Re install the wheel and check for a correctly tightened quick release skewer of the wheel that should be mounted on the opposite side of the caliper 9 Squeeze the lever blade several times pump to push the pads to their proper position 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 run in the brake Never contaminate brake pads with oil or grease this causing permanent loss of brake power Contaminated pads are definitely killed and must be replaced WWw magura com the passion people 8 Repairs Disc brake serv
10. e The following chapter 9 describes how the filling has to be done www magura com 04 the passion people Jj 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 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 servi ce kit Code 0721 294 including all necessary tools 3 Prepare the transparent filler tube by pushing in by hand the M6 barbed fitting on which you have mounted an O ring before 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 and the heatplugs as described on page 12 and slide the YELLOW transport device as shown with its THIC
11. ent versions There are versions for frames and forks which meet the International Standard IS for disc brake installation We also offer front brake versions with special cali per holders for the Manitou Postmount PM and others see exploded view All versions on magura com 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 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 ATTENTION The treatment of suspension fork 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 Mount the caliper holder on the caliper with a 3 mm Allen key Please follow carefully the mounting instructions that come with the respective caliper holder Tightening torque 3 Nm 26 in Ibs Mount now the caliper onto the fork or the frame Use a 5 mm allen key Tightening torque
12. ere already exists enough literature concerning wheels so just a few tips how a well built downhill disc brake wheel has to be Use spokes with a diameter of 2 34 mm arc 2 0 mm e g DT ALPINE 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 forward 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 Mount the quick release of the wheel on the opposite side of the caliper English 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 positi on to realize the necessary tightening torque wWwww magura com the passion people 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 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 i
13. genuine MAGURA brake pads LLI brake pads Gustav M PERFORMANCE Type 1 1 code 0721 340 for maximum brake power brake pads Gustav M ENDURANCE Type 1 2 code 0721 018 series pad with optimized longevity 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 possible serious injury 13 Warranty TCNEN MAGURA is giving a 5 year leakproof warranty on brake levers master ur cylinder and brake calipers Watch out for the red info sheet in the middle of this and calipers 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 2006 max
14. ice 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 Gustav M is a high pressure system and comes with a reinforced hose the MAGURA Disc Tube which will show this label The Disc Tube needs an additional insert for a proper fitting Never mix and match either the hoses or other parts from the other MAGURA disc brake 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 ao O b 0 2 Prepare a new hose Use only the reinforced MAGURA Disc Tube hose One end this hose comes with a pressed fitting 90 or 0 which has to be screwed into the caliper as described above Tightening torque 6 Nm 51 in lbs Never shorten this hose at the end with the pressed fitting You could no longer use the hose then 3 Tighten the prepared end of the new hose with O fitting onto the caliper Tightening torque 6 Nm 51 in lbs 4 Hose with a 90 fitting do not forget the washer between bolthead and fitting arrow 5 Mount the brake hose as described in chapter 6 After the installation of a new hose you will always have to refill the brak
15. ion and have they enough air pressure Test this with your fingers Lift up your bike and turn the wheels of your bike An insufficient rotation might be due to damaged tires broken axles and or broken spokes 7 Pick up your bike and let it drop from a moderate height Listen for any rattling noises If any are heard check the bearings and all screwed connections 8 Always follow the instructions given in the owner s manual of your bicycle Never use your bicycle if any of the points mentioned above relate to your bicycle Consult a professional bike mechanic if you feel unsure about this A faulty bicycle may result in serious accidents with possible fatal injuries to 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 with discs 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 remove carefully the wheels Make sure that the rotors are not damaged deformed or contaminated with lubricants If the bike is transported upside down squeeze the lever blade before hold pressure and fix the lever blade in this position with a rubber band or a cable tie During transpo
16. is removed www magura com UN the passion people Jj 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 posi tion until the lever feel becomes very firm 9 Correctly mounted disc brake wheel English The rotor has to run directly between the brake pads for a drag free function If ever this is not the case re position the caliper with the 0 2 mm spacers O K wrong Do not worry when you hear friction between rotor and pads A slight drag is normal with the floating caliper system of a Gustav M This does not influen ce the function and the power of your disc brake Nevertheless your wheel should spin freely at least ten times after being pushed by hand Note a slight drag might also happen after a brake pad change or in case of an incorrectly installed wheel In the case of a constantly dragging disc brake causing noise your frame or fork 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
17. m 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 for your rear brake according to the instructions that are included in the kit www magura com UN the passion people Jj Hold the hose carefully so that it cannot snap away arrow Cut the hose squarely The sleeve nut can be re used The olive and the insert cannot be reused and must be replaced 5 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 6 or clamp the mounting device as shown into a vice and hammer the insert carefully into the hose If your frame is not equipped for routing hydraulic hoses you should now mount the hose fitting kit for your rear brake according to the instructions that are included in the kit English 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 Ibs 8 Always check for correct installation by pulling on the hose Make sure that the system has no le
18. nly 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 Although the Gustav M disc brake system is relatively simple you should not overestimate your technical skills We therefore advise you to leave the following 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 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 so far Take your bicycle to a safe area to learn the proper braking technique and operation of your new brakes and your bike 2 Check that the front brake is still actuated by the lever on the side you are used to braking with Should this not be the case you will have to train to your new setup otherwise any unintended front wheel manoeuvre may cause an accident leading
19. o become loose Serious accidents with severy injury might result 2 Always make sure that the brake lever pressure is o k by pulling he 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 Changing pressure points during a ride might be the result of having air in the brake system See hints about about filling and bleeding on pages 15 16 www magura com PO 4 the passion people Jj 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 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 dishwater or alcohol See further hints about changing the brake pad change on pages 11 13 5 Release your brake lever and check whether your wheel moves freely and with out drag Check eventually whether the wheels are correctly mounted and if the quick release skewers are tightened sufficiently Also see page 9 English 6 Are your tires in a good condit
20. ra bikeparts de WWW Magura com Finland Best Brakes Ky phone 050 591 5863 fax 019 388485 info bestbrakes inet fi France MAGURA Service Center France phone 0825 886295 indigo fax 03 81 88 49 92 sav_france magura de Great Britain MAGURA Bike Parts UK Ltd phone 01530 837195 fax 01530 811286 service_uk magura de Greece Nikos Maniatopoulos S A phone 2610 993 045 fax 2610 990 424 amarket idealbikes gr Hong Kong MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw Hungary Mali Bicycle Technology phone 01 4207563 fax 01 4205321 mali mali hu Ireland Beara Bike Trading phone 064 89134 fax 064 41334 wschmidtqgindigo ie Hotline Helpdesk phone 0190 648124 41 ct pro Minute aus dem deutschen Festnetz werktaglich von 9 bis 15h fax 07333 962651 service magura de Italy Areab phone 0438 435550 fax 0438 439847 info areab it Japan MC International phone 06 6536 0901 fax 06 6536 0907 mcinter mx1 alpha web ne jp Korea MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw Lativa SIA ELKOR STILS phone 371 7070750 fax 371 7070456 sport elkor lv Luxemburg Transmission phone 32 10 244646 fax 32 10 244777 info transmission be Netherlands NZ Parts phone 010 2340468 fax 010 2340824 nzparts tiscali nl Norway Botolfsen phone 022 630610 fax 022 970662 info botolfsen no Portugal LPL Artigos Desporti
21. riety 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 con formity with the bicycle Disc brake calipers can generate a lot of heat during extreme riding con ditions 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 English 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 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 Tightening torque 4 Nm 34 in lbs Hint Tighten the brake lever so that it can still rotate around the handlebar in case of a crash This old motocross trick will reduce considerably the risk of a damaged brake lever The MAGURA disc brake Gustav M is available in differ
22. rt 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 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 Unpack your Gustav M disc brake brake lever master cylinder connected through the brake hose with the brake calliper with transport device calliper holder with fitting bolt ATTENTION remove YELLOW transport device only shortly before installation of the wheel rotor fitting bolts for caliper Allen key 5 2 pieces fitting bolts for rotor Torx key T25 6 pieces 0 2 mm spacers 8 pieces 10 hose inserts 2 pieces 11 olives 2 pieces 12 Torx T25 key 13 Allen key 2 ees Does OND Specifications modifying and improving this product are subject to change without prior notice www magura com I 4 the passion people JJ The brake levers calipers and hoses of the different MAGURA disc brake models are completely different and not compatible Never mix and match parts from the different 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 va
23. s 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 correct transport page 5 Check hose connections and hose for leaks replace hose if necessary pages 14 15 align brake caliper with 0 2 mm spacers page9 remove any paint or powder coating and care for an even contact surface without burrs page 7 Increase tightening of q r 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 pagel2 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 section Stay tuned www magura com WE Ol DU the passion people Jl ipi 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 1700 mm 2500 mm 0 fitting code 0721 203 code 0721 386 90 fitting code 0721 337 code 0721 641 Watch out for the genuine hose with yellow MAGURA marker anni A Use only
24. sing Brake lever master cylinder Brake caliper and rotor MAGURA Gustav M MAGURA Gustav M On the fully hydraulic MAGURA disc brake system Gustav M the braking force is transmitted to the braking surface by a mineral oil column The movement of the lever blade moves a piston which is integrated in the brake lever master cylinder The piston pushes the mineral oil column through the brake hose in the direction of the brake calliper where two pistons sitting one beside the other on which the outer brake pad is fixed are pushed out Once the outer pad touches the rotor the caliper is moved horizontally outwards on two guides floating design and presses also the inner pad against the rotor The friction between the brake pads and the rotor slows down the bicycle and causes both the rotor and the brake caliper to heat up English 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 Gustav M disc brake offers a super ior braking power even with little hand force applied no matter what the weather conditi ons should be Particularly in wet weather conditions disc brakes are much more respon sive 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 braking mai
25. suck any overflowing oil The rag around the brake lever and the caliper prevents overflowing oil from dropping down and contaminating and killing the brake pads Push the complete contents of the filing syringe through the system 9 The reservoir has to be full to the top before replacing the membrane and the cover 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 screws 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 syringe and screw in the bmm allen bleeding screw Tightening torque 6 Nm 51 in lbs Remove the transport device re install the heatplugs brake pads mount the caliper on the caliper holder the the wheel that s it 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 can no longer be used and should be replaced A contaminated rotor can be cleaned with warm dishwater or alcohol Www magura com Tg the passion people JJ 10 The disc brake wheel The downhill disc brake wheel Th
26. 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 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 The Gustav M is the ONLY MAGURA disc brake for which we give green light for downhill competition or tandem use Never overestimate your skills and respect other riders Always brake down your bike with both brakes 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 the 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 t
27. vos phone 021 4835354 fax 021 4835362 lol netcabo pt Singapore MAGURA ASIA Inc phone 886 4 23106839 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 m SAT MAGURA Bicisport S lo para reparaciones y servicio phone 93 3404480 fax 93 3404480 m Bicicletas Monty phone 93 6667111 fax 93 6667112 monty monty es m Casa Masferrer phone 93 8463444 fax 93 8465355 cmcenter casamasferrer com m Comet phone 943 331393 fax 943 551407 comet comet es m Representaciones Spinola amp Perez phone 619 702946 fax 93 2317731 c perez spinolaperez com tne PrAssion people Sweden Jaguarverken AB phone 060 669800 fax 060 669809 info jaguarverken se Switzerland m Intercycle phone 041 9266511 fax 041 9266355 info intercycle com m Amsler amp Co phone 052 6473636 fax 052 6473637 info amsler ch Taiwan MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw USA MAGURA USA phone 6183952200 fax 6183954711 magura magurausa com www magurausa com
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