Single Piston Hydraulic Brake Installation and
Contents
1. fatal injuries There are 3 different types of caliper Be sure to follow the instructions specific to your type International Standard International Standard 74mm Caliper Front Caliper Rear Caliper Warning When following any of the procedures below be sure to keep your hands and fingers from getting caught in the disc Failure to do so could result in injury A Tools Required Screwdrivers Torx T25 driver Torque Wrench Allen Drivers 2mm 4mm 5mm Pliers Needle Nose B Torque Requirements Disc Screws 50 5 in lbs 5 65 55 Nm Handle Bar Master Cylinder Clamp Screw 30 35 In lbs_ 3 39 3 95 Nm Caliper Bleeder 2 0 in lbs 23 Nm Torque to Seal Do not Over torque Caliper Mount Bolts 80 5 in lbs 9 04 55 Nm Hose Connections 60 5 in lbs 6 78 55 Nm C Mounting the Disc to the Hub Note Mounting the brake disc to the wheel is a simple matter but one that requires care If the wheel has to be rebuilt have it done by a qualified technician using a 3 cross spoke pattern We recommend the use of a steel quick release skewers only Te Clean the disc and hub mounting surface with isopropyl alcohol not disc brake cleaners 2 Place the disc on the hub mounting surface Be sure that the arrow on the disc is pointing 1 in the same direction of the forward wheel rotation 6 4 3 Using a Torx T25 driver install tighten and torque the disc screws to D 55 in lb 6 2Nm in a star patter2. C Hose Removal and Assembly The follow procedures are to be used when replacing or removing the hose Master Cylinder and Caliper hose Removal 1 To take the hose off of the master cylinder end slide the hose support down the hose 2 Using a 8mm box wrench remove the hose nut and slide it all the way down the hose Note sometimes it is best to first cut the hose and used the box end of the 8mm wrench to better grab the 8mm hose nut 3 Slide the hose off the end of the master cylinder caliper There will be some residual fluid in the hose and master cylinder caliper Be careful to avoid spilling that fluid 4 A new compression bushing and hose insert will be needed each time the hose is re installed Remove the old compression bushing and hose insert by cutting the hose next to the compression bushing The cut needs to be clean with no fraying ends Master Cylinder and Caliper Hose Assembly 1 Cut the hose to the desired length with good scissors or cable cutters The cut end must be clean and perpendicular to the hose itself 2 Slide the nose cone onto master cylinder side of the hose 3 Slide the hose nut and compression bushing over the hose Always use a new compression bushing 4 Push the longer end of the barbed hose insert into the end of the hose Be sure it is inserted flush with the end of the hose Always use a new hose insert 5 Slide the hose into the master cylinder caliper and install the hose nut Be sure that the
3. damage caused by alterations or modifications of new Hayes Disc Brakes or parts or by normal wear accidents improper maintenance damages caused by the use of parts of different manufactures improper use or abuse of the product or failure to follow the instructions contained in an instruction manual for Hayes Disc Brake Any modifications made by the user will render the warranty null and void The cost of normal maintenance or replacement of service items which are not defective shall be paid for by the original purchaser This warranty is expressly in lieu of all other warranties and any implied are limited in duration to the same duration as the expressed warranty herein Hayes Disc Brake shall not be liable for any incidental or consequential damages If for any reason warranty work is necessary return the brake to the place of purchase In the USA contact Hayes Disc Brake for a return authorization number RA at 888 686 3472 At that time instructions for repair return or replacement shall be given Customers in countries other than USA should contact their dealer or local Hayes Disc Brake distributor Hayes Disc Brake LLC 5800 W Donges Bay Rd Mequon WI 53092 Technical Assistance Line 1 888 686 3472 www hayesdiscbrake com
4. hose is inserted completely into the master cylinder caliper end Be sure the hose remains inserted while tightening 6 Using a 8mm open end wrench torque the hose nut to 60 5 in lbs 6 78 55 Nm 7 Bleed the system Removing Pads Brake Pads Note Inner and outer pads are the same So _ Hose Fitting D Bleeding the System Air entrapped in the hydraulic system of the disc brakes can decrease performance of the system and should be removed by bleeding the system and replenishing the system with new brake fluid The system is filled by pumping fluid from the lowest point at the caliper through the system to the highest point the bleeder on the master cylinder Caution Use only new DOT 4 or DOT 3 brake fluid from a closed sealed container Use of any other fluid can cause the rubber parts to degrade and cause the brake to fail Caution DOT 4 or DOT 3 brake fluid will strip paint Use extreme caution to avoid getting DOT 4 or DOT 3 brake fluid on paint If DOT 4 or DOT 3 brake fluid comes in contact with paint wipe it off immediately and rinse with isopropyl alcohol Warning If you get any brake fluid on the brake pads discard them and replace with new pads If you get any brake fluid on the disc clean it thoroughly with isopropyl alcohol Warning DOT 4 and DOT 3 brake fluid can be an irritant when it comes into contact with human tissue Bleed Fitting For skin contact brake fluid should be washed o
5. 45 17419D Single Piston Hydraulic Brake overs Installation and Service The Following procedures cover the installation of Hayes Disc Brakes items purchased as an sol aftermarket item When you need to install any of the disc brake components a qualified TM technician with the proper tools should do that installation work Improper installation could cause severe or fatal injuries Warning When following any of the procedures below be sure to keep your hands and fingers from getting caught in the disc Failure to do so could result in injury Warning With use disc brake components may become very hot Always allow components to cool before attempting to service your bike J O Congratulations You have either purchased a new bicycle with the Hayes Disc Brake System or you have purchased Hayes Disc Brake system or service parts as an aftermarket item The purpose of this information sheet is to help you get the most out of that system Personal Preference and Adjustment In most case the Hayes Disc Brake system has been pre assembled for your bike However there are a couple of adjustments that you can make to match your particular physical characteristics or personal preferences e Positioning the Master Cylinder and Lever 1 Loosen but do not remove the handle bar clamp screw 2 Then position the Master Cylinder and Lever on the handlebar in your desired position 3 Torque the handlebar clamp screw to 30 35 in lbs 3 39 3 35 Nm e Le
6. aster cylinder 13 With the bottle still being squeezed close the caliper bleeder Torque should be only to seal the bleeder Do Not Over Torque Then release and remove the bottle and filler hose 14 Remove the hose and fitting from the master cylinder and insert the aluminum reservoir plug 15 Clean the caliper and master cylinder with isopropyl alcohol Take great care to remove all brake fluid because if the fluid comes into contact with the disc or brake pads performance will forever be greatly reduced 16 Clean the disc with isopropyl alcohol if it is contaminated with oil or brake fluid 17 Replace the caliper s rubber bleeder cap the brake pads and the wheel disc assembly 18 Center the caliper over the disc 19 Check all hose connection for leakage Tighten if any are found ROD O ONO OI Filler Bottle Attachment Any Hayes Disc Brake found by the factory to be defective in materials and or workmanship within two years from the date of purchase will be repaired or replaced at the option of the manufacturer free of charge when received at the factory with proof of purchase freight prepaid Any other warranty claims not included in this statement are void This includes assembly costs for instance by the dealer which shall not be covered by Hayes Disc Brake This warranty does not cover breakage bending or damage that may result from crashes or falls This warranty does not cover any defects or
7. e caliper wall resulting in brake failure 4 Using a 5mm Allen wrench adjust the outer pad adjuster leaving a 015 020 38 50mm gap between the outer pad and the disc 5 Adjust the amount of lever travel by adjusting the gap between the disc and pad of either the outer pad adjuster or the fixed inner pad adjuster Warning Adjusting more than a 020 50mm gap on either side of the disc may cause the lever to go to the bar causing brake failure 6 Spin the wheel Check that it spins freely and that the gaps between the pad and the disc are equal If the gaps are unequal or if there is drag readjust the caliper following the needed steps listed above Hint A white piece of paper can be used as a background to help sight down the disc looking for equal clearance between the pads and disc 7 Repeat above procedure for other wheel N Checking Pad Gaps r _ Service should only be performed by someone familiar with the necessary service procedures possessing a good knowledge of mechanical procedures and equipped with proper tools and equipment Incorrect service or repair may reduce braking performance and could lead to a safety or personal hazard situation If you have any doubts about the procedure described due to limited experience or because of the lack of necessary tools and equipment contact your local dealer or mechanic All torque requirements should be adhered to Remember always Think Safety A C
8. e outer pad adjuster or the fixed inner pad adjuster Warning Adjusting more than a 020 50mm gap on either side of the disc may cause the lever to go to the bar causing brake failure 8 Spin the wheel Check that it spins freely and that the gaps between the pad and the disc are equal If the gaps are unequal or if there is drag readjust the caliper position by loosening the mounting bolts and adjusting the caliper as needed Hint A white piece of paper can be used as a background to help sight down the disc looking for equal clearance between the pads and disc 9 When the gaps are equal and the wheel spins freely without drag torque the mounting bolts to 110 in lbs 12 43Nm 10 Repeat above procedure for other wheel disc screw torqueing sequence Fork Adaptor E Mounting the International Standard Caliper to the Frame or Fork Note The International Standard calipers are to be only used with a 6 disc and a quick release front fork 1 Remove the wheel s Mount the caliper to the frame using 2 M6 x 1 0 18 4mm long mount bolts Re install the wheel s Using a 5mm Allen wrench position the fixed inner pad adjuster flush with the caliper body leaving a 015 020 38 50mm gap between the fixed inner pad and the disc Warning Be sure the inner brake pad is adjusted so the pad material is extending past the caliper wall Adjusting the inner pad too far counter clockwise will cause the disc to hit th
9. ff in flowing water For eye contact the eye area should be irrigated with flowing water immediately and continuously for 15 minutes Consult with medical personnel If effects occur from inhaling brake fluid fumes move to an area with fresh air Consult a physician If brake fluid is ingested induce vomiting and consult medical personnel Used brake fluid should be disposed of in accordance with local laws Bleed Kit Assembly Screw the cap onto the end of the bottle Cut a 2 5cm section of hose Push the short section of hose over the cap until it slides past the ridge on the cap Push the long section of hose into the master cylinder bleed fitting NOTE There are two fittings with the kit The silver aluminum fitting is to be used with the SO1E Bleeding the System 1 Remove the wheel 2 Remove the brake pads so that any spilled fluid does not contaminate the pads See above instructions for pad removal 3 Position the bike in a stand so that the brake caliper bleeder screw is perpendicular to the ground and the reservoir plug on the master cylinder is the highest point on the brake system This can be done by loosening the master cylinder clamp screws and rotating the master cylinder upright on the handlebars NOTE For the SO1E the bike should remain horizontal to the ground and the lever should remain parallel to the ground 4 Remove the master cylinder reservoir and press the fitting with the hose into the hole The ot
10. her end of the hose should go into a cup or bottle to catch the excess fluid Be sure not to submerge the end of the hose in fluid Hint Taping a spoke to a bottle and bending it to hook around the handlebars makes a convenient hanger NOTE The SOLE master cylinder reservoir plug is an aluminum plug which needs to be removed with your fingers or a small flat head screwdriver DO NOT remove the two T 10 Torx bolts holding the cap on The SO1E requires the use of the silver aluminum bleed fitting included in the bleed kit Completely remove the caliper bleeder s rubber cap Fill the plastic filler bottle with fresh DOT 3 or DOT 4 brake fluid Close the caliper bleeder Place the hose from the fluid bottle onto the caliper bleeder Pump the fluid bottle until there is no air in the hose Open the caliper bleeder 1 4 turn 0 Squeeze the fluid bottle firmly forcing fluid into the caliper for a count of five Stop squeezing until the bottle returns to its natural shape When the squeeze is released air should be drawn out of the caliper Continue alternately squeezing the fluid bottle for a count of five and releasing until no air bubbles come out of the caliper 11 After all the air is out of the caliper squeeze the bottle until fluid comes out at master cylinder with no air bubbles 12 While squeezing the bottle quickly stroke the lever to the handlebars and release Repeat this until no more air bubbles come out of the m
11. leaning and Care The brake disc and pads should only be cleaned with isopropyl alcohol not disc brake cleaner B Brake Pad Change Due to wear contamination or damage the brake pads will on occasion have to be replaced The following procedure is to be followed for that change of brake pads Remove the wheel 2 Using a 5mm Allen wrench turn the inner pad adjuster counter clock wise until one engagement thread is exposed 3 Using a needle nose pliers remove the outer pad first Note The outer pad is the pad away from the wheel To do this pull the tab in the center of the pad backing plate toward the center of the caliper and out The pad is held in with a magnet Note If you do not remove the outer pad first you will not be able to remove the pads 4 Repeat the above steps for the inner pad Note The inner and outer brake pads are identical To replace the pads 5 Using a needle nose pliers install the inner pad first Note The inner pad is the pad closest to the wheel Use the tab in the center of the pad backing plate to push the new pads into place Angle the pad slightly until the force of the magnet pulls the pad into place 6 Now repeat the procedure for the outer pad 7 Install the wheel 8 Using a 5mm Allen wrench adjust the inner pad adjuster to the proper gap Note See installation instructions above for proper set up Caution Do not try to turn the adjuster past its stopping point Doing so may damage the brake
12. n sequence Ro D Mounting the 74mm Caliper to the Frame or Fork Note If you have a International Standard style caliper skip to section E Remove the wheel s 2 Mount the caliper to the frame or mount bracket using 2 M6 x 1 0 18 4mm long mount bolts and 2 mount washers Snug the bolts but leave them loose enough so that caliper will move on its slots Warning For Manitou forks you will need to use 2 M6 x 1 0 22mm long mount bolts These bolts are supplied in your aftermarket kit or supplied from the bike manufacture Failure to use the longer bolt may result in fork damage that will not allow you to tighten down your caliper properly 3 Re install the wheel s 4 Using a 5mm Allen wrench position the fixed inner pad adjuster flush with the caliper body Warning Be sure the inner brake pad is adjusted so the pad material is extending past the caliper wall Adjusting the inner pad too far counter clockwise will cause the disc to hit the caliper wall resulting in brake failure 5 Position the caliper in its natural center position over the disc Tighten the mount bolts to 80 5 in lbs 9 04 55 Nm leaving a 015 020 38 50mm gap between the fixed inner pad and the disc 6 Using a 5mm Allen wrench adjust the outer pad adjuster leaving a 015 020 38 50mm gap between the outer pad and the disc 7 Adjust the amount of lever travel by adjusting the gap between the disc and pad of either th
13. ver Reach Adjustment Adjust the brake lever reach by using a 2 0mm Allen wrench and turning the push rod that goes through the lever adjuster bushing Do not attempt to force the adjustment screw beyond its limits Burnish Disc brakes require a special burnish period to achieve maximum braking power This burnish period last for about 30 40 stops During this period some noise may occur Recommended Fluids and Lubricants Use only DOT 3 or DOT 4 brake fluid Do not use any petroleum based lubricants as this will cause the rubber parts to swell Hayes recommends the use of DOT 3 or DOT 4 brake fluid Clean the disc and pads only with isopropyl alcohol This brake has been designed for use on a single person mountain bike The use on any other vehicle or device will void the warranty and can cause serious injury As a serious rider you are well aware of the need to practice safety in all aspects of the sport This includes service and maintenance practices as well as riding practices Before each ride always check your brakes for proper function and the brake pads for wear When you ride always wear a helmet If you have purchased a bike new with Hayes disc brakes already installed you will not immediately be required to follow all of the following procedures When you need to install any of the disc brake components that installation work should be done by a qualified technician with the proper tools Improper installation could cause severe or
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