wner s manual - starbike.com

Owner's manual

01_2011-10

KOlumnentitel

3

COntents

3

intrOduCtiOn

Foreword....................................... 4Legend.......................................... 4

teChniCal speCifiCatiOns

Dimensions................................... 7Delivery.specifications.................. 7

safety

Intended.use................................. 8Fundamental.safety..precautions................................... 8Assembly.&.maintenance........... 8On.the.road................................. 9Transport.&.storage.................... 9

assembly

Fitting.the.disc.brake.................. 10Fit.disc.brake.rotor.................... 10Fit.adapter................................. 11Fit.brake.calliper........................ 12Fit.brake.lever............................ 12Adjust.brake.calliper................. 13Install.the.brake.hose..on.the.bicycle............................ 14Install.the.brake.hose..in.the.frame............................... 15Shorten.brake.hose.................. 16Adjust.brake.lever..................... 18Adjust.pressure.point................ 19

On the rOad

Before.every.ride........................ 20On.the.road................................. 20

maintenanCe

Regular.maintenance................. 21Check.wear.and.tear................. 21Change.brake.pads.................. 22

Venting./Filling............................. 24

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KOlumnentitel

SIMPLY MORE POWER4

intrOduCtiOn

SIMPLY MORE POWER

This.Instruction.Manual.is.an.integral.part.of.your.BrakeForceOne.product.and.contains.information.on.the.professional.assembly,.tools.required.and.safe.use.and.maintenance.Read.this.manual.carefully.prior.to.assembling.or.using.your.BrakeForceOne.product..Observe.and.follow.all.assembly,.operation.and.maintenance.instructions.in.this.manual.and.in.the.manuals.provided.by.third.party.manufacturers.whose.products.you.have.used.on.your.bicycle.(handlebar,.stem,.fork,.frame,.hubs,.wheels,.quick.release.skewer,.etc.).Please.remember.that.the.assembler.of.your.BrakeForceOne.product.is.responsible.for.the.suitability.and.compatibility.of.all.components.connected.with.your.BrakeForceOne.product.

Failure to observe the instructions in this manual can lead to serious or fatal accidents.

legend.) The.index.finger.instructs.you.to.perform.a.particular.action.ÎÎ The.arrow.shows.results.or.requirements.LL This.notice.gives.you.additional.information.or.tips.

This safety message indicates a hazardous situation which, if not avoided, could result in fatal or serious injury.

This safety message indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

This note warns you about anticipated material damage.

fOrewOrd

Intr

od

uc

tIo

n

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intrOduCtiOn

5

Keep.this.manual.safe.for.other.users.of.your.BrakeForceOne.product..Make.sure.that.all.users.read,.understand.and.observe.this.manual.If.you.ever.sell.or.give.away.your.BrakeForceOne.product,.this.manual.should.be.transferred.to.the.new.owner.as.well.

The.images.in.this.manual.may.differ.with.respect.to.your.BrakeForceOne.product;.the.required.steps.are.the.same.for.all.types,.however,.unless.stated.otherwise.The.type.of.your.BrakeForceOne.disc.brakes.is.stated.on.the.brake..calliper (fig. 1).Please.note.that.the.way.your.bike.brakes.will.change.as.a.result.of.fitting.your.new.BrakeForceOne.disc.brakes...Get.used.to.the.braking.characteristics.of.your.new.BrakeForceOne.disc.brakes.during.the.first.few.rides.(response,.delay,.dosing,.etc.).

1

At.www.brakeforceone.com.you.can.find.many.more.tips.and.information.about.your.BrakeForceOne.product,.as.well.as.accessories,.spares.and.tools..You.can.also.contact.the.BrakeForceOne.team.directly.We.wish.you.good.riding.and.lots.of.fun.on.your.bikeThe.BrakeForceOne.Team

6

KOlumnentitel

SIMPLY MORE POWER6


SIMPLY MORE POWER

tec

hn

Ica

l s

pe

cIf

Ica

tIo

ns

B

C

D

E PostMount IS 2000

M5×12

T25

M6×18 T25

M6×18 T25

M6×18 T25

M6×18 T25

M6×18

T25

M6×18

T25

M6×16 T25

M6×16 T25

A1

2

3 4

7 8 9 10 11

65

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7

*. Not.included.with.the.brakes:**. Attention.when.using.disc.brake.rotors.from.other.manufacturers!

Type BFO1 (1) Brake lever 1-finger

Hose length – VR / HR / HR tandem (optional)

mm.

900./.1700./.2500A Ø Handlebar clamping 22.2B Base clearance 74.0C Ø Mounting, max. 10.0GB Adjustable range, horizontal 3.0E Ø /thickness BFO disc brake rotor* 160.•.180.•.203.(6".•.7".•.8")./.1.92.±.0.02

Ø / Thickness, disc brake rotor, min.– max.** 140.–.203./.1.5.–.2.0Braking performance see.www.brakeforceone.com.>>>.ENGINEERING.>>>.Test.report.Velotech

(2) Brake calliper – (3) Inner ring – (4) Transport safety with integrated tire lever – (5) Hose tie (2 pcs) mm. 140×3.6 (6) Brake pad (set incl. securing pin) –

dimensiOns

OVERVIEw BFO AdApTER* MOunTInG BAsE,

sTAndARdØ dIsC BRAkE ROTOR

140 160 180 203

FOR

k

Is 2000 – Art.No..31268 (11) Art.No..31267 (10) Art.No..31266 (9)

pM6 – Direct.fitting Art.No..31265 (8) Art.No..31264 (7)

pM7 – – Direct.fitting Art.No..31265 (8)

pM8 – – – Direct.fitting

FRA

ME

Is 2000 Art.No..31268 (11) Art.No..31267 (10) Art.No..31266 (9) –pM5 Direct.fitting Art.No..31265 (8) Art.No..31264 (7) –pM6 – Direct.fitting Art.No..31265 (8) Art.No..31264 (7)

pM7 – – Direct.fitting Art.No..31265 (8)

pM8 – – – Direct.fitting

& delivery speCifiCatiOns

8

KOlumnentitel

SIMPLY MORE POWER8

safety

SIMPLY MORE POWER

sa

fety intended use

Any use other than that intended can cause accidents resulting in fatal or serious injury.

BrakeForceOne.(BFO).disc.brakes.have.been.developed.and.envisaged.exclusively.Î– For.assembly.on.normal.bicycle.suspension.fork.and.bicycle.rigid.fork.Î– For.assembly.on.normal.bicycle.frames.(also.tandems).Î– For.assembly.on.mounting.bases.according.to.IS.2000.or.PostMount.(PM5,.PM6,.PM7,.PM8).standard.

fundamental safety preCautiOnsAssembly & maintenanceBFO.disc.brakes.have.an.increased.braking.force.compared.to.other.brake.systems...The.factors.maximum.braking.performance.(.–.see.dimensiOns,.page.7),.system.weight.(rider.+bicycle.+luggage+trailer),..speed.and.grip.and.diameter.of.the.disc.brake.rotor.together.are.responsible.for.the.peak.loads.that.can.affect.other.bicycle.parts...Take.this.into.account.when.selecting.the.bicycle.components.affected.by.this,.such.as.fork,.frame,.hub,.quick.release.skewer,..handlebar.and.stem..Use.stable.and.technically.high.quality.components..Get.your.bicycle.shop.to.advise.you.on.safe.combinations.and.sensible.sizes..For.attachments.and.accessories.(adapter,.disc.brake.rotors,.brake.pads),.you.should.ideally.use.BFO.originals.–.these.are.tested.and.safe.You.should.also.rely.on.your.common.sense.and.avoid.any.unreasonable.behaviour!

Risk of accident through disc brake malfunction due to faulty or incorrect fitting.Î– Never.overestimate.your.technical.capabilities..Have.installation.and.maintenance.work.performed.by.a.specialist.workshop.for..bicycles..This.is.the.only.way.to.ensure.that.work.is.conducted.in.a.professional.manner.Î– Never.make.changes.to.the.BFO.brakes.(e.g..filing,.drilling,.painting,.etc.).Î– Never.try.to.move.the.brake.calliper.or.brake.handle.or.to.open.them.at.an.incorrect.location.(e.g..angled.outlet,.etc.).Î– Never.try.to.clean.oily.brake.pads..Replace.oily.brake.pads.immediately.with.new.ones.Î– Always.apply.new.medium-strength.threadlocking.if.used,.secured.screws.are.being.re-used.Î– Only.use.BFO.original.parts.(spares,.brake.hose,.screws).and.BFO.oil.Î– Ideally,.use.BFO.original.accessories.(adapter,.disc.brake.rotors,.brake.pads).Î– Always.adhere.to.all.stated.min./max.-.values.–.see.dimensiOns,.page.7.Î– Always.use.a.torque.wrench.designed.for.the.required.tightening.torque.Î– Always.maintain.the.bicycle.in.technically.perfect.working.and.order.and.clean.condition.

KOlumnentitel

9

safety

9

On the roadAlways.remember.that.riding.a.bicycle.involves.potential.danger.for.the.rider.and.other.road.users,.as.well.as.for.the.bicycle.and.its..components..Despite.the.use.of.safety.gear.and.complete.safety.equipment,.accidents.that.cause.serious.or.fatal.injury.can.occur.You.should.also.rely.on.your.common.sense.and.avoid.any.unreasonable.behaviour!

Risk of accident due to component malfunction.Î– Before.every.ride,.make.sure.that.both.brakes.work.properly.Î– Before.every.ride,.make.sure.that.the.disc.brake.rotor.and.brake.pad.thickness.is.sufficient..–.see.Check wear and tear,.page.21.Î– Before.every.ride,.make.sure.that.the.mounting.bases.at.the.fork.and.frames.are.not.damaged.(cracks,.breaks,.etc.).Î– Before.every.ride,.make.sure.that.the.quick.release.system.on.both.wheels.is.correctly.fitted.and.that.neither.wheel.can.be.released.inadvertently.Î– Before.every.ride,.make.sure.that.brake.lever,.handlebars.and.stem.are.correctly.fitted.and.cannot.be.turned.Î– Check.both.brakes.for.damage.and.that.they.work.properly.after.every.crash.Î– Never.ride.with.a.BFO.disc.brake.if.there.is.visible.damage,.unusual.noise.or.of.there.is.doubt.about.its.integrity..If.this.is.the.case,.get.a.bicycle.repair.shop.or.BFO.directly.to.check.the.BFO.disc.brake.

Risk of accident caused by improper behaviour or improper equipment during riding.Î– Always.obey.the.traffic.regulations.of.the.country.where.you.ride.your.bicycle.(lights,.etc.),.and.the.respective.conditions.regarding.mountain.biking.in.nature.Î– Always.wear.a.high.quality.cycling.helmet.(e.g..ANSI.certified).that.is.in.excellent.condition.and.clothing.that.is.not.restrictive.Î– Always.only.ride.your.bicycle.if.you.are.in.good.physical.condition.and.your.bicycle.and.all.of.its.components.are.working.perfectly.Î– Always.use.both.brakes.when.braking.Î– Always.remember.the.longer.braking.time.and.to.look.ahead.in.wet.conditions.Î– Always.remember.the.longer.braking.time.and.to.look.ahead.when.increasing.the.bike's.weight.(luggage,.trailer,.etc.).

Transport & storage

Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Î– Always.place.transport.protection.between.the.brake.pads.if.wheels.have.been.removed.Î– Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.

10

KOlumnentitel

SIMPLY MORE POWER10

assembly

SIMPLY MORE POWER

as

se

mb

ly fitting the disC braKe

6 N·m (53 lbf·in) max.

T25

M5 × 12

2

LL The.excellent.braking.properties,.the.reliable.stability.and.the.precise.dimensional.stability.of.your.BFO.disc.brakes.are.achieved.with.BFO.original.accessories.–.BFO.disc.brake.rotors,.BFO.brake.pads,.BFO.adapter...Ideally,.use.BFO.original.accessories..Accessories.from.other.manufacturers.may.have.a.negative.impact.on.braking.quality,.stability.and.dimensional.stability.of.your.BFO.disc.brakes..When.using.accessories.from.other.manufacturers,.make.sure.that.they.correspond.to.the.required.dimensions.–.see.dimensiOns,.page.7.The.assembly.steps,.maintenance.information,.tightening.torque,.etc..in.this.manual.refer.exclusively.to.BFO.original.parts.and..accessories.

.) Secure.the.bicycle.frame.in.a.suitable.stand.ÎÎ Fork,.stem.and.handlebar.must.be.fitted..) Remove.wheels,.if.necessary.

Fit disc brake rotor

Risk of accident as a result of unexpected braking performance due to unsuitable disc brake rotor / brake pads combination.Î– Ensure.that.the.selected.combination.goes.together.Î– Ideally,.combine.BFO.disc.brake.rotor.with.BFO.brake.pads.

Risk of accident caused by disc brake rotor malfunction.Î– Always.use.the.manufacturer's.original.screws.Î– Always.apply.the.prescribed.tightening.torque.

.) Insert.the.disc.brake.rotor.in.the.correct.direction.(arrow.visible).into.the.mounting.base.of.the.hub.

.) Tighten.all.6.screws.by.hand.–.approx..2–3.revolutions.

.) Tighten.the.screws.in.the.stated.order.(by.cross).with.a.tightening.torque.of.6.N·m.(53.lbf·in).(fig. 2).

.) Thoroughly.clean.and.remove.grease.from.the.disc.brake.rotor.with.an..appropriate.solvent.(brake.cleaner,.alcohol,.etc.).

KOlumnentitel

11

assembly

11

Fit adapter

Risk of accident from damaged brake calliper holding due to unsuitable adapter.Î– Never.use.adapters.that.require.the.use.of.concave./.convex.washers.Î– Ideally,.use.BFO.adapters.

Risk of accident caused by brake calliper holder malfunction.Î– Always.use.the.adapter.manufacturer's.original.screws.Î– Always.apply.the.prescribed.tightening.torque.Î– Make.sure.that.the.brake.calliper.sits.level.and.torsion-free.on.the.adapter.or.directly.on.the.mounting.base.(PM).

.) Identify.fork.and.frame.assembly.base.standard.(manufacturer).

.) Calculate.the.diameter.of.the.disc.brake.rotor.corresponding.to.the.adapter.–.see.Overview bfO adapter,.page.7.

.) Ensure.that.you.have.the.appropriate.adapter.

.) Ensure.that.the.contact.surfaces.of.the.mounting.base.are.precisely.milled.and.free.from.lacquer.residue.

.) Make.sure.that.the.adapter.sits.level.and.torsion-free.on.the.the.mounting.base.

.) Lightly.grease.the.contact.surfaces.of.the.mounting.base.with.installation.grease.LL If.you.have.checked.in.the.Overview bfO adapter.that.no.adapter.is.required.for.assembling.your.disc.brake.("direct.fitting"),.please.skip.the.next.3.steps.

.) Insert.the.adapter.in.the.correct.position.in.the.mounting.base.(fig. 3).

.) Tighten.both.screws.by.hand.–.approx..2–3.revolutions.

.) Tighten.screws.gradually.one.at.a.time.until.a.tightening.torque.of.8.N·m.(71.lbf·in).is.reached.

PostMount IS 2000


T25

M6 × 18

T25

M6 × 18

8 N·m (71 lbf·in) max. 3

12

KOlumnentitel

SIMPLY MORE POWER12

assembly

SIMPLY MORE POWER

Fit brake calliperLL If.necessary.–.see.Install the brake hose in the frame.,.page.15.

Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Î– Leave.the.transport.protection.in.the.brake.calliper.until.the.wheel.is.fitted.with.the.assembled.disc.brake.rotor.Î– Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.

damage to the brake hose.Î– Never.bend.the.snap,.forcibly.bend.or.twist.the.brake.hose.

LL First.assemble.the.brake.calliper.with.slight.tightening.torque..The.adjust-ment.and.final.assembly.with.correct.cabling.and,.if.applihose,.shortening.of.the.brake.hose,.must.be.performed.with.the.wheel.fitted.

.) Place.brake.calliper.in.position.(fig. 4).

.) Tighten.both.screws.by.hand.–.approx..2–3.revolutions.

.) Gently.tighten.screws.ÎÎ The.brake.calliper.must.not.wobble.greatly.any.more,.but.must.be.able.to.move.slightly.from.side.to.side.in.its.oblong.holes.(fig. 4).

Fit brake leverLL The.brake.lever.for.the.front.brake.is.typically.on.left-hand.side.of.the.handle-bar..However,.you.are.free.to.choose.the.location.–.the.BFO.brake.lever.can.be.fitted.on.the.left.or.on.the.right.

.) Connect.the.brake.lever.with.the.brake.hose.so.that.the.brake.hose.already.follows.the.correct.path...Take.any.fixing.points.on.the.fork/frame.into.account.

.) Position.the.brake.lever.such.that.you.can.reach.the.lever.from.the.grip..comfortable.with.the.index.finger.–.see.Adjust brake lever,.page.18.

.) Tighten.screws.gradually.one.at.a.time.until.a.tightening.torque.of.2.5.N·m.(22.lbf·in).is.reached.(fig. 5).ÎÎ Slot.(X).on.the.clamp.must.be.the.same.at.top.and.bottom.

T25

M6 × 16

4

=X

=X

T25

M5 × 12

2,5 N·m (22 lbf·in) max.

5

KOlumnentitel

13

assembly

13

Adjust brake calliper.) Make.sure.that.the.screws.on.the.brake.calliper.are.loose.ÎÎ The.brake.calliper.must.not.wobble.greatly.any.more,.but.must.be.able.to.move.slightly.from.side.to.side.in.its.oblong.holes (fig. 4).

.) Turn.the.pressure-point.setting.wheel.clockwise.to.the.limiter.(-).(fig. 6).(zero.position).ÎÎ The.brake.pads.are.in.the.most.open.position..) Remove.the.transport.protection.from.the.brake.calliper.

Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Î– Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.

LL Install.the.lever.for.the.front.quick.release.skewer.on.the.right,.in.order.to.reduce.the.risk.of.injury.(cutting,.burning).from.the.disc.brake.rotor.when.removing.the.front.wheel.

.) Fit.the.wheel.–.carefully.move.the.disc.brake.rotor.between.the.brake.pads.

.) Install.and.close.the.quick.release.skewer.

.) Pull.the.brake.lever.strongly.several.times,.then.hold.it.

.) Tighten.screws.gradually.one.at.a.time.until.a.tightening.torque.of.8.N·m.(71.lbf·in).is.reached. (fig. 7).

.) Make.sure.that.the.disc.brake.rotor.runs.freely.and.in.the.center.between.the.pads.–.if.necessary.repeat.the.installation.

6


T25

M6 × 16

7

14

KOlumnentitel

SIMPLY MORE POWER14

assembly

SIMPLY MORE POWER

Install the brake hose on the bicycle.

Risk of injury from undesired contact with the brake hose.Î– Carefully.lay.the.brake.hose.tight.to.the.fork.and.frame.Î– Carefully.fix.the.brake.hose.securely.(e.g..hose.ties,.etc.).Î– Take.the.cushioning.of.the.spring.elements.when.laying.the.hose.Î– Observe.the.minimum.distance.(10.mm).from.the.tire.Î– Shorten.brake.hose.to.correct.length.–.see.Shorten brake hose,.page.16.

damage to the brake hose.Î– Observe.the.minimum.distance.(20.mm).from.the.disc.brake.rotor.(damage.from.overheating).Î– Never.squeeze.the.brake.hose.forcibly.with.hose.ties.Î– Never.bend.the.snap,.forcibly.bend.or.twist.the.brake.hose.Î– Take.any.fixing.points.on.the.fork/frame.into.account.

LLWhen.fitting.the.brake.hose,.always.start.from.the.angled.outlet.of.the.brake.calliper..The.angle.outlet.can.be.adjusted.without.a.tool.by.applying.some.pressure..Never.loosen.the.closing.screw.

.) Adjust.the.angled.outlet.with.the.thumb.to.create.a.harmonious,.bend-free.brake.hose.curve.to.the.next.fixing.point.(fig. 8).

.) Make.sure.that.the.minimum.distance.(20mm).between.the.brake.hose.and.the.disc.brake.rotor.is.not.undercut.anywhere.

.) Fix.the.brake.hose.securely.(e.g..hose.ties,.etc.).at.appropriate.locations.ÎÎ Catching.of.the.hose.must.be.excluded.as.much.as.possible..) Make.sure.that.the.string.elements.can.work.freely.without.bending.or..scuffing.the.brake.hose.

.) Make.sure.that.the.minimum.distance.(10mm).between.the.brake.hose.and.the.tire.is.not.undercut.anywhere.

.) Make.sure.that.the.handlebar.can.be.moved.in.both.directions.to.the.full.extent.without.overstretching.the.brake.hose,.trapping.or.bending.it.

8

KOlumnentitel

15

assembly

15

Install the brake hose in the frame.LL If.your.bicycle.frame.has.an.internal.hose.guide,.the.fitting.sequence.is.dif-ferent.for.the.rear.disc.brake..In.this.case,.start.by.laying.the.brake.hose.or.fitting.the.brake.lever.

damage to the brake hose.Î– Observe.the.minimum.distance.(20.mm).from.the.disc.brake.rotor.(damage.from.overheating).Î– Never.bend.the.snap,.forcibly.bend.or.twist.the.brake.hose.

Irreparable damage to the brake hose.Î– Always.shorten.the.brake.hose.at.the.brake.lever.–.never.at.the.brake.calliper.Î– Never.shorten.the.brake.hose.with.a.side.cutter.or.saw..

Loss of oil.Î– Never.use.the.brake.lever.while.the.brake.system.is.open.

Irreparable damage to the brake pads.Î– Make.sure.that.no.oil.spills.onto.the.disc.brake.rotor.or.brake.pads.

.) Fit.the.brake.hose.to.the.handlebar.–.see.Fit brake lever,.page.12.–.and.immediately.turn.it.vertically.upward.(fig. 9).

.) Gently.tighten.screws.(1).

.) Remove.cover.(2).from.the.union.nut.(3).LLHold.brake.hose.tightly.when.cutting,.avoid.vibrations..) Cut.brake.hose.directly.behind.the.union.nut.using.hose.cutters.(e.g..BFO.Cutter)..Remove.cover.(2).

.) Cover.the.cut.brake.hose.with.insulation.tape.or.similar.so.that.it.can.still.be.fed.into.the.hose.guide.in.the.frame.

.) Feed.the.brake.hose.through.the.hose.guides.

.) Fit.brake.calliper.–.see.Fit brake calliper,.page.12.

.) Adjust.the.angled.outlet.with.the.thumbs.(fig. 8).and.follow.the.next.cabling.steps.–.see.Install the brake hose on the bicycle.,.page.14.

.) Loosen.union.nut.(3).(A/F.8).

.) Carefully.pull.brake.hose.out.of.the.brake.lever (fig. 10).

.) If.necessary,.shorten.brake.hose.and.connect.–.see.Shorten brake hose,.page.16.

8 mm

T25 1

2

3

9

8 mm

3

10

16

KOlumnentitel

SIMPLY MORE POWER16

assembly

SIMPLY MORE POWER

shorten brake hoseLL It.is.possible.that.the.brake.hose.for.your.BFO.disc.brake.will.have.to.be.shortened..You.must.check.whether.a.longer.or.steeper.stem,.a.higher..handlebar.or.a.general.increase.in.the.height.of.the.stem-handlebar.unit.is.required..If.you.shorten.the.hose.too.much.it.cannot.be.lengthened!

Irreparable damage to the brake hose.Î– Always.shorten.the.brake.hose.at.the.brake.lever.–.never.at.the.brake..calliper.Î– Never.shorten.the.brake.hose.with.a.side.cutter.or.saw.

Loss of oil.Î– Never.use.the.brake.lever.while.the.brake.system.is.open.


.) Loosen.screws.(1) (fig. 11).

.) Turn.the.brake.lever.upwards.

.) Gently.tighten.screws.(1).

.) Remove.cover.(2).from.the.union.nut.(3).

.) Hold.brake.hose.tightly.when.loosening,.avoid.vibrations.

.) Loosen.union.nut.(3).(A/F.8).

.) Carefully.pull.brake.hose.out.of.the.brake.lever..

.) Hold.the.brake.hose.at.the.height.of.the.inlet.hole.to.the.base.of.the.brake.lever.(fig. 12).

.) For.the.rear.brake,.move.the.handlebar.fully.in.both.directions.and.check.whether.the.brake.hose.is.long.enough.

.) The.brake.hose.for.the.front.brake.should.form.a.harmonious,.bend-free.curve.to.the.next.fixing.point.with.the.fork.decompressed.ÎÎ Both.brake.hoses.can.be.pulled.tight.–.without.bending.–.as.the.brake.lever.will.be.turned.to.the.correct.position.again.later.

.) Mark.brake.hose.at.the.corresponding.position.

8 mm

T25 11

12

1

2

3

KOlumnentitel

17

assembly

17

LL Before.cutting,.place.cloth.beneath.the.marked.position.on.the.brake.hose.–.oil.drops.from.the.cut.end..

.) Cut.brake.hose.at.the.marked.location.using.hose.cutters.(e.g..BFO.Cutter).

.) Put.cover.(2).and.union.nut.(3).on.the.brake.hose.

.) Fix.brake.hose.in.the.appropriate.hose.holder.(4).(vise,.clamp,.etc.).(fig. 13).

.) Insert.new.inner.ring (5).into.the.brake.hose.with.a.plastic.hammer.carefully.and.straight,.to.the.limiter.

.) Insert.the.brake.hose.into.the.hose.opening.to.the.limiter.and.hold.tight.until.the.union.nut.has.been.tightened.fully.

.) First.tighten.union.nut.(3).by.hand.(fig. 14).

.) Tighten.union.nut.with.a.tightening.torque.of.4.N·m.(35.lbf·in).

.) Pull.the.brake.lever.strongly.several.times.ÎÎ If.a.considerable.pressure.point.can.be.felt.immediately,.the.brake.must.not.be.vented...If.a.pressure.point.is.only.achieved.after.pulling.the.brake.lever.several.times,.the.brake.must.be.vented.–.see.venting /filling,.page.24.

.) Pull.the.brake.lever.strongly,.then.hold.it.

.) Make.sure.that.oil.is.not.escaping.from.any.part.of.the.brake.system.

.) Slide.cover.(2).over.the.union.nut.

.) Make.sure.tha.the.brake.pads.do.not.come.into.contact.with.oil..Replace.oliy.brake.pads.immediately.with.new.ones.

.) Turn.brake.lever.to.correct.position.–.see.Fit brake lever,.page.12.

13


8 mm

14

2

35

4

3

2

18

KOlumnentitel

SIMPLY MORE POWER18

assembly

SIMPLY MORE POWER

Adjust brake leverLL You.can.adjust.the.size.of.the.grip.of.your.BFO.brake.lever.to.the.size.of.your.hand..The.handlebar.grips.must.be.fitted.for.this..Remember.that.the.pressure.point.of.your.brake.will.change.as.a.result.of.the.adjustment.to.the.grip.and,.if.applihose,.will.have.to.be.adjusted.–.see.Adjust pressure point,.page.19.

.) Turn.setting.screw.(6).1.revolution.clockwise.(+).(fig. 15).ÎÎ The.brake.lever.moves.approx..3.mm.closer.to.the.handlebar.LL From.the.zero.position,.it.is.possible.to.turn.the.setting.screw.a.max..of.5.revolutions.

+ -

2,5 mm

15

6

KOlumnentitel

19

assembly

19

16

Adjust pressure pointLL You.can.adjust.the.pressure.point.of.your.BFO.disc.brake.individually..This.is.also.necessary.as.the.wear.and.tear.on.your.brake.pads.and.disc.brake.rotor.increases,.as.the.closed.system.of.the.BFO.disc.brake.does.not.adjust.automatically.–.see.Check wear and tear,.page.21..synonymouslyThe.pressure.point.of.your.BFO.disc.brake.is.equivalent.to.the..distance.between.the.brake.pads.and.disc.brake.rotor.LL If.the.pressure.point.feels.soft.and.spongy,.the.disc.brake.must.be.vented.–.see.venting /filling,.page.24


.) Turn.the.pressure-point.setting.wheel.clockwise.to.the.limiter.(-).(fig. 16).(zero.position).

.) Pull.the.brake.lever.strongly.several.times.ÎÎ Brake.pads.have.moved.to.the.maximum.distance.from.the.disc.brake.rotor.ÎÎ Pressure.point.felt.after.longer.movement.of.brake.lever..) Turn.the.pressure-point.setting.wheel.on.the.brake.lever.2–3.notches.coun-terclockwise.(+).

.) Pull.the.brake.lever.strongly.several.times.ÎÎ Brake.pads.have.moved.tight.to.the.disc.brake.rotor.ÎÎ Pressure.point.felt.after.short.movement.of.brake.lever..) Check.whether.the.disc.brake.rotor.moves.between.the.brake.pad.freely.and.without.rubbing.

.) If.necessary,.reduce.(-).or.increase.(+).the.pressure.point.until.it.meets.your.personal.preference.LL From.the.zero.position,.it.is.possible.to.turn.the.pressure-point.setting.wheel.a.total.of.approx..8.notches.until.new.BFO.brake.pads.touch.or.rub.against.a.new.BFO.disc.brake.rotor.

20

KOlumnentitel

SIMPLY MORE POWER20

On the rOad

SIMPLY MORE POWER

befOre every ride

Risk of accident due to components malfunction.Î– Before.every.ride,.make.sure.that.both.brakes.work.properly.Î– Before.every.ride,.make.sure.that.the.disc.brake.rotor.and.brake.pad.thickness.is.sufficient..–.see.Check wear and tear,.page.21.Î– Before.every.ride,.make.sure.that.the.mounting.bases.at.the.fork.and.frames.are.not.damaged.(cracks,.breaks,.etc.).Î– Before.every.ride,.make.sure.that.the.quick.release.system.on.both.wheels.is.correctly.fitted.and.that.neither.wheel.can.be.released.inadvertently.Î– Before.every.ride,.make.sure.that.brake.lever,.handlebars.and.stem.are.correctly.fitted.and.cannot.be.turned.

On the rOad

Risk of accident due to component malfunction.Î– Check.both.brakes.for.damage.and.that.they.work.properly.after.every.crash.Î– Never.ride.with.a.BFO.disc.brake.if.there.is.visible.damage,.unusual.noise.or.of.there.is.doubt.about.its.integrity..If.this.is.the.case,.get.a.bicycle.repair.shop.or.BFO.directly.to.check.the.BFO.disc.brake.

Risk of accident caused by malfunctioning brakes.Î– Always.use.both.brakes.when.braking.Î– Always.remember.the.longer.braking.time.and.to.look.ahead.in.wet.conditions.Î– Always.remember.the.longer.braking.time.and.to.look.ahead.when.increasing.the.bike's.weight.(luggage,.trailer,.etc.).

Risk of burning from overheated disc brake rotor.Î– Before.touching,.make.sure.that.the.disc.brake.rotors.have.cooled.sufficiently.–.especially.after.a.long.downhill.ride.

Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Î– Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.Î– Always.carry.transport.protection.

on t

he r

oa

d

ma

Inte

na

nc

e

KOlumnentitel

21

maintenanCe

21

regular maintenanCeLL The.maintenance.intervals.required.for.your.BFO.disc.brake.depend.on.how.often.and.in.which.weather.conditions.it.is.used..The.following.maintenance.measures.should.be.conducted.more.frequently.if.the.bicycle.is.used.in.extreme.conditions.(rain,.dirt,.long.distances,.etc.).

Corrosion and material damage from penetrating water.Î– Never.use.a.high-pressure.cleaner.or.steam.cleaner.–.the.seals.in.the..components.are.not.designed.to.withstand.this.pressure.Î– Also.be.careful.with.a.water.hose..Never.spray.the.seal.areas.directly (fig. 17).

Check wear and tear

Risk of accident caused by brake malfunction.Î– Regularly.check.wear.and.tear.of.brake.pads./disc.brake.rotors.Î– Never.ride.with.brake.pads/disc.brake.rotors,.if.their.wear.limit.has.been.reached..Replace.worn.brake.pads/disc.brake.rotors.immediately.–.see.Change brake pads,.page.22.

damage to disc brake rotor from contact to pad carrier plates.Î– Regularly.check.wear.and.tear.of.brake.pads./disc.brake.rotors.

.) Remove.wheel.

.) For.each.brake,.measure.both.brake.pads.with.an.appropriate.gauge.ÎÎ Wear.limit.=.Brake.pad.(incl..carrier.plate).t.<.2.5.mm.(fig. 18).LL Brake.pads.can.wear.at.an.angle.–.if.in.doubt.or.in.the.limit.area,.measure.while.dismantled.–.see.Change brake pads,.page.22.

2,5 mm min.!

t < 2,5 mm

t

18

17

ma

Inte

na

nc

e

22

KOlumnentitel

SIMPLY MORE POWER22

maintenanCe

SIMPLY MORE POWER

1,7 mm min.!

t < 1,7 mm

t

t

t

19

.) Measure.the.disc.brake.rotor.on.the.braking.surface.at.several.points.(1).with.an.appropriate.gauge.ÎÎ The.lowest.result.is.the.level.of.wear.and.tear.ÎÎ Wear.limit.=.Disc.brake.rotor.t.<.1.7.mm.(fig. 19).LLWith.a.new.disc.brake.rotor,.always.also.fit.new.brake.pads.

Change brake padsLLChanging.the.brake.pads.on.your.BFO.disc.brake.differs.from.the.procedure.you.may.know.from.other.disc.brakes...Carefully.check.and.observe.the.following.steps,.otherwise.air.may.enter.the.brake.system.

.) Remove.wheel.

.) Turn.the.pressure-point.setting.wheel.10.notches.clockwise.(-) (fig. 20).

.) Carefully.separate.the.brake.pads.with.a.flat,.broad.screwdriver.or.flat.tire.lever.until.a.higher.counter-pressure.can.be.felt.

.) Turn.the.pressure-point.setting.wheel.10.notches.clockwise.(-).again.

.) Carefully.separate.the.brake.pads.again.until.a.higher.counter-pressure.can.be.felt.

.) Repeat.this.alternative.procedure.1–2.times.until.the.carrier.plates.(2).of.the.pads.almost.touch.the.brake.calliper.

10 „clics“20

1

1

2

KOlumnentitel

23

maintenanCe

23

2 mm3 N·m (27 lbf·in) max. 21

Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Î– Never.use.the.brake.lever.if.no.brake.pads.are.fitted.Î– Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.

.) Unscrew.safety.pin.(2).(fig. 21).

.) Remove.pads.

.) Thoroughly.remove.brake.dust.and.other.dirt.

.) Insert.new.pads.in.correct.orientation.ÎÎ Carrier.plate.outwardly.faces.brake.cylinder..) Screw.new.safety.pin.through.the.eyes.(3).of.the.carrier.plate.and.tighten.with.a.tightening.torque.of.3.N·m.(27.lbf·in).



.) Pull.the.brake.lever.strongly.several.times.

.) Make.sure.that.the.disc.brake.rotor.runs.freely.and.in.the.center.between.the.pads.

.) If.necessary,.adjust.brake.calliper.–.see.Adjust brake calliper,.page.13.

.) If.necessary,.adjust.pressure.point.–.see.Adjust pressure point,.page.19.

Risk of accident from undesirable low braking performance because of new brake pads or new disc brake rotors.Î– Get.familiar.with.the.braking.performance.of.new.brake.pads./.disc.brake.rotors.Î– Adjust.speed.during.the.initial.phase.with.new.brake.pads./.disc.brake.rotors.

2 3

24

KOlumnentitel

SIMPLY MORE POWER24

maintenanCe

SIMPLY MORE POWER

venting /fillingLL Your.BFO.disc.brake.does.not.have.to.be.refilled.regularly..Only.fill.or.vent.your.BFO.disc.brake.if.there.is.a.reason.for.this.(e.g..soft,.spongy.pressure.point,.new.brake.hose,.repair.after.loss.of.oil,.etc.).LL Filling.and.venting.only.differ.in.respect.of.the.amount.of.oil.required..In.the.following.description,.only.the.term."Venting".is.used...Proceed.in.exactly.the.same.way.for.filling.

To.vent.your.BFO.disc.brake,.you.need.the.components.that.are.typically..available.in.a.standard.venting.kit.(e.g..VAR):2×.syringes.(30–50.ml),.2×.hoses,.2×.connector.(M5)Also:.1×.BFO.transport.protector,.1×.BFO.oil

Irreparable damage to all disc brake seals.Î– Never.use.syringes,.hoses.or.connectors.which.have.already.been.in..contact.with.DOT.brake.fluid.


.) Insert.connectors.into.the.hose.to.the.limiter.

.) Place.hose.onto.the.syringe.to.the.limiter.

.) Submerge.the.filling.syringe's.connector.(1).fully.in.the.BFO.oil.

.) Fill.the.filling.syringe.(1).completely.so.that.no.air.remains.(fig. 22).

.) Push.in.the.plunger.on.the.venting.syringe.(2).to.the.limiter.

.) Remove.wheel.

.) Make.sure.that.the.screw.on.the.angled.outlet.and.the.screw.cap.on.the.piston.column.are.positioned.vertically.above.each.other.(fig. 23).ÎÎ Trapped.air.can.only.be.removed.optimally.in.this.position..) Unscrew.the.cap.(3).from.the.filling.opening.(brake.calliper)..) Screw.the.filling.syringe.connector.(1).into.the.filling.opening.–.gently.tighten.

22

2,5 mmM5 × 8

23

21

1

3

KOlumnentitel

25

maintenanCe

25

.) Remove.brake.lever.from.the.handlebars.

.) Unscrew.the.cap.(4).from.the.venting.opening.(brake.lever).

.) Screw.the.venting.syringe's.connector.(2).into.the.venting.opening.–.gently.tighten.

.) Position.and.fix.the.brake.lever.vertically.–.venting.opening.on.top.(fig. 24).–.if.possible,.directly.on.the.handlebar.ÎÎ Trapped.air.can.only.be.removed.optimally.in.this.position.

LLMake.sure.that.both.syringes.are.vertical.during.the.venting.so.that.no.air.is.inadvertently.pushed.into.the.braking.system.–.fix.if.required.

.) Turn.the.pressure-point.setting.wheel.clockwise.to.the.limiter.(-).(fig. 25).(zero.position).

.) Carefully.separate.the.brake.pads.with.a.flat,.broad.screwdriver.or.flat.tire.lever.until.the.pads.of.the.carrier.plates (5).almost.touch.the.brake.calliper.

.) Place.BFO.transport.protection.between.the.brake.pads.

2,5 mmM5 × 6

24

25

2

4

5

26

KOlumnentitel

SIMPLY MORE POWER26

maintenanCe

SIMPLY MORE POWER

.) Push.oil.from.the.filling.syringe.(1).into.the.braking.system.(fig. 26).ÎÎ Make.sure.that.no.air.is.pushed.into.the.braking.system..) Actuate.the.brake.lever.2–3.times.on.the.handlebars.while.pushing.the.oil.in.ÎÎ Oil.and.air.bubbles.collect.in.the.venting.syringe.(2)..) Gently.tap.on.the.venting.syringe.ÎÎ Air.bubbles.in.the.syringe.rise.

.) Push.oil.from.the.venting.syringe.(2).into.the.braking.system.(fig. 27).ÎÎ Make.sure.that.no.air.is.pushed.into.the.braking.system.ÎÎ Oil.and.air.bubbles.collect.in.the.filling.syringe.(1)..) Gently.tap.on.the.filling.syringe.ÎÎ Air.bubbles.in.the.syringe.rise.

.) Repeat.these.processes.(fig. 26/27).until.no.more.air.bubbles.are.seen.in.the.syringes.

.) Remove.the.transport.protection.from.the.brake.calliper.

.) Carefully.separate.the.brake.pads.with.a.flat,.broad.screwdriver.or.flat.tire.lever.until.the.pads.of.the.carrier.plates (5).almost.touch.the.brake.calli-per (fig. 25).

pollution.Î– Do.not.let.the.oil.enter.the.wastewater.or.soil.Î– Collect.oils.no.longer.used.and.give.them.to.a.professional.waste.disposal.company.

26

27

12

12

KOlumnentitel

27

maintenanCe

27

.) Unscrew.the.venting.syringe's.connector.from.the.venting.opening.(brake.lever).LL Do.not.mix.up.the.screw.caps.for.the.brake.lever.and.brake.calliper!.) Screw.the.screw.cap.(4).into.the.venting.opening.and.tighten.with.a..tightening.torque.of.2.5.N·m.(22.lbf·in) (fig. 28).

.) Clean.oil.off.brake.lever.

.) Turn.brake.lever.to.correct.position.–.see.Fit brake lever,.page.12.

.) Unscrew.the.filling.syringe.connector..from.the.filling.opening.(brake.calli-per).LL Do.not.mix.up.the.screw.caps.for.the.brake.lever.and.brake.calliper!.) Screw.the.screw.cap.(3).into.the.filling.opening.and.tighten.with.a.tightening.torque.of.2.5.N·m.(22.lbf·in) (fig. 28).ÎÎ Your.BFO.disc.brakes.have.now.been.vented.


.) Clean.oil.off.brake.calliper.

.) Make.sure.that.the.brake.pads.do.not.come.into.contact.with.oil..Replace.oily.brake.pads.immediately.with.new.ones.



.) Pull.the.brake.lever.strongly.several.times,.then.tighten.

.) Make.sure.that.oil.is.not.escaping.from.any.part.of.the.brake.system.

.) Make.sure.that.the.disc.brake.rotor.runs.freely.and.in.the.center.between.the.pads.

.) If.necessary,.adjust.brake.calliper.–.see.Adjust brake calliper,.page.13.

.) Make.sure.that.the.disc.brake.reacts.straight.away.and.has.a.clearly.defined.pressure.point.

.) If.necessary,.adjust.pressure.point.–.see.Adjust pressure point,.page.19.


2,5 mmM5 × 8

2,5 mmM5 × 6


28

4

3

KontaktFrank Stollenmaier

Gartenstraße 107 D-72074 Tübingen

Tel.: +49 7071 969 86-37Fax: +49 7071 969 [email protected]

ImpressumBrake Force One GmbHGartenstraße 107 · D-72074 TübingenSteuer Nr.: 86111/39850USt Id : DE 275153056HRB Stuttgart 734838www.brakeforceone.com

wner s manual - starbike.com

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