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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
4
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
KOlumnentitel
5
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
teChniCal speCifiCatiOns
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
KOlumnentitel
7
teChniCal speCifiCatiOns
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.Ζ For.assembly.on.normal.bicycle.suspension.fork.and.bicycle.rigid.fork.Ζ For.assembly.on.normal.bicycle.frames.(also.tandems).Ζ 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.Ζ 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.Ζ Never.make.changes.to.the.BFO.brakes.(e.g..filing,.drilling,.painting,.etc.).Ζ Never.try.to.move.the.brake.calliper.or.brake.handle.or.to.open.them.at.an.incorrect.location.(e.g..angled.outlet,.etc.).Ζ Never.try.to.clean.oily.brake.pads..Replace.oily.brake.pads.immediately.with.new.ones.Ζ Always.apply.new.medium-strength.threadlocking.if.used,.secured.screws.are.being.re-used.Ζ Only.use.BFO.original.parts.(spares,.brake.hose,.screws).and.BFO.oil.Ζ Ideally,.use.BFO.original.accessories.(adapter,.disc.brake.rotors,.brake.pads).Ζ Always.adhere.to.all.stated.min./max.-.values.–.see.dimensiOns,.page.7.Ζ Always.use.a.torque.wrench.designed.for.the.required.tightening.torque.Ζ 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.Ζ Before.every.ride,.make.sure.that.both.brakes.work.properly.Ζ Before.every.ride,.make.sure.that.the.disc.brake.rotor.and.brake.pad.thickness.is.sufficient..–.see.Check wear and tear,.page.21.Ζ Before.every.ride,.make.sure.that.the.mounting.bases.at.the.fork.and.frames.are.not.damaged.(cracks,.breaks,.etc.).Ζ Before.every.ride,.make.sure.that.the.quick.release.system.on.both.wheels.is.correctly.fitted.and.that.neither.wheel.can.be.released.inadvertently.Ζ Before.every.ride,.make.sure.that.brake.lever,.handlebars.and.stem.are.correctly.fitted.and.cannot.be.turned.Ζ Check.both.brakes.for.damage.and.that.they.work.properly.after.every.crash.Ζ 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.Ζ Always.obey.the.traffic.regulations.of.the.country.where.you.ride.your.bicycle.(lights,.etc.),.and.the.respective.conditions.regarding.mountain.biking.in.nature.Ζ Always.wear.a.high.quality.cycling.helmet.(e.g..ANSI.certified).that.is.in.excellent.condition.and.clothing.that.is.not.restrictive.Ζ Always.only.ride.your.bicycle.if.you.are.in.good.physical.condition.and.your.bicycle.and.all.of.its.components.are.working.perfectly.Ζ Always.use.both.brakes.when.braking.Ζ Always.remember.the.longer.braking.time.and.to.look.ahead.in.wet.conditions.Ζ 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.Ζ Always.place.transport.protection.between.the.brake.pads.if.wheels.have.been.removed.Ζ 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.Ζ Ensure.that.the.selected.combination.goes.together.Ζ Ideally,.combine.BFO.disc.brake.rotor.with.BFO.brake.pads.
Risk of accident caused by disc brake rotor malfunction.Ζ Always.use.the.manufacturer's.original.screws.Ζ 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.Ζ Never.use.adapters.that.require.the.use.of.concave./.convex.washers.Ζ Ideally,.use.BFO.adapters.
Risk of accident caused by brake calliper holder malfunction.Ζ Always.use.the.adapter.manufacturer's.original.screws.Ζ Always.apply.the.prescribed.tightening.torque.Ζ 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
8 N·m (71 lbf·in) max.
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.Ζ Leave.the.transport.protection.in.the.brake.calliper.until.the.wheel.is.fitted.with.the.assembled.disc.brake.rotor.Ζ Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.
damage to the brake hose.Ζ 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.Ζ 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
8 N·m (71 lbf·in) max.
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.Ζ Carefully.lay.the.brake.hose.tight.to.the.fork.and.frame.Ζ Carefully.fix.the.brake.hose.securely.(e.g..hose.ties,.etc.).Ζ Take.the.cushioning.of.the.spring.elements.when.laying.the.hose.Ζ Observe.the.minimum.distance.(10.mm).from.the.tire.Ζ Shorten.brake.hose.to.correct.length.–.see.Shorten brake hose,.page.16.
damage to the brake hose.Ζ Observe.the.minimum.distance.(20.mm).from.the.disc.brake.rotor.(damage.from.overheating).Ζ Never.squeeze.the.brake.hose.forcibly.with.hose.ties.Ζ Never.bend.the.snap,.forcibly.bend.or.twist.the.brake.hose.Ζ 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.Ζ Observe.the.minimum.distance.(20.mm).from.the.disc.brake.rotor.(damage.from.overheating).Ζ Never.bend.the.snap,.forcibly.bend.or.twist.the.brake.hose.
Irreparable damage to the brake hose.Ζ Always.shorten.the.brake.hose.at.the.brake.lever.–.never.at.the.brake.calliper.Ζ Never.shorten.the.brake.hose.with.a.side.cutter.or.saw..
Loss of oil.Ζ Never.use.the.brake.lever.while.the.brake.system.is.open.
Irreparable damage to the brake pads.Ζ 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.Ζ Always.shorten.the.brake.hose.at.the.brake.lever.–.never.at.the.brake..calliper.Ζ Never.shorten.the.brake.hose.with.a.side.cutter.or.saw.
Loss of oil.Ζ Never.use.the.brake.lever.while.the.brake.system.is.open.
Irreparable damage to the brake pads.Ζ Make.sure.that.no.oil.spills.onto.the.disc.brake.rotor.or.brake.pads.
.) 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
4 N·m (35 lbf·in) max.
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
Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Ζ Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.
.) 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.Ζ Before.every.ride,.make.sure.that.both.brakes.work.properly.Ζ Before.every.ride,.make.sure.that.the.disc.brake.rotor.and.brake.pad.thickness.is.sufficient..–.see.Check wear and tear,.page.21.Ζ Before.every.ride,.make.sure.that.the.mounting.bases.at.the.fork.and.frames.are.not.damaged.(cracks,.breaks,.etc.).Ζ Before.every.ride,.make.sure.that.the.quick.release.system.on.both.wheels.is.correctly.fitted.and.that.neither.wheel.can.be.released.inadvertently.Ζ 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.Ζ Check.both.brakes.for.damage.and.that.they.work.properly.after.every.crash.Ζ 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.Ζ Always.use.both.brakes.when.braking.Ζ Always.remember.the.longer.braking.time.and.to.look.ahead.in.wet.conditions.Ζ 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.Ζ 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.Ζ Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.Ζ 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.Ζ Never.use.a.high-pressure.cleaner.or.steam.cleaner.–.the.seals.in.the..components.are.not.designed.to.withstand.this.pressure.Ζ 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.Ζ Regularly.check.wear.and.tear.of.brake.pads./disc.brake.rotors.Ζ 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.Ζ 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.Ζ Never.use.the.brake.lever.if.no.brake.pads.are.fitted.Ζ 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).
.) 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.
.) 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.Ζ Get.familiar.with.the.braking.performance.of.new.brake.pads./.disc.brake.rotors.Ζ 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.Ζ Never.use.syringes,.hoses.or.connectors.which.have.already.been.in..contact.with.DOT.brake.fluid.
Irreparable damage to the brake pads.Ζ Make.sure.that.no.oil.spills.onto.the.disc.brake.rotor.or.brake.pads.
.) 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.Ζ Do.not.let.the.oil.enter.the.wastewater.or.soil.Ζ 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.
Loss of oil, air and damage to seals due to excessive release of brake calliper pistons.Ζ Never.use.the.brake.lever.if.there.is.no.transport.protection.or.disc.brake.rotor.between.the.brake.pads.
.) 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.
.) 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.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 N·m (22 lbf·in) max.
2,5 mmM5 × 8
2,5 mmM5 × 6
2,5 N·m (22 lbf·in) max.
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