hayes-disc-brakes 45-17692ecfull User Manual

ANUAL

Congratulations. You have purchased a Hayes Disc Brake system.  This Manual is
intended to provide the information necessary for normal maintenance and service of the
Hayes Disc Brake system.  Although the steps and procedures are relatively

 simple,

 they

should not be attempted until you are thoroughly familiar with the entire set of procedures.
Images have been provided to help you in the steps and procedures.

Warning: 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.
Warning: 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 fatal injuries.
Warning: 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.
Warning: With use, disc brake components may become very hot.  Always allow
components to cool before attempting to service your bike.
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:  For riders using the brakes in downhill conditions, it is recommended that you
use the 8" disc version of the Hayes Brake. Not all frames and forks will accept and 8"
disc.  Please check with your frame or fork manufacturer or 

www.hayesdiscbrake.com f

or

8" disc compatibility.  Consistently using the 6" disc in downhill conditions may cause the
brake fluid to boil.

In most cases, 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.

•

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 15-20 in-lbs (1.7-2.26 Nm)

•

Adjusting the amount of power the brake provides can be done by turning the “Power Adjustment Dial”.  Turning the dial clockwise will reduce the amount of power the brakes provides.
Turning the dial counter clockwise will increase the power the brake provides.

        Warning :  DO NOT attempt to force the “Power Adjustment Dial” beyond its limits.

Note: When adjusting the “Power Adjustment Dial” it will change the lever reach.  Follow the instructions to set your lever reach.

•

Adjust the brake lever reach by turning the reach adjustment knob. Turning the knob counter clockwise will adjust the lever closer to the handle bar.  Turning the knob clockwise will
adjust the lever farther from the handle bar.
Warning : Do not attempt to force the adjustment screw beyond its limits.
Warning : Due to the different diameters of grips and twist shifters, DO NOT adjust the reach adjustment screw too far counter clockwise.  Doing so could allow the lever blade to
contact the grip, which may reduce braking power.

•

The banjo on the caliper can be rotated to accommodate your frame or fork.  Loosen the banjo bolt ¼ turn and rotate the banjo to the desired location. (Note: loosening the banjo bolt
more than ¼ turn may introduce air in the system). Tighten the banjo bolt  to 60 +/- 5 in/lb (6.7 +/- .5 Nm).

Disc brakes require a special burnish period to achieve maximum braking power.  This burnish period  will last for about 30-40 stops.  During this period some noise may occur.

U

se 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.

Within this manual are specifically labeled comments intended to bring special attention to a general procedure or detailed step.  Be aware of, and understand, the meaning of  these labels.

Warning: Means that there is the possibility of personal injury to you or to others.
Caution:  Means that there is the possibility of damaging the brake or the bike.
Note: Provides general information.
Hint: Provides information that can help you properly complete a specific procedure.

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