hayes-disc-brakes 45-17692ecfull User Manual
B. Bleeding
Air trapped 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.
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. For skin contact, brake fluid should be washed off 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.
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 (Figure 4 C)
1. Screw the cap onto the end of the bottle.
2. Cut a 2" section of hose
3. Push the short section of hose over the cap until it slides past the ridge on the cap
4. Push the long section of hose into the master cylinder bleed fitting.
NOTE: There are three fittings with the kit. The black plastic fitting is to be used with the “El Camino”.
2. Cut a 2" section of hose
3. Push the short section of hose over the cap until it slides past the ridge on the cap
4. Push the long section of hose into the master cylinder bleed fitting.
NOTE: There are three fittings with the kit. The black plastic fitting is to be used with the “El Camino”.
•
•
•
•
•
Bleeding the System
1. Remove the wheel.
2. Remove the brake pads so that any spilled fluid does not contaminate the pads. (See “Maintenance” instructions for pad removal)
3. Push the caliper pistons all the way into their bores using the box end of a 9mm end wrench. Caution: Don’t push on the post in the center of the piston because that will
bend the post.
4. Position the bike in a stand so that the brake caliper bleeder screw is perpendicular to the ground, and the reservoir bleeder screw on the master cylinder is the highest
point on the brake system. NOTE: For the “El Camino” the bike should remain horizontal to the ground, and the lever should remain in its normal riding position.
(Figure 4 - A and B)
5. Remove the master cylinder bleed screw and press the fitting with the hose into the hole (note: there is one on each side of the master cylinder body, when bleeding
only remove the bleed screw pointing up). The other end of the hose should go into a cup or bottle to catch the excess fluid. (Note: you will need to provide your own
catch bottle) 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
2. Remove the brake pads so that any spilled fluid does not contaminate the pads. (See “Maintenance” instructions for pad removal)
3. Push the caliper pistons all the way into their bores using the box end of a 9mm end wrench. Caution: Don’t push on the post in the center of the piston because that will
bend the post.
4. Position the bike in a stand so that the brake caliper bleeder screw is perpendicular to the ground, and the reservoir bleeder screw on the master cylinder is the highest
point on the brake system. NOTE: For the “El Camino” the bike should remain horizontal to the ground, and the lever should remain in its normal riding position.
(Figure 4 - A and B)
5. Remove the master cylinder bleed screw and press the fitting with the hose into the hole (note: there is one on each side of the master cylinder body, when bleeding
only remove the bleed screw pointing up). The other end of the hose should go into a cup or bottle to catch the excess fluid. (Note: you will need to provide your own
catch bottle) 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 (Figure 4 B)
6. Completely remove the caliper bleeder’s rubber cap.
7. Fill the plastic filler bottle with fresh DOT 3 or DOT 4 brake fluid.
8. Close the caliper bleeder.
7. Fill the plastic filler bottle with fresh DOT 3 or DOT 4 brake fluid.
8. Close the caliper bleeder.
9. Place the hose from the fluid bottle onto the caliper bleeder. Pump the fluid bottle until there is no air in the hose. (Figure 4 C)
10.Open the caliper bleeder 1/4 turn.
11. 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
10.Open the caliper bleeder 1/4 turn.
11. 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.
12. After all the air is out of the caliper; squeeze the bottle until fluid comes out at the master cylinder with no air bubbles.
13. While squeezing the bottle, quickly stroke the lever to the handlebars, and release. Repeat this until no more air bubbles come out of the master cylinder.
14. 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
13. While squeezing the bottle, quickly stroke the lever to the handlebars, and release. Repeat this until no more air bubbles come out of the master cylinder.
14. 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.
15. Remove the hose and fitting from the master cylinder and insert the bleed screw.
16. 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,
16. 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.
17 Clean the disc with isopropyl alcohol if it is contaminated with oil or brake fluid.
18. Replace the caliper’s rubber bleeder cap, the brake pads, and the wheel/disc assembly.
19. Pump the brake lever to push the pads to the proper location.
20. Center the caliper over the disc.
18. Replace the caliper’s rubber bleeder cap, the brake pads, and the wheel/disc assembly.
19. Pump the brake lever to push the pads to the proper location.
20. Center the caliper over the disc.
C. Master Cylinder Service
(Figure 5)
The right hand and left hand master cylinders are identical and will be rebuilt in the same manner. Rebuilding must be done with the master cylinder removed from the bike.
NOTE: The Power Adjustment Dial is a non-serviceable item. DO NOT try to repair or replace the assembly.
•
Master Cylinder Hose Removal
(See instruction under Hose Removal and Assembly)
•
•
•
•
•
Lever Blade Removal
1. Remove the lever blade by first removing the two 2.5mm Allen head bolts on each side of the master cylinder.
2. Remove the two plastic bushings that fit between the sides of the lever and the body.
3. Firmly grab and pull the “push rod reach adjustment knob” and remove it from the push rod.
4. Using a 2.5mm Allen wrench, turn the push rod clockwise until it is removed from the adjuster bushing and the thread retention bushings.
2. Remove the two plastic bushings that fit between the sides of the lever and the body.
3. Firmly grab and pull the “push rod reach adjustment knob” and remove it from the push rod.
4. Using a 2.5mm Allen wrench, turn the push rod clockwise until it is removed from the adjuster bushing and the thread retention bushings.
•••••
Lever Blade Assembly
1. Put the adjuster bushing and thread retention bushings into the hole in the lever. Using a 2.5mm Allen wrench, thread the push rod through the hole in the bushing.
2. Firmly push the reach adjustment knob onto the end of the push rod. Note: Be sure it securely snaps over the retaining ring.
3. Put both plastic lever bushings into the lever, and then slide the lever into place. Line up the washers with the hole in the lever and the holes in the master cylinder body.
4. Drop the pivot pin through the body, lever bushings, and lever hole. Tighten the 2.5mm Allen heads bolts until tight.
2. Firmly push the reach adjustment knob onto the end of the push rod. Note: Be sure it securely snaps over the retaining ring.
3. Put both plastic lever bushings into the lever, and then slide the lever into place. Line up the washers with the hole in the lever and the holes in the master cylinder body.
4. Drop the pivot pin through the body, lever bushings, and lever hole. Tighten the 2.5mm Allen heads bolts until tight.
•
Master Cylinder Piston
Note: it is not necessary to remove the hose from the master cylinder
1. Remove the lever blade. (Note: see instructions)
2. Remove the push rod, master cylinder piston, and spring by removing the snap
ring and washer using a snap ring tool. DO NOT attempt to take the rubber seals
1. Remove the lever blade. (Note: see instructions)
2. Remove the push rod, master cylinder piston, and spring by removing the snap
ring and washer using a snap ring tool. DO NOT attempt to take the rubber seals
off of the master cylinder piston.
Warning: Always wear safety glasses when removing a snap ring.
3. Clean and inspect the inside of the master cylinder and all parts. Replace those
parts that are damaged with new service parts. Thoroughly clean all of the parts
3. Clean and inspect the inside of the master cylinder and all parts. Replace those
parts that are damaged with new service parts. Thoroughly clean all of the parts
by spraying them with isopropyl alcohol and wiping them with a clean rag.