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1. WoRKSHOP 2004 Deutsch o English v Francais gt Nederlands gt Italiano Espa ol printed in germany MAGURA 2003 All rights reserved wWwww magura com serviceQgmagura de Table of Contents 1 Introduction 3 2 Safety instructions before the first ride 4 3 Safety instructions before every ride 4 5 4 Transport of the bicycle 5 9 Brake installation 6 9 6 Shortening the hose 10 11 7 Maintenance 12 13 8 Repairs 14 15 9 Bleeding and Filling 15 17 10 Trouble Shooting 17 11 The disc brake wheel 18 12 Accessories 19 20 13 Warranty 20 14 Spare parts exploded view 21 WARNING This symbol means possible danger for your health and even life if you do not follow the instructions given respectively if the necessary safety measures are not followed Pec ad you of inappropriate handling that might cause serious damage to e N the material and or the environment NOTE This symbol gives you additional information about the general handling of the product or gives hints to paragraphs in this manual which have to be read carefully mie www magura com d serviceQgmagura de 1 Welcome to the Brake People Brake lever master cylinder MAGURA Julie Congratulations You have purchased a fully hydraulic MAGURA disc brake proud ly Made in Germany You will be amazed at the awesome braking power and the minimum amount of maintenance that is necessary on our stoppers Good2. 5 Remove the transport device shortly before installing the wheel and mount the wheel 6 Squeeze now the brake lever hold the pressure and tighten the fitting bolts B Tightening torque 6Nm 51 in lbs If you have a Manitou fork proceed exactly in the same way but dismount the quickmount adaptor beforehand 7 However you must use the black 1mm spacers between fitting eyelets and cali per on a Julie rear brake If necessary you might have to use here as well additional 0 2mm spacers for a clean and drag free positioning of the calliper because frames are very often not well enough aligned The transport device prevents the brake pads from being pushed out too far by unintended lever squeeze It is impossible then to install the wheel with the rotor So never throw away the transport device Keep it and always clip it between the brake pads when the wheel is removed www magura com v serviceQgmagura de Install the wheel by positioning the rotor between the brake pads and fixing the wheel in the dropouts Close the quick release of your wheel which you should mount on the opposite side of the brake caliper and tighten it sufficiently As to thru axle hubs or wheels consult the manual of the respective fork manufacturer Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm 8 Correctly mounted disc brake wheel English The rotor has to run d
3. brake hose see page 10 onwards braking at least 30 times from a speed of 30km h to achieve the maximum 3 New brakes and new rotors or brake pads must always be run in by brake power Take your bike to a safe place to run in the brake 4 While riding in extreme riding conditions total weight of bike plus rider over 100kg and or a gradient of more than 15 always use both brakes simultaneously to slow your bike down 5 Do not use the Julie disc brake for downhill sport or on tandems Any misuse might cause serious accidents with fatal injuries to yourself and others 6 Are you familiar with the other components on your bike such as gears clipless pedals and suspension units Always practise using your bike in a safe area to improve your handling abilities before using it on the road Consult the user s manual of your bike to learn more about this 7 For your own safety always wear a helmet when you ride a bicycle Make sure as well that you wear suitable clothing and footwear 3 Before every ride Always check carefully the following points 1 Always make sure that the quick release skewers of your wheels and seat post are correctly mounted and closed incorrectly installed quick release skewers might cause the fixed items to become loose Serious accidents with severe injury may result 2 Always make sure that the brake lever pressure is o k by pulling the lever blade and ensuring that full braking performance is achieved
4. before the lever blade touches the handlebars If this is not the case pull the lever blade several times pump until the brake pads touch the rotor Changing pressure points during a ride might be the result of having air in the brake system See hints about filling and bleeding from on pages 15 16 www magura com v serviceQgmagura de 7 3 Always make sure that the brake system does not have any leaks by activating the lever blade holding it and checking the hose connections and reservoir cover for eventual leaks Also see page 11 4 Always protect your rotors and brake pads from oil and lubricants e g by lubri cating your chain Avoid detergents and soap on the brake pads Contaminating the pads with oil and lubricants will cause a permanent loss of braking power Such contami nated pads can no longer be used and should be replaced Clean a contaminated rotor with dishwater or alcool See further hints about changing the brake pads on pages 11 13 5 Release your brake lever and check whether your wheel moves freely and without drag Check eventually whether the wheels are correctly mounted and if the quick relea se skewers are tightened sufficiently Also see page 9 English 6 Are your tires in a good condition and have they enough air pressure Test this with your fingers Lift up your bike and turn the wheels of your bike An insufficient rotati on might be due to damaged tires broken axles and or broken spok
5. to know that you are not alone millions of riders worldwide rely on them and every day our numbers are increasing Brake caliper and rotor MAGURA Julie On the fully hydraulic MAGURA disc brake system Julie the braking force is trans mitted to the braking surface by a mineral oil column The movement of the lever blade moves a piston which is integrated in the brake lever master cylinder The piston pus hes the mineral oil column through the brake hose in the direction of the brake caliper where two pistons on which the brake pads are fixed are pushed out The friction bet ween the brake pads and the rotor slows down the bicycle and causes both the rotor and the brake calliper to heat up Never touch either the rotor or the brake caliper after long braking as this may cause serious burns You will be pleased to find out that the MAGURA Julie disc brakes offer a superior braking power even with little hand force applied no matter what the weather conditions should be Particularly in wet weather conditions disc brakes are much more responsive than rim brakes and transmit their enormous power immediately after activating the brake lever Disc brakes dont t wear your rims down However if they have been mounted incorrect ly they might cause a squealing noise during braking mainly during wet weather conditi Ons This manual contains important information about the safe installation operation and maintenance of your MAGURA di
6. 16 fax 0312 698025 tomas kubin vanekpraha cz Denmark Borandia APS Finland France phone 47 107172 fax 47 107066 borandia borandia dk Best Brakes Ky phone 050 591 5863 fax 019 388485 info bestbrakes inet fi MAGURA Service Center France seulement SAV via d tail lants phone 49 7125 153 290 fax 49 7125 153 184 sav_france magura de Maillon phone 05 56386300 fax 05 56386301 maillon sarl wanadoo fr Cycles Lapierre phone 03 80525186 fax 03 80520851 florian robin cycles lapierre fr Great Britain Greece MAGURA Bike Parts UK Ltd phone 01530 837195 fax 01530 811286 service_uk magura com Nikos Maniatopoulos phone 061 993045 fax 061 990424 idealman hol gr Casa Masferrer phone 93 8463444 fax 93 8465355 cmcenter casamasferrer com Comet phone 943 331393 fax 943 551407 comet comet es Representaciones Spinola amp Perez Hong Kong Spain MAGURA ASIA Inc phone 886 4 23283739 fax 886 4 23283734 service magura com tw Mali Bicycle Technology phone 01 4207563 fax 01 4205321 mali mali hu Hungary Ireland Beara Bike Trading phone 619 702946 phone 064 89134 fax 93 2317731 fax 064 41334 c perez spinolaperez com wschmidt indigo ie Sweden Jaguarverken AB Israel R S Sport phone 060 669800 phone 0972 99584174 fax 060 669809 fax 0972 99584174 info jaguarverken s lironl rssport com Switzerland Italy Weinert Intercyc phone 0421 81217 fax 0421 83680 weinert iol it Ja
7. ads must be changed clean rotor with dish water or alcohol Push back the brake pads with transport device or a flat blade screwdriver pagel 2 brake pad change page 12 change hose or defective brake lever or calliper page 14 You will find further tips on our website www magura com in the FAQ www magura com v serviceQgmagura de 12 accessories MAGURA disc brake service kit code 0721 294 contains everything that you need for bleeding and repairing a brake ATTENTION the kit does NOT include a spare hose MAGURA braided hose for all MAGURA disc brakes easily shortened with a cable cutter 1 700mm 0 fitting code 0721 203 lt 90 fitting code 0721 337 o Watch out for the genuine hose with yellow MAGURA marker of c Use only genuine MAGURA brake pads LLI brake pads Performance Type 4 1 code 0721 304 series pad for maximum brake power brake pads Endurance Type 4 2 code 0721 684 series pad for maximum brake power Use only genuine MAGURA accessories Any parts manufactured by other Z2 manufacturers like lever blades hoses or brake pads have not been tested and Z h approved by MAGURA and consequently nothing can be said about their short Z AQ and long term function Never use those parts All warranty and product liability y 4 claims will be void in case of misuse l Never change the paint the finish or the consistence of your brake This might cause total failure of the whole system with
8. allation 1 Tools for installation maintenance Allen key 2 3 and 5 transport mounting device sharp knife 8mm open end wrench flat blade screw driver Torx T25 key Torx T7 key delivered with the brake 4 XA Always insert the allen and torx keys completely to avoid damaging the bolt heads Unpack your Julie disc brake brake lever master cylinder connected through the brake hose with the brake caliper with transport device IS Postmount with quickmount adaptor ATTENTION remove YELLOW transport device only shortly before installation of the wheel rotor diameter front 180mm rear 160mm fitting bolts for caliper Allen key 5 2 pieces fitting bolts for rotor Torx key T25 6 pieces black 1mm spacers 2 pieces only necessary for rear brakes olives 2 pieces 10 Torx T25 key 11 Allen key 2mm not shown hose fitting kit for rear brake comes with all rear brakes Co N e WO 0O NOOI A specifications modifying and improving this product are subject to change without prior notice www magura com v serviceQgmagura de The brake levers calipers and hoses of the different MAGURA disc brake models are completely different and not compatible Never mix and match parts from the two models Any misuse might cause serious accidents MAGURA manufacture these braking systems according to the valid standards and make many rigorous product tests Because of t
9. ceQgmagura de Never squeeze the lever blade without the brake pads in place and the wheel mounted If this happened by accident push back the pistons with mounted brake pads by using the transport device or a flat blade screwdriver 4 Minimum thickness of a brake pad including the holder is 2 5mm Use only genuine MAGURA brake pads Tip check the pad wear with the groove of the YELLOW transport device Pad does NOT fit to the groove picture o k Pad does fit to the groove change the pads English Use only genuine MAGURA brake pads MAGURA cannot guarantee a cor rect function of the brake if you use brake pads from other manufacturers which were not tested Using other pads might cause poor braking and cause serious injury All warranty claims will be void in case of misuse 5 Clean on the occasion of the brake pad change the brake body with a clean rag Make sure that the friction side of the new brake pads points towards the rotor 6 Secure the new pads with the new cotter pin which is delivered with the pads Check the correct fitting of the pads by pulling them 7 Tighten the end of the cotter pin with a screwdriver or pliers Check the correct fitting of the cotter pin by pulling it 8 Check whether the pistons are fully pushed back and whether the pads are flush with the calliper body Push the brake pads back with the transport device or a flat blade screwdriver as described on page Re install the whe
10. e hose A The Julie is a low pressure system and comes with the same nylon hose that is used on MAGURA rim brakes Do NOT use the reinforced hose of the other disc brakes with Disc Tube imprint and do NOT mix and match items of different MAGURA disc brakes Any misuse might cause serious accidents Never touch either the rotor or the brake calliper after long braking as this may cause serious burns 1 Remove the wheel so that you have free access to the brake calliper Push back both brake pads by putting the transport device or a flat blade screwdriver into the gap Move the screwdriver slowly back and forth until both calliper pistons are fully retracted and flush with calliper body Never push back the pistons without the brake pads mounted Open the brake system only after having fully pushed back the brake pads 2 Loosen the brake lever clamping screw with a 5mm allen key Turn the brake lever and ensure that the reservoir is horizontal Squeeze slightly the lever blade and Slide the 2mm allen key between brake lever and lever blade 3 Slide the hose protection Unscrew the sleeve nut on the brake lever with an 8mm open end wrench and pull the hose out carefully Hold the hose carefully to avoid any loss of oil Do not squeeze the lever blade with the system open 4 Put the hose on a workbench and shorten it with a sharp knife The best tool is the MAGURA cutter code 0321 233 Do not use saws or pliers If your f
11. el and check for a correctly tightened quick release skewer of the wheel 9 Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm New brakes and or new rotors or brake pads must always be run in by braking at least 30 times from a speed of 30km h to achieve the maximum brake power Take your bike to a safe place to run in the brake Never contaminate brake pads with oil or grease this causing permanent loss of brake power Such contaminated pads can no longer be used and should be replaced wWwww magura com serviceQgmagura de 8 Repairs disc brake service kit code 0721 294 Don t panic if the hose snaps With the disc brake service kit and a separately available spare hose see spare parts pages 21 22 this can be repaired easily The Julie is a low pressure system and comes with the same nylon hose that is used on MAGURA rim brakes Do NOT use the reinforced hose of the other disc brakes with Disc Tube label and do NOT mix and match items of different MAGURA disc brakes Any misuse might cause serious accidents 1 Remove the damaged hose from both the brake lever and the calliper Cut off the barbed adapter calliper connection with a sharp knife Slide both the sleeve nut and hose protector on the other side All mentioned parts can be re used Throw away the damaged hose 2 Prepare a new hose the nylon hose of the Julie disc brake is id
12. entical with the one of the MAGURA rim brakes Clamp the hose as shown with the help of the two clamping jaws code 0321 239 into a vice Hose has to stick out 1 5cm as shown Use a nylon mallet to tap the barbed adapter carefully into the hose The barbed a dapter must be installed as shown Never heat up the hose to install the barbed adapter This might cause the hose to burst with total failure of the complete brake system 3 Correctly installed barbed adapter 4 Tighten the prepared end of the new hose onto the calliper Pe Tightening torque 4Nm 34 in Ibs d EL ghtening torq www magura com v serviceQgmagura de 5 Measure the requested length of the hose you need and shorten the hose accordingly with a sharp knife Slide on the hose protector sleeve nut and a new olive onto the hose Push the hose with the new olive fully into the brake lever and tighten the sleeve nut with an 8mm open end wrench Tightening torque 4Nm 34 in lbs After the installation of a new hose you will always have to refill the brake The following chapter 9 describes who the filling has to be done English Brake Oil MAGURA disc brakes use as transmission medium low viscosity mineral oil the biodegradable MAGURA ROYAL BLOOD Contrary to DOT brake fluid the MAGURA ROYAL BLOOD does not irritate human skin or strip the paint of your frame Moreover it does not absorb water like DOT and does not have to be changed regularly What sounds
13. es 7 Pick up your bike and let it drop from a moderate height Listen for any rattling noises If any are heard check the bearings and all screwed connections 8 Always follow the instructions given in the owner s manual of your bicycle Never use your bicycle if any of the points mentioned above relate to your bicycle Consult a professional bike mechanic if you feel unsure A faulty bicy cle may result in serious accidents with possible fatal injuries of the rider Be careful to check always to check the following points 4 Transport of the bicycle In case of a disc brake equipped bicycle you should always keep in mind the following points Never activate the lever blade without the brake pads in place and the wheels mounted In case this should have happened see page 10 of this manual Never throw away the transport device which has been delivered with the brake Always clip it between the brake pads whenever the wheel is removed e g transport of the bike Always carefully removed wheels Make sure that the rotors are not damaged deformed or contaminated with lubricants If the bike is transported upside down squeeze with mounted wheel or transport device the lever blade before hold pressure and fix the blade in this position with a rubber band or a cable tie During transport in an aircraft you can leave your brake as it is e g you do not have to empty it wWwww magura com serviceQgmagura de 5 Brake Inst
14. evable is a fact you can use your brakes over years without having to touch them except brake pad change Always make sure that the brake system does not have any leaks by activating the lever blade holding it and checking the hose connections and reservoir cover for eventual leaks Consult a trained technician in case of leaks Leaks cause poor braking performance with possible serious accidents As to hints about repairs of the hose see page 14 onwards Brake pads wear control and replacement Brake pad wear The brake pads are subject to wear due to friction bet ween rotor and pads The Julie disc brake features a fully automatic pad wear adjustment Regularly check the thickness of your brake pads and replace them if necessary Control and replacement of the brake pads Never touch either the rotor or the brake calliper after long braking as this may cause serious burns 1 Remove the wheel so that you have free access to the brake calliper Push both brake pads back by putting the transport device or a flat blade screwdriver into the gap Move the screwdriver slowly back and forth until both calliper pistons are fully retracted and flush with calliper body Never push back the pistons without the brake pads mounted 2 Remove the cotter pin that holds the brake pads 3 Pull out the brake pads Their ears make this very easy Clean the pads with a dry rag that is free of oil and grease www magura com v servi
15. he large variety of forks and frames available on the market it is impossible for MAGURA to test all possible combinations If you mount any of our brake systems always make sure that the brakes are in conformity with the bicycle Disc brake calipers can generate a lot of heat during extreme riding condi tions The resulting heat transfer from the caliper to the fork and or frame can have a negative influence on the mechanical characteristics of both the fork and or the frame English Insufficient heat transfer from the brake caliper to the frame and the fork caused by fork and or frame components having low heat transfer characteri stics e g carbon rear triangles can cause the brake to overheat with the pos sibility of a total failure of the brake system This can cause serious personal injury to yourself and or others With respect to product liability we remind all our users that any manufac turer also bike mechanic or end consumer is responsible for the correct function of the complete bicycle in this context Improper combinations and insufficient installation can cause damage and serious accidents 2 Mount the brake lever to the handlebar with a 5mm allen key If you install your brake lever the first time you ll hear a crack do not worry because of that Tightening torque 4Nm 34 in Ibs The MAGURA Julie disc brake is compatible with frames and forks which meet the international standard IS for disc brake installation B
16. ick releases with titanium or aluminum axles for your wheel sets in combination with a disc brake You will not be in a positi on to realize the necessary tightening torque wWwww magura com serviceQgmagura de 11 Trouble Shooting problem not enough brake power no pressure point Squealing brake contaminated brake pads contaminated rotor wheel cannot be mounted rattling noise and rough deceleration leaking hose or brake section Stay tuned led reason brake was not run it oil lubricants on rotor and or pads air in the system leaking systems badly aligned frame Paint powder coating on fitting eyelets Wheel g r skewer insuffi ciently tightened Insufficiently tightened wheel spokes carelessness carelessness Lever blade was pulled with removed wheel brake pads worn holder of pads is wearing the rotor accident incorrect installation solution break in the brake page4 clean the rotor with warm dishwater or alcohol replace contaminated brake pads bleeding the brake pagel 5 Correct transport page 5 Check hose connections and hose for leaks replace hose if necessary pages 14 15 align brake calliper with 0 2mm spacers page9 remove any paint or powder coating and care for an even contact surface without burrs page Increase tightening of q r skewer and mount it on opposite side of calliper check for an evenly spoked wheel with high spoke tension brake p
17. ided hose 0 1700mm 0721 203 2500mm 0721 386 6 Nm 51 in Ibs 10x 0720 411 4 Nm 34 in Ibs hubs Pro S 10x 0720 931 front silver 0150 035 2 5Nm 22 in lbs front black 0150 037 rear silver 0150 036 rear black 0150 038 Comp front silver 0721 148 Sas a front black 0721 155 rear silver 0721 149 rear black 0721 156 Fun calliper Postmount 74 front black 0721 355 black rear black 0721 357 0721 563 Quickmount cpl 0721 694 6 Nm 51 in lbs 0721 304 2x 0721314 Type 4 1 Performance l 0721 684 2x COAT Type 4 2 Endurance Specifications are subject to change without prior notice MAGURA Bike Parts GmbH amp Co Heinrich Kahn Strafe 24 D 89150 Laichingen phone 49 0 7333 9626 0 fax 49 0 7333 9626 17 info magura bikeparts de Hotline Helpdesk phone 49 0 7125 153 180 daily 9 12h and 13 16h CET fax 49 0 7125 153 184 service magura de MAGURA Partners and Service Centers Worldwide Andorra Australia Austria Belgium Canada Esports Jorma phone 376 844133 fax 376 843022 jorma correu andornet ad TMO Sports phone 02 9695 7744 fax 02 9695 7844 service velovita com au Funbike phone 0662 6362450 fax 0662 6362455 funbike funbike at Transmission phone 010 244646 fax 010 244777 info transmission be MAGURA USA phone 618 3952200 fax 618 3954711 magura magurausa com Czech Republic Vanek Praha phone 0312 6980
18. irectly under the separation line of the caliper halves see arrow If ever this is not the case re position the calliper with the 0 2mm spacers Ek E n N Lo O K wrong wrong In the case of a constantly dragging disc brake causing noise your frame could be miss aligned In such a case you should contact your dealer who can care to this with the MAGURA Gnann o mat disc optimizer for a totally even surface of the disc brake mounts These are absolutely necessary for a drag free function of your brake Do not worry when you hear friction between rotor and pads A slight drag is normal on disc brakes with automatic pad wear adjustment during the break in period This drag will disappear after a while The reason for this is that the brake pads find their optimum working position towards the rotor only after a slight wear during the break in period Slight drag might also happen after a brake pad change or in case of an incorrectly installed wheel New brakes and or new rotors or brake pads must always be run in by breaking at least 30 times from a speed of 30km h to achieve the maximum brake power Take your bike to a safe place to run in the brake Reach adjust is done with a 2mm Allen key Turning key clockwise lever blade moves away from the handlebar turning counterclockwise blade moves to the handlebar wWwww magura com serviceQgmagura de 6 Shorten th
19. ound the brake lever Tighten the cover screw until the cover is flush with the reservoir Use only the original Torx T7 bolt Any other screw will lead to leaks damages and failure of the whole system Tightening torque 0 6Nm 5 in Ibs 11 Remove the syringe and screw in the 3mm allen bleeding screw Tightening torque 2 5Nm 22 in Ilbs Re position the brake calliper tightening torque 6Nm 51 in Ibs Re install the brake pads and the wheel English Always pull the lever blade several times pump until the brake pads touch the rotor Always check for correct installation by activating the lever blade and checking for eventual leaks Never contaminate brake pads with oil or grease this causing permanent loss of brake power Contaminated pads are definitely dead and must be repla ced A contaminated rotor can be cleaned with warm dishwater or alcohol 10 The disc brake wheel The XC disc brake wheel There already exists enough literature concerning wheels so just a few tips how a well built X country disc brake wheel has to be Use spokes with a diameter of 2mm arc 1 8mm which you cross three times No radial lacing with disc brake wheels Head inside spokes arc outside spokes have to be pulled i e these spokes point for ward on the front wheel on the back wheel these spokes point forward on the rotor side and backwards on the drive side All spokes have to be stressed equally and high Never use ultra lightweight qu
20. pan MC International phone 06 6536 0901 fax 06 6536 0907 mcinter mx1 alpha web ne jp Korea MAGURA ASIA Inc phone 886 4 23283739 fax 886 4 23283734 service magura com tw Luxemburg Transmission phone 0032 10 244646 fax 0032 10 244777 info transmission be Netherlands NZ Parts phone 010 2340468 fax 010 2340824 nzparts worldonline nl Botolfsen phone 022 630610 fax 022 970662 info botolfsen no LPL Artigos Desportivos phone 021 4835354 fax 021 4835362 Iplenetcabo pt Singapore MAGURA ASIA Inc phone 886 4 232837 fax 886 4 23283734 service magura com Factory Store phone 06 3481705 fax 06 3481705 factorystore siol net South Africa Cycles Africa phone 011 678 1548 fax 011 678 1548 cunning mweb co za SAT MAGURA Bicisport S lo para reparaciones y servicio phone 93 3404480 fax 93 3404480 Bicicletas Monty phone 93 6667111 fax 93 6667112 monty monty es phone 6183952200 fax 6183954711 magura magurausa com Norway Portugal Slowenia Spain ermany MAGURA 10 2003 All rights
21. possible heavy bodily injury www magura com v serviceQgmagura de 13 Warranty MAGURA is giving a 5 year leakproof warranty on brake levers master cylinder and brake callipers Watch out for the red info sheet in the middle of this manual This warranty is void when damage to the brake has occurred from the following abuse mixing and matching the brake with parts from other manufacturers damage of the exterior finish caused by improper use any attempt to disassemble the whole brake modifications non factory changes or improper service We expressly point out that a warranty claim is only accepted with a clear proof of purchase payment receipt of the dealer and recommend to register your brake online on magura com www magura com v serviceQgmagura de spare parts 2003 max tightening torques Torx T7 key 0720 847 0721 207 10x 0 6 Nm 5 in lbs 10x 0720 927 black with 2 finger lever blade 0721 305 left 0721557 right 0721556 black with 4 finger lever blade left 0721 559 10x 0720918 4Nm 34 in lbs 2x 2 finger alloy silver 0721317 2x 0721214 2x 4 finger alloy silver 0721318 10x 0720405 10x 0720446 20x 0720916 Torx T25 screws 0721 057 4 Nm 34 in lbs 6x Torx T25 key 0721 204 O front O180mm V 6 holes 0721 621 int standard clad rear O160mm 6 holes 0721 001 int standard hose 2300mm 0321 227 bra
22. rame is not equipped for routing hydraulic lines you should now mount the hose fitting kit available as separate accessory see magura com for your rear brake according to the instructions that are included in the kit www magura com v serviceQgmagura de Hold the hose carefully so that it cannot snap away Cut the hose squarely The sleeve nut can be re used The olive cannot be re used and must be repla ced 5 Slide on the sleeve nut and a new olive onto the hose Push the hose with the sleeve nut and the new olive fully into the brake lever and tighten the sleeve nut with an 8mm open end wrench Tightening torque 4Nm 34 in lbs 6 Always check for correct installation by pulling on the hose Make sure that the system has no leaks Squeeze the lever blade hold pressure and check hose connections and the reservoir cover for eventual leaks Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm If you cannot realize this bleed the brake see page 15 onwards English wWwww magura com serviceQgmagura de 7 Maintenance Brake Oil MAGURA disc brakes use a transmission medium low viscosity mineral oil the biodegradable MAGURA ROYAL BLOOD Contrary to DOT brake fluid the MAGURA ROYAL BLOOD does not irritate human skin or strip the paint of your frame Moreover it does not absorb water like DOT and does not have to be changed regularly What sounds unbeli
23. s shown Unscrew bleeding screw with a 3mm Allen key Screw in the prepared syringe and tighten it with an open end 8mm spanner Place now a rag which has to be free of oil or lubricants around the reser voir and more important around the brake calliper Care for a clean working environment No dirt or particles may come into the brake system 6 Unscrew the Torx T7 reservoir cover screw and remove the cover with the mem brane sitting below Begin to slowly press the oil contents of the filing syringe through the system until no further air bubbles can be seen 7 Press the MAGURA ROYAL BLOOD oil through the system Use a second syringe to suck any overflowing oil at the reservoir Then pull the filler syringe to suck oil back Repeat procedure 3 4 times and actuate CAREFULLY the lever blade simultaneously Make sure that there is always enough oil in the reservoir when you suck the oil with the filling syringe 8 Use the second syringe to suck any overflowing oil The rag around the brake lever and the calliper prevents overflowing oil from dropping down and contaminating and killing the brake pads Push the complete contents of the filing syringe through the system 9 The reservoir has to be full to the top before replacing the membrane and the cover www magura com v serviceQgmagura de 10 Replace the cover with the membrane onto the reservoir Oil will spill during this procedure therefore do not forget to place a rag ar
24. sc brake We urge you to read it carefully become familiar with its contents and follow our recommendations to help make your new braking experience enjoyable and trouble free Although the Julie disc brake system is relatively simple you should not overestimate your technical skills We therefore advise you to leave the follo wing operations to a trained technician of a professional bike shop Should there be any further questions or problems we warmly recommend that you visit our website www magura com where you will always find the newest and hottest tips about all our products Stay tuned with the Brake People Thank you for your confidence in our products enjoy your ride and your new MAGURA disc stoppers Happy trails English wWwww magura com serviceQgmagura de 2 Before the first ride 1 Are you already familiar with hydraulic disc brakes Our brakes might be much more powerful than the stoppers on which you relied on so far Take your bicycle to a safe area to learn the proper braking technique and operation of your new brakes and your bike 2 Check that the fornt brake is still actuated by the lever on the side your are used to braking with Should this not be the case you wll have to train to your new setup otherwise any unintended front wheel braking manoeuvre may cause an accident leading to possible serious injury If in doubt get a trained technician to swap the hoses For further hints concerning swapping of the
25. unbelievable is a fact you can use your brakes over years without having to touch them except brake pad change 1 Loosen slightly the clamping screw of the brake lever with a 5mm allen key and turn the brake lever so that the reservoir is positioned horizontal Slightly tighten the clamp screw in that position 2 For filling and bleeding a MAGURA disc brake you will need the disc brake service kit Code 0721 294 including all necessary tools wWwww magura com serviceQgmagura de 3 Prepare the transparent filler tube by pushing in by hand the M6 barbed fitting Put the other end of the filler tube on the syringe and fill the syringe completely with MAGURA ROYAL BLOOD mineral oil Fill the syringe completely and make sure that there are no air bubbles inside Turn the syringe eventually to push out air bubbles 4 Remove the brake pads as described on page 12 and slide the YELLOW trans port device as shown with its THICK END between the calliper pistons Squeeze slight ly the lever blade pump to tighten the transport device Only use the YELLOW trans port device for this procedure the formerly used black one is not suitable for this work 5 Fix the calliper so that the connecting bolts of the calliper arrow are positioned horizontally If you do not follow meticulously this advice a proper bleeding of the brake will fail t might be necessary that you have to unscrew the calliper for that or to turn the fork bike a
26. y dismounting the Quickmount adaptor the front brake is also compatible with Manitou forks with Postmount mounts Never mount the brakes with adapters or brackets from other manufacturers All warranty will be void in case of any misuse Use only direct mounting parts from MAGURA or the frame or fork s manufacturer Make sure that the caliper fitting eyelets on your frame or fork are free of any paint powder coating or burrs arrows If this is not the case you should contact your dealer who will be able to clean the surfaces providing an absolutely flat even mounting surfa ce also see page 9 ATTENTION The treatment of suspension lower legs made of magnesium might be dangerous because of corrosion Always follow the safety instructions given by the respective manufacturer Always make sure after having treated the disc brake mounts that these are protected against corrosion by using an appropriate protective paint wWwww magura com serviceQgmagura de 3 Mounting on forks and frames that meet the International Standard Mount the caliper onto the fork or the frame bolts A Use a 5mm allen key Tightening torque 6Nm 51 in lbs Do not tighten yet the bolts B 4 Mount the rotor with the 6 Torx T25 bolts onto the hub Watch out for the cor rect rotation direction of the rotor laser arrow Use only new original bolts or thread lock if you use old bolts Tighten the bolts in a crossed pattern Tightening torque 4Nm 34 in lbs
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