English - Magura
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1. 20x 0720 916 English 0720 446 10x 4 Nm 34 in lbs banjo fitting 2x 10x 0720 405 0321 285 EVO2 EVO2 adaptor complete silver 0721 853 silver 0721 846 black 0721 847 silver 0721 908 black 0721 907 20x 0720 441 6 Nm 51 in Ibs NS a 10x 0720 442 ei j 10x 0720 933 4 5 Nm QS 39 in lbs 0721186 10 59 um 0721 855 10x 6 Nm 51 in lbs 0720 934 10x 0720 846 6 Nm 51 in lbs braided hose kit fof 2 brakes quick release silver Q MENOS 0721 203 S only 1700 mm main hose Q 5 Nm 43 inlbs 0720 865 2x b 4 Nm 34 in lbs v i MAGURA Bike Parts GmbH amp Co KG MAGURA Partners and Service Centers Worldwide Andorra Esports Jorma phone 376 844133 fax 376 843022 jorma pcorreu andornet ad Australia TMO Sports phone 02 9695 7744 fax 02 9695 7844 service velovita com au Austria MAGURA Service Center Austria phone 0662 643703 fax 0662 643802 service_austria magura de Belgium Transmission phone 010 244646 fax 010 244777 infogxtransmission be Canada MAGURA USA phone 618 3952200 fax 618 3954711 magura magurausa com Czech Republic Sport 04 phone 0312 698016 fax 0312 698025 info scottsports cz Denmark Borandia APS phone 47 107172 fax 47 107066 borandia borandia dk MAGURA 2005 All rights reserved Printed in Germany 0689 610 06 2002. worsAashop Tele WwWw magura com Italiano the passion people e ge OL un LLI Www magura com the passion people Summary 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 5 Warranty 5 6 Brake installation 6 9 7 Installation FIRM tech 10 8 Shortening and routing the hose 11 9 maintenance brake pad change 13 10 Filling and bleeding 14 11 Repairs 15 12 Brake pads 16 13 Accessories 17 14 Spare parts exploded view 18 19 GGG 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 ATTENTION This symbol warns you of inappropriate handling that might cause serious damage to 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 For your own safety you should not overestimate your technical skills We advise you to leave the following works in case of any doubts to a professional bike mechanic www magura com the passion people 1 Welcome to the Passion People Brake lever master cylinder MAGURA HS 33 Congratulations You have purchased a fully hydraulic MAGURA rim brake proudly Made in Germany
3. You will be amazed at the awesome braking power and the mini mum amount of maintenance that is ne cessary on our stoppers Good to know that you are not alone millions of riders worldwide rely on them and every day our numbers are increasing Brake calliper slave cylinders MAGURA HS 33 On the fully hydraulic MAGURA rim brake systems HS 33 and HS 11 the braking force is transmitted 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 pushes the mineral oil column through the brake hose in the direction of the brake calliper slave cylinders where two pistons on which the brake pads are clipsed are pushed out The friction between the brake pads and the rim slows down the bicycle and causes a heating of the rim English Never touch the rim after long braking as this may cause serious burns You will be pleased to find out that the MAGURA rim brakes offer a superior braking power even with little hand force applied no matter what the weather conditions should be Please note however that rim brakes are generally not as powerful in the wet in in snowy conditions mainly and that the reaction of the brake will be slightly retarded under these circumstances Our rim brakes cause a wear of your rims So do not forget to check regularly your rims This manual contains important information about the safe installation o
4. phone 022 630610 fax 022 970662 info botolfsen no Portugal LPL Artigos Desportivos phone 021 4835354 fax 021 4835362 lol netcabo pt Singapore MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw Slowenia Maraton D O O phone 386 0 74990870 fax 4386 0 74990872 maraton siol net Slowakia AGF Invest s r o phone 02 62859549 fax 02 62859052 info agfinvest sk South Africa Cycles Africa phone 011 678 1548 fax 011 678 1548 cunning mweb co za Spain m SAT MAGURA Bicisport S lo para reparaciones y servicio phone 93 3404480 fax 93 3404480 m Bicicletas Monty phone 93 6667111 fax 93 6667112 monty monty es m Casa Masferrer phone 93 8463444 fax 93 8465355 cmcenter casamasferrer com m Comet phone 943 331393 fax 943 551407 comet comet es m Representaciones Spinola amp Perez phone 619 702946 fax 93 2317731 c perez spinolaperez com tne PrAssion people Sweden Jaguarverken AB phone 060 669800 fax 060 669809 info jaguarverken se Switzerland m Intercycle phone 041 9266511 fax 041 9266355 info intercycle com m Amsler amp Co phone 052 6473636 fax 052 6473637 info amsler ch Taiwan MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw USA MAGURA USA phone 6183952200 fax 6183954711 magura magurausa com www magurausa com
5. 5 Apollo 11 Germany Heinrich Kahn Stra e 24 D 89150 Laichingen info magura bikeparts de www magura com Finland Best Brakes Ky phone 050 591 5863 fax 019 388485 info bestbrakes inet fi France MAGURA Service Center France phone 0825 886295 indigo fax 03 81 88 49 92 sav_france magura de Great Britain MAGURA Bike Parts UK Ltd phone 01530 837195 fax 01530 811286 service_uk magura de Greece Nikos Maniatopoulos S A phone 2610 993 045 fax 2610 990 424 amarket idealbikes gr Hong Kong MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw Hungary Mali Bicycle Technology phone 01 4207563 fax 01 4205321 maligymali hu Ireland Beara Bike Trading phone 064 89134 fax 064 41334 wschmidt indigo ie Hotline Helpdesk phone 0190 648124 41ct pro Minute aus dem deutschen Festnetz werkt glich von 9 bis 15h fax 07333 962651 service magura de Italy Areab phone 0438 435550 fax 0438 439847 fltslerbietlsfte Japan MC International phone 06 6536 0901 fax 06 6536 0907 mcinter mx1 alpha web ne jp Korea MAGURA ASIA Inc phone 886 4 23106839 fax 886 4 23283734 service magura com tw Lativa SIA ELKOR STILS phone 371 7070750 fax 371 7070456 sport elkor lv Luxemburg Transmission phone 32 10 244646 fax 32 10 244777 info transmission be Netherlands NZ Parts phone 010 2340468 fax 010 2340824 nzparts tiscali nl Norway Botolfsen
6. cycle 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 bicycle may result in serious accidents with possible fatal injuries of the rider 4 Transport of the bicycle For a transport in an aircraft you can leave your brake as it is e g you do not have to empty it Beside of this there are no further activities necessary Always make sure that the hose is not snapped or damaged during transport 5 Warranty kamen MAGURA is giving a 5 year leakproof warranty on brake levers master GES cylinder and brake callipers if you register your brake online on magura com and calipers 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 online registration on magura com wWww magura com the passion people 6 Brake Mounting 1 Tools for mounting maintenance Allen key 2 3 and 5 mm 8 mm open end wrench sharp knife delivered with the brake Please insert the allen key com
7. der to change your wheel or the brake pads Quick release tension is adjusted similar to standard version c f page 8 2 Close the quick release Push the brake cylinder back towards the fork Close the quick release by doing the same That s all A booster is not necessary with FIRM tech and not foreseen either It is not possible to mount one 3 Adjust the brake pads to the rim width with the 5 mm allen screw which is integra ted in the brake cylinder By turning the screw clockwise the pad approaches to the rim 4 With FIRM tech you adjust the brake pad to the rim on both sides with the 5 mm allen screw Shorten the hose and pad wear adjustment as described in the respective chapters www magura com dii d W I the passion people 8 Shorten and route the hose 1 HS 33 Turn the red Turbo Pad Adjuster TPA fully back in direction and unscrew if necessary the 2mm reach adjust screw as well 2 HS 11 Turn the 4 mm allen bolt fully counterclockwise 3 If your frame is not equipped for routing hydraulic lines you can find in our accessory program the hose clips English 4 and hose guides 5 Unscrew the 8 mm sleeve nut at the slave cylinder 6 Pull out the hose carefully Never activate the lever blade with the system open Hold the tubing carefully in order to avoid any loss of oil wWwww magura com the passion people 7 Put the hose on a hard surface Cut the hose squarely j
8. ers four different brake pad compounds for different riding styles and rim surfaces black 0321 406 standard brake pad for polished rim surfaces Series pad on all brake models red 0720 423 race oriented brake pad for polished rim surfaces Excellent for trials grey 0321 407 standard brake pad for hard anodized black and ceramic coated rims green 0720 439 race oriented brake pad for hard anodized black and ceramic coated rims ATTENTION Do not forget that the brake pads are subject to an increased wear if you use ceramic coated rims so check them regularly All brake pads are sold as a complete set of 4 pieces www magura com dii d W I the passion people 13 accessories 1 Stainless steel hosekit Cool looks and totally bomb proof Available as kit for a complete brake set 0720 846 and as single hose in a 1700 mm length 0721 203 2 Hose guides 0721 214 for all those who care for a clean and esthetic hose routing along the toptube Installation Is a snap The guides are just screwed into the cablestops The hydraulic hose is simply clipped in 2 pieces 3 MAGURA 90 hose fitting kit 0321 285 makes the necessary 90 hose connection possible onto brake levers for recumbents HPV s or on time trial bars Only compatible with HS 33 2 pieces English 4 HS 11 alloy lever blades On a lot of bikes which come with MAGURAs as OE equipment you often find simple composite lever blades The Passi
9. g oil will work but needs to be flushed out after the return to civilization Never use DOT brake liquid Pay close attention not to have any air in the tube or syringe Remove bleed screw bmm allen screw at the slave cylinder Fit filled syringe and filler tube and fix it with an 8mm open end wrench 3 HS 33 Turn the brake lever HS 33 on the handlebar from the horizontal position until it is in the shown 20 angle Turn back fully the TPA knob in the position HS 11 Turn the brake lever on the handlebar horizontal Turn fully back the 4 mm pad ad justment screw Remove the bleed screw in the brake lever 4 Install the vent tube and hold its end into the oil bottle 5 Push the oil through the system Use the whole content of the syringe You can see air in the form of small bubbles in the vent tube 6 The bleeding procedure is completed when no more air bubbles can be seen in the vent tube Remove the vent tube and replace the bleed screw Tightening torque 4 Nm 34 in Ibs Remove syringe from slave cylinder and replace the bleed screw Tightening torque 4 Nm 34 in lbs Return brake lever to its normal riding position and clamp correctly Tightening torque 4 Nm 34 in Ibs They system is correctly bled when the pads move immediately upon activating the lever blade Adjust the pad rim clearance with the TPA or the allen adjustment bolts see chapter maintenance pad change Check the entire system for oil leaks Chec
10. glish Brake pad wear adjustment as shown above When the red TPA HS 33 models is turned all the way in the 4 mm allen bolt is in flush with the lever blade HS 11 it is time to change the pads Before changing the pads you must always screw back the adjusting screws to their start position 3 New 1 and worn 2 brake pad When your brake pads are worn as shown it is time to change them 4 To change the brake pads open the quick release remove the brake from the canti stud pull out the old pad and then just snap in a new one After removing the wheel pull out the old pad and snap in a new one on the other side That s all Www magura com the passion people 10 Filling and bleeding The filling and bleeding of a MAGURA brake is not a routine work This is due to the fact that the MAGURA Royal Blood hydraulic oil does not absorb water like DOT brake liquid in cars and on motorcycles A filling and bleeding of a MAGURA is therefore only necessary in case of an incorrect installation or a tubing change after a crash Only use MAGURA Royal Blood hydraulic oil never DOT brake li quid 1 The service kit contains everything you need which you need for bleeding or repai ring your MAGURA brake d Push by hand a barbed fitting into both the transparent filler and vent tubes 2 Put the filler tube on the syringe and fill completely with MAGURA ROYAL BLOOD mineral oil In the case of an emergency cookin
11. k the flawless performance high power and excellent modulation wWwww magura com the passion people 11 Repairs 1 Repair of a HS 11 main hose with barbed adaptor connection 2 To do this clamp the hose as shown with the help of the two clamping jaws into a vice 1 5 cm of the hose have to stick out of the clamp Use a nylon mallet to tap the barbed fitting into the tubing The barbed fitting must be installed as shown Never use a lighter or a heatgun to soften the hose 3 Screw the repaired hose into the prepared thread English 4 Correctly installed repaired hose on an HS 11 The barbed fitting is flush with the brake lever arrow The brake now has to be re filled as described in the chapter filling and bleeding Further repair tips In case of a damaged brake cylinder crossover hose proceed as described above from points 1 to 4 Spare brake levers and slave cyclinders are delivered dry If you have to replace a brake lever or slave cylinder the MAGURA system has to be bled twice after changing the defective item Activate the lever blade after the first bleed to chase all air bubbles and to make sure that the oil is well distributed in the new part Leaking brake levers and slave cylinders have to be replaced as complete units Due to product liability reasons MAGURA neither offers spare pistons nor internal seal repair kits wWwww magura com the passion people 12 brake pads MAGURA off
12. n not in place this is purely to help show the details better Mounting a MAGURA brake with the wheels in place is much simpler for this reason if at all possible do not remove the wheels 7 The upper cones of the adaptor must fit properly into the drill of the EVO2 moun ting plate Mount the left side with an Allen key no 5 6 Nm 51 in Ibs Do not tighten fully yet the bolts 8 Before you install the right side check out how easy it is to change MAGURA brake pads Simply click them in Slide the right side onto the canti stud and close the quick release Wwww magura com the passion people 9 Side view of a correctly installed EVO2 unit There is a sufficient clearance between upper cone of the adaptor and fork booster arrow 1 The washer is installed between canti stud and EVO2 mounting plate arrow 2 10 Push the slave cylinders towards the rim while adjusting them properly i e PARALLEL to he rim Care for a correct adjustment of the brake pads that have to be parallel to the rim 11 Pull slightly the lever blade to push back the slave cylinders and tighten the bolts when you have a gap of 2 mm between rim flanc and brake pads 12 A perfectly aligned MAGURA brake brake pads parallel to the rim distance pad rim 2 mm on both sides Connection hose between the brake cylinders points inboard i e frame fork Quick release points up when it is closed Respect at any rate the indicated tighteni
13. ng torques 6Nm 4 5Nm 51 in lbs 39 in lbs 13 Check the quick release tension when it is closed Increase it if necessary by turning in the quick release bolt clockwise 4 5 Nm 39 in lbs 14 EVO 2 booster installation The side with the wide drill is mounted on the quick release side of the adaptor Do not forget the washer under the head of the fitting bolt Max tightening torque is 6Nm 51in lbs On the opposite side the round drill of the EVO 2 booster just slips over the mounted bolt wWwww magura com the passion people 15 Reach adjust only available with HS 33 is done with a 2 mm Allen key Turning key clockwise lever moves to the handlebar turning counterlclockwise lever moves away from the handlebar 16 Brake pad wear adjustment HS 33 Turn the red Turbo Pad Adjuster TPA in direction Pads move towards the rim 17 Brake pad wear adjustment HS 11 Turn 4 mm Allen screw clockwise pads move towards the rim English wWwww magura com the passion people 7 Installation of FIRM tech models If you are the proud owner of a MAGURA suspension fork with FIRM tech equipment mounting the brakes is a breeze Fit the fork and mount the brake lever to the handlebar as described Fit the slave cylinders of the brake as shown on page 18 of this manual 1 Check out the double quick release comfort To open it push the quick release in direction of the wheel you can now move the brake cylin
14. on People offer a lar ge range of tuning lever blades in quality aluminium for example the lever blades for the HS 11 Available in silver 0721087 All lever blades are sold in a set of 2 pieces wWwww magura com the passion people 14 spare parts 2006 max tightening torques HS 33 silver left 0721 849 right 0721 848 black left 0721 851 right 0721 850 HS 11 left 0721 961 10x 0720 405 right 0721 962 x 10x 0720 446 4 Nm 34 in Ibs 10x 0720 916 10x 0720 931 2 5 Nm 22 in lbs 10x 0720 931 2 5 Nm 22 in Ibs 10x 0720 848 4 Nm g 34 in lbs amp composite 2x 0721 086 aluminium 2x 0721 087 M6 M6 silver 0720 902 10x 0720 918 4 Nm 34 in lbs black 0721 238 10x 0721 187 0720 446 10x 4 Nm 34 in lbs 0720 411 10x 4 Nm 34 in lbs grey 4x 0321 407 0720 916 10x black 4x 0321 406 red 4x 0720 423 M6 M8 green 4x 0720 439 silver 0720 903 black 0721 239 0721177 0722 240 10x 4 5 Nm 0721178 10x 5 Nm 43 in lbs 07211706 0721179 10x Specifications are subject to change without prior notice Wwww magura com the passion people HS 33 0720 921 10x HS 11 0720 927 10x 2x 0721 852 0720 931 10x 2 5 Nm 22 in lbs 20x 0720 424 Ps 0720 849 10x ei 6 Nm 51 in lbs lo 2x 0721 995 10x 0720 923 0720 918 10x 4 Nm 34 in lbs
15. ore the lever blade touches the handlebars In case of changing pressure points during a ride you might have air in the brake system See hints about filling and bleeding from on pages 14 16 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 brake lever for eventual leaks Also see page 11 4 Always protect your rims and brake pads from oil and lubricants e g by lubrica ting your chain www magura com the passion people Contaminating the pads with oil and lubricants will cause a permanent loss of braking power Clean contaminated rims and pads with isopropyl alcool or with warm dishwater See further hints about the brake pad change on page 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 release skewers are tightened sufficiently 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 spokes 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 English 8 Always follow the instructions given in the owner s manual of your bi
16. peration and maintenance of your MAGURA rim brakes 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 All setup steps will be explained on the HS 33 rim brake Any differences with the HS 11 model will be clearly mentioned Although the MAGURA rim brake systems are relatively simple you should not overestimate your technical skills We therefore advise you to leave the following works to a trained technician of a professional bike shop In case of any further questions or problems we warmly recommend to visit our website www magura com where you will always find the newest and hottest tips about all our products On magura com you can also download this manual in a more convenient A4 format Stay tuned with the Passion People Thank you for your confidence in our products enjoy your ride and your new MAGURA stoppers Happy trails wWwww magura com the passion people 2 Before the first ride 1 Are you already familiar with hydraulic rim brakes Our brakes might be much more powerful than the stoppers on which you relied 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 front brake is still actuated by the lever on the side you are used to braking with Should this not be the case you will have to train to your new setup othe
17. pletely to avoid damaging the bolts Unpack your MAGURA brake and arrange all parts The quantities mentioned here refer to after market sales boxes including a complete brake set 1 Preassembled brake filled and bled ready for mounting 2 pieces 1a brake lever or master cylinder 1b brake cylinder or slave cylinder 1c EVO2 adaptor 1d quick release cantistud U washers 4 pieces fitting bolt for EVO2 adaptor 2 pieces quick release or hourglass bolt 2 pieces EVO2 mounting plate 2 pieces olives 2 pieces EVO 2 booster and washer 2x pU MI Del Contents in the sales box may vary mainly in the US www magura com the passion people 1 Mount the brake lever onto the handlebar Tightening torque 4 Nm 34 in lbs Hint Tighten the brake lever so that you can still turn it by hand on the handlebar when you apply big forces This old motocross trick will reduce crash damages 2 Screw in the quick release bolt into the left frontwheel resp right rearwheel canti stud seen in rotation direction 3 Mount a canti stud washer on both canti studs flat side pointing up Tip to prevent losing the washers use silicon glue to semi permanently fix them on the studs English 4 Use only ONE washer per stud 5 Slide the EVO2 mounting plate on the canti studs 6 EVO2 label has to be legible from assembly position and must not stand upside down In the following pictures the wheel is often is ofte
18. rwise 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 the swapping of the brake hose see page 11 onwards 3 While riding in extreme conditions total weight of bike plus rider over 100 kg and or a gradient of more than 15 always use both brakes simulta neously to slow your bike down 4 Do not use a MAGURA rim brake for downhill sport Any misuse might cause serious accidents with fatal injuries both to yourself and others 5 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 saffe area to improve your handling abilities before using it on road Consult the user s manual of your bike to learn more about this 6 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 bef
19. ust behind the olive using a y cutter never use pliers or a saw 8 The olive must be replaced Hold the hose carefully so that it cannot spring away Cut squarely and on a hard surface to achieve a clean cut Never use pliers or a saw Throw away the hose piece with the fitted olive Slide off the sleeve nut Slide the hose carefully through the heatshrink tube Measure the correct length of the hose don t forget to turn the handlebars and cut the tubing as described 9 The black olive cannot be mounted incorrectly as it is symetrical Push the hose all the way into the slave cylinder 10 Do not crossthread After initial start by hand use an 8 mm open end wrench Tightening torque 4 Nm 34 in Ibs 11 Always check for correct installation by pulling on the hose Make sure that the system has no leaks by activating the levers and checking all connec tions www magura com dii d W I the passion people 9 Maintenance brake pad change 1 brake pad wear adjustment HS 33 Turn the red Turbo Pad Adjuster TPA in direction Pads move towards the rim 2 brake pad wear adjustment HS 11 Turn 4mm Allen screw clockwise pads move towards the rim MAGURA brakes do not need any special maintenance after correct installation Regular bleeding is absolutely not necessary because the MAGURA Blood mineral oil does not contract water like DOT brake liquid used in cars on motorcycles and competi tors products En
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