WS LOUISE 2011 D.indd
Contents
1. 4 Install the hose as described in chapter 6 After the installation of a new hose you will always have to refill the brake The following chapter 9 describes how the filling and bleeding has to be done 9 Filling and bleeding a brake 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 unbelievable is a fact you can use your brakes over years without having to touch them except brake pad check and change Use exclusively MAGURA ROYAL BLOOD any other oil will damage the seals of your brake what will result in total failure of the brake 1 Loosen slightly the clamping screw of the brake lever with a 5mm allen key and ensure that the reservoir points upwards approx 15 from the horizontal position 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 including all necessary tools 3 Prepare the transparent filler tube by pushing in by hand the M 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 sy2. D injuries for the rider 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 11 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 defor med or contaminated with lubricants If the bike is transported upside down squeeze before the lever blade hold pressure and fix the lever blade in this position with a rubber band or a cable tie as shown on the right photo For a transport in an aircraft you can leave your brake as it is e g you do not have to empty it THE PASSION PEOPLE 5 Brake installation 1 Tools for installation maintenance Allen key 2 2 5 3 and 5 transport mounting device sharp knife 8 mm open end wrench flat blade screw driver Torx T25 key Torx T7 key delivered with the brake Always insert the allen and torx keys completely to avoid damaging the bolt heads Unpack your Louise disc brake brake lever master cylinder connected through the brake hose with the brake caliper with transport device ATTENTION remove the transport device only shortly
3. res shouldn t cost the earth one X COUNTRY Race orientated means for us the minimum weight that is technically possible Every gram extra weight can be the decisive factor between winning or losing for you the racer maniac e O XC RACE Marta FR 203 203 Marta SL Magnesium 203 203 Marta SL Magnesium 180 180 Marta SL Magnesium 160 160 Specifications subject to change wit hout prior notice Louise 203 203 Marta SL 203 203 Marta SL 180 180 Marta 203 203 Louise 180 180 Julie HP 203 203 Marta 180 180 Julie HP 180 180 Marta SL 160 160 pea Marta 160 160 Louise 160 160 Julie HP 160 160 Table of contents 1 Introduction 4 2 Safety instructions before the first ride 5 3 Safety instructions before every ride 5 6 4 Transport of the bicycle 6 5 Brake installation 7 10 6 Shorten the hose 11 12 7 Maintenance Brake pad change 13 14 8 Repairs 15 9 Bleeding and Filling 16 17 10 The disc brake wheel 18 11 Accessories 18 12 Trouble Shooting 19 13 Warranty 19 14 Spare parts exploded view Tuning adaptors 20 21 WARNING This symbol means possible danger for your health and even life if you do not follow the instructions given resp if the necessary safety measures are not followed ATTENTION This symbol warns you of inappropriate handling that might cause heavy damage to the material and or the environment NOTE
4. the lever blade to chase tiny air bubbles that might hide within the system The job is done when no air bubbles can be seen after having follo wed the steps above several times 10 Before you remove the syringe on the reservoir make sure that there is only a small quantity of oil inside Place a rag around the brake lever and the caliper thus pre venting overflowing oil from dropping down and contaminating and killing the brake pads Remove the syringe and close the end that was inserted into the reservoir quickly with your finger Empty the remaining content of the syringe into an container 11 Close the plug on the reservoir cover as shown by pressing it by hand into the drill That s it 12 Remove the filling syringe and screw in the 5mm allen bleed screw Tightening torque 2 5 Nm 22 in lbs Re install the brake pads and the wheel 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 killed and MUST be replaced A contaminated rotor can be cleaned with MAGURA brake cleaner warm dishwater or alcohol English 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 wh
5. 5x10 2x M6x18 white 0722 528 silver 0722 529 black 0722 530 Specifications are subject to change without prior notice 15 Adaptors mounting alternatives for Louise 2009 Adapter Nr Scheibendurchmesser mm Anbau Bremse Bestellnummer Adaptor Rotor diameter mm installation brake order code Adaptateur Diametre disque mm montage frein r f rence N 5 203 Int Standard 6 VR Front AV 0722 321 N 6 180 Postmount 6 VR Front AV 0722 322 N 7 203 Postmount 6 VR Front AV 0722 323 N 8 203 Rockshox Boxxer 2009 0722 324 N 9 203 Int Standard HR Rear ARR 0722 325 N 10 180 Int Standard HR Rear ARR 0722 424 N 11 160 Int Standard 6 VR Front AV 0722 425 203 Int Standard 8 Fox 40 180 Int Standard 6 VR Front AV Julie 2005 2008 160 Int Standard HR Rear ARR Julie 2005 2008 N 12 180 Int Standard 6 VR Front AV 0722 426 180 Int Standard HR Rear ARR Julie 2005 2008 160 Int Standard 6 HR Rear ARR N 14 210 Int Standard 6 VR Front AV Julie 2005 2008 0722 453 190 Int Standard HR Rear ARR Julie 2005 2008 N 15 210 Postmount 6 Julie 2005 2008 0722 454 N 26 203 Postmount 7 MAGURA Thor 0724 131 N 27 160 Postmount 5 0724 495 N 28 180 Postmount 5 0724 496 Direktanbau 203 Postmount 8 VR Front AV Direct mount 180 Postmount 7 VR Front AV MAGURA Thor Montage direct 140 Postmount 5 HR Rear ARR 160 Postmount 6 VR Front AV 180 Postmount 6
6. Deutsch I WORKSHOP 2011 DISC BRAKES English Francais Nederlands Italiano THE PASSION PEOPLE MAGURA WWW magura com Espa ol Our disc brake range recommended use Gustav M Marta FR 203 203 Marta SL Magnesium 203 203 Marta SL Magnesium 180 180 Marta SL Magnesium 160 160 Marta SL 203 203 Marta SL 180 180 Marta SL 160 160 Marta 203 203 Marta 180 180 Marta 160 160 Louise 203 203 Louise 180 180 Louise 160 160 julie HP 203 203 julie HP 180 180 julie HP 160 160 Ground contact isn t that important to you There is almost no terrain where a Freerider won t go Tough and stable components are amust have Here they are O O FREERIDE Gustav M There are bikers out therefor whom uphill is just a means to an end The downhill fun is having absolute priority for them With lots of travel and robust compo nents the Enduros must cope with technically hairy downhills and bike park weekends 2 ENDURO You re an all roun der You love long and sweeping trails up as well as down The optimummix of light weight and stability is the hall mark of your AllMountain com ponents meant for abroad spectrum of use ALL MOUNTAIN Mile after mile over the dusty trails as well ashard fast tar mac On every ride your bike shouldbe the epitome of uncomplicated and naturally the parts for your X country adventu
7. Heat Eater must NOT move during compression of the fork and or frame 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 peri od 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 duri ng the break in period Slight drag might also happen after a brake pad change or in case of an incorrectly installed wheel In case of a constantly dragging disc brake causing noise your frame is badly aligned In such a case you should contact your dealer who can care 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 New brakes and or new rotors or brake pads must always be run in by breaking at least 30 times from a speed of 30 km h to achieve the maximum brake power Take your bike to a safe place to run in the brake 10 Reach adjust is done with a 2 5 mm Allen key Turning key clockwise lever blade moves away from the handlebar turning counterclockwise blade moves to the hand lebar On Louise models without BAT feature you find the reach adjust screw under the black dust cover of the lever blade WARNING The reach adjust screw becomes very firm when you risk to overtig hten it Do not continue to screw it in out in such a
8. This symbol is giving you additional information about the general handling of the product or gives hints to paragraphs of this manual which have to be read carefully English 1 Welcome to the Passion People Brake lever master cylinder MAGURA Louise Congratulations You have purchased a fully hydraulic MAGURA disc brake proudly Made in Germany You will be enthusias tic about the awesome braking power and the very little maintenance that is necessa ry on our stoppers Good to know that you are not alone millions of users worldwide rely on them and every day we re becoming morel Brake caliper and rotor MAGURA Louise On the fully hydraulic MAGURA disc brake system MAGURA Louise 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 caliper where two pistons on which the brake pads are fixed are pushed out The friction between the brake pads and the rotor is slowing down the bicycle and causes a heating of both the rotor and the brake caliper 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 Louise disc brakes offer a superior braking power even with little hand force applied no matt
9. VR Front AV Julie 2005 2008 WARNING Always make sure that the fixing bolts are screwed in to a depth of at least 8 mm This corresponds to around 8 full turns Should this not be the case longer bolts with a minimum hardness of 8 8 should be used and secured using blue Loctite Specifications are subejct to change without prior notice Visit our website magura com for further information tech tips and free online help English gt CHECK OUT OUR WORLDWIDE PARTNERS AND SERVICE CENTERS ON MAGURA COM Deutschland MAGURA Bike Parts GmbH Co KG Heinrich Kahn Strasse 24 89150 Laichingen phone 49 0 7333 9626 0 fax 49 0 7333 9626 17 info magura bikeparts de USA MAGURA USA 724 West Clem 62450 Olney Illinois phone 6183952200 fax 6183954711 magura magurausa com MAGURA 2010 All rights reserved Printed in Germany 0689 724 07 2010 MAGURA Asia Limited Co No 160 Sec 1 Chang an Road 40743 Taichung City Taiwan phone 886 4 2316 3388 fax 886 04 2315 4030 info magura com tw gt SIE FINDEN UNSERE WELTWEITEN HANDELSPARTNER UND SERVICE CENTER AUF MAGURA COM MAGURA Apollo 11 Germany
10. before installation of the wheel rotor fitting bolts for rotor Torx T25 6 pieces fitting bolts for caliper Allen key 5 2 pieces adaptor with fitting bolts depending on model 9 hose inserts 2 pieces 10 olives 2 pieces 11 Torx T25 key 12 2mm Allen key pos A A BZ Specifications modifying and improving this product are subject to change without prior notice Specs may vary depending on model version English 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 different models Any misuse might cause serious accidents MAGURA manufacturers these braking systems according to the valid standards and based on profound product tests Because of the 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 bicy cle Disc brake calipers can generate a lot of heat during extreme riding conditions 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 Insufficient heat transfer from the brake caliper to the frame and the fork caused by fork and or frame components having low heat transfer characteristics e g carbon rear triangles can cause t
11. case Misuse can lead to brake failure The adjust screw must not be flush wih the drill in the lever blade Re install the dust cover once you have adjusted the reach adjust properly 11 Bite Adjust Technology BAT Turning clockwise Bite point becomes firmer Turning counterclockwise Bite point becomes softer WARNING Do not adjust the reach adjust in the closest position to the handle bar in combination with a BAT adjuster that is screwed in to the maximum as well This could result in an unsufficient lever movement and brake power Check out after every change of the BAT and or reach adjust the function of the brake to get used to the changed handling of the brake 6 Shorten the hose Louise is a high pressure system and comes with a reinforced hose the MAGURA Disc Tube wearing also this imprint The Disc Tube needs an additional insert for a proper fitting Never mix and match the parts from the MAGURA Louise with the ones of our rim brakes or other manufacturers brakes Any misuse might cause serious accidents Never touch either the rotor or the brake caliper after long braking as this may cause serious burns 1 Remove the wheel so that you have free access to the brake caliper Push both pistons with brake pads mounted back by putting the transport device or a flat blade screwdriver into the gap Move the screwdriver slowly back and forth until both caliper pistons are fully retracted and flush with caliper bod
12. connections and reservoir cover for eventual leaks Also see page 12 4 Always protect your rotors and brake pads from oil and lubricants e g by lubricating 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 Those pads are definitely killed and cannot be saved They have to be replaced Clean a contaminated rotor with MAGURA brake cleaner warm dishwater or alcohol See further hints about the brake pad change on pages 13 14 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 sufficiently tightened Also see pages 8 10 6 Are your tires in a good condition and are they sufficiently pressurized Test this with your fingers Lift up your bike and turn the wheels of your bike An insufficient rotation 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 Be careful in case of any rattling noise 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 ever a proper function of the points mentioned above is not guaranteed Consult a professional bike mechanic if you feel NW unsure A faulty bicycle might cause serious accidents with possible serious
13. eel has to be Use spokes with a diameter of 2 mm arc 1 8 mm which you cross three times No radial lacing with disc brake wheels Head inside spokes arc outside spokes have to be pulled e these spokes point forward 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 Mount the q r skewer of the wheel on the opposite side of the caliper Never use ultra lightweight quick releases with titanium or aluminum axles for your wheel sets in combination with a disc brake You will not be in a position to realize the necessary tightening torque 11 Accessories MAGURA disc brake service kit 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 Order codes see on page 20 Watch out for the genuine hose with yellow MAGURA marker Use only genuine MAGURA brake pads brake pads Performance Type 6 1 code 0722 418 series pad for maximum brake power brake pads Endurance Type 6 2 code 0722 419 with optimized longevity Use only genuine MAGURA accessories Any parts manufactured by other manufacturers like lever blades hoses or brake pads have not been tested and approved by MAGURA and consequently nothing can be said about their short and long term function Never use t
14. eeze 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 16 onwards THE PASSION PEOPLE 7 Maintenance Brake Oil MAGURA disc brakes use a transmission medium low viscosity mineral oil the 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 unbelievable is a fact you can use your brakes over years without having to touch them except brake pad check and change Use exclusively MAGURA ROYAL BLOOD any other oil will damage the seals of your brake what will result in total failure of the brake 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 that cause poor braking performance with possible serious accidents As to hints about repairs of the hose see page 15 onwards English Brake pads wear control and replacement Brake pad wear The brake pads are subject to wear due to friction between rotor and pads All Louise disc brakes feature a fully a
15. er 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 shortly after activating the brake lever Disc brakes do not cause a wear of your rims In case of insufficient mounting conditions they might however cause a squealing noise during braking mainly in wet weather condi tions This manual contains important information about the safe installation operation and maintenance of your MAGURA disc 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 Please note that the Louise brake is delivered in different versions with different rotor diameters and for different fitting alternatives for which we offer a variety of adaptors The basic installations steps remain however always the same Although the Louise disc brake system is relatively simple you should not ove restimate your technical skills We therefore advise you to leave the following works to a trained technician of a professional bike shop This workshop manual is part of the product that must not be sold without it 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 pro ducts and free online help around the clock in our forum You can also d
16. he brake to overheat with the possibility 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 manufacturer also bike mechanic or end consumer is responsible for the correct function of the complete bicycle in this context Improper combinations and insufficient installation might cause damage and serious accidents 2 Mount the brake lever to the handlebar with a 5 mm allen key Tightening torque 4 Nm 34 in lbs Hint Tighten the brake lever so that it can still rotate around the handlebar in case of a crash This old motocross trick will reduce considerably the risk of a damaged brake lever and the costly consequences The MAGURA disc brake Louise is compatible with frames and forks which meet the International Standard IS and for Postmount PM mounts Depending on the mounting standard and or rotor size adaptors are used for a proper installation cf table on page 21 Never mount the brakes with adapters or brackets from other manufacturers All warranty will be void in case of any misuse Use only direct moun ting 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 is able to care for the absolutely necessary even surface with the hel
17. hose parts All warranty and product liability claims will be void in case of misuse Never change the paint the finish or the consistence of your brake This might cause total failure of the whole system with possible serious consequences 12 Trouble shooting problem reason solution not enough brake power brake not run in break in brake page 5 no pressure point oil lubricants on rotor and clean rotor with or pads MAGURA brake cleaner warm dish water or alcool Replace contaminated pads air in the system Bleed brake page 16 Correct transport page 6 p leaking system Check hose connections and hose for leaks Replace hose 00 if necessary page 16 cC y page 16 T Squealing brake badly aligned frame align brake caliper correctly page 9 paint powder coating on disc remove any paint or powder mounts coating and care for an even contact surface without burrs page 8 9 wheel q r skewer insuffi increase tightening mount ciently tightened q r skewer on opposite side Insufficiently tightened wheel of caliper care for evenly spokes spoked wheel Contaminated brake pads carelessness change brake pads Contaminated rotor carelessness clean rotor with MAGURA brake cleaner warm dish water or alcohol Wheel cannot be mounted Lever blade was pulled with push back the brake pads removed wheel with transport device or a flat screwdriver page 11 Rattling noise and rough brake pads worn holder of deceleration pads is
18. ing to the user chart on page 2 of this manual Any misuse might cause heavy accidents with fatal injuries for you and others 6 Are you familiar with the other components on your bike such as shifting clipless pedals and suspension units Always train the perfect handling of your bike in a safe area before using it in the public traffic 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 your clothing and footwear are suitable 3 Before every ride or after a crash 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 get loose Serious falls with heavy bodily injury might be the 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 before the lever blade touches the hand lebars If this is not the case pull the lever blade several times pump until the brake pads touch the rotor 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 16 17 3 Always make sure that the brake system does not have any leaks by activating the lever blade holding it and checking the hose
19. o far by unintended lever squeeze when the wheel is removed It is impossible then to install the wheel with the rotor So never throw away the transport device but keep it and always clip it between the brake pads as shown when the wheel is removed 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 7 Squeeze the lever blade several times pump to push the pads to their proper position until the lever feel becomes very firm Tighten now the caliper fitting bolts Tightening torque 6 Nm 51 in lbs 8 For Postmount 6 installation in combination with a 160mm rotor Postmount 7 with 180mm rotor or Postmount 8 with a 203mm rotor on the front you do not need an adaptor Mount the caliper DIRECTLY onto the fork with MOUNTED wheel and rotor For a better understanding the mounted wheel is not shown on this picture Do not tighten the caliper bolts yet Squeeze the lever blade and keep the pressure Tighten now the bolts Tightening torque 6 Nm 51 in lbs Further mounting alternatives cf page 21 of this manual 9 Hose routing with the Heat Eater fitting The Heat Eater fitting of the Louise caliper allows a 45 rotation for the optimum hose routing without using tools Fix the hose on the fork and or frame after you have found the ideal position the
20. ounted If this happened by accident push back the pistons by using the transport device or a flat blade screwdriver Use only genuine MAGURA brake pads MAGURA cannot guarantee a correct function of the brake if you use brake pads from other manufacturers which were not tested Using other pads e g sinterized ones might cause poor braking overheating of the system and resulting total brake failure causing serious acci dents All warranty claims will be void in case of misuse 4 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 5 Secure the new pads with the fitting screw a new one is delivered with the new pads Tightening torque 1 Nm 9 in lbs Check the correct fitting of the pads by pulling them The fitting bolt of the pads has to be correctly installed e g it has to go through the drills of the pad holders and then correctly screwed into the caliper 6 Re install the wheel and check for a correctly tightened quick release skewer of the wheel which should be mounted on the opposite side of the caliper 7 Squeeze the lever blade several times pump to push the pads to their proper positi on 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 30 km h to achieve the maximum brake power Take your bike to a safe place to r
21. ownload on magura com this manual in a convenient A4 format Stay tuned with the Passion People Thank you for your confidence in our products enjoy your ride and your new MAGURA disc stoppers Happy trails 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 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 whether you activate the front brake with the brake lever which you are used to braking on the front If ever this is not the case you will have to train your new setup because any unintended braking might cause an accident with possi ble serious injury Make change the hose connection by a trained technician in case of any doubts Further hints concerning the swapping of the brake hose see page 11 onwards 3 New brakes and new rotors or brake pads must always be run in by breaking at least 30 times from a speed of 30 km h to achieve the maximum brake power Take your bike to a safe place to run in the brake English 4 In case of extreme riding conditions total weight of bike plus rider over 100 kg 220 Ibs and or a gradient of more than 15 always use both brakes simultaneously to brake your bike down Avoid constant braking on long descents as this might cause overheating and total failure of the system 5 Use the brakes accord
22. p of the MAGURA Gnann o mat disc optimizer tool also see page 10 ATTENTION The facing of suspension fork 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 protec tive paint 3 Mount the adaptor onto the fork or the frame Use a 5 mm allen key Please follow carefully the mounting instructions that come with the respective adaptor If you use a thru axle hub on the front you might have to use thicker 3 mm spacers depending on fork model These are available separately code 0720 829 Tightening torque 6 Nm 51 in lbs 4 Caliper installation Mount the caliper with MOUNTED wheel and rotor onto the adaptor For a better understanding the mounted wheel is not shown on this picture Do not tighten the caliper bolts yet Squeeze the lever blade and keep the pressure Tighten now the bolts Tightening torque 6 Nm 51 in lbs English 5 Mount the rotor with the 6 Torx T25 bolts onto the hub Use only new original bolts or thread lock if you use the old ones again Tighten the bolts in a cross pattern Tightening torque 4 Nm 34 in lbs Install a MAGURA rotor in Centerlock version according to the tech sheet that comes with the rotor 6 The transport device prevents the brake pads from being pushed out to
23. ringe eventually to push out air bubbles 4 Remove the brake pads as described on page 14 and slide the transport device as shown with its THICK END between the caliper pistons Squeeze slightly the lever blade pump to tighten the transport device It is advisable to fix the device with a rubber band on the caliper 5 Fix the Heat Eater fitting of the caliper so that it points UPWARDS lUnscrew now the bleed screw with a 5 mm allen key Screw in the prepared syringe and tighten it with a 8 mm open end spanner Place now a rag which has to be free of oil or lubricants around the reservoir and more important around the brake caliper Care for a clean working environ ment No dirt or particles may come into the brake system 6 Remove ONLY the bleed plug of the reservoir with a 2 5mm Allen key that you insert into the plug before turning it slightly The reservoir cover and the membrane underneath remain on the brake lever 7 Put the second syringe of the service kit WITHOUT PLUNGER into the opened drill of the reservoir cover Push oil from the brake caliper upwards until the oil column arrives in the syring on the reservoir You will see air bubbles now 8 Now suck the oil carefully back with the filling syringe on the brake caliper Make sure that there is always enough oil in the reservoir syringe when you suck back the oil with the filling syringe You will see air bubbles again 9 Actuate in addition CAREFULLY
24. un in the brake Never contaminate brake pads with oil or grease this causing permanent loss of brake power Contaminated pads are definitely killed and must be replaced 8 Repairs Disc brake service kit Don t panic if the hose snaps With the disc brake service kit and a separately available spare hose see spare parts pages 20 21 this can be repaired easily Louise is a high pressure systems and comes with a reinforced hose the MAGURA Disc Tube wearing also this imprint The Disc Tube needs an additional insert for a proper fitting Never mix and match either the hoses or parts from other manufacturers Any misuse might cause serious accidents 1 Remove the damaged hose from both the brake lever and the caliper English 2 Prepare a new hose Use only the reinforced MAGURA Disc Tube wearing also this imprint One end of this hose comes with a pressed fitting with blue loctite threadlock which has to be screwed into the Heat Eater as described above The hose is available with 0 and 90 fittings c f page 20 Tightening torque 6 Nm 51 in lbs Use with all Louise models with adjustable Heat Eater hose fitting only the hose that comes with the fitting with blue loctite threadlock arrow NEVER shorten the MAGURA Disc Tube hose at the end with the pressed fitting You could no longer use this hose then 3 Tighten the prepared end of the new hose onto the Heat Eater Tightening torque 6 Nm 51 in lbs
25. utomatic pad wear adjustment Regularly check the thickness of your brake pads and replace them if necessary CHANGE AL WAYS BOTH PADS SIMULTANEOUSLY Control of the brake pad wear Never touch either the rotor or the brake caliper after long braking as this may cause serious burns Squeeze the lever blade with the wheel mounted an hold the pressure Check out whether the finger of the transport device fits in between the ears of the brake pads On the picture on the left this is NOT the case the pads must be chan ged Here the finger of the transport device fits between the ears of the brake pads The pads are still o k Remember The lever has to be pulled during this procedure Use for this a rubber band or a cable tie Replacement of the brake pads 1 Remove the wheel so that you have free access to the brake caliper Push both brake pads fully back by putting the transport device or a flat blade screwdriver into the gap Move the screwdriver slowly back and forth until both caliper pistons are fully retracted and flush with the caliper body Never push back the pistons without the brake pads mounted the pistons could be damaged otherwise 2 Remove the brake pad fitting screw with a 2mm allen key 3 Pull out the brake pads Their ears make this very easy Minimum thickness of a brake pad plus holder is 2 5 mm Never squeeze the lever blade without the brake pads in place and the wheel m
26. wearing and dama brake pad change page 13 ging the rotor Leaking hose or brake accident incorrect instal change hose or defective lation brake lever caliper page 15 13 Warranty leakproof MAGURA is giving a 5 year leak proof warranty on brake levers master WARRANTY on levers cylinder and brake calipers brake cylinders and calipers Watch out for the red info sheet in the middle of this manual 14 Spare parts 2011 max tightening torques 0722 533 lever blade repair kit 1x 0722 525 BAT Carbon 1x 0722 526 BAT Alu 1x 0720 847 Torx T7 key T 10x 0721 000 0 6 Nm Ts Qo 09 0724 044 07 22 531 0724 134 weiss 0722 535 silver 0722 536 black incl bolt Storm SL Rotor 6 holes IS 203 mm 0724 404 180 mm 0724 403 160 mm 0724 402 140 mm 0724 401 Louise Carbon white left 0724 133 right 0724 132 Louise BAT black left 0724 331 0720 825 10x right 0724 330 0720916 20x Louise black left 0722 524 right 0722 523 0720 446 10x 4Nm P 0720 405 10x 0721 057 6x 4 Nm 0721 204 Torx T25 key 0722 636 hose 250 cm 6 Nm Storm Rotor 6 holes IS 0721 386 braided hose 250 cm 6 Nm 203 mm 0724 400 180 mm 0724 399 160 mm 0724 398 0722 421 10x 6 Nm 10 x 0720 848 2 5 Nm 0721 418 Type 6 1 Performance 0721 419 Type 6 2 Endurance Titanium bolt kit 0722 562 a 0720 828 10x 1 Nm 1x M5x18 6x M
27. y English Never push back the pistons without the brake pads mounted Open the brake system only after having pushed back fully the brake pads 2 Loosen the brake lever clamping screw with a 5 mm allen key Turn the brake lever and ensure that the reservoir points approx 15 upwards from the horizontal positi on 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 hose cutter Do not use saws or pliers Hint Hold the hose carefully so that it cannot snap away Cut the hose squarely The sleeve nut can be re used The olive and the insert cannot be reused and must be replaced 5 Press by hand a new insert into the hose until it is fully seated Clamp the hose into the groove of the mounting device as shown 6 or clamp the mounting device as shown into a vice and hammer the insert careful ly into the hose 7 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 8 mm open end wrench Tightening torque 4 Nm 34 in lbs 8 Always check for correct installation by pulling on the hose Make sure that the system has no leaks Squ
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