OBE Hydraulic Disc Brake
Contents
1. OBE Hydraulic Disc Brake Installation and Service Manual Haraka copyright 2006 2008 N Original Bike Engineering Ltd www discobrakes com v008 ORIGINAL BIKE ENGINEERING Contents TEROCUIGUIGN MCN EE NM RTT eee Rae mae 3 DefINitiONS RD ODIT DO DII DLL ILTC 3 Important Safety Information cccecee ese e eee ee eset eee sense eneeeaeeenaees 4 CVS ea NE UW usa er Len 6 Tools Required for Installation esses meme nnn nnn 6 Fitting the Disc ROtOFrs osea ose n R ERR RR ERR ER UR RR UR RR RIO RUE Re ER ER 6 Fitting the lever and master cylinder sssssssssssesseme mene 7 Fitting thie Calipers 2 eee teeth rer eR te paaaiaateaara cries Y ERIERREEDTA A iR TI RR UA 7 Securing the Hose amp Completing the Installation sssssssssssrrssrrrssrrrsrrrrsrrrrsrrrns 8 Bedding In PeHO ds LT EE 8 Personal Settings vi csediscsdseddecsdacdincudecd incu ADU PANNUNA NCAA AETR ANEREN EAAS 9 To Position the Master Cylinder and Lever eessessesseeeeenn nnns 9 Lever Reach Adjustment os oed o aede petia eb a etn xxt dh 9 Transport of the DIC Y Cle ite tic 5 ced ER 9 SEMVieS Gc Malltenarte sisii iii eer eoo eta oo em copre e ope ec oeque 10 Brake Pads eec tet ede een dtt a eid dee deat 10 Pad Removal 25 ots isa ene eed nk Fed Rd e en C e DC OO Fr o EX E 10 Pad Insertion ce in eS ERE ERR ERE LaS aa 10 GIeailitiass Seseintt Sa Maitt a ort ac uitu oci fused ecu esed tanta T 11 Piston2. For spare parts consult www discobrakes com 15 Warranty Original Bike Engineering OBE Disc Brakes are warranted for a period of 12 months from original purchase date against defects in materials and workmanship The warranty only applies to the original owner and a proof of purchase is required The product must be returned to OBE before any warranty claim can be processed Any product that OBE finds to be defective will be repaired or replaced at the discretion of OBE This warranty does not cover bending damage or breakage that has resulted or may have resulted from crashes or falls This warranty does not cover any damage or defects caused by alterations or modifications of OBE Disc Brakes or parts thereof or by normal wear improper maintenance damage s caused by the use of other manufacturers parts improper use or abuse of the product or failure to follow instructions contained in an instruction manual for OBE Disc Brakes Any modifications made by the user will render the warranty null and void The cost of normal maintenance or replacement of service items that are not defective shall be paid for by the original purchaser OBE shall not be held liable for any indirect special or consequential damages This warranty does not affect your statutory rights 16
3. Personal Settings To Position the Master Cylinder and Lever 1 Loosen the handlebar clamp screws using a Torx T25 screwdriver 2 Position the Master Cylinder and Lever on the handlebar in your preferred location and at your preferred angle 3 Tighten the handlebar clamp screws to a torque of 3 4 Nm 30 in Ibs Lever Reach Adjustment In most cases the factory settings for lever reach adjustment will be suitable for your bike If necessary use a flat blade screwdriver to adjust the lever reach by turning the push rod that goes through the lever Warning Do not attempt to force the adjustment screw beyond its limits Transport of the bicycle When transporting a disc brake equipped bicycle you should keep the following points in mind e Insert the transport spacer supplied with the brake between the brake pads whenever the wheel is removed from the bike e Never depress the brake lever without the brake pads in place and the wheels mounted e Make sure that the rotors are not damaged deformed or contaminated with lubricants e Do not transport the bike upside down e For transport in an aircraft there is no need to empty the fluid from the hydraulic system you can leave the brake as it is Service amp Maintenance Brake Pads Replace the brake pads when the friction material has worn down to 0 6mm Warning Do not wait until the friction material has worn down to the metal as the brake rotor will get
4. damage to the brake system resulting in brake failure Warning Only use new good quality brake fluid Using poor quality or old brake fluid will decrease performance and may result in vapour lock Warning Carefully read the instructions that come with the brake fluid Warning Only use new brake fluid that has come from a closed bottle Always replace the brake fluid bottle s cap to prevent contamination Some DOT fluids absorb moisture and will deteriorate and spoil Warning Brake fluid will strip paint so wipe any spillage up immediately and clean the area thoroughly with isopropyl alcohol Warning Discard old brake fluid in a responsible manner and in accordance with local laws Do not pollute drains or the environment 11 Warning DOT brake fluid can be an irritant Avoid contact with skin amp eyes and do not ingest Wear safety glasses when handling brake fluid and bleeding or maintaining your brakes Follow the instructions provided with the brake fluid in case of contact with eyes skin or if ingested Procedure for Bleeding 1 Remove the wheels to prevent contamination of the disc rotors 2 Remove the brake pads to prevent contamination Follow the Pad Removal instructions in this manual 3 Push the caliper pistons back as far as they will go using the boxed end of a 10mm wrench Warning Do not push on the post in the centre of the piston because it will bend and will need to be replaced 4 Inser
5. hose and fittings for any kinks or damage to the reinforcing braiding Check the master cylinder body and caliper for damage Check the hose and fittings for any leaks by activating the lever holding it and checking the hose connections and reservoir cover for leaking brake fluid Check that the brake operates amp bites onto the brake rotor The lever should not pull back to the handlebar If it does see the maintenance section to rectify it Warning Do not ride your bike unless your wheels move freely without drag If your brake rotor is dragging on your pads it will cause premature brake pad wear and inconsistent braking which may cause injury Check that your wheels are mounted correctly and all fastenings are correctly tightened Follow the procedures in this manual to ensure your brakes are setup correctly Recommendation If using quick release skewers we recommend the use of steel skewers only Recommendation We recommend a 3 cross spoke pattern If the wheel has to be rebuilt it should be done by a qualified technician Installation The following procedures cover the installation of OBE Disc Brakes A qualified technician with the correct tools should carry out installation of any disc brake components Improper installation could cause severe or fatal injuries The disc brake system is supplied fully assembled containing brake fluid and is factory bled Recommendation To start with you should install
6. the brake as supplied without disconnecting the hose After using the brake for a while you may want to consider shortening the hose or routing it through your frame Tools Required for Installation Torx T25 driver Open end wrenches 6mm 8mm 10mm Hose cable cutters Small flat head and Philips screwdrivers Allen screwdrivers Hex keys 4mm and 5mm Torque wrench Fitting the Disc Rotors Mounting the brake disc rotor to the wheel requires care The disc rotor is compatible with International Standard 6 bolt hubs Recommendation We advise the use of thread lock on disc rotor bolts to enhance the locking and prevent them from unscrewing Do not use a permanent adhesive 1 Clean the disc and the hub mounting surface with isopropyl alcohol Warning Do not use disc brake cleaner 2 Place the disc on the hub s mounting surface Be sure that the arrow on the disc is pointing in the same direction of the forward wheel rotation Warning Be sure to install the disc rotor with the right side facing upward Failure to do so may result in failure of the disc and severe injury If the disc is the right way around you will be able to see the arrow on the disc rotor while tightening the bolts The arrow and text on the disc rotor faces outwards from the hub 3 Use a Torx T25 screwdriver to tighten the disc screws to 5 6 NM 50 in Ibs For even tightening tighten each screw a little at a time and skip alternate screws in the tightening s
7. Important Safety Information Warning As a serious rider you are aware of the need to practice safety in all aspects of the sport This includes service and maintenance practices as well as riding practices Before each ride always check that your brakes are functioning correctly and check and replace the brake pads if worn When you ride always wear a helmet Warning Installation of the disc brake system or any of its components should be carried out by a qualified technician with the correct tools Improper installation could cause severe or fatal injuries Warning This brake has been designed for use on a single person mountain bike only Using it on any other vehicle or for any other purpose will void the warranty and could cause serious injury Warning Disc brake parts can become extremely hot with use Always allow parts to cool before attempting to service your bike Never touch either the brake rotor or the brake caliper after braking as this may cause serious burns Wait for parts to cool down before doing any work on them Warning When following any of the installation or servicing procedures make sure you keep your hands and fingers away from getting caught in the brake rotor Failure to do this can result in injury Warning For downhill riding use a 203mm 8 Inch brake rotor Before installing a 203mm brake rotor on your frame or fork ensure that your frame or fork is capable of accepting it Check with your frame or for
8. damaged and the brake may not function causing serious or fatal injury Pad Removal 1 Remove the wheel 2 Slowly push the brake pads apart by inserting pieces of thin card between them until they are far enough apart to remove one brake pad and then the other Warning Do not use a screwdriver or sharp object to prize the pads apart as this will ruin the brake pads and they will need to be replaced 3 Push one of the pads using its tab on its metal back plate towards the middle of the caliper then pull to disengage the small spring holding it on to a post in the center of the piston Remove the pad once it is disengaged from the post 4 Repeat for the other pad 5 When the pads have been removed follow the Pad Insertion procedure Pad Insertion 1 Push the caliper pistons back as far as they will go using the boxed end of a 10mm wrench Warning Do not push on the post in the centre of the piston because it will bend and will need to be replaced 2 Put the outer pad in first Note that the pads are different Use the tab in the centre of the metal backing plate to push the new pad into place by angling it and pushing gently until its spring snaps into place 3 Check the pad is properly locked into place amp repeat for the inner pad 4 Re install the wheel 5 With the bike upright squeeze the lever several times pump until the lever feel becomes firm This will push the pads to their correct position 6 New pa
9. ds will need to be bedded in by following the instructions in this manual 10 Cleaning Warning The brake disc rotor and pads should not be cleaned with disc brake cleaner Use only isopropyl alcohol Pistons Pushed Out If the brake lever is pulled without the disc rotor or the transport spacer between the pads the caliper pistons will be pushed out amp the brake pads will be too close together This will prevent the re installation of the wheel disc rotor or will prevent the wheel from spinning freely Bleeding the System Bleeding means pumping new brake fluid into the system to replace the existing fluid and push out any trapped air and water Air trapped in the hydraulic system of the disc brake will decrease the performance and feel of the brake making it feel spongy The air can be removed by bleeding If the hose length is shortened or the hose is detached to route it through the frame or the right amp left lever s hoses are swapped due to local convention or personal preference and there is loss of brake fluid during the procedure the brake will need to be bled Warning If you get brake fluid on the brake pads they are ruined and dangerous to use Replace them with new pads If you get brake fluid on the disc clean it thoroughly using isopropyl alcohol Do not use disc brake cleaner Warning OBE Hydraulic brakes use DOT4 or DOT5 1 brake fluid only If you use any other fluid it will cause serious
10. eplace the rubber diaphragm The fluid will overflow Close the bleed nipple and remove the hose Wipe away excess fluid from the caliper and lever Warning Do not over tighten the bleed nipple on the caliper 16 Replace the master cylinder reservoir cap and gently tighten the 4 allen screws with a 2mm allen key Warning Do not over tighten the master cylinder reservoir cap allen screws 17 Replace the pads by following the procedure for Pad Insertion 18 Check for system leaks Changing the brake fluid For normal use change the brake fluid every 3 to 4 years For extreme use change the brake fluid every year To change the brake fluid follow the bleeding procedure Fill the master cylinder reservoir five times and pump the fluid through the system each time Hose Changes Your OBE hydraulic disc brake is supplied fully assembled and factory bled The hose length will suit the majority of forks and frames However you may wish to make hose changes for example in the following circumstances e To shorten the hose e To detach the hose and route it through the frame e To replace a damaged hose e To swap right and left brake levers to suit your personal preference or the normal setup used in your locale If the following procedure is carried out carefully and correctly there should be no fluid loss and there is no need to re bleed the hydraulic system 1 Remove the wheels to prevent contamination of the rotors 2 Remo
11. equence until all 6 screws are equally tightened 4 After 12 hours of use check and re tighten the disc rotor screws Warning To avoid burns do not touch the disc immediately after use Fitting the lever and master cylinder 1 Mount the brake lever to the handlebar with a Torx T25 screwdriver There is no need to remove the grips or other controls Tighten to 3 4 Nm 30 in Ibs 2 Route the brake hose along the frame fork to the calipers taking care to avoid parts of the bike where the hose could be potentially trapped such as near rear suspension linkages or could rub against moving parts such as the wheels and avoiding sharp bends in the hose Fitting the Calipers Warning When following any of the procedures below be sure to keep your hands and fingers from getting caught in the brake rotor Failure to do so could result in injury 1 Remove the wheel any calipers and adaptors already fitted to the frame or the fork and check for the following e Make sure that the caliper fitting eyelets on your frame or fork are free of any paint powder coating or burrs The eyelets on a new frame or fork need to be checked carefully A newly painted frame or fork will need to have its caliper fitting eyelets faced If unsure have them faced by a qualified technician using the proper facing tool Recommendation Before fitting a disc brake have a qualified technician machine the frame amp fork mounts with a facing too
12. er adaptor and the frame or the fork mounts This involves some trial and error until the correct positioning is achieved Spin the wheel and check that it spins freely and that the gaps between the pads and the disc are equal If necessary loosen the mounting bolts and repeat steps 5 and 6 until the wheel spins freely and the space between pads and disc are equal on either side of the disc When finished torque the mounting bolts to 12 4 Nm 110 in Ibs Warning For post mount forks torque the mounting bolts to 9 Nm 80 in Ibs Securing the Hose amp Completing the Installation 1 After the caliper and lever have been mounted onto the bike secure the hose to the frame using zip ties or hose guides Check that The handlebar is unrestricted e The hose cannot be trapped in moving parts e The hose does not rub on moving parts e The hose does not kink at any time 2 With the bike upright on its wheels squeeze the lever several times pump until the lever feel becomes firm This will push the pads to their correct position on either side of the rotor 3 New pads and rotors will need to be bedded in by following the instructions in this manual Bedding In Period To achieve maximum braking power and brake pad longevity new brake pads and new rotors need to be bedded in Take your bike to a safe place amp stop hard 30 to 40 times from about 20 mph 30 kph During the bedding in period some noise may occur
13. k manufacturer Warning Using a 160mm 6 Inch brake rotor for downhill riding may cause the brake fluid to overheat or even boil and may cause brake failure resulting in serious injury Warning If you suspect damage to your brakes always get them checked by a qualified technician Warning Before using your brakes for the first time ensure that the lever you expect to operate the front brake right or left does in fact operate the front brake If this is not the case the hoses should be swapped to avoid unintentional braking and potential risk of accidents and injury Follow the procedure in this manual to swap the hoses or ask a qualified technician if you are unsure Warning If you notice changing braking points during a ride you may have air in your brake system and you should stop riding Before using the brake system again the brakes must be bled using the procedures outlined in this manual Warning Always protect your brake rotors and brake pads from oils lubricants detergents and soaps Such substances contaminate the pads and cause a permanent loss of braking power Contaminated pads must be replaced before riding Warning If your bike is involved in a crash you must check your brakes before riding to ensure they are functioning properly Check that all components are securely mounted to the handlebar frame and fork Check that the pads are properly seated amp retained within the caliper Check the
14. l to ensure they are square to the axis of the hub e Ensure that the brake pads are fully retracted in the caliper New brakes are supplied fully retracted with the plastic transport spacer inserted between the pads If you need to do this yourself follow the procedure for Pad Removal in this manual and then follow the procedure for Pad Insertion Recommendation Do not remove the transport insert until you are ready to install the wheel 2 If you have an adaptor to install between the caliper and frame or caliper and fork mount it to the frame or fork using the two 2 M6 adaptor bolts and two 2 washers supplied with the OBE brake Leave the bolts loose enough so that the adaptor can be moved in its slots for alignment 3 Mount the caliper to the frame or adaptor using the two 2 M6 caliper bolts Leave them loose enough so that caliper can be moved for alignment with the brake rotor 4 Remove the plastic transport insert from each caliper amp re fit the wheels securely Recommendation Keep the plastic transport insert in a safe place for future use Re insert it between the brake pads whenever you remove the wheels 5 If you have fitted an adaptor move it until it is just free of the circumference of the disc rotor Tighten the adaptor bolts to a torque of 12 4 Nm 110 in Ibs 6 Centralise the caliper equally on either side of the disc rotor using the shim washers provided by fitting them between the calip
15. lacing the hose due to damage or a leak the hose can be disconnected from the caliper in the same way as it is disconnected from the lever 14 Troubleshooting The following table provides a quick reference to causes amp solutions of most common problems Refer to the relevant section in this manual for the correct procedures to follow for each solution A qualified technician should carry out all work Symptom Possible Problem Solution Lever pulls right back to the handlebar Pads not re set after a service Pump the lever Air in system Bleed system only occurs after long periods of braking Water in system Bleed system No braking power New pads or rotor not bedded in correctly Bed in new pads rotor Disc is dirty Clean disc Pad contaminated Replace pads Disc rubbing on pads Wheel not seated correctly Re install wheel Caliper not centered over rotor Realign caliper Not enough clearance between pads amp rotor Push pistons back into caliper Warped disc Replace disc Spongy lever feel Air in system Bleed system Frame or fork mounts out of alignment Face frame fork mounts Incorrect fluid used Replace seals and Bleed system Pads fall out Damaged piston Replace piston Damaged Pads or Spring Replace Pads Fluid Leak Crash damage Very old seals
16. s PUSHER Qut erede e eei Lek tell d ee ed end vae e e A 11 Bleeding the SVvSEeITES deu cox deci cex vdd ecexodex imm de cox vexit exo dox coded edes 11 Procedure for BleediNg erris estet etn x FR IRR X e RERO RE RR Rn en RI RH ORE a 12 Changing the brake fluid 5n creto i to De hae tee pir rh i rra ER re Rr gd 13 dose ClHiatigdes secto odd ctae DLL M AM I AL 13 JTEOBUDIGSDODEEDO ortos ea cb nita nom ed no Ce Dd bita nod a iaa D ea bd bead 15 lu rlgeinis decr RR PEU 16 Introduction Congratulations you have purchased a fully hydraulic disc brake system by Original Bike Engineering This manual contains important information about the safe installation operation and maintenance of your disc brake We urge you to read it carefully become familiar with its contents and follow its recommendations to help make your new braking experience enjoyable and trouble free Although relatively little maintenance is required you should not attempt to carry out any maintenance procedure until you are thoroughly familiar with the entire set of procedures Do not overestimate your technical skill if in any doubt leave installation and maintenance to a qualified technician Definitions Warning These matters must be abided by as there is the possibility of personal injury to yourself or to others Recommendation It is advisable that these matters are abided by for the safe installation and maintenance of this brake system
17. t a spacer between the pistons to prevent them pushing back out during the bleeding procedure 5 Loosen the lever handlebar clamp screws using a Torx T25 screwdriver and reposition the brake lever so that the master cylinder is level and horizontal Slightly tighten the screws in this position 6 Remove the master cylinder cap by removing the 4 allen screws using a 2mm allen key Then remove the rubber diaphragm inside 7 Place the closed end of a 6mm spanner over the bleed nipple on the brake caliper Fit a length of approximately 30cm of clear plastic hose onto the bleed nipple and put the other end into an empty container to catch the fluid Ensure that the hose is a tight fit 8 Fill the master cylinder reservoir with brake fluid 9 Open the bleed nipple on the caliper one quarter of a turn 10 Slowly pull the brake lever to the handlebar and hold 11 Close the bleed nipple amp release the lever The bleed nipple must be closed before the lever is released to avoid sucking air into the system 12 Repeat steps 8 9 and 10 until no further air is seen coming out of the bleed nipple Refill the master cylinder reservoir as required during this procedure 13 Make sure the pistons are fully pushed back into the caliper If not follow step 3 again to push the pistons back 14 Hang a towel around the master cylinder to soak up any spills and then fill the master cylinder reservoir for the last time 12 15 R
18. ve the brake pads to prevent contamination Follow the Pad Removal instructions in this manual 13 3 Push the caliper pistons back as far as they will go using the boxed end of a 10mm wrench Insert a spacer to keep the pistons apart Warning Do not push on the post in the centre of the piston because it will bend and will need to be replaced 4 At the lever slide off the plastic hose connector shroud and slide it away from the connector 5 Unscrew the hose connector fitting using an 8mm open ended wrench and slide it down the hose 6 Detach the hose by gently pulling Warning Once separated hold the hose carefully as it contains brake fluid that could leak out easily 7 Make the hose change s For example e Trim the hose to the desired length using a hose cutter tool to give a clean square cut Warning Do not shorten the hose to such an extent as to hamper or restrict handlebar movement e Route the hose through fork or frame guides taking care o To avoid tight bends which could cause kinks o To avoid routing the hose such that it could get trapped in moving parts o That the hose does not rub on moving parts such as the wheels 8 Pull the lever very gently and when a small drop of brake fluid is visible at the end of the connector push the hose onto the connector 9 Slide the connector fitting back into place amp tighten 10 Slide the plastic hose connector shroud back into place If rep
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