Hydraulic Disc Brake, Installation, Maintenance, and Service Manual
Contents
1. 1 35 RetainingWasher 1 36 Retaining Ring 1 37 PushRodSeal 1 38 Adjuster Bushing 1 39 Lever 1 ee 32 Return Spring 33 Master Cylinder Piston with Cups 1 34 PushRod 1 35 Retaining Washer 1 36 Retaining Ring 1 38 Adjuster Bushing 22 40 Master Cylinder Body 1 41 Clamp Screw 2 42 Reservoir Cap Screws 2 43 Reservoir Plug amp 1 44 Reservoir Cap 1 45 Bladder 1 46 Lever Pin Bushings 2 47 LeverPin LT N48 Lever 11 International Standard Front Q R International Standard Front 20mm 6 Disc 8 Disc Standard Quick Release Hub 20 mm Hub Part 98 15068 Part 98 15069 Rock Shox Boxxer 8 Disc 20mm Hub Part 98 15071 Manitou Sherman International Standard Front 20mm 8 Disc 6 Disc 20mm or Standard Quick Release 20mm Hub Part 98 15072 Part 98 15282 Rock Shox Psylo 8 8 Disc 20mm or Standard Quick Release Part 98 15604 19 International Standard Rear International Standard Rear 6 Disc 8 Disc Part 98 15073 Part 98 15074 International Standard Rear 22mm Caliper 6 Disc Part 98 15281 202. 4 Repeat the steps for the other side pad To replace the pads 4 Using the boxed end of a 10mm wrench push the caliper pistons back until they bottom This will give you more room to fit in the new pads Take care not to push on the aluminum post in the center of the piston Caution Don t push on the post in the center of the piston because that will bend the post Walk the piston back and forth until the piston is all the way back in the bore Do the same thing on the other side Note There are two different brake pads an inner and ANC U outer or a right and a left On the outer pad the tab is Pushing the Pistons offset On the inner pad the tab is in the center Back Put the outer pad in first Use the tab in the center of the pad backing plate to push the new pads into place Angle the pad slightly so the post is towards the center of the caliper and push the pad until it snaps into place Check that the pad is locked into position Now repeat the procedure for the outer pad Install the wheel Outer and Inner Brake Pads B Piston s Pumped Out If the brake lever is stroked without the disc between the pads and this is possible when brake pads are being changed the self adjusting feature will allow the pads to push out The caliper pistons will be pumped out of their bore This will cause excessive drag on the disc when the wheel and disc are reinstalled or even make it impossible to install the whe
3. a Karr HAYES Hydraulic Disc Brake Installation Maintenance and Service Manual HFX Mag HFX Mag Plus HFX 9 HFX 9 HD This manual is intended to provide the information necessary for normal maintenance and service of the Hayes Disc Brake system Although the steps and procedures are relatively simple they should not be attempted until you are thoroughly familiar with the entire set of procedures Photographs of actual hardware have been provided to help you in the steps and procedures Within this manual are specifically labeled comments intended to bring special attention to a general procedure or detailed steps Be aware of and understand the meaning of these labels Warning Means that there is the possibility of personal injury to yourself or to others Caution Means that there is the possibility of damaging the brake or the bike Note Provides general information Hint Provides information that can help you properly complete a specific procedure To help you become familiar with some of the terms associated with disc brakes and in particular the Hayes Disc Brake we provide the following glossary Burnish The breaking in period of a disc brake system until the brake achieves full power Bleed Removing the air from a full hydraulic system Bladder The part on the Hayes Disc Brake system that contains the fluid reservoir The bladder expands as the fluid heats up and expands and contracts as the c
4. Make sure the seal is not twisted Install hose connection to the G2 caliper Using a 10mm open end wrench torque the hose connection to 60 5 in lb G2 Caliper Hose Assembly G1 Hose Assembly Generation 1 1 2 4 5 Locate the end of hose with permanent crimp attached Cut the permanent crimp off of the hose This permanent crimp is not needed with the Generation 1 G1 caliper The end must be clean and perpendicular to the hose itself Slide the G1 caliper hose nut and compression bushing over the hose Always use a new compression bushing Note The G1 caliper hose nut has internal threads and G1 Caliper Hose Assembly the compression bushing is a silver color Slide the hose over the barbed end on the caliper banjo and install the hose nut Using a 10mm open end wrench torque the hose nut to 40 in Ib plus one full rotation HFX 9 HFX 9 HD Master Cylinder Hose Assembly 1 2 8 9 Locate the end of hose without the permanent crimp attached Cut the hose to the desired length with good scissors or cable cutters The cut end must be clean and Las perpendicular to the hose itself Slide the HFX 9 nose cone onto the hose Note The HFX 9 nose cone is the smaller of the two included 9 Hose Assembly Slide the HFX 9 hose nut and compression bushing over the hose Always use a new compression bushing Note The HFX 9 hose nut has external threads and the compress
5. cylinder end slide the hose support down the hose Remove the hose nut by loosening the nut and sliding it all the way down the hose 1 Slide the hose off the end of the master cylinder There will be some residual fluid in the hose and master cylinder Be careful to avoid spilling that fluid Caution For the HFX Mag and HFX Mag Plus pull the hose off straight off Not doing so may result in a broken cartridge tip A new compression bushing will be needed each time the hose is re installed Remove the old compression bushing by cutting the hose next to the compression bushing The cut needs to clean with no fraying ends Note Check the hose length for adequate travel If too short replace hose G2 Caliper Hose Removal Generation 2 1 2 To take the hose off the caliper end loosen the hose connection with a 10mm open end wrench Remove the hose connection completely from the caliper Be sure that the hose connection seal is not lost Note The end of the G2 caliper hose is a permanent crimp Therefore the connection cannot be trimmed to size or repaired Shortening of the hose must be done at the master cylinder end If the caliper hose connection is damaged the hose must be completely replaced with a new hose with a permanent crimp attached Hose Assembly G2 Caliper Hose Assembly Generation 2 1 2 3 4 Locate end of hose with the permanent crimp attached Place the hose connection seal over the threaded end
6. tools should do that installation work Improper installation could cause severe or fatal injuries A Tools Required Torx T25 driver Open end wrenches 6mm 8mm 10mm Scissors or cable cutters Small Phillips screwdriver Torque wrench Small flathead screwdriver Allen drivers 2 0mm and 5mm B Mounting the Disc to the Hub Note Mounting the brake disc to the wheel is a simple matter but one that requires care If the wheel has to be rebuilt have it done by a qualified technician using a 3 cross spoke pattern We recommend the use of steel quick release skewers only 1 Clean the disc and the hub mounting surface with isopropyl alcohol not disc brake cleaners 2 Place the disc on the hub mounting surface Be sure that the arrow on the disc is pointing in the same direction of the forward wheel rotation 3 Using a Torx T25 driver install tighten and torque the disc screws to 55 in lbs 6 2 Nm in a star pattern sequence 4 Check and re torque the disc screws after 12 hours Screws Warning Do not touch the disc immediately after use it will be hot C Mounting the Caliper to the Frame or Fork Remove the wheel s 2 Forsome installations it will be necessary to mount an adapter to accept the Hayes Disc Brake caliper Mount the fork adapter to the fork using 2 M6 x 1 0 18 4mm long mount bolts Torque the bolts to 110 in lbs 12 43Nm 3 Mountthe caliper to the frame or fork adapter using 2
7. Lever Pin Bushing Jam Nut Lever Pin Bladder Retainer Cartridge Gasket Cartridge Return Spring Master Cylinder Piston with Cups Push Rod Retaining Washer Retaining Ring Push Rod Seal Adjuster Bushing Lever Return Spring Master Cylinder Piston with Cups Push Ro Retaining Washer Retaining Ring Adjuster Bushing Master Cylinder Bod Clamp Screw Reservoir Cap Screws Reservoir Plug Reservoir Cap Bladder Lever Pin Bushings Lever Pin Lever ftem _ 44 45 46 48 Ni ala 3 po pol lt gt ES gt gt N Master Cylinder Lever Bod Clamp Screws Lever Pin Bushing Jam Nut Lever Pin Bladder Retainer Cartridge Gasket Cartridge Return Spring Master Cylinder Piston with Cups Push Rod Retaining Washer Retaining Ring Push Rod Seal Adjuster Bushing Lever Return Spring Master Cylinder Piston with Cups Push Rod Retaining Washer Retaining Ring Adjuster Bushing Master Cylinder Bod Clamp Screw Reservoir Cap Screws Reservoir Plug Reservoir Cap Bladder Lever Pin Bushings Lever Pin Lever Description Quantity HEM 24 LevrBody 1 25 ClampScrews 2 26 Lever Pin Bushing 1 27 28 Lever 1 29 BladderRetainer 1 30 Cartridge Gasket 1 31 Cartridge 1 32 Return Spring 1 1 33 Master Cylinder Piston with Cups 1 34 PushRod
8. M6 x 1 0 18 4mm long mount bolts and 2 mount washers the bolts but leave them loose enough so that the caliper will move on its slots 4 Re install the front wheel 5 Squeeze and hold the brake lever While holding the brake lever shake the caliper to position it in its natural centered position over the disc While still squeezing the lever tighten the mounting bolts Warning Do not adjust the caliper while the caliper is hot Warning Do not adjust the caliper while the wheel is spinning 7 8 Release the lever spin the wheel Check that it spins freely and that the gaps between the pad and the disc are equal If the gaps are unequal or there is drag readjust the caliper position by loosening the mounting bolts and adjusting the caliper as needed Hint A white piece of paper can be used as a background to help sight down the disc looking for equal clearance between the pads and the disc When the gaps are equal and wheel spins freely without drag torque the mounting bolts to 110 in lbs 12 43 Nm Repeat the procedure for the other wheel C Hose Removal and Assembly The hose assembly procedure is different for the different brake models and design variations Pay close attention to which procedure applies for your Hayes disc brake system Hose Removal HFX 9 HFX 9 HD HFX Mag and HFX Mag Plus Master Cylinder and G1 Generation 1 Caliper Hose Removal To take the hose off of the master
9. aliper pistons move out as the brake pads wear Full Hydraulic A Hydraulic system where pressure is generated directly through activation of the lever Master Cylinder The part on the Hayes Disc Brake system that generates pressure in the full hydraulic system The master cylinder is activated through the lever Caliper The part of the Hayes Disc Brake system that holds the brake pads and clamps on the disc to slow the wheel Recommended Fluids and Lubricants Use only DOT 3 or DOT 4 brake fluid Do not use any petroleum based lubricants as this will cause the rubber parts to swell Hayes recommends the use of DOT 4 or DOT 3 brake fluid Clean the disc and pads only with isopropyl alcohol Personal Preference Adjustments In most cases the Hayes Disc Brake system has been pre assembled for your bike However there are a couple of adjustments that you can make to match your particular physical characteristics or personal preferences Positioning the Master Cylinder and Lever 1 Loosen but do not remove the handlebar clamp screw 2 Then position the Master Cylinder and Lever on the handlebar in your desired position 3 Torque the handlebar clamp screw to HFX Mag or Mag Plus 15 20 in lbs 1 69 2 25 Nm HFX 9 30 35 in lbs 3 38 3 94 Nm Lever Reach Adjustment 1 Adjustthe brake lever reach by using a 2 0 mm Allen wrench and turning the push rod that goes through the lever adjusting bushing Do not attempt to fo
10. bleed kit Bottle to catch drained fluid Fresh DOT 4 or DOT 3 brake fluid Small Phillips and flat screwdriver Approved O ring Lubricant Hammer and Drift Punch Warning Always wear safety glasses when servicing the brake system or other components of your bike 11 Torque Disc Screws 50 5 in lbs 5 65 55 Nm Handlebar Master Cylinder Clamp Screw HFX Mag HFX Mag Plus 15 20 in lbs 1 7 2 26 Nm HFX 9 30 35 in Ibs 3 39 3 95 Nm Master Cylinder Jam Nut 50 in lbs 5 in Ibs 5 65 55 Nm Caliper Bleeder 2 0 in lbs 23 Nm Torque to seal Do not overtorque Caliper Bridge Bolts 110 10 in lbs 12 43 1 1 Nm Caliper Mount Bolts 110 10 in lbs 12 43 1 1 Nm Hose Connection Master Cylinder HFX Mag HFX Mag Plus 40 in lbs 4 52 Nm 1 full rotation HFX 9 60 5 in lbs 6 78 55Nm Caliper G1 40 in lbs 4 52 Nm 1 full rotation 2003 G2 60 5 in lbs 6 78 55Nm Any Hayes Disc Brake found by the factory to be defective in materials and or workmanship within two years from the date of purchase will be repaired or replaced at the option of the manufacturer free of charge when received at the factory with proof of purchase freight prepaid This includes assembly costs for instance by the dealer which shall not be covered by Hayes Disc Brake This warranty does not cover breakage bending or damage that may result from crashes or falls This warranty does not cover any
11. defects or damage caused by alterations or modifications of new Hayes disc Brakes or parts or by normal wear accidents improper maintenance damages caused by the use of parts of different manufacturers improper use or abuse of the product or failure to follow instructions contained in an instruction manual for Hayes Disc Brake Any modifications made by the user will render the warranty null and void The cost of normal maintenance or replacement of service items which are not defective shall be paid for by the original purchaser This warranty is expressly in lieu of all other warranties and any implied are limited in duration to the same duration as the expressed warranty herein Hayes Disc Brake shall not be liable for any incidental or consequential damages If for any reason warranty work is necessary return the brake to the place of purchase In the USA contact Hayes Disc Brake for a return authorization number RA at 888 686 3472 At that time instructions for repair return or replacement shall be given Customers in countries other than USA should contact their dealer or local Hayes Disc Brake distributor RES 4 p Ce 8 9 E 9 ose Insert ompression Bushing ose Nut 1 ose Cone ose Connection G2 Hose _ __ o o O Hose Connection Seal pa VION O c cowIc NINNIN Caliper G2 ia e 15 Master Cylinder Lever Bod Clamp Screws
12. el and disc To fix this problem 1 2 Remove the brake pads from the caliper if they are not already removed Hint If the pads are pushed together tight slide a series of thin cards between the pads to initiate a gap and enlarge the gap until it is large enough to pull the pads out If you are going to replace the pads anyway you can use a screwdriver instead of the cards to create the gap But the screwdriver will break the friction material apart and the pads will definitely have to be discarded With the pads removed push the pistons all the way back into the caliper using the box end of a 10 mm end wrench Caution Don t push on the post in the center of the piston because that will bend the post Walk the piston back and forth until the piston is all the way back in the bore Do the same thing on the other side When the pistons are back into their bores replace the pads putting them in at a slight angle so that the spring catches the post on the piston C Cleaning and Care The brake disc and pads should only be cleaned with isopropyl alcohol not disc brake cleaner This service segment is designed to assist the reader with the service and repair of Hayes Disc Brakes Read and be familiar with the instructions The user should have a good knowledge of mechanical procedures and should be equipped with proper tools and equipment Incorrect service or repair may reduce braking performance and could lead to a safe
13. ion bushing is a gold color Push the longer end of the HFX 9 barbed hose insert into end of hose Be sure it is inserted flush with the end of hose Always use a new hose insert Place the hose inset o ring over the exposed end of the hose insert Slide hose with hose inset and o ring into the HFX 9 master cylinder and install the hose nut Be sure that the hose is inserted completely into the master cylinder end Be sure the hose remains inserted while tightening Using a 8mm open end wrench torque the hose nut to 60 5 in Ib Bleed the system HFX Mag HFX Mag Plus Master Cylinder Hose Assembly 1 2 Locate the end of hose without the permanent crimp attached Cut the hose to the desired length with good scissors or cable cutters The cut end must be clean and perpendicular to the hose itself Slide HFX Mag nose cone onto the hose Note The HFX Mag nose cone is the larger of the two Slide the HFX Mag hose nut and compression bushing HFX Mag Hose Assembly over the hose Always use a new compression bushing Note The HFX Mag hose nut has internal threads and the compression bushing is a silver color Slide the hose over the barbed end on the master cylinder cartridge and install the hose nut Using a 10mm open end wrench torque the hose nut to 40 in Ib plus one full rotation Bleed the system A Bleed Kit Assembly Screw the cap onto the end of the bottle Cut a 2 section of hose Push the short sec
14. ke fluid 8 Close the caliper bleeder 9 Place the hose from the fluid bottle onto the caliper bleeder Pump the fluid bottle until there is no air in the hose 10 Open the caliper bleeder 1 4 turn 11 Squeeze the fluid bottle firmly forcing fluid into the caliper for a count of five Stop squeezing until the bottle Filler Bottle returns to its natural shape When the squeeze is released Attachment air should be drawn out of the caliper Continue alternately squeezing the fluid bottle for a count of five and releasing until no air bubbles come out of the caliper 12 After all the air is out of the caliper squeeze the bottle until fluid comes out at master cylinder with no air bubbles 13 While squeezing the bottle quickly stroke the lever to the handlebars and release Repeat this until no more air bubbles come out of the master cylinder 14 With the bottle still being squeezed close the caliper bleeder Torque should be only to seal the bleeder Caution Do not over torque Then release and remove the bottle and filler hose Maintenance Procedures Due to wear contamination or damage the brake pads will on occasion have to be replaced A Brake Pad Change 1 2 3 Remove the wheel Using the tab in the center of the pad backing plate pull the pad toward the center of the caliper and out There is a spring that holds them in place That spring LE snaps on to the post at the center of the piston
15. ng DOT 4 or DOT 3 brake fluid can be an irritant when it comes into contact with human tissue For skin contact brake fluid should be washed off in flowing water For eye contact the eye area should be irrigated with flowing water immediately and continuously for 15 minutes Consult with medical personnel If effects occur from inhaling brake fluid fumes move to an area with fresh air Consult a physician If brake fluid is ingested induce vomiting and consult medical personnel Used brake fluid should be disposed of according to local laws Remove the wheel 2 Remove the brake pads so that any spilled fluid does not contaminate the pads Using the tab in the center of the pad backing plate pull each pad toward the center of the caliper and out There is a spring that holds the pad in place That spring snaps on to the post at the center of the piston 3 Push the caliper pistons all the way into their bores using the box end of a 10 mm end wrench Caution Don t push on the post in the center of the piston because that will bend the post Walk the piston back and forth until the piston is all the way back in the bore Do the same thing on the other side Position the bike in a stand so that the brake caliper bleeder screw is perpendicular to the ground and so that the bleed screw HFX Mag or reservoir plug HFX 9 on the master cylinder is the highest point on the brake system This can be done by loosening the master cylinder clam
16. p screws and rotating the master cylinder upright on the handlebars Note For the HFX Mag bike should be in the stand with the front wheel higher than the rear at a 45 degree angle and the lever should point up at a 45 degree angle For a left hand lever turn the handlebars all the way to the right and for the right hand lever turn the handlebars all the way to the left Note For the HFX 9 the bike should remain horizontal to the ground and the lever should remain parallel to the ground A 5 Remove the master cylinder bleed screw HFX Mag or reservoir plug HFX 9 and press the fitting with the hose into the hole The other end of the hose should go into a cup or bottle to catch the excess fluid Be sure not to submerge the end of the hose in fluid Hint Taping a spoke to a bottle and bending it to hook around the handlebars makes a convenient hanger Note The HFX Mag master cylinder bleed fitting is a Phillips head screw and requires the use of the clear cone shape bleed fitting included in the bleed kit SS Note The HFX 9 master cylinder reservoir plug is a ats plastic cap which needs to be removed with your fingers or a small flat head screwdriver DO NOT remove the two T 10 Torx bolts holding the cap on The HFX 9 requires the use of the silver aluminum bleed fitting included in the bleed kit 6 Completely remove the caliper bleeder s rubber cap 7 Fill the plastic filler bottle with fresh DOT 3 or DOT 4 bra
17. rce the adjustment screw beyond its limits Burnish Disc brakes require a special burnish period to achieve maximum braking power This burnishing period lasts for about 30 40 stops During this period some noise may occur This brake has been designed for use on a single person mountain bike The use on any other vehicle or device will void the warranty and can cause serious injury For riders using the brakes in downhill conditions it is recommended that you use the 8 version of the Hayes brake This includes the HFX Mag or HFX 9 HD Hayes brakes with 8 discs Not all frames and forks will accept an 8 disc Please check with your frame and fork manufacturer or www hayesdiscbrake com for 8 disc compatibility Consistently using the 6 disc in downhill conditions may cause the brake fluid to boil As a serious rider you are probably well 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 your brakes for proper function and the brake pads for wear When you ride always wear a helmet The following procedures cover the installation of Hayes Disc Brakes purchased as aftermarket item If you have purchased a bike new with Hayes Disc Brakes already installed you will not immediately require all of the procedures When you need to install any of the disc brake components a qualified technician with the proper
18. tion of hose over the cap until it slides past the ridge on the cap Push the long section of hose into the master cylinder bleed fitting Note There are two fittings with the kit The clear cone shaped fitting is to be used with the HEX Mag and HFX Mag Plus The silver aluminum fitting is to be used with the HFX 9 B Bleeding the System Dope Air entrapped in the hydraulic system of the disc brakes can decrease performance of the system and should be removed by bleeding the system and replenishing the system with new brake fluid The system is filled by pumping fluid from the lowest point at the caliper through the system to the highest point the bleeder on the master cylinder Note The bleed instructions include steps for the HEX Mag and HFX 9 brake systems Read them carefully since instructions vary for the type of brake system you have Caution Use only new DOT 4 or DOT 3 brake fluid from a closed sealed container Use of any other fluid can cause the rubber parts to degrade and cause the brake to fail Caution DOT 4 or DOT 3 brake fluid will strip paint Use extreme caution to avoid getting DOT 4 or DOT 3 brake fluid on paint If DOT 4 or DOT 3 brake fluid comes in contact with paint wipe it off immediately and rinse with isopropyl alcohol Warning If you get any brake fluid on the brake pads discard them and replace with new pads If you get any brake fluid on the disc clean it thoroughly with isopropyl alcohol Warni
19. ty or personal hazard situation If you have any doubts about the procedure described due to limited experience or because of the lack of necessary tools and equipment contact your local dealer or mechanic Remember always Think Safety 10 A Troubleshooting The following chart provides a quick reference as to the possible cause and the normal corrective action for the most common problems Problem Lever goes to the handlebar Disc rubbing on the pads Spongy Lever No braking power Pads fall out Fluid loss B Tools Possible Cause Bad Bleed Bad Cartridge System Leak Caliper not centered over disc Inadequate clearance Bent Disc Bad Bleed Dirty disc Contaminated pads Bent or broken piston Bent or missing spring Banjo leaking Hose leaking Master cylinder bleeder Master cylinder cartridge Corrective Action Re bleed Replace Cartridge and re bleed Look for leak and see Fluid loss below Re center the caliper Push pistons back Replace Disc Re bleed Clean disc with alcohol Replace pads Replace piston post Replace pads Replace banjo O rings Tighten hose nut Replace hose Replace compression bushing Replace bleeder screw amp O ring Replace bleeder Rebuild master cylinder assembly Box Open end wrenches 6mm 8mm 10mm amp 13mm Allen wrenches 2 0mm 4mm amp 5mm Torque wrench With 4mm amp 5mm bits amp Torx T25 Driver Isopropyl alcohol Hayes
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