Hope Tech C2 Brake User Manual
Hope Technology
Disc brake Installation
and
Service Manual
XC4
Closed 2
Open 2
DH4
Hope Technology
UK Head Office and Manufacturing
Hope Mill, Skipton Road
Barnoldswick
Lancashire
BB18 6EN
United Kingdom
Tel : + 44 (0)1282 851200
Fax : + 44 (0)1282 851201
Website : www.hopetech.com
Documentation revisi on 1.0
USA Sales
Hope Technology Inc.
40234 Dutton Street
Cherry Valley, CA 92223
Tel : (+1) 909 769 1654
Toll Free : (+1) 800 303 6863
Fax: (+1) 909 845 4467
Contents
1. Introduction .................................................................................................4
1.1. Instruction manual coverage............................................................................. 4
1.2. Safety first......................................................................................................... 4
1.3. System identification......................................................................................... 4
2. Installation...................................................................................................7
2.1. The bicycle wheel ............................................................................................. 7
2.2. Attaching the disc rotor to the hub.................................................................... 7
2.3. Attaching the lever............................................................................................ 8
2.4. Attaching the caliper......................................................................................... 8
2.5. Personal settings .............................................................................................. 8
2.6. Break in period.................................................................................................. 9
2.7. On the trail ........................................................................................................ 9
3. Service......................................................................................................11
3.1. Regular maintenance...................................................................................... 11
3.2. Changing the brake pads................................................................................ 11
3.3. Bleeding the brake.......................................................................................... 12
3.4. Shortening or re-routing the hose................................................................... 15
3.5. Hose change................................................................................................... 16
3.6. Caliper half change – piston removal.............................................................. 16
3.7. Torque settings............................................................................................... 17
4. Troubleshooting ........................................................................................18
5. Parts lists...................................................................................................21
5.1. Pro lever for the XC4 and Closed 2 brake..................................................... 22
5.2. Pro lever for the DH4 and Open 2 brake ........................................................ 24
5.3. Sport lever for the XC4 and Closed 2 brake................................................... 26
5.4. Sport lever for the DH4 and Open 2 brake ..................................................... 28
5.5. XC4 caliper ..................................................................................................... 30
5.6. Closed 2 caliper.............................................................................................. 32
5.7. Open 2 caliper................................................................................................. 34
5.8. DH4 caliper..................................................................................................... 36
6. Warranty ...................................................................................................38
7. New 2001 Disc brakes..............................................................................39
4
1. Introduction
Thank you for purchasing a Hope Technology disc brake system. Please read the
contents of this service manual to fully acquaint yourself with the correct installation and
safe operation of your brake.
1.1. Instruction manual coverage
This manual covers the installation and servicing of the hydraulic disc brake calipers
XC4, Closed 2, Open 2 and DH4, and the brake levers Pro and Sport.
This manual also covers our two discontinued brakes called the Sport and Pro. For
reference purposes the Pro disc brake is identical to a Closed 2 caliper supplied with a
Pro lever, the Sport disc brake is identical to a Closed 2 supplied with a Sport lever.
New 2001 products – please refer to section 7 for late additions to this manual.
1.2. Safety first
This brake system must be fitted by a competent cycle mechanic using the correct
tools. Incorrect installation can result in brake failure that can cause serious personal
injuries.
Your braking performance will improve in almost all riding conditions but care must be
taken to ride within your own ability. The stopping power of any bicycle is always limited
by the traction of the tire on the ground so take the time to become familiar with your
new brake and its braking characteristics.
Before each ride always check the brake for proper function and the brake pads for
wear and that there is no system damage resulting in fluid leaks.
If you have any doubts or questions please contact your dealer or the appropriate Hope
distributor for your country.
1.3. System identification
There are four caliper designs, the XC4, Closed 2, Open 2 and DH4. Each of these
calipers can be used with either a Pro or Sport lever.
The Pro and Sport levers are supplied in either a Closed or Open system configuration
depending on which caliper is being used.
The following table shows examples of each caliper. The caliper profiles can vary
depending on the disc rotor size and bolt mounting pattern and the table shows
common examples.
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Caliper identification
The XC4 caliper
A small caliper with 4 pistons. The
caliper has the word HOPE
machined into the side.
Closed system.
The caliper must be used with a
closed system lever.
The Closed 2 caliper
A caliper with 2 pistons. The caliper
has the word HOPE machined into
the side.
Closed system.
The caliper must be used with a
closed system lever.
165mm front caliper shown.
The Open 2 caliper
A caliper with 2 pistons. The caliper
has the letter ‘O’ machined into the
side of the caliper below the Hope
logo.
Open system.
This caliper must be used with an
open system lever.
185mm front caliper shown.
The DH4 caliper
A caliper with 4 pistons. The caliper
has the word HOPE O4 machined
into the side.
Open system.
The caliper must be used with an
open system lever.
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Lever identification
The Pro lever
Closed system configuration
A two finger lever with a silver pad
adjustment screw.
The Pro lever
Open system configuration
A two finger lever with a fixed master
cylinder cap.
The Sport lever
Closed system configuration
A four finger lever with a silver pad
adjustment screw.
The Sport lever
Open system configuration
A four finger lever with a fixed
master cylinder cap.
Under no circumstances should you use a Closed system caliper with an Open system
lever (and vice versa). A mismatched system will not work and result in brake failure.
7
2. Installation
The disc brake system is supplied fully assembled and bled, i.e. containing brake fluid.
The Cycle Dealer is responsible for supplying the caliper with the correct bolt mounting
pattern to fit your particular fork or frame. Some installations may require an additional
mount bracket as advised by your dealer.
In the first instance it is recommended that you install the brake as supplied without
disconnecting and routing the hose through frame guides (if present) or attempting to
shorten the hose. Once you have experienced the fully working brake you may decide
at a later date to make some hose routing or shortening modifications as described
later in this manual.
2.1. The bicycle wheel
The wheel should be built by a skilled wheelbuilder using a 3 cross lacing pattern and
correctly tensioned. Your dealer will advise whether the hub in your wheel is compatible
with this Hope disc brake. There are two types of compatible hubs; splined Hope hubs
that require a 5 bolt disc spider (purchased separately) and International Standard 6
bolt hubs (made by Hope and other hub manufacturers) where the disc rotor bolts
directly to the hub.
2.2. Attaching the disc rotor to the hub
For Hope splined hubs fit the spider to the hub splines
and ensure it is squarely seated before securing it with
the spider lockring. Hubs using a spider require a disc
rotor with a 5 bolt pattern.
Attach the disc rotor to the hub with the orientation of the
rotor arms as shown in Figure 1 (6 bolt disc rotor shown).
It is recommended that a mild engineering adhesive
often referred to as ‘threadlock’ is used on the bolt
threads to prevent them unscrewing. Do not use a
permanent adhesive or this will prevent removing the
disc rotor at a later date.
Replace the wheel with the attached disc rotor in the
forks (or frame) making sure the wheel axle is sitting
square in the dropouts and that the wheel skewer is
correctly tightened.
FORWARD ROTATION OF WHEEL
Figure 1
8
2.3. Attaching the lever
Attach the lever assembly to the handlebars and route the caliper down to the fork disc
mount or along the frame to the rear disc mount. Take care to avoid situations that can
damage the brake hose when the bicycle is used such as trapping the hose within
suspension fork or rear suspension linkage movements, and also to avoid chaffing on
the tire.
The lever will work in any position providing the master cylinder is not totally upside
down. The master cylinder need only be horizontal when bleeding the system.
2.4. Attaching the caliper
Before attaching the caliper ensure that the brake pads are fully retracted in the caliper.
New brakes will be supplied fully retracted, if you need to perform this operation
yourself then on the XC4 and Closed 2 brakes turn the brake lever master cylinder
screw adjuster anti clockwise (see Figure 4). For the Open 2 and DH4 brakes remove
the pads to avoid damaging them and gently prise the pistons back with a plastic tire
lever (or similar).
The aim is to position the caliper central over the disc rotor using some of the supplied
shim washers between the caliper and disc mount to achieve the central positioning.
This is trial and error until the correct position is achieved.
When the caliper (and lever) are attached, secure the hose to the frame using ties or
hose guides and check for unrestricted handlebar movement and that the hose is not
trapped or pinched.
2.5. Personal settings
Finger reach
This refers to the position of the lever blade relative to the bars. There are two
procedures for setting the reach depending on whether you have the Pro or Sport lever.
For the Pro lever slacken the grub screw
A (see Figure 2) then adjust the position
of the lever using the adjuster screw B.
When the correct position is achieved
gently tighten the grub screw A.
Figure 2
9
For the Sport lever adjust the grub screw
C (see Figure 3) at the front of the lever
to achieve the desired position. Then
undo the locknut D and adjust the screw
E leaving a small amount of freeplay in
the lever. Re tighten the locknut D.
Figure 3
Lever travel (pad position)
This is the amount of lever travel between the brake’s off
and on position.
For the XC4 and Closed 2 brakes this can be set using
the screw adjuster on top of the lever master cylinder
(see Figure 4, Pro lever shown). Screwing clockwise will
move the pads closer to the disc rotor thus reducing lever
travel, screwing anti-clockwise moves the pads away
from the disc thus increasing lever travel.
For the DH4 and Open 2 brakes there is no manual
adjustment and lever travel is determined by the piston
seals in the caliper body which retract the pads. When the brake pads have been
manually retracted (by pushing the pistons back into their bores) these calipers will
require several pulls of the lever to reset themselves, during this period the lever may
travel all the way to the bars.
Figure 4
2.6. Break in period
Before riding check the correct action of the brake and that braking effort is applied as
the lever is pulled. To achieve the maximum braking effort the new brake pads need
bedding in. Bed in the pads by riding a short distance with the brake applied, it also
helps to pour clean water over the caliper and pads whilst bedding in. This procedure
will achieve good braking performance but will reach its full potential after a few rides.
2.7. On the trail
The XC4 and Closed 2 brakes
These brakes feature the thumbwheel adjuster (see Figure 4) on the brake lever master
cylinder which is used to adjust the position of the brake pads relative to the disc rotor.
Turning clockwise will move the pads closer to the disc rotor, screwing anti-clockwise
moves the pads away from the disc. There are two situations where adjustment is
necessary :
1. Compensating for pad wear. As the pads wear you need to reposition the pads
closer to the disc rotor.
1
2. Compensating for over heating. Extreme heating of the brake due to long descents
with heavy braking may cause the brake fluid to expand and push the brake pistons
(and pads) closer to the disc in which case you may need to back off the pads using
the thumbwheel adjuster, then readjusting as the brake cools down.
The DH4 and Open 2 brakes
These brakes do not provide any means of manual pad adjustment. They do however
feature an expansion chamber within the brake lever master cylinder which
automatically compensates for pad wear and similarly compensates for fluid expansion
as the brake heats up and cools down.
With the caliper correctly centred relative to the disc there should be no disc rub on the
DH4 and Open 2 brakes. Even if there is a slight amount of disc rub it will not slow the
bike down in any way and will not be audible against the ground noise from the tires.
If you remove your wheels from your bicycle take care not to pull the brake levers
otherwise the pistons can pump out. If this happens then simply push the pistons back.
If the pistons are so far out that the pads are touching then you will need to remove the
pads in order to get at the pistons. If you transport your bicycle with the wheels
removed then it is advisable to insert a piece of packing between the pads to keep
them in place.
0
1
3. Service
3.1. Regular maintenance
Cleaning your brake
The braking performance will be severely reduced if the disc rotor and pads become
contaminated with oil, brake fluid or after-market degreasing and cleaning agents.
Clean your brake with water.
If the disc rotor becomes contaminated it can be cleaned by wiping with a rag with
isopropyl alcohol or disc brake cleaning products designed specifically for bicycle disc
brakes. Heavily contaminated brake pads will need replacing.
Checking for system leaks
Check the hose for any damage such as chaffing against the bike, or whenever the bike
has been rough handled or dropped. A split hose (however tiny) will cause a system
leak which will severely impair braking performance. A damaged hose will need
replacing.
Check the caliper and lever assemblies for any signs of fluid loss. See the
Troubleshooting section for fixing any problems.
Checking the brake pads
The brake pads will need replacing when the friction material is worn down to 0.5mm.
Do not wait until the friction material has worn through to the backing plate because the
brake will not function and you will damage the disc rotor.
3.2. Changing the brake pads
1. Remove the wheel.
2. Remove the split pins using pliers (and the pad retaining spring on the XC4 caliper)
and slide out the old pads from the caliper.
3. Retract the pistons on the XC4 and Closed 2 brakes by turning the brake lever
master cylinder screw adjuster anti clockwise. For the Open 2 and DH4 brakes
gently prise the pistons back using a plastic tire lever (or similar).
4. Clean the inside of the caliper with a clean rag and insert the new brake pads, (and
retaining spring on the XC4 caliper) and new split pins. The new pads must be
genuine Hope compatible pads for the appropriate caliper.
5. Refit the wheel and adjust the pad position, (see section 2.5).
1
1
6. Bed in the new pads (see section 2.6).
3.3. Bleeding the brake
Bleeding the brake is the procedure whereby new brake fluid is introduced into the
system either as a replacement or to flush out any trapped air.
There are several reasons why a bleed operation may be necessary, for example
shortening a brake hose, changing the brake fluid, or to remedy a situation described
later in the troubleshooting guide (section 4).
There are two distinct procedures for bleeding your disc brake depending on which
brake system you have purchased, please make sure you select the correct procedure.
But first a few important notes on brake fluid.
Brake fluid
This Hope disc brake contains
motor accessory stores. If you cannot obtain DOT 5.1 then DOT 4 is acceptable but you
must flush out all the old DOT 5.1 first.
Use of other types of brake fluid, in particular mineral oil, will seriously damage your
brake and cause brake failure.
Please read the care instructions that come with the DOT brake fluid, in particular we
draw your attention to the following:
Use only new brake fluid from a closed bottle and replace the bottle’s cap
•
afterwards to prevent contamination of the fluid (DOT 5.1 fluid absorbs moisture).
Brake fluid will strip paint so wipe off any spillage immediately and clean the area
•
with isopropyl alcohol.
Brake pads contaminated with brake fluid will need replacing because the braking
•
performance of the pad will be greatly diminished.
Discard old brake fluid in a responsible manner and do not pollute drains or the
•
environment.
DOT 5.1
hydraulic brake fluid which is available from
Bleeding the XC4 and Closed 2 disc brake
Item number references refer to the diagram of the Pro lever in section 5.1. The
procedure is identical if you have a Sport lever.
Wear safety glasses.
1. Remove the wheel and brake pads to prevent contamination.
2. If necessary reposition the brake lever so that the lever and master cylinder is
horizontal to the ground.
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