Hope Tech Trial Zone User Manual

www.hopetech.com

HOPE TECHNOLOGY (IPCO) LTD
Hope Mill
Barnoldswick, Lancashire
BB18 5PX, United Kingdom

Technical enquiries : Sales enquiries :
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Trial Zone brake usage chart

ENDURO

TRIALS

N/A

N/A

N/A

N/A

N/A

N/A

DH / FREERIDE

ALL MOUNTAIN

CROSS COUNTRY

XC RACING

CYCLO CROSS / ROAD

HYDRAULIC DISC BRAKE SYSTEM

MODEL YEAR 2012

Trial Zone

Master Cylinder

Trial Zone

Caliper

QUICK INSTALLATION

GUIDE

WARNING PLEASE READ FIRST

. This brake system is designed for Trial use only, any other application could
result in brake overheating and failure.
. Don’t overestimate your technical capacities. This brake system must be fitted
by a competent cycle mechanic using the correct tools. Incorrect installation
could result in brake failure that could cause serious or fatal injuries.
. Please refer to the website videos and technical documents for more informa­tion including servicing and maintenance - www.hopetech.com / Tech support
section.
The video logo indicates you can find some useful tips on the website
. This brake system has been designed to be used only on two-wheel vehicles
with human propulsion. Any other application is not advisable and could result
in the failure of this product.
. Your brake system will generate heat during braking. Never touch either the
disc or caliper after long braking period as this could cause severe burns.
. Before each ride always check the brake for proper function, the brake pad for
wear and that there is no system damage resulting in fluid leaks.
. It’s common sense to also check that your wheel’s quick release systems are
securely installed and tightened.
. Your braking performance will improve in almost all conditions. Please take
time to become familiar with your new brake. Always ride within your own
ability.
. Brake pad contaminated with brake fluid, chain lubricant or unsuitable bike
cleaner will need replacing because the overall brake performance will be
greatly diminished.
. If you have any doubts or questions please contact your dealer or the appropri­ate distributor for your country.
.

If you decide to ignore these important safety warnings and instructions, you
are doing so at your own risk and Hope Technology cannot be held responsible
for any consequences resulting of the misuse of the brake system.

INTRODUCTION

Congratulations, you have just acquired the Trial Zone hydraulic disc brake system.
Please note that this brake system has been specially designed for Trial use only.
The Trial Zone master cylinder will deliver the right brake pressure to the caliper
whilst keeping its solid and positive feel. It features a split clamp for easy fitting,
integrated reservoir for bleeding and adjustable lever reach.
With its two oversize pistons, the one piece Trial Zone caliper will offer both power
and stiffness for the most efficient clamping of the disc.
The Trial Zone brake is supplied with our standard custom black hose in order to
associate high performance with the lowest weight.
Rotors are only available in stainless steel in several diameters. Please not that this
brake isn’t compatible with any floating disc, use the specific rotors designed for the
Trial Zone brake.

Again bear in mind that this brake system is only designed for Trial bikes (brake
on, brake off at low speed) any other use could result in brake failure.

BOX CONTENTS

1

TOOLS REQUIRED

Once again, don’t overestimate your technical skills. If you are not familiar with
this sort of installation we advise that this brake system should be fitted by a
competent cycle mechanic.

+ Torx T25 driver

+ Torx T15 driver
+ 5mm Allen key
+ 4mm Allen key

+ 2mm Allen key
+ Flat blade screw driver
+ 8mm spanner

2

1. Brake system, fully bled

2. M6 x 18mm caliper bolts

INSTALLATION STEPS

Please refer to the website videos and technical documents if you

more information about setting up this brake system, servicing

require
and maintenance. www.hopetech.com / Tech support section

1. ATTACHING THE DISC TO THE HUB

With this brake system it is highly recommended that you use only HOPE rotors. Our
discs have been especially developed to work in association with our calipers and
brake pads.

a) Attach the disc rotor to the hub using the
bolts provided

b) Make sure that the laser marked arrow on
the disc is pointing in the same direction as the
forward wheel rotation.

c) Using a Torx 25
a cross pattern. Recommended tightening torque
5-6 N.m

: A mild engineering adhesive could be

Note
used on disc bolts to prevent them unscrewing.
Do not use permanent adhesive.

2. ATTACHING THE LEVER TO THE BARS

a) Attach the lever assembly to the handlebars. When

are happy with the orientation of the lever, tighten

you
alternately
Recommended tightening torque : 4-5 N.m.

b) Route the hose and caliper down to the fork brake

mount or along the frame to the rear brake mount.

Avoid situations that could damage the brake hose and/or your bike frame
and components

Note:

In the first instance it is recommended that you install your brake as supplied
without disconnecting and routing the hose through frame guide (if present) or
attempting to shorten the hose.

At a later date you can shorten the brake hose if required. For this operation,
follow the intructions in the how to videos of our website.

3. ATTACHING THE CALIPER TO THE FORK OR FRAME

The TRIAL
therefore sometim es need to use an adaptor
brake mounts.

Mainly on IS mounts, to ensure that the caliper
squealing or
of your fork or frame are clear of any paint or burrs.

We recommend that you machine the tabs
Spot Facing tool.

3.1 MOUNTING THE CALIPER ON POSTMOUNT TYPE MOUNTS

Be careful not to get
your fingers caught in the disc
when following these steps

Note : We do not

at this point. See section 4 regarding the alignment of pistons.

driver tighten the disc bolts in

the M5 clamp bolts using a 4mm Allen key.

ZONE caliper is both availab le in a postmount and I S type. You will

bad lever feel - prior to fitting the brake, it is important that the tabs

=

=

fig 1

recommend pumping the lever to push pads out to align caliper

bracket to fit the caliper on some

is properly aligned and to help avoid

using a suitable tool such as HOPE

a) Before attaching the caliper ensure
that the brake pads are fully retracted in
the caliper. If not, gently push the piston
back using a plastic tyre lever or
something similar. Beware not to
damage the pads. Take them off if
necessary. Push on the left hand side
pad backplate to push the right hand
side piston and vice versa.

b) Mount the wheel fitted with the
rotor, ensuring correct fitment in
dropouts.

c) Position the caliper on the mount
slightly tighten the two M6 bolts.

d) At both front and rear of the
caliper, adjust its position so it is central
over the rotor (see arrows on fig 1) then
tighten the two M6 bolts using a 5mm
Allen key. Recommended tightening
torque 8-9 N.m.

and

fig 2

- With an IS type caliper :

If

you have an IS caliper (n°5) it will fit straight

onto IS forks and frame brake mounts.

The aim is to position the caliper central over
the disc using some of the supplied shim
washers between the caliper and brake
mounts to achieve the central positioning.
This is a trial and error until the correct position
is achieved.

4. CENTRALISE THE PADS OVER THE DISC

This step is very important and mustn’t be ignored.

Gently pump the lever in order to bring the pads closer to the disc. One pad might
enter in contact with the disc before the other. If this happens, hold the disc against
the pad that is already in contact with the disc to allow the other one to move.

For an optimised lever feel, both pads
same time and allow the same clearance (see arrows) when retracted. The disc
should not be flexing at any time.

must enter in contact with the disc at the

fig 3

INSERT
SHIMS

=

pad

rotor

pad

=

PERSONAL SETTINGS

RIAL ZONE master cylinder

The T
only allows the adjustment of
the finger reach.

The finger reach adjustment
refers to the initial position of the
lever blade relative to the bars.

Use a 2mm Allen key, turn the
adjuster screw clockwise to

+

-

-

+

BREAK IN PERIOD AND MAINTENANCE

Before riding and before every ride, check the correct action of the brake and that

braking effort is applied as the lever is pulled.

To achieve the maximum braking performance, the new pads will need bedding

this will take a short period of time.

To bed in the pads, ride a short distance whilst alternatively gently applying the
brake on and off without attempting to stop. This procedure will achieve good
braking performance but will reach its full potential after a few rides.

About maintenance tips refers to our “how to” videos on the web

For brake bleeds use only dot 5.1 or dot 4 brake fluid from a clean container.

WARRANTY

increase the reach and
anticlockwise to reduce it.

in,

site.

3.2 MOUNTING THE CALIPER ON IS TYPE MOUNTS

- With a postmount type caliper :

On IS mount you will have to use an adaptor bracket to be able to fit the brake

caliper.

a) According to the rotor size and type of mounts, attach the suitable adaptor
bracket onto the brake tabs and tighten the two M6 bolts using a 5mm Allen key.
Recommended tightening torque 8-9 N.m. Illustration fig 2.

b) Follow the same instructions as fitting the brake onto a postmount (see
previous section). Illustration fig 3.

All Hope Technology disc brake systems are covered for one year from original

of purchase against manufacturer defects in material and workmanship. Proof

date
of purchase
to Hope Technology to process any warranty claim.

This

comply by the recommendations given in this manual.

This warranty does not affect your statutory rights.

is required. Products must be returned to the original place of purchase or

warranty does not cover any damage caused through mis-use or failing to

TrialZone /11.11/ISS1