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Clara 2002
User Manual
10 pgs615.69 Kb0

Magura Clara 2002, Julie 2002 User Manual

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1. Welcome to the Brake People!
Brake lever (master cylinder) MAGURA Julie
Brake caliper and rotor
MAGURA Julie
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 Clara and Julie disc brakes offer a superior braking power even with little hand force applied, no matter 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 conditions.
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.
All steps will be explained on the Julie model. Any differences with the Clara model will be clearly mentioned.
although the Clara and Julie disc brake systems are relatively simple you should not overestimate your technical skills! We therefore advise you to leave the following works to a trained technician of a professional bike shop.
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 products. Stay tuned with the Brake People! Thank you for your confidence in
our products, enjoy your ride and your new MAGURA disc stoppers!
Happy trails!
Congratulations! You have purchased a fully hydraulic MAGURA disc brake proudly „Made in Germany“. You will be enthusiastic about the awesome braking power and the very little maintenance that is necessary on our stop­pers. You are not alone, millions of users worldwide rely on them and every day we’re becoming more.
1. Introduction 3
2. Safety instructions before the first ride 4
3. Safety instructions before every ride 4-5
4. Transport of the bicycle 5
5. Brake installation 6-9
6. Shorten the hose 9-11
7. Maintenance 11-13
8. Repairs 13-15
9. Bleeding and Filling 15-16
10. Trouble Shooting 17
11. The disc brake wheel 18
12. Accessories 19
13. Warranty 19
14. Spare parts exploded view 20-21
Table of Contents
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:
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.
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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 handlebars. 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 15/16.
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3. 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. (Also see page 11)
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 dishwater or alcohol. See further hints about the brake pad change on pages 11- 13.
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 page 9)
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 unsu­re. A faulty bicycle might cause serious accidents with possible fatal injuries of the rider!
Always check carefully the following points:
1. Are you already familiar with hydraulic disc brakes? Our brakes might be much more powerful than the stoppers on which you relied on 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 possible heavy bodily injury. Change the hose connection by a trained technician in case of any doubts.
Further hints concerning the swapping of the brake hose see page 10 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 30km/h to achieve the maximum brake power. Take your bike to a safe place to run in the brake.
4. In case of extreme riding conditions (total weight of bike plus rider over 100kg and/or a gradient of more than 15%) always use both brakes simultaneously to brake your bike down.
5. Do not use the Clara and Julie disc brake for downhill sport or on tandems! 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.
2. Before the first ride
3. Before every ride
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 moun-
ted. In case this should have happened see page 10 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, deformed or contaminated with lubricants.
Do not transport the bike upside-down.
For a transport in an aircraft you can leave your brake as it is, e.g. you do not have to empty it.
4. Transport of the bicycle
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Unpack your Clara or Julie disc brake:
1. brake lever (master cylinder) connected through the
2. brake hose with the
3. brake caliper with transport device (shown is International Standard version; ATTENTION: remove
4. YELLOW transport device only shortly before installation of the wheel!)
5. rotor (diameter Clara: front and rear 160mm)
(diameter Julie: front 180mm, rear 160mm)
6. fitting bolts for caliper Allen key 5 (2 pieces)
7. fitting bolts for rotor Torx key T25 (6 pieces)
8. 0,2mm spacers (8 pieces)
9. black 1mm spacers (2 pieces, only necessary for Julie rear brakes)
10. hose inserts (2 pieces, only necessary for Clara)
11. olives (2 pieces)
12. Torx T25 key
13. Allen key 2
not shown: hose fitting kit for rear brake (comes with all rear brakes)
specifications modifying and improving this product are subject to change without prior notice.
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The brake levers, calipers and hoses of Julie and Clara are completely dif­ferent and not compatible! Never mix and match parts from the two 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 bicycle.
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 the 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 5mm allen key. If you install your
brake lever the first time you’ll hear a crack, do not worry because of that. Tightening torque 4Nm/34 in.lbs
The MAGURA disc brakes Clara and Julie are compatible with frames and forks which meet the international standard (IS) for disc brake installation. Only the front brakes are available with a special Postmount caliper. Never mount the brakes with adapters or brackets from other manufacturers. All warranty will be void in case of any misuse! Use only direct mounting 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 help of the MAGURA Gnann-o-mat disc optimizer tool (also see page 9).
1. Tools for installation (+maintenance)
Allen key 2*, (3) and 5 transport/mounting device* sharp knife 8mm 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.
5. Brake Installation
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