User manual DAHON ALFINE DISC BRAKE SYSTEM TECHNICAL SERVICE INSTRUCTIONS

[. . . ] General Safety Information WARNING · Please use extra caution to keep your fingers away from the rotating disc brake rotor during installing or servicing the wheel. The rotor is sharp enough to inflict severe injury to your fingers if caught within the openings of moving rotor. · The calipers and rotor will become hot when the brakes are operated, so do not touch them while riding or immediately after dismounting from the bicycle, otherwise you may get burned. Check that the brake components have cooled down sufficiently before attempting to adjust the brakes. [. . . ] · When the bicycle wheel has been removed, it is recommended that pad spacers should be installed. The pad spacers will prevent the piston from coming out if the brake lever is depressed while the wheel is removed. · If the brake lever is depressed without the pad spacers installed, the pistons will protrude further than is normal. Use a flat-tipped screwdriver or similar tool to push back the brake pads, while being careful not to damage the surfaces of the brake pads. (If the brake pads are not installed, push the pistons straight back in, while being careful not to damage them. ) If it is difficult to push the brake pads or pistons back, remove the reservoir tank cover and then try again. (Note that some oil may overflow from the reservoir tank at this time. ) · Use isopropyl alcohol, soapy water or a dry cloth when carrying out cleaning and maintenance of the brake system. Do not use commercially-available brake cleansers or silencing agents, as they can cause damage to parts such as seals. · Do not remove the pistons when disassembling the calipers. · If the rotor is worn, cracked or warped, it should be replaced. · Parts are not guaranteed against natural wear or deterioration resulting from normal use. · For maximum performance we highly recommend Shimano lubricants and maintenance products. < For left lever > Wire ring method < Front > < Rear > Becomes stiff Wire Wire 5. With the brake lever depressed, open and close the bleed nipple in rapid succession (for approximately 0. 5 seconds each time) to release any air bubbles which may be in the calipers. Repeat this procedure about 2 to 3 times. For C-shaped guides and the usual type of cable stoppers, use the special Shimano cable supporter (sold separately) to secure as shown in the illustration. Tightening torque: 0. 3 - 0. 5 N·m {2. 7 - 4. 4 in. lbs. } < C-shaped guide > < Usual type of cable stopper > Adding mineral oil and bleeding air Bleed nipple 1. With the pad spacers still attached to the calipers, place the bicycle into a bicycle stand or similar as shown in the illustration. Set the brake lever so that it is parallel to the ground, and then remove the reservoir tank cover. Brake lever should be parallel to ground Tightening torque: 4 - 6 N·m {35 - 53 in. lbs. } Operate the brake lever several times and check whether the brakes operate normally or not. Also check that there are no oil leaks visible. 6. Fill the reservoir tank with oil and then replace the reservoir tank cover. Fill the reservoir tank to overflowing with oil while replacing the cover to ensure that no air bubbles remain inside the reservoir tank. In addition, be careful not to get any oil on parts such as the rotor and brake pads. Tightening torque: 0. 3 - 0. 5 N·m {2. 7 - 4. 4 in. [. . . ] Push the piston back in straight, without bending it. Note that some oil may overflow from the reservoir tank at this time. I Installation of the rotor (SM-RT62) Rotor installation ring < Front > If oil periodically comes out from the bleed nipple, tighten the bleed nipple for a while. 3. Install the brake pads and the pad spacers B (red). Depress the brake lever as far as it will go, and then operate it several more times so that the two pistons all move to their initial positions. 5. [. . . ]