User manual HAYES DISC BRAKES 6 INCH POST MOUNT

[. . . ] Failure to do so could result in injury. Warning: With use, disc brake components may become very hot. Always allow components to cool before attempting to service your bike. Starting Out Congratulations. You have either purchased a new bicycle with the Hayes Disc Brake System, or you have purchased Hayes Disc Brake system or service parts as an aftermarket item. [. . . ] If the gaps are unequal, or if 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 disc. When the gaps are equal and the wheel spins freely (without drag), torque the mounting bolts to 110 in-lbs (12. 43Nm) 10. disc screw torqueing sequence Fork Adaptor E. Mounting the "International Standard" Caliper to the Frame or Fork Note: The "International Standard" calipers are to be only used with a 6" disc and a quick release front fork. 1. Mount the caliper to the frame using (2) M6 x 1. 0 18. 4mm long mount bolts. Using a 5mm Allen wrench, position the fixed inner pad adjuster flush with the caliper body leaving a . 015" - . 020" (. 38 - . 50mm) gap between the fixed inner pad and the disc. Warning: Be sure the inner brake pad is adjusted so the pad material is extending past the caliper wall. Adjusting the inner pad too far counter clockwise will cause the disc to hit the caliper wall resulting in brake failure. Using a 5mm Allen wrench, adjust the outer pad adjuster leaving a . 015" - . 020" (. 38 - . 50mm) gap between the outer pad and the disc. Adjust the amount of lever travel by adjusting the gap between the disc and pad of either the outer pad adjuster or the fixed inner pad adjuster. Warning: Adjusting more than a . 020" (. 50mm) gap on either side of the disc may cause the lever to go to the bar causing brake failure. Note: See installation instructions above for proper set-up. Caution: Do not try to turn the adjuster past its stopping point. Doing so may damage the brake. Removing Pads C. Hose Removal and Assembly The follow procedures are to be used when replacing or removing the hose. Master Cylinder and Caliper hose Removal 1. To take the hose off of the master cylinder end, slide the hose support down the hose. Using a 8mm box wrench, remove the hose nut and slide it all the way down the hose. Note: sometimes it is best to first cut the hose and used the box end of the 8mm wrench to better grab the 8mm hose nut. Slide the hose off the end of the master cylinder / caliper. There will be some residual fluid in the hose and master cylinder / caliper. Be careful to avoid spilling that fluid. A new compression bushing and hose insert will be needed each time the hose is re-installed. Remove the old compression bushing and hose insert by cutting the hose next to the compression bushing. [. . . ] If effects occur from inhaling brake fluid fumes, move to an area with fresh air. If brake fluid is ingested, induce vomiting and consult medical personnel. Used brake fluid should be disposed of in accordance with local laws. Bleed Fitting Bleed Kit Assembly 1. Screw the cap onto the end of the bottle. [. . . ]