MECHANICAL DISC BRAKE INSTALLATION
45-20182L
This manual is intended to provide the information necessary for installation, set-up, normal maintenance and service of Hayes
Mechanical Disc Brake systems. We highly recommend installation be performed by a qualied mechanic. These instructions can be
downloaded from the Hayes Disc Brake website at www.hayesbicycle.com.
As a serious rider you are well aware of the need to practice safety in all aspects of the sport. This includes service and maintenance
practices as well as riding practices. Before each ride, always check your brakes for proper function and the brake pads for wear. When
you ride, always wear a helmet.
Warning: When you need to install any of the disc brake components, that installation work should be done by a qualied technician
with the proper tools. Improper installation could cause severe or fatal injuries.
Warning: This brake has been designed for use on a single person mountain bike. The use on any other vehicle or device will void the
warranty and can cause serious injury.
Caution: With use, disc brake components may become very hot. Always allow components to cool before attempting to service your bike.
Warning: When following any of the procedures below, be sure to keep your hands and ngers from getting caught in the disc. Failure to do
so could result in injury.
Warning: Do not adjust the caliper while the wheel is spinning.
Warning: Do not adjust the caliper while the caliper is hot.
Warning: If your bike is involved in a fall or crash it is recommended your brakes are checked by a qualied mechanic before riding to
ensure they are functioning properly. The following checks should be performed: Check that all components are securely mounted
to the handlebar,frame, fork, or wheel; check for proper pad installation and retention; check master cylinder body and caliper for
damage. Always have a qualied bike mechanic check your brakes if you suspect damage.
Mounting the Disc to the Hub
1. Clean the disc and hub mounting surface with isopropyl alcohol (not disc brake cleaners).
2. Place the disc on the hub mounting surface. Be sure that the arrow on the disc is pointing in the same direction of the forward
wheel rotation.
3. Using a Torx T25 driver, install, tighten, and torque the disc screws to 50±5 in-lb (5.65±0.55Nm), in a star pattern sequence. (FIG. 1)
Caution: The disc and pads should be periodically inspected for wear and damage. The minimum disc thickness is 1.52mm.
The minimum pad thickness is 0.25mm.
Mounting the Caliper to Frame or Fork
NOTE: IF your brake caliper has the Crosshair Alignment System please refer to the Crosshair Installation instructions on our website.
1. For some installations it will be necessary to mount a bracket to the frame or fork to accept the Hayes Mechanical Brake. Mount
the bracket to the frame or fork using (2) M6 x 1.0 x 18.4mm mount bolts. Torque the bolts to 80±5 in-lb (9±0.5Nm).
2. Mount the caliper to the frame or fork adapter using (2) M6 x 1.0 x 18.4mm long mount bolts and (2) mount washers. Snug the
bolts, but leave them loose enough so that the brake caliper will move on its slots. (FIG. 2 & 3)
3. Re-install the wheel.
4. Set lever reach adjustment per the lever manufacturer’s instructions. Doing this rst prevents this adjustment from aecting
other adjustments.
5. Install the cable through the brake lever and spin the lever adjusting barrel down tight to the closed position.
6. Install the cable through its housing and through the cable anchor screw and washer.
7. Seat the cable housing snugly at the brake lever and the brake caliper.
8. Pull the cable wire tight and tighten the cable anchor screw to 60±5 in-lbs (6.8±0.5Nm). If the brake is the MX Comp, tighten
cable anchor screw to 70±5 in-lbs (7.9±0.5Nm)
9. Insert Feel’r Gauge so that the rotor is sandwiched between the gauge and tighten the inboard pad adjuster tight, holding the
gauge to the rotor. Lightly tighten each mount screw, alternating between each bolt until nal torque is achieved.
Hint: If you do not have the Hayes Feel’r Gauge, you can use two business cards, one on each side of the rotor.
10. Back the inboard adjuster o to release the Feel’r Gauge.
11. Spin the wheel. Check that it spins freely and that the gaps, between the pad and the disc, are equal. 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. (FIG. 4) 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 the disc.
12. Trim the excess cable and crimp a cable end on the end of the trimmed cable. (FIG 5)
13. When the gaps are equal and wheel spins freely (without drag), torque the mounting bolts to 80±5 in-lbs (9.04Nm). For post
mount forks, torque the mounting bolts to fork manufacturer’s specications.
1
3
2
4
5
6
/
SERIES
SAFETY INFORMATION
INSTALLAION
Tools Required
• Torx T25 driver • Torque Wrench
• Cable Cutters • Safety Glasses
• Hex Wrench: 2mm, 5mm • Hayes Feel’r Gauge (optional)
Part Torque (in-lb) Torque (Nm)
Disc Screw 50±5 5.6±0.5
Mount Bolt 80±5 9.0±0.5
Cable Anchor Screw 60±5 6.8±0.5
Cable Anchor Screw (MX COMP) 70±5 7.9±0.5
INSTALLATION AND ASSEMBLY TORQUE VALUES
FIG. 1
FIG. 2
FIG. 3
FIG. 5
FIG. 4
Tel: 888.686.3472
Email: techsupport@hayesbicycle.com
Tel: +49 89 203237450
Email: techsupportEU@hayesbicycle.com
USA
EU
www.hayescomponents.com
To Next Page
Need help?
General
