2. Mounting the brake system on the bicycle 1 Assembly of rotor




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Giant MPH-3
Disc Brake System
Model Year 2002


Owners Manual
June 2001.





Contents:

1. Warnings



Please read this owners manual carefully.
Improper assembly of the wheels or malfunction of the brake system may be extremely hazardous and could cause accidents, even fatal ones. Be sure to learn the proper braking technique and operation of your bicycle.
Consult your professional bicycle dealer and this owners manual for this.




Giant recommends not using this system for any downhill competition.
It is particularly suited for cross country use.

Giant advises to have your wheels laced by an expert mechanic.
Improper tightening of the spoke nipples or thin spokes may result in deformation of the wheel and can cause serious accidents.

Protect vital parts of the bike from spilling brake fluid by holding a rag around the brake fluid reservoir, and use protective gloves and safety goggles when working with brake fluid.
Brake fluid spillage (for instance on the rotor) can cause contamination of the brake pads.

2. Mounting the brake system on the bicycle




2.1 Assembly of rotor








Place the rotor on the hub flange taking care that the arrows on the internal part of the rotor are pointing in the direction of rotation of the wheel.









Mount the rotor with the six M5 bolts onto the hub with a T25 Torx key to a torque of 4 Nm.
Tighten the bolts in a crossed pattern.

Threads of new bolts have been coated with blue material that prevents that bolts come loose. Always use LoctiteTM Primer (#7649) and LoctiteTM blue Removable Threadlock (#242) or similar material on thread of these bolts during
re-assembly.










Then install the wheel into the frame / front fork with the rotor at the left hand side and fix the wheel in the dropouts.






Warning!
It is essential that the disc is clean (free from grease or oil residues) to avoid contaminating the brake pads and to insure perfect braking.
Grease can be removed from the rotors with a citrus based cleaner.



    1. Assembly of brake lever







Place a complete brake lever assembly onto the handlebar.









Set the brake lever to the right position.
Tighten the fixing bolt with a 4 mm. Allen-key.
Recommended tightening torque: 6 Nm.










Blow compressed air into the grip through a small hole at the end and slide the grip over the handlebar.









    1. Assembly of hose





Length and attachment of hoses:

The hoses have to be attached to the frame and fork so that they do not contact the wheel or tire, or interfere with the travel of the suspension or the action of steering. Use the bike’s cable guides and zip ties to attach the hoses. Also be sure that the hose is not so long as to possibly snag on anything while riding.

A hose that is too short may cause steering problems but can also cause strain on the hose which may result in the hose getting disconnected from the caliper of brake lever.

For maximum efficiency of the system, it is very important that the hoses are without kinks and have the correct length.
Changing the length of a hose should be done by an authorised Giant dealer.





After assembling the brake lever, put the caliper (front brake) from the front side to the backside through the opening between left hand fork leg and front wheel and fix the caliper to the dropout
(see: “assembly of caliper”).

Fix the hose of the front brake to the front fork.
Use zip-ties or other parts to fix the hose to the fork brace and the lower fork leg
(left hand side).









Fix the hose of the rear brake to the frame.
Push the hose into the hose guides on the top tube and the left hand seat stay.






    1. Assembly of caliper “Post Mount” (Manitou forks)







  1. Assemble the front brake caliper to the Giant postmount adapter (see picture) and use a 5 mm. Allen-key to tighten the two M6 fixing bolts.
    Notes:
    - the lower bolt for the front caliper is shorter !
    - watch the orientation of the “GIANT” logo !
    - recommended tightening torque: 9 Nm.




  1. Hold the postmount adapter with the front caliper close to the disc brake mount on the front fork / frame, with the rotor placed between the brake pads.
    Screw in the two M6 fixing bolts, but don’t tighten them.
    The postmount adapter should be able to move.



  2. Now squeeze the brake lever, so the rotor is clamped by the caliper.

    Use a 5 mm. Allen-key to tighten the M6 fixing bolts.

    Recommended tightening torque: 9 Nm.




  1. Now you can release the brake lever.







Threads of new bolts have been coated with blue material that prevents that bolts come loose.
Always use LoctiteTM Primer (#7649) and LoctiteTM blue Removable Threadlock (#242) or similar material on thread of these bolts during re-assembly.





Make sure that the brake pads are well centered and balanced.


Pull the brake lever to see if the brake pads are actuated well.

If the procedure has been followed well, the caliper (and brake pads) is set parallel to the rotor and the rotor is exactly in middle of the brake pads.
If necessary, release the bolts that fix the postmount adapter to the front fork.

Repeat the whole procedure mentioned above or just move the postmount adapter a bit.
Don’t forget to tighten the fixing bolts again.



2.5 Assembly of caliper “International Standard”







Hold the caliper close to the disc brake mount on the front fork / frame, with the rotor placed between the brake pads.
Screw in the two M6 fixing bolts, but just a few threads.

Note: the lower bolt for the front caliper is shorter!
Now squeeze the brake lever, so the rotor is clamped by the caliper.

The space between the caliper and the disc mount has to be filled up with washers.

Make an estimation how big the gap is, so, how many washers are needed. Try !
For both the upper and the lower caliper fixing bolts.

Example:

If the gap is approx. 1 mm., you may need 4 washers of 0.25 mm. thickness.













Use washers of 0.25 or 0.5 mm. thickness for each bolt to set the caliper (brake pads) parallel to the rotor and to set the rotor exactly in middle of the brake pads.



Put the washers between the frame/fork mount and the caliper.










Threads of new bolts have been coated with blue material that prevents that bolts come loose.
Always use LoctiteTM Primer (#7649) and LoctiteTM blue Removable Threadlock (#242) or similar material on thread of these bolts during
re-assembly.

Recommended tightening torque: 9 Nm.



Use a 5 mm. Allen-key to tighten the M6 fixing bolts.

Note: the lower bolt for the front caliper is shorter!








Make sure that the brake pads are well centered and balanced.


Pull the brake lever to see if the brake pads are actuated well.
If the procedure has been followed well, the caliper (and brake pads) is set parallel to the rotor and the rotor is exactly in middle of the brake pads.

If necessary, release the bolts that fix the brake caliper to the fork and remove or add washers.
Don’t forget to tighten the fixing bolts again.



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