User manual DAHON ALFINE DISC BRAKE SYSTEM TECHNICAL SERVICE INSTRUCTIONS

[. . . ] Vapor lock is a phenomenon in which the oil inside the brake system becomes heated, which causes any water or air bubbles inside the brake system to expand. If other types of oil are used, it may cause problems with brake operation, and cause the system to be unuseable. · Be sure to use only oil from a freshly-opened container, and do not re-use oil which has been drained from the bleed nipple. Old oil or already-used oil may contain water which could cause vapor lock in the brake system. [. . . ] · 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. · 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. 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. 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. lbs. } Reservoir tank Hose Calipers Maintenance I Brake pad replacement Note: The S500 brake system is designed so that as the brake pads become worn, the pistons gradually move outward to automatically adjust the clearance between the rotor and the brake pads. Therefore, you need to push the pistons back to their original positions when replacing the brake pads. If oil adheres to the brake pads after oil is added, or if the brake pads are worn down to a thickness of 0. 5 mm, replace the brake pads. Installation The following tools are needed to assemble this product. Usage location Rotor installation ring Brake lever fixing bolt Caliper fixing bolt / Adapter fixing bolts Brake pad fixing shaft Brake hose fixing bolt Reservoir tank cover Cable supporter Bleed nipple TL-LR15 Allen key 5 mm Allen key 5 mm Radio pliers 8 mm wrench Phillips screwdriver #1 Phillips screwdriver #2 Socket wrench 7 mm Bag Socket wrench (7mm) Tube Brake pads 7. [. . . ] The normal condition is for the lever to be stiff at this point. Rotor I Mineral oil replacement < Rear > Adapter fixing bolts Caliper fixing bolts Caliper fixing bolts It is recommended that you replace the oil inside the reservoir tank if it becomes severely discolored. Attach a tube with a bag to the bleed nipple, and then open the bleed nipple and drain out the oil. You can operate the brake lever at this time to help the oil to drain out. After draining the fluid, pour in fresh brake fluid while referring to "Adding the mineral oil and bleeding air". [. . . ]