2001 MPH 3 Owners Manual
2001 MPH 3 Owners Manual
2001 MPH 3 Owners Manual
1. Warnings 3
3. Adjustment 9
3.1 Pad clearance adjustment 9
3.2 Lever reach adjustment 10
3.3 Angle of the brake fluid reservoir 10
4. Tightening torque 11
5. Maintenance 12
5.1 General 12
5.2 Replacement of brake pads 14
5.3 Bleeding procedure 15
- Pag. 2. -
1. Warnings
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.
- Pag. 3. -
2. Mounting the brake system on the bicycle
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.
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.
- Pag. 4. -
2.2 Assembly of brake lever
- Pag. 5. -
2.3 Assembly of hose
- Pag. 6. -
2.4 Assembly of caliper “Post Mount” (Manitou forks)
2. 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.
Threads of new bolts have been coated with blue material that prevents that bolts come
loose.
TM TM
Always use Loctite Primer (#7649) and Loctite blue Removable Threadlock (#242)
or similar material on thread of these bolts during re-assembly.
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.
- Pag. 7. -
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!
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.
Put the washers between the frame/fork mount and the caliper.
Pull the brake lever to see if the brake pads are actuated well.
Make sure that the brake pads are well centered and
balanced.
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.
- Pag. 8. -
3. Adjustment
Turn the adjust knob of the brake lever’s brake fluid reservoir and
pull the brake lever until you have found the best braking position
for your hand
(to set the pressure point of the braking system to personal
preference).
Due to normal pad wear during riding, the clearance between the
pads and rotor will increase.
So, it’s important to check the adjustment before and during each
ride.
If you’re not able to adjust the brake system to the desired braking point (position of your hand or brake
lever blade when the brake pads engage the rotor), please check if the pads are worn out.
If so, replace place them.
If no, please consult your authorised Giant dealer.
- Pag. 9. -
3.2 Lever reach adjustment
Note:
Make sure that it’s possible to turn the
adjust knob. If the adjuster touches the
lever bracket (clamp), turning may be
impossible !
- Pag. 10. -
4. Tightening torque
Bleeder:
Lock screw brake fluid reservoir:
8 Nm.
5 Nm.
Lever - handlebar :
6 Nm.
Brake pads:
4 Nm.
5.1 General
Proper maintenance of a bike equipped with MPH DISC BRAKES is important to insure years of trouble
free safe riding.
Check by dealer.
Take your bicycle to an authorised Giant dealer for periodic service and inspection of MPH
braking systems. Parts such as brake pads, hoses and seals, can be adversely affected by use,
dirt and ultraviolet radiation. The MPH brake system has to be checked by a dealer once a year
or more often if the bike is used in extreme conditions.
High-pressure.
DO NOT use high-pressure water or air hoses to clean bike. This can force dirt into parts of the
hydraulic braking system, which may cause damage.
Adjust knob.
By turning the big adjust knob on the fluid reservoir of the brake lever, it is possible to set the
pressure point of the braking system to personal preference.
Also, in the same way, brake pad wear can be compensated and brake pad to rotor clearance
can be adjusted.
If the knob is turned clockwise but the space between the brake pads and the rotor remains too
much (the brake lever has to be pulled too far), the brake pads have to be checked for wear.
- Pag. 12. -
Check tightening torque.
Tightening torque of fasteners and bleeders has to be checked frequently. Loose bolts may
cause that parts come off, a loose bleeder may cause the braking system to leak.
This can lead to severe injury or death.
TM
Loctite .
TM TM
Always use Loctite Primer (#7649) and Loctite blue Removable Threadlock (#242) or
similar material on thread of fixing bolts of calipers and rotors during re-assembly.
- Pag. 13. -
5.2 Replacement of brake pads
When to change ?
Before each ride, check the wear pattern of the pads (both front and rear).
The back plate of the brake pad should not touch the rotor.
Replace the pads if there is not enough material left,
or if high frequency noise occurs during braking.
Note:
Do NOT use MPH brake pads “model year 2000” (2 holes in each pad).
These pads do not fit into the MPH-2 (model year 2001) and MPH-3 (model year 2002) calipers.
- Pag. 14. -
5.3 Bleeding procedure
When to bleed ?
Whenever the system lost brake fluid or air came into it.
For example:
- After replacement or disassembly of :
brake lever or
caliper or
hose or
bleeder
- After shortening a hose
- Lack of brake fluid in MPH brake system due to leakage
- Replace brake fluid for MPH at least every two years
- When the braking systems feels spongy, perhaps there is air inside the hydraulic system.
Advice:
It’s better to remove wheels and brake pads before working with brake fluid.
Leakage of brake fluid on brake pads or rotor will ruin these parts.
1. Turn the adjustment knob of the fluid reservoir on the brake lever
anti-clockwise all the way to create max. volume inside the
reservoir.
At least 10 full turns.
- Pag. 15. -
4. Fill the syringe with DOT 4 or DOT 5.1 brake fluid from a new
bottle:
Put the syringe in the bottle with the nozzle under the fluid level
and pull the piston of the syringe.
The MPH brake sets have been filled by Giant with DOT 4 brake
fluid.
5. Push the syringe on the open end of the short transparent tube.
In case most of the brake fluid is still in the MPH disc brake system (for example after shortening a hose
or switching front- and rear brake from one side from the handlebar to the other) skip step 6 to 10 and
continue with step 11.
Otherwise, if there is no or almost no brake fluid inside the MPH disc brake system (for example when
replacing all the brake fluid once per year or 2 years, or after complete disassembly of the caliper and/or
the master cylinder), continue with step 6.
6. Take the bleeder cover (rubber cap) off from the calipers’ bleeder
and mount the second (long) transparent tube. Put the other end of
this tube into a bottle or cup that can contain brake fluid.
- Pag. 16. -
9. While squeezing the syringe, pull the brake lever fast and release
the lever slowly.
New brake fluid will come into the hydraulic circuit eliminating most
of the air that maybe in there.
Continue until the fluid flow from the calipers’ bleeder through the
long transparent tube is not any longer interrupted by air bubbles.
Step 6 - 10 will take approx. 5 minutes, but in most cases it's not necessary, because there is still brake
fluid in the hoses, levers and/or calipers.
So, in those cases, you can skip these steps and continue from this point.
And now the fine-tuning can start: the MPH system has to be made 100% air-free.
This will take approx. 10 - 15 minutes.
Make sure that the adjustment knob of the brake fluid reservoir
(brake lever) is turned anti-clockwise completely.
The filling hole of the brake fluid reservoir should remain the
highest point and the brake caliper the lowest point of the MPH
system until the end of this procedure.
So, air can go up in the MPH system and escape via the short
transparent tube into the syringe. Brake fluid will go down into the
MPH system.
- Pag. 17. -
12. By pulling the brake lever fast and releasing it slowly (the brake
lever will pump the air up and the brake fluid down) and by
tapping on the MPH brake hose, the air bubbles will go up.
Via the short transparent tube and via the brake fluid in the
syringe, the air bubbles will go out of the MPH brake system. This
can be checked visually very easily.
Don't squeeze the syringe!
air
13. While pulling the brake lever and releasing it frequently, turn the
adjustment knob of the brake fluid reservoir clockwise (in) and
anti-clockwise (out) a few times, to push the last bits of air out of
the reservoir.
Turn the knob all the way in and out, approx. 10 full turns.
15. Turn the adjustment knob of the master cylinder anti-clockwise all
the way, to have the largest brake fluid volume inside the
reservoir.
At least 10 full turns.
16. Disconnect the syringe from the small transparent tube and
unscrew the connector from the brake fluid reservoir.
17. Turn the adjust knob of the fluid reservoir clockwise carefully, until
you see the oil appear in the small hole for the lock screw.
- Pag. 18. -
18. Reinstall lock screw, cap and O-ring.
If the small lock screw is screwed in, there should be no air left in
the reservoir.
A little bit brake fluid will be spilled.
Use absorbing paper or a rag to remove this.
19. Tighten the lock screw well into the master cylinder.
Recommended tightening torque lock screw: 5 Nm.
20. Pull the brake lever and check the function of the MPH brake
system: both sides actuated, disc in center, correct distance
brake pads to rotor ?
21. Turn the adjuster, pull the brake lever and check the function of
the MPH brake system again.
Repeat step 20 and 21 until the function is okay.
Warnings !
F To avoid brake fluid spillage on the rotors or brake pads, causing contamination of the brake pads,
it is advisable to cover the vital parts with a rag before proceeding and to take out the wheels.
F If the bleeder is not sufficiently tightened when using the disc brake, brake fluid may leak on the
rotor, causing loss of friction between brake pads and rotor. This can have serious consequences
for the rider.
F Protect vital parts of the bike from spilling brake fluid by holding a rag around the fluid reservoir.
Brake fluid is hazardous and aggressive and damages not only your skin, but the paintjob and
plastic parts of the bike as well.
Use protective gloves and safety goggles when working with brake fluid.
F Once there is brake fluid or lubricants like oil, grease, Teflon™ and silicone spray on the brake
pads, they are worthless: no more brake function.
So, don't forget to protect brake pads and rotors when working with brake fluid or lubricants.
Or, even better, remove these parts.
F Use DOT 4 or DOT 5.1 brake fluid only. DOT 4 and DOT 5.1 brake fluid should not be mixed !
The MPH brake sets have been filled by Giant with DOT 4 brake fluid.
- Pag. 19. -
6. Trouble shooting and -prevention
When this happens, the rider MUST stop riding to let the
brake system cool down. No liquid shall be used to cool the
brake components. That will lead to distortion of the rotors
and change the characteristics of the materials.
Meanwhile, the rotors and the calipers should NOT BE
TOUCHED, because they can be very hot.
Short
If the rider keeps using the brakes, the brake fluid will be
heated to 150º C. or more. Then the brake pads will wear out
very quickly.
If the pads are worn, the brake force is decreased, even if the
brake lever is pulled completely to the handlebars (see
illustration on the left). This is extremely dangerous.
When to change? Before each ride, check the wear pattern of the pads (both front and rear).
The back plate of the brake pad should not touch the rotor.
Replace the pads if there is not enough material left,
or if high frequency noise occurs during braking.
How to change? See: “Maintenance; replacement of brake pads”.
Remarks: Only use MPH genuine parts.
Do NOT use MPH brake pads “model year 2000” (2 holes in each pad).
Two pads must be replaced at the same time.
- Pag. 20. -
Parts: Rotors
When to change? If, after assembly to the hub, the rotor is not straight (more than 0.3 mm. out
of line).
If there are serious damages on rotor surface that lead to longer braking
distance.
How to change? See the instruction “Mounting the brake system on the bicycle”.
Remarks: Only use MPH genuine parts.
Replace the six rotor fixing screws as well.
See “Mounting the brake system on the bicycle; assembly of rotor”:
six fixing screws should be tightened in a crossed pattern.
TM
Loctite (or a similar product) has to be used.
- Pag. 21. -
Parts: Calipers
When to change? Brake fluid holes choked up, two pistons do not work properly at the same
time.
Brake fluid leakage due to seal failure.
Malfunction of calipers.
How to change? This should be done by your authorised Giant dealer.
Remarks: Only use MPH genuine parts.
Use washers (0.25 mm. thickness) to adjust brake pads parallel to rotors
and to set the rotors exactly in middle of the brake pads.
TM
Loctite (or a similar product) has to be used.
Note that there is difference between front and rear calipers.
Watch the orientation of “MPH” characters:
Front Rear
- Pag. 22. -
Parts: Brake lever
When to change? Brake fluid holes choked up: the adjuster does not work.
Brake fluid holes choked up: the piston does not work properly.
Brake fluid leakage due to seal failure.
The clamp doesn’t fix the master cylinder effectively.
Mal-function of brake lever.
How to change? This should be done by your authorised Giant dealer.
Remarks: Only use MPH genuine parts.
Note that there is difference between right and left brake lever.
Small parts are the same, but the way these small parts are assembled is
different.
Left Right
- Pag. 23. -
Parts: Hose
Parts: Bleeder
- Pag. 24. -