STATE BICYCLE CO HDM-1 All Road 1 Hydraulic Brake Instruction Manual

STATE BICYCLE CO HDM-1 All Road 1 Hydraulic Brake

Product Information

Specifications

• Model HDM-1
• Model HDM-3/3E
• Model HDC-3/3E
• Model HDM-5/5E
• Model HDC-5/5E
• Model HDR-3

Product Usage Instructions

Tools and Supplies
Highly specialized tools and supplies are required for the installation of your State Bicycle Co. components. We recommend that you have a qualified bicycle mechanic install your State Bicycle Co. components. The following tools and supplies are needed:

• T25 Torx wrench
• 4mm Allen key
• 5mm Allen key
• Cross point screwdriver
• 8mm spanner

Disc Brake Installation
To install the disc brake, follow these steps:

1. Install the 6-Bolt Rotor using the T25 Torx wrench.
2. Install the Brake Lever by tightening the M5 clamp bolts with a 4mm Allen key to a torque of 4~6Nm.
3. Install the Caliper by pulling the brake lever and tightening the caliper bolts with a 5mm Allen key to a torque of 8~12Nm. Make sure to choose the correct bolt length for proper thread engagement.
4. Connect the Inner Routing Hose by inserting the hose through the frame and using a cross-point screwdriver to remove the M2 screw. Hold the hose in the right position to avoid a mineral oil leak.
5. Insert the Hose Boot, Compression Nut, and Compression Fitting into the hose in the correct sequence.
6. Remove the M8 screw with a 5mm Allen key and add a few drops of mineral oil if any drips out during the process.
7. Hold the hose to have push-in force to the lever body and use an 8mm spanner to tighten the compression nut with 79N.m.
8. Insert the hose into the brake lever hole until it touches the the bottom surface, then insert the compression fitting and tighten the compression nut.
9. Assemble the Hose Boot to the compression nut.

Reach Adjustment
To adjust the reach of the brake lever, follow these steps:

1. Turn the reach adjust clockwise to move the lever blade away from the handlebar.

Mineral Oil Bleeding Procedure
To bleed the hydraulic disc brake with mineral oil, follow these steps:

1. Prepare the Syringes by threading a bleed clamp assembly onto a syringe plunger and assembling two Mineral Brake oil syringes.
2. Fill Syringes with mineral oil:
3. Fill one syringe for the brake lever with Mineral Brake Oil until it is about 3/4 full. Hold the syringe upright, cover the tip with a shop towel, and depress the plunger just enough to remove any air bubbles. The syringe should still be close to 3/4 full.
4. Close the clamp on both syringes.
5. Prepare the Caliper:
6. Remove the wheel from the bicycle according to the wheel manufacturer’s instructions. Do not allow mineral brake oil to come into contact with suspension seals, brake pads, or rotors. Clean contaminated rotors and seals with isopropyl alcohol. You must replace the brake pads if they become contaminated.

FAQ

• Q: Can I install the disc brake myself?
  A: We recommend that you have a qualified bicycle mechanic install your State Bicycle Co. components to ensure proper installation and safety.

• Q: What torque should I use when tightening the caliper bolts?
  A: Use a 5mm Allen key to tighten the caliper bolts with a torque of 8~12Nm.

• Q: How do I adjust the reach of the brake lever?
  A: Turn the reach adjust clockwise to move the lever blade away from the handlebar.

• Q: Can I use any type of oil for the mineral oil bleeding procedure?
  A: No, you should use Mineral Brake Oil specifically designed for hydraulic disc brakes.

SAFETY INSTRUCTIONS
You must read and understand the Safety Instructions document included with your product before proceeding with installation. Improperly installed components are extremely dangerous and could result in severe and/or fatal injuries. If you have any questions about the installation of these components, consult a qualified bicycle mechanic.

Tools and Supplies
Highly specialized tools and supplies are required for the installation of your State Bicycle Co. components. We recommend that you have a qualified bicycle mechanic install your State Bicycle Co. components.

Hose Shortening Tool

• Order Number: 10.90.00010.000
• Function: cutting hose/press in needle

Disc Brake Installation

6-Bolt Rotor Installation

Install the rotor with the new, threadlock prepped rotor bolts. Tighten the rotor bolts one turn in an alternating sequence until a torque of 6.2 N·m (55 in-lb) is achieved for each bolt with T25 wrench.

Brake Lever Installation

Use 4mm Allen key to tighten the M5 clamp bolts with 4~6Nm torque

Caliper Installation

Pull the brake lever, and use a 5mm Allen key to tighten the caliper bolts with 8~12Nm. Must choose the correct bolt length for proper thread engagement. Riding a bike with improper bolt engagement can allow the brakes to disengage from the bicycle, which can lead to a crash and serious injury or death to the rider.

Inner Routing Hose Connection

Insert the hose through the frame, use cross point screwdriver to take out the M2 screw, and hold the hose in the right position to avoid a mineral oil leak.

Insert the Hose Boot, Compression Nut, and Compression Fitting into the hose in the correct sequence.

1. Remove the M8 screw with a 5mm Allen key. Add a few drops of mineral oil if some were dripped out during the process.
2. Hold the hose to have the push-in force to the lever body, and use an 8mm spanner to tighten the compression nut with 7-9N.m
3. Insert the hose into the brake lever hole until the hose touches the bottom surface, insert the compression fitting, and tighten the compression nut.
4. Hose boot assembled to the compression nut

Reach Adjustment

Turn the reach adjust clockwise to move the lever blade away from the handlebar.

Mineral Oil Bleeding Procedure

1. Prepare the Syringes
   Thread a bleed clamp assembly onto a syringe plunger. Assemble two Mineral Brake oil syringes.

2. Fill Syringes with mineral oil

3. Fill the syringe for the brake lever with Mineral Brake Oil until it is about 3/4 full. Hold the syringe upright, cover the tip with a shop towel, and depress the plunger just enough to remove any air bubbles. The syringe should still be close to 3/4 full.

4. Close the clamp on both syringes

5. Prepare the Caliper

6. Remove the wheel from the bicycle according to the wheel manufacturer’s instructions. Do not allow mineral brake oil to come into contact with suspension seals, brake pads, or rotors. Clean contaminated rotors and seals with isopropyl alcohol. You must replace the brake pads if they become contaminated.

7. Remove the brake pads from the caliper and hold the bleeding block into the caliper

8. Use a T10 TORX wrench to remove the caliper bleed screw. Thread the empty syringe into the caliper bleed port.

9. Prepare the Lever

10. Use a T10 TORX to remove the bleed screw from the lever. Oil will drip out of the bleed port. Clean any mineral brake oil that drips from the bleed port with isopropyl alcohol and a shop towel.

11. Thread the 3/4 full syringe into the lever bleed port

12. Bleed the System

13. Open the valve or the clamp on the syringe at the lever and caliper.

14. Hold the syringe vertically. Gently push the plunger down, stopping before air enters the hose tube. Oil will fill the syringe at the brake caliper. If the oil in the syringe at the caliper is discolored, continue to push all the oil out of the system. Restart the bleed procedure with new fluid in both Syringes.

15. Hold the syringe at the caliper vertically while slowly pressing down on the syringe plunger at the caliper, and push the oil located at the caliper towards the brake lever. Stop before any air enters the hose tube at the caliper.

16. If needed: repeat steps 5.2 and 5.3 until only a small amount of bubbles appear.

17. Close the valve or the clamp at the caliper and the lever. Unthread the syringe from the caliper. Use a T10 TORX to install the bleed screw

18. Open the valve or clamp on the syringe at the lever. Squeeze and release the lever blade 3-5 times.

19. Close the valve or clamp on the syringe at the brake lever. Remove the syringe at the lever from the lead port. Install the bleed screw. Use a T10 TORX to tighten the bleed screw.

20. Clean any mineral brake oil that drips from the bleed port with isopropyl alcohol and a shop towel. Spray isopropyl alcohol on the brake lever and caliper and clean them with a shop towel.

21. Install brake pad.

Disc Bed-in Procedure

All new disc brake pads and rotors should be put through a wear-in process called ‘bed-in’. The bed-in procedure, which should be performed prior to your first ride, ensures the most consistent and powerful braking feel along with the quietest braking in most riding conditions. The bed-in process heats up the brake pads and rotors, which deposits an even layer of brake pad material (transfer layer) to the braking surface of the rotor. This transfer layer optimizes braking performance.

The bed-in process requires you to perform heavy braking. You must be familiar with the power and operation of disc brakes. Braking heavily when not familiar with the power and operation of disc brakes could cause you to crash, which could lead to serious injury and/or death. If you are unfamiliar with the power and operation of disc brakes, you should have the bed-in process performed by a qualified bicycle mechanic.

To safely achieve optimal results, remain seated on the bike during the entire bed-in procedure. Do not lock up the wheels at any point during the bed-in procedure.

• Accelerate the bike to a moderate speed, then firmly apply the brakes until you are at walking speed. Repeat approximately twenty times.
• Accelerate the bike to a faster speed, then very firmly apply the brakes until you are at walking speed. Repeat approximately ten times.
• Allow the brakes to cool before any additional riding.
• After bed-in the caliper may need to be re-centered. Consult the Caliper Centering and Torque Section.

Power-Off Switch Adjustment

Use a 2mm Allen key to release the M4 lock screw, and rotate the adjust bolt clockwise or counterclockwise with a 7mm spanner until the power off switch can work properly when pressing the lever blade for 10~15mm. Tighten the M4 lock screw with 1.5Nm torque.

Maintenance

• We recommend to bleed your mineral oil brakes every other year to remove accumulated air. Bleed your brakes more often if you ride frequently, on aggressive terrain that requires heavy braking, and/or in sub-freezing temperatures.
• Routinely check the rotor bolts, clamp bolts, and caliper bolts for the correct torque values; never ride with loose bolts. Inspect disc brake pads for wear every month. When the thickness of the backing plate and pad material is 3 mm or less, they are worn and need to be replaced.

Service Parts

Contact Information

State Bicycle Co.

• wwww.statebicycle.com.
• [email protected].

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