TRP Tektro Rotors Instruction Manual

TRP Tektro Rotors

Product Information

Specifications:

• Brand: TRP/Tektro
• Product: Rotors
• Warranty: 2 years from original retail purchase
• Manufacturer: TRP Cycling Components
• Contact Information:
  • Toll-Free: 1-877-807-4162
  • Direct: 1-650-965-4442
  • Email: info@trpcycling.com
  • Website: www.trpcycling.com

Product Usage Instructions

Safety Warnings & Information:

• Disc brakes offer increased performance over cable systems.
• Allow time to learn and adapt to braking characteristics.
• Avoid touching hot rotors or calipers during and after use.
• Leaking oil indicates potential brake failure; stop immediately.
• Check brake function after a fall or crash.
• Maintain pad thickness of at least 0.8mm, keep pads clean.
• Designed for use on a single-rider bicycle only.
• Consult a qualified mechanic if unsure about assembly or maintenance.
• Use only TRP/Tektro branded replacement mineral oil for servicing.
• Maintain cleanliness of pads, rotors, and system for optimal performance.

Required Tools:

• Six-Bolt Rotor
• CenterLock Rotor
• Lock Rings (Internal and External notches)

Product Warranty:
TRP hydraulic disc brakes are covered against manufacturing defects for two years from the original retail purchase date. The warranty does not cover damage from improper installation, lack of maintenance, crashes, or excessive use.

Frequently Asked Questions (FAQ):

• Q: Can I use other disc brake fluids instead of TRP/TEKTRO branded mineral oil?
  A: No, using other disc brake fluids, especially DOT-based oils, will harm the braking system and compromise performance. Stick to TRP/TEKTRO branded mineral oil for servicing.

• Q: What should I do if I notice my braking performance is greatly impaired?
  A: Check for contamination on pads or rotors. If contaminated with oil or impurities, clean them thoroughly to restore optimal braking performance.

SAFETY WARNINGS & INFORMATION

• WARNING – Disc brakes offer a significant increase in performance over traditional cable actuated systems. Follow the break-in recommendations listed in this manual, allow yourself time to learn and become accustomed to the braking characteristics.
• WARNING – Disc brakes, calipers, and rotors get VERY HOT during regular use. DO NOT touch or attempt to service the rotor or caliper until you’ve allowed for sufficient cooling to occur.
• WARNING – Leaking oil indicates a potential BRAKE FAILURE. If you’re system is leaking oil stop immediately and determine the nature of the problem. DO NOT continue to ride a leaking system.
• WARNING – If your bike is involved in a fall or crash, fully check the brake function including: the lever, caliper and rotor are securely attached to the bike, pads are correctly installed and functioning, the cable, (if applicable) is operating smoothly and the lever feels firm when applying the brake. Always have a qualified mechanic check the brakes if you have any doubts.
• WARNING – Pad thickness must be at least 0.8mm of pad material. Confirm this before each ride. Keep pads clean and free of oil or hydraulic fluid. If pads become contaminated, discard and replace.
• WARNING – TRP/Tektro braking systems are designed for use on a single rider bicycle. Use of these system on any other vehicle or apparatus will void the warranty, possibly causing you great personal harm or injury.
• CAUTION – Read this manual completely before attempting to install or work on your TRP/Tektro brakes. If you are unfamiliar with any element of assembly or maintenance of TRP/Tektro braking systems please consult a qualified mechanic for assistance.
• CAUTION – Only use TRP/TEKTRO branded replacement mineral oil when servicing the brakes. Other disc brake fluids, ESPECIALLY DOT based oils, will harm the system and compromise braking performance.
• CAUTION – Cleanliness is a very important part of any maintenance of a TRP/Tektro brake system. If the pads or rotor become contaminated with oil, or if the system becomes contaminated with impurities, braking performance will be greatly impaired.
• CAUTION – As with any oil, precautions in handling and clean up of any spills should be handled according to accepted best practices as governed by your state or country. Our Mineral oil is non-toxic, but clean up any spills promptly and completely.

If Mineral Oil gets in your eyes IMMEDIATELY FLUSH WITH WATER for several minutes and go to the hospital. If Mineral oil gets on your skin RINSE IMMEDIATELY with soap and water. Do not inhale Mineral Oil, it is harmful. If inhaled move to a well ventilated environment and proceed to the hospital for appropriate care. If you ingest Mineral oil it may cause vomiting and/or diarrhea.

TRP hydraulic disc brakes are warranteed against manufacturing defects in materials and / or workmanship for a period of two years from the date of original retail purchase. Not covered under this warranty is damage resulting from improper installation, adjustment or maintenance, lack of maintenance, alterations, crashes or use judged by TRP to be excessive or abusive. For warranty related questions or more information please contact a TRP Service Center or email at info@trpcycling.com

REQUIRED TOOLS

• For Six-Bolt Rotor:
  • T25 Torx Wrench
  • Torque Wrench
• For CenterLock Rotor:
  • CenterLock Ring Installation Tool (16 External Notch or 12 Internal Notch)
  • Lock Ring (12 mm or 15/20 mm Axle)
  • Isopropyl Alcohol
  • Clean Towel or Rag

ROTORS AND LOCK RINGS

ROTORS
Rotors come in a variety of mounting styles that are specifically related the the hub. Rotors can be mounted with six T25 Torx bolts or a single lock ring. Six-bolt rotors come in one-piece or two-piece construction. Centerlock rotors come in two-piece construction. Each rotor can have a different initial thickness; 1.8 mm thick or 2.3 mm thick. 2.3 mm thick rotors are typically used in e-bike and downhill specific applications whereas 1.8 mm thick rotors are used in lighter weight applications such as cross-country and trail riding. Rotors come in several different diameters; Ø140 mm, Ø160 mm, Ø180 mm, Ø203 mm, Ø220 mm, and Ø223 mm. It is up to the rider to determine which rotors will suite their riding style.

LOCK RINGS
Centerlock rotors use either a lock ring with internal notches or external notches. Lock rings with internal notches are used for hubs with a 12 mm axle. Lock rings with external notches are used for hubs with 15 mm and 20 mm axles.

ROTOR MINIMUM THICKNESS

INSTALLATION & ADJUSTMENT

MOUNTING SIX-BOLT ROTORS
Before installing the new rotor, clean the mounting surface of the hub thoroughly with isopropyl alcohol and a clean towel or rag. Install the rotor onto the hub using the 6 T25 bolts and a T25 Torx wrench. Tighten the rotor bolts to 4 – 6 Nm in an alternating pattern. (Fig 1) Clean the braking surfaces of the rotor using isopropyl alcohol and a clean towel or rag.
NOTE: Rotor must be installed with the “rotation” arrow pointing in the same direction as the forward rotation of the wheel.

MOUNTING CENTERLOCK ROTORS
Before installing the new rotor, clean the mounting surface of the hub thoroughly with isopropyl alcohol and a clean towel or rag. Determine the size of lock ring you will need. (12 mm axles use the smaller lock ring with 12 internal notches. 15 and 20 mm axles use the larger lock ring with 16 external notches.) Install the rotor on the hub and hand tighten the lock ring. For 12 mm axles use a cassette installation tool. (Fig 2) For 15 mm and 20 mm axles use a bottom bracket installation tool. (Fig 3) Tighten the lock ring to 40 Nm. Clean the braking surfaces of the rotor using isopropyl alcohol and a clean towel or rag.
NOTE: Rotor must be installed with the “rotation” arrow pointing in the same direction as the forward rotation of the wheel.

PAD AND ROTOR BED-IN PROCEDURE

• Bedding in your new pads and rotors is critical to the performance of the brakes. Properly bedding-in your pads and rotors will ensure the highest performance and best operating conditions.
• Accelerate your bike to a moderate speed and apply the brakes. Slow the bike to a walking speed and then release the brakes. Repeat this process 15 – 20 times to transfer the pad material to the braking surface of the rotor. You will feel the brakes becoming more powerful throughout this process.
• Accelerate your bike to a higher speed and apply more pressure to the brake lever until at a walking speed. Release the lever and repeat this process 10 – 15 times. Allow the brakes to cool before continuing to ride.
  NOTE: Do not come to a complete stop at any time during this process. Doing so can lead to uneven pad material deposition and can affect the performance of the brakes while riding.

TROUBLESHOOTING GUIDE

Braking power loss| Glazed pads| Remove the pads and remove the top layer with sand paper. Scuff the braking surface of the rotor with sand paper or steel wool. Clean with isopropyl alcohol and a clean rag or towel.
---|---|---
Contaminated Pads and/or Rotor| Replace the pads AND the rotor. If you replace only the pads or only the rotors, there is a risk of continued contamination.
Noise at certain points in rotation| Bent rotor| Identify where the rotor is bent and use rotor truing tool to bend it the opposite direction. Repeat until rotor is no longer bent. Replace the rotor if you or a bike shop is unable to correct the issue.
Constant squeal when brakes are applied| Worn pads| Replace pads
Uneven braking surface in rotor| Replace rotor
Contaminated Pads and/or Rotor| Replace the pads AND the rotor. If you replace only the pads or only the rotors, there is a risk of continued contamination.

GENERAL MAINTENANCE

• PAD REPLACEMENT
  Pads should be replaced if they become contaminated or have less than 2.5mm thickness. (Pad friction material & metal backing plate). (Fig 4)

• BEFORE RIDING

  • Check the pads for wear or contamination.
  • Check the hose for cracking, wear or deformation. Replace if necessary.
  • Check that the brake system is operating correctly.

• AFTER RIDING

  • Remove any mud or contamination from the rotor slot on the caliper.
  • Clean the caliper body with a cloth.

• AT REGULAR INTERVALS

  • Check the oil level in the reservoir.
  • Lubricate the brake lever pivot with grease.
  • Check to make sure that all the bolts are tightened to the correct torque specifications.

BRAKE LEVERS

SAFETY WARNINGS & INFORMATION

• WARNING – Disc brakes offer a significant increase in performance over traditional cable actuated systems. Follow the break-in recommendations listed in this manual, allow yourself time to learn and become accustomed to the braking characteristics.
• WARNING – Disc brakes, calipers, and rotors get VERY HOT during regular use. DO NOT touch or attempt to service the rotor or caliper until you’ve allowed for sufficient cooling to occur.
• WARNING – Leaking oil indicates a potential BRAKE FAILURE. If you’re system is leaking oil stop immediately and determine the nature of the problem. DO NOT continue to ride a leaking system.
• WARNING – If your bike is involved in a fall or crash, fully check the brake function including: the lever, caliper and rotor are securely attached to the bike, pads are correctly installed and functioning, the cable, (if applicable) is operating smoothly and the lever feels firm when applying the brake. Always have a qualified mechanic check the brakes if you have any doubts.
• WARNING – Pad thickness must be at least 0.8mm of pad material. Confirm this before each ride. Keep pads clean and free of oil or hydraulic fluid. If pads become contaminated, discard and replace.
• WARNING – TRP/Tektro braking systems are designed for use on a single rider bicycle. Use of these system on any other vehicle or apparatus will void the warranty, possibly causing you great personal harm or injury.
• CAUTION – Read this manual completely before attempting to install or work on your TRP/Tektro brakes. If you are unfamiliar with any element of assembly or maintenance of TRP/Tektro braking systems please consult a qualified mechanic for assistance.
• CAUTION – Only use TRP/TEKTRO branded replacement mineral oil when servicing the brakes. Other disc brake fluids, ESPECIALLY DOT based oils, will harm the system and compromise braking performance.
• CAUTION – Cleanliness is a very important part of any maintenance of a TRP/Tektro brake system. If the pads or rotor become contaminated with oil, or if the system becomes contaminated with impurities, braking performance will be greatly impaired.
• CAUTION – As with any oil, precautions in handling and clean up of any spills should be handled according to accepted best practices as governed by your state or country. Our Mineral oil is non-toxic, but clean up any spills promptly and completely.

If Mineral Oil gets in your eyes IMMEDIATELY FLUSH WITH WATER for several minutes and go to the hospital. If Mineral oil gets on your skin RINSE IMMEDIATELY with soap and water. Do not inhale Mineral Oil, it is harmful. If inhaled move to a well ventilated environment and proceed to the hospital for appropriate care. If you ingest Mineral oil it may cause vomiting and/or diarrhea.

TRP hydraulic disc brakes are warranteed against manufacturing defects in materials and / or workmanship for a period of two years from the date of original retail purchase. Not covered under this warranty is damage resulting from improper installation, adjustment or maintenance, lack of maintenance, alterations, crashes or use judged by TRP to be excessive or abusive. For warranty related questions or more information please contact a TRP Service Center or email at info@trpcycling.com

REQUIRED TOOLS

• 2 mm Hex Wrench
• 4 mm Hex Wrench
• 5 mm Hex Wrench
• 6 mm Hex Wrench
• 8 mm Wrench
• Torque Wrench
• Isopropyl Alcohol
• Clean Towel or Rags

POST MOUNT ADAPTERS

INSTALLATION & ADJUSTMENT

• MOUNTING THE BRAKE LEVERS
  Use a 4 mm hex wrench to remove the brake lever clamp bolt and open the clamp. Install the brake lever onto the bar and reinstall the clamp bolt. With the brake lever in the preferred position, tighten the clamp bolt using the 4 mm hex wrench. (Fig 1)
  Recommended brake lever clamp tightening torque: 3 – 5 Nm* (Refer to handlebar manufacturer’s specifications)

• MOUNTING THE BRAKE CALIPERS
  Insert the brake hose into the frame/fork and route it according to your frame/fork manufacturer’s specification. Mount the caliper to the frame/fork using the appropriate bolts and necessary adapter. Tighten the caliper mountin bolts using a 5 mm hex wrench and then back off a quarter turn. After the brake hose is connected to the lever, press the lever blade to help in centering the caliper. With the caliper centered with the rotor, tighten the mounting bolts with the 5 mm hex wrench. (Fig 2)
  Recommended caliper tightening torque: 6 – 8 Nm* (Refer to fork or frame manufacturer’s specifications)

• INSTALLING THE BRAKE HOSE
  TRP hydraulic brake systems come from the factory with a barb pre-installed in the hose. There is also a 2mm allen screw installed into the barb. DO NOT remove the screw until after the hydraulic hose is routed to prevent fluid loss. Measure your hose length and determine how much brake hose to remove. Remove the plastic plug from the lever using a 6mm allen wrench. DO NOT press the brake lever – doing so will cause excessive brake fluid loss and require a full bleed of the system. Remove the EZ plug from the barb in the brake line using a 2mm allen wrench. Install the olive, compression nut, and cover onto the hose and press the hose into the lever, ensuring the barb has seated fully. Use an 8mm wrench to tighten the compression nut into the brake lever. Install the cover onto the compression nut to complete installation.
  Compression nut tightening torque: 5 – 7 Nm

• PAD AND ROTOR BED-IN PROCEDURE
  Bedding in your new pads and rotors is critical to the performance of the brakes. Properly bedding-in your pads and rotors will ensure the highest performance and best operating conditions.
  Accelerate your bike to a moderate speed and apply the brakes. Slow the bike to a walking speed and then release the brakes. Repeat this process 15 – 20 times to transfer the pad material to the braking surface of the rotor. You will feel the brakes becoming more powerful throughout this process. Then accelerate your bike to a higher speed and apply more pressure to the brake lever until at a walking speed. Release the lever and repeat this process 10 – 15 times. Allow the brakes to cool before continuing to ride.

  • NOTE: Do not come to a complete stop at any time during this process. Doing so can lead to uneven pad material deposition and can affect the performance of the brakes while riding.
  • NOTE: This braking system is designed for use with 2.3 mm thick rotors. For optimal results, use TRP 2.3 mm thick rotors. 1.8 mm thick rotor are not recommended to be used with this system.

GENERAL MAINTENANCE

• PAD REPLACEMENT
  • Pads should be replaced if they become contaminated or have less than 2.5mm thickness. (Pad friction material & metal backing plate). (Fig 8)
• BEFORE RIDING
  • Check the pads for wear or contamination.
  • Check the hose for cracking, wear or deformation. Replace if necessary.
  • Check that the brake system is operating correctly.
• AFTER RIDING
  • Remove any mud or contamination from the rotor slot on the caliper.
  • Clean the caliper body with a cloth.
• AT REGULAR INTERVALS
  • Check the oil level in the reservoir.
  • Lubricate the brake lever pivot with grease.
  • Check to make sure that all the bolts are tightened to the correct torque specifications.

HYDRAULIC OIL FOR BRAKES

• Hazard statements:
  • H304 May be fatal if swallowed and enters airways.
  • H412 Harmful to aquatic life with long-lasting effects.
• Precautionary statements:
  • P101 If medical advice is needed, have product container or label at hand.
  • P102 Keep out of reach of children.
  • P301+P310 IF SWALLOWED: Immediately call a POISON CENTER/doctor.
  • P331 Do NOT induce vomiting.
  • P405 Store locked up.
  • P501 Dispose of contents/container to local/regional/national international regulations.
• Description of first aid measures:
  • General information In case of accident or unwellness, seek medical advice immediately (show directions for use or safety data sheet if possible).
  • After inhalation In case of accident by inhalation: remove casualty to fresh air and keep at rest. In case of respiratory tract irritation, consult a physician.
  • After contact with skin Gently wash with plenty of soap and water. In case of skin irritation, seek medical treatment.
  • After contact with eyes Rinse cautiously with water for several minutes. In case of troubles or persistent symptoms, consult an ophthalmologist.
  • After ingestion Rinse mouth thoroughly with water. Let water be drunk in little sips ( dilution effect). Do NOT induce vomiting. In all cases of doubt, or when symptoms persist, seek medical advice.

ASIA:
TEKTRO Technology Corporation 138, Minjhu Street Sioushuei Changhua 504 Taiwan
Tel: +886-7683999
www.tektro.com

US:
TEKTRO USA
688 W Amidan Dr, BLDG 4X-1 Ogden, UT 84404 USA
Tel: 801-648-7079
www.tektro-usa.com

Europe:
TEKTRO Europe GmbH
August-Bebel-StraBe 10
67454 HaBloch Germany
Hotline: +49-6324-96797-20
service@tektro.eu

TRP Cycling Components
688 W. Amidan Dr. 4X-1
Ogden, UT 84404
Toll Free: 1-877-807-4162
Direct: 1-650-965-4442
Email: info@trpcycling.com
Web: www.trpcycling.com

References

• TRP Cycling

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