TOOLS AND EQUIPMENT REQUIRED
2mm, 3mm, 5mm hex wrench , T25 Torx® wrench, 8mm open end wrench, Birzman Pad Gap Tool (optional)
MOUNTING THE ROTOR TO THE HUB
Attach the rotor to the hub with the supplied Torx® bolts and tighten in an alternating pattern with a T25 Torx®
wrench. Final tightening torque: 3-4 Nm (26-35 in-lb). [ref. A-1]
NOTE - The rotor must be installed with the “rotation” arrows pointing in the same direction as the forward
rotation of the wheel.
INSTALLING FLATMOUNT ADAPTORS
Select the correct adapter (front or rear) for the size of rotor.
Front caliper:
Attach the FF-5 adapter to the caliper in correct orientation for 140mm or 160mm rotor.
Tighten the two M5x13 bolts to a torque of 5-7 Nm (44-62 in-lb).
Attach the adapter to fork using the two M5x14 bolts. Align the caliper to the rotor, (using a gap or
alignment tool,) and tighten to a torque of 5-7 Nm (44-62 in-lb).
Rear caliper:
With 140mm rotor: Insert mounting bolt into the frame and make sure it is protruding 7mm through the frame.
Attach the caliper to bolt .
With 160mm rotor: Attach F-6 adapter to brake caliper and tighten bolt to a torque of 5-7Nm (44-62 in-lb).
Then attach adapter to the frame with mounting bolt .
Make sure the pads are correctly positioned in the caliper. Do not tighten the bolts at this stage.
With the caliper mounting bolts still loose, squeeze the brake lever. The caliper will correctly center itself to the
rotor. You may also use a disc brake gap or alignment tool. Maintaining pressure on the brake lever, tighten
the caliper mounting bolts. Final tightening torque: 6-8Nm (53-71 in-lb).
MOUNTING THE BRAKE LEVERS
Route the hydraulic hose through the handle bar and attach the brake lever to the bar. (Depending on your
style of base bar, some hose length modification may be needed.)
After installed onto the bar, lightly tighten both clamp screws on the bottom of the lever using a 3mm allen
wrench. (Do not tighten bolt until brake lever is on the bar as this may affect clamp performance.)
Test out the rider position on the bike – your base bar length may need to be adjusted. Cut the handle bars in
small increments (up to 10mm at a time) until position is comfortable. [ref. B-1]
Remove the coupler plug using a 6mm allen wrench. Try not to move the hose too much to prevent fluid loss.
Remove the EZ plug from the barb in the caliper line using a 2mm allen wrench. Install the hose into the
coupler, ensuring the barb has seated fully.
Using an 8mm wrench on the coupler and another 8mm wrench on the compression nut, tighten the
compression nut to connect the lines. Tighten the compression nut to 5-7 Nm (44-62 in-lbs).
Tighten clamp bolts to 3-4 Nm (26-35 in-lbs) to finish installation [ref. B-2]
MOUNTING THE BRAKE CALIPERS
The brakes will 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.
Mount the caliper to the frame/fork using the appropriate bolts and necessary flat mount adapter. [see
Flat-mount Adapters Orientation.] Insert the brake hose into the frame/fork and route it according to your
frame/fork manufacturer’s specification.
Install the compression nut onto the hose with the threaded portion pointing away from the caliper.
Install the olive with the tapered portion pointing toward the compression nut.
MODIFYING HOSE LENGTH
Disconnect the hose coupler from the caliper line. Pull the hose back away from the coupler. Some fluid may
drip out. Measure your hose length and determine how much hose to cut off. Make sure you leave enough
hose for full rotation of your handlebars.
Cut the hose to the determined length using a hydraulic hose cutter.
Using a new compression nut, olive, and barb, slide the compression nut onto the hose with the threaded
portion pointing towards the coupler. Install the olive with the tapered portion facing the compression nut.
Install the barb ensuring that it is fully seated within the cut end of the hydraulic hose. [ref. C-1]
Reinsert the hose into the coupler and tighten the compression nut to 5-7 Nm (44-62 in-lbs).
The process can be repeated at the lever side of the coupler following the steps outlined above.
If cutting the hose near the brake lever, be sure to leave a minimum of 25mm of hose to reconnect the
coupler.
PAD AND ROTOR BREAK-IN PROCESS
Ride slowly and apply the brakes 10-20 times to seat the pads flat with the rotors. If there is rubbing on the rotor,
recenter the caliper on the rotor as outlined above.
INSTALLATION & ADJUSTMENT
A-1. Rotor torquing sequence
5
2
6
3
1
4
D-1. Replace new pad
2.5 mm
Pad wear Indicator
PAD REPLACEMENT
Pads should be replaced if they become contaminated or have less than 2.5mm thickness (Pad friction material &
metal backing plate). (See D-1)
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.
GENERAL MAINTENANCE
Instructions on bleeding the brakes can
be found on www.trpcycling.com or
on www.youtube.com/user/TRPBrakes
Barb
Olive
Compression
Nut
10m
B-1 Cut the bars sections at a time and recheck rider
fit with new brake lever position.
C-1 Install cap, nut and olive before installing the
barb. Note that the olive has a flat end and a tapered
end. The flat end is oriented up, toward the brake
lever; the tapered end goes into the compression nut
B-2 Tighten the clamp screws to 3-4 NM.
