Hope Technology Disc brake Installation and Service Manual XC4 Closed 2 Open 2 DH4
Hope Technology UK Head Office and Manufacturing USA Sales Hope Mill, Skipton Road Barnoldswick Lancashire BB18 6EN United Kingdom Hope Technology Inc. 40234 Dutton Street Cherry Valley, CA 92223 Tel : + 44 (0)1282 851200 Fax : + 44 (0)1282 851201 Website : www.hopetech.com Documentation revision 1.
Contents 1. 2. Introduction .................................................................................................4 1.1. Instruction manual coverage............................................................................. 4 1.2. Safety first ......................................................................................................... 4 1.3. System identification ......................................................................................... 4 Installation .......
1. Introduction Thank you for purchasing a Hope Technology disc brake system. Please read the contents of this service manual to fully acquaint yourself with the correct installation and safe operation of your brake. 1.1. Instruction manual coverage This manual covers the installation and servicing of the hydraulic disc brake calipers XC4, Closed 2, Open 2 and DH4, and the brake levers Pro and Sport. This manual also covers our two discontinued brakes called the Sport and Pro.
Caliper identification The XC4 caliper A small caliper with 4 pistons. The caliper has the word HOPE machined into the side. Closed system. The caliper must be used with a closed system lever. The Closed 2 caliper A caliper with 2 pistons. The caliper has the word HOPE machined into the side. Closed system. The caliper must be used with a closed system lever. 165mm front caliper shown. The Open 2 caliper A caliper with 2 pistons.
Lever identification The Pro lever Closed system configuration A two finger lever with a silver pad adjustment screw. The Pro lever Open system configuration A two finger lever with a fixed master cylinder cap. The Sport lever Closed system configuration A four finger lever with a silver pad adjustment screw. The Sport lever Open system configuration A four finger lever with a fixed master cylinder cap.
2. Installation The disc brake system is supplied fully assembled and bled, i.e. containing brake fluid. The Cycle Dealer is responsible for supplying the caliper with the correct bolt mounting pattern to fit your particular fork or frame. Some installations may require an additional mount bracket as advised by your dealer.
2.3. Attaching the lever Attach the lever assembly to the handlebars and route the caliper down to the fork disc mount or along the frame to the rear disc mount. Take care to avoid situations that can damage the brake hose when the bicycle is used such as trapping the hose within suspension fork or rear suspension linkage movements, and also to avoid chaffing on the tire. The lever will work in any position providing the master cylinder is not totally upside down.
For the Sport lever adjust the grub screw C (see Figure 3) at the front of the lever to achieve the desired position. Then undo the locknut D and adjust the screw E leaving a small amount of freeplay in the lever. Re tighten the locknut D. Figure 3 Lever travel (pad position) This is the amount of lever travel between the brake’s off and on position. For the XC4 and Closed 2 brakes this can be set using the screw adjuster on top of the lever master cylinder (see Figure 4, Pro lever shown).
2. Compensating for over heating. Extreme heating of the brake due to long descents with heavy braking may cause the brake fluid to expand and push the brake pistons (and pads) closer to the disc in which case you may need to back off the pads using the thumbwheel adjuster, then readjusting as the brake cools down. The DH4 and Open 2 brakes These brakes do not provide any means of manual pad adjustment.
3. Service 3.1. Regular maintenance Cleaning your brake The braking performance will be severely reduced if the disc rotor and pads become contaminated with oil, brake fluid or after-market degreasing and cleaning agents. Clean your brake with water. If the disc rotor becomes contaminated it can be cleaned by wiping with a rag with isopropyl alcohol or disc brake cleaning products designed specifically for bicycle disc brakes. Heavily contaminated brake pads will need replacing.
6. Bed in the new pads (see section 2.6). 3.3. Bleeding the brake Bleeding the brake is the procedure whereby new brake fluid is introduced into the system either as a replacement or to flush out any trapped air. There are several reasons why a bleed operation may be necessary, for example shortening a brake hose, changing the brake fluid, or to remedy a situation described later in the troubleshooting guide (section 4).
3. Remove the master cylinder cap (item 23) using a 26mm spanner. 4. Place the closed end of an 8mm spanner over the bleed nipple on the brake caliper. Fit a length of clear plastic hose (approximately 30cm) onto the bleed nipple and place the free end into an empty container. The hose should be a snug fit and not fall off, the free end does not need to be submerged under brake fluid. 5. Fill the master cylinder reservoir with brake fluid. 6. Open the bleed nipple a 1/4 turn.
Bleeding the Open 2 and DH4 disc brake Item number references refer to the diagram of the Pro lever in section 5.2. The procedure is identical if you have a Sport lever. Wear safety glasses. 1. Remove the wheel and brake pads to prevent contamination. 2. Push the caliper pistons back into their bores and insert a spacer between the pistons to prevent them coming out during the bleed operation. 3. If necessary reposition the brake lever so that the lever and master cylinder is horizontal to the ground.
When to change the brake fluid For high performance usage, typically downhill racing and applications that use lots of braking effort it is recommended you change the brake fluid once per year. For normal use change the fluid every four years. To change the brake fluid follow the preceding instructions for bleeding the brake and ensure that the master cylinder is filled (and pumped through) at least four times. 3.4.
3.5. Hose change If the hose becomes damaged such that a system leak (however small) occurs then replace the hose. Try to identify how the original damage occurred to prevent the same thing happening again. A new length of genuine Hope Technology hydraulic hose will need purchasing. Follow the procedure for shortening/re routing the hose in section 3.4. Note, in section 3.4, the hose is disconnected from the lever in the same manner as described for disconnecting from the caliper. 3.6.
For the XC4 and DH4 calipers (2 pistons per caliper half) you should try to eject the pistons simultaneously. If one piston is moving faster than the other then apply finger pressure to one piston to allow the other to catch up. 6. Clean the piston. The new caliper half will include a new piston seal. Wipe the inside of the bore with clean brake fluid and gently push the piston into it. For the DH4 and Open 2 caliper the piston will push all the way to the bottom.
4. Troubleshooting Do not operate the bicycle with defective brakes. Outlined below are some of the common problems and solutions. If the problem persists then contact your dealer or the Hope distributor for your country. No braking power Symptoms Solution The lever operates as normal but the brake does not deliver a good braking force. The brake pads are new and not fully bedded in. Follow the instructions in section 2.6. The disc rotor and pads may be contaminated.
Spongy lever Symptoms Solution Reduced braking power and spongy feel when pulling the lever. Air in the system. Re bleed the system (see section 3.3). If the problem persists then there may be a system leak described below. System leak Symptoms Solution Hydraulic oil can be seen on the outside of the system, usually associated with a loss of braking performance. A typical cause is after a crash which has wrenched the hose and damaged other items on the brake.
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5.
[ EXPLODED DIAGRAM ] 22 5.1.
HBSP51L PRO MASTER CYLINDER ASSEMBLY (left) HBSP51R PRO MASTER CYLINDER ASSEMBLY (right) HBSP52 PRO MASTER CYLINDER CLAMP HBSP53 PRO PISTON - MASTER CYLINDER HBSP54 PRO SPRING - MASTER CYLINDER HBSP06 PISTON SEAL FRONT. - MASTER CYL. HBSP07 PISTON SEAL REAR - MASTER CYL. HBSP55 PRO DUST COVER - MASTER CYL. HBSP56 PRO ADJUSTER SCREW - MASTER CYL.
[ EXPLODED DIAGRAM ] 24 5.2.
HBSP51L PRO MASTER CYLINDER ASSEMBLY (left) HBSP51R PRO MASTER CYLINDER ASSEMBLY (right) HBSP52 PRO MASTER CYLINDER CLAMP HBSP53 PRO PISTON - MASTER CYLINDER HBSP54 PRO SPRING - MASTER CYLINDER HBSP06 PISTON SEAL FRONT. - MASTER CYL. HBSP07 PISTON SEAL REAR - MASTER CYL. HBSP55 PRO DUST COVER - MASTER CYL. HBSP56 PRO ADJUSTER SCREW - MASTER CYL.
[ EXPLODED DIAGRAM ] 26 5.3.
PART NO.
[ EXPLODED DIAGRAM ] 28 5.4.
HBSP02 SPORT LEVER MOUNT HBSP03 SPORT MASTER CYLINDER HBSP04 SPORT PISTON - MASTER CYLINDER HBSP05 SPORT SPRING - MASTER CYLINDER HBSP06 PISTON SEAL FRONT. - MASTER CYL. HBSP07 PISTON SEAL REAR - MASTER CYL. HBSP08 CLAMP SCREW HBSP09 M6 LOCKNUT HBSP10 SPORT CIRCLIP - MASTER CYLINDER HBSP11 SPORT CIRCLIP – MOUNT HBSP12 SPORT DUST COVER - MASTER CYL. HBSP13 SPORT PLUNGER - MASTER CYL.
[ EXPLODED DIAGRAM ] 5.5.
PART NO. HBSP61 HBSP62 HBSP63 HBSP64 HBSP65 HBSP66 HBSP67 HBSP68 HBSP69 HBSP70 HBSP71 ITEM 1 2 3 4 5 6 7 8 9 10 11 XC4 PISTON PLATE - CALIPER 1 8 1 1 1 1 2 1 1 1 1 QTY.
[ EXPLODED DIAGRAM ] 5.6.
HBSP31 HBSP32 HBSP39 HBSP40 HBSP35 HBSP34 HBSP33 HBSP41 HBSP38 HBSP37 HBSP36 1 2 3 4 5 6 7 8 9 10 11 1 6 1 2 1 1 1 1 1 1 1 QTY 22 21 20 19 18 17 16 15 14 13 12 ITEM 33 HOSE ALUMINIUM SHROUD BRASS OLIVE STRAIGHT CONNECTOR SEALING WASHER M6 X 20 CAPSCREW HBSP46 HBSP47 HBSP43 HBSP44 90 DEG CONNECTOR 90 DEG BOLT C2/O2 DISC SPIDER HBSP45:6 M5 X 8 LOW HEAD CAP SCREW HBSP30 HBSP29 HBSP28 HBSP27 HBSP26 HBSP42 PART NO.
[ EXPLODED DIAGRAM ] 5.7.
PART NO. HBSP83 HBSP84 HBSP85 HBSP40 HBSP86 HBSP34 HBSP33 HBSP41 HBSP45:6 HBSP44 ITEM 1 2 3 4 5 6 7 8 9 10 SPIDER 1 6 2 1 1 1 1 1 1 1 QTY 19 18 17 16 15 14 13 12 11 35 HBSP47 90 DEG BOLT HBSP46 90 DEG CONNECTOR HBSP30 HOSE HBSP29 ALUMINIUM SHROUD HBSP28 BRASS OLIVE HBSP27 STRAIGHT CONNECTOR HBSP26 SEALING WASHER HBSP42 M6 X 20 CAPSCREW HBSP43 C2/O2 DISC ITEM PART NO.
[ EXPLODED DIAGRAM ] 5.8.
PART NO.
6. Warranty Hope Technology disc brakes are warranted for a period of one full year from original purchase against defects in materials and workmanship. The warranty only applies to the original owner and proof of purchase is required. Hope cannot process any warranty claim until the product has been returned to the factory. Any Hope product that is returned to the factory and is found by Hope to be defective in materials or workmanship will be repaired or replaced at the option of Hope.
7. New 2001 Disc brakes For 2001 we have made several changes to the open system brakes. The key changes to the new brakes are shown below. Enduro 4 caliper This caliper replaces the DH4. It uses the same pads and seals as the previous DH4. The major change is to the caliper body, which has been refined and made more compact. These changes reduce the weight and make the bleeding process easier due to the improved fluid flow within the caliper.
