Neat Road Brake Caliper Installation Tip

I thought I would present a little tech trick in our shop (and probably others) that keeps a road brake caliper from rotating on its anchor bolt when bumped slightly or installing wheels.  One of our guys told everyone about it last year and since then, we have had great success with it.

It is quite simple and makes great sense. Usually there is a small serrated washer or smooth alloy washer placed on the anchor bolt between the caliper and the frame for both correct positioning and the use of a ‘softer’ metal to grip the caliper to the anchor nut from the frame.  See below.

Washer is placed over the anchor bolt hereBefore you place this washer onto the anchor bolt, apply a small amount of grip assembly paste to the surface at the base of the anchor bolt, as shown below.Applying the grip assembly paste with an acid brush

A little more than necessary, for visual purposes.

Then, install the alloy washer and apply a little more grip assembly paste to the side of the washer facing the frame or fork, shown below.

Installing the alloy washer Rear brake with grip assembly paste applied

That will give the brake much more staying power without any ill side effects.  The paste also helps protect carbon frame surface mounting points.  No more will that little bump while moving or transporting your bike knock the caliper out of alignment, which will help performance longevity after tuning and avoid uneven brake pad wear.  Hope this helps your shop or your own bikes as well as it has ours.

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One article I am currently working on deserves a little preview while assembling all of the material.  It’s based on reducing weight on your bike for the least and most practical cost.  For instance, we carry Specialized tubes in our shop of both the regular and lightweight turbo pre-talc’d styles.  I knew that the rubber quality is slightly higher in the turbo tubes and that they weighed somewhere below the regular ones.  So I weighed them to see exactly what the weight savings was.  A regular tube weighs out at about 100g.  The lightweight tube costs about two dollars more, yet comes in at only about 70g.  So, for four dollars, you can save 60g on your bike.  This alone doesn’t do much (though the ride quality will improve slightly), but a few tricks like this will add up to a considerable savings.  I know of a lot of much more expensive proportions of dollars/weight savings that might make sense when you have exhausted some of these more ‘stealth’ weight saving options.  More tips like this to come in the article.

– SNC

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Specialized Turbo Parts Installation

The Turbo S comes mostly assembled in a large sturdy box from Specialized that also has plastic support handles in lieu of simple cardboard ones since it still does weigh about 48 pounds.  The battery is separately packaged in the box in additional cardboard and usually has a decent charge right from the start.  I always un-package it and plug it into the included AC charger so it is at full charge once the bike is ready to ride.

The handlebars and stem need to be installed onto the steerer tube of the fork ) appropriately spaced with the right amount of spacers.  Once this is done, any remaining packaging is recycled and removed.

The seatpost is installed with grease (for alloy) and fiber grip paste (for carbon on the older models).  Right before install the two wires coming from the saddle’s LED need to be connected to the opposing two wires coming from the seat tube.  One of each set will have a blue line on it.  Connect those two and then connect the other two.  Coil the additional wire into the seatpost as you mount it into the frame.  Torque the seatpost binder bolt to a value of 5Nm.  Clamp the bike in the stand with moderate pressure to hold the bike firm while finishing the build and tuning.Turbo Integrated Tailight

The Turbo S uses a MegaEVO386 bottom bracket and compatible crank (30mm spindle).  I remove the crank and use a torque wrench to check the outboard bearing bottom bracket cups to 40Nm.  I then make sure to use a thicker grease on the spindle before installing it into the BB.  This helps ensure that there are no creaking or clicking issues.  Most of the time, I find that the factory build installs it correctly and I have to just double check it.EVO386 Bottom Bracket

I then take both wheels off of the bike.  The front is a thru-axle as is the rear wheel.  Both are necessary to adequately support the wheel in the frame.  After greasing the thru-axle and checking to make sure the cassette lockring is tight, I true and tension both wheels.  Nearly every time I find the wheels are already well-built and simply detension the wheel from shipping and production and lubricate the spoke nipples.Rear wheel motor specThru axle and torque spec

After getting the wheels ready, I like to take care of a few things on the bike that is easier to do without the wheels on.  I wipe the frame down with rubbing alcohol at all points of contact between parts and components. For instance, this would include crank arm pedal threads, both front and rear dropouts, all frame fitting contact points (where cable and wires enter and exit the frame), brake calipers (with pads removed), handlebars, the surface area under the grips, and the rotors on the wheels.  Then the wheels are installed and torqued to the required spec with a torque wrench.

At this point the handlebar is installed, the bottom bracket checked, the wheels checked and trued and cleaned, and the frame is prepped.  After the wheels are installed, it is time to center the brake calipers on the rotors.  At this time, it is also suggested to toque the rotor bolts to spec as well (3.5-5Nm).  Loosen the top and bottom mounting bolts for each caliper and  until they move freely back and forth.  Normally there is blue Loctite on these bolts.  If none is present, apply some.  Then, with the mounting bolts loose, use one hand to press down on the caliper body and with the other hand, squeeze the brake lever.  Slowly snug down the top and bottom mounting bolts until the body does not move easily.  Release the brake lever and place a white piece of paper below the caliper and rotor.  You should be able to easily see the space on each side of the rotor from the pad.  If it is uneven, slightly loosen each of the mounting bolts and center the pads over the rotor.  Once this is done, tighten and torque the bolts to spec and spin the wheel.  Listen for any sound of rubbing and observe that the rotor is true and straight.WP_20140515_008

Shift through the gears in the rear until the chain is positioned in the largest cog (the lowest gear).  Set the LOW limit screw so that the derailleur may very slightly go past the last cog (about a half of a millimeter).  Then, down shift and use the barrel adjuster to correct the cable tension for the smoothest shifting.  Once the chain is positioned in the smallest cog (the highest gear), adjust the HIGH limit screw so the chain is in line with the cog.WP_20140515_018

Now that the ‘bicycle’ parts have been checked and tuned, it is time to install the frame fittings the wires enter and exit.  These are small 2mm hex bolts that should have a small amount of blue Loctite on them.  If they don’t apply some.  Avoid using a ball head hex key to install or remove these as it tends to either strip the bolt head or simply not apply enough bite to turn the bolt.WP_20140515_011

Check the rubber pad in the frame slot for the battery to make sure it is flush against the base of the panel and is covering the wires that run the length of the down tube.  Then, clean the contact points at the top and bottom of the battery slot and on the battery with isopropyl alcohol and place the battery in the frame bottom side first.  When the top half connects into the frame, you should hear a distinct click, indicating the battery is installed correctly.  Attempt to wiggle the battery to ensure it is installed right and test its removal by turning the key located near the bottom bracket on the non-drive side.  Keep this key handy at all times!  It is ridiculously hard to remove the battery without the key.

With the battery installed, the Turbo is ready to rock!  Press the power button on the battery to start up the system.  Now on to the electronic parts and diagnosis!

 

– SNC

 

 

SRAM Road Hydro Disc Install & Review (New) & Pinarello Dogma F8 Frameset Unveiled

I thought I would write a review of how to install and adjust / bleed the newest road hydraulic disc components from SRAM (the SB700 series).  They just arrived at the shop a few days ago and I was anxious to see what the differences were and how they would perform once installed.  As normal, there were some easier parts and more difficult ones and I am sure I will encounter new challenges with it for each new frame it’s installed on.

This review is based off of a popular frame — the Specialized SWORKS Crux.  It’s cable routing was designed to use road hydraulic brakes (or mechanical) and was the first one in the shop to be updated.  Here goes.

This is the group right out of the package.  This is the SB700 series and it also came with Zipp Service Course SL tape (black), new rotors/pads, and caliper bleed blocks.

The Shipment New SRAM Hydro  The S Series CaliperThe S700 hydraulic road lever

The front and rear setups were in separate boxes and packaged well.  The only thing that I would have liked to have seen would be a printed copy of the bleed procedure.  However, I did find it easily online here

This bike stayed in the shop from the initial recall and so removal of the recalled hydraulic brakes was fairly quick and easy.  I cut the lines for the rear brake because of the internal routing and pulled the line through after installing this little connector and hose plug to avoid DOT fluid dripping through the frame.

The first thing I did was to clean all of the surfaces the components would be installed to with isopropyl alcohol.  This leaves no residue and provides the cleanest contact surface.  Before this, I also disconnected and removed the old derailleur cables.  Installation of the brake/shift lever is next and was mounted using a small amount of grip paste behind the handlebar mounting bracket to ensure stable placement and zero movement while riding.  Photos below.

Installed rear lever Old lever marking for replacmentInstalled rear lever

 

Once the lever was installed, I checked out the caliper to notice any differences.  These next photos are of the caliper installed and on the bench.  I figure it is more useful to know as many things as possible before the install and some of these things were discovered throughout the installation.

The caliper beside the diagram of parts The removable hose / barb/ olive for trimming 92 Caliper brake pads Bleed block

 

In the above photos, you will notice that the caliper looks about like any other hydraulic caliper out there with a few minor differences.  First, the hose can be cut and sized for the frame at the banjo.  Where older style brakes seemed to always have the crimped metal cap on the hose where it meets the banjo on the caliper, there is a standard 8mm fitting bolt that compresses an olive and barb into the body of the banjo.  Secondly, the pads are uniquely shaped compared to other SRAM/Avid brakes.  Lastly, the safety retainer clip for the bolt that hold the brake pads in the caliper is clipped on the inside of the body, where the edge of the pick is pointing in the second photo.  As a side note, I just realized the potential to use the bleed block as a tool to hold the hose while installing a barb by squeezing the end of the bleed block that is slotted.

Next, the front caliper was installed and appropriate measuring for the hose was fitted for the frame.  I used the smaller cylindrical caliper mounting spacers and found it to look sleek and minimal while providing a stable “post” for the caliper to mount to.

Brand new rotors Installing the front caliper  Installed caliper and rotor on front wheelEasy hose cutting and sizing

 

Cutting and sizing the hose for the front brake was relatively easy and required about the same time as it does for a mountain hydraulic brake.  With no internal routing for the front brake, it simply passes in a nice arc in front of the head tube and follows by a retainer clip on the fork down to the caliper.  Pivot washers and new mounting hardware were all included (a 12mm top spacer and a 7.5mm bottom spacer for a 140mm rotor)(A standard adaptor was also included for a larger rotor).

Now, I’ll cover the installation for the rear brake and then go over the bleed procedure last.  The rear brake hose, as mentioned earlier, is routed through the frame, below the bottom bracket to the non-drive side of the bottom bracket cable guides for the derailleur cables, and out of the rear non-drive chain stay to the caliper.  The caliper mounts directly to the frame mounts along with pivot washers.

One of the important factors in internal routing for hydraulic hoses (and full-length housing) is being able to wrap cushioning around it to prevent rattling in the frame every time the bike hits a bump.  Specialized had provided a spiral foam insulator that was wrapped on the excess of the hose and pushed into the frame where it passed below the bottom bracket (shown below)

The bottom of the photo is where the insulator is pushed into the down tube.  It is incredibly helpful to use some sort of snaking light to illuminate the inside of the frame so the derailleur cables can be checked for crossing when installed (also internally routed).  It’s an easy thing to miss with all of the other focus points of the install and will definitely lead to terrible shifting.  I left the hose for the install as long as possible (cutting it about two inches from the banjo on the brake caliper) so there would be plenty to use for correctly sizing to the frame.  I would note that gloves are definitely useful and necessary while routing the cable so no DOT fluid contacts the skin.

Cable liners routed for derailleur cables Hose plug and tool for routing through the frame Installing new barb and olive onto the cut and sized hose The installed caliper before attaching the hose Rear rotor (and still works for racks on bikes)

The routing through the frame wasn’t as difficult as I thought it would be since the hose was fairly rigid and could be easily seen with the light shown into the frame. Using the little red plug also marginally helped to prevent lots of air from entering the system while installing, which made bleeding the brake quicker and more effective afterward.

The pads lined up to the rotors well for the front and rear.  The pad spacers were held in place well and resisted falling out (great for packing and transporting).  Before bleeding both brakes, I went ahead and installed the derailleur cables back onto the components and adjusted as necessary.

Once the rotors, levers, shifter cables, hydraulic hoses, and calipers were all installed, it was definitely evident and expected that one or two bleeds would be required to get the correct actuation of the lever.  Initial pulls on the lever yielded solid piston movement in the caliper — even with air in the system.

The bleed procedure is quite normal and easy.  The bleed port on the lever is located at the topmost section of the grip, underneath the rubber.  A standard T10 fitting right in the center connected to a 1/4th filled bleed syringe with DOT 5.1 fluid and a hose clamp.  The inner part of the caliper body bolt is the second fitting (also T10) for the 1/2 filled syringe of DOT 5.1 fluid with a hose clamp.  Past this, the bleed procedure is described in depth, step by step at the link mentioned at the start of the article.

Lever bleed port T10 Caliper bleed port T10 Remember this clip! Bleed manual off of website for Road Hydraulic

 

A few things to remember — clean the entire caliper with isopropyl alcohol after bleeding the brake and before reinstalling the brake pads.  Use the included bleed block.  Do not forget the clip for the retainer bolt on the caliper that holds the pads in place.  While not critical for the brake to function, it is a safety clip so the pads do not vibrate out and cause the pistons to contact the rotor in the event of a failure.  Lastly, always go through the bleed procedure step by step.  As noted in the manual, it may be necessary to bleed the brake more than once for the initial install.  I bled the rear brake twice and the front brake once (due to less air exposure than the rear and great results after the first bleed).

I checked the position of the brake pads in relation to the rotor and centered them on either side by loosening and tightening the mounting bolts and placing a white sheet of paper below the caliper (which makes it incredibly easy to see the space between each brake pad and its respective side of the disc rotor).  Once fine-tuned, I test rode it around the area outside our shop and was noticeably impressed.

The shifting performance felt better than the original hydraulic version and slightly better than the mechanical 22 groups.  The brake pads were burnished to the rotors with about 40-50 hard stops and responded quickly to fast braking and slower modulation.  The reach can also be adjusted for quicker pad contact and shorter distance to the handlebars.

All in all, I thought the install took an appropriate amount of time and was well prepared for by SRAM.  The bleed procedure is quite like their mountain brakes, which is easy and was convenient to perform with a brand new bleed kit included with each set of brakes.  The braking power was solid and adequate.  I’ll be awaiting real ride feedback from riders picking them up as I finish installing the others.

Please let me know if you have any questions or comments regarding this article or in your own install as I am always looking to expand the knowledge base to provide accurate instructions and review.  Thanks for the support!

– S.N.C.

As a final note, we also just got a shipment of the new Pinarello Dogma F8 — an incredibly light frame with post hardware rolling in at about 980g!  Below are photos of the frame before the build and I’ll have build photos in the next week as five are already getting ready to head out to the road for takeoff!

 

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