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Giant MPH-3 - MODEL YEAR 2002 Owner's Manual

Disc brake system model year 2002
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Giant MPH-3
Disc Brake System
Model Year 2002
Owners Manual
June 2001.
Fixation calipers and rotors: International Standard
Fully hydraulic disc brake system
2 piston closed system
Brake levers with reach adjusters
Pressure point & brake pad clearance adjustable
"on the fly"
Easy brake pad replacement
Standard "DOT 4 or DOT 5.1" brake fluid

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  • Page 1 Giant MPH-3 Disc Brake System Model Year 2002 Owners Manual June 2001. Fixation calipers and rotors: International Standard Fully hydraulic disc brake system 2 piston closed system Brake levers with reach adjusters Pressure point & brake pad clearance adjustable “on the fly”...

  • Page 2: Table Of Contents

    Contents: Warnings Mounting the brake system on the bicycle 2.1 Assembly of rotor 2.2 Assembly of brake lever 2.3 Assembly of hose 2.4 Assembly of caliper “Post Mount” (Manitou forks) 2.5 Assembly of caliper “International Standard” Adjustment 3.1 Pad clearance adjustment 3.2 Lever reach adjustment 3.3 Angle of the brake fluid reservoir Tightening torque...

  • Page 3: Warnings

    It is particularly suited for cross country use. Giant advises to have your wheels laced by an expert mechanic. Improper tightening of the spoke nipples or thin spokes may result in deformation of the wheel and can cause serious accidents.

  • Page 4: Mounting The Brake System On The Bicycle

    Mounting the brake system on the bicycle 2.1 Assembly of rotor Place the rotor on the hub flange taking care that the arrows on the internal part of the rotor are pointing in the direction of rotation of the wheel. Mount the rotor with the six M5 bolts onto the hub with a T25 Torx key to a torque of 4 Nm.

  • Page 5: Assembly Of Brake Lever

    2.2 Assembly of brake lever Place a complete brake lever assembly onto the handlebar. Set the brake lever to the right position. Tighten the fixing bolt with a 4 mm. Allen-key. Recommended tightening torque: 6 Nm. Blow compressed air into the grip through a small hole at the end and slide the grip over the handlebar.

  • Page 6: Assembly Of Hose

    For maximum efficiency of the system, it is very important that the hoses are without kinks and have the correct length. Changing the length of a hose should be done by an authorised Giant dealer. After assembling the brake lever, put the...

  • Page 7: Assembly Of Caliper "Post Mount" (Manitou Forks)

    2.4 Assembly of caliper “Post Mount” (Manitou forks) 1. Assemble the front brake caliper to the Giant postmount adapter (see picture) and use a 5 mm. Allen-key to tighten the two M6 fixing bolts. Notes: - the lower bolt for the front caliper is shorter ! - watch the orientation of the “GIANT”...

  • Page 8: Assembly Of Caliper "International Standard

    2.5 Assembly of caliper “International Standard” Hold the caliper close to the disc brake mount on the front fork / frame, with the rotor placed between the brake pads. Screw in the two M6 fixing bolts, but just a few threads. Note: the lower bolt for the front caliper is shorter! Now squeeze the brake lever, so the rotor is clamped by the caliper.

  • Page 9: Adjustment

    If you’re not able to adjust the brake system to the desired braking point (position of your hand or brake lever blade when the brake pads engage the rotor), please check if the pads are worn out. If so, replace place them. If no, please consult your authorised Giant dealer. - Pag. 9. -...

  • Page 10: Lever Reach Adjustment

    3.2 Lever reach adjustment Find out the best lever reach by using a 2.5 mm. Allen-key to adjust the screw as shown in the illustration. For big hands: turn clockwise / inwards to increase the distance between the handlebar and the lever blade. For small hands: turn anti-clockwise / outwards to reduce the distance between the handlebar and the lever...

  • Page 11: Tightening Torque

    Tightening torque Bleeder: Lock screw brake fluid reservoir: 8 Nm. 5 Nm. Lever - handlebar : 6 Nm. Brake pads: 4 Nm. Calipers - frame / fork: 9 Nm. 6 rotor fixing screws: 4 Nm. Bolt Tool needed Recommended tightening torque Rotor fixing screws T25 Torx key 4 Nm.

  • Page 12: Maintenance

    Check by dealer. Take your bicycle to an authorised Giant dealer for periodic service and inspection of MPH braking systems. Parts such as brake pads, hoses and seals, can be adversely affected by use, dirt and ultraviolet radiation. The MPH brake system has to be checked by a dealer once a year or more often if the bike is used in extreme conditions.
  • Page 13 Check tightening torque. Tightening torque of fasteners and bleeders has to be checked frequently. Loose bolts may cause that parts come off, a loose bleeder may cause the braking system to leak. This can lead to severe injury or death. Loctite Always use Loctite Primer (#7649) and Loctite...

  • Page 14: Replacement Of Brake Pads

    5.2 Replacement of brake pads When to change ? Before each ride, check the wear pattern of the pads (both front and rear). The back plate of the brake pad should not touch the rotor. Replace the pads if there is not enough material left, or if high frequency noise occurs during braking.

  • Page 15: Bleeding Procedure

    5.3 Bleeding procedure When to bleed ? Whenever the system lost brake fluid or air came into it. For example: After replacement or disassembly of : brake lever or caliper or hose or bleeder After shortening a hose Lack of brake fluid in MPH brake system due to leakage Replace brake fluid for MPH at least every two years When the braking systems feels spongy, perhaps there is air inside the hydraulic system.
  • Page 16 Make sure that the syringe is filled with the same kind of fluid as in the brake system. The MPH brake sets have been filled by Giant with DOT 4 brake fluid. 5. Push the syringe on the open end of the short transparent tube.
  • Page 17 9. While squeezing the syringe, pull the brake lever fast and release the lever slowly. New brake fluid will come into the hydraulic circuit eliminating most of the air that maybe in there. Continue until the fluid flow from the calipers’ bleeder through the long transparent tube is not any longer interrupted by air bubbles.
  • Page 18 12. By pulling the brake lever fast and releasing it slowly (the brake lever will pump the air up and the brake fluid down) and by tapping on the MPH brake hose, the air bubbles will go up. Via the short transparent tube and via the brake fluid in the syringe, the air bubbles will go out of the MPH brake system.
  • Page 19 Or, even better, remove these parts. Use DOT 4 or DOT 5.1 brake fluid only. DOT 4 and DOT 5.1 brake fluid should not be mixed ! The MPH brake sets have been filled by Giant with DOT 4 brake fluid. - Pag. 19. -...

  • Page 20: Trouble Shooting And -Prevention

    Trouble shooting and -prevention When riding down a slope, continuous braking with MPH disc brake will generate a lot of heat. The heat will be conducted to the brake fluid. The temperature of fluid can increase up to Long 120º C. or more. As shown in the illustration, the stroke of brake lever will become shorter.
  • Page 21 Parts: Rotors max. 0.3 mm. When to change? If, after assembly to the hub, the rotor is not straight (more than 0.3 mm. out of line). If there are serious damages on rotor surface that lead to longer braking distance. How to change? See the instruction “Mounting the brake system on the bicycle”.
  • Page 22 Brake fluid leakage due to seal failure. Malfunction of calipers. How to change? This should be done by your authorised Giant dealer. Remarks: Only use MPH genuine parts. Use washers (0.25 mm. thickness) to adjust brake pads parallel to rotors and to set the rotors exactly in middle of the brake pads.
  • Page 23 Only use MPH genuine parts. Use DOT 4 or DOT 5.1 brake fluid only. DOT 4 and DOT 5.1 brake fluid should not be mixed ! The MPH brake sets have been filled by Giant with DOT 4 brake fluid. - Pag. 23. -...
  • Page 24 Can’t get air out of system when bleeding. How to change? See “Maintenance; bleeding procedure”. For safety reasons, it’s better to leave this to your authorised Giant dealer. Remarks: Only use MPH genuine parts. Make sure that the threads are completely coated.

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