802 operating manual my10 gb

8/2/2019 802 Operating Manual MY10 Gb

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MANUALE ISTRUZIONI

OPERATING MANUALMANUEL DINSTRUCTIONS

BETRIEBSANLEITUNG

MANUAL DE INSTRUCCIONES


2/16Fom - Mzo 2009 17

WARNING! BEFORE INSTALLING AND USING THIS NEW FORMULA SRL PRODUCT IT ISCRITICAL TO YOUR SAFETY THATYOUREAD AND STRICTLY ADHERE TO THE INSTRUC-TIONS IN THIS MANUAL. FAILURE TO DO SO COULD CAUSE SERIOUS INJURY, DEATHAND INVALIDATE YOUR LEGAL RIGHTS.

KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE AS IT CONTAINS IN-FORMATION CRITICAL TO YOUR SAFETY.

WARNING! DONT TRY TO DISASSEMBLE OR MODIFY IN ANY WAY THIS NEW FORMULASRL PRODUCT!SERVICE ON THIS PRODUCT MUST BE PERFORMED ONLY BY QUALIFIED PROFESSIONALMECHANICS WHO ARE FAMILAR WITH AND UNDERSTAND THE TECHNICAL DETAILS OFHOW THIS PRODUCT WORKS.IF YOU DECIDE TO IGNORE THIS IMPORTANT SAFETY WARNING, YOU ARE DOING SO AT

YOUR OWN RISK AND AT NO LEGAL LIABILITY TO FORMULA SRL OR ITS DISTRIBUTORS.

Note: AS FOR ANY MANUAL, THIS ONE MAY BE UPDATED. CONTACT YOUR MECHAN-IC, OR CHECK OUR WEB SITE REGULARLY, (www.ormula-brake.com) TO RECEIVEANY SUCH UPDATES.Thi mn povid inomtion o nd pop monting nd o th bking tm; ndo it otin mintnnc. B oowing th contind in thi mn o wi n tht thbking tm h th bt pomnc nd opting i, ong with voiding th mot commonc o ccidnt tht m t om impop option nd mintnnc.

WARNING: C oow saFeTy rules o pop bking tm nction.In thi hndbook o wi nd th oowing t notic:CAUTION: Dict o ttntion towd n pctic which cod t in dmgto th qipmnt.WARNING: Dict o ttntion towd n pctic which cod t in poninj o dmg to th qipmnt.

GENERAL SAFETY RULES

FOrMula srl bk hv bn dignd o on two-wh vhic with hmn pop-ion on. an oth ppiction i dngo nd m t in th i o thi podct.FOrMula srl dcin n nd ponibiit o th t o thi podct i d o nppiction oth thn which it i intndd.

FOrMula srl bk high-pomnc podct, oing pio bking ov nomBk. a t bking oc i qid to ock p th wh. B w tht ockdwh cn mk o o conto nd cn b th c o n ccidnt nd inj. In-dpth

knowdg bot th nction nd t o thi podct qid bo . Th i ponib o ning nd ing th coct bking tchniq; cont th Own-

Mn o th bicc, k poion bicc d o dvic, o contct Fom

GB


3/16Fom - Mzo 200918

o ddition dti nd commndtion. Tt th bk nd o bking tchniq on ft nd vn gond bo ing th bik in

mo v condition. Bk nti o th o bicc. Th impop tp nd o th bk cn

mk o o conto nd c n ccidnt, with th potnti to c io inj. Do not pc o hnd co to o within moving pt; w tong v-ngd

gov ning nitivit nd pow gip. Do not chng th pmt o th bking tm to obtin oth pomnc thn thotbihd b th mnct.

Bo tting n monting option, c chck o dngo condition t th wokit. I too dk, vib ight oc nd mk th wok pop bo tt-ing wok.

Concntt nd tk th d pction bo ing componnt which cod c dm-g.

Whn ing th bik, it i dvib to w hmt nd to id with c nd n o

ponibiit. a pciizd mintnnc option mt b cid ot o b ponn thoizd b

FOrMula srl. Dont toch th c o th dic oto with o b hnd th nt oi on o kin

cn compomi pomnc. aw w cn tx gov whn hnding th dic oto. Dic bk gt v hot whn d. WarNING: NeVer toch th cip o th oto immdi-

t t . Mk th bk hv cood down bo woking on thm. Bo , chck to n th ont bk v i on th id o th hndb o

cctomd to hving it on. I th v i on th oth id, ddn bking cn c o i-

o inj. Hv poion mchnic wp th poition o th v i th incoct. a high bking od (tot wight ov 100 Kg nd n incin o ov 15%) wi mn nc-

dction in o pd nd th o both bk whn bking.

BRAKING SYSTEM SAFETY RULES

Bo ch , chck tn o coct toq. Toq ting ppid in thimn nd n ppopit toq wnch i qid to pom thi chck.

Th bk oto mt b intd on wh tht itb o thi tp o bk tm. awh with n incint pok ction o with di pok cing cn bk nd nom o th bking tm nd c io inj o n ccidnt. Chck with o whmnct BeFOre inttion to n comptibiit.

Chck th pok tnion nd condition qnt. a dmgd pok m bk ddn ndint with th bking tm. Thi m t in io pon inj o ccidnt. Thbik m o ok mt b itb o monting th bking tm.

Th m nd th ok o th bicc mt b itb o thi tp o bking tm. Th p-pot, iz nd poition o th componnt wi on nction pop i th tm i intndd

o with dic bk. It is critical to cross-check your rame and ork manuacturers manuals on all theparts critical to the braking system and veriy that the torque ratings match theratings ound in this manual. In the case o inconsistency o the values, dont install


4/16Fom - Mzo 2009 19

the braking system. Mk th bicc i cn bo doing n mintnnc on th bk. Nv int th bk ing dpt o ppot ppid b oth mnct. Doing

o wi void th wnt nd Fom o ibiit. On oigin Fom podct.

On podct commndd in thi mn, othwi o cn dmg th tm nd

th bk wi b nib nd potnti dngo. Dont t bk fid o oth oi o g d o bicting th bicc com into contctwith th dic oto. I thi do hppn, cn th dic ing iopop coho ONly.

Dont t bk fid o bicnt com into contct with th bk pd. I thi do hppn,th bk pd wi b contmintd nd MusT b pcd bo th nxt .

On DOT 4 bk fid om nw bott. NeVer od fid, o fid tht h bn bdot o th tm. Od fid cn contin wt nd thi wi compromise the perormanceand unction o the system.

a nw bk, nw bk pd nd nw dic hv to bd in. Thi qi t t 50 ppic-

tion o th bk t pd o 30 Km/h bo th bk ch th mximm pomnc.Mk o in zon wh th i no od tc to bd th bk in.

Beore every ride, mk th no fid k in th tm b pping th v ndhoding it down it wi go. Chck th ho connction nd th bk fid voio n k. Cont poion mchnic i th fid k. a fid k cn c io ccidnt!

THe BraKING sysTeM May NOT HaVe THe HIGHesT BraKING eFFICIeNCy WHeN NeW,THereFOre a BreaK IN PerIOD aND lONGer sTOPPING DIsTaNCes sHOulD Be allOWeDFOr uNTIl THe sysTeM Is BrOKeN IN aND OPerTaING NOrMally.

Th cinc o th bk dpnd on mn cto which FOrMula srl h no contoov. Th incd th pd o th bik, th wh-tin contct, th bk v ppic-tion oc, th coct inttion nd mintnnc o th bk, th hdic bk fid, thv, th bk ho o pd, th condition o th bik, th wight o th id, th coctbking tchniq, th wth condition, th tp nd condition o th tin, nd mnoth cto.

We recommend using medium strength Loctite (Loctite 222 or 242) on all threadedasteners. Ater applying Loctite and tting the astener, clean any excess Loctitewith a cloth. Let the Loctite dry or at least 24 hours BEFORE use.


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ENVIRONMENTAL NOTEIn od to gd th nvionmnt, p to th imp intction o th coctdipo o Fom podct.1) Th pckging mti do not qi pci dipo pction bc it i not dng-

o in n w; w ggt ccing pp nd ptic.

2) It i o commndd to dipo o th mt pt t .3) In gd to th bk iqid DOT4, it i commndd to oow th intction in th t

ht vib om: http://ppot.om-bk.com.In th c o th itm mntiond bov, it i commndd to dipo o th wt oow-ing th ntion dictiv thogh pciid compni.

FOREWORDRecommended lubricants and cleaning products

Hydraulic brake fuidu on DOT 4 sp hdic bk fid om d contin. Dont v th bott oDOT fid opn o ong tim thi podct bob moit in th i nd thi wi chng itphic popti, io cting th cinc o th bk. Chng th oi in th tmv to mximiz pomnc.

WARNING: Bid dmging pint, th bk tm fid i xtm hzdo i itcom in contct with th o kin. In th vnt o contct fh with h wtnd k mdic itnc immdit. In th vnt o kg o ccidnt contctwith th DOT4 bk iqid, p to th t ht vib on th intnt t:http://support.ormula-brake.com.

Greaseu iicon g o ePDM . Fom commnd:uNIsIlKON TKN 1011 b KluBer.

WARNING: Do not bicnt oi in th oth option pin o th piton (hown b th owin th g) bc it incd ePDM O-ring.

CAUTION: u o inppopit tp o g mcompomi th intgit o th nd c dm-g to th tm nd tho to th .

WARNING: The Loctite used in some parts

ound in this product can be dangerous i itcomes into contact with your eyes or skin.


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1.1 INSTALLING THE BRAKE ROTORWARNING! DONT TRY TO DISASSEMBLE OR MODIFY IN ANY WAY THIS NEWFORMULA SRL PRODUCT!Service on this product must be perormed only by qualied proessional me-chanics who are amilar with and understand the technical details o how thisproduct works.

I you decide to ignore this important saety warning, you are doing so at yourown risk and at no legal liability or Formula srl or its distributors.

WARNING: Cont THe saFeTy reGulaTIONs ond in thi mn.

CAUTION: yo mt toq wnch to int th dic oto bot.

WARNING: en th dic oto int hot bo woking on it b tting it it o mini-mm o 10-15 mint. lt it coo i nc.

Pc bk dic 1 on hb 2 o n mbd wh withth mking cing otwd. Mk th ow 3 onth dic fng indict th coct diction o ottion.Tightn th 6 Ms cw ppid with TOrX T25 bit/too.Tightn th 6 cw in t pttn to toq tting o6 Nm5%. C cn th dic with iopop cohoto mov n tc o g o oi. Mont th wh ndc with th oigin tn.

CAUTION:Whn moving th cw, w mk to pp mdim tngth octit nd nth toq tting coct b ing toqwnch.

Th g how th ccptb p o 0.5 mm btwnth intn pid 1a nd xtn dic 1.

WARNING: I th indictd p i gt thn0.5 mm pc th nti dic oto mb.

3

0,5 mm

2

1

1a

1


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Installing the pump KIT- Fit th pmp bod 4a to th hnd b poitioning it

hown in th g nd ointting it in th did poi-tion.

- Fix th pmp bod 4a b monting th co 5a o thtth indiction UP c th pp pt ( hown in th

g). Fit tightn th pp cw 5 to toq ttingo 2.5/3 Nm5% nd thn cw 5b to toq ttingo 2.5/3 Nm5% ing TOrX T15 (r1) nd TOrXT25 (rX) bit.

I th ho ngth nd to b djtd, contct th mn-ct, i not pocd with th poitioning o th ho onth bicc, c oowing th intction givn bow:

- th ho nd to b ttchd to th ok o m in w tht do not int with th fow o fidthogh th ho;

- th ho hod not mk cv m thn 20 mmdi nd hod not int with n moving pt oth bicc.

WARNING:an incoct montd ho o hotht i in contct with moving pt o th bicc, cn

compomi bking pomnc nd c ioccidnt.

CAUTION: at th bk h bn intd, mk th hnd b tn ; i th bk hogt in th w, mk th qid djtmnt otht it do not o contct th mnct.

Installing the caliperTo dpt m o ok to th vio dimt o bkoto vib, FOrMula srl ppi dint dptwhich cn b montd btwn th ok o m nd thbk cip.

CAUTION: On coct monting o th tm ndit vio ppot mnt wi n th t oth ccit nd th xcption pomnc o FOr-

Mula srl dik bk.

5b4a

55a

5b

5 5a

5b

4a

5

5a

5b

55a

RX

R1


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Fit th cip to th ok, pocding oow:

INTERNATIONAL STANDARD MOUNT OR SIMILARWARNING! DONT TRY TO DISASSEMBLE OR MODIFY IN ANY WAY THIS NEWFORMULA SRL PRODUCT!Service on this product must be perormed only by qualied proessional me-

chanics who are amilar with and understand the technical details o how thisproduct works.I you decide to ignore this important saety warning, you are doing so at yourown risk and at no legal liability or Formula srl or its distributors.

CAUTION: yo mt toq wnch to mb th tn.

CAUTION: Whn moving th cw, w mk tht mdim tngth octit ippid whn mbing, nd tht th coct toq wnch tting d.

CAUTION: Cont th mn o th dpto to which dpto o nd.

R1 - RX - The One - MEGA

- attch th dpt 6 to th m o ok with th owcing th diction in which th wh tn. Tightn

cw 9a with 6 mm an wnch to toq ttingo 9 Nm5%, pping mdim tngth thd ock,i not pnt.

CAUTION: Mk wh 9 intd bombing tn 8.

- Pc th gipp 7 on th dpt 6. F tightn cw8 with 5 mm an wnch, pping mdim tngththd ock, i not pnt. loon th cw jtnogh to ow th gipp to mov.

- P th bk v 2-3 tim o tht th cip 11 cnt- it on th dic. app p to th v ndcw th cip xing cw 12 into th dpt to toq tting o 9 Nm5% nd pp mdim tngthloctit, i not d pnt.

7

6

9A

9

8

8

9A

9

1112

12


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POST MOUNT COUPLINGWARNING! DONT TRY TO DISASSEMBLE OR MODIFY IN ANY WAY THIS NEWFORMULA SRL PRODUCT!Service on this product must be perormed only by qualied proessional me-chanics who are amilar with and understand the technical details o how thisproduct works.

I you decide to ignore this important saety warning, you are doing so at yourown risk and at no legal liability or Formula srl or its distributors.CAUTION:yo mt toq wnch to mb th tn.

CAUTION: Whn moving th cw, w mk tht mdim tngth octit ippid whn mbing, nd tht th coct toq wnch tting d.

CAUTION: Cont th mn to which dpto o nd.

CAUTION: Mk th wh intd bo mbing th tn.

CAUTION: Whn monting th cip onto th ok, chck tht th cip bod i notin contct with th ok it.

R1 - RX - The One - Mega1) Installing directly onto a POST MOUNT ork- Fit th cip 13 to th ok pt tightning cw 15

with 5 mm an wnch (i not d pnt, p-

p mdim tngth loctit) ving th cip tomov.Mk tht th wh 15a pnt btwn thcw 15 nd th cip 13.

- app p to v o th cip tt nd tth m tim tightn th ixing cw 15 to toqo 9Nm5%.

2) Installing with POST MOUNT 180 adaptor- Fit th pci wh 17 onto th cw 18 ping t-

tntion to mtch th concv nd convx po (i notd pnt, pp mdim tngth loctit) nd o-owing th od hown in th g, int th cwmbd in cip 19 nd dpto 20 mking thow point pwd.

- scw th mb onto th ok withot tightningdown, ving th cip to mov.

- app p to v o th cip tt nd t thm tim tightn th xing cw 18 to toq o 9Nm5%.

1718

20 19

1817

1513 15a

15a

15

long

short


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3) Installing with adaptor on POST MOUNT ork- Fit dpto 21 on th ok mking th ow i point-

ing pwd.- Tightn cw 22 to toq tting o 9 Nm5% with

5 mm an wnch pping mdim tngth loctit, inot d pnt.

- Fit cip 23 on dpto 21.- scw in xing cw 24 ight with 5 mm anwnch ving th cip to mov. app mdimtngth loctit, n thi i d pnt.

- app p to v o th cip 23 tt nd tth m tim tightn xing cw 24 to toq o 9Nm5%.

WARNING: Nv int th Fom bk tm with dpt tht not p-pid b Fom . Thi wi void th wnt. To void io ccidnt on ptmd b Fom nd montd on dignd pt ok nd m.

Tn th wh ow, mking tht th dik i cntdon th pd nd tht non o th pt com into contctwith th oth.Pom 2 o 3 tt bking ction to bing th pd to thcoct ditnc om th dik.

WARNING: Th bk tm qi bk inpiod to obtin top pomnc. W commndnning th bik t pd o 30 Km/h nd bkingit t t 50 tim owing it to com to top(tking th qid pction) bo conidingth tm bokn in nd cint.

22

21

24

2322 24


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2 SET UPWARNING! DONT TRY TO DISASSEMBLE OR MODIFY IN ANY WAY THIS NEWFORMULA SRL PRODUCT!

svic on thi podct mt b pomd on b qid poion mchnic who mi with nd ndtnd th tchnic dti o how thi podct wok.I o dcid to igno thi impotnt t wning, o doing o t o own ik nd t no

g ibiit o Fom o it ditibto.


2.1 Positioning the R1 leverTo poition v 25 (ditnc B) to mt o nd, djtcw 26 with 2 mm an wnch.

WARNING: Th hd o djt cw 26 mt

potd t t 0,5 mm om th thdd int.

2.1 Positioning the RX leverTo poition v 29 (ditnc B) to mt o nd, djtcw 30 with 2 mm an wnch.

WARNING: Th hd o djt cw 30 mtpotd t t 0,5 mm om th thdd int.

0,5 mm

0,5 mm

B

25

26

B

29

30


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3 PAD REPLACEMENTWARNING! DONT TRY TO DISASSEMBLE OR MODIFY IN ANY WAY THIS NEWFORMULA SRL PRODUCT!Service on this product must be perormed only by qualied proessional me-chanics who are amilar with and understand the technical details o how thisproduct works.

I you decide to ignore this important saety warning, you are doing so at yourown risk and at no legal liability or FORMULA SRL or its distributors.

WARNING: Cont THe saFeTy reGulaTIONsond in thi mn.

Version R1- loon th xing pin 36 o th pd, ing TOrX T15

pnn.

Version RX - The One - Mega- rmov np ing 38 nd oon xing pin 39 o th

pd, ing 3 mm an wnch.

- rmov th pd 40 nd th ping.- C cn th piton inid th cip, ing

bh okd in iopop coho.- C cn th dic ing coth okd in iopop

coho.

36

40

36

38

39


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- Tmpoi pt th WOrN pd bck in poition nd, -ing ft bd cwdiv to ph down btwn thpd, ph th piton bck inid th cip.

- rmov th won pd.- Int th nw pd with th ping.

NOTE: th pd idntic nd cn b pcd on th to ight id.

Version R1- Chck th intgit o th nti-ooning ing 37 pcd

on th xing pin 36.- Tightn ixing pin 36 o th pd to toq tting o

2 Nm5% with TOrX T15 pnn.

Version RX - The One - Mega- Tightn ixing pin 39 o th pd to toq tting o

2 Nm5% with 3 mm an wnch, thn pt np ing38 bck in pc.

WARNING:Whn mbing th tn, wmk th toqd down to th ight toqtting.CAUTION:yo mt w toq wnch to

mb tn.CAUTION: Nv pp th v withot th pd in pc o with th wh movd. Ithi do hppn o wi hv to p th bk pd bck into th cip with cnft-bdd cwdiv.CAUTION:Whn inting nw bk pd, b v c to void contmintion withoi o g.WARNING:at hving cid ot thi option, mk th tm wok popb poming 50 bking tt. On th bik t hving md th tm iwoking pop. I thi i not th c, contct poion mchnic.WARNING: Bo ch mk th cw nd bot tightnd to th co-ct toq ond in th pnt mn.CAUTION: Dont wo i o cn h th bk dic nd pd bbing ight. Thi noiwi dipp th bk d; nw bk pd mt bd in to nd th coctpoition on th dic. yo m h ight bbing noi t chnging th bk pd oi th wh hnt bn ttd pop.WARNING: Dont bk pd ppid b oth mnct. Thi wod void ownt. On oigin Fom podct.

CAUTION:Whn tnpoting th bik with th wh o, w t th vnt pcbtwn th bk pd.

36

38

39

37


14/16Fom - Mzo 2009 29

4 MAINTENANCE


Th piodic cning o thi bking tm ing itb biodgdb dging podcttht dont dmg th tm i nc.

WARNING: IsOPrOPyl alCOHOl i commndd to cn th dic bk. Th on oth podct m b hzdo to th .WARNING: Do not toch th oto ight t it it might c o v inj.

WARNING:at cing ot thi option, pom 50 bking tt to mk thbk woking pop.

READ CAREFULLY!

FOrMula srl xtnd to th oigin pch o it bk imitd wnt tht th bk o dct in mti nd/o wokmnhip o piod o two om dt o p-ch. Th bdn o poo o ch pch dt h b th conm.

WHAT PROTECTION DO I RECEIVE FROM THE WARRANTY?

FOrMula srl wi, t it diction, pi o pc th dctiv podct nd wnt.

WARRANTY CONDITIONS AND LIMITATIONS

1. Thi wnt ppi on to th oigin own o th FOrMula srl podct. FOrMula srldo not wnt n cond hnd-mchndi;

2. Th vidit o thi wnt i bjct to th pop ppiction o th oowing cim po-cd:

() - Th cim mt b inititd within ight (8) d o dicov o th potnti dct;(b) - ev cim mt b bmittd to th FOrMula srl D om which th podct w

pchd, with th ndtnding, howv, tht th diction to th ccptbiit oth cim i xciv FOrMula;

(c) - On FOrMula srl D cn hip to FOrMula srl th gd dctiv podct, withth ccompning docmnttion.

Failure to comply with these procedures will invalidate the claim; in which case theproduct will be made available to the owner or thirty (30) days and then destroyed.

3. Thi wnt do not pp to:

) Cot nd tnpottion dmg dict o indict iing ot o th ppiction o thi


15/16Fom - Mzo 200930

wnt incding, bt not imitd to, th tnpottion o th podct om FOrMula srl toth own domici, o om th own domici to FOrMula srl;

b) Dmg to th podct ting om:

1. ab, ttion, mihnding, mi incding, bt not imitd to th i to th pod-ct o th ppo it w dignd nd mnctd o (such purposes include cross

country and downhill UCI organized competitions) nd, gn, to oow th wn-ing nd intction contind in FOrMula Own Mn;2. rpi pomd b non oth thn FOrMula srl D;3. accidnt, , ct o God, o n c otid FOrMula conto;4. Th o cooiv gnt on th podct;5. Th poongd xpo o th podct to th mnt nd/o ovnt;

c) I and to the extent the serial number and/or production code has been deliberatelyaltered, damaged or removed;

d) In case o modication o the product;e) In case o normal wear and tear and, in general, to parts subject to normal wear and

tear. Such parts include: - discs - pistons - brake pads - washers - hoses - oil.) In case o damage to the product caused by the use o parts o dierent manuactur-

ers, and/or not compatible, suitable and/or authorized by Formula srl or use onFormula srl products.

6. rti, who, impot o non bid FOrMula srl m not modi thiwnt in n w.

7. Thi wnt do not ct th ight o th conm odd b ppicb w no thight iing ot o th contct with th ti. In th bnc o n ppicb w,howv, thi wnt wi b th conm on gd nd nith FOrMula srl non FOrMula srl D no n Oci FOrMula srl Impot wi b ponib o nincidnt, pci o conqnti dmg incd dict o indict viotion o nxpicit o impicit wnt o thi podct.

8. Th vidit nd intpttion o thi wnt h b govnd b, contd nd nocdin ccodnc with, th intn w o It. an contov iing ot o thi wnt hb boght in ont o th Pto Fom.

PLEASE NOTE: In reerence to Article n. 1341 o the Italian Civil Code, you, the con-sumer, are hereby explicitly requested to read careully and understand the ramica-tions o Clauses 1 through 8 which submit to conditions and limitations some o yourlegal rights with respect to FORMULA SRL.


16/16

Formula srl

Via Erbosa, 63 - 59100 Prato (Italia)

Tel. +39 0574 603 609

Fax +39 0574 611 046

Information may be enhanced for improvement without prior notice. All rights reserved.Le informazioni possono essere modificate senza preavviso. Tutti i diritti riservati.

802 operating manual my10 gb

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