Giant MPH-3Disc Brake System

Model Year 2002

Owners ManualJune 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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Contents:

1. Warnings 3

2. Mounting the brake system on the bicycle 42.1 Assembly of rotor 42.2 Assembly of brake lever 52.3 Assembly of hose 62.4 Assembly of caliper “Post Mount” (Manitou forks) 72.5 Assembly of caliper “International Standard” 8

3. Adjustment 93.1 Pad clearance adjustment 93.2 Lever reach adjustment 103.3 Angle of the brake fluid reservoir 10

4. Tightening torque 11

5. Maintenance 125.1 General 125.2 Replacement of brake pads 145.3 Bleeding procedure 15

6. Trouble shooting and -prevention 20

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1. Warnings

Please read this owners manual carefully.Improper assembly of the wheels or malfunction of the brakesystem may be extremely hazardous and could cause accidents,even fatal ones. Be sure to learn the proper braking techniqueand operation of your bicycle.Consult your professional bicycle dealer and this owners manualfor this.

Giant recommends not using this system for any downhillcompetition.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 mayresult in deformation of the wheel and can cause seriousaccidents.

Protect vital parts of the bike from spilling brake fluid by holding arag around the brake fluid reservoir, and use protective glovesand safety goggles when working with brake fluid.Brake fluid spillage (for instance on the rotor) can causecontamination of the brake pads.

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2. Mounting the brake system on the bicycle

2.1 Assembly of rotor

Place the rotor on the hub flange taking care thatthe arrows on the internal part of the rotor arepointing in the direction of rotation of the wheel.

Mount the rotor with the six M5 bolts onto the hubwith a T25 Torx key to a torque of 4 Nm.Tighten the bolts in a crossed pattern.

Threads of new bolts have been coated with bluematerial that prevents that bolts come loose.Always use LoctiteTM Primer (#7649) andLoctiteTM blue Removable Threadlock (#242) orsimilar material on thread of these bolts duringre-assembly.

Then install the wheel into the frame / front forkwith the rotor at the left hand side and fix thewheel in the dropouts.

Warning!It is essential that the disc is clean (free from grease or oil residues) to avoid contaminatingthe brake pads and to insure perfect braking.Grease can be removed from the rotors with a citrus based cleaner.

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2.2 Assembly of brake lever

Place a complete brake lever assembly onto thehandlebar.

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 smallhole at the end and slide the grip over thehandlebar.

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2.3 Assembly of hose

Length and attachment of hoses:The hoses have to be attached to the frame and fork so that they do not contact the wheel or tire, orinterfere with the travel of the suspension or the action of steering. Use the bike’s cable guides and zipties to attach the hoses. Also be sure that the hose is not so long as to possibly snag on anything whileriding.A hose that is too short may cause steering problems but can also cause strain on the hose which mayresult in the hose getting disconnected from the caliper of brake lever.For maximum efficiency of the system, it is very important that the hoses are without kinks and have thecorrect length.Changing the length of a hose should be done by an authorised Giant dealer.

After assembling the brake lever, put thecaliper (front brake) from the front side to thebackside through the opening between lefthand fork leg and front wheel and fix thecaliper to the dropout(see: “assembly of caliper”).

Fix the hose of the front brake to the frontfork.Use zip-ties or other parts to fix the hose tothe fork brace and the lower fork leg(left hand side).

Fix the hose of the rear brake to the frame.Push the hose into the hose guides on thetop tube and the left hand seat stay.

Zip-tie

Zip-tie

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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 M6fixing bolts.Notes:- the lower bolt for the front caliper is shorter !- watch the orientation of the “GIANT” logo !- recommended tightening torque: 9 Nm.

2. Hold the postmount adapter with the front caliper close to the discbrake mount on the front fork / frame, with the rotor placedbetween the brake pads.Screw in the two M6 fixing bolts, but don’t tighten them.The postmount adapter should be able to move.

3. Now squeeze the brake lever, so the rotor is clamped by thecaliper.

Use a 5 mm. Allen-key to tighten the M6 fixing bolts.

Recommended tightening torque: 9 Nm.

4. Now you can release the brake lever.

Pull the brake lever to see if the brake pads are actuated well.

If the procedure has been followed well, the caliper (and brakepads) is set parallel to the rotor and the rotor is exactly in middle ofthe brake pads.

If necessary, release the bolts that fix the postmount adapter to thefront fork.Repeat the whole procedure mentioned above or just move thepostmount adapter a bit.Don’t forget to tighten the fixing bolts again.

Threads of new bolts have been coated with blue material that prevents that bolts comeloose.Always use LoctiteTM Primer (#7649) and LoctiteTM blue Removable Threadlock (#242)or similar material on thread of these bolts during re-assembly.

Make sure that the brake pads are wellcentered and balanced.

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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 thecaliper.

The space between the caliper and the disc mount has to be filledup with washers.Make an estimation how big the gap is, so, how many washers areneeded. Try !For both the upper and the lower caliper fixing bolts.Example:If the gap is approx. 1 mm., you may need 4 washers of 0.25 mm.thickness.

Put the washers between the frame/fork mount and the caliper.

Use a 5 mm. Allen-key to tighten the M6 fixing bolts.Note: the lower bolt for the front caliper is shorter!

Pull the brake lever to see if the brake pads are actuated well.

If the procedure has been followed well, the caliper (and brakepads) is set parallel to the rotor and the rotor is exactly in middle ofthe brake pads.

If necessary, release the bolts that fix the brake caliper to the forkand remove or add washers.Don’t forget to tighten the fixing bolts again.

Use washers of 0.25 or 0.5 mm. thickness for each boltto set the caliper (brake pads) parallel to the rotor andto set the rotor exactly in middle of the brake pads.

Threads of new bolts have been coated with bluematerial that prevents that bolts come loose.Always use LoctiteTM Primer (#7649) and LoctiteTM blueRemovable Threadlock (#242) or similar material onthread of these bolts duringre-assembly.

Recommended tightening torque: 9 Nm.

Make sure that the brake pads are well centered andbalanced.

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3. Adjustment

3.1 Pad clearance adjustment

Turn the adjust knob of the brake lever’s brake fluid reservoir andpull the brake lever until you have found the best braking positionfor your hand(to set the pressure point of the braking system to personalpreference).

Turning inwards (clockwise):distance between the brake pads becomes smaller, so, smallerbrake lever stroke required.

Turning outwards (anti-clockwise):distance between the brake pads becomes bigger, so, biggerbrake lever stroke required.

Due to normal pad wear during riding, the clearance between thepads and rotor will increase.So, it’s important to check the adjustment before and during eachride.

Brake pad wear can be compensated and brake pad to rotorclearance can be adjusted.Turn the adjust knob clockwise to bring the brake pads closer tothe rotor.

(Illustration: caliper, brake pads and rotor).

If you’re not able to adjust the brake system to the desired braking point (position of your hand or brakelever 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.

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3.2 Lever reach adjustment

Find out the best lever reach by using a2.5 mm. Allen-key to adjust the screw as shown inthe illustration.

For big hands:turn clockwise / inwards to increase the distancebetween the handlebar and the lever blade.

For small hands:turn anti-clockwise / outwards to reduce thedistance between the handlebar and the leverblade.

3.3 Angle of the brake fluid reservoir

The function of the small screw (see picture) closeto the lever blade is setting the angle of themaster cylinder.Use a 2 mm. Allen-key to loosen the screw andadjust the angle of the master cylinder.

Note:Make sure that it’s possible to turn theadjust knob. If the adjuster touches thelever bracket (clamp), turning may beimpossible !

After this, tighten the screw again.

Note:Not too tight: Otherwise the mastercylinder will be deformed. Tighten thescrew just enough to fix the mastercylinder.

Screw Lever blade

Adjust knob

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4. Tightening torque

Bolt Tool needed Recommended tightening torque

Rotor fixing screws T25 Torx key 4 Nm.Lever fixing bolts 4 mm. Allen-key 6 Nm.Caliper fixing bolts 5 mm. Allen-key 9 Nm.Bleeder 10 mm. wrench 8 Nm.Brake pad fixing bolt 3 mm. Allen-key 4 Nm.Lock screw brake fluid reservoir 3 mm. Allen-key 5 Nm.

Lock screw brake fluid reservoir:5 Nm.

Lever - handlebar :6 Nm.

Bleeder:8 Nm.

Calipers - frame / fork:9 Nm.

Brake pads:4 Nm.

6 rotor fixing screws:4 Nm.

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5. Maintenance

5.1 General

Proper maintenance of a bike equipped with MPH DISC BRAKES is important to insure years of troublefree safe riding.

Check by dealer.Take your bicycle to an authorised Giant dealer for periodic service and inspection of MPHbraking 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 yearor more often if the bike is used in extreme conditions.

High-pressure.DO NOT use high-pressure water or air hoses to clean bike. This can force dirt into parts of thehydraulic braking system, which may cause damage.

Brake fluid, lubricants on brake pads and rotors.It is essential that the rotor is clean (free from grease or oil residues) to avoid contaminating thebrake pads and insure perfect braking.To avoid brake fluid spillage on the rotors or brake pads, causing contamination of the brakepads, it is advisable to cover the vital parts with a rag before maintenance of the hydraulicsystem is done, or when lubricating parts of the bike.If brake fluid comes in contact with paint or plastic bike parts, wipe it off immediately.If you get any brake fluid on the brake pads, discard them and replace with new pads.

DOT 4 or DOT 5.1 brake fluid.The fluid in this braking system (use DOT 4 or DOT 5.1 brake fluid only!), besides possiblydamaging the paintjob and some plastic parts on the bike, is extremely hazardous in case ofcontact with eyes or skin. Use protective gloves when working with brake fluid.We recommend to replace the brake fluid in the system at least every 2 years. This fluidnaturally absorbs water, which will result in a lower boiling point for the brake fluid and cancause poor braking.Do not mix DOT 4 and DOT 5.1 brake fluid!The MPH brake sets have been filled by Giant with DOT 4 brake fluid.

Washing and cleaning.After riding (off road) in the dirt, clean the bike (and the components of the braking system) asusual with water, soap, washing-up liquid, etc.Remember: do not use high-pressure water or air hoses.After washing the bike or riding in the wet, take the wheels out of the bike.If the wheels remain in the bike, water may stay between brake pads and rotors and causecorrosion.After wiping dry with a clean soft cloth, remove all dirt from the brakes with a soft brush.

Thickness of brake pads.Check thickness of brake pads before every ride. Replace pads before they are worn down tothe back plate to assure proper function and to prevent damage to the rotor.

Adjust knob.By turning the big adjust knob on the fluid reservoir of the brake lever, it is possible to set thepressure point of the braking system to personal preference.Also, in the same way, brake pad wear can be compensated and brake pad to rotor clearancecan be adjusted.If the knob is turned clockwise but the space between the brake pads and the rotor remains toomuch (the brake lever has to be pulled too far), the brake pads have to be checked for wear.

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Check tightening torque.Tightening torque of fasteners and bleeders has to be checked frequently. Loose bolts maycause that parts come off, a loose bleeder may cause the braking system to leak.This can lead to severe injury or death.

LoctiteTM.Always use LoctiteTM Primer (#7649) and LoctiteTM blue Removable Threadlock (#242) orsimilar material on thread of fixing bolts of calipers and rotors during re-assembly.

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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.

1. To replace brake pads it is necessary to take thewheel out of the frame / fork.

2. Use a 3 mm. Allen-key to unscrew the brakepad fixing bolt of the caliper.

Unscrew the small screw only (3 mm. Allen-key).DON’T LOOSEN THE 2 BIGGER SCREWS(5 MM. ALLEN-KEY) BECAUSE IN THAT CASETHE WHOLE CALIPER WILL COME APARTAND LOOSE BRAKE FLUID !!!

3. Then, remove the pads.

4. Turn the adjust knob of the master cylinder anti-clockwise. At least 10 full turns.

5. Using a brush, clean the inner cavity of thepistons to eliminate any deposits and trace ofdirt.

6. Insert two new pads inside of the caliper, put thebrake pad fixing bolt back into the caliper andtighten it to a torque of 4 Nm.

7. Turn the adjust knob of the master cylinderclockwise until you see there’s no clearancebetween brake pads and rotor.

8. Turn the adjust knob of the master cylinderanti-clockwise and pull the brake lever until youfind the best braking position on your hand.

Note:Do NOT use MPH brake pads “model year 2000” (2 holes in each pad).These pads do not fit into the MPH-2 (model year 2001) and MPH-3 (model year 2002) calipers.

Warnings:- If the bolt is not tightened well, it

can cause a hazardous situation.- Do make sure the bolt goes

through the hole of each pad.

Loosen

DO NOTLOOSEN

DO NOTLOOSEN

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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 orcaliper orhose orbleeder

- 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.

Advice:It’s better to remove wheels and brake pads before working with brake fluid.Leakage of brake fluid on brake pads or rotor will ruin these parts.

1. Turn the adjustment knob of the fluid reservoir on the brake leveranti-clockwise all the way to create max. volume inside thereservoir.At least 10 full turns.

2. Use a 3 mm. Allen-key to unscrew the M5 lock screw from themaster cylinders’ fluid reservoir. Remove screw, cap and O-ring.

3. Connect the short, transparent tube on the fluid reservoir / mastercylinder, by screwing the connector (brass colour) in the threadedhole for the lock screw.Do this by hand and no too tight. Don't use a tool. If it's too tight,the connectors’ rubber O-ring will be deformed too much and it willleak air and fluid.

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4. Fill the syringe with DOT 4 or DOT 5.1 brake fluid from a newbottle:Put the syringe in the bottle with the nozzle under the fluid leveland pull the piston of the syringe.

Use DOT 4 or DOT 5.1 brake fluid only.DOT 4 and DOT 5.1 brake fluid should not be mixed.Make sure that the syringe is filled with the same kind of fluid as inthe brake system.

The MPH brake sets have been filled by Giant with DOT 4 brakefluid.

5. Push the syringe on the open end of the short transparent tube.

In case most of the brake fluid is still in the MPH disc brake system (for example after shortening a hoseor switching front- and rear brake from one side from the handlebar to the other) skip step 6 to 10 andcontinue with step 11.Otherwise, if there is no or almost no brake fluid inside the MPH disc brake system (for example whenreplacing all the brake fluid once per year or 2 years, or after complete disassembly of the caliper and/orthe master cylinder), continue with step 6.

6. Take the bleeder cover (rubber cap) off from the calipers’ bleederand mount the second (long) transparent tube. Put the other end ofthis tube into a bottle or cup that can contain brake fluid.

7. Unscrew the calipers’ bleeder just a bit with a wrench 10 mm.(¼ to ½ turn).

8. Start squeezing the syringe and don't stop squeezing until it ismentioned in this manual (step 10).

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9. While squeezing the syringe, pull the brake lever fast and releasethe lever slowly.New brake fluid will come into the hydraulic circuit eliminating mostof the air that maybe in there.Continue until the fluid flow from the calipers’ bleeder through thelong transparent tube is not any longer interrupted by air bubbles.

If necessary, re-fill the syringe during this process.When doing this, close the bleeder (on the caliper) and don’t openit before the re-filled syringe is connected to the fluid reservoir andthe syringe is squeezed again.

10. With the syringe still squeezed, retighten the bleeder.Now, squeezing the syringe can be stopped.Remove the long transparent tube and put the rubber cap back onthe bleeder.Tightening torque bleeder: 8 Nm.

Step 6 - 10 will take approx. 5 minutes, but in most cases it's not necessary, because there is still brakefluid in the hoses, levers and/or calipers.So, in those cases, you can skip these steps and continue from this point.

And now the fine-tuning can start: the MPH system has to be made 100% air-free.This will take approx. 10 - 15 minutes.

11. Keep the calipers’ bleeder, etc. closed.No need to touch the caliper.

Make sure that the adjustment knob of the brake fluid reservoir(brake lever) is turned anti-clockwise completely.

The syringe should be filled for at least 25%, and connected tothe brake fluid reservoir on the brake lever.

The filling hole of the brake fluid reservoir should remain thehighest point and the brake caliper the lowest point of the MPHsystem until the end of this procedure.So, air can go up in the MPH system and escape via the shorttransparent tube into the syringe. Brake fluid will go down into theMPH system.

The syringe should be kept in upright position.

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12. By pulling the brake lever fast and releasing it slowly (the brakelever will pump the air up and the brake fluid down) and bytapping on the MPH brake hose, the air bubbles will go up.Via the short transparent tube and via the brake fluid in thesyringe, the air bubbles will go out of the MPH brake system. Thiscan be checked visually very easily.Don't squeeze the syringe!

13. While pulling the brake lever and releasing it frequently, turn theadjustment knob of the brake fluid reservoir clockwise (in) andanti-clockwise (out) a few times, to push the last bits of air out ofthe reservoir.Turn the knob all the way in and out, approx. 10 full turns.

14. If no air-bubbles come up through the brake fluid column in thesyringe any longer, we can assume that the MPH system is 100%without air.

15. Turn the adjustment knob of the master cylinder anti-clockwise allthe way, to have the largest brake fluid volume inside thereservoir.At least 10 full turns.

16. Disconnect the syringe from the small transparent tube andunscrew the connector from the brake fluid reservoir.

17. Turn the adjust knob of the fluid reservoir clockwise carefully, untilyou see the oil appear in the small hole for the lock screw.

air

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18. Reinstall lock screw, cap and O-ring.If the small lock screw is screwed in, there should be no air left inthe reservoir.A little bit brake fluid will be spilled.Use absorbing paper or a rag to remove this.

19. Tighten the lock screw well into the master cylinder.Recommended tightening torque lock screw: 5 Nm.

20. Pull the brake lever and check the function of the MPH brakesystem: both sides actuated, disc in center, correct distancebrake pads to rotor ?

21. Turn the adjuster, pull the brake lever and check the function ofthe MPH brake system again.Repeat step 20 and 21 until the function is okay.

Warnings !F To avoid brake fluid spillage on the rotors or brake pads, causing contamination of the brake pads,

it is advisable to cover the vital parts with a rag before proceeding and to take out the wheels.

F If the bleeder is not sufficiently tightened when using the disc brake, brake fluid may leak on therotor, causing loss of friction between brake pads and rotor. This can have serious consequencesfor the rider.

F Protect vital parts of the bike from spilling brake fluid by holding a rag around the fluid reservoir.Brake fluid is hazardous and aggressive and damages not only your skin, but the paintjob andplastic parts of the bike as well.Use protective gloves and safety goggles when working with brake fluid.

F Once there is brake fluid or lubricants like oil, grease, Teflon™ and silicone spray on the brakepads, they are worthless: no more brake function.So, don't forget to protect brake pads and rotors when working with brake fluid or lubricants.Or, even better, remove these parts.

F 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.

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6. Trouble shooting and -prevention

When riding down a slope, continuous braking with MPH discbrake will generate a lot of heat. The heat will be conducted tothe brake fluid. The temperature of fluid can increase up to120º C. or more. As shown in the illustration, the stroke ofbrake lever will become shorter.

When this happens, the rider MUST stop riding to let thebrake system cool down. No liquid shall be used to cool thebrake components. That will lead to distortion of the rotorsand change the characteristics of the materials.Meanwhile, the rotors and the calipers should NOT BETOUCHED, because they can be very hot.

If the rider keeps using the brakes, the brake fluid will beheated to 150º C. or more. Then the brake pads will wear outvery quickly.If the pads are worn, the brake force is decreased, even if thebrake lever is pulled completely to the handlebars (seeillustration on the left). This is extremely dangerous.

After the temperature has reduced, the adjuster on the brakelever can be turned clockwise to bring the brake pads closerto the rotor (to compensate the pad wear out).

Parts: 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.

How to change? See: “Maintenance; replacement of brake pads”.Remarks: Only use MPH genuine parts.

Do NOT use MPH brake pads “model year 2000” (2 holes in each pad).Two pads must be replaced at the same time.

Long

Short

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Parts: Rotors

When to change? If, after assembly to the hub, the rotor is not straight (more than 0.3 mm. outof line).If there are serious damages on rotor surface that lead to longer brakingdistance.

How to change? See the instruction “Mounting the brake system on the bicycle”.Remarks: Only use MPH genuine parts.

Replace the six rotor fixing screws as well.See “Mounting the brake system on the bicycle; assembly of rotor”:six fixing screws should be tightened in a crossed pattern.LoctiteTM (or a similar product) has to be used.

max. 0.3 mm.

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Parts: Calipers

When to change? Brake fluid holes choked up, two pistons do not work properly at the sametime.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 rotorsand to set the rotors exactly in middle of the brake pads.LoctiteTM (or a similar product) has to be used.Note that there is difference between front and rear calipers.Watch the orientation of “MPH” characters:

Front Rear

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Parts: Brake lever

When to change? Brake fluid holes choked up: the adjuster does not work.Brake fluid holes choked up: the piston does not work properly.Brake fluid leakage due to seal failure.The clamp doesn’t fix the master cylinder effectively.Mal-function of brake lever.

How to change? This should be done by your authorised Giant dealer.Remarks: Only use MPH genuine parts.

Note that there is difference between right and left brake lever.Small parts are the same, but the way these small parts are assembled isdifferent.

Parts: Brake fluid

When to change? After replacement of :- brake lever or- calipers or- hose or- bleederLack of brake fluid in MPH brake system due to leakage.Replace brake fluid for MPH at least every two years.

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.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.

Left Right

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Parts: Hose

When to change? 1. Hose leakage (e.g. due to impact).2. The connector / connector nut can't be tightened, resulting in brake fluid

leakage.3. At least after two years use.

How to change? This should be done by your authorised Giant dealer.Remarks: 1. Only use MPH genuine parts.

2. Use two copper washers at both ends.

Parts: Bleeder

When to change? 1. Bleeder loosened and tightened more than 5 times.2. 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: 1. Only use MPH genuine parts.2. Make sure that the threads are completely coated.