CLEAN THE OUTSIDE OF THE BRAKE LINES, CALIPER, AND LEVER WITH THE DETERGENT
AND HOT WATER SOLUTION, RINSE WITH CLEAN WATER, AND ALLOW TO AIR DRY, AND
WASH YOUR HANDS! IF THE ROTORS ARE CONTAMINATED WITH BRAKE FLUID, CLEAN
THEM WITH THE DETERGENT AND HOT WATER SOLUTION, RINSE WITH CLEAN WATER,
AND ALLOW TO AIR DRY. IF THE PADS ARE CONTAMINATED, DISCARD THEM AND USE NEW
PADS.
1. Thread the caliper pad clearance adjusters all the way out (for maximum pad clearance.)
2. Remove the wheels and the brake pads from the bike. Pull back the plastic cover at the brake
lever, exposing the brake line threaded sleeve fitting.
3. Using an 8mm wrench, unthread the fitting
and pull the brake line out of the brake lever
master cylinder. Slide the cover and threaded
fitting up the brake line well clear of where
you'll be cutting.
Do not activate the brake lever with the line
disconnected!
4. Use a razor knife or hydraulic tubing cutter
to trim the hydraulic line to the desired length.
Cut the end of the tubing square and at least
1cm from the end to avoid cutting the old tub-
ing insert. Do not use a serrated knife or a pli-
ers-type cutter, as these will damage the end
of the brake line.
5. Slip a new compression ferrule over the cut
end of the tubing, on far enough so that
0.5mm of tubing extends through the ferrule.
Orient the fitting with the sharp edge toward the threaded sleeve (away from the brake lever master
cylinder). Then press the barbed end of a new hydraulic line insert into the end of the tubing. There
should be no more than 1.6mm between the end of the tubing insert and the compression ferrule.
See Fig. 7.
Important: Use a new compression ferrule and line insert each time the brake line is shortened.
Several spares are included with the brake set.
6. Press the end of the tubing into the master cylinder until the ferrule makes contact with the inside
of the master cylinder, checking to make sure that the brake line is clear of tires and wheels or any
other possible snags. Slide the threaded sleeve up to the master cylinder and screw it in, being care-
ful not to cross thread the fitting. Tighten the threaded sleeve to 69-78 In-Lbs. (8-9 Nm.)
7. Tug gently on the brake line to make sure the fitting is fully threaded in.
8. Before reinstalling the wheels or brake pads, or riding the bike, you must bleed the brake system.
See the next section on brake bleeding for instructions.
BRAKE SYSTEM BLEEDING AND FLUID CHANGE
CAUTION: USE ONLY CODA DISC BRAKE FLUID. OTHER TYPES OF BRAKE FLUID MAY NOT
BE COMPATIBLE WITH THE EXPERT DISC'S SEALS AND HYDRAULIC SYSTEM.
CAUTION: REMOVE WHEEL AND PADS FROM THE SYSTEM BEFORE BLEEDING THE BRAKE
SYSTEM! MAKE SURE THAT THE PADS AND BRAKE ROTOR STAY CLEAN AND FREE OF OIL,
GREASE, AND BRAKE FLUID. BEFORE HANDLING THE BRAKE PADS OR ROTOR, CLEAN
8.
Fig. 7
