SR SUNTOUR Disc Brake Owner's Manual DR-XCC-MC - dbap GmbH

SR SUNTOUR Disc Brake Owner’s Manual DR-XCC-MC
DR-XCC-MC mechanical disc brake gives you the best fitted products which have been delicately
designed and passed severe field and lab tests to achieve the best braking performance.
Usually the disc brake you purchased has been correctly installed and properly adjusted in
bikes by authorized dealers or retailers. In some cases you may buy the disc brake package
independently to replace your existing direct-pulled or regular canti-brake of your bike. Although
the SR SUNTOUR disc brake is designed for easy installation, it is suggested to install
by trained and experienced technicians or mechanics with proper tools. If you decide to install
it by yourself, please read and follow the manual’s instructions carefully before installation.
This manual provides you important information about installation, operation and maintenance.
If you have any problems with installation or braking performance, please stop installing or riding
and contact your nearest authorized retailer for assistance.
Features:
1. 7/8/9 speed compatible.
2. Easy installation and low maintenance.
3. International standard fittings.
4. Brake pads of high friction level for all weather.
5. Quick and easy pad replacement.
6. Compatible with regular V-type brake lever.
7. Manual-adjusting turning knob for pads wearing off both sides.
Components Required:
1. Caliper: 1 per wheel
2. Levers: “V” stroke brake levers, 1 pair.
3. Rotor: 2 mm Stainless steel rotor, 1 per wheel, Front rotor = 160mm,
Rear rotor = 160mm (For Manitou© 2000 fork, Front rotor : 160mm).
4. Mounting Bolts: M6 x 18mm with washer, qty 4 (qty 2 for Manitou® 2000 fork)
5. Rotor mounting screws: M5 x 11mm, qty 6 per rotor
Tools required
• Allen wrench 5mm
• cable cutter
• pliers
Disc Brake Owner’s Manual DR-XCC-MC, page

Installation Steps:
Please read these instructions thoroughly prior to attempting installation for a better understanding
of this product and how it works. If you are unsure as to a component, installation
procedure, or have any other relevant questions, please contact a professional bicycle dealership.
step1. Mount rotor to hub by aligning bolt holes on rotor with holes on hub rotor
flange, arrow side out. Using the M5 x 11mm screws, secure in a star pattern
tightly. (locking torque 40-50 kg-cm) [photo 1]
Caution:
1. Be sure to seat the hex wrench firmly into the bolt head before tightening or
loosening. Failure to do so may result in a stripped out bolt head.
2. The mounting screws will need to be replaced after multiple installations and
removals, as the Nylock compound wears off after 3-4 uses. Please contact
a Professional Bike shop to obtain replacements.
3. Turn several turns into threads with hand and then use tools when tightening
mounting bolts and the cable fixing bolt to prevent stripping the threads.
step2. Install wheel into fork/frame. Check wheel for proper alignment in dropouts,
then tighten the wheel securely. [photo 2]
step3. Remove compression module from between brake pads.
step4. Mount caliper to fork or frame using the 2 M6 x 18mm Allen head bolts with
washers on the side of adapter. Secure tightly. (locking torque 55-65 kg-cm)
(The sticker on the back side of adapter indicates F=10.5 for front wheel and
R=15.25 for rear wheel.) [photo 3]
step5. Push the brake arm to lock the rotor. The caliper will move automatically and
adjust into position. Securely tighten the mounting bolts (2 - M6 x 18mm) on
the caliper side on the adapter. (locking torque 55-65 kg-cm) Then release the
brake arm. [photo 4]
step6. Turn pad adjuster B on the rear side of caliper about 1/5 turn (72deg.) counter-clockwise
to make the right pad clearance. [photo 5]
step7. Spin wheel in forward rotating direction. Rotor should run freely between
brake pads. If not, turn back the pad adjuster B on the rear side of caliper
about 1/5 turn (72deg.) clockwise and loosen the mounting bolts ( 2 - M6 x
18mm) on the caliper side on the adapter and repeat step5, 6.
step8. Install lever onto handlebar, Adjust angle to rider preference. Tighten clamp
bolt securely. Loosen adjusting barrel and lock nut so that the grooves on
the adjusting barrel, lock nut, and lever are aligned. Lightly lubricate cable
with clear or white grease. Secure cable end into lever. Guide cable through
grooves, tighten the lock nut against the top of the adjusting barrel and screw
the adjusting barrel fully into the lever body. Slide cable through housing.
[photo 6]
Disc Brake Owner’s Manual DR-XCC-MC, page

step9. Guide housing through cable guides on frame (rear brake only). Guide cable
through cable anchor. Cable should be between the cable lock plate and
the brake arm. Snug cable fixing bolt. Zip tie cable to fork. (front brake only)
Tension cable without acting brake arm. Cable should be tight with no sag.
Secure cable fixing bolt tightly. (locking torque: 55-65 kg-cm) [photo 7] Cut
excess cable leaving approximately 5cm length. Install cable end cap and
crimp tight.
Caution:
The angle position of the brake arm has been specially designed. Do not change
its angle position while pulling the brake cable. Otherwise, the brake performance
will be affected. Besides, be sure not to adjust the adjusting barrel on the
lever casually or it will also make bad influence on the brake performance.
step10. Test the brake by squeezing the brake lever several times to determine if the
clamping pressure is adequate. The brake pad clearance has been set at the
factory. The brake actuating stroke on the lever end will be about 1-2cm. (recommended).
If the clamping pressure is not good (brake actuating position not
right), the possible reasons are:
1. The brake cable is not tight during fixing the fixing bolt on the brake arm.
Solution: Inspect the brake housing making sure the cable is secured in the lever and
all ferrules are seated properly in the cable guides. Retighten the brake cable if it is not
taut.
Warning:
Do not use the brake lever adjusting barrels to tension the cable. This will cause
the brake modulation to change, resulting in decreased braking action.
2. The clearance between pads is not right or the rotor contact pads.
Solution: View the position of the rotor in the slot of the caliper:
1) If the rotor is in the center line of the slot, adjust the pad clearance per Brake
Pad Adjustment instructions.
2) If the rotor is not in the center line of the slot, disassemble the mounting bolts
(2-M6 x 18mm) on the caliper side on the adapter and remove caliper, then adjust
according to step 4, 5 of Brake Pad Replacement instructions.
Notice:
The braking performance may be less than 100% at first until the pads are
broken-in and can achieve their normal braking performance. After the first few
rides, re-tension the brake cable to take up the initial cable stretch that occurs.
Disc Brake Owner’s Manual DR-XCC-MC, page

Repair and Maintenance:
Brake Pad Adjustment
The brake pads will be worn off during braking, which means the clearance between
two pads will be bigger and the braking feeling will be worse. Therefore, it might be
necessary to adjust the clearance between two pads by turning the pad adjusters so as
to get the original braking performance.
step1. Right turn (clockwise) pad adjuster A till A side brake pad touches rotor, check
rotor not to be pushed by brake pad with eyes. [photo 8]
step2. Right turn (clockwise) pad adjuster B till B side brake pad touches rotor, then
there is no gap between rotor and both pads. [photo 5]
step3. Left turn (counterclockwise) both pad adjusters A and B about 1/5 turn
(72deg.) and get the right clearance between rotor and both pads. The brake
actuating stroke on the lever end will be about 1-2cm. (recommended). Turn
more will get more clearance and turn less will get less.
Caution:
Brake Pad Replacement
Be sure not to adjust the barrel adjuster on the lever casually or it will make bad
influence on the brake performance.
Check the brake pads for wear. At 0.5mm or less for the thickness of brake lining, the
pads are worn and must be replaced for continued safe braking.
Tools required: Pliers
step1. Loosen the mounting bolts (2 - M6 x 18mm) on the caliper side on the adapter
and remove caliper. Left turn (counterclockwise) both pad adjusters A and B to
the dead end. [photo 9]
step2. Pull pad (A side) out through the slot of the caliper with pliers or with hand first
and then pull pad (B side) out. [Photo 10, 11] Clean out the caliper. Dispose of
the old pads properly.
step3. Insert new pads according to the opposite procedure of removing pads.
step4. Put caliper into rotor with the slot matching. Right turn pad adjuster B to another
dead end, then right turn pad adjuster A till it clamp rotor tight. Left turn
(counterclockwise) pad adjusters B about 1/5 turn (72deg.) and get the right
position of pads
Disc Brake Owner’s Manual DR-XCC-MC, page

LIMITED WARRANTY
SR SUNTOUR warrants the disc brake to be free from defects in materials and workmanship
under normal use for a period of two years from the date of purchase. In no
event shall this limited warranty apply to any defect of the suspension fork caused by:
improper installation, disassembly, reassembly, intentional breakage or damage, alterations
or modifications to the rear shock by the user or other party or any unreasonable
use or abuse of the product or any use for which this product was not intended.
The obligation of this limited warranty shall be limited to repairing or replacing the
disc brake or any part for which there is a defect in materials or workmanship during
the two years following the date of purchase. To validate this limited warranty the purchaser
must submit this warranty card to SR SUNTOUR within 30 days after purchase
of the disc brake. Any alteration of, or tampering with the warranty card automatically
terminates this limited warranty.
SR SUNTOUR makes no express or implied warranties of fitness or merchatability of
any kind, except as set forth above. SR SUNTOUR’s liability hereunder is expressly
limited to repair or replacement of the product. Under no circumstances will SR
SUNTOUR be liable for incidental or consequential damages. Some jurisdictions do
not allow the exclusion or limitation of liability of incidental or consequential damages,
so the above exclusion may not apply to you. This warranty gives you specific rights
and you may have other rights which vary from jurisdiction to jurisdiction. In all places,
the purchaser should contact the place of purchase for information about warranty
service.
Contact and Service address
check our web site http://www.srsuntour-cycling.com for local distrutors and
service centres.
SR SUNTOUR INC.
No.7 Hsing Yeh Road, Fu Hsing Ind.
Zone.
Changhua.50606
Taiwan, R.O.C.
Phone: +886 (4) 7695115
Fax: +886 (4) 769 4028
E-mail: orders@srsuntour.com.tw
SR SUNTOUR USA
P.O. Box 61988
Vancouver WA 98666
Canada
Phone: +1 (360) 737 6450
Fax: 1 (360) 737 6452
E-mail: service@usulcorp.com
SR SUNTOUR EUROPE GMBH
Am Marschallfeld 6a
83626 Valley
Germany
Phone: +49 / (0)8024 / 3 03 81 52
Fax: +49 / (0)8024 / 4 73 09 84
E-mail: service@srsuntoureurope.
com
Disc Brake Owner’s Manual DR-XCC-MC, page