Formula 4 Racing User manual

MANUALE ISTRUZIONI
OPERATING MANUAL
MANUEL D’INSTRUCTIONS
BETRIEBSANLEITUNG
MANUAL DE INSTRUCCIONES
MANUALE ISTRUZIONI
OPERATING MANUAL
MANUEL D’INSTRUCTIONS
BETRIEBSANLEITUNG
MANUAL DE INSTRUCCIONES

GB
LIMITED WARRANTY
Congratulations on your purchase of this genuine Formula product. If any
component of the this new Formula product (hereinafter referred to as “war-
ranted item”) is found to be defective in materials or workmanship within the
terms and conditions of this Limited Warranty (the "Agreement"), the defecti-
ve component will be repaired or replaced, at the option of Formula (herei-
nafter referred to as “Formula”), free of charge, within thirty (30) days after
receipt of the product by Formula.
1. NOT COVERED. This warranty does not cover damage resulting from
accidents,alteration,neglect,misuseorabuse,contamination,lackofrea-
sonable or proper maintenance, corrosion, improper assembly, repairs
improperly performed or replacement parts improperly installed, use of
replacement parts or accessories not conforming to Formula 's specifica-
tions, use of component parts not manufactured or supplied by Formula ,
modifications not recommended or approved in writing by Formula , or
normal wear and deterioration occasioned by the use of the product. This
warranty also does not cover any expenses related to the transportation
of the warranted item to or from an authorized Formula Service Center,
risk of loss of the item while in transit, labor costs to remove the product,
or compensation for inconvenience or loss of use or profits while the pro-
duct is not in service.
2. PURCHASER. This warranty is made only with the original purchaser of
the product and does not extend to any third parties. The rights of the
Purchaser under this warranty may not be assigned.
3. TERM. Thislimited warranty shall applyonly in those instanceswhere the
defect in material or workmanship appears within twelve (12) months of
the date of purchase of the warranted items by the original Purchaser.
This term shall not be extended for any items repaired or replaced under
warranty.
4. ENTIRE AGREEMENT. This warranty supersedes any and all oral,
express, implied or written warranties, statements or undertakings that
may previously have been made, and contains the entire agreement of
the parties with respect to the warranty of this product. Any and all war-
ranties not contained in thisAgreement are specifically excluded.
5. DAMAGES. Except as expressly provided by this warranty, Formula
Formula SHALL NOT BE RESPONSIBLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES ASSOCIATED WITH THE USE OF
THE WARRANTED ITEM OR A CLAIM UNDER THIS AGREEMENT,
WHETHER THE CLAIM IS BASED ON CONTRACT, TORT OR
OTHERWISE. The foregoing statements of warranty are exclusive and
in lieu of all other remedies. Some states do not allow the exclusion or
limitation of incidental or consequential damages, so thus limitation or
exclusion may not apply to you.
6. DISCLAIMER. ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE AND ALL IMPLIED
WARRANTIESARISINGFORMACOURSEOF DEALING,USAGEOF
TRADE, BY STATUTE OR OTHERWISE, IS HEREBYSTRICTLY LIMI-

TEDTOTHETERM OF THIS WRITTEN WARRANTY. ThisAgreement
shall be the sole and exclusive remedy available to the Purchaser with
respect to this purchase. In the event of any alleged breach of any war-
ranty or any legal action brought by the purchaser based on alleged negli-
gence or other tortuous conduct by Formula , the Purchaser's sole and
exclusive remedy will be repair or replacement of defective materials as
stated above. No dealer and no other agent or employee of Formula is
authorizedto modify,extendor enlarge this warranty. The performance of
any warranty service under thisAgreement is not an admission or agree-
ment that the design or manufacture of a product is defective.
7. PROCEDURE. In the event of a defect covered by this warranty, the pur-
chaser should contact an authorized Formula Service Center or :
To be honored, claims must be submitted within the twelve (12) month
warranty period and within thirty (30) days of discovery of the defect or
nonconformity. The determination whether the defect is covered by this
warranty is within the sole discretion of Formula. Formula reserves the
right to discontinue products and to change specifications for existing pro-
ducts at any time without notice and shall not be obligated to incorporate
new features into products previously sold, even if those products are
returned under a warranty claim. Formula may replace defective parts
with similar parts of similar quality in the event that identical parts are una-
vailable
The purchaser must obtain advance authorization in writing before retur-
ning any product to a Formula Service Center for warranty inspection. A
return authorization number will be issued and must conspicuously
appear on the outside of the product's packaging. The issuance of an
authorization number does not constitute acceptance of the claim, which
will be evaluated by the Service Center upon its inspection of the product.
The product should be securely packed to prevent damage during ship-
ment and must be accompanied by a letter specifying or including the fol-
lowing items of information:
a. dated receipt or other proof of date of retail purchase;
b. a copy of this warranty;
c. Formula part number;
d. detailed description of the problem experienced with the product,
including a chronology of efforts made to correct the problem;
e. identification of the components used in conjunction with the product;
f. estimate of product usage: (i.e. accumulated time in service); and
g. yourname,address,andwrittenauthorizationtoshiptherepaired pro-
duct back to you freight collect ("C.O.D.").
8. OTHER RIGHTS. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state.
9. APPLICABLE LAW. Any disputes arising out of this Agreement or the
use of this product will be governed by the laws of the country of Italy and
will be decided by the Courts of Prato Italy.
10.WARNING.
This warranty is subject to the Italian laws.

GB
GENERAL INDEX
S.1 General rules
S.2 General safety rules
S.3 Braking system safety rules
Foreword
1.0 Installation
1.1 Installation of the brake rotor
1.2 Installing the kit
2.0 Operating guidelines
2.1 Lever reach adjustment
2.2 Hose lenght adjustment
2.3 Air bubble removal
3.0 Maintenance
3.1 Brake fluid replacement
S.1 GENERAL RULES
This manual provides information for a safe and proper mounting
and use of the braking system and for its rational maintenance.
Constant compliance of its rules assures the braking system’s
best performances, duty economy, a longer lifetime and allows to
avoid common causes of accidents which may occur during
operation and maintenance.
• WARNING Follow carefully the SAFETY RULES for a proper
use of the braking system.
In this handbook, within each paragraph, you will find the following safety
notices:
•CAUTION: Directs your attention toward unsafe practices
which could result in damages to the equipment.
• WARNING: Directs your attention toward unsafe practices
which could result in personal injury or damages to the
equipment.

S.2 GENERAL SAFETY RULES
• FORMULA’s brakes have been designed to be exclusively used on
two-wheel vehicles driven by human propulsion. Any other
application may result in personal injury and voids the warranty by
raising the manufacturer FORMULA from any and all
responsibilities for possible damages.
• Theoperatorcharged with the installation shall be skilled, know well
the braking system and have read both this operating manual and
the relevant enclosed documents from front to back.
• Do not introduce your hands close to or within moving parts;
always use strong five-fingered gloves ensuring sensitivity and a
powerful grip.
• Do not change the parameters of the braking system to obtain other
performances than those established by the manufacturer.
• Before starting any mounting operations, carefully check for
dangerous conditions of the working site. If too dark, use all
available light sources and make sure they work properly
before starting to work.
• Concentrate and take the due precautions before using
components which could cause damages.
• When using the bike, it is advisable to wear an helmet and to drive
with care and sense of responsibility.
• All extraordinary maintenance operations have to be carried
out solely by personnel authorized by FORMULA.
S.3 BRAKING SYSTEM SAFETY RULES
• The brake rotor has to be assembled on wheels conceived
to be used with a disk brake. A wheel with spokes of
insufficient section or with radially spoked wheels may
collapse under the action exerted by the braking system and
result in serious personal injury or accidents.
• Check the spoke tension and condition frequently.
Adamaged spoke may break suddenly, interfere with the braking
system and result in serious personal injury or accidents.
The bike frame or fork shall be suitable for mounting the braking
system. Only in this case, the correct dimensioning of the supports
and the suitable positioning of the elements which form it is
assured.
• Do not install the braking system by using adapters or supports
supplied by other manufacturers. This will void the braking system
warranty immediately. Use only parts manufactured or
recommended by FORMULA.
• THE BRAKING SYSTEM MAY NOT HAVE THE HIGHEST
BRAKING EFFICIENCY WHEN NEW, THEREFORE A BREAK
IN PERIOD AND LONGER DISTANCES SHOULD BE
ALLOWED FOR UNTIL THE SYSTEM IS BROKEN IN.

FOREWORD
Recommended lubricants and clea-
ning products
Hydraulic brake fluid
Use only DOT 4 or Shell’s Donax
UB® hydraulic brake fluid from
sealed containers.
Do not leave the container open over a
period of time because this product
absorbs the moisture in the air, which
alters its physical characteristics.
Formula recommends to replace the
fluid in the system every 2 years.
WARNING
Besides damaging the
paintjob, the brake system’s
fluid is extremely hazardous if
it comes in contact with the
eyes or skin. In the event of
eye contact flush with fresh
water and seek medical
assistance immediately.
Grease
Use silicon grease for EPDM seals.
Formula recommends: UNISILKON
TKN 1011 by KLUBER.
WARNING
Use of inappropriate type of grease
may compromise the integrity of
the seals and cause damage to the
system and therefore to the user.
Donax UB
Brake and Clutch Fluid
Universal Brake fluid
Execeeds DOT 3
and DOT 4
1.0 L e
Fig. 1
Fig. 2

1.0 INSTALLATION
1.1 Installing the brake
rotor
WARNING: read the safety rules
Place the disc brake A(fig. 1) on the
hub Bof a pre-assembled wheel,
paying attention to the rotation sense
given by the arrow Cengraved on the
rotor’s flange, and lock it in place with
the specific M5 screws supplied which
have to be tighten in a crosswise
fashion with a 5,75 Nm ± 5%.
Accurately clean the rotor from any
trace of grease or oil with isopropyl
alcohol.
Fig. 3
Fig. 4
1
1.2 Installing the kit
Proceed followingly:
-Place the pump body on the bar in
the desired position and lock it in
place with the screw (1) using a tigh-
tening torque of 2,5 Nm ± 5%.
The two screws have to be tigh-
tened alternately and at the
same distance.
If the hose length needs to be adjusted
see paragraph 2.3, if not proceed with
the positioning of the hose on the bicy-
cle, bearing the following in mind:
– thehose needs to beattached to the
fork or frame in a way that does not
interfere with the free flow of fluid
through the hose;
–the hose should not make curves
smaller than a 40 mm diameter and
should not interfere with any moving
part of the bicycle;
–for easy assembly of the hoses on
the bicycle, formula has developed a
custom made hose holder zip tie
that can be ordered as an
accessory.

WARNING
An incorrectly mounted hose or
a hose that comes in contact
with moving parts of the bicycle,
can significantly degrade braking
performance and cause serious
accidents.
To adapt the frames or forks to the
various diameters of brake rotors avai-
lable, FORMULA supplies different
adapters which can be mounted
between the fork or frame and the
brake caliper.
CAUTION
Only a correct mounting of the
system and it’s various support ele-
ments ensures the safety of the
cyclist and the exceptional perfor-
mance of FORMULA disk brakes.
Mount the front caliper on the fork
frame by using only screws A(fig.5)
that come with the system, making
sure that the front caliper is the one
with double lightening slots Band
the inscription “FRONT”.
Mount the rear caliper on the fork
frame by using screws C(Fig.6)
that come with the system, making
sure that the rear caliper is the one
with a single lightening slot and the
inscription “REAR”.
-First apply a light adhesive on the
screws and fix at 9Nm ±5% torque.
WARNING
Never install the Formula brake
system with adapters that are
not supplied by Formula. This
will void the warranty. To avoid
serious accidents use only
parts made by Formula and
Fig. 5
A
AB
B
C
C
D
Fig. 6

Fig. 7
= =
mounted on specially preset
forks and frames.
Mount the wheel and lock it in place
with the quick release fix it with the
fasteners, turn it slowly to check that
the rotor is in the center of the brake-
pads and none of the pads rub on the
rotor (fig. 7).
Before riding the bike squeeze the
brake lever 2 or 3 times in order to
bring the pads at the right distance
from the rotor.
WARNING
The brake system needs a break
in period. FORMULA suggests to
brake at least a hundred times
before considering the system
broken in and fully efficient.
2.0 OPERATING INSTRUC-
TIONS
2.1 Lever reach adjust-
ment
To adjust the lever position it is neces-
sary to remove the locking knob A
(Fig.8) and with a TORX® -T15 wren-
ch act on the internal screw of the
lever by regulating the distance H
according to your preferences. Lock
the knob in place again after comple-
ting the adjustments.
WARNING
Lever adjustments should be
made one time only when
mounted on the handlebar for
the first time.
WARNING
If damaged, it is vital to change
the dust cover. Failure to
observe this, results in grave
danger for the user.
B
Fig. 8

2.2 Hose lenght adjustment
Remove the hose fitting connector
A(Fig 9) using an 8mm open
wrench to loosen it. Once you
have decided for the desired hose
lenght, cut the part in excess using
a cutter. Insert connector Aagain in
the hose and cut to measure
making sure not to cause any oil
leakage then assemble a new
biconical bush Band a new plug C
and tighten them firmly. Slightly coat
the biconical bush Band the screw
thread with some grease then
retighten on the connector Dthe
parts left on the pump.
WARNING
Be careful while using a
razorsharp cutter or blade.
Do not use blades or saws that
could deform or lacerate the
hose in such a way to cause loss
of fluid or inefficiency of the
system.
AN UNNECESSARILY SHORT
HOSE NOT ONLY CAUSES
STEERING PROBLEMS but can
also cause strain on the hose
which may result in its
disconnection from the caliper or
pump lever. Using the correct
lenght of the hose is vital to
achieve maximum efficiency of
the system.
WARNING
Should biconical bush B (Fig 8)
not be tightened enough, as
prescribed, it might come loose
while riding. This causes hose
detachment and consequently a
dangerous situation for the rider
and for anyone found nearby.
DCB
A
Fig. 9

Note: Put a small quantity of
grease on the connector’s
thread.
2.3 Air bubble removal
Foreword
These operations, if necessary,
must be performed after
completing hose adjustment.
- Use a screwdriver introduced in
the specific slots to loosen and
remove cover E(Fig. 10).
-Loosen the grub screw C(Fig. 10)
and remove the O-ring from the
coupling screw head having care
not to damage the particularly
small-sized O-ring.
-Place the syringe Dfilled with 10 ml
of oil on the coupling and screw it
firmly in place.
-Pulltheleverandlockitto the hand-
le bar by means of an elastic, as
shown in figure 12.
- With the syringe always steered
upward slowly suck out all the air
containedinthepipe.Thepresence
of air in the pipe is evidenced by the
bubblescoming up throughthe fluid
head contained in the syringe;
- Release the syringe piston and
repeat the procedure as many
times as necessary until you have
removed all the air from the pipe.
WARNING
Before removing the syringe it
is necessary to release the
pump lever that had previously
been locked (Fig. 12).
Check out the quantity of oil
contained in the membrane
inside the pump and if neces-
sary slightly press on the syrin-
ge piston to fill up the membra-
ne.
Attention, an excessive pressu-
re may damage the membrane.
Fig. 11
C
E
Fig. 10
Fig. 12

-Remove then the syringe from the
connector.
-Reassemble the grub screw and
the O-ring paying the latter special
attention.
Remark:
To invert the brake controls
procede as follows:
-Detach connector A (fig 13)
from its pump and invert both
hoses. Reassemble by
proceeding as in 2.3.
Fig. 13
3.0 MAINTENANCE
WARNING: read the safety rules
Periodically clean the caliper in relation
to the bike use, the route length, and
the weather conditions using a
biodegradable degreaser suitable for
the caliper.
Carefully clean all moving parts.
CAUTION:
ISOPROPYL ALCOHOL is
recommended to clean the disc
brake. The use of any other
product may be hazardous to
the user.
CAUTION: Do not touch the
rotor right after its use as it
might cause you severe injury.
3.1 Changing the brake
fluid
Periodically, in relation to the bike
use it is necessary to entirely
change the system’s brake fluid.
This operation must be carried
out only by personnel authorized
by Formula.

CERTIFICATO DI GARANZIA
WARRANTY CERTIFICATE
Data di acquisto/Date Purchased Nome e Cognome/Name Si approvano espressamente le clausule, delle condizioni di garanzia,9) Foro competente, 10) Scelta della legislazione in
deroga degli art.1341-1342 cod. civ.
Condizioni di Garanzia / Warranty Conditions The point 7 and 8 are exspressly, according to Art. 1341-1342 civil code. Tel./Phone Citt‡/City Indirizzo/Address
Da compilare e spedire/To be filled in and sent
Timbro del rivenditore/Retailer's stamp
Firma/Signature
Stato/State
Mod. Et‡/Age Cap/Zip
Numero di serie/Seriel number

Conservare compilato/Coupon to be kept fillet-in
CERTIFICATO DI GARANZIA
WARRANTY CERTIFICATE
Data di acquisto/Date Purchased Nome e Cognome/Name Si approvano espressamente le clausule, delle condizioni di garanzia,9) Foro competente, 10) Scelta della legislazione in deroga degli art.1341-1342 cod. civ. Condizioni di Garanzia / Warranty Conditions The point 7 and 8 are exspressly, according to Art. 1341-1342 civil code. Tel./Phone Citt‡/City Indirizzo/Address
Timbro del rivenditore/Retailer's stamp
Firma/Signature
Stato/State
Mod. Et‡/Age Cap/Zip
Numero di serie/Seriel number

12
4
3
5
6
7
8
9
10
11
12
30
31
32
13
29
28
27
24
22
21
25
26 16
15
14
34
33
23
20
17 18 19
POMPA
Pumpl ever
Maître-cylindre
Pumpe
Bomba

37
36
35
52
53 54 55
56
59
58
51
50
0039
40
48
41
57
47
0038
44 45
49
46
42
43
PINZA FRENO
Caliper
Etrier
Bremssattel
Pinza

Note:
Note
Note
Note
Note:

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