Magura JULIE User manual

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printed in germany © MAGURA 2004 All rights reserved
WORKSHOP2005
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1. Introduction 3
2. Safety instructions before the first ride 4
3. Safety instructions before every ride 4-5
4. Transport of the bicycle 5
5. Brake installation 6-9
6. Shortening the hose 10-11
7. Maintenance 12-13
8. Repairs 14-15
9. Bleeding and Filling 15-17
10. Trouble Shooting 17
11. The disc brake wheel 18
12. Accessories 19-20
13. Warranty 20
14. Spare parts exploded view 21
Table of Contents
WARNING:
This symbol means possible danger for your health and even life if you do not follow
the instructions given respectively if the necessary safety measures are not followed.
ATTENTION:
This symbol warns you of inappropriate handling that might cause serious damage to
the material and/or the environment.
NOTE:
This symbol gives you additional information about the general handling of the
product or gives hints to paragraphs in this manual which have to be read carefully.

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1. Welcome to the Passion People!
On the fully hydraulic MAGURA disc brake system Julie the braking force is trans-
mitted to the braking surface by a mineral oil column. The movement of the lever blade
moves a piston, which is integrated in the brake lever (master cylinder). The piston pus-
hes the mineral oil column through the brake hose in the direction of the brake calliper,
where two pistons, on which the brake pads are fixed, are pushed out. The friction bet-
ween the brake pads and the rotor slows down the bicycle and causes both the rotor
and the brake calliper to heat up.
Never touch either the rotor or the brake calliper after long braking as this
may cause serious burns.
You will be pleased to find out that the MAGURA Julie disc brakes offer a superior
braking power even with little hand force applied, no matter what the weather conditions
should be. Particularly in wet weather conditions disc brakes are much more responsive
than rim brakes and transmit their enormous power immediately after activating the
brake lever.
Disc brakes dont’t wear your rims down. However, if they have been mounted incorrect-
ly, they might cause a squealing noise during braking, mainly during wet weather conditi-
ons.
This manual contains important information about the safe installation,
operation and maintenance of your MAGURA disc brake. We urge you to read
it carefully, become familiar with its contents and follow our recommendations
to help make your new braking experience enjoyable and trouble free.
Although the Julie disc brake system is relatively simple you should not
overestimate your technical skills! We therefore advise you to leave the follo-
wing operations to a trained technician of a professional bike shop.
Should there be any further questions or problems we warmly recommend that you
visit our website www.magura.com where you will always find the newest and hottest
tips about all our products. On magura.com you can also download this manual in a
convenient A4 format. Stay tuned with the Passion People!
Thank you for your confidence in our products, enjoy your ride and your
new MAGURA disc stoppers!
Happy trails!
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Brake lever (master cylinder)
MAGURA Julie
Brake calliper and rotor
MAGURA Julie
Congratulations! You have purchased a
fully hydraulic MAGURA disc brake proud-
ly „Made in Germany“. You will be amazed
at the awesome braking power and the
minimum amount of maintenance that is
necessary on our stoppers. Good to
know that you are not alone, millions of
riders worldwide rely on them and every
day our numbers are increasing.

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1. Always make sure that the quick release skewers of your wheels and seat post
are correctly mounted and closed.
incorrectly installed quick release skewers might cause the fixed items to
become loose. Serious accidents with severe injury may result!!
2. Always make sure that the brake lever pressure is o.k. by pulling the lever blade
and ensuring that full braking performance is achieved before the lever blade touches
the handlebars. If this is not the case, pull the lever blade several times (pump) until the
brake pads touch the rotor.
Changing pressure points during a ride might be the result of having air in the brake
system.
See hints about filling and bleeding from on pages 15/16.
4
Always check carefully the following points:
1. Are you already familiar with hydraulic disc brakes? Our brakes might be much
more powerful than the stoppers on which you relied on so far.
Take your bicycle to a safe area to learn the proper braking technique and operation of
your new brakes and your bike.
2. Check that the fornt brake is still actuated by the lever on the side your
are used to braking with. Should this not be the case you wll have to train to
your new setup, otherwise any unintended front wheel braking manoeuvre may
cause an accident leading to possible serious injury! If in doubt get a trained
technician to swap the hoses. For further hints concerning swapping of the
brake hose see page 10 onwards.
3. New brakes and new rotors or brake pads must always be run in by
braking at least 30 times from a speed of 30km/h to achieve the maximum
brake power. Take your bike to a safe place to run in the brake.
4. While riding in extreme riding conditions (total weight of bike plus rider
over 100kg and/or a gradient of more than 15%) always use both brakes
simultaneously to slow your bike down.
5. Do not use the Julie disc brake for downhill sport or on tandems! Any misuse
might cause serious accidents with fatal injuries to yourself and others!
6. Are you familiar with the other components on your bike such as gears, clipless
pedals and suspension units? Always practise using your bike in a safe area to improve
your handling abilities before using it on the road. Consult the user’s manual of your bike
to learn more about this.
7. For your own safety always wear a helmet when you ride a bicycle. Make sure as
well that you wear suitable clothing and footwear.
2. Before the first ride
3. Before every ride

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3. Always make sure that the brake system does not have any leaks by activating
the lever blade, holding it and checking the hose connections and reservoir cover for
eventual leaks. (Also see page 11)
4. Always protect your rotors and brake pads from oil and lubricants (e.g. by lubri-
cating your chain). Avoid detergents and soap on the brake pads. Contaminating the
pads with oil and lubricants will cause a permanent loss of braking power. Such contami-
nated pads can no longer be used and should be replaced! Clean a contaminated rotor
with dishwater or alcool. See further hints about changing the brake pads on pages
11- 13.
5. Release your brake lever and check whether your wheel moves freely and without
drag. Check eventually whether the wheels are correctly mounted and if the quick relea-
se skewers are tightened sufficiently. (Also see page 9)
6. Are your tires in a good condition, and have they enough air pressure? Test this
with your fingers. Lift up your bike and turn the wheels of your bike. An insufficient rotati-
on might be due to damaged tires, broken axles and/or broken spokes.
7. Pick up your bike and let it drop from a moderate height. Listen for any rattling
noises. If any are heard check the bearings and all screwed connections.
8. Always follow the instructions given in the owner’s manual of your bicycle.
Never use your bicycle if any of the points mentioned above relate to your
bicycle! Consult a professional bike mechanic if you feel unsure. A faulty bicy-
cle may result in serious accidents with possible fatal injuries of the rider! Be
careful to check always to check the following points:
In case of a disc brake equipped bicycle you should always keep in mind
the following points:
Never activate the lever blade without the brake pads in place and the wheels
mounted. In case this should have happened see page 10 of this manual.
Never throw away the transport device, which has been delivered with the brake.
Always clip it between the brake pads whenever the wheel is removed (e.g. transport
of the bike).
Always carefully removed wheels. Make sure that the rotors are not damaged,
deformed or contaminated with lubricants.
If the bike is transported upside-down squeeze (with mounted wheel or
transport device!) the lever blade before, hold pressure and fix the blade in
this position with a rubber band or a cable tie.
During transport in an aircraft you can leave your brake as it is, e.g. you do not
have to empty it.
4. Transport of the bicycle
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Unpack your Julie disc brake:
1. brake lever (master cylinder) connected through the
2. brake hose with the
3. brake calliper with transport device (IS/Postmount with quickmount adaptor)
ATTENTION: remove
4. YELLOW transport device only shortly before installation of the wheel!)
5. rotor (diameter front 180mm, rear 160mm)
6. fitting bolts for calliper Allen key 5 (2 pieces)
7. fitting bolts for rotor Torx key T25 (6 pieces)
8. black 1mm spacers (2 pieces, only necessary for rear brakes)
9. olives (2 pieces)
10. Torx T25 key
11. Allen key 2mm
not shown: hose fitting kit for rear brake (comes with all rear brakes)
specifications modifying and improving this product are subject to
change without prior notice.
1
2
3
8
7
4
10
9
11
12
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1. Tools for installation (+maintenance)
Allen key 2*, (3) and 5
transport/mounting device*
sharp knife
8mm open end wrench
flat blade screw driver
Torx T25 key*
(Torx T7 key)
(*delivered with the brake)
Always insert the allen and torx keys completely to avoid damaging
the bolt heads.
5. Brake Installation
6

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The brake levers, callipers and hoses of the different MAGURA disc brake
models are completely different and not compatible! Never mix and match
parts from the two models. Any misuse might cause serious accidents!
MAGURA manufacture these braking systems according to the valid standards and
make many rigorous product tests. Because of the large variety of forks and frames
available on the market it is impossible for MAGURA to test all possible combinations.
If you mount any of our brake systems always make sure that the brakes are in confor-
mity with the bicycle.
Disc brake callipers can generate a lot of heat during extreme riding con-
ditions. The resulting heat transfer from the calliper to the fork and/or frame
can have a negative influence on the mechanical characteristics of both the
fork and/or the frame.
Insufficient heat transfer from the brake calliper to the frame and the fork,
caused by fork and or frame components having low heat transfer characteri-
stics (e.g. carbon rear triangles) can cause the brake to overheat, with the pos-
sibility of a total failure of the brake system. This can cause serious personal
injury to yourself and/or others.
With respect to product liability we remind all our users that any manufac-
turer (also: bike mechanic or end consumer!) is responsible for the correct
function of the complete bicycle in this context. Improper combinations and
insufficient installation can cause damage and serious accidents!
2. Mount the brake lever to the handlebar with a 5mm allen key. If you install your
brake lever the first time you’ll hear a crack, do not worry because of that. Tightening
torque 4Nm/34 in.lbs
The MAGURA Julie disc brake is compatible with frames and forks which
meet the international standard (IS) for disc brake installation. By dismounting
the Quickmount adaptor, the front brake is also compatible with Manitou forks
with Postmount mounts. Never mount the brakes with adapters or brackets
from other manufacturers! All warranty will be void in case of any misuse! Use
only direct mounting parts from MAGURA or the frame or fork’s manufacturer!
Make sure that the calliper fitting eyelets on your frame or fork are free of any
paint, powder coating or burrs. (arrows). If this is not the case you should contact your
dealer who will be able to clean the surfaces, providing an absolutely flat/even mounting
surface (also see page 9).
ATTENTION: The treatment of suspension lower legs made of magnesium
might be dangerous because of corrosion! Always follow the safety instructions
given by the respective manufacturer! Always make sure after having treated
the disc brake mounts that these are protected against corrosion by using an
appropriate protective paint.
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3. Mounting on forks and frames that meet the International Standard:
Mount the calliper onto the fork or the frame (bolts “A”). Use a 5mm allen key.
Tightening torque: 6Nm/51 in.lbs. Do not tighten yet the bolts “B”
4. Mount the rotor with the 6 Torx T25 bolts onto the hub. Watch out for the cor-
rect rotation direction of the rotor (laser arrow). Use only new original bolts or thread
lock if you use old bolts. Tighten the bolts in a crossed pattern! Tightening torque:
4Nm/34 in.lbs.
5. Remove the transport device shortly before installing the wheel and mount
the wheel.
6. Squeeze now the brake lever, hold the pressure and tighten the fitting bolts “B”.
Tightening torque: 6Nm/51 in.lbs.
If you have a Manitou fork proceed exactly in the same way, but dismount
the quickmount adaptor beforehand.
7. However you must use the black 1mm spacers between fitting eyelets and calli-
per on a Julie rear brake. If necessary you might have to use here as well additional
0,2mm spacers for a clean and drag free positioning of the calliper because frames are
very often not well enough aligned.
The transport device prevents the brake pads from being pushed out too
far by unintended lever squeeze. It is impossible then to install the wheel with
the rotor. So never throw away the transport device. Keep it and always clip
it between the brake pads when the wheel is removed.
B
A

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Install the wheel by positioning the rotor between the brake pads and fixing the
wheel in the dropouts. Close the quick release of your wheel which you should mount
on the opposite side of the brake calliper and tighten it sufficiently. As to thru-axle
hubs or wheels consult the manual of the respective fork manufacturer.
Squeeze the lever blade several times (pump) to push the pads to their proper
position until the lever feel becomes very firm.
8. Correctly mounted disc brake wheel.
In the case of a constantly dragging disc brake causing noise your frame could
be miss-aligned. In such a case you should contact your dealer who can care to this
with the MAGURA Gnann-o-mat disc optimizer for a totally even surface of the disc brake
mounts. These are absolutely necessary for a drag free function of your brake.
Do not worry when you hear friction between rotor and pads. A slight drag
is normal on disc brakes with automatic pad wear adjustment during the break-
in period. This drag will disappear after a while. The reason for this is that the
brake pads find their optimum working position towards the rotor, only after a
slight wear during the break-in period. Slight drag might also happen after a
brake pad change or in case of an incorrectly installed wheel.
New brakes and/or new rotors or brake pads must always be run in by
breaking at least 30 times from a speed of 30km/h to achieve the maximum
brake power. Take your bike to a safe place to run in the brake.
Reach adjust is done with a 2mm Allen key. Turning key clockwise: lever
blade moves away from the handlebar, turning counterclockwise: blade moves to
the handlebar.
9
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The Julie is a low-pressure system and comes with the same nylon hose
that is used on MAGURA rim brakes. Do NOT use the reinforced hose of the
other disc brakes with “Disc Tube” imprint and do NOT mix and match items
of different MAGURA disc brakes!” Any misuse might cause serious accidents!
Never touch either the rotor or the brake calliper after long braking as this
may cause serious burns.
1. Remove the wheel so that you have free access to the brake calliper.
Push back both brake pads by putting the transport device or a flat blade screwdriver
into the gap. Move the screwdriver slowly back and forth until both calliper pistons are
fully retracted and flush with calliper body.
Never push back the pistons without the brake pads mounted! Open the
brake system only after having fully pushed back the brake pads.
2. Loosen the brake lever clamping screw with a 5mm allen key. Turn the brake
lever and ensure that the reservoir is horizontal. Squeeze slightly the lever blade and
slide the 2mm allen key between brake lever and lever blade.
3. Slide the hose protection. Unscrew the sleeve nut on the brake lever with an
8mm open-end wrench and pull the hose out carefully. Hold the hose carefully to
avoid any loss of oil! Do not squeeze the lever blade with the system open!
4. Put the hose on a workbench and shorten it with a sharp knife. The best tool is
the MAGURA cutter (code 0321 233). Do not use saws or pliers!
If your frame is not equipped for routing hydraulic lines you should now mount the
hose fitting kit (available as separate accessory, see magura.com) for your rear brake
according to the instructions that are included in the kit.
6. Shorten the hose