Magura Louise Carbon 2009 Instruction manual

THE PASSION PEOPLE
www.magura.com
THE PASSION PEOPLE
WORKSHOP 2009
English

2
THE PASSION PEOPLE
www.magura.com
THE PASSION PEOPLE
www.magura.com
FREERIDE ENDURO ALL MOUNTAIN X C RACE
Gustav MGustav M
Marta SL 180/180Marta SL 180/180
Marta SL 203/203Marta SL 203/203
Marta SL Magnesium 203/203Marta SL Magnesium 203/203
Marta SL Magnesium 180/180Marta SL Magnesium 180/180
Marta SL Magnesium 160/160Marta SL Magnesium 160/160Marta SL Magnesium 160/160
Marta SL 160/160Marta SL 160/160
Marta 160/160Marta 160/160
Louise 203/203Louise 203/203
Louise 180/180Louise 180/180
Louise 160/160Louise 160/160
Julie HP 203/203Julie HP 203/203
Julie HP 180/180Julie HP 180/180
Julie HP 160/160Julie HP 160/160
Marta 180/180Marta 180/180
Marta 203/203Marta 203/203
X - COUNTRY
Our disc brake range | recommended use
Specifications subject to change wit-
hout prior notice
Ground contact
isn’t that important
to you. There is
(almost), no terrain
where a Freerider
won’t go. Tough and
stable components
are amust have.
Here they are.
There are bikers out
therefor whom
uphill is just a
means to an end.
The downhill fun is
having absolute
priority for them.
With lots of travel
and robust compo-
nents the Enduros
must cope with
technically hairy
downhills and bike-
park weekends..
You’re an all-roun-
der. You love long
and sweeping trails,
up as well as down.
The optimummix of
light weight and
stability is the hall
mark of your
AllMountain com-
ponents meant for
abroad spectrum of
use.
Mile after mile over
the dusty trails as
well ashard fast tar-
mac. On every ride
your bike shouldbe
the epitome of
uncomplicated –
and naturally the
parts for your X-
country adventures
shouldn’t cost the
earth.
Race-orientated
means for us the
minimum weight
that is technically
possible. Every
gram extra weight
can be the decisive
factor between win-
ning or losing for
you, the racer
maniac.

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3
1. Introduction 4
2. Safety instructions before the first ride 5
3. Safety instructions before every ride 5-6
4. Transport of the bicycle 6
5. Brake installation 7-10
6. Shorten the hose 11-12
7. Maintenance/Brake pad change 13-14
8. Repairs 15
9. Bleeding and Filling 16-17
10. The disc brake wheel 18
11. Accessories 18
12. Trouble Shooting 19
13. Warranty 19
14. Spare parts exploded view/Tuning adaptors 20-21
Table of contents
WARNING:
This symbol means possible danger for your health and even life if you do not follow the
instructions given resp. if the necessary safety measures are not followed.
ATTENTION:
This symbol warns you of inappropriate handling that might cause heavy damage to the
material and/ or the environment.
NOTE:
This symbol is giving you additional information about the general handling of the
product or gives hints to paragraphs of 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 MAGURA Louise the braking force is
transmitted 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 pushes
the mineral oil column through the brake hose in the direction of the brake caliper, where
two pistons, on which the brake pads are fixed, are pushed out. The friction between the
brake pads and the rotor is slowing down the bicycle and
causes a heating of both the rotor and the brake caliper.
Never touch either the rotor or the brake caliper after long braking as this may
cause serious burns.
You will be pleased to find out that the MAGURA Louise 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 shortly after activating the brake lever.
Disc brakes do not cause a wear of your rims. In case of insufficient mounting conditions
they might however cause a squealing noise during braking, mainly in 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.
Please note that the Louise brake is delivered in different versions with different
rotor diameters and for different fitting alternatives for which we offer a variety of
adaptors. The basic installations steps remain however always the same.
Although the Louise disc brake system is relatively simple you should not over-
estimate your technical skills! We therefore advise you to leave the following works
to a trained technician of a professional bike shop.
This workshop manual is part of the product that must not be sold without it.
In case of any further questions or problems we warmly recommend to visit our website
www.magura.com where you will always find the newest and hottest tips about all our pro-
ducts and free online help around the clock in our forum. You can also download on
magura.com 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!
Brake lever (master cylinder)
MAGURA Louise®
Brake caliper and rotor MAGU-
RA Louise®
Congratulations! You have purchased a fully
hydraulic MAGURA disc brake proudly
„Made in Germany“. You will be enthusia-
stic about the awesome braking power and
the very little maintenance that is neces-
sary on our stoppers. Good to know that
you are not alone, millions of users world-
wide rely on them and every day we’re
becoming more!!

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5
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 get
loose. Serious falls with heavy bodily injury might be the 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 hand-
lebars. If this is not the case, pull the lever blade several times (pump) until the brake pads
touch the rotor.
In case, of changing pressure points during a ride you might have air in the brake
system. See hints about filling and bleeding from on pages 16/17.
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 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 whether you activate the front brake with the brake lever, which you
are used to braking on the front. If ever this is not the case you will have to train
your new setup because any unintended braking might cause an accident with possi-
ble serious injury! Make change the hose connection by a trained technician in case
of any doubts.
Further hints concerning the swapping of the brake hose see page 11 onwards.
3. New brakes and new rotors or brake pads must always be run in by
breaking at least 30 times from a speed of 30 km/h to achieve the maximum brake
power. Take your bike to a safe place to run in the brake.
4. In case of extreme riding conditions (total weight of bike plus rider
over 100 kg/220 lbs. and/or a gradient of more than 15 %) always use both brakes
simultaneously to brake your bike down. Avoid constant braking on long descents as
this might cause overheating and total failure of the system.
5. Use the brakes according to the user chart on page 2 of this manual. Any
misuse might cause heavy accidents with fatal injuries for you and others!
6. Are you familiar with the other components on your bike such as shifting, clipless
pedals and suspension units? Always train the perfect handling of your bike in a safe area
before using it in the public traffic. 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 your clothing and footwear are suitable.
2. Before the first ride
3. Before every ride or after a crash

THE PASSION PEOPLE
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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 12)
4. Always protect your rotors and brake pads from oil and lubricants (e.g. by lubricating
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. Those pads are defi-
nitely killed and cannot be saved. They have to be replaced! Clean a contaminated rotor
with MAGURA brake cleaner, warm dishwater or alcohol. See further hints about the brake
pad change on pages 13/14.
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 release
skewers are sufficiently tightened. (Also see pages 8-10)
6. Are your tires in a good condition, and are they sufficiently pressurized? Test this
with your fingers. Lift up your bike and turn the wheels of your bike. An insufficient rotation
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. Be careful in case of any
rattling noise. 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 ever a proper function of the points mentioned above is
not guaranteed. Consult a professional bike mechanic if you feel
unsure. A faulty bicycle might cause serious accidents with possible serious
injuries for the rider!
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 11 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 before the lever blade,
hold pressure and fix the lever blade in this position with a rubber band or
a cable tie as shown on the right photo.
For a 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

1
2
3
6
8
7
4
11
9
10
12
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5. Brake installation
Unpack your Louise disc brake:
1. brake lever (master cylinder) connected through the
2. brake hose with the
3. brake caliper with transport device; ATTENTION:
4. remove the transport device only shortly before installation of the wheel!
5. rotor
6. fitting bolts for rotor Torx T25 (6 pieces)
7. fitting bolts for caliper Allen key 5 (2 pieces)
8. adaptor with fitting bolts (depending on model)
9. hose inserts (2 pieces)
10. olives (2 pieces)
11. Torx T25 key
12. 2mm Allen key
Specifications modifying and improving this product are subject to
change without prior notice. Specs may vary depending on model version!
1. Tools for installation (+maintenance)
Allen key 2*, (2,5, 3) and 5
transport/mounting device*
sharp knife
8 mm 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!

THE PASSION PEOPLE
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The brake levers, calipers and hoses of the different MAGURA disc brake models
are completely different and not compatible! Never mix and match parts from the dif-
ferent models! Any misuse might cause serious accidents!
MAGURA manufacturers these braking systems according to the valid standards and
based on profound 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 conformity with the bicy-
cle.
Disc brake calipers can generate a lot of heat during extreme riding conditions.
The resulting heat transfer from the caliper 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 caliper to the frame and the fork, cau-
sed by fork and or frame components having low heat transfer characteristics (e.g.
carbon rear triangles) can cause the brake to overheat, with the possibility 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 manufacturer
(also: bike mechanic or end consumer!) is responsible for the correct function of the
complete bicycle in this context. Improper combinations and insufficient installation
might cause damage and serious accidents!
2. Mount the brake lever to the handlebar with a 5 mm allen key. Tightening torque 4
Nm/ 34 in.lbs
Hint: Tighten the brake lever so that it can still rotate around the handlebar in case of
a crash. This old motocross trick will reduce considerably the risk of a damaged brake lever
and the costly consequences.
The MAGURA disc brake Louise is compatible with frames and forks which meet
the International Standard (IS) and for Postmount (PM) mounts. Depending on the
mounting standard and/or rotor size adaptors are used for a proper installation (cf.
table on page 21). Never mount the brakes with adapters or brackets from other
manufacturers! All warranty will be void in case of any misuse! Use only direct moun-
ting parts from MAGURA or the frame or fork’s manufacturer!
Make sure that the caliper 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
is able to care for the absolutely necessary even surface with the help of the
MAGURA Gnann-o-mat disc optimizer tool (also see page 10).
ATTENTION: The facing of suspension fork 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. Mount the adaptor onto the fork or the frame. Use a 5 mm allen key. Please follow
carefully the mounting instructions that come with the respective adaptor! If you use a thru-
axle hub on the front you might have to use thicker 3 mm spacers (depending on fork
model). These are available separately (code: 0720 829).
Tightening torque: 6 Nm/ 51 in.lbs.
4. Caliper installation: Mount the caliper with MOUNTED wheel and rotor onto the
adaptor. For a better understanding the mounted wheel is not shown on this picture. Do not
tighten the caliper bolts yet! Squeeze the lever blade and keep the pressure. Tighten now
the bolts. Tightening torque: 6 Nm/ 51 in.lbs.
5. Mount the rotor with the 6 Torx T25 bolts onto the hub. Use only new original bolts
or thread lock if you use the old ones again. Tighten the bolts in a cross pattern. Tightening
torque: 4 Nm/ 34 in.lbs.
Install a MAGURA rotor in Centerlock version according to the tech sheet that comes
with the rotor.
6. The transport device prevents the brake pads from being pushed out too far by unin-
tended lever squeeze when the wheel is removed. It is impossible then to install the wheel
with the rotor. So never throw away the transport device but keep it and always clip it bet-
ween the brake pads as shown when the wheel is removed.
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 caliper and tighten it sufficiently.
7. Squeeze the lever blade several times (pump) to push the pads to their proper
position until the lever feel becomes very firm. Tighten now the caliper fitting bolts.
Tightening torque: 6 Nm/ 51 in.lbs.
8. For Postmount 6” installation in combination with a 160mm rotor, Postmount 7” with
180mm rotor or Postmount 8” with a 203mm rotor on the front you do not need an adaptor.
Mount the caliper DIRECTLY onto the fork with MOUNTED wheel and rotor. For a better
understanding the mounted wheel is not shown on this picture. Do not tighten the caliper
bolts yet! Squeeze the lever blade and keep the pressure. Tighten now the bolts. Tightening
torque: 6 Nm/ 51 in.lbs. Further mounting alternatives cf. page 21 of this manual.
9

THE PASSION PEOPLE
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9. Hose routing with the Heat Eater fitting.
The Heat Eater fitting of the Louise caliper allows a 45° rotation for the optimum hose rou-
ting without using tools. Fix the hose on the fork and/or frame after you have found the
ideal position, the Heat Eater must NOT move during compression of the fork and/or
frame!
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 peri-
od. 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.
In case of a constantly dragging disc brake causing noise your frame is badly
aligned. In such a case you should contact your dealer who can care 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.
New brakes and/or new rotors or brake pads must always be run in by
breaking at least 30 times from a speed of 30 km/h to achieve the maximum brake
power. Take your bike to a safe place to run in the brake.
10. Reach adjust is done with a 2,5 mm Allen key. Turning key clockwise: lever
blade moves away from the handlebar, turning counterclockwise: blade moves to the hand-
lebar. On Louise models without BAT feature you find the reach adjust screw under the black
dust cover of the lever blade.
WARNING: The reach adjust screw becomes very firm when you risk to overtigh-
ten it. Do not continue to screw it in/ out in such a case. Misuse can lead to brake
failure! The adjust screw must not be flush wih the drill in the lever blade. Re-install
the dust cover once you have adjusted the reach adjust properly.
11. Bite Adjust Technology (BAT):
Turning clockwise: Bite point becomes firmer
Turning counterclockwise: Bite point becomes softer.
WARNING: Do not adjust the reach adjust in the closest position to the handleb-
ar in combination with a BAT adjuster that is screwed in to the maximum as well.
This could result in an unsufficient lever movement and brake power. Check out after
every change of the BAT and/or reach adjust the function of the brake to get used to
the changed handling of the brake.

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11
Louise is a high-pressure system and comes with a reinforced hose, the „MAGU-
RA Disc Tube“ wearing also this imprint. The Disc Tube needs an additional insert for
a proper fitting. Never mix and match the parts from the
MAGURA Louise with the ones of our rim brakes or other manufacturers’ brakes! Any
misuse might cause serious accidents!
Never touch either the rotor or the brake caliper after long braking as
this may cause serious burns.
1. Remove the wheel so that you have free access to the brake caliper.
Push both pistons with brake pads mounted back by putting the transport device or
a flat blade screwdriver into the gap. Move the screwdriver slowly back and forth until both
caliper pistons are fully retracted and flush with caliper body.
Never push back the pistons without the brake pads mounted! Open the brake
system only after having pushed back fully the brake pads.
2. Loosen the brake lever clamping screw with a 5 mm allen key. Turn the brake lever
and ensure that the reservoir points approx. 15° upwards from the horizontal ppoossiittiioonn.
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 hose cutter. Do not use saws or pliers!
6. Shorten the hose

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Hint:Hold the hose carefully so that it cannot snap away! Cut the
hose squarely! The sleeve nut can be re-used. The olive and the insert
cannot be reused and must be replaced!
5. Press by hand a new insert into the hose until it is fully seated. Clamp the hose into
the groove of the mounting device as shown...
6. ...or clamp the mounting device as shown into a vice and hammer the insert careful-
ly into the hose.
7. Slide on the sleeve nut and a new olive onto the hose. Push the hose with the sleeve
nut and the new olive fully into the brake lever and tighten the sleeve nut with
an 8 mm open-end wrench. Tightening torque: 4 Nm/34 in.lbs.
8. Always check for correct installation by pulling on the hose. Make
sure that the system has no leaks. Squeeze the lever blade, hold pressure
and check hose connections and the reservoir cover for eventual leaks.
Squeeze the lever blade several times (pump) to push the pads to their proper
position until the lever feel becomes very firm. If you cannot realize this, bleed the
brake (see page 16 onwards).

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Brake Oil: MAGURA disc brakes use a transmission medium low viscosity mineral oil,
the MAGURA ROYAL BLOOD. Contrary to DOT brake fluid the MAGURA ROYAL BLOOD
does not irritate human skin or strip the paint of your frame. Moreover it does not absorb
water like DOT and does not have to be changed regularly. What sounds unbelievable is a
fact: you can use your brakes over years without having to touch them (except brake pad
check and change!) Use exclusively MAGURA ROYAL BLOOD, any other oil will damage the
seals of your brake what will result in total failure of the brake!
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. Consult a trained technician in case of leaks that cause poor braking
performance with possible serious accidents!
As to hints about repairs of the hose see page 15 onwards.
Brake pads: wear, control and replacement
Brake pad wear: The brake pads are subject to wear due to friction between rotor and
pads. All Louise disc brakes feature a fully automatic pad wear adjustment. Regularly
check the thickness of your brake pads and replace them, if necessary! CHANGE
ALWAYS BOTH PADS SIMULTANEOUSLY!
Control of the brake pad wear
Never touch either the rotor or the brake caliper after long braking as this may
cause serious burns.
Squeeze the lever blade with the wheel mounted an hold the pressure.
Check out whether the “finger” of the transport device fits in-between the “ears” of the
brake pads. On the picture on the left this is NOT the case, the pads must be changed!
Here the “finger” of the transport device fits between the “ears” of the brake pads. The
pads are still o.k. Remember: The lever has to be pulled during this procedure. Use
for this a rubber band or a cable tie.
Replacement of the brake pads
1. Remove the wheel so that you have free access to the brake caliper.
Push both brake pads fully back by putting the transport device or a flat blade screwdriver
into the gap. Move the screwdriver slowly back and forth until both caliper pistons are fully
retracted and flush with the caliper body.
Never push back the pistons without the brake pads mounted, the pistons could
be damaged otherwise.
7. Maintenance

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2. Remove the brake pad fitting screw with a 2mm allen key.
3. Pull out the brake pads. Their „ears“ make this very easy. Minimum thickness of a
brake pad plus holder is 2,5 mm.
Never squeeze the lever blade without the brake pads in place and the wheel
mounted! If this happened by accident push back the pistons by using the transport
device or a flat blade screwdriver.
Use only genuine MAGURA brake pads! MAGURA cannot guarantee a
correct function of the brake if you use brake pads from other manufacturers, which
were not tested! Using other pads (e.g. sinterized ones!) might cause poor braking,
overheating of the system and resulting total brake failure causing serious accidents!
All warranty claims will be void in case of misuse!
4. Clean on the occasion of the brake pad change, the brake body with a clean rag.
Make sure that the friction side of the new brake pads points towards the rotor.
5. Secure the new pads with the fitting screw, a new one is delivered with the new
pads. Tightening torque: 1 Nm/ 9 in.lbs. Check the correct fitting of the pads by pul-
ling them. The fitting bolt of the pads has to be correctly installed e.g. it has to go
through the drills of the pad holders and then correctly screwed into the caliper.
6. Re-install the wheel and check for a
correctly tightened quick release skewer of the wheel which should be mounted
on the opposite side of the caliper.
7. Squeeze the lever blade several times (pump) to push the pads to their proper positi-
on until the lever feel becomes very firm.
New brakes and/or new rotors or brake pads must always be run in by braking
at least 30 times from a speed of 30 km/h to achieve the maximum brake power.
Take your bike to a safe place to run in the brake.
Never contaminate brake pads with oil or grease this causing permanent loss of
brake power! Contaminated pads are definitely killed and must be
replaced!

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15
Disc brake service kit
Don’t panic if the hose snaps! With the disc brake service kit and a separately available
spare hose (see spare parts pages 20/21), this can be repaired easily.
Louise is a high-pressure systems and comes with a reinforced hose, the
„MAGURA Disc Tube“ wearing also this imprint. The Disc Tube needs an additional
insert for a proper fitting. Never mix and match either the hoses or parts from other
manufacturers. Any misuse might cause serious accidents!
1. Remove the damaged hose from both the brake lever and the caliper.
2. Prepare a new hose: Use only the reinforced MAGURA Disc Tube (wearing also this
imprint). One end of this hose comes with a pressed fitting with blue loctite threadlock,
which has to be screwed into the Heat Eater as described above.
The hose is available with 0° and 90° fittings (c.f. page 20)
Tightening torque: 6 Nm/ 51 in.lbs.
Use with all Louise models with adjustable Heat Eater hose fitting only the hose
that comes with the fitting with blue loctite threadlock (arrow!).
NEVER shorten the MAGURA Disc Tube hose at the end with the pressed
fitting! You could no longer use this hose then.
3. Tighten the prepared end of the new hose onto the Heat Eater.
Tightening torque: 6 Nm/ 51 in.lbs.
4. Install the hose as described in chapter 6.
After the installation of a new hose you will always have to refill the brake. The
following chapter 9 describes how the filling and bleeding has to be done.
8. Repairs

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9. Filling and bleeding a brake
Brake Oil: MAGURA disc brakes use as transmission medium low viscosity mine-
ral oil, the biodegradable MAGURA ROYAL BLOOD. Contrary to DOT brake fluid the
MAGURA ROYAL BLOOD does not irritate human skin or strip the paint of your frame.
Moreover it does not absorb water like DOT and does not have to be changed regular-
ly. What sounds unbelievable is a fact: you can use your brakes over years without
having to touch them (except brake pad check and change!) Use exclusively MAGURA
ROYAL BLOOD, any other oil will damage the seals of your brake what will result in
total failure of the brake!
1. Loosen slightly the clamping screw of the brake lever with a 5mm allen key and
ensure that the reservoir points upwards approx. 15° from the horizontal position.
Slightly tighten the clamp screw in that position.
2. For filling and bleeding a MAGURA disc brake you will need the disc brake service kit
including all necessary tools.
3. Prepare the transparent filler tube by pushing in by hand the M6 barbed fitting. Put
the other end of the filler tube on the syringe and fill the syringe completely with MAGURA
ROYAL BLOOD mineral oil. Fill the syringe completely and make sure that
there are no air bubbles inside. Turn the syringe eventually to push out air bubbles.
4. Remove the brake pads as described on page 14 and slide the transport device as
shown with its THICK END between the caliper pistons. Squeeze
slightly the lever blade (pump) to tighten the transport device. It is advisable to fix the devi-
ce with a rubber band on the caliper.
5. Fix the Heat Eater fitting of the caliper so that it points UPWARDS!. IUnscrew now
the bleed screw with a 5 mm allen key. Screw in the prepared syringe and tighten it with a 8
mm open end spanner.
Place now a rag, which has to be free of oil or lubricants around the reservoir
and, more important, around the brake caliper. Care for a clean working environment!
No dirt or particles may come into the brake system!

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17
6. Remove OONNLLYYthe bleed plug of the reservoir with a 2,5mm Allen key that you insert
into the plug before turning it slightly. The reservoir cover and the membrane underneath
remain on the brake lever!
7. Put the second syringe of the service kit WITHOUT PLUNGER into the opened drill
of the reservoir cover. Push oil from the brake caliper upwards until the oil column arrives in
the syring on the reservoir. You will see air bubbles now.
8. Now suck the oil carefully back with the filling syringe on the brake caliper. Make
sure that there is always enough oil in the reservoir syringe when you suck back the oil with
the filling syringe! You will see air bubbles again.
9. Actuate in addition CAREFULLY the lever blade to chase tiny air bubbles that might
hide within the system. The job is done when no air bubbles can be seen after having follo-
wed the steps above several times.
10. Before you remove the syringe on the reservoir make sure that there is only
a small quantity of oil inside. Place a rag around the brake lever and the caliper thus pre-
venting overflowing oil from dropping down and contaminating and killing the brake pads.
Remove the syringe and close the end that was inserted into the reservoir quickly with your
finger. Empty the remaining content of the syringe into an container.
11. Close the plug on the reservoir cover as shown by pressing it by hand into the drill.
That’s it!
12. Remove the filling syringe and screw in the 5mm allen bleed screw.
Tightening torque: 2,5 Nm/ 22 in.lbs. Re-install the brake pads and the wheel.
Always pull the lever blade several times (pump) until the brake pads touch the
rotor. Always check for correct installation by activating the lever blade and checking
for eventual leaks. Never contaminate brake pads with oil or grease this causing per-
manent loss of brake power! Contaminated pads are definitely killed and MUST be
replaced! A contaminated rotor can be cleaned with MAGURA brake cleaner, warm
dishwater or alcohol.

THE PASSION PEOPLE
www.magura.com 18
The XC disc brake wheel
There already exists enough literature concerning wheels, so just a few tips how
a well-built X-country disc brake wheel has to be.
Use spokes with a diameter of 2 mm (arc)/ 1,8 mm which you cross three times.
No radial lacing with disc brake wheels!
Head-inside-spokes (=arc-outside-spokes have to be pulled, i.e. these spokes point
forward on the front wheel; on the back wheel these spokes point forward on the rotor side
and backwards on the drive side. All spokes have to be stressed equally and high.
Mount the q/r skewer of the wheel on the opposite side of the caliper!
Never use ultra lightweight quick releases with titanium or aluminum
axles for your wheel sets in combination with a disc brake. You will not be
in a position to realize the necessary tightening torque!
10. The disc brake wheel
11. Accessories
MAGURA disc brake service kit
contains everything that you need for bleeding and repairing a brake.
ATTENTION: the kit does NOT include a spare hose!
MAGURA braided hose for all MAGURA disc brakes
easily shortened with a cable cutter
Order codes see on page 20.
Watch out for the genuine hose with yellow MAGURA marker!!
Use only genuine MAGURA brake pads!
brake pads Performance Type 6.1 code 0722 418
series pad for maximum brake power.
brake pads Endurance Type 6.2 code 0722 419
with optimized longevity.
Use only genuine MAGURA accessories! Any parts manufactured by other
manufacturers like lever blades, hoses or brake pads have not been tested and
approved by MAGURA and consequently nothing can be said about their short and
long-term function. Never use those parts! All warranty and product liability claims
will be void in case of misuse!
Never change the paint, the finish or the consistence of your brake. This might
cause total failure of the whole system with possible serious consequences!

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19
problem reason solution
12. Trouble shooting
not enough brake power
no pressure point
Squealing brake
Contaminated brake pads
Contaminated rotor
Wheel cannot be mounted
Rattling noise and rough
deceleration
Leaking hose or brake
brake not run in
oil/lubricants on rotor and/or
pads
air in the system
leaking system
badly aligned frame
paint/powder coating on disc
mounts
wheel q/r skewer insuffi-
ciently tightened
Insufficiently tightened wheel
spokes
carelessness
carelessness
Lever blade was pulled with
removed wheel
brake pads worn, holder of
pads is wearing and dama-
ging the rotor
accident, incorrect installati-
on
break in brake (page 5)
clean rotor with MAGURA
brake cleaner, warm dish
water or alcool. Replace con-
taminated pads!
Bleed brake (page 16)
Correct transport (page 6)
Check hose connections and
hose for leaks. Replace hose
if necessary (page 16)
align brake caliper correctly
(page 9)
remove any paint or powder
coating and care for an even
contact surface without burrs
(page 8/9)
increase tightening; mount
q/r skewer on opposite side
of caliper; care for evenly
spoked wheel
change brake pads
clean rotor with MAGURA
brake cleaner, warm dish
water or alcohol
push back the brake pads
with transport device or a flat
screwdriver (page 11)
brake pad change (page 13)
change hose or defective
brake lever/caliper (page 15)
13. Warranty
MAGURA is giving a 5-year leak proof warranty on brake levers (master
cylinder) and brake calipers.
Watch out for the red info sheet in the middle of this manual!

THE PASSION PEOPLE
www.magura.com 20
14. Spare parts 2009/max. tightening torques
0722 533 lever blade repair kit (1x)
0722 527 (1x)
0721 778 (10x)
0722 525 BAT Carbon (1x)
0722 526 BAT Alu (1x)
0722 531
0722 418 Type 6.1
Performance
0722 419 Type 6.2
Endurance
0722 416 (1x)
0722 421 (10x)
0721 314
10 x 0720 848 2,5 Nm
0722 534 titanium grey
0722 535 silver
0722 536 black
incl. bolt
(10x) 0724 044 0,4 Nm
(10x) 0721 000 0,6 Nm
Louise Carbon/titanium grey
links 0722 520
rechts 0722 519
Louise BAT/silver
links 0722 522
rechts 0722 521
Louise/black
links 0722 524
rechts 0722 523
Ventidisc 6 holes (IS)
203 mm 0722 569
180 mm 0722 568
160 mm 0722 567
Louise Carbon/titanium gray 0722 528
Louise BAT/silver 0722 529
Louise/black 0722 530
SL Rotor 6 holes (IS)
203 mm 0722 332
180 mm 0721 456
160 mm 0721 455
Titanium bolt kit 0722 562
1x M5x18 0737 812
6x M5x10 0737 813
2x M6x18 0737 811
SL Rotor Rohloff Speedhub
180 mm 0721 931
160 mm 0721 930
Ventidisc/Centerlock
with lockring
203 mm 0722 572
180 mm 0722 571
160 mm 0722 570
0721 057 (6x) 4 Nm
0720 847 Torx T7 key
0721 204 Torx T25 key
0722 636 hose 250 cm 6 Nm
0721 641 braided hose 250 cm 6 Nm