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Welcome to the Formula Brake Workshop

Welcome to the Formula Brake Workshop. Overview. Overview Formula history Specialized brake models Functionality of master cylinder Brake system components R1 S, TH1 R Why we use DOT4 Requirements for a working brake Troubleshooting. Technical Workshop Lever blade replacement

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Welcome to the Formula Brake Workshop

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  1. Welcome to the Formula Brake Workshop

  2. Overview Overview • Formula history • Specialized brake models • Functionality of master cylinder • Brake system components R1 S, TH1 R • Why we use DOT4 • Requirements for a working brake • Troubleshooting Technical Workshop • Lever blade replacement • Hose trimming • Pad replacement • Bleeding procedure • Master cylinder rebuild • Caliper piston cleaning Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 2

  3. About Formula Brakes • Founded in 1987 and still a family owned company. • Early expertise in motorcycle components. • Headquarter in Prato , Italy. • Two facilities for production in Tuscany. • Subsidiaries in Taiwan, France, Germany, USA and Canada. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 3

  4. About Formula Brakes • Disc brakes for MTB since 1993. • First to successfully produce and distribute disc brakes for MTB. • Focus on quality, weight and performance • Lightest and strongest brakes. • All current models feature a radial flip-flop master cylinder and 1 piece calipers. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 4 4

  5. R1 S • Forged radial master cylinder (MC). • High capacity integrated reservoir. • Removable handlebar clamp. • Flip-Flop master cylinder assembly. • Aluminium forged lever blade. • Hard anodized MC piston. • Lever integrated tool free reach adjust. • Lever throw adjustment via FCS valve. • One-piece PM caliper body with 22mm pistons. • Top and bottom vented caliper eliminates overheating effects. • Top-loading pads simplify pad changes. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 5

  6. THE ONE R • High capacity, integrated reservoir. • Removable handlebar clamp. • Flip-Flop master cylinder assembly. • Hard anodized MC piston. • Aluminium forged lever blade. • Lever integrated tool free reach adjust. • Lever throw adjust via FCS valve. • Patent-pending forged one-piece post mount style caliper. • 24 mm caliper pistons provide amazing stopping power. • Top and bottom vented caliper eliminates overheating effects. • Top-loading pads simplify pad changes. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 6

  7. Functionality of the Master Cylinder • Animation M/C • Cross section R1 S Pump with FCS Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 7

  8. Functionality of FCS Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 8

  9. R1 S Master Cylinder Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 9

  10. R1 S M/C spare parts Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 10

  11. R1 S Caliper Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 11

  12. R1 S Caliper Spare Parts Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 12

  13. THE ONE R Master Cylinder Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 13

  14. THE ONE R M/C Spare Parts Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 14

  15. THE ONE R Caliper Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 15

  16. THE ONE R Caliper Spare Parts Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 16

  17. Why we use DOT4 DOT4 • Low level of compressibility  stable performance / Lever feel. • Constant viscosity  consistent lever feel. • Higher dry and wet boiling point than mineral oil  fade resistant. • Less hygroscopic than DOT 5.1  Requires less bleeding/service. • Recommended bleed of the system every 6 to 12 months. Recommended fluids for brake service • Use DOT4 Brake fluid only! • High percent Isopropyl alcohol for cleaning the system and the discs. • Brake cleaner only for cleaning and mobilizing the caliper pistons. • Silicone grease for seals and parts. NO TEFLON BASED GREASE. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 17

  18. Requirements for proper function First engagement of caliper pistons • When brand new or after long periods non-actuation, caliper pistons can stick to the quadrings limiting their free movement. To free the pistons, pull the brake lever several times and then reset them by pushing them back into caliper body. • Adjust pistons with included spacer. Checking the lever stroke • The lever stroke of Formula Brakes is around 20mm. The cause of an excessively short stroke is most frequently excessive fluid in the system caused by expansion. Even when not in use, the hydroscopic nature of DOT fluid causes it to expand over time and the system will need to be equalized by burping out excess fluid before the correct amount of free-stroke is realized. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 18

  19. Requirements for proper function Mounting points • Frame and Fork mounting points must be properly aligned, faced and free of paint. • Always use medium strength thread-locker for mounting fasteners. • Always use washers under bolt heads for caliper mounting. • Always torque all fasteners to spec. Cleaning • Rotors must be free of grease or oils for proper function. Before the initial use, clean the rotors with a high % isopropyl alcohol on a clean rag. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 19

  20. Troubleshooting Caliper pistons don‘t reset all the way • Excess fluid in the system. • Dry and/or heavily dirty caliper pistons. • Friction at quadrings is too low. • Caliper oxidation. Inconsistent lever contact point • Air in the system • Dry and/or heavily dirty caliper pistons. • Friction at quadrings is too high. • Caliper oxidation. • Leaking membrane. • Pump piston damage. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 20

  21. Troubleshooting Lever blade does not fully return • Seals experienced expansion after exposure to non-approved oil or grease (WD40, Triflow etc.). • Lever pivot contaminated. • Lever blade fixing screws over-torqued causing binding. Rotor rub • Check caliper pistons to ensure proper movement and retraction. • Check rotors trueness. • Check to ensure wheel is fully seated in dropouts. • Check mounting points of Caliper, adapter and rotor for correct alignment. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 21

  22. Troubleshooting Brake squeals • Contaminated pads/rotor. • Caliper pistons retraction limited. • Pads not properly bedded in. • Bent pad spring contacting rotor when pistons actuating. • Rotors overheated and glazed (brake track is black/discolored). • Frequency vibration on frame, wheels or fork. • Pad type not appropriate for riding style. • Wet conditions. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 22

  23. Contact Information Formula USA Formula North America Christoph Vogl 414 Hwy 21 Bypass Fort Mill, SC 29715 Tel: 803.547.7010 Email: cvogl@formula-brake.com Charlie Schneider 405 East D Street, ste c Petaluma, CA 94952 Tel: 707. 540.6137 Email: info@formulabrakeusa.com Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 23

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