TRP HYLEX Installation Instructions page 2

INSTALLATION & ADJUSTMENT
TOOLS AND EQUIPMENT REQUIRED
The following tools are necessary to install the Tektro hydraulic disc brake:
2mm hex wrench
8mm open end wrench
MOUNTING THE ROTOR TO THE HUB
Attach the rotor to the hub with the supplied Torx® bolts and tighten in an alternating pattern with
a T25 Torx® wrench. Final tightening torque: 4-6 Nm (35-53 in-lb).
NOTE - The rotor must be installed with the "rotation" arrows pointing in the same direction as the
forward rotation of the wheel.
INSTALLING FLATMOUNT ADAPTORS
Select the correct adapter (front or rear) for the size of rotor.
Front caliper -
Attach the adapter to the caliper in correct direction for 140mm or 160mm rotor.
Tighten the two M5x13 bolts to a torque of 5-7 Nm.
Attach the adapter to fork using the two M5x14
or alignment tool,) and tighten to a torque of 5-7 Nm.
Rear caliper -
With 140mm rotor: Insert mounting bolt
through the frame. Attach the caliper to bolt
With 160mm rotor: Attach F-6 adapter to brake caliper and tighten bolt
(44-62 in-lb). Then attach adapter to the frame with mounting bolt
Make sure the pads are correctly positioned in the caliper. Do not tighten the bolts at this stage.
With the caliper mounting bolts still loose, squeeze the brake lever. The caliper will correctly center
itself to the rotor. You may also use a disc brake gap or alignment tool. Maintaining pressure on
the brake lever, tighten the caliper mounting bolts. Final tightening torque: 6-8 Nm (53-71 in-lb).
MOUNTING THE BRAKE LEVERS
Pull back the rubber hood to expose the 5mm hex head clamping nut - loosen and slide onto bar.
Place the levers in an appropriate position and tighten to 4-6 Nm (35-53 in-lb).
Route the brake hose along the handlebar. As with all hydraulic hose, there should be no kinks or
bends that collapse the housing.
Once you have the lever assembly positioned appropriately, you can adjust the reach of the
blade by 2mm Allen wrench to suit your preference.
MODIFYING HOSE LENGTH
Pull to remove the plastic cap and unscrew the compression nut.
Pull on the hose to free it from the caliper. Some fluid may drip out. Measure the new hose length
making sure you have enough free length for full rotation of your handlebars. Cut the hose to the
desired length using a hydraulic hose cutter. (Hylex uses a banjo fitting on the hose end at the
brake lever, which is not replaceable. This is the reason for cutting the hose at the caliper. )
Important: Slide on the plastic cap, compression nut, then the olive with the tapered end oriented
to engage the compression nut.
Install the barb ensuring that it is fully seated within the cut end of hydraulic tubing.
Reinsert the hose into the caliper and tighten the compression nut to 4-6 Nm (35-53in-lbs).
GENERAL MAINTENANCE
PAD REPLACEMENT
Pads should be replaced if they become contaminated or have less than 2.5mm thickness (Pad friction material
[ref. D-1]
& metal backing plate).
BEFORE RIDING
Check the pads for wear or contamination.
Check the hose for cracking, wear or deformation. Replace if necessary.
Check that the brake system is operating correctly.
AFTER RIDING
Remove any mud or contamination from the rotor slot on the caliper.
Clean the caliper body with a cloth.
AT REGULAR INTERVALS
Check the oil level in the reservoir.
Lubricate the brake lever pivot with grease.
Check to make sure that all the bolts are tightened to the correct torque specifications.
For questions about setup, usage or general inquiries, please contact TRP by e-mail at
info@trpbrakes.com or by phone toll free in US, 877-807-4162 or outside US 1-801-648-7079.
5mm hex wrench
Birzman Pad Gap Tool (optional)
bolts. Align the caliper to the rotor, (using an gap
into the frame and make sure it is protruding 7mm
.
[ref. B-2]
T25 Torx® wrench
[ref. A-1]
to a torque of 5-7 Nm
.
[ref. B-1]
[ref. C-1]
5
2
4
6
A-1. Rotor torquing sequence
B-1 Tighten clamp nut with 5mm hex wrench
B-2 Adjust lever reach
C-1 Install cap, nut and olive before installing
the barb!
2.5 mm
Pad wear Indicator
D-1. Replace new pad
Instructions on bleeding the brakes can
be found on www.trpbrakes.com or
on www.youtube.com/user/TRPBrakes
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