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Trickstuff MAXIMA Service Manual

Brake pump
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SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP
V2024_02
CONTENT
1. GENERAL INFORMATION
2. SAFETY
3. TOOLS
4. SERVICE DIRETTISSIMA/MAXIMA PUMP
1.
General information
1.
Read the manual completely before using the products and follow the instructions
contained in these instructions when installing, using and maintaining the product in
order to avoid personal injury and damage to property.
2. The installation and maintenance of Trickstuff products require a basic knowledge of
handling bicycle components and should only be performed by qualified bicycle
mechanics. During installation or maintenance, clean working conditions must be ensured
so that dirt entry into the brake systems is avoided.
3. If any of the instructions in this manual are unclear, do not proceed with installation or
maintenance. Contact your local Trickstuff dealer or the Trickstuff support-team.
2.
Safety
The installation, use and maintenance of Trickstuff products requires that you have read and
understood the following safety instructions.
1. General safety instructions
•
Always follow the instructions in the manual when working on Trickstuff products.
•
We recommend only Trickstuff products for the use with Trickstuff brakes.
•
When working on the system, pay attention to appropriate personal protective equipment
such as gloves and safety goggles.
•
Trickstuff products are to be used exclusively in accordance with their intended use.
Otherwise the user assumes the responsibility.
Warning!
Improper installation, use and maintenance of components pose a considerable
risk and can lead to accidents with serious injuries including death.
2. Brake pads and brake discs
•
Visually inspect the brake pads and rotors before each ride:
o Worn brake pads and/or brake discs can lead to sudden brake failure.
o Lubricants such as oil or grease on the brake pad or brake disc can limit the
effectiveness of the brake.
o Corrosion can cause the friction material to detach from the backing plate,
resulting in brake failure. Replace brake pads that show signs of rust
immediately.
TRICKSTUFF® GMBH
SCHWABENMATTEN 17A
79292 PFAFFENWEILER
GERMANY
TECH-SUPPORT@TRICKSTUFF.DE
SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP
V2024_02. PAGE 1 OF 27

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  • Page 1 3. If any of the instructions in this manual are unclear, do not proceed with installation or maintenance. Contact your local Trickstuff dealer or the Trickstuff support-team. Safety The installation, use and maintenance of Trickstuff products requires that you have read and understood the following safety instructions. 1. General safety instructions •...
  • Page 2 • Trickstuff brakes are only as good as the pilot who uses them. Proper braking technique is essential. Improper braking can lead to accidents with serious injuries. o Permanent braking should be avoided. When braking, do not drag the brake steadily, but brake in bursts if the ground will allow.
  • Page 3 Assembly grease (e.g. Interflon assembly grease) • Medium strength thread locker (e.g. Loctite 243) • High strength thread locker (e.g. Loctite 638) TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 3 OF 27...
  • Page 4 To service the brake pump, one service kit is required for each brake pump (i.e. two kits for one set of brakes). • Regular service: KIT SEALS & PISTON DRT+MXA PUMP OIL ASM TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 4 OF 27...
  • Page 5 TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 5 OF 27...
  • Page 6 You will also need the appropriate tools to remove the brake from the bike in accordance with the operating instructions. Note: Trickstuff brakes are designed for use with organic, biodegradable Trickstuff "Bionol" oil. Never use DOT brake fluids (e.g. DOT4/5/5.1/etc.), otherwise the seals of the brake system will be damaged and the brake can no longer be used without an inspection.
  • Page 7 4. Service brake pump The following service manual includes service for the whole brake pump assembly, its disassembly and exchange of all seals. The process is identical for Direttissima and MAXIMA brake pumps. Preparation 1. Fix your bike in a bike stand and dismount the wheels.
  • Page 8 3. Remove the brake pump from your handlebar including clamps and interfaces. Use tools according to the respective manual. Note the lever distance to adjust it to the same setting after the service. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 8 OF 27...
  • Page 9 4. Use an 8mm open-end-wrench to remove the brake hose from the brake pump. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 9 OF 27...
  • Page 10 Disassembly of the brake pump 1. Remove the dial for tool-free reach adjustment using a 7mm open-end-wrench and a HEX2mm key. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 10 OF 27...
  • Page 11 2. Remove both pivot bolts (upper and lower) using a HEX3mm key. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 11 OF 27...
  • Page 12 3. Use a HEX2mm key to remove the lever blade from the piston rod. Use a shop towel to clean the lever blade and put it aside, further service on the lever blade is not necessary. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 12 OF 27...
  • Page 13 4. Remove the circlip with circlip pliers (e.g. Knipex 44 11 J1) from the pump housing. The used circlip should be replaced and not used again. Note: Please dispose of the to-be-replaced parts according to your local recycling guidelines. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 13 OF 27...
  • Page 14 Note: Take care not to scratch the cylinder surface during this step. Remove the pump piston from the spring and dispose of both of them. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 14 OF 27...
  • Page 15 6. Remove the three bolts from the reservoir cap (2x M2+1x M3) using HEX2mm and HEX1.5mm keys. Take out the membrane and discard it. Soak up leaking oil with a shop towel. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 15 OF 27...
  • Page 16 You can dry the pump with compressed air or by putting it on a household radiator for some time. 9. Use a flashlight to check the cylinder surface for cleanliness, scratches and possible damage/debris. If you find your cylinder surface damaged, please contact the Trickstuff- Support. TRICKSTUFF® GMBH...
  • Page 17 Note (MAXIMA): Now is the time to put the correct MAXIMA-Cap on the left/right pump housing, left and right reservoir cap differ in logo orientation! Regularly, the logo faces away from the rider. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 17 OF 27...
  • Page 18 In this case, take off the membrane again and check it for damages optically, then give the assembly another try. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 18 OF 27...
  • Page 19 3. Mount the new piston spring on a new pump piston. Apply a small amount of grease (e.g. Interflon Assembly Grease) to the primary seal as shown in the picture. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 19 OF 27...
  • Page 20 4. Push the pump piston into the pump housing. This should show only minimal resistance. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 20 OF 27...
  • Page 21 Note: Circlips have a sharp and a dull outer edge. When mounting the circlip, make sure the sharp edge is engaged, it has to face outwards (“sharp edge facing  left  in picture below”). TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 21 OF 27...
  • Page 22 Best way is to do it like shown in the image below. Check the circlip for correct seating, it „clicks” when it seats itself correctly. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 22 OF 27...
  • Page 23 Note: Confirm that you reuse the right lever with the right pump housing again and vice versa. Otherwise the bolt for play adjustment (see image below) can’t be reached with the tool later on. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 23 OF 27...
  • Page 24 Note: Apply thread locker to the inner threads, as shown in the picture below. This way you avoid fixing the bearings to the pivot bolts. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 24 OF 27...
  • Page 25 9. Before mounting the dial back onto the piston rod, make sure to apply medium thread locker to this connection as well. Use a 7mm open-end wrench for tightening. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 25 OF 27...
  • Page 26 This eliminates play in the lever movement. Apply torque to the locking bolt until the play is gone, but only so much that it doesn’t prevent you from manually turning the dial. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 26 OF 27...
  • Page 27 4. Bleed the brake system according to the respective manual and mount it back on your bike Technical changes, errors and misprints excepted. TRICKSTUFF® GMBH SCHWABENMATTEN 17A 79292 PFAFFENWEILER GERMANY TECH-SUPPORT@TRICKSTUFF.DE SERVICE MANUAL – DIRETTISSIMA/MAXIMA PUMP V2024_02. PAGE 27 OF 27...