1. Welcome to the Formula Brake Workshop

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

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

10. R1 S M/C spare parts
Description
Position
Code
R1 S Complete: R1x front brake 85cm
FD86085XMY
R1 S Complete: R1x rear brake 170cm
FD86170XMY
(Left-XO) R1 Complete master cylinder
All the parts (Exc. 27) FD
(Right-XO) R1 Complete master cylinder FD
R1 Complete master cylinder body
1-2-3 FD
Complete black lever kit (TFRA Red) FD
FCS Kit (Red anodized) 27 FD
Piston kit
(grease/grasso) FD
Screw reservoir kit
19-20 FD
(Black) Master cylinder clamp and screws FD
X0 Left Master cylinder clamp and screws
---- FD
X0 Right master cylinder clamp and screws FD
Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 10

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

12. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011
R1 S Caliper Spare Parts
Description
Position
Code
Rx Complete caliper (red anodized cap)
All the parts (Exc ) FD
Rx caliper body 1
FD-C284-04
Screws kit
6-7-8 FD
Piston kit
3-3-(grease/grasso) FD
ORing Kit FD
Sintered brake pads kit “Mega/The one/R1/Rx” (BOX)
2-2-11 FD
Screw pads Seeger Kit (50 pcs)
12(50 pcs) FD
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
Description
Position
Code
THE ONE S Complete:T heOne fr front brake 90cm without disc/adaptor
FD86090XER
THE ONE S Complete: TheOne fr front brake 175cm without disc/adaptor
FD86175XER
(Left-XO) RX Complete master cylinder
All the parts (Exc. 11 – 28) FD
(Right-XO) RX Complete master cylinder FD
Rx Complete master cylinder body Black FD
Complete black lever kit (TFRA Red) FD
FCS Kit (Red anodized) 28 FD
Piston kit FD
Screw reservoir kit
11-12 FD
(Left) Master cylinder clamp and screws
1-2(2 Pcs.) FD
(Right) Master cylinder clamp and screws FD
X0 Left Master cylinder clamp and screws
---- FD
X0 Right master cylinder clamp and screws FD
Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 14

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

16. THE ONE R Caliper Spare Parts
Description
Position
Code
The One Complete caliper
All the parts (Exc ) FD
Screws kit FD
Piston kit (2 pcs)
3-3(grease) FD
O-Ring Kit FD
Sintered brake pads kit “Mega/The one/R1/Rx” (BOX)
8-8-9 FD
Screw pads Seeger Kit (50 pcs)
7 (50 pcs) FD
Disc Ø160mm - 6 bolt (Solid) 3 FD
Disc Ø180mm - 6 bolt (Solid) FD
Disc Ø203mm - 6 bolt (Solid) FD
Hose joint kit FD
70 cm Complete hydraulic hose
All the parts FD
Adaptor for rear Ø160mm I.S. 5 FD
Front adaptor P.M. for Ø180mm P.M. 6” 9 FD
Front adaptor P.M. for Ø203mm P.M. 6” 11 FD
Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 16

17. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011
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. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011
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
Friction at quadrings is too high.
Leaking membrane.
Pump piston damage.
Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011 20

21. Formula Workshop SBC Service Center Salt Lake City Aug 8th, 2011
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. Formula Workshop SBC Service Center
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. Formula Workshop SBC Service Center
Contact Information
Formula USA
Formula North America
Charlie Schneider
405 East D Street, ste c
Petaluma, CA 94952
Tel:
Christoph Vogl
414 Hwy 21 Bypass
Fort Mill, SC 29715
Tel:
Formula Workshop SBC Service Center
Salt Lake City Aug 8th, 2011 23