1. Install the front caliper to the fork using a 5mm allen wrench and the 2 supplied mounting bolts shown in (figure 1) . The bike should arrive with the bolts loosely installed to the caliper adapter.
2. Install the brake rotor to the front wheel using the 6 supplied mushroom head bolts. The rotor and 6 bolts are located in the parts box. Be sure any arrows or writing on the rotor are facing out away from the wheel as shown in (figure 2). Tighten the 6 bolts securely in a cross pattern.
3. The front and rear rotors should now be checked to be true. This is best done at the same time the wheels are being trued by utilizing a truing stand. Correct any distortions in the rotors using a disk brake truing fork. Make small bends in the correct direction to the proper places until there is no longer any noticeable run-out in the rotor.
4. Once the wheels are assembled to the bike, the calipers can now be adjusted.
First loosen the cable retaining bolt (figure 4)
and back out the inner pad (figure 5) to gain maximum space between the pads and the rotor.
Turn the barrel adjuster (figure 6) all the way in then back it out approximately a half turn.(figure 6)
Loosen the two bolts that attach the caliper to the adapter. These bolts have convex and concave washers that allow the caliper to be pivoted as well as to be slid side to side. Using one hand to manipulate the caliper and the other to snug the bolts, center the caliper over the rotor so there is equal space between the rotor and the pads on both sides. (Tip) Don't tighten the bolts all at one time. Alternate back and forth from one to the other to prevent movement of your adjustment. The correct result can be seen in (figure 7). Also be sure the friction surface of the pads are parallel to the friction surface of the rotor.
Adjust the inner pad by turning the adjuster (Figure 5) in until the pad is as close as possible to the rotor without the rotor dragging on the pad as the wheel is being turned.
Repeat this step for the outer pad but use the cable pinch-bolt and the barrel adjuster to achieve the desired clearance between the pad and the rotor. (Tip) With one hand pull the tension out of the brake cable and rotate the brake arm on the caliper to reduce the clearance between the rotor and pad. Once in the desired position tighten the cable pinch-bolt (Figure 4) to secure the cable. Small adjustments can be made with the barrel adjuster (Figure6) to fine tune the clearance and pull of the lever.
Check your work by pulling the brake lever. It will have a firm feel and approximately two fingers width fit between the lever and the handlebars. If the pull feels spongy, the brakes were not correctly adjusted and need to closely inspected to be sure all steps were followed. Pay special attention to the parallelism of the caliper to the rotor. Cable stretch and the settling of the cable housing may initially occur requiring readjustment of the cable.