Operating instructions

ManualsBrandsax-lightness ManualsBicycleengage

Mounting brakes and brake cables

Bowden cables transmit the rider’s signals between

the brake levers/shifter units and the brakes. It is

not least the net brake mounting and cable routing

which makes for a perfect functioning of the brake.

Unscrew the sleeve nut from the brake fastening bolt.

Slide the AX-Lightness and engage brake with the

long bolt into the fork and that with the short one

into the rear frame

(a). Insert the grease-free sleeve

nut from behind into the fork and screw it slightly

onto the brake bolt

(b).

Use a 6 mm Allen key to screw the nut fully to the

end. A secure xing is achieved with 8 to 10 full turns;

by then you should feel a resistance. If you do not feel

a resistance, you must use a longer sleeve nut. Ask

your AX-Lightness and engage dealer for advice.

Bring the AX-Lightness and engage brake in a sym-

metrical position and tighten the sleeve nut to a

torque value of 2 to 3 Nm by using a torque wrench

(c).

Pull the brake lever to the handlebars and slide the

cable through the brake lever and in the rear through

the borehole in direction of the handlebars. Check

the proper position of the cable mount in the brake

lever and make sure the nipple engages in the re-

cess. The largest opening range for Shimano levers is

achieved by rst releasing the shift lever and then by

moving it entirely inwards, as you do when shifting.

Slip the outer brake cable housing over the brake

cable and move it from the handlebar side into the

brake lever until it stops inside (d). Do not use cable

stops! Keep in mind that a coat of grease is applied by

Shimano inside the cable housings on the side with

the lettering. The lettering should therefore show to

the grips.

Route the cable housing in the front along the han-

dlebars and, if available, along the crimp to the thick-

ened are beside the centre of the handlebars. This

is where the bar tape ends later on and the cable

comes out. Fix the cable housings with adhesive tape

in this area. Route the outer brake cable housing in a

large bend to the front wheel brake

(e).

Press the brake calliper together and hold the cable

housing tight nearby the counterbearing on the

brake arm to determine the actual length. Make sure

the cable housing is not bent. Mark where you want

to cut the cable housing.

Before routing the Bowden cables of the rear wheel

brake, turn the handlebars to the full left or right po-

sition to determine the longest length required (f).

With the handlebars turned it must still be possible

to move the cable up or downwards along the head

tube without bending or getting stuck at the headset.

Turn the handlebars from its farthest left to its farthest

right position. The handlebars must remain freely

movable, the outer housings must remain slack and

not be in the way of another cable.

Pull out all inner cables so far that you can be sure

that they are out of the area where you use the cut-

ting tool.

Cut the outer housings to the desired length by using

a special cable cutter, e.g. from Shimano or Park Tool,

or a highly sharp side cutter (g). Make sure the cables

are cut at right angle, thus ensuring a rm contact at

the cable stops.

If they are not, grind the housing end vertically to the

pull direction (h). Using a grinding wheel would ease

this grinding, requires however a good feel for it, as

the friction reducing plastic housing is at risk of melt-

ing as a result of the created heat inside. If necessary,

cool it down with water.

Blunt tools crush the cables unnecessarily and require

a lot of reworking. If necessary, reshape the round

outer housing, if they were crushed.

30 31

Brakes

front

rear