TEKTRO HD-M735 Hydraulic Disc Brake Set Instruction Manual

Product Overview

The TEKTRO HD-M735 Hydraulic Disc Brake Set offers a high-power and controllable braking system designed for bicycles. This set features an open system with a unique F4 (front) and R2 (rear) piston configuration, providing efficient stopping power and modulation. It is engineered for easy installation, adjustment, and maintenance, making it a reliable choice for various cycling needs.

Key Features:

• High power and controllable braking system
• Open System, F4 X R2 piston design
• Easy Installation, Adjustment, and Maintenance
• Forged Aluminum Lever / Cast Aluminum Bracket
• Reach Adjustment for personalized comfort
• Two-piece hinged bracket for convenient mounting
• Front: 4-piston caliper, Rear: 2-piston caliper
• Easy top-loading pad replacement
• High-performance Metal Ceramic compound brake pads
• Includes Wave Type (TR180-53) 180mm rotors for high heat dispersion and tolerance

Package Contents

Upon opening your TEKTRO HD-M735 Hydraulic Disc Brake Set, please verify that all components are present:

• Brake caliper x2 (Front and Rear)
• Brake lever x2 (Left - front and Right - rear)
• Hose x2 (Front: 900 mm / Rear: 1500 mm)
• Brake pad x2 (pre-installed in calipers)
• 180mm Rotor x2 (Wave Type TR180-53)
• Mounting bolts (for calipers and rotors)

Note: This item is supplied in OEM packaging and does not include retail packaging.

Setup and Installation

Proper installation is crucial for optimal performance and safety. If you are unsure about any steps, it is recommended to seek assistance from a qualified bicycle mechanic.

1. Rotor Installation

Attach the 180mm Wave Type rotors to your wheel hubs using the provided mounting bolts. Ensure the bolts are tightened securely according to manufacturer specifications (typically 4-6 Nm, consult your hub manufacturer's guidelines if available).

Image: Two 180mm Wave Type disc brake rotors, ready for installation on wheel hubs.

2. Caliper Mounting

Mount the front (4-piston) and rear (2-piston) calipers to your bike's frame/fork using the appropriate adapters and bolts. Ensure the calipers are aligned correctly over the rotors. The calipers feature an adjustment mechanism to help center them over the rotor, preventing rubbing.

Image: Close-up of the TEKTRO HD-M735 4-piston front brake caliper, showing its robust design.

Image: Close-up of the TEKTRO HD-M735 2-piston rear brake caliper, highlighting its compact form.

3. Brake Lever Installation

Install the brake levers on your handlebars. The two-piece hinged bracket design allows for installation without removing grips. Use a 4mm hex tool to secure the levers. Ensure the levers are positioned comfortably for your hands and fingers, allowing for easy reach adjustment.

Image: The TEKTRO HD-M735 hydraulic brake lever, showing the "MINERAL OIL" marking.

Image: Another view of the TEKTRO HD-M735 hydraulic brake lever, emphasizing its ergonomic design.

4. Connecting Hydraulic Hoses

Connect the hydraulic hoses from the levers to the calipers. Be careful to prevent oil from leaking out during this process, as this can affect braking performance. Tighten the oil pipe securely. Route the hoses through your bike's frame or along existing cable guides, ensuring they do not interfere with steering or suspension movement.

5. Bleeding the System (If Necessary)

The brakes are typically pre-bled from the factory. However, if you experience a spongy lever feel or have disconnected the hoses, you may need to bleed the system. Refer to a comprehensive hydraulic brake bleeding guide or consult a professional mechanic for this procedure. TEKTRO hydraulic brakes use mineral oil.

Operating Instructions

Hydraulic disc brakes offer superior stopping power and modulation compared to mechanical systems. Familiarize yourself with their feel before riding in challenging conditions.

• Brake Lever Feel: The levers should feel firm and consistent throughout their pull. A spongy feel indicates air in the system, requiring bleeding.
• Modulation: Hydraulic brakes allow for fine control over braking force. Practice applying varying pressure to the levers to understand the brake's response.
• Bedding-in: New brake pads and rotors require a "bedding-in" period to achieve full performance. Perform several moderate stops from a cruising speed, gradually increasing braking force. Avoid hard stops during this initial phase.

Maintenance

Regular maintenance ensures the longevity and performance of your TEKTRO HD-M735 brakes.

• Brake Pad Inspection: Regularly check brake pad wear. Replace pads when the friction material is less than 0.5mm thick. The top-loading design makes pad replacement easy.
• Rotor Cleaning: Keep rotors clean and free of oil, grease, or dirt. Use a clean cloth and isopropyl alcohol to wipe them down.
• Fluid Level Check: Periodically check the hydraulic fluid level in the master cylinder reservoir (located in the brake lever). Top up with TEKTRO-approved mineral oil if necessary.
• Bleeding: Bleed the brake system annually or whenever the lever feel becomes spongy.
• Bolt Torque: Periodically check all mounting bolts (caliper, rotor, lever) for proper torque.

Troubleshooting

Here are solutions to common issues you might encounter with your hydraulic disc brakes:

• Spongy Lever Feel: This usually indicates air in the hydraulic system. The system needs to be bled.
• Brake Rubbing Noise:
  1. Caliper Alignment: Loosen the caliper mounting bolts slightly, squeeze the brake lever firmly, and then re-tighten the bolts while holding the lever. This helps center the caliper.
  2. Bent Rotor: Inspect the rotor for any bends or warps. A bent rotor may need to be trued or replaced.
• Reduced Braking Power:
  1. Contaminated Pads/Rotor: Clean the rotor with isopropyl alcohol. If pads are contaminated with oil or grease, they may need to be replaced.
  2. Worn Pads: Check pad wear and replace if necessary.
  3. Air in System: Bleed the brake system.
• Squealing Noise:
  1. Contaminated Pads/Rotor: Clean as above.
  2. Improper Bedding-in: Re-bed the brakes.
  3. Loose Caliper: Ensure caliper mounting bolts are tightened to spec.

Specifications

Warranty and Support

Specific warranty information for the TEKTRO HD-M735 Hydraulic Disc Brake Set is not provided in the product details. Please refer to the manufacturer's official website or contact your retailer for detailed warranty terms and conditions.

For technical support, spare parts, or further assistance, please contact TEKTRO customer service or visit their official support channels.