Owner's manual

HYMEC
 Contents
Graphic Area
Introduction
Preface.......................................8
Legend.......................................8
Technical specifications
– Overview
..................................................9
Safety
Intended use.............................10

Basic safety instructions...........10

Installation
Installing the HYMEC...............12
Preparing the motorcycle........... 12
Installing the clutch control
(master cylinder)........................ 12
Aligning & laying out .
the hydraulic hose..................... 13
Opening the hydraulic hose....... 13
Installing the clutch actuator .
(slave cylinder).......................... 14
Checking/setting .
clutch clearance......................... 15
Adjusting the control lever......... 15
On the Road
Filling/bleeding .
the clutch actuation system....... 16
Service
................................................17

3
 Graphic Area Graphic Area

4
5
1

2
1

8 mm
6 N·m± 0,5 N·m (53 lbf·in± 4 lbf·in) A1 3

1
8 6 7

2 9 10 11

8 mm
8 N·m± 1,5 N·m (71 lbf·in± 13 lbf·in) B1 TD

4
 Graphic Area
STANDARD STANDARD vario STANDARD bolt

1 2 1 2 3

4–6 mm
4–6 mm 4–6 mm
REARMOUNT REARMOUNT vario

1 2 1 2

4–6 mm 4–6 mm C1

5
 Graphic Area
STANDARD vario STANDARD vario REARMOUNT vario

1 1

5 6

2 2 4 3

D1 D2 D3

10 mm
5 N·m± 0,5 N·m (44 lbf·in± 4 lbf·in) D4

6
 Graphic Area

REACH ADJUST

E1

2
4
1

6 mm
F1 F2 2 N·m± 0,2 N·m (2 lbf·in± 4 lbf·in) F3

7
 Introduction
Introduction

Preface Legend
Thank you for your selection of a MAGURA product ))The pointing finger prompts you to perform an action.
– Made in Germany. ÎÎ The arrow shows results or requirements.
This owner's manual is an integral part of your MAGURA product LLThis notice gives you additional information or tips.
and gives you details of the required tools, correct installation, safe (3) refers to an item number in the graphic area – e. g. Pos. ô.
use, maintenance and setup options. [B2] refers to a figure in the graphic area – e. g. Fig. B2.
Please read this manual carefully before you install or use your
This symbol means that notices or figures exclusively
STANDARD
MAGURA product. Observe and follow all instructions for assembly,
apply to the corresponding type or variant.
operation and maintenance in this manual – and also in the user
instructions for your motorcycle. This
+ symbol refers to a specific mounting instruction – down-
load from [Link].

Failure to observe the instructions in this manual can lead to serious

or fatal accidents. This notice warns you about a dangerous situation which can lead
to serious or fatal injury if not avoided.
Remember that the mechanic who installs your MAGURA product
is responsible for the suitability and compatibility of all the compo-
nents technically linked to your MAGURA product. This notice warns you about a dangerous situation which can lead
You can find the figures referred to below in the folder in the cover. to minor or slight injury if not avoided.
The figures may differ slightly from your MAGURA product; how-
ever, the required steps are the same for all types and variants – if
This notice warns you about the risk of material or environmental
not stated to the contrary.
damage.
Due to the many different models of motorcycles, it is unfortunately
not possible to cover every variant in this manual.
See [Link] for specific mounting instructions for various Keep this manual for other users of your MAGURA product. Make
models of motorcycles – you can find assistance with specific sure that each user reads, understands and observes this manual.
­questions in SERVICE, FAQs, DOWNLOADS or CONTACT. If you sell or give away your MAGURA product, be sure to hand
During the first few rides using your new MAGURA product, over this manual to the new owner.
­familiarise yourself with characteristics that may have changed
(lever paths, pressure points etc.) on your motorcycle. We wish you great success and a great ride
Your MAGURA Team

8
 Technical specifications – Overview
Technical specifications – Overview

LLSome of the features detailed are optional variants. Your MAGURA HYMEC clutch actuation system is designed the way it was specified
by you or your dealer.

Type name HYMEC

Variant Off-Road Street
Hydraulic hose Fiber-reinforced high-pressure pipeline
Hydraulic fluid MAGURA Blood (mineral oil)
Clutch control (master cylinder) [TD] Axial
Clutch lever (1) Long • Short Black • Silver
Reach Adjust – grip width adjustment (2) tools not required
clamp ( 3) Ø, mm 22.2 Standard clamp • mirror clamp
Starter switch (4) Option
Choke lever
Decompression lever (5 ) Option
Hot-start lever
Clutch actuator (slave cylinder) [TD] STANDARD REARMOUNT
Slave fixture (fastening point) (6 ) Before slave cylinder After slave cylinder
Actuating rod (dimension) (7) mm Option1
Bleed/fill (8) Easy Fill
Dolly block ( 9) Option1
Nipple adapter (10) Option1
Built-in sleeve (11) Option1
1 Depending on the make and model of motorcycle.

LLSee the current MAGURA Powersports catalog at [Link] for much more information on options, variants, accessories and
extras.
9
 Safety
Intended use Basic safety instructions
Safety

Always remember that riding a motorcycle entails risk both for the
rider and other road users, and for the motorcycle and its compo-
Any use other than the intended use can lead to accidents that
nents. Despite the use of safety gear and complete safety equip-
cause serious or fatal injury.
ment, accidents that cause s­ erious or fatal injury can occur.
The hydraulic MAGURA HYMEC clutch actuation system is Always use your common sense and avoid any unreasonable
­designed and intended exclusively for ­actions!
–– replacing an existing system for clutch actuation on motorbikes. Installation & Maintenance
–– combination with a motorcycle clutch in an original manufac-
turer's condition.
Danger of accident due to system failure caused by incorrect or
–– operation without a return spring.
­impermissible installation work.
–– operation with mineral oil (MAGURA Blood).
–– In many motorcycle models work steps that are only schemati-
The MAGURA HYMEC clutch control (master cylinder) is designed cally shown in this manual are demanding and may in many
and intended exclusively for cases only be possible with specialised manufacturer's tools and
–– installation on conventional motorcycle handlebars. new parts (gaskets, holders, etc.).
Do not overestimate your technical skills. Have installation and
The hydraulic MAGURA HYMEC clutch actuation system must maintenance work carried out in a motorcycle repair workshop.
under no circumstances be combined and used with parts (clutch This is the only way to ensure that work is conducted in a profes-
lever, hose, etc.) of other manufacturers! sional manner.
–– Never carry out any work or make any changes (e. g. disassembly,
Before installing your hydraulic MAGURA HYMEC clutch actuation shortening hoses, grinding/painting, etc.) to your MAGURA
system and any associated dolly block, make sure that they are ­product that are not specifically permitted and described in the
compatible with the model of your motorcycle! owner's manual.
For information see the current MAGURA Powersports catalogue –– Do not press the actuating rod of the HYMEC clutch actuation
and [Link]. system into the slave cylinder by hand. Move the actuating rod
only with the clutch control.
–– Always observe all min./max. values stated.
–– For assembly steps that require a specific tightening torque for a
screw union, always use a torque wrench set up for the required
torque.
–– Always make sure that your motorcycle is securely supported
(main stand, workshop stands) before starting installation or

10
 Safety
maintenance work. –– Always use the front and rear wheel brakes simultaneously.
–– Always disconnect the earth wire from your motorcycle battery –– Always observe the traffic regulations in the country where you
before starting installation or maintenance work. are riding with your motorcycle (lighting, reflectors, etc.).
–– Always maintain your motorcycle in technically perfect working –– When riding, always wear a high quality (e.g. ECE standard
order. 22/05), undamaged motorcycle helmet and clothing that fits
–– Check the clutch for correct clearance and for wear at regular snugly but does not impair your actions.
intervals. –– Only ride your motorcycle if you are in good physical condition
Danger of accident due to improper accessories. and your motorcycle and all of its components are in perfect
–– Use only original MAGURA screws and spare parts and for working order.
bleeding and filling the MAGURA Blood (mineral oil).
–– Do not use DOT brake fluids, hydraulic oils or other fill media. Transport & Storage
–– To fix the HYMEC hydraulic hose, always use the original fasteners
of your motorcycle manufacturer. Danger of accident due to damaged components.
–– Do not store your MAGURA HYMEC clutch actuation system at
On the Road
ambient temperatures below -15 °C (5 °F) or above 55 °C (131 °F).

Danger of accident due to component failure. Protection of the environment

–– Check that the clutch separates correctly before every ride.
–– After each crash, check your clutch for damage and make sure it Dispose of used hydraulic fluid, lubricants and oil correctly and in
operates correctly. accordance with the legal requirements – never discard them in the
–– Never use your clutch if damage (e. g. traces of oil, cracks, etc.) sewage system or in the ground.
is visible, you can hear unusual noises or if you have any doubts
about its integrity. In this case, have your clutch checked in a
specialist motorcycle workshop.

Danger of accident due to improper behaviour or improper equip-

ment during riding.
–– Always match your speed to the current road, weather conditions
and the total weight.
Particularly in wet conditions and a high gross weight (e.g. luggage),
your braking distance will be significantly increased – always ride
cautiously and be ready to brake.

11
 Installation
Installing the HYMEC Installing the clutch control (master cylinder)
Installation

Before installing your hydraulic MAGURA HYMEC clutch actuation ))Make sure that the size of your handlebar fits your control – see
system and any associated dolly block, make sure that they are Technical specifications – Overview, page 9.
compatible with the model of your motorcycle! ))Make sure that your control does not interfere with the operation
For information see the current MAGURA Powersports catalogue of other controls (switches, levers etc.).
and [Link].
))Make sure that the retaining screws are always coated with fresh
))See if+applicable. screwlock (medium strength) before installation.
Preparing the motorcycle
Important – see Basic safety instructions, page 10! Damage to the hydraulic hose.
))Remove panels (cowlings, seat, clutch cover, etc.) if necessary Prior to installing the clutch control ensure the optimum routing of
– handle, clean and store gaskets, fasteners, buffers, etc. care- the hydraulic hose – see Aligning & laying out the hydraulic hose, page 13
fully. – use the existing fastening points.
ÎÎ The clutch actuation system to be replaced is easy to access at
–– If necessary, rout the slave cylinder with hydraulic hose through
all fastening points. the corresponding openings (cable ducts, etc.) – according to the
))If necessary, hook off the Bowden cable on the choke, hot start, routing of the dismantled Bowden cable.
or decompression lever. –– Do not buckle the hydraulic hose.
))If necessary, disconnect cables of the starter switch.
))Remove rear-view mirror if necessary. ))Install and align the control on the handlebar. [A1]
ÎÎ Arrow points to the outside.
))Remove the clutch control.
))Tighten the retaining screw (1) with a tightening torque of
))Note down the routing of the Bowden cable (e.g. photograph).
6 N·m ± 0.5 N·m (53 lbf·in ± 4 lbf·in).
))Loosen the Bowden cable on all fastening points.
LLControls can be rotated by hand when forced. It is advantageous
))If necessary, clean fasteners and fastening points.
))Store fasteners.
if the control can rotate in the event of a fall. This reduces the
))Hook off the clutch cable on the release lever.
danger of irreparable damage to the handlebar or control.
))Dismantle the Bowden cable from the dolly block. ))If necessary, hook the Bowden cable onto the choke, hot start, or
))Remove the Bowden cable or pull it out of the eyelets, ducts, etc. decompression lever – and set later.
ÎÎ The clutch actuation system to be replaced is dismantled.
))Connect the starter switch.
))Dismantle the return spring on the release lever. ))If necessary, install the rear-view mirror – and set later.
))Clean the release lever, nipple seat and surroundings.
))Dismantle, clean and store the dolly block.

12
 Installation
Aligning & laying out the hydraulic hose LLIf you want to lay the hydraulic hose inside the motorcycle frame
LLThe MAGURA HYMEC hydraulic hose cannot be shortened or or through narrow openings (cable ducts, etc.), you must open
lengthened. the clutch actuation system on the clutch control – see Opening
The length of the hydraulic hose is such that it corresponds to the hydraulic hose, page 13.
the original condition of the model of your motorcycle. If you A thin wire may be helpful for inserting.
require a shorter or longer hydraulic hose, you can obtain this Thread it through the appropriate openings in the opposite direc-
from your specialist supplier. tion and attach it to the end of the hydraulic hose with adhesive
tape. However, do not insert the wire into the hydraulic hose – oil
loss!
Danger of accident due to restricted or blocked steering and riding
Carefully pulling with the wire and pushing the hydraulic hose at
movements because hydraulic hose is too short or too long.
the same time will make it easier to find the outlet.
–– Make sure that there is full steering movement in both directions.
–– Make sure that all springs can function freely.
–– Keep the length of the hydraulic hose as short as possible and Opening the hydraulic hose
as long as necessary.
Danger of accident due to system failure caused by faulty installa- Oil loss.
tion. –– Do not actuate the control lever if the hydraulic hose is discon-
–– Make sure that the hydraulic hose cannot be crushed, jammed or nected.
stretched in any position (steering, suspension). –– Handle the open control carefully – store in a vertical position.
–– Make sure that the hydraulic hose cannot exert tension or pres- –– Handle the open hydraulic hose carefully – do not shake it,
sure in any position (steering, suspension) on the slave cylinder. knock it or hit it.
–– Make sure that the hydraulic hose remains at least 30 mm from –– Have clean, absorbent and lint-free cloths ready – wipe any
the hot exhaust or engine parts in all positions (steering, suspen- ­leaking oil away immediately.
sion).
))Dismantle the control from handlebar.
))Fix the hydraulic hose along the optimum position at the specified
))Push the hose cover (1) upwards. [B1]
or suitable points – use available fasteners and fastening points.
))Screw the hose connection (2) out of the control.
))If necessary, fix the hydraulic hose to suitable points with addi-
))If necessary, now lay out the hydraulic hose – see Aligning & laying
tional cable ties. out the hydraulic hose, page 13.
))If necessary, adjust the hose connection to the slave cylinder to
))First screw the hose connection into the brake lever by hand, then
the optimum routing of the hose – see Installing the clutch actuator tighten it with a tightening torque of 8 N·m ± 1.5 N·m (71 lbf·in ± 13 lbf·in).
(slave cylinder), page 14.
))Remove any oil residues thoroughly.

13
 Installation
))Pull and hold the clutch lever several times and check: LLThe following installation sequence is of a schematic nature – the
No oil is leaking from any part of the clutch actuation system. clutch construction of your motorcycle may specify a different,
Pressure point is clearly noticeable and does not change. more practical sequence.
LLIn general it is not necessary to bleed the hydraulic hose after LLYour hydraulic MAGURA HYMEC clutch actuation system is such
opening/closing it. However, if air has entered the system and that it corresponds to the original condition of your motorcycle
the slave cylinder no longer responds to the pull on the lever, you model.
must bleed the clutch actuation system. If difficulties arise during installation, it is possible that the original
))Push hose cover on the sleeve nut. condition of your motorcycle has been changed (different clutch,
holder offset, etc.).
))Install the clutch control to the handlebar – see Installing the clutch
control (master cylinder), page 12. ))Make sure that the retaining screws are always coated with fresh
screwlock (medium strength) before installation.
Installing the clutch actuator (slave cylinder) )) – STANDARD
see bolt. +

There are 5 different fastening variants of the HYMEC slave cylinder:

STANDARDFastening point is at the front, Danger of accident due to a failing clutch caused by incorrect or im-
plugged floating, non-adjustable permissible installation work.
Fastening
STANDARD vario point is at the front, –– Do not press the actuating rod into the slave cylinder by hand.
plugged floating, adjustable –– Move the actuating rod only with the clutch control.
Fastening
STANDARD bolt point is at the front, –– Do not damage the actuating rod (bend, scratch, squash, etc.).
screwed, non-adjustable –– Always secure the actuating rod in the nipple seat.

Fastening point is at the rear,

REARMOUNT )) Screw the
STANDARD adjusting nut (1) on the thread up to the
vario
hooked in floating, non-adjustable stop – hold the setscrew against the hexagon (2) [D1].
Fastening point is at the rear,
REARMOUNTvario
))Plug or hang the slave cylinder onto the dolly block.
plugged floating, adjustable
)) Plug the sleeve (3) and washer (4) onto the thread.
REARMOUNTvario
At the fastening point (1) the slave cylinder supports itself on the Screw the adjusting nut (5) flush on the thread – hold the set-
dolly block (2) or clutch housing (3), [C1]. screw against the hexagon (6) [D3].
LLIf a MAGURA dolly block (9) [TD] is enclosed with your HYMEC, ))Hang the actuating rod in the nipple seat on the release lever – if
use it – otherwise use the original. necessary, use nipple adapter (10) [TD].
))Secure the actuating rod in the nipple seat (split pin, or similar).
))Ensure that the actuating rod can be moved freely – bend the
nipple seat slightly open.

14
 Installation
))Install the dolly block on the motorcycle. Clutch clearance is too small:
)) STANDARD vario Screw the adjusting
REARMOUNTvario nut in the direc- )) Adjust
STANDARDthe dolly block (2) [C1].
tion of the dolly block up to the stop – hold the setscrew against )) Adjust the
STANDARD adjusting nut (1) – hold the setscrew
vario
the hexagon. [D2]/ [D3] against the hexagon (2) [D3].
In case the hydraulic hose does not run optimally: )) – STANDARD
see bolt. +
)) Adjust the dolly block (2) [C1].
REARMOUNT
))Unscrew the screw plug (7) slightly – maximum 30° – and hold it
[D4]. )) Adjust the adjusting nut (5) – hold the setscrew
REARMOUNTvario
against the hexagon (6) [D3] – if necessary, use a longer
))Press the hose connection towards the optimum path.
sleeve (3).
))Tighten screw plug with a tightening torque of 5 N·m ± 0.5 N·m
(44 lbf·in ± 4 lbf·in).
Adjusting the control lever
Checking/setting clutch clearance LLYou can adjust the position of the lever (Reach Adjust – grip width)
of your MAGURA control as required.
This adjustment does not affect the clutch clearance!
Increased clutch wear.
–– Always maintain the specified clutch clearance.
–– The clutch clearance cannot be checked on the clutch control. Danger of accident due to a failing clutch caused by lever travel that
Always check the clutch clearance on the slave cylinder! is too short.
–– Make sure that the clutch separates correctly.
))Pull the slave cylinder from the dolly block (2) or clutch housing (3) –– Enlarge the reach if necessary.
[C1].
))Make sure that the gap (clutch clearance) lies in the range ))Turn the adjusting wheel (1) out (-) or in (+). [E1]
ÎÎ The clutch lever moves closer to or further away from the handle­
­between 4–6 mm. [C1]
bar.
Clutch clearance is too high:
)) Fit a suitable spacer washer in between – if necessary,
STANDARD
adjust the dolly block (2) [C1].
)) Adjust the
STANDARD adjusting nut (1) – hold the setscrew
vario
against the hexagon (2) [D3].
)) – STANDARD
see bolt. +
)) Adjust the dolly block (2) [C1].
REARMOUNT
)) Adjust the adjusting nut (5) – hold the setscrew
REARMOUNTvario
against the hexagon (6) [D3] – if necessary, use a shorter
sleeve (3).

15
 Installation
Filling/bleeding the clutch actuation system ))Continue the process until you cannot see any more air bubbles.
On the Road

))Tighten the bleed valve with a tightening torque of 2 N·m ± 0.2 N·m

Danger of accident due to system failure caused by incorrect or (18 lbf·in ± 2 lbf·in).
­impermissible installation work. ))Disconnect filling syringe with hose.
–– Always take the specified precautions and care when working ))Remove any hydraulic fluid residues thoroughly.
with hydraulic fluids.
))Pull and hold the control lever several times and check:
–– Use only MAGURA Blood (mineral oil).
No hydraulic fluid is leaking from any part of the system.
–– Use only fresh, clean hydraulic fluid from tightly closed containers.
The pressure in the clutch actuation system is immediate, the
LLTo fill and bleed your MAGURA clutch actuation system you will clutch is actuated correctly.
require a filling syringe (1), an appropriate filling line (2) and the ))Repeat the filling and bleeding process if necessary.
correct hydraulic fluid (3). [F1] ))Make sure that the level of the hydraulic fluid is 8 mm below the
))Fill the filling syringe and hose with hydraulic fluid. upper edge of the expansion reservoir.
))Make sure that there is no air in the filling syringe and filling line. ))Add or remove hydraulic fluid as required.
))Insert bellows (5) into the expansion reservoir. [F2]
))Loosen the retaining screw (1). [A1]
))Close the expansion reservoir with the lid.
))Align the control horizontally.
))Tighten the retaining screw with a tightening torque of
6 N·m ± 0.5 N·m (53 lbf·in ± 4 lbf·in).
))Remove the lid (4) and bellows (5) from the expansion reservoir.
[F2]
))Connect the filling syringe with hose tightly to the bleed valve (6)
of the slave cylinder (clutch actuator). [F3]
))Open the bleed valve of the slave cylinder.
))Press hydraulic fluid slowly through the system from the filling
syringe.
))Make sure that the expansion reservoir does not overflow.
))Actuate the control lever several times and let it snap.
ÎÎ Air bubbles will rise in the expansion reservoir.
))Draw the hydraulic fluid slowly through the system into the filling
syringe.
))Make sure that the expansion reservoir does not run empty.

16
 Service

Service
LLFor information about spare parts and accessories, as well as
contact data in the expert MAGURA supplier network, see the
current MAGURA Powersports catalogue and [Link].

17
LLUnsere weltweiten Handelspartner und Service Center finden Sie unter [Link]
LLCheck out our worldwide partners and service centers at [Link]

Deutschland Asia USA

MAGURA Bike Parts MAGURA Asia Limited Co. MAGURA USA
GmbH & Co. KG No. 9, Industrial Park, 10th Road 724 West Clem
Eckisstraße 6 Taichung City 62450 Olney, Illinois
D-72574 Bad Urach 40755 Taichung City, Taiwan
phone +49 71 25 96 94 6-0 phone +886 4 23 59 85 55 phone +1 618 395-2200
fax +49 71 25 96 94 6-17 fax +886 4 23 59 99 10 fax +1 618 395-4711
info@[Link] info@[Link] magura@[Link]

© MAGURA 2016
All rights reserved
Printed in Germany
2 600 337 – 07-2016
Umschlag & Inhalt:
[Link]