Complete Step-by-Step Guide

Installing a hydraulic disc brake system—especially with internal cable routing—requires precision and proper tools. This guide will walk you through the installation of the Bolide hydraulic disc brake, ensuring stability, safety, and optimal performance.

Preparation Before You Begin

Before starting, make sure all the required components and tools are available:

Required Components

1. Hydraulic disc brake caliper

2. Hydraulic disc brake lever

3. Rubber sleeve

4. Compression nut

5. Olive (copper sleeve)

Required Tools

6. 5mm Allen wrench

7. 6mm Allen wrench

8. PH00 Phillips screwdriver

9. Torque wrench

Having everything ready will make the installation smoother and prevent mid-process interruptions.

（As shown in photo 1）

Step-by-Step Installation Guide

Step 1: Route the Hydraulic Hose & Install the Caliper

1. Guide the hydraulic hose through the internal routing ports of your bike frame.

2. Position the caliper on the frame or fork.

3. Use a 5mm Allen wrench to tighten the caliper bolts securely.

4. Ensure the caliper is aligned with the brake rotor to prevent rubbing.

Tip: A correctly aligned caliper significantly reduces noise and improves braking efficiency.

Step 2: Mount the Brake Lever & Remove Sealing Caps

1. Fix the brake lever onto the handlebar using a 5mm Allen wrench, placing it in a comfortable riding position.

2. Remove the sealing screw on the brake lever with a 6mm Allen wrench.

3. Remove the sealing screw at the end of the hydraulic hose using a PH00 screwdriver.

4. After removing the caps, your components should resemble the diagrams referenced as P4 and P5 in the original manual.

Important:

• Do NOT pull the brake lever after removing the sealing caps—this will cause mineral oil leakage.

• Identify the two reference marks on the hose. They will guide you later during hose insertion.

Step 3: Install the Rubber Sleeve, Compression Nut & Olive

1. Slide the rubber sleeve onto the hydraulic hose.

2. Thread the compression nut onto the hose.

3. Slide the olive (copper sleeve) onto the hose.

Important:
When placing the olive, leave a 3mm gap between the olive’s outer edge and the top of the hose.

Step 4: Insert the Hose into the Brake Lever

1. Firmly insert the hose (with all components assembled) into the brake lever’s connection port.

2. Push the hose in until the first marked line (12mm) is no longer visible.

   • The second line (25mm) should remain outside and will help you check whether the installation is successful.

3. Hand-tighten the compression nut to temporarily secure the connection.

Incorrect Situation ：
The mark visible→hose not fully inserted（wrong)

Correct Situation：
The mark hidden一hose fully seated( right)

Step 5: Torque the Compression Nut

1. Set your torque wrench to 6 N·m.

2. While tightening the compression nut, use your other hand to continuously press the hose inward to ensure it remains fully seated inside the brake lever.

3. Do not stop applying pressure until the torque wrench completes the tightening.

Critical Warning:
If you release the hose while torquing, the hose may retract, resulting in an incomplete connection. This can cause brake failure.

Step 6: Final Checks & Functional Test

1. Confirm Proper Installation

A successful installation is indicated when:

• The second marked line (25mm) is fully covered by the compression nut.

• No gaps or movement are visible at the hose–lever connection.

If the second mark is still visible, the installation must be redone.

2. Perform a Functional Test

• Squeeze the brake lever around 15 times.

• Confirm:

  • Smooth lever feel

  • Proper oil pressure

  • No oil leaks

  • No rotor rubbing

If you notice sponginess, leakage, or abnormal resistance, disassemble and reinstall the components.

Conclusion

By following this guide, you can install the Bolide hydraulic disc brake system safely and correctly. Proper installation ensures strong, consistent braking performance and long-term reliability. If you’re unsure at any step or encounter abnormal resistance, it’s best to consult a professional mechanic.

Note

1. This installation guide applies to all hydraulic brake models available on our website, including ZOOM HB-876E, BUCKLOS HD-E735, BUCKLOS HD-E635, and IIIPRO E500.

Product specifications and compatibility may vary slightly depending on the model. For optimal performance and safety, please follow all instructions carefully and consult a professional technician if you are unsure about any step in the installation process.

2. Internal cable routing is not limited to e-bikes. It is a design choice used in many types of bicycles, including mountain bikes, road bikes, and e-bikes. The goal is to hide the hydraulic hose or cables inside the frame for a cleaner appearance, better protection, and reduced air resistance.