DIY Installation of Ekar Disc Brake 13sp Brake Sets for Gravel Bikes

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The Campagnolo Ekar Disc Brake 13-speed system is a high-performance braking setup designed for gravel bikes. This brake set offers a seamless balance of power, modulation, and durability, ensuring your bike is ready for tough off-road conditions. In this guide, we will cover the installation, adjustment, maintenance, troubleshooting, and compatibility of the Ekar Disc Brake 13sp [paid link] system.

Tools Required

To install and maintain the Campagnolo Ekar Disc Brake 13-speed, you will need the following tools:

  • 5mm Allen wrench
  • Torque wrench
  • 2.5mm Allen wrench
  • Brake rotor tool (for installation/removal)
  • Cable cutters
  • Brake bleed kit (if needed)
  • Hydraulic fluid (if required for bleeding)
  • 10mm wrench (for caliper mounting bolts)
  • Torque wrench (for rotor mounting bolts)

Installation of the Ekar Disc Brake 13sp Brake Set

Step 1: Prepare Your Bike

Before installing the Ekar Disc Brake system, ensure that your bike frame and fork are compatible with the system. The Ekar 13sp Disc Brake system uses flat-mount calipers and a 6-bolt rotor mounting system. Make sure your bike has the appropriate mounts for these components.

Step 2: Install the Brake Rotors

  1. Position the brake rotor on the hub’s mounting surface.
  2. Secure the rotor by tightening the bolts in a star pattern to ensure even torque distribution. Use a torque wrench to tighten the rotor bolts to the recommended 6 Nm torque specification.

Step 3: Mount the Calipers

  1. Place the caliper onto the flat-mounts on your frame or fork.
  2. Align the caliper so that the rotor runs smoothly between the brake pads.
  3. Use the 10mm wrench to tighten the caliper mounting bolts to the recommended 8 Nm torque setting.

Step 4: Install the Brake Levers

  1. Slide the brake levers onto the handlebars, positioning them comfortably for your riding style.
  2. Tighten the brake lever clamp bolts using a 5mm Allen wrench to 6-8 Nm torque.

Step 5: Connect the Brake Lines

  1. Install the brake lines onto the lever and caliper using the appropriate fittings and connectors.
  2. If you’re using hydraulic brakes, ensure the lines are free of air bubbles by gently squeezing the brake lever while ensuring that fluid flows correctly through the system.

Step 6: Adjust the Brake Pads

  1. Check the brake pad alignment to ensure they are correctly positioned relative to the rotor.
  2. Adjust the pad position if needed by loosening the caliper mounting bolts and shifting the caliper slightly.
  3. Once the pads are properly aligned, tighten the caliper bolts to the recommended torque.

Adjusting the Ekar Disc Brake 13sp System

Brake Pad Alignment

Ensure that the brake pads are aligned properly with the rotor. Misalignment can cause noise or reduced braking performance. To adjust, gently loosen the caliper bolts, shift the caliper to align the pads, and then retighten the bolts.

Lever Reach Adjustment

The Ekar levers have an adjustable reach feature, allowing you to fine-tune the distance between the lever and the handlebars. Use the small tool provided to adjust the reach to your preference.

Brake Fluid and Bleeding

If your brake feels spongy, you may need to bleed the hydraulic system. Follow the instructions provided with the bleed kit to remove air from the system. Bleeding should be done if there are any signs of inconsistent braking performance, or if you’ve just installed new brake lines.

Maintenance of the Ekar Disc Brake 13sp System

Regular Checks

  • Brake Pads: Inspect brake pads for wear and replace them as needed. Typically, you will need to replace the pads every 1,000 to 1,500 miles, depending on usage and conditions.
  • Rotor Surface: Check the rotor surface for any significant wear or warping. Replace the rotor if it is excessively worn or damaged.
  • Brake Fluid: Periodically check the brake fluid level and top it off as necessary to maintain proper braking performance.

Cleaning

To maintain optimal performance, regularly clean the brake calipers, rotors, and pads. Use a clean cloth and mild degreaser to wipe away dirt and debris. Avoid getting the pads too wet with cleaning fluid, as this can reduce their effectiveness.

Cable and Housing

For mechanical brakes, check the cables and housings regularly for signs of wear or fraying. Lubricate the cables to ensure smooth operation. If any cables are damaged, replace them immediately.

Troubleshooting Common Set-Up Issues

Spongy Brakes

A spongy brake lever is often caused by air trapped in the hydraulic brake lines. Bleed the brakes using the brake bleed kit to remove any air and restore firm braking performance.

Squeaking Brakes

If your brakes are squeaking, it may be due to contaminated brake pads or rotors. Clean the rotor with a suitable brake cleaner and replace the pads if necessary.

Uneven Pad Wear

If one side of the brake pad wears faster than the other, it could be a sign that the caliper is misaligned. Loosen the caliper, adjust its position, and then retighten the bolts.

Rotor Rub

If the rotor is rubbing against the brake pads, it may need to be aligned. Loosen the caliper mounting bolts and reposition the caliper until the rotor spins freely without touching the pads.

Customization and Optimization for Better Performance

Brake Levers Adjustment

Adjust the brake lever reach for comfort and control. Finding the right reach helps in better modulation and allows for smoother braking when navigating gravel trails.

Optimizing Brake Fluid

Ensure the brake fluid is at the right level and of the correct type. Low or degraded fluid can compromise braking power. Regular fluid changes will keep the braking system responsive and reliable.

Rotor Selection

For more aggressive gravel riding or wet conditions, consider upgrading to a larger rotor size. Larger rotors provide increased stopping power and are better suited for high-speed or heavy-load braking.

Comparison with Similar Models

The Campagnolo Ekar Disc Brake 13sp system is specifically designed for gravel riding, offering a balance of lightweight construction and powerful braking performance. When compared to other gravel-specific brake systems like the Shimano GRX or SRAM Force, the Ekar system stands out due to its precise modulation and strong lever feel. The main advantage of the Ekar system is its ability to provide consistent and powerful braking over long distances, especially on rough and uneven terrain.

Unlike SRAM or Shimano’s hydraulic systems, the Campagnolo Ekar’s lever design allows for excellent ergonomics and comfort, reducing hand fatigue during long gravel rides. However, it may require more maintenance due to its finely tuned hydraulic components, especially for riders who regularly ride in muddy or wet conditions.

Understanding Compatibility with Other Drivetrain Components

The Ekar Disc Brake system is designed to integrate seamlessly with the Campagnolo Ekar 13-speed drivetrain. However, if you’re looking to mix components from different brands, such as a Shimano or SRAM groupset, it’s important to verify compatibility, especially when it comes to the brake levers and rotors. Mixing different hydraulic systems is not recommended, as compatibility issues with fluid and hydraulic design may arise.

To ensure optimal performance, use the Ekar brake system with Campagnolo’s other gravel-specific components, such as the Ekar cranks, derailleurs, and cassette. This will allow you to maximize the system’s reliability, performance, and ease of maintenance.

By following this guide, you can confidently install, adjust, and maintain the Campagnolo Ekar Disc Brake 13sp system, ensuring your gravel bike is equipped with reliable and powerful braking performance for any adventure.