Inside the new Hayes Prime Brake System

Feb 25, 2010
by Mike Levy  
Hayes Removes The Covers On Their New Prime Brake System

Not long ago Hayes released some blurry teasing images of their new Prime brake system. Inside you'll find two videos explaining just what exactly is behind those blurred out pixels and what makes the Prime different from anything else.

Read on...Source: Hayes Brakes

Watch the video to see Poppet Cam technology explained
Views: 12,441    Faves: 4    Comments: 3

Contact adjustment, also known as dead stroke or dead band adjustment, changes the point in the lever stroke where the brake pads come in contact with the rotor. Poppet cam technology accomplishes this without affecting the lever’s home position. Some riders prefer a very short stroke, or throw, when they squeeze the brake lever blade. Others like a lot of lever travel. The poppet cam adjustment covers both, and everything in between. Additionally, you can use our Top-Hat tool free reach adjustment to dial the lever blade position closer to the grip or further away. This feature combined with the poppet cam stroke adjustment allows the rider to tune the Prime brake exactly how they like it. This tuning can be done in the shop or at the trailhead before the ride, but the Prime takes it a step further. The tool-free dials and short adjustment ranges enable the rider to make stroke and reach tweaks on the fly, with the flick of the thumb. No other brake can do this for you. Top-Hat sets start point. Poppet cam sets end point (tire lock point). The two can be adjusted individually without affecting each other.

Hayes Poppet Cam exposed
Hayes Poppet Cam exposed

The poppet cam design has a flow path five times larger than that of the Stroker’s three port-timing holes. This increased flow will eliminate lever pump caused by heat buildup. Additionally, the reservoir allows the brake to compensate for brake pad wear. As the pads shed material, the pistons will slip and allow the pads to stay close to the rotor rub area. When these pistons slip, additional brake fluid is needed behind them. This equalization can only occur with a properly sized reservoir and an efficient flow path.

Poppet Cam animation video
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The bore of the Prime master cylinder does not have port-timing holes drilled into it. In a traditional system, a port or ports must be drilled through the bore in order for the brake fluid to be able to vent into and from the reservoir. This traditional design has been in production for decades and is a relatively simple and cost-effective design. However, the rubber primary cup or seal of the master cylinder piston must cross over these holes every time the brake lever is squeezed, and then back across when it is released. This wears on the rubber cup over time. Additionally, any burrs or imperfections in the port-timing holes will accelerate this wear.

Hayes Prime Details

Improved Reach Adjust

Tool-free design that is independent of the contact adjustment. This feature has improved durability and aesthetics over the existing Stroker design. Additionally, mechanical advantage is fixed regardless of lever home position. This means you get the same power and feel with the lever set close to the grip as you do with it set further away.

Mechanical Leverage Ratio

Increased throughout the entire lever stroke, resulting in a high power level later in the stroke. This promotes progressive braking that is more predictable (modulation).

Hydraulic Power Ratio

20% increase in hydraulic ratio over the Stroker Trail. Higher clamp force on the rotor is reached with the same given input at the lever blade.

• A new four layer low expansion hose tuned for the Prime’s high mechanical and hydraulic ratios.
• New low noise and high Mu two-piece rotor. At 110 grams for the 6” version, it is also lighter.
• Nickel plated, titanium and anodized aluminum fasteners resist corrosion and maintain the high-end finish.
• New press fit Titacon CL 500 bushings are used in the master cylinder body.
• A new two-piece design that allows the master cylinder to be removed without affecting other handlebar components.

Prime floating rotor is available in 140, 160, 180, 203, 224 mm
Prime floating rotor is available in 140, 160, 180, 203, 224 mm

Look out for an upcoming test in the future!

Visit the Hayes Prime website to get more info


  • 9 1
 Lol, why the f you hate it? I think you have maybe one neg experienc with this brake, and now you are saying that its BS....
  • 3 0
 I think Hayes went a little overboard with the sheer complexity of these brakes, sure it's great, but at what cost to the consumer? Avid brakes do their job well, and keep it realitivly to the poinT in terms of the internal mechanics. I believe the K.I.S.S principle applies here.
  • 1 0
  • 2 0
 nobody should knock this stuff till they've had extensive time in the saddle with them. I'm a happy elixir owner, but I'm not gunna lie, the hayes stroker trails are a great brake. What's to say these won't follow in their steps?
  • 2 0
 my trails feel so cheap, and the pins holding the lever are soooo loose. vertict-NOT A FAN OF HAYES!!!
  • 2 0
 ive never had a problem with the hayes brakes ive used, i had a pair of cheap hayes soles that worked great for years never had a single problem. the hayes nines i have now seem pretty good. that being said my favorite brakes ive ever owned are shimano deore hydros. everyone who complains about disc brakes like this needs to reconsider the alternative: rim brakes.
  • 2 0
 That poppet cam technology is quite nice Smile On older hayes brakes you can do the same thing by adding oil under pressure. This technology is really simple but a lill' bit late as the others said. The first ones to add this compression adjust to brakes where Gatorbrake and Giant [fugly brakes ,but they did their job] Smile I'd try the new primes tho
  • 13 8
 hayes dont suck they are just less expensive
  • 21 7
 hate to bust hayes bubble, but this is hardly new or exciting.
  • 9 3
 Exactly what I was thinking! There are much simpler methods using a grub screw against the lever body on the other side of the lever blade pivot from your fingers to set your reach, and what is normally your reach adjust found on pretty much any brake to set the bite point - All of course without this increadably complicated system Hayes seems to have 'invented' here.
  • 3 2
 so they are trying to copy hope, avid and shimano with on the fly adjustment built into the lever, not exactly new technology, just hayes are only just catching up lol
  • 13 2
 I dont understand what everybody is bitching about?!?

my hayes worked very good for several years, never had any probs with them.
  • 4 2
 Once you get extensive time on a set of decent high end brakes you will understand what everyone is bitching about. I used to think the same about my El Camino's untill I switched to Hope's 6-Pot offering.
  • 6 4
 yeah, I understand your point.

but reading those comments sounds like they are crappy brakes, which they just aren´t! Wink

I think it´s good that they put effort in their braking system and try to support us riders with better quality parts!

btw, I switched to Shimano this year, pretty good stuff if you ask me Smile
  • 1 2
 avid taper bore! so simple yet so affective like look at this
  • 2 1
 yeah to be honest they are the last ones to come out with a technology to match their competitions
  • 2 0
 not to say they arent good cuz they do look nice. just a little late. ello poppet
  • 1 1
 any one notice the size it said 152mm on the rotor and there is no 152mm listed wtf
  • 1 0
 I think it is 1.52mm min. wear measurement for the rotor.
  • 1 1
 ^that's not rotor size that's the torque rating for the bolts - 152nm
  • 1 1
 Nice call.
  • 6 0
 No it's the thickness. 152 NM is a shitload of torque!! Especially when a Avid disc needs 6.2 NM...
  • 4 0
 Me = FAIL!! If I'd used my eyes I might have spotted that it clearly says Thickness. I blame the early hour and lack of coffee. Facepalm lol
  • 1 1
 "Bunkey"-Exactly what I was thinking! There are much simpler methods using a grub screw against the lever body on the other side of the lever blade pivot from your fingers to set your reach, and what is normally your reach adjust found on pretty much any brake to set the bite point - All of course without this increadably complicated system Hayes seems to have 'invented' here.

you arent understanding, this isnt for setting the reach, all that screw does is adjust the lever closer or farther from you grip. this keeps the reach in the same location and changes where the break actually engages, some brake you have to pull almost to the grip before in engages, this makes that adjustable so you can have the brake engage anywhere you want, you can pull the level half a cm if you want or all the way to the grip and still have your reach in the same location. very similar to to what avids pad contact adjustment does
  • 2 0
 'this isnt for setting the reach, all that screw does is adjust the lever closer or farther from you grip' As far as I am aware, that is called the reach. This grub screw also keeps the lever in the same position, thus allowing you to use what would normally be the reach adjustment to control the bite point by mimicking lever pull. I have this setup on my Echo lever for my HS33 brake.
  • 1 0
 Nine's are a great recreational brake that I used to run before I started getting a bit more serious. I also know that Hayes makes decent brakes at a pretty good price (Nine's i.e.)

but I'm sorry, once you get your hands on some Juicy 7's, Saints, or Codes you will pretty much never turn back to Hayes.
  • 2 1
 *sigh* hayes might as well just give up, no one trusts the new stuff. look at a cross section of an avid elixir r, and its sooo much simpler than this new brake. an elixir will last longer, feel better, and have the unparalleled great avid reputation
  • 3 0
 Too many hayes haters, hayes work great. No new technology needed, the old hayes nines still work awesome for most aplications, the stroker aces are just amazing.
  • 1 0
 I read this and thought to myself: "so Hayes has finally caught up to the juicy seven (which has been out since what 2000?)" then i see the rotor and think "and had a baby with hope"

I think this brake will be an improvement to the Hayes line up, However some how Hayes has managed to miss the biggest issue with there brakes. They have no "saftey" click so if you fall you are out a master cylender and most likely a lever. It was when i busted my Hayes brake i swore to never run them until that click was added.
  • 1 0
 Avid probably had a patent on the "pad contact adjustment" that is on the Juicy sevens and the patent probably went public this year. Looks to me like Hayes copied avid technology and spiced it up with "on the fly adjustments" even though you can make on the fly adjustments to 7's as well.
  • 2 0
 So what was the blurry parts one the earlier post? The cam? IDK maybe I'm a tard.
  • 1 0
 You are correct, the blurred out bit was the small cam dial. Also new are the two videos that really explain how the system works.
  • 1 0
 Cause shimano and avid definatly dont already have this yet, SO REVOLUTIONARY!
  • 3 2
 I'll stick to my Stroker Rydes this year and see how they hold up.
  • 2 1
 how often do u bleed those?
  • 1 0
 never... ive had stroker trails and my firend had a avid code he bleed it once a month i have never in this year...
  • 1 0
 nice, thanks
  • 1 0
 is this going to be something dh like the ace or more xc oriented?
  • 1 2
 I haven't eperimented with many different brakes but I've never had an issue with, or reason to replace my Juicy's.
  • 1 2
 This is kind of cool, but to me i'm just nervous of to many moving parts and catastrophic failure at the wrong time
  • 1 1
 these are going to be so good
  • 1 1
 Do brakes really need to be that complicated? like really.
  • 10 12
 new technology with the same cheap construction!
  • 10 2
 Did you watch the videos? look at the cut away thats not cheap and nasty
  • 2 1
 sorry but out of the countless hayes brakes ive tried, every single one from old school mags and 9s to new stroker aces and trails all of them have had a shifty and cheap feeling to them.. but i also have met plenty of ppl still using old pairs of mags on thier new rigs. just my observation that they feel far far far less stiff and quality to my few pairs of avids ive owned. i really hope that these new ones are stiff and strong, hayes needs to prove me wrongbefor i spend money on them
  • 3 2
 I'm with you. I've had too many bad experiences with the Stroker Trials that I sold A LONG time ago to ever consider ditching my awesome Elixir SL's and Elixir CR's. Plus, having such great past experiences with Codes and Juicy 7's, I'm sold on SRAM stuff.
  • 1 1
  • 1 3
 for dh, at least put the XT,, or saint if you got extra penny ... others is not
  • 2 2
 except there shimano!!!
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