Abstract: A brake lever assembly includes a handle mount having a fluid reservoir formed in a lever housing, a cylinder engaged into the lever housing and having one or more apertures communicative with a bore of the cylinder and the fluid reservoir of the lever housing for receiving a piston, a brake handle pivotally coupling to the lever housing with a pivot shaft and pivotally coupled to the piston with a link rod, the lever housing is made of lighter materials, such as plastic or composite materials with a molding process and with a decreasing manufacturing cost, the lever housing is molded onto the cylinder, or the cylinder is engaged into the lever housing after the lever housing is molded.

Abstract: A brake disc for cycle brake systems includes an outer peripheral portion, a hub portion, and an air circulating device attached to the brake disc, and inclined relative to the brake disc, to propel and circulate air around the brake disc when the brake disc is rotated. For example, the air circulating device includes a number of spokes or fan blades secured between the outer peripheral portion and the hub portion of the brake disc, and inclined relative to the brake disc. The fan blades may be secured to the spokes.

Abstract: A disc brake device for cycles includes a housing having two brake shoes disposed beside a brake disc, an actuating member for operating the brake shoes, and a cam secured to the actuating member. The cam includes an outwardly extended cam, and a brake cable has an inner wire adjustably secured to the lever at different locations or distances relative to the cam, for allowing the inner wire to actuate onto the cam with different torques with the lever. The lever has a number of recessed for adjustably receiving the inner wire which may be secured to the lever with a fastener.

Abstract: A method for manufacturing a front fork of a cycle includes forming and disposing a prototype in a mold cavity of a mold device for forming a peripheral space between the mold device and the prototype. A plastic material is then filled into the peripheral space formed between the mold device and the prototype for forming an outer protective layer on the prototype. The sharp edges and projections and/or the dirt and the greasy materials are preferably removed from the prototype before the outer protective layer is formed on the prototype of the front fork.