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1. NEEDLE NOSED PLIERS x x SNAPRINGPLIERS INTERNAL x x avi o x x x isoPROPYLALCOHOL x ewm e x x o pot PHILLIPS HEAD screworIveR fo ox LAIR COMPRESOR WITH BLOW GUN CHUCK 1 x y soapywaren x J x jicecoupeeverace x Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL HYDRAULIC DISC BRAKE LEVER OVERHAUL ELIXIR R CR INTRODUCTION Avid brake lever assemblies need to be serviced in order to optimize braking function If brake fluid is leaking from any area of the brake lever assembly there may be damage or wear and tear to the internal moving parts If your brake was filled with fluid OTHER than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the housing assembly Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function LEVER OVERHAUL SERVICE INSTRUCTIONS GETTING STARTED Remove brake lever from handlebar Remove caliper from fork or frame If dirty clean with soapy water and a clean rag Pull hose boot off compression nut and slide down hose not pictured 2 Elixir CR Use an 11 mm open ended wrench to hold the hose
2. GEN 0000000000362 Rev A CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT BRAKE PADS AND PAD H SPRING REMOVAL o9 2 Remove e clip from guide pin groove on top of the caliper using a sharp pick 3 Using a 2 5 mm hex wrench remove the guide pin from the caliper 4 Squeeze the pads together so they clear the pis tons and pull to remove brake pads and h spring from caliper CALIPER DISASSEMBLY AND SERVICE 5 Using a 4 mm hex wrench loosen all four caliper body bolts until there is slight gap in the caliper halves This will ease banjo bolt removal 6 Using two 4 mm hex wrenches loosen and remove the banjo sleeve bolt and banjo shoulder bolt 7 Completely remove all four caliper body bolts separate the caliper body into its two halves and remove the banjo 8 Using sharp pick remove the o rings from underneath the heads of both the banjo sleeve bolt and banjo shoulder bolt and replace with new o rings 9 Using a sharp pick remove the banjo o rings on both the right and left side of the caliper halves and replace with new o rings BRAKE PISTON REMOVAL AND SERVICE 10 Using an air compressor chuck insert chuck nozzle into banjo bolt hole Hold caliper in a rag in one hand using your thumb or finger to seal the backside of the banjo bolthole Squeeze the air chuck and force air into the banjo bolt hole The compressed air will unseatthe caliper piston from the piston pockets IMPORTANT BE SURE TO POINT THE CALIPER IN
3. OND PAD PUSH IT OUT FROM THE OPEN TOP OF THE CALIPER WITH A PICK OR YOUR FINGER 3 Removethe spring pad clip from the outside of the caliper 4 Inspect and measure the total thickness of each brake pad with a ruler If the total thickness is less than 3 mm you need to replace both brake pads not pictured NOTE IF THE BACKING PLATE AND PAD MATERIAL IS THICKER THAN 3 MM YOU CAN SIMPLY RE INSTALL YOUR BRAKE PADS AS OUTLINED IN STEP 5 INSTALL THE NEW PADS AND H SPRING 5 Position the h spring between the two pads The curved handle of inner pad should face toward the inboard side of the caliper Squeeze the pad and spring assembly together then firmly push into the caliper until it clicks into place indicating itis properly secured in the caliper body THIS CONCLUDES THE DISC BRAKE PAD REPLACEMENT INSTRUCTIONS YOU DID A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 55 56 CODE CODE 5 INTRODUCTION Avid brake pads should be replaced when the total thickness ofthe backing plate and pad friction material is less than 3mm Replacing worn brake pads will improve braking performance New brake pads are subjectto a break in period It may take anywhere from 20 to 40 complete stops to break in Avid pads You may begin to notice an increase in braking power after the first ride Brake noise can occur during the break in period as well as off and on througho
4. 36 Align both caliper halves together and insert the caliper body bolts The short bolt goes in the hole near the cable anchor and the long bolt goes in the hole near the housing stop Torque both bolts to 75 90 in Ib NOTE BE CAREFUL TO KEEP THE PAD RETAINER IN PLACE WHILE JOINING THE HALVES TOGETHER Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL N EXTENDED 4 LEG SPRING TENSION NOTCH PAD RETAINER 43 CALIPER OVERHAUL ASSEMBLY SERVICE INSTRUCTIONS INSTALL THE NEW PADS AND SPRING e 36 Assemble the spring between the new left and right pads Align the spring to the pad as shown Squeeze the brake pad and spring clip assembly together then press firmly into the caliper until it clicks into place The pad marked R goes on the spoke side of the brake 37 Push the upper and lower boots onto the integrated cable stop 38 Place the cable anchor plate on the cable anchor bolt grease the bolt lightly and install into the torque arm not pictured 39 Re mountthe caliper onto the bike 40 Set up the brake by following the procedures in the Avid Ball Bearing Disk Brake Installation Guidelines Be sure to torque to the proper value COMPLETING BALL BEARING DISC BRAKE CALIPER OVERHAUL You are almost ready to ride but first it s a good idea to test your brakes by pulling on the lever extremely hard as hard as you can imagine yourself pulling the lever while you re riding several ti
5. Set star wheel worm assembly aside NOTE DO NOT RE INSTALL STAR WHEEL AND WORM GEAR BACK INTO LEVER ASSEMBLY AT THIS POINT IMPORTANT REPLACE THE STAR WHEEL AND WORM GEAR IF IT IS DAMAGED CRACKED OR BROKEN OR IF YOU ARE SWITCHING SIDES OF LEVER BODY OR ROTATING BRAKE LEVER TO OTHER SIDE OF BAR LEVER BLADE PUSHROD REMOVAL Code 5 Juicy 5 7 Carbon Ultimate Only Holding the lever in both hands place your thumbs near the pivot and push The lever gently snaps into the open position Using a 2 5mm hex wrench T 8 Torx for Juicy Carbon Ultimate unthread lever pivot set screw and remove completely Using a small hex wrench push lever pivot pin through lever body and remove GEN 0000000000362 Rev A LEVER OVERHAUL SERVICE INSTRUCTIONS C LEVER BLADE PUSHROD REMOVAL CONT Juicy 3 Only Use a 2mm hex wrench and unthread the lever pushrod completely by turning clockwise Pull lever blade away from lever body OR Code 5 Juicy 5 7 Carbon Ultimate Only Pull lever blade away from lever body and remove pushrod pin from worm gear It will pop out Remove pushrod from lever Replace pushrod dust boot if damaged Clean if not damaged Insert pushrod dust boot back onto pushrod with the open end facing the pin and the closed end toward threads Re install pushrod into lever blade Pushrod unthreads and threads back into lever blade not pictured IMPORTANT REPLACE LEVER BLADE AND OR PUSHROD IF EITHER IS B
6. A SAFE DIRECTION YOU MAY WANT TO DO THIS INSIDE A PLASTIC BAG TO PREVENT THE PISTON FROM CAUSING INJURY OR BECOMING LOST NOTE BECAUSE OF THE NATURE OF A FOUR PISTON CALIPER BOTH PISTONS IN EACH HALF OF THE CALLIPER MAY NOT BE UNSEATED SIMULTANEOUSLY TO REMOVE THE SECOND PISTON USE YOUR THUMB TO SEAL THE EMPTY PISTON POCKET OR FIND A METRIC SOCKET EXTENSION THAT FITS SNUGLY INTO THE PISTON POCKET AND SEAL THE TOP OF THE EXTENSION WITH YOUR THUMB REPEAT STEP 10 TO REMOVE THE LAST PISTON 11 Remove the square edge o ring from inside each piston pocket using a sharp pick and place with new o rings 12 Remove both banjo bolt bleed screws from the top of the caliper body using a T 10 Torx wrench 13 Remove the o rings from the bleed screws and replace with new o rings Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 37 38 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT 14 15 16 17 18 19 20 21 22 23 24 CALIPER ASSEMBLY Inspect the caliper pistons for damage and replace if necessary Insertthe caliper brake pistons back into each half of the caliper body NOTE GENTLY ROLLING THE PISTONS CLOCKWISE AS YOU INSTALL WILL HELP WITH INSTALLATION Place banjo sleeve bolt into the left half out board side of the caliper Slide banjo onto the sleeve bolt and set the banjo angle to the desired angle Align both caliper halves together and insert the banjo shoulder bolt and the four ca
7. Brake sleeves Brake pads Chains Sprockets Cassettes Shifter and brake cables inner and outer Handlebar grips Shifter grips Jockey wheels Disc brake rotors Wheel braking surfaces Bottomout pads Bearings Pawls Transmission gears Tools This warranty shall not cover damages caused by the use of parts of different manufacturers This warranty shall not cover damages caused by the use of parts that are not compatible suitable and or authorized by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use AVID BRAKE SERVICE We recommend that you have your Avid brakes serviced by a qualified bicycle mechanic Servicing Avid brakes requires knowledge of brakes components as well as the special tools and fluids used for service Used brake fluid should be recycled or disposed of in accordance to local and federal regulations NEVER pour brake fluid down a sewage or drainage system or into the ground or a body of water This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols TM and respectively Copyright SRAM Corporation 2008 For exploded diagram and part number information please refer to the Spare Parts Catalog available on our website at www sram com For order information please contact your local SRAM distributor or dealer Information contained in this publication is subjectto change at any time without prior notice F
8. OUT WITH THE FORCE OF THE SPRINGS DO NOT LOOK INSIDE WHILE REMOVING TO AVOID POTENTIAL EYE DAMAGE Using needle nosed pliers carefully remove coupling retainer coupling assembly Coupling retainer should slide out from lever body easily Hold lever body assembly upside down and drop the piston spring assembly into your hand It should slide out easily OR Juicy 7 Carbon Ultimate Only Rotate worm gear retaining clip with a small flathead screwdriver or sharp pick until the end of the clip protrudes pastthe gap in the lever body push end of clip to rotate within groove Using needle nosed pliers grasp the clip to remove from the lever body Insert a large flathead screwdriver into wide slot in top of worm gear and turn counterclockwise Unthread worm gear completely and slide pull worm gear out of lever body assembly Worm gear coupling is located inside worm gear The piston spring below piston inside lever body should force piston assembly out of lever body If the spring does not aid piston removal use a sharp hooked pick to pull piston and spring assembly from lever body Be careful not to damage the piston NOTE IF THE WORM GEAR COUPLING IS CRACKED PULL COUPLING OUT OF GEAR AND REPLACE COUPLING CAN WEAR OUT OVER TIME AND CRACK ULTIMATE ULTIMATE JUICY 7 CARBON ULTIMATE With piston spring assembly removed from lever body remove the piston from the spring Using a small flathead screwdriver remove sprin
9. OVERHAUL SERVICE INSTRUCTIONS TROUBLESHOOTING STICKY OR SLOW BRAKE PAD RETURN FEEL Before completely disassembling your caliper it s worth trying to loosen the sticky piston Try the following Clamp bicycle in bicycle work stand Spin affected wheel Lightly squeeze brake lever and watch brake pads when lever is released Determine which side of the caliper has a slow returning brake piston Remove caliper from bicycle If you have a mounting bracket it is recommended to remove that too or just remove the caliper leaving the bracket on the fork or frame Using a pair of needle nosed pliers remove both brake pads and h spring Using an 11 mm box wrench press working piston into caliper body Squeeze brake lever slowly to move sticky piston inward Press the piston back into the caliper again Repeat these steps to correct caliper piston inner o ring position Both pistons should now be moving freely Re install h spring and pads into caliper Re install caliper onto bicycle Spin wheel and check function If there is no improvement continue with caliper service GETTING STARTED 1 Remove brake caliper from fork or frame and remove the caliper mounting bracket and CPS hardware from the caliper Set aside in correct order not pictured BRAKE PAD AND H SPRING REMOVAL 2 Using needle nosed pliers grab one of the pad tabs and slide the pad toward the center of the caliper this disengages the pad backing plate fro
10. REMOVAL CONT 15 Using snap ring pliers remove the retaining ring located in the lever body atthe base of the push rod Remove pushrod and internal piston spring assembly IMPORTANT THE INTERNAL PISTON SPRING ASSEMBLY IS PRELOADED AND WILL COME OUT OF THE LEVER BODY QUICKLY BE SURE TO POINT THE ASSEMBLY IN A SAFE DIRECTION OR INTO A PLASTIC BAG 16 Using a T 10 Torx wrench remove the Pad Adjust Knob Remove the detent ball bearing and spring located directly beneath the Pad Adjust Knob with a pick IMPORTANT BE CAREFUL NOT TO LOSE THE DETENT BALL BEARING AND SPRING WHEN REMOVING THE PAD ADJUST KNOB YOU MAY WANT TO HOLD OVER A CLEAN RAG WHILE PERFORMING THIS STEP 17 Gently push the bevel gear out of the lever body from the backside using a pick or your thumb PISTON SPRING ASSEMBLY OVERHAUL 18 Remove the spring from the piston spring assembly 19 Using a small flathead screwdriver remove the spring coupling from the piston followed by the cupseal glide ring and secondary quadseal o ring 20 Install a new quadseal o ring followed by the glide ring and a new cupseal with the open end out not pictured 21 Install the spring coupling back onto the piston and snap the return spring back onto the spring coupling INTERNALS INSTALLATION 22 Install the bevel gear into the gear bore and hold in place with your finger 23 Install the detent spring and ball into the lever body 24 Align the Pad Adjust Knob wit
11. TO PREVENT THE PISTON CAUSING INJURY OR BECOMING LOST 11 Remove the square edge o ring from inside each caliper body half with a sharp pick and replace with new square edge o rings Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 27 28 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT 12 13 14 15 16 17 18 19 20 21 22 23 CALIPER ASSEMBLY Inspect caliper pistons for damage and replace if necessary Re install caliper brake pistons into each half of the caliper body Make sure the piston slots are vertical in caliper body this keeps the fluid slots on the back side of piston lined up with fluid ports Using a sharp pick remove and replace the outboard caliper body o ring Using a T 30 Torx and an 8 mm open ended wrench re install the caliper body bolts and torque to 8 5 10 2 N m 75 90 in Ib Using a T 10 Torx wrench remove bleed screw Using a sharp pick remove bleed screw o ring This o ring may be a little hard to see Replace with a new bleed screw o ring Re install banjo bolt bleed screw into banjo bolt and tighten with T 10 Torx wrench BRAKE PAD INSTALLATION Measure the total thickness of each pad pad backing plate and pad material If there is less than 3 mm of total width replace both brake pads not pictured Be sure the h spring is oriented to the pads as shown Align the hole in the h spring with the holes in the pad tabs Squeeze the pad a
12. The Avid Technical Manual assumes you are performing a complete overhaul of the entire braking system and separates brake service into four main service categories 1 hydraulic disc brake lever overhaul 2 disc brake caliper overhaul 3 hydraulic disc brake hose length adjustment amp bleeding 4 disc brake pad replacement You will need to know what style of brakes you have in order to service successfully service them Some brakes to do not use all four service categories If you are unsure of the style of your brakes contact your local Avid dealer for assistance BRAKE STYLE amp SERVICE CATEGORIES ALL BRAKES The following chart lists the serviceable brake models in the 2009 Avid product line It details each brake model style and the corresponding service categories Important You must bleed your brakes if you overhaul the levers and or the calipers on a hydraulic disc brake system Overhauling the levers and or calipers introduces small amounts of air into the system Failure to bleed the brakes to remove this air can degrade the performance of your brakes which could lead to serious and or fatal injury while riding BRAKE STYLE SERVICE CATEGORIES HYDRAULIC MECHANICAL LEVER CALIPER HOSE ADJUST PAD BRAKE MODELS DISC DISC OVERHAUL OVERHAUL amp BLEED REPLACEMENT CODE CODES Lx x BB7 Mountain and Road o I X LL L ea o GEN 0000000000362 Rev A TOOLS NEEDED FOR SERVICE ALL BRAKES
13. a 2 5 mm hex wrench remove the guide pin from the caliper Pull and remove both brake pads and h spring Using a 10 mm box wrench press working piston into caliper body Squeeze brake lever slowly to move sticky piston inward Press the piston back into the caliper again Repeat these steps to correct caliper piston inner o ring position Both pistons should now be moving freely Re install spring pad clip h spring and pads into caliper Re install caliper onto bicycle Spin wheel check function If there is no improvement continue with caliper service GETTING STARTED 1 Remove brake caliper from fork or frame and remove the caliper mounting bracket and CPS hardware from the caliper Set aside in correct order not pictured BRAKE PAD AND H SPRING REMOVAL 2 Remove e clip from guide pin groove on top of the caliper Using a 2 5 mm hex wrench remove the guide pin from the caliper 3 Pull and remove both brake pads and h spring NOTE IF THE TOTAL THICKNESS OF THE BACKING PLATE AND PAD FRICTION MATERIAL IS LESS THAN 3 MM THE BRAKE PADS NEED TO BE REPLACED GEN 0000000000362 Rev A CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT ELIIXIR CR ONLY BRAKE HOSE BANJO BOLT REMOVAL AND O SERVICE 4 Using an 8 mm open end or box wrench loosen banjo bolt Brake fluid will leak so hold over a container to catch fluid 5 Pull banjo bolt completely out of caliper Dump all caliper brake fluid into container 6 Remove and
14. cam 30 Install the lever blade onto the cam and return spring making sure the exposed spring leg is seated into the hole on the lever blade With your thumb roll the cam on the brake lever so that the lever pivot holes are aligned NOTE YOU CAN USE A 5 MM CABLE FERRULE AS A TOOL TO HOLD THE CAM AND LEVER BLADE TOGETHER AS YOU INSTALL THE ASSEMBLY TO THE LEVER BODY 31 Press pushrod coupling back into slot in cam 32 Insertthe lever blade assembly into the lever body at a slight angle The pushrod coupling should snap firmly onto the exposed pushrod 33 Rotate the lever so that the pivot and lever body bores are aligned and push the lever pivot sleeve bolt through the bearing Using a 4 mm hex wrench tighten sleeve bolt to 2 2 5 N m 17 22 in Ib NOTE IF YOU USED A FERRULE TOOL IN STEP 30 INSTALLING THE PIVOT SLEEVE BOLT WILL PUSH OUT THE FERRULE TOOL BE SURE THE BOLT TOOL IS COMPLETELY REMOVED FERRULE TOOL GEN 0000000000362 Rev A LEVER OVERHAUL SERVICE INSTRUCTIONS CONT LEVER BLADE CAM INSTALLATION CONT 33 Squeeze the lever a few times to ensure thatthe lever depressed and returns fully not pictured 34 Rotate the Pad Adjust Knob to the full in and the full out position to ensure full range of adjustment not pictured 35 Install the bladder reservoir cap using a T 10 Torx wrench and tighten to 1 1 2 N m 8 7 10 4 in Ib THIS CONCLUDES THE LEVER OVERHAUL SERVICE INSTRUCTIONS YOU HAVE D
15. guide pin through the caliper body halves and the brake pads Using a 2 5 mm hex wrench tighten the guide pin to 0 9 1 1 N m 80 97 in Ib 9 Remove the pad tool The h spring will snap the pads into position 10 Using your thumb or finger install the e clip into the groove on the end ofthe guide pin THIS CONCLUDES THE DISC BRAKE PAD REPLACEMENT INSTRUCTIONS YOU DID A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY GEN 0000000000362 Rev A BB7 MOUNTAIN amp ROAD INTRODUCTION Avid brake pads should be replaced when the total thickness ofthe backing plate and pad friction material is less than 3mm Replacing worn brake pads will improve braking performance New brake pads are subjectto a break in period It may take anywhere from 20 to 40 complete stops to break in Avid pads You may begin to notice an increase in braking power after the first ride Brake noise can occur during the break in period as well as off and on throughout the life of the brake pads This is normal and should not affect braking performance Noise is dependent upon factors such as brake setup rider weight riding style braking style and riding conditions i e dust soil and contamination of friction surfaces PAD REPLACEMENT REMOVE THE OLD PADS Turn both adjuster knobs all the way out counterclockwise then squeeze the pad tabs together and pull both pads and pad spring clip straight out of the caliper 2 Inspectand measure the total thic
16. replace o ring on banjo bolt and banjo CALIPER DISASSEMBLY AND SERVICE 7 Using an 8 mm and T 30 Torx loosen and remove the caliper body bolts 8 Separate caliper body halves and open caliper assembly 9 Using a sharp pick remove small banjo hole body half o ring BRAKE PISTONS REMOVAL AND SERVICE 10 Inboard Caliper Body Half Using an air compressor chuck insert chuck nozzle into banjo bolt hole Hold caliper in one hand pointing caliper piston in a safe direction Hold one finger over the banjo bolt through hole on opposite side of caliper body so air does not escape Squeeze the air chuck and force air into the banjo bolt hole while holding caliper body Compressed air unseats the caliper piston from the caliper Pull out completely and remove piston IMPORTANT POINT THE CALIPER IN A SAFE DIRECTION USE A CLOTH OR A PLASTIC BAG TO PREVENT THE PISTON CAUSING INJURY OR BECOMING LOST Outboard Caliper Body Half Using an air compressor chuck insert chuck nozzle into banjo bolt hole Hold caliper in one hand pointing caliper piston in a safe direction Hold one finger over the banjo bolt through hole on opposite side of caliper body so air does not escape Squeeze the air chuck and force air into the banjo bolt hole while holding caliper body Compressed air unseats the caliper piston from the caliper Pull out completely and remove piston IMPORTANT POINT THE CALIPER IN A SAFE DIRECTION USE A CLOTH OR A PLASTIC BAG
17. star wheel assemblies Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function LEVER OVERHAUL SERVICE INSTRUCTIONS GETTING STARTED o9 Remove brake lever from handlebar Remove caliper from fork or frame If dirty clean with soapy water and a clean rag Pull hose boot off compression nut and slide down hose not pictured 2 Using an 8 mm or 5 16 line wrench and socket wrench loosen and remove compression nut from lever body Turn counterclockwise to remove Unthread completely by hand and slide compression nut down hose Pull brake hose and compression fitting from lever body 3 Allow any brake fluid to drain into a container Hold lever assembly over container and pump lever to remove any brake fluid inside lever assembly NOTE IF THE SYSTEM HAS BEEN CONTAMINATED WITH THE WRONG FLUID YOU WILL NEED TO FLUSH ALL THE PARTS WITH SOAPY WATER AND ALLOW TO DRY FULLY PRIOR TO REBUILDING YOU WILL ALSO NEED TO INSTALL A NEW HOSE RESERVOIR COVER BLADDER REMOVAL 4 Using a T 10 Torx small Phillips screwdriver for Juicy 3 remove both reservoir cover screws 5 Remove reservoir cover cap and bladder from lever assembly Additional brake fluid will drain from lever Hold lever over container and allow fluid to drain Set lever assembly down on clean towel not pictured 6 Holding the reservoir cover remove bladder from reservoir cover Re
18. stop in place and use an 8 mm open ended wrench to unscrew the hose compression nut Elixir R Use an 8 mm open ended wrench to unscrew the hose compression nut Unthread the compression nut completely by hand and slide it down the hose Pull brake hose and compression fitting from lever body 3 Allow any brake fluid to drain into a container Hold lever assembly over container and pump lever to remove any brake fluid inside lever assembly NOTE IF THE SYSTEM HAS BEEN CONTAMINATED WITH THE WRONG FLUID YOU WILL NEED TO FLUSH ALL THE PARTS WITH SOAPY WATER AND ALLOW TO DRY FULLY PRIOR TO REBUILDING YOU WILL ALSO NEED TO INSTALL A NEW HOSE LEVER ASSEMBLY Take a few moments and familiarize yourself with the internal components of your brake lever This will assist you in identifying the D components while you service your brake l l e Y AD EXPLODED VIEW ELIXIR R CR LEVER ASSEMBLY 4 5 LEVER BODY PIVOT BUSHING 1 REACH ADJUST SCREW PISTON SPRING LEVER BLADE J LEVER BOLT PISTON BLADDER ASSEMBLY REACH ADJUST SPRING K PIVOT PIN SNAP RING REACH ADJUST KNOB GEN 0000000000362 Rev A 10 11 Copyright O SRAM CORPORATION 2009 AVID TECHNICAL MANUAL LEVER OVERHAUL SERVICE INSTRUCTIONS CONT REMOVE LEVER Use a small phillips screwdriver and remove the screw from the reach adjust knob Use a 3mm hex and remove the lever bolt Carefully pull and remove the reach
19. 25 BRAKE PISTON INSTALLATION Inspect caliper pistons for damage and replace if necessary not pictured Install inboard piston through the pad opening pressing it flush into the caliper body with an 11 mm box wrench Install piston cap through pad opening Using an 8 mm hex wrench thread piston cap counter clockwise until snug into caliper body Install the outboard piston through the pad opening and press it flush into the caliper body with an 11 mm box wrench Using a T 10 Torx install caliper body assembly bleed screw BRAKE HOSE BANJO BOLT INSTALLATION Insert banjo bolt back into caliper banjo bolt hole setting the banjo angle to the desired angle Hand thread and tighten with 8 mm box wrench to 4 9 5 9 N m 43 52 in Ib Be careful not to pinch the banjo bolt o ring during installation Using a T 10 Torx wrench remove banjo bolt bleed screw Using a sharp pick remove bleed screw o ring This o ring may be a little hard to see Replace with a new bleed screw o ring Re install banjo bolt bleed screw into banjo bolt and tighten with T 10 Torx wrench BRAKE PAD INSTALLATION Measure the total thickness of each pad pad backing plate and pad material If there is less than 3 mm of total width replace both brake pads not pictured Position the h spring between the two pads The curved handle of inner pad should face toward inboard side of caliper Squeeze the pad and spring assembly together then firmly push in
20. 29 0000000000 NAD ved e5iutu 59Jj ys Bua POWEREDEYS RAT SRAM CORPORATION WARRANTY EXTENT OF LIMITED WARRANTY SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase This warranty only applies to the original owner and is not transferable Claims under this warranty must be made through the retailer where the bicycle or the SRAM compo nent was purchased Original proof of purchase is required LOCAL LAW This warranty statement gives the customer specific legal rights The customer may also have other rights which vary from state to state USA from province to province Canada and from country to country elsewhere in the world To the extent that this warranty statement is inconsistent with the local law this warranty shall be deemed modified to be consistent with such law under such local law certain disclaimers and limi tations of this warranty statement may apply to the customer For example some states in the United States of America as well as some governments outside of the United States including provinces in Canada may a Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations LIMITATIONS OF LIABILITY To the extent allowed by loca
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22. ENT OR DAMAGED 18 INTERNALS REMOVAL Take a few moments and familiarize yourself with the internal components of your brake lever This will assist you in identifying the components while you service your brake Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL Juicy 3 Juicy 5 7 CARBON ULTIMATE EXPLODED VIEW JUICY 3 LEVER ASSEMBLY 1 LEVER BODY SPRING SPRING COUPLING PRIMARY CUP SEAL PISTON ttt 4 SECONDARY SEAL SNAP RING WASHER PUSHROD CROSS DOWEL K LEVER EXPLODED VIEW CODE 5 JUICY 5 LEVER ASSEMBLY LEVER BODY SPRING SPRING COUPLING PRIMARY CUP SEAL PISTON Hi SECONDARY SEAL COUPLING ASSEBMLY COUPLING RETAINER COUPLING RETAINING RING PUSHROD K PUSHROD DUST BOOT L LEVER EXPLODED VIEW JUICY 7 CARBON ULTIMATE LEVER ASSEMBLY LEVER BODY SPRING SPRING COUPLING PRIMARY CUP SEAL PISTON SECONDARY SEAL WORM GEAR COUPLING L LEVER WORM GEAR C CLIP PUSHROD K PUSHROD DUST BOOT 15 LEVER OVERHAUL SERVICE INSTRUCTIONS CONT 19 20 2 22 Slide piston coupling out of piston not pictured 23 INTERNALS REMOVAL Code 5 Juicy 3 5 Only Using straight internal snap ring pliers remove coupling retaining ring Pull retaining ring from inside the lever body IMPORTANT PULL RETAINING RING OUT SLOWLY THE COUPLING RETAINER COUPLING ASSEMBLY MAY POP
23. ES KEEP IN MIND THAT YOU ARE SIMPLY CHASING BUBBLES OUT OF THE SYSTEM AVID RECOMMENDS THAT YOU BLEED YOUR BRAKES AT LEAST ONCE A YEAR TO ENSURE OPTIMAL PERFORMANCE IF YOU RIDE FREQUENTLY OR IN AGGRESSIVE TERRAIN YOU SHOULD BLEED YOUR BRAKES MORE OFTEN YOU WILL PERFORM 3 BASIC OPERATIONS WHEN BLEEDING AVID BRAKES BLEED THE HOSE BLEED THE CALIPER BLEED THE LEVER PREPARE THE SYRINGES 1 Fillone syringe 1 2 full with Avid Hi Perfor mance DOT Fluid and fill the other syringe 1 4 full 2 Hold each syringe with the tip pointed up and tap the side of the syringe with your finger to bring any air bubbles to the top Place a towel around the tip and slowly push the air bubbles out of the syringe NOTE YOU WILL NOT BE ABLE TO REMOVE ALL THE BUBBLES PREPARE THE CALIPER JUICY 3 5 7 ULTIMATE amp CARBON ONLY 3 Remove the wheel from your bike Remove the brake pads and spreader clip from the caliper and insertthe appropriate Bleed Block This will help prevent DOT fluid from contaminating your brake pads not pictured 4 Usethe T 10 Torx wrench to remove the caliper bleed port screw from the center of the banjo bolt 5 Make sure the fluid in the 1 2 full syringe is pushed all the way to the tip no air gap then thread into the caliper bleed port PREPARE THE CALIPER CODE CODE 5 ONLY 6 Remove the wheel from your bike Remove the brake pads and spreader clip from the caliper and insertthe appropriate Bleed Block This w
24. ONE A GREAT JOB AND ARE READY TO MOVE ON TO CODE HYDRAULIC DISC BRAKE CALIPER OVERHAUL PAGE 29 ENJOY Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 23 DISC BRAKE CALIPER OVERHAUL 26 ELIXIR R CR INTRODUCTION Avid caliper assemblies need to be serviced in order to optimize braking function If caliper brake piston motion is sticky or lacks a positive and smooth return the caliper body brake piston o ring may be out of place or damaged If your brake was filled with brake fluid other than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist Commonly used INCORRECT fluid is mineral oil or DOT 5 which is silicone based Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function CALIPER OVERHAUL SERVICE INSTRUCTIONS TROUBLESHOOTING STICKY OR SLOW BRAKE PAD RETURN FEEL Before completely disassembling your caliper it s worth trying to loosen the sticky piston Try the following Clamp bicycle in bicycle work stand Spin affected wheel Lightly squeeze brake lever and watch brake pads when lever is released Determine which side of the caliper has a slow returning brake piston Remove caliper from bicycle If you have a mounting bracket it is recommended to remove that too or just remove the caliper leaving the bracket on the fork or frame Remove e clip from guide pin groove on top of the caliper Using
25. STRUCTIONS CONT CALIPER ASSEMBLY O 14 Inspect caliper pistons for damage and replace if necessary Re install caliper brake pistons into each half of the caliper body 15 Install a new banjo bolt o ring into the banjo bolt hole on outboard side of caliper body 16 Insert and thread caliper bolt into caliper clos estto banjo bolt hole Ensure new caliper banjo bolt o ring is not unseated from its position not pictured 17 Insert remaining two caliper body bolts and tighten all three bolts with a 4 mm hex wrench to 4 9 5 9 N m 43 52 in Ib 18 Insert banjo bolt back into caliper into banjo bolt hole Hand thread and tighten with 8 mm box wrench to 4 9 5 9 N m 43 52 in Ib Be careful notto pinch either of these o rings during instal lation 19 Using a T 10 Torx wrench remove banjo bolt bleed screw 20 Using a sharp pick remove bleed screw o ring This o ring may be a little hard to see Replace with a new bleed screw o ring 21 Re install banjo bolt bleed screw into banjo bolt and tighten with T 10 Torx wrench BRAKE PAD INSTALLATION 22 Insert spring pad clip into outer side of caliper 23 Measure the total thickness of each pad pad backing plate and pad material If there is less than 3 mm of total width replace both brake pads not pictured 24 Position the h spring between the two pads The curved handle of inner pad should face toward inboard side of caliper Squeeze the pad and spring assembly t
26. The following chart is a list of the tools needed to service on your 2009 model year Avid brakes While this chart is intended to be comprehensive itis still only a guide The tools required for each step of service are detailed in the text of each service section Keep in mind your specific brakes may not require every tool listed LEVER CALIPER HOSE ADJUST amp PAD TOOLS OVERHAUL OVERHAUL BLEED REPLACEMENT SAFETY STARTING EQUIPMENT SAFETY GLASSES APRON RUBBER GLOVES CLEAN RAGS LINT FREE OIL PAN CLEAN WORK AREA WRENCHES PLIERS 2 5 MM HEX 4 HEX T 8 TORX T 10 TORX T 30 TORX 8 MM OPEN END OR BOX WRENCH 11 MM OPEN END OR BOX WRENCH TORQUE WRENCH NEEDLE NOSED PLIERS SNAP RING PLIERS INTERNAL E CLIP TOOL OPTIONAL MISC TOOLS KITS AVID BLEED KIT HYDRAULIC LINE CUTTERS OR VERY SHARP HOUSING CUTTERS SHARP PICK ISOPROPYL ALCOHOL SMALL AND LARGE FLATHEAD SCREWDRIVERS PHILLIPS HEAD SCREWDRIVER AIR COMPRESSOR WITH BLOW GUN CHUCK SOAPY WATER ICE COLD BEVERAGE SAFETV STARTING EQUIPMENT y sareryelasses aeron x x x ugmwmesuwRED x x porran x CLEAN x x JWRENCHES PLIERS y pawwux x x amex a x perm pnm x x y parnm poso L L y JSMMOPENENDORBOXWRENCH JIMMOPENENDORBOXWRENCH x froravewrence
27. adjust knob and attached spring IMPORTANT POINT THE REACH ADJUST KNOB AWAY FROM YOUR EYES WHEN REMOVING THE SPRING IS PRE LOADED AND MAY POP OUT SUDDENLY WITH THE KNOB Pull back on the lever to fully open and disengage the push rod from the piston Use a small hex wrench to push the pivot pin out of the lever Pull straight back on the lever blade and remove NOTE THE PIVOT BUSHINGS MAY FALL OUT OF THE LEVER BLADE THIS IS SIMPLY RE INSERT THEM INTO THE LEVER BLADE Use long snap ring pliers and remove the snap ring in the lever body along with the piston bladder assembly NOTE THE PISTON BLADDER ASSEMBLY IS ATTACHED TO THE SNAP RING Inspect the bladder for damage If damaged replace the entire piston bladder and snap ring assembly Remove the piston spring Use a pick to remove and replace both the piston glide ring and o ring Do NOT re install the piston spring atthis time IMPORTANT BE CAREFUL NOT TO DAMAGE THE PISTON GLAND WITH THE PICK IMPORTANT DO NOT RE INSTALL THE PISTON SPRING AT THIS TIME Lubricate the piston bladder assembly by dipping it into DOT 5 1 fluid and allow the excess fluid to drip off TIP YOU CAN ALSO USE DOT COMPATIBLE GREASE AS A LUBRICANT 12 13 14 15 16 17 18 LEVER OVERHAUL SERVICE INSTRUCTIONS CONT LEVER INSTALLATION Use long snap ring pliers and re install the piston bladder assembly into the lever body Slide lever blade and push rod as
28. at are squeezed beyond the outside edges of the banjo or bolt remove and replace Repeat installation steps 28 Wipe assembled caliper with soapy water to remove any brake fluid 29 Re install caliper onto bicycle following the installation and torque specifications called out in the user manual THIS CONCLUDES THE CALIPER OVERHAUL SERVICE INSTRUC TIONS YOU HAVE DONE A GREAT JOB AND ARE READY TO MOVE TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT AND BLEEDING ENJOY Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 39 40 2 Turn both adjuster knobs all the way out BB7 MOUNTAIN amp ROAD INTRODUCTION Avid caliper assemblies need to be serviced in order to optimize braking function If caliper brake piston motion is sticky or lacks a positive and smooth return the caliper body brake piston o ring may be out of place or damaged Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function CALIPER OVERHAUL DISASSEMBLY SERVICE INSTRUCTIONS TROUBLESHOOTING NOT PICTURED The most common issue with the BB7 is that the outboard pressure foot can become dislodged if the outboard adjustment knob is turned too far clockwise without the rotor in the caliper wheel off or caliper removed The brake is not broken nor does it require disassembly to replace the pressure foot To replace the pressure foot turn the outb
29. e ban jo bolt hole Compressed air unseats the inboard caliper piston from the caliper Pull the piston out of the caliper body through pad opening NOTE YOU MAY NEED TO USE A PAIR OF NEEDLE NOSED PLIERS TO PULL THE PISTON OUT OF THE CALIPER BODY BE CAREFUL NOT TO SCRATCH THE PISTON IF YOU SCRATCH THE PISTON YOU WILL NEED TO REPLACE IT IMPORTANT BE SURE TO POINT THE CALIPER IN A SAFE DIRECTION YOU MAY WANT TO DO THIS INSIDE A PLASTIC BAG TO PREVENT THE PISTON FROM CAUSING INJURY OR BECOMING LOST Using an 8 mm hex wrench turn the piston cap clockwise to push the outboard piston into and out of the caliper body Pull the piston out of the caliper body through the pad opening Press the piston cap into the caliper body and remove through the pad opening Using a sharp pick remove the piston cap o ring and replace with a new o ring Using a sharp pick remove the inboard and out board quad seal o rings from the caliper body and replace with new o rings NOTE WHEN INSTALLING THE NEW QUAD SEAL 0 RINGS USE THE FLAT SIDE OF A PICK TO SEAT THE O RING INTO THE O RING GROOVE BY MOVING IT AROUND THE ENTIRE SEAL Using a T 10 Torx remove caliper body assembly bleed screw Using a sharp pick remove bleed screw o ring and replace with a new one Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL e 33 34 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT 15 16 17 18 19 20 2 22 23 24
30. e caliper Set aside in correct order not pictured BRAKE PAD AND H SPRING REMOVAL 2 Using needle nosed pliers grab one of the pad tabs and slide the pad toward the center of the caliper this disengages the pad backing plate from the post in the center of the piston then pull the pad straight out Repeatfor other pad NOTE IF THE H SPRING DOESN T COME OUT WITH THE SECOND PAD PUSH IT OUT FROM THE OPEN TOP OF THE CALIPER WITH A PICK OR YOUR FINGER 3 Remove the spring pad clip from the outside of the caliper Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 29 30 10 11 12 13 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT NOTE IF THE TOTAL THICKNESS OF THE BACKING PLATE AND PAD FRICTION MATERIAL IS LESS THAN 3 MM THE BRAKE PADS NEED TO BE REPLACED BRAKE HOSE BANJO BOLT REMOVAL AND SERVICE Using an 8 mm open end or box wrench loosen banjo bolt Brake fluid will leak so hold over a container to catch fluid Pull banjo bolt completely out of caliper Dump all caliper brake fluid into container Remove o rings on each side of brake hose banjo and replace with new o rings Insert banjo bolt back into brake hose banjo Ensure outside banjo o ring is not damaged by banjo bolt threads This may cause a leak Set hose and banjo bolt aside CALIPER DISASSEMBLY AND SERVICE Loosen all three caliper body bolts with a 4 mm hex wrench There are three different bolt lengths Set aside
31. en the total thickness ofthe backing plate and pad friction material is less than 3mm Replacing worn brake pads will improve braking performance New brake pads are subjectto a break in period It may take anywhere from 20 to 40 complete stops to break in Avid pads You may begin to notice an increase in braking power after the first ride Brake noise can occur during the break in period as well as off and on throughout the life of the brake pads This is normal and should not affect braking performance Noise is dependent upon factors such as brake setup rider weight riding style braking style and riding conditions i e dust soil and contamination of friction surfaces PAD REPLACEMENT PUSH THE PISTONS BACK IN 1 The Juicy calipers are self adjusting Therefore the pistons need to be pushed back into their original position in the body before the new pads can be installed The best way to do this is with the old pads still in the caliper to protect the pistons Place a flat blade screwdriver between the old pads and gently rock it back and forth pushing the pistons back into their bores not pictured REMOVE THE OLD PADS AND H SPRING 2 Using needle nosed pliers grab one of the pad tabs and slide the pad toward the center of the caliper this disengages the pad backing plate from the post in the center of the piston then pull the pad straight out Repeatfor other pad NOTE IF THE H SPRING DOESN T COME QUT WITH THE SEC
32. ench to remove the lever bleed port screw 14 Make sure the fluid in the 1 4 full syringe is pushed all the way to the tip no air gap then thread into the lever bleed port NOTE IT IS NOT NECESSARY TO REPOSITION THE ANGLE OF THE BRAKE LEVER ON THE HANDLEBAR YOU MAY HAVE A SMALL AMOUNT DOT FLUID DRIP FROM THE BLEED PORT SCREW THIS IS NORMAL JUST HAVE A TOWEL HANDY TO WIPE OFF ANY EXCESS AFTER THE SYRINGE IS INSTALLED BLEED THE SYSTEM BLEED THE HOSE 15 Hold the caliper syringe upright in your right hand and the lever syringe upright in your left hand 16 Gently push on the caliper syringe plunger to move fluid from the caliper syringe into the lever syringe until the lever syringe is increased to 1 2 full and the caliper syringe is decreased to 1 4 full NOTE YOU SHOULD SEE BUBBLES FILL INTO THE LEVER SYRINGE 17 Close the red syringe clamp on the lever 18 Pull the brake lever all the way to the bar with your finger and hold it there until instructed to release the lever in a later step If you don t want to hold the lever with your finger have a friend hold itor you can fasten it with a toe strap or rubber bands Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 49 50 BLEEDING PROCEDURE CON 19 20 2 22 23 24 BLEED THE SYSTEM BLEED THE CALIPER With your right hand gently pull out on the caliper syringe plunger to create a vacuum then gently push in on the plunger to
33. flush into underside of reservoir cover Make sure you have the correct orientation NOTE DO NOT RE INSTALL RESERVOIR COVER AT THIS TIME BLEED SCREWS REMOVAL 8 Using a T 10 Torx wrench remove both bleed screws 9 Using a sharp pick remove both o rings on bleed screws and replace 10 Install bleed screws back into lever body LEVER BLADE CAM REMOVAL 11 Using two 4mm hex wrenches loosen and remove the lever pivot shoulder bolt and lever pivot sleeve bolt NOTE YOU MAY NEED TO PUSH THE SHOULDER BOLT OUT WITH A PICK OR SIMILAR TOOL 12 Rotate the lever and cam assembly toward the handlebar clamp Carefully remove the lever blade and return spring from the cam 13 Slide a hex wrench through the bearing in the cam and pull the gently pull the cam off the end of the pushrod 14 Remove the pushrod coupling from the cam with needlenose pliers If the pushrod coupling remains connected to the pushrod pull it off with needlenose pliers INTERNALS REMOVAL Take a few moments and familiarize yourself with the internal components of your brake lever This will assist you in identifying the components while you service your brake W LEVER BODY F QUAD SEAL K CAM SPRING G GEAR COUPLING L CAM SPRING SPRING COUPLING H PUSHROD M LEVER PRIMARY CUP SEAL PUSHROD COUPLING GLIDE RING J C CLIP 20 GEN 0000000000362 Rev A LEVER OVERHAUL SERVICE INSTRUCTIONS CONT INTERNALS
34. g coupling from piston Do not scratch any plastic parts piston or o rings If damaged you will need to replace the piston Remove and replace piston secondary seal small o ring on top of piston a UY 7 CARBON 1 Ando JUICY 7 CARBON ULTIMATE GEN 0000000000362 Rev A LEVER OVERHAUL SERVICE INSTRUCTIONS CONT INTERNALS REMOVAL CONT O 24 Remove primary cup seal lower large black seal from piston with sharp pick and slide new coupling seal onto base of piston Ensure it sits flush flat end first flush against piston open end out 25 Re install spring coupling back onto piston and coupling seal into open end of seal 26 Re install spring onto coupling The coupling lightly snaps onto piston INTERNALS INSTALLATION 27 Insert spring piston assembly back into lever body spring first 28 Code 5 Juicy 5 Only Insert coupling retainer and coupling assembly onto top of piston inside lever body The v shape of the retainer should be positioned in the lever blade groove Using straight internal snap ring pliers insert coupling retaining ring above coupling retainer and into groove in lever body Ensure retaining ring snaps into place securely OR Juicy 7 Carbon Ultimate Only Slide worm gear coupling geared end first into narrow end of worm gear The coupling slides directly into inner worm gear threads Insert worm gear and coupling assembly onto top of piston inside lever body Insert
35. h the bevel gear and install the knob using a T 10 Torx wrench Tighten the knob to 1 1 2 N m 8 7 10 4 in Ib The bevel gear should now be secure and you no longer need to hold it in place with your finger Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 21 22 LEVER OVERHAUL SERVICE INSTRUCTIONS CONT INTERNALS INSTALLATION CONT O 25 Install the piston spring assembly into the lever body IMPORTANT ALIGN THE BLACK PISTON KEY ON THE PISTON GEAR INTO THE KEYWAY ON THE LEVER BODY 26 Push the piston spring assembly far enough into the lever body to completely depress the spring While the spring is depressed inserta pin gauge a small drill bit or 1 5 mm hex will work into the compensating port to hold the assem bly compressed in the lever body IMPORTANT DO NOT LOOK DIRECTLY INTO LEVER BODY WHILE PERFORMING THIS STEP DEPRESSING THE SPRING PUTS IT INTO A PRELOADED CONDITION AND IT CAN EJECT RAPIDLY FROM THE LEVER BODY IF THE PIN GAUGE IS NOT PROPERLY INSTALLED 27 Install the pushrod then washer onto the top of the piston gear Install the retaining ring in the groove of the lever body using a pair of snap ring pliers and orient the ring holes away from the lever body opening 28 Remove the gauge pin from the compensating port The piston assembly will snap into place against the pushrod and washer LEVER BLADE CAM INSTALLATION 29 Insert a leg of the lever return spring into the hole on the lever
36. ill help prevent DOT fluid from contaminating your brake pads not pictured 7 The Code caliper features two bleed port screws on either side on the banjo fitting It s recommended that you use the bleed port on the left side of the banjo fitting during normal bleed ing Use the T 10 Torx wrench to remove the caliper bleed screw from the caliper body 8 Make sure the fluid in the 1 2 full syringe is pushed all the way to the tip no air gap then thread into the caliper bleed port GEN 0000000000362 Rev A BLEEDING PROCEDURE CONT PREPARE THE CALIPER Q ELIXIR R ELIXIR CR 9 Remove the wheel from your bike Remove the brake pads and spreader clip from the caliper and insert the appropriate Bleed Block This will help prevent DOT fluid from contaminating your brake pads not pictured 10 Use the T 10 Torx wrench to remove the caliper bleed port screw from the caliper body 11 Make sure the fluid in the 1 2 full syringe is pushed all the way to the tip no air gap then thread into the caliper bleed port PREPARE THE LEVER 12 Reach Adjust For models equipped with Reach Adjust ensure that the reach is not adjusted so far out that it causes the lever blade to bottom out on the lever body Doing so can make bleed ing the brake impossible not pictured Pad Contact Adjust For models equipped with Pad Contact Adjust set the adjustment so it is turned all the way out not pictured 13 Use the T 10 Torx wr
37. in correct order Separate caliper body halves and open caliper assembly Using a sharp pick remove small banjo hole body half o ring BRAKE PISTONS REMOVAL AND SERVICE Inboard Caliper Body Half Using an air compressor chuck insert chuck nozzle into banjo bolt hole Hold caliper in one hand pointing caliper piston in a safe direction Squeeze the air chuck and force air into the banjo bolt hole while holding caliper body Compressed air unseats the caliper piston from the caliper Pull out completely and remove piston IMPORTANT POINT THE CALIPER IN A SAFE DIRECTION USE A CLOTH OR A PLASTIC BAG TO PREVENT THE PISTON CAUSING INJURY OR BECOMING LOST Outboard Caliper Body Half Using an air compressor chuck insert chuck nozzle into banjo bolt hole Hold caliper in one hand pointing caliper piston in a safe direction Hold one finger over the banjo bolt through hole on opposite side of caliper body so air does not escape Squeeze the air chuck and force air into the banjo bolt hole while holding caliper body Compressed air unseats the caliper piston from the caliper Pull out completely and remove piston IMPORTANT POINT THE CALIPER IN A SAFE DIRECTION USE A CLOTH OR A PLASTIC BAG TO PREVENT THE PISTON CAUSING INJURY OR BECOMING LOST Remove the square edge o ring from inside each caliper body half with a sharp pick and replace with new square edge o rings GEN 0000000000362 Rev A CALIPER OVERHAUL SERVICE IN
38. kes Pull on the lever extremely hard as hard as you can imagine yourself pulling the lever while you re riding several times Make sure and look around the hose nut on the lever and the banjo bolt on the caliper for any leaks Make one last check of all the bolts and fittings If everything checks out YOU ARE READY TO RIDE Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 51 DISC BRAKE PAD REPLACEMENT 54 ELIXIR R CR INTRODUCTION Avid brake pads should be replaced when the total thickness of the backing plate and pad friction material is less than 3mm Replacing worn brake pads will improve braking performance New brake pads are subjectto a break in period It may take anywhere from 20 to 40 complete stops to break in Avid pads You may begin to notice an increase in braking power after the first ride Brake noise can occur during the break in period as well as off and on throughout the life of the brake pads This is normal and should not affect braking performance Noise is dependent upon factors such as brake setup rider weight riding style braking style and riding conditions i e dust soil and contamination of friction surfaces PAD REPLACEMENT REMOVE PAD RETAINER BOLT Startby removing the E clip on the wheel side of the caliper then unscrew the retainer bolt us ing a 2 5 mm hex wrench Remove the retainer bolt all the way PUSH THE PISTONS BACK IN 2 The Elixir calipers are
39. kness of each brake pad with a ruler If the total thickness is less than 3 mm you need to replace both brake pads not pictured NOTE IF THE BACKING PLATE AND PAD MATERIAL IS THICKER THAN 3 MM YOU CAN SIMPLY RE INSTALL YOUR BRAKE PADS AS OUTLINED IN STEP 3 AND FOLLOW THE PROCEDURES FOR PAD WEAR ADJUSTMENT INSTALL THE NEW PADS AND SPRING 3 Assemble the spring between the new left and right pads Align the spring to the pad as shown Squeeze the brake pad and spring clip assembly together then press firmly into the caliper until it clicks into place The pad marked R goes on the spoke side of the brake PAD WEAR ADJUSTMENT NOT PICTURED The BB7 has a manual pad wear adjustment feature You can use this feature to compensate for brake pad wear until the pads need to be replaced with two very simple adjustments Turn both the inboard and outboard red adjusting knobs clockwise one or two clicks as needed to restore your brake to optimum settings Do NOT use your barrel adjuster to compensate for pad wear A pad wear indicator is atthe center of each knob As the knob is turned in the indicator will retract deeper into the knob giving a visual indication of approximately how much the pads have worn THIS CONCLUDES THE DISC BRAKE PAD REPLACEMENT IN STRUCTIONS YOU HAVE DONE A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 57 VVORLD HEADOUARTERS SR
40. l and spring Then remove the hex hole washer REMOVE DRIVE CAM OUTBOARD PRESSURE FOOT ASSEMBLY 8 Using a 5 mm hex remove the 2 caliper body bolts NOTE THE BOLTS ARE DIFFERENT LENGTHS 9 Carefully remove the inboard caliper body half and set aside 10 Remove the pad retaining clip and set aside 11 Pull outthe drive cam outboard pressure foot assembly Be careful notto lose any ofthe three ball bearings 12 Use a 5mm hex to remove the outboard caliper body half from the bike and set aside DRIVE CAM DISASSEMBLY 13 Use small needle nosed pliers or a schrader valve core tool to turn the foot screw clockwise until it is completely unthreaded from the drive cam This will separate the outer pressure foot from the cam assembly Remove the foot screw from the drive cam REMOVE PRESSURE FOOT 14 Using a T 25 Torx wrench turn the inboard pressure foot clockwise until itis free from the inboard caliper body half Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 41 42 CALIPER OVERHAUL CLEANING amp INSPECTION INSTRUCTIONS 15 16 17 18 19 20 CLEANING Clean all metal parts in alcohol including the cable anchor bolt and plate Clean the cable seal boots and outer caliper body seal in mild soap and water Rinse and dry all parts completely not pictured CALIPER BODY INSPECTION Inspect both caliper body halves for any damage pay close attention to all threaded surface
41. l law except for the obligations specifically set forth in this warranty statement In no event shall SRAM or its third party suppliers be liable for direct indirect special incidental or consequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and or adjusted ac cording to the respective SRAM technical installation manual The SRAM user manuals can be found online at www sram com www rockshox com or www avidbike com This warranty does not apply when the product has been modified This warranty does not apply when the serial number or production code has been deliberately altered defaced or removed This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturer s specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not apply to normal wear and tear Wear and tear parts are subject to damage as a result of normal use failure to service according to SRAM recommendations and or riding or installation in conditions or applications other than recommended EXAMPLS OF WEAR AND TEAR Dust seals Bushings Air sealing o rings Glide rings Rubber moving parts Foam rings Rear shock mounting hardware and main seals Stripped threads and bolts aluminum titanium magnesium or steel Upper tubes stanchions
42. large flathead screwdriver into open end flat slot of worm gear Turn clockwise to thread worm gear into lever body Press down into worm gear while the gear threads into lever body You will feel spring resistance as you turn Worm gear threads will engage the threads in lever body Turn clockwise until worm gear is completely inside lever body then back off three turns This is the correct installation setting Using needle nosed pliers insert worm gear retaining clip above worm gear Position one end of clip into groove and slowly but firmly push down on clip with pliers until clip snaps 4 firmly into place in groove Rotate clip until ends are inside of groove IMPORTANT ENDS OF CLIP MUST NOT PROTRUDE PAST LEVER BODY GROOVE OR EXTEND INTO LEVER SLOT GAP IN LEVER BODY 7 GARBON ULTIMATE Cy 7 CARBON Y Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL JUICY 7 ULTIMATE y JUICY 7 CARBON ULTIMATE LEVER OVERHAUL SERVICE INSTRUCTIONS CONT 29 30 31 32 33 34 35 LEVER PUSHROD INSTALLATION Juicy 3 Only Place washer onto pushrod Insert pushrod and washer into lever body so that pushrod sets on top of the piston Using straight internal snap ring pliers push retaining ring into lever body so that piston is compressed and retaining ring snaps into place This holds piston assembly and pushrod inside lever bod
43. liper body bolts Using two 4 mm hex wrench tighten the banjo bolt to 2 9 3 4 N m 26 30 in Ib Using a 4 mm hex wrench tighten the caliper boldy bolts to 5 9 6 3 N m 52 56 in Ib Using a T 10 Torx install the two bleed screws back into the top of the caliper body and tighten to 6 7 N m 5 6 in Ib BRAKE PAD INSTALLATION Inspect and measure each brake pad If there is less than 3 mm of total pad thickness pad backing and pad friction material replace both brake pads not pictured Position the h spring between the two pads NOTE THE CODE PADS ARE SYMMETRICAL THERE IS NOT A LEFT OR RIGHT ORIENTATION Locate the pad installation feature of the pad spacer tool Insert the pad handles into the pad installation tool so it holds the pads together Insert the pads and pad tool into the caliper until the holes in the top of the pads are aligned with the guide pin holes in the top of the caliper Insert the guide pin through the caliper body halves and the brake pads Using a 2 5 mm hex wrench tighten the guide pin to 1 5 1 9 N m 13 17 in Ib Remove the pad tool The h spring will snap the pads into position Using your thumb or finger install the e clip into the groove on the end ofthe guide pin GEN 0000000000362 Rev A CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT FINISHING UP NOT PICTURED 27 Visually check your work Inspect banjo bolt and banjo for any protruding o rings If there are any o rings th
44. m the post in the center of the piston then pull the pad straight out Repeat for other pad NOTE IF THE H SPRING DOESN T COME OUT WITH THE SECOND PAD PUSH IT OUT FROM THE OPEN TOP OF THE CALIPER WITH A PICK OR YOUR FINGER NOTE IF THE TOTAL THICKNESS OF THE BACKING PLATE AND PAD FRICTION MATERIAL IS LESS THAN 3 MM THE BRAKE PADS NEED TO BE REPLACED GEN 0000000000362 Rev A 10 11 12 13 14 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT BRAKE HOSE BANJO BOLT REMOVAL AND SERVICE Using an 8 mm open end or box wrench loosen banjo bolt Brake fluid will leak so hold over a container to catch fluid Pull banjo bolt completely out of caliper Pour all caliper brake fluid into container Remove o ring from brake hose banjo and banjo bolt and replace with new o rings Insert banjo bolt back into brake hose banjo Ensure outside banjo o ring is not damaged by banjo bolt threads This may cause a leak Set hose and banjo bolt aside BRAKE PISTON REMOVAL AND SERVICE Using an 11 mm box wrench gently push out board piston into caliper body until itis flush with the inside of the caliper Gently press a flathead screwdriver against the outboard piston while pointing the caliper in a safe direction you want to remove the inboard piston first so you need to hold the outboard piston in place Using an air compressor chuck insert chuck nozzle into banjo bolt through hole Squeeze the air chuck and force air into th
45. mbly FINISHING UP Clean the entire lever assembly with soapy water and clean rag not pictured THIS CONCLUDES THE LEVER OVERHAUL SERVICE INSTRUCTIONS YOU HAVE DONE A GREAT JOB AND JUICY ULTIMATE PS READY TO MOVE ON TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE CALIPER OVERHAUL ENJOY Install the pivot pin set screw into the lever H blade and tighten with a 2 5mm hex wrench NOTE THIS CONCLUDES THE LEVER OVERHAUL SERVICE Muicy 7 CARBON JUICY 3 GEN 0000000000362 Rev A INTRODUCTION Avid brake lever assemblies need to be serviced in order to optimize braking function If brake fluid is leaking from any area of the brake lever assembly there may be damage or wear n tear to the internal moving parts If your brake was filled with fluid OTHER than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the reservoir cap bladder and star wheel assemblies Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function CODE LEVER OVERHAUL SERVICE INSTRUCTIONS GETTING STARTED o9 Remove brake lever from handlebar Remove caliper from fork or frame If dirty clean with soapy water and a clean rag Pull hose boot off compression nut and slide down hose not pictured 2 Using an 8mm crow s foo
46. mes Check that the caliper closes and returns properly Make one last check of all the bolts and fittings If everything checks out YOU ARE READY TO RIDE 44 GEN 0000000000362 Rev A HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT amp BLEED 46 ELIXIR R CR JUICY 3 5 7 CARBON ULTIMATE CODE CODE 5 INTRODUCTION Avid brakes come with the hoses attached and bled If you don t need to change the hose length then you should not need to bleed the system again However if you performed a lever and or caliper overhaul you will need to bleed your brakes Bleeding is one of the most important steps in topping off the performance of any hydraulic brake system Any air inside a hydraulic brake system degrades the performance of the brake The goal of bleeding is to remove the air that is trapped in the hoses caliper or lever CHANGING HOSE LENGTHS RE CHECK HOSE ROUTING 1 Since you can tlengthen the hose after you have cut it take a moment and re check the routing of the hoses Be sure to account for suspension movement and check that the bars turn freely by turning the bars all the way from side to side Make sure the hoses are properly secured as well not pictured REMOVE HOSE FROM LEVER 2 Juicy Code amp Elixir R Use an 8 mm open ended wrench to unscrew the hose compression nut Elixir CR Use an 11 mm open ended wrench to hold the hose stop in place and use an 8 mm open ended wrench to unscrew the hose compres
47. nd spring assembly together then insert into the caliper as a unit Firmly push until the assembly is seated into place Using a 2 5 mm hex wrench install the pad retainer bolt and tighten to 0 9 1 1 N m 8 9 5 in Ib Install the E clip on the wheel side of the caliper making sure it sits in the groove of the retainer bolt FINISHING UP NOT PICTURED Visually check your work Inspect banjo bolt and banjo for any protruding o rings If there are any o rings that are squeezed beyond the outside edges of the banjo or bolt remove and replace Repeat installation steps Wipe assembled caliper with soapy water to remove any brake fluid Re install caliper onto bicycle following the installation and torque specifications called out in the user manual THIS CONCLUDES THE CALIPER OVERHAUL SERVICE INSTRUC TIONS YOU HAVE DONE A GREAT JOB AND ARE READY TO MOVE ON TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT AND BLEEDING ENJOY GEN 0000000000362 Rev A JUICY 3 5 7 CARBON INTRODUCTION Avid caliper assemblies need to be serviced in order to optimize braking function If caliper brake piston motion is sticky or lacks a positive and smooth return the caliper body brake piston o ring may be out of place or damaged If your brake was filled with brake fluid other than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist Commonly used INCORRECT fluid is mineral oil or DOT 5 which is
48. necessary to restore proper brake function CALIPER OVERHAUL SERVICE INSTRUCTIONS TROUBLESHOOTING STICKY OR SLOW BRAKE PAD RETURN FEEL Before completely disassembling your caliper it s worth trying to loosen the sticky piston To do so try the following Clamp bicycle in bicycle work stand Spin affected wheel Lightly squeeze brake lever and watch brake pads when lever is released Determine which side of the caliper has a slow returning brake piston Remove caliper from bicycle If you have a mounting bracket itis recommended to remove thattoo or just remove the caliper leaving the bracket on the fork or frame Remove e clip from guide pin groove on top of the caliper using a sharp pick Using a 2 5 mm hex wrench remove the guide pin from the caliper Pull and remove both brake pads and h spring Using a 10 mm box wrench press working piston into caliper body Squeeze brake lever slowly to move sticky piston inward Press the piston back into the caliper again Repeatthese steps to correct caliper piston inner o ring position Both pistons should now be moving freely Re install spring pad clip h spring and pads into caliper Re install caliper onto bicycle Spin wheel check function If there is no improvement continue with caliper service GETTING STARTED Remove brake caliper from fork or frame and remove caliper mounting bracket and CPS hardware from caliper Set aside in correct order not pictured
49. oard adjuster knob counter clockwise until it stops If the knob doesn t stop then the foot screw the end of which can be seen in the center of the knob has become disengaged from the knob and possibly from the threads inside the drive cam In this case remove the knob then using a pair of small needle nosed pliers or a schrader valve tool turn the the foot screw all the way back out until it stops Now the pressure foot can be replaced Relocate the pressure foot into the bore then give it a firm push in the center It will click back into place If you removed the knob replace it and you re done GETTING STARTED Remove the cable anchor bolt and plate then pull the cable housing and inner wire free of the caliper Remove the rubber cable boots REMOVE THE BRAKE PADS counterclockwise then squeeze the pad tabs together and pull both pads and pad spring clip straight out of the caliper GEN 0000000000362 Rev A CALIPER OVERHAUL DISASSEMBLY SERVICE INSTRUCTIONS CONT REMOVE THE OUTBOARD KNOB 3 Remove the outboard pad knob with a small flat head screwdriver Be careful not to mar the surface of the torque arm 4 Turnthe foot screw which is now exposed counter clockwise until it stops REMOVE TORQUE ARM 5 Hold the spring loaded torque arm securely in y y place OT SCREW 6 Remove the torque arm fixing nut using an 11 mm wrench Remove the lockwasher 7 Remove the torque arm outer body sea
50. ogether then firmly push into the caliper until it clicks into place indicat ing itis properly secured in the caliper body FINISHING UP NOT PICTURED 24 Visually check your work Inspect banjo bolt and banjo for any protruding o rings If there are any o rings that are squeezed beyond the outside edges of the banjo or bolt remove and replace Repeat installation steps 25 Wipe assembled caliper with soapy water to remove any brake fluid 26 Re install caliper onto bicycle following the installation and torque specifications called out in the user manual THIS CONCLUDES THE CALIPER OVERHAUL SERVICE INSTRUC TIONS YOU HAVE DONE A GREAT JOB AND ARE READY TO MOVE TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT AND BLEEDING ENJOY Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 32 JUICY ULTIMATE INTRODUCTION Avid caliper assemblies need to be serviced in order to optimize braking function If caliper brake piston motion is sticky lacks a positive and smooth return the caliper body brake piston o ring may be out of place or damaged If your brake was filled with brake fluid other than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist Commonly used INCORRECT fluid is mineral oil or DOT 5 which is silicone based Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function CALIPER
51. or the latest technical information please visit our website at www sram com Your product s appearance may differ from the pictures diagrams contained in this catalog Product names used in this document may be trademarks or registered trademarks of others TABLE OF CONTENTS cdagiliexpirpdm K 5 BRAKE STYLE amp SERVICE CATEGORIES TOOLS NEEDED FOR SERVICE pah HYDRAULIC DISC BRAKELEVER OVERHAUL ws ELA 210 CODE 5 JUICY 3 5 7 CARBON ULTIMATE CODE da ras 19 DISC BRAKECALIPER OVERHAUL 25 226 JUICY 3 5 7 29 JUICY ULTIMATE 32 CODE CODE 5 36 BB7 MOUNTAIN SCR AD cette treten 40 HYDRAULIC DISC BRAKEHOSE LENGTH ADJUSTMENT amp BLEED ELIXIR CR JUICY 3 5 7 CARBON ULTIMATE CODE CODES 46 DISC BRAKEPAD REPLACEMENT 53 ELIXIR UR 254 JUICY 3 5 7 CARBON ULTIMATE 55 CODE CODE 5 ntes 256 BBP ROAD ads 57 Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL SAFETY FIRST At SRAM Corporation we care about YOU Please ALWAYS wear your safety glasses when servicing your Avid brakes Protect your eyes Wear your safety glasses GEN 0000000000362 Rev A GETTING STARTED GETTING STARTED HELPFUL HINTS
52. place with new bladder if contaminated and leaking fluid NOTE POSSIBLE CAUSES OF LEAKING BLADDER AND OR RESERVOIR INCLUDE BRAKE SYSTEM MAY HAVE TOO MUCH FLUID BLADDER MAY HAVE SPLIT AND OR BLADDER MAY BE CONTAMINATED Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 13 10 11 12 13 14 15 16 17 LEVER OVERHAUL SERVICE INSTRUCTIONS CONT RESERVOIR COVER BLADDER INSTALLATION Insert new bladder into cover and seat flush into underside of reservoir cover Make sure you have the correct orientation Place reservoir cover and bladder back onto lever body Install and tighten cover cap screws short screw closest to lever clamp Tighten both screws with a T 10 Torx small Phillips head screwdriver for Juicy 3 BLEED SCREWS REMOVAL Use a T 10 Torx wrench to remove both bleed screws Using a sharp pick remove both o rings on bleed screws and replace Install bleed screws back into lever body NOTE FOR JUICY 3 5 PLEASE MOVE ON TO THE LEVER BLADE PUSHROD REMOVAL PROCEDURES STAR WHEEL AND WORM REMOVAL JUICY 7 CARBON amp ULTIMATE ONLY Remove retaining e clip with sharp pick or small flathead screwdriver Juicy 7 Carbon Only Unthread star wheel and worm from lever body Unthread by hand pull out to remove from lever assembly OR Juicy Ultimate Only Unthread worm from lever body using a 2 5 mm hex Using a pick insert into gear hole and push bushing out of lever body
53. pression fitting over the end of the hose with the new hosebarb RE INSTALL THE HOSE 9 Push the hose firmly into the lever until it stops 10 While holding the hose in place slide the com pression fitting and compression nut up to the lever or hose stop not pictured Juicy Code amp Elixir R Finger tighten the com pression nut until you feel it bottom out Elixir CR Hold the hose stop in place and finger tighten the compression nut until you feel it bottom out 11 Juicy Code amp Elixir R While continuing to push the hose into the lever body use an 8 mm open ended wrench to tighten the compression nut to the proper torque Elixir CR While continuing to push the hose into the hose stop use an 11 mm open ended wrench to hold the hose stop in place and use an 8 mm open ended wrench to tighten the com pression nutto the proper torque If your compression fitting is alloy tighten to 5 N m 47 in Ib If your compression fitting is steel tighten to 7 8 N m 70 in Ib 12 Slide the boot if applicable back into place not pictured IMPORTANT CUTTING DOWN THE HOSE INTRODUCES A SMALL AMOUNT OF AIR INTO THE SYSTEM WHICH CAN DEGRADE THE PERFORMANCE OF YOUR BRAKES AT THIS POINT IT IS NECESSARY TO BLEED THE BRAKES TO RESTORE THEM TO OPTIMAL PERFORMANCE PLEASE CONTINUE ON TO BLEEDING PROCEDURES Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 47 48 BLEEDING PROCEDURE WHEN BLEEDING AVID BRAK
54. pressur ize the system Repeatthis procedure several times until large bubbles stop coming out of the caliper NOTE BE CAREFUL NOT PULL OUT TOO HARD ON THE PLUNGER OR YOU WILL PULL AIR PAST THE PLUNGER SEAL AND YOU WILL BE THERE ALL DAY TRYING TO GET BUBBLES OUT Once the large bubbles atthe caliper have stopped apply a small amount of pressure on the syringe plunger and slowly let the pressure extend the brake lever you have been holding with your finger If you fastened the lever with a toe strap or rubber bands remove these first but keep the lever pulled in with your finger then apply pressure on the syringe plunger not pictured NOTE YOU WILL FEEL THE PRESSURE AT YOUR FINGER ON THE LEVER JUST LET THE FLUID EXTEND THE LEVER BACK TO ITS ORIGINAL POSITION Remove the syringe from the caliper and re install the bleed port screw NOTE THERE WILL BE EXCESS DOT FLUID THAT SPILLS OUT AS YOU RE INSTALL THE BLEED PORT SCREW THIS IS NORMAL BE SURE TO WIPE THE FLUID OFF THE CALIPER WITH A TOWEL AND WATER BLEED THE SYSTEM BLEED THE LEVER Open the red syringe clamp on the lever Gently pull out on the lever syringe plunger to create a vacuum then gently push in on plunger to pressurize the system Squeeze and release the brake lever ten times allowing the lever to snap back to it s starting position after squeez ing this helps break loose the bubbles Repeat this procedure several times until large bubbles stop coming ou
55. s SMALL PART INSPECTION Check ball bearing and cam ramps for excessive wear NOTE IT IS NORMAL TO SEE BALL TRACKS IN THE CAM RAMPS Check the threads of the drive cam foot screw inner pressure foot cable anchor bolt and torque arm fixing nut for damage Check the spring for any signs of damage Check the cable seal boots for nicks tears or cracking A amp 2l 22 23 24 CALIPER OVERHAUL ASSEMBLY SERVICE INSTRUCTIONS ASSEMBLE CALIPER Very lightly grease the inner pressure foot threads Using a T 25 Torx wrench thread the inner pressure foot into the outboard caliper body half until the pressure foot is flush with the inner face ofthe caliper body Very lightly grease the foot screw threads tip of stem end on outer pressure foot and the ramps of the drive cam Using small needle nosed pliers or a Schrader valve tool thread the foot screw into the drive cam completely but do not tighten GEN 0000000000362 Rev A CALIPER OVERHAUL ASSEMBLY SERVICE INSTRUCTIONS ASSEMBLE CALIPER CONT 25 Insert the stem end of the outer pressure foot into the hole in the end of the drive cam and install by firmly pressing it straight in 26 Lightly grease the ramps ofthe fixed cam in the outboard caliper body 27 Place the ball bearings into the ramps of the fixed cam 28 Insert the Drive Cam Outer Pressure Foot assembly through the hole in the outboard caliper body Rotate the cam
56. s against each other to ensure the ball bearings are seated properly in both sets of ramps 29 Apply a high strength thread lock such as Loctite 272 to the drive cam threads IMPORTANT BE CAREFUL NOT TO ALLOW ANY THREAD LOCK TO ENTER THE AREA AROUND THE FOOT SCREW 30 Hold the Drive Cam in place and re install the return spring outer seal and washer with hex hole NOTE THE SPRING LEG THAT EXTENDS AWAY FROM THE SPRING SHOULD POINT AWAY FROM THE CALIPER BODY THE NOTCH IN THE OUTER SEAL SHOULD FACE AWAY FROM THE CALIPER BODY AND BE LOCATED UNDERNEATH THE SPRING LEG 31 Install the torque arm aligning the spring leg with the spring tension notch on the back of the torque arm When engaged correctly the spring adjuster screw will be driven againstthe spring leg on the back of the torque arm Press the torque arm onto the flats of the drive cam shaft Make sure the arm is fully seated and hold firmly with your thumb 32 Place the lockwasher on the drive cam with the rounded side toward the caliper body Thread on the torque arm fixing nut by hand then torque to 55 60in Ib IMPORTANT DO NOT OVER TIGHTEN THE TORQUE ARM FIXING NUT 33 Install the outboard adjuster knob by aligning the rectangle tab of the foot screw with the rectangular hole in the the knob then press it on firmly 34 Re install the pad retainer in the outboard caliper body 35 Apply a high strength thread lock such as Loctite 272 to the 2 caliper bolts
57. self adjusting the pistons need to be pushed back into the body to their original position before the new pads can be in stalled The safest way to do this is with the old pads still in the caliper to protect the pistons Place a flat blade screwdriver between the old pads then carefully rock it back and forth pushing the pistons back into their bores not pictured REMOVE THE OLD PADS 3 Grabthe pad tabs and pull straight out 4 Inspect and measure the total thickness of each brake pad with a ruler If the total thickness is less than 3 mm you need to replace both brake pads not pictured NOTE IF THE BACKING PLATE AND PAD MATERIAL IS THICKER THAN 3 MM YOU CAN SIMPLY RE INSTALL YOUR BRAKE PADS AS OUTLINED IN STEP 5 INSTALL THE NEW PADS AND SPREADER 5 Besurethe spreader clip is oriented to the pads as shown Align the hole in the spreader clip with the holes in the pad tabs Squeeze the pad and clip assembly together then insert into the caliper as a unit Firmly push until the assembly is seated into place 6 Install the pad retainer bolt and tighten to 0 9 1 1 N m 80 97 in Ib Install the E clip on the wheel side ofthe caliper making sure it sits in the groove of the retainer bolt THIS CONCLUDES THE DISC BRAKE PAD REPLACEMENT INSTRUCTIONS YOU DID A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY GEN 0000000000362 Rev A JUICY 3 5 7 CARBON ULTIMATE INTRODUCTION Avid brake pads should be replaced wh
58. sembly straight into lever body until you hear an audible click indicating the push rod is fully seated in the piston Align the hole in lever blade with the slot in lever body and re install the pivot pin so it sits flush IMPORTANT MAKE SURE THE PIVOT BUSHINGS ARE INSTALLED Slide the reach adjust bolt through the pivot pin hole and slide the piston spring over the bolt Place the reach adjust knob onto the spring compress the spring and slide the reach adjust knob into place in the lever body Use a 3 mm hex to thread the lever bolt so the slot in the bolt is aligned with the hole in the knob Use a small phillips screwdriver and re install the screw for the reach adjust knob Tighten until snug THIS CONCLUDES THE LEVER OVERHAUL SERVICE INSTRUCTIONS YOU HAVE DONE A GREAT JOB AND ARE READY TO MOVE ON TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE CALIPER OVERHAUL ENJOY GEN 0000000000362 Rev A CODE 5 JUICY 3 5 7 CARBON ULTIMATE INTRODUCTION Avid brake lever assemblies need to be serviced in order to optimize braking function If brake fluid is leaking from any area of the brake lever assembly there may be damage or wear and tear to the internal moving parts If your brake was filled with fluid OTHER than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the reservoir cap bladder and
59. silicone based Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function CALIPER OVERHAUL SERVICE INSTRUCTIONS TROUBLESHOOTING STICKY OR SLOW BRAKE PAD RETURN FEEL Before completely disassembling your caliper it s worth trying to loosen the sticky piston Try the following Clamp bicycle in bicycle work stand Spin affected wheel Lightly squeeze brake lever and watch brake pads when lever is released Determine which side of the caliper has a slow returning brake piston Remove caliper from bicycle If you have a mounting bracket it is recommended to remove that too or just remove the caliper leaving the bracket on the fork or frame Using a pair of needle nosed pliers remove both brake pads and h spring Remove the spring pad clip from the outside of the caliper Using an 11mm box wrench press working piston into caliper body Squeeze brake lever slowly to move sticky piston inward Press the piston back into the caliper again Repeat these steps to correct caliper piston inner o ring position Both pistons should now be moving freely Re install spring pad clip h spring and pads into caliper Re install caliper onto bicycle Spin wheel and check function If there is no improvement continue with caliper service GETTING STARTED Remove brake caliper from fork or frame and remove the caliper mounting bracket and CPS hardware from th
60. sion nut NOTE IF YOUR BRAKE HAS A HOSE BOOT PULL THE BOOT AWAY FROM THE LEVER TO ACCESS THE COMPRESSION NUT IF THE BOOT STICKS CAREFULLY PRY UP A CORNER WITH SOMETHING THAT WON T HARM IT LIKE A PENCIL TIP AND SPRAY SOME ALCOHOL BETWEEN THE BOOT AND THE LEVER WORK THE ALCOHOL IN THE BOOT SHOULD LOOSEN UP AND SLIDE EASILY DOWN THE HOSE 3 Pullthe hose from the lever wiggling it if neces sary Be careful DOT fluid will drip from the hose Try notto spill too much fluid because any fluid that drips out will create bubbles that you ll have to eliminate later 4 Slidethe nut and boot if applicable down the hose and away from the end where you ll be cut ting Do notto engage the brake lever while the hose is removed not pictured GEN 0000000000362 Rev A CHANGING HOSE LENGTHS CONT DETERMINE PROPER HOSE LENGTH amp CUT Q 5 Determine where you need to cut the hose by holding it up to the lever in the position you like Make sure to leave a gentle bend in the hose with enough length to freely turn the bars all the way from side to side Double check this part because you can t go back after you cut 6 The groove in the lever nose marks the spot where you ll cutthe hose Cutthe hose using hydraulic hose cutters or very sharp cable housing cutters not pictured INSTALL NEW FITTINGS 7 While holding the hose firmly thread a new hosebarb into the end ofthe hose using a T 10 Torx wrench 8 Slide a new com
61. t included in Avid Bleed Kit and socket wrench or use a flare nut 8mm wrench loosen and remove compression nut from lever body Turn counterclockwise to remove Unthread completely by hand and slide compression nut down hose Pull brake hose and compression fitting from lever body 3 Allow any brake fluid to drain into a container Hold lever assembly over container and pump lever to remove any brake fluid inside lever assembly NOTE IF THE SYSTEM HAS BEEN CONTAMINATED WITH THE WRONG FLUID YOU WILL NEED TO FLUSH ALL THE PARTS WITH SOAPY WATER AND ALLOW TO DRY FULLY PRIOR TO REBUILDING YOU WILL ALSO NEED TO INSTALL A NEW HOSE RESERVOIR COVER BLADDER REMOVAL 4 Using a T 10 Torx wrench remove the reservoir cover screws 5 Remove reservoir cover cap and bladder from lever assembly Additional brake fluid will drain from lever Hold lever over container and allow fluid to drain Set lever assembly down on clean towel not pictured 6 Holding the reservoir cover remove bladder from reservoir cover Replace with new bladder if contaminated and leaking fluid NOTE POSSIBLE CAUSES OF LEAKING BLADDER AND OR RESERVOIR INCLUDE BRAKE SYSTEM MAY HAVE TOO MUCH FLUID BLADDER MAY HAVE SPLIT AND OR BLADDER MAY BE CONTAMINATED Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 19 LEVER OVERHAUL SERVICE INSTRUCTIONS CONT RESERVOIR COVER BLADDER REMOVAL CONT 9 7 Insert new bladder into cover and seat
62. t of the lever NOTE BE CAREFUL NOT PULL OUT TOO HARD ON THE PLUNGER OR YOU WILL SUCK AIR PAST THE PLUNGER SEAL INTO THE FLUID AND CREATE MORE BUBBLES THAT YOU WILL HAVE TO ELIMINATE Once the large bubbles at the lever have stopped apply a small amount of pressure on the syringe plunger then remove the syringe and re install the bleed port screw NOTE THERE WILL BE A SMALL AMOUNT OF EXCESS DOT FLUID THAT SPILLS OUT AS YOU REMOVE THE SYRINGE AND RE INSTALL THE BLEED PORT SCREW THIS IS NORMAL BE SURE TO WIPE THE FLUID OFF THE LEVER WITH A TOWEL GEN 0000000000362 Rev A BLEEDING PROCEDURE CONT FINAL TOUCH NOT PICTURED 25 Spray isopropyl alcohol or water onto a towel and wipe off the brake lever and caliper to re move any excess DOT fluid you may have missed before 26 Remove the Bleed Block from the caliper and re install the brake pads and spreader clip 27 Re install your wheel according to the manufac turer s instructions Empty the syringes into a sealed container and dispose of the fluid properly Remember used DOT fluid should be recycled or disposed of in accordance to local and federal regulations NEVER pour used DOT fluid down a sewage or drainage system or into the ground or a body of water Do not re use this fluid Do not leave the hose clamps closed this will damage the clear tubing on the syringes TEST THE SYSTEM You are almost ready to ride but first it s good idea to test your bra
63. to the caliper until it clicks into place indicat ing it is properly secured in the caliper body GEN 0000000000362 Rev A CALIPER OVERHAUL SERVICE INSTRUCTIONS CONT FINISHING UP NOT PICTURED 24 Visually check your work Inspect banjo bolt and banjo for any protruding o rings If there are any o rings that are squeezed beyond the outside edges of the banjo or bolt remove and replace Repeat installation steps 25 Wipe assembled caliper with soapy water to remove any brake fluid 26 Re install caliper onto bicycle following the installation and torque specifications called out in the user manual THIS CONCLUDES THE CALIPER OVERHAUL SERVICE INSTRUC TIONS YOU HAVE DONE A GREAT JOB AND ARE READY TO MOVE TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT AND BLEEDING ENJOY Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 35 CODE CODE 5 INTRODUCTION Avid caliper assemblies need to be serviced in order to optimize braking function If caliper brake piston motion is sticky or lacks a positive and smooth return the caliper body brake piston o ring may be out of place or damaged If your brake was filled with brake fluid other than DOT 4 or 5 1 damage to all rubber and plastic internal parts may exist Commonly used INCORRECT fluid is mineral oil or DOT 5 which is silicone based Inspection and or replacement of these parts due to any of the above situations will be
64. ut the life of the brake pads This is normal and should not affect braking performance Noise is dependent upon factors such as brake setup rider weight riding style braking style and riding conditions i e dust soil and contamination of friction surfaces PAD REPLACEMENT REMOVE OLD BRAKE PADS AND H SPRING 1 Remove e clip from guide groove on top of the caliper using a sharp pick 2 Using a 2 5 mm hex wrench remove the guide pin from the caliper 3 Squeeze the pads together so they clear the pis ton and pull to remove brake pads and h spring from caliper 4 Inspect and measure the total thickness of each brake pad with a ruler or the pad thickness slot on the pad spacer tool If the total thickness is less than 3 mm or it fits into the slot you need to replace both brake pads not pictured NOTE IF THE BACKING PLATE AND PAD MATERIAL IS THICKER THAN 3 MM OR THE SLOT YOU CAN SIMPLY RE INSTALL YOUR BRAKE PADS AS OUTLINED IN STEPS 5 10 INSTALL THE NEW PADS AND H SPRING 5 Position the h spring between the two pads NOTE THE CODE PADS ARE SYMMETRICAL THERE IS NOT A LEFT OR RIGHT ORIENTATION 6 Locate the pad installation feature of the pad spacer tool Insert the pad handles into the pad installation tool so it holds the pads together 7 Insert the pads and pad tool into the caliper until the holes in the top of the pads are aligned with the guide pin holes in the top of the caliper 8 Insertthe
65. y Line up pushrod with the threaded hole in the cross dowel of the lever Using 2mm hex thread the pushrod completely by turning counter clockwise OR Code 5 Juicy 5 Only Line up pushrod pin with slotin coupling retainer Insert pushrod pin into coupling retainer Pushrod pin snaps into slot OR Juicy 7 Carbon Ultimate Only Line up pushrod pin with slot in worm gear coupling wide slot in center of worm gear coupling Insert pushrod into worm gear coupling Pushrod pin snaps into worm gear inner coupling slot Insert s into lever body one on each side The bushing lip larger end should be on inside of lever body Line up lever pivot pin hole with bushing holes Insert pivot pin back into lever and bushings Use your thumb to press down on pivot pin and JUICY 3 snap it into place OR INSTRUCTIONS FOR CODE 5 JUICY 3 b PLEASE MOVE ON TO ULTIMATE STEP 37 FINISHING UP PROCEDURES STAR WHEEL AND WORM INSTALLATION JUICY 7 CARBON 31 ULTIMATE ONLY NOTE JUICY ULTIMATE IS NOT EQUIPPED WITH A STAR WHEEL KNOB HOWEVER THE PROCEDURE IS SIMILAR Juicy 7 Carbon Only Press star wheel worm bushing back into lever body with thumb Thread star wheel worm assembly back into lever body OR Juicy Ultimate Only Press bushing back into lever body with thumb Using a 2 5mm hex thread onto worm Using a pair of needle nosed pliers or a retaining clip tool press the retaining clip onto end of worm to secure lever asse

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