X0Trail Service Manual
Contents
1. Aero bar pads Foam rings e Chains e Wheel braking surfaces e Corrosion e Rear shock mounting e Sprockets Bottomout pads e Tools hardware and main seals e Cassettes e Bearings e Motors Upper tubes stanchions e Shifter and brake cables inner Bearing races e Batteries Notwithstanding anything else set forth herein this warranty is limited to one year for all electronic and electronic related components including motors controllers battery packs wiring harnesses switches and chargers The battery pack and charger warranty does not include damage from power surges use of improper charger improper maintenance or such other misuse 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 authorised by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use TABLE OF CONTENTS BRAKE SERVICE OVERVIEW a A A Ad 5 LEVER OVERHAUL M a 6 LEVEREXPEODED MEN ld acts RO DO picasa gn ia nod ie coc tues as 6 PART SAND TOOLS NEEDED FOR SERVICE into leia nooo oa oo ooo ooo nl o ono oo Bo ae delia 6 CALIPER OVERHAUL virai aaea aaa a aaa iia iones add aa ase od aa ua dos ea n 14 CAHIPEREXPEODE DV EV Sex oto ee boat a el ea ooo en 14 PARTS AND TOOTS NEEDED FOR SERVIC EB suk HUR ete E E E ss 14 TROUBLE SHION eo on 15 HOSE CENGTH ADJUSTMEN T2. 80 mm from the centerline of the handlebar If the lever is too far out it can make bleeding the brake impossible 8 Use the T10 TORX to remove the lever bleed port screw Make sure the fluid in the 1 4 full syringe is pushed all the way to the tip so that there is no air gap then thread into the lever bleed port It is not necessary to reposition the angle of the brake lever on the handlebar You may have a small amount of DOT fluid drip from the bleed port screw this is normal Just have a clean rag handy to wipe off any excess after the syringe is installed 27 BRAKE BLEED PROCEDURE Hold both syringes upright 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 You should see bubbles form in the lever syringe 11 Close the syringe clamp on the lever 12 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 it or you can fasten it with a zip tie or rubber band 13 Pull out on the caliper syringe plunger to create a vacuum then gently push in on the plunger to pressurize the system Repeat this procedure several times until large bubbles stop coming out of the caliper Do not pull the plunger past the end
3. Kit Nitrile gloves Avid Bleed Block Isopropyl alcohol e T10 TORX Clean lint free rag e 2 5 and 4 mm hex wrenches Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid e Pick A A Bleed Block High Performance y actual bleed block DOT Fluid may differ Avid Bleed Kit Contents BRAKE BLEED PROCEDURE Bleeding Avid brakes forces air bubbles out of the system We recommend 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 When bleeding brakes you may notice discoloration of the old fluid as it exits the system into the syringe at the lever If the fluid is severely discolored this indicates that the fluid is very old In this case bleeding the system twice in order to completely remove the old fluid is recommended Fill one syringe 1 2 full with Avid High Performance 5 1 DOT Fluid and fill the other syringe 1 4 full 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 clean rag around the tip and slowly push the air bubbles out of the syringe Close the hose clamp on each syringe o0 o Q a ak i bo 0 00 209 8 T 2 De gas the fluid in the 1 2 full syringe Leave the hose clamp shut and pull on a 0 of the plunger Bubbles will form in the brake fluid While the plunger is still pulled do O 2o 8 d
4. end of the hose until it is flush Slide a new compression fitting over the end of the hose with the new hose barb Push the hose firmly into the lever until it stops While holding the hose in place slide the compression fitting and compression nut up to the lever or hose stop HOSE LENGTH ADJUSTMENT For models with a compression nut and a hex hose stop While continuing to push the hose into the hose stop use an 11mm open end wrench to hold the hose stop in place and use an 8 mm flare nut wrench to tighten the compression nut to the proper torque For models with a compression nut only While continuing to push the hose into the lever body use an 8 mm flare nut wrench to tighten the compression nut to 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 lb 9 Slide the boot back into place After completing the hose length adjustment bleed the brakes for optimal performance Click here for detailed brake bleed instructions 24 HOSE LENGTH ADJUSTMENT BRAKE BLEED PROCEDURE Avid brakes are the most powerful and precise hydraulic brakes on the market A key reason behind this is the ability to optimize brake performance with a perfect bleed The goal of bleeding is to remove any air that is trapped in the hose caliper or lever Air trapped in a hydraulic brake system degrades the performance of the brake The fol
5. on the wrench through the fluid flow port in the master cylinder head Place a clean rag under the lever body to wipe up any fluid that may spill out Return spring eyelet LEVER OVERHAUL Use the pliers to apply downward pressure to the lever body and remove the snap ring Remove the piston bladder assembly Do not look directly into the lever body while performing this step The internal piston spring assembly is preloaded and will come out of the lever body quickly which can result in injury Wear safety glasses Lubricate a new piston bladder snap ring assembly by dipping it into Avid High Performance 5 1 DOT Fluid You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant LEVER OVERHAUL 10 Insert the piston bladder assembly into the lever body with the keyed section of the piston retainer oriented toward the opening in the lever body Use the snap ring pliers to push the piston bladder assembly into the lever body and secure the snap ring in its groove Orient the snap ring eyelets opposite the opening in the lever body You can also use a 10 mm deep socket against the snap ring to push the piston bladder snap ring assembly into the lever body If you push the snap ring past its groove you can use the 2 mm hex in the vise to push on the assembly from inside the fluid flow port which will seat the snap ring into the groove LEVER OVERHAUL 12 Insert the lever blade in
6. rinon e E E AE E ENE Eaa 21 PARTS AND TOJLSNEE DED FORSERVICE srpyrii roe br A 21 BRAKE BLEED PROCEDURE iccccssccassssasancuancaransantenscenaasswubimenatauneacassaeteadecseansancapianeaadecacensmasbeuaswanasasswaduncadanazansessanssancaseaabpaccenannacsans 25 PARTSAND TOOLS NEEDED FOR SERVICE aterea aE E E E id 25 PAD REPLACEMENT INSTRUCTIONS kiria a a a A a ao a aE 31 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE ssccssscsseenecenseessensennseneeenseenseonssunssoesaonsenesenaesnseensauesecassnousonseneeuanssags 32 SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your products Protect yourself Wear your safety gear SAFETY INSTRUCTIONS Always wear safety glasses and nitrile gloves when working with DOT fluid Place an oil pan on the floor underneath the area where you will be working on the brake Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water DOT fluids will damage painted surfaces If any fluid comes in contact with a painted surface i e your frame or printing on the brakes wipe it off immediately and clean with isopropyl alcohol or water Removal of paint and or printing by DOT fluid is not covered under warranty Do not allow any brake fluid to come in contact with the brake pads If this occurs the pads are co
7. 2013 XO Trail Service Manual GEN 0000000004233 Rev B 2013 SRAM LLC SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein 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 component was purchased Original proof of purchase is required all warranties including any implied warranties of reasonable care merchantibility or fitness for a particular purpose are hereb disclaimed 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 limitations 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 Kingd
8. ack and forth to push the pistons completely into their bores 3 Pull on the brake pad tabs to remove the pads and pad spreader clip Place the spreader clip between the pads as shown Align the hole in the spreader clip with the holes in the brake pad tabs Squeeze the pad and clip assembly together then insert it into the caliper from the top of the caliper Push the pad clip assembly into the caliper until the holes in the spreader clip brake pads and caliper are aligned 5 Insert the pad retainer bolt into the outboard side of the caliper through the pad spreader and pads and into the inboard side of the caliper Use a 2 5 mm hex wrench to thread the pad retainer bolt into the caliper then tighten it to 0 6 0 9 N m 5 8 in lb Replace the e clip onto the pad retainer bolt 31 2 5 mm hex 0 6 0 9 N m 5 8 in lb PAD REPLACEMENT INSTRUCTIONS DISC BRAKE PAD AND ROTOR BED IN PROCEDURE All new brake pads and rotors should be put through a wear in process called bed in The bed in procedure which should be performed prior to your first ride ensures the most consistent and powerful braking feel along with the quietest braking in most riding conditions The bed in process heats up the brake pads and rotors which deposits an even layer of brake pad material transfer layer to the braking surface of the rotor It this transfer layer that optimizes braking performance The bed in process requires you to perform heavy bra
9. aliper o ring and install it onto the banjo bolt Place the inboard caliper half onto the banjo bolt Place the banjo fitting onto the threads of the banjo bolt Turn the bolt into the fitting until it stops Do not tighten the banjo bolt yet Install the caliper body bolt and use a torque wrench with a T25 TORX bit socket to tighten it to 9 7 11 7 N m 86 104 in Ib Hold the banjo fitting at the desired angle Use a torque wrench with an 8 mm flare nut crowfoot to tighten the banjo bolt to 9 7 11 7 N m 86 104 in lb 9 7 11 7 N m 86 104 in Ib 9 7 11 7 N m 86 104 in Ib CALIPER OVERHAUL Insert the Bleed Block into the caliper in place of the brake pads You will need to bleed your brakes before reinstalling the brake pads Click here for detailed brake pad removal instructions 14 Spray isopropyl alcohol on the caliper and clean it with a rag Visually check your work If there are any o rings that are protruding beyond the outside edges of the banjo or bolt remove and replace the o rings then repeat the installation process Overhauling the caliper introduces a small amount of air into the system It is necessary to bleed the brakes for optimal performance Click here for detailed brake bleed instructions 20 CALIPER OVERHAUL HOSE LENGTH ADJUSTMENT SAFETY INSTRUCTIONS Always wear safety glasses and nitrile gloves when working with DOT fluid Place an oil pan on the floor underneath the area where you w
10. ay isopropyl alcohol between the boot and the lever Work the alcohol in the boot should loosen up and slide easily down the hose HOSE LENGTH ADJUSTMENT K 4 22 For models with a compression nut and a hex hose stop Use an 11 mm open end wrench to hold the hose stop in place and use an 8 mm flare nut wrench to unthread the compression nut For models with a compression nut only Use an 8 mm flare nut wrench to unthread the compression nut Pull the hose from the lever Be careful DOT fluid will drip from the hose Try not to spill too much fluid because any fluid that drips out will create bubbles that you ll have to eliminate later Slide the nut down the hose and away from the end where you ll be cutting Do not pull the brake lever while the hose is removed Determine where you need to cut the hose by holding it up to the lever in the position you like 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 measurement The groove in the lever nose marks the spot where you ll cut the hose Cut the hose using hydraulic hose cutters or very sharp cable housing cutters Compression nut Measure twice cut once HOSE LENGTH ADJUSTMENT 23 Apply Avid DOT Grease to the threads of a new hose barb the compression fitting outer surfaces and compression nut threads While holding the hose firmly use a T10 TORX to thread the hose barb into the
11. ed apply a small amount of pressure on the syringe plunger then remove the syringe and reinstall the bleed port screw There will be a small amount of excess DOT fluid that spills out as you remove the syringe and reinstall the bleed port screw this is normal be sure to wipe the fluid off the lever with a clean rag Spray isopropyl alcohol or water onto a clean rag and wipe off the brake lever and caliper to remove any excess DOT fluid 2 Visually check your work Inspect the 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 the o rings and then repeat the installation process 21 Remove the Bleed Block from the caliper and reinstall the brake pads and spreader clip Click here for detailed brake pad installation instructions 22 Reinstall your wheel according to the manufacturer s instructions 23 Before riding test your brakes Pull on the lever as hard as you would during riding several times Make sure to look around the compression nut on the lever and the banjo bolt on the caliper for any leaks Make one last check of all the bolts and fittings 50 BRAKE BLEED PROCEDURE PAD REPLACEMENT INSTRUCTIONS Remove the e clip from the pad retainer bolt Use a 2 5 mm hex wrench to remove the pad retainer bolt from the caliper Place a flat blade screwdriver between the brake pads then carefully rock it b
12. ex wrench tooled reach adjust models only T10 T25 TORX wrench T10 T25 TORX bit socket 11 mm open end wrench 8 mm flare nut wrench 8 mm flare nut crowfoot Torque wrench LEVER OVERHAUL Use a T25 TORX wrench to remove the brake clamp bolt from the Discrete clamp MMX or XLoc XLoc requires removal of the shifter Remove the brake lever from the handlebar Pull the hose boot off the compression nut and slide it down the hose Discrete Clamp 2 Use an 11 mm open end wrench to hold the hose stop in place and use an 8 mm flare nut wrench to remove the hose compression nut Pull the brake hose and compression fitting from the brake lever body 3 Pour the brake fluid into an oil pan Squeeze the lever to pump excess brake fluid from inside the lever assembly If the system has been contaminated with the wrong fluid flush all the parts with soapy water rinse and allow to dry prior to rebuilding Install all new seals and a new hose 4 Use a T10 TORX to remove the pivot bolts from both sides of the lever LEVER OVERHAUL 5 Use a pick to disengage the return spring eyelet from the spring anchor tab Turn the reach adjuster counter clockwise until the adjuster disengages from the pushrod Tooled reach adjust models Use a 3 mm hex wrench to turn the reach adjuster Remove the lever from the lever body Clamp a 2 mm hex wrench into a bench vise with the tool positioned vertically Insert the lever body
13. ill be working on the brake Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water DOT fluids will damage painted surfaces If any fluid comes in contact with a painted surface i e your frame or printing on the brakes wipe it off immediately and clean with isopropyl alcohol or water Removal of paint and or printing by DOT fluid is not covered under warranty Do not allow any brake fluid to come in contact with the brake pads If this occurs the pads are contaminated and must be replaced For best results use only Avid High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid PARTS AND TOOLS NEEDED FOR SERVICE 2 Pull the hose boot away from the lever to access the compression 21 Safety glasses e Hydraulic hose cutters or very sharp cable housing cutters Nitrile gloves e TIO TORX Isopropyl alcohol e 8 mm flare nut wrench Clean lint free rag e 11 mm open end wrench Avid DOT Grease or DOT 5 1 or 4 compatible grease e Torque wrench Make sure the hoses are properly secured to the bicycle and check the routing of each hose Account for suspension movement and be sure the handlebars can move freely by turning the bars all the way from side to side nut If the boot sticks use a zip tie to pry up a corner of the boot and spr
14. king You must be familiar with the power and operation of disc brakes Braking heavily when not familiar with the power and operation of disc brakes could cause you to crash which could lead to serious injury and or death If you are unfamiliar with the power and operation of disc brakes you should have the bed in process performed by a qualified bicycle mechanic To safely achieve optimal results remain seated on the bike during the entire bed in procedure Do not lock up the wheels at any point during the bed in procedure Accelerate the bike to a moderate speed then firmly apply the brakes until you are at walking speed Repeat approximately twenty times 2 Accelerate the bike to a faster speed Then very firmly apply the brakes until you are at walking speed Repeat approximately ten times Allow the brakes to cool prior to any additional riding 52 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE WWW Sfam com
15. lowing instructions will walk you through our simple bleed procedure Avid brakes come with hoses attached and bled If you don t need to change the hose length you do not need to bleed the system prior to installation Supplemental video instruction is available at www sram com en service SAFETY INSTRUCTIONS Always wear safety glasses and nitrile gloves when working with DOT fluid Place an oil pan on the floor underneath the area where you will be working on the brake Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water DOT fluids will damage painted surfaces If any fluid comes in contact with a painted surface i e your frame or printing on the brakes wipe it off immediately and clean with isopropyl alcohol or water Removal of paint and or printing by DOT fluid is not covered under warranty Do not allow any brake fluid to come in contact with the brake pads If this occurs the pads are contaminated and must be replaced Do not re use fluid Do not leave the hose clamps closed this will damage the clear tubing on the syringes For best results use only Avid High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid PARTS AND TOOLS NEEDED FOR SERVICE 25 Safety glasses e Avid Bleed Kit or Avid Professional Bleed
16. ntaminated and must be replaced For best results use only Avid High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid BRAKE SERVICE OVERVIEW Avid brake systems need to be serviced periodically to optimize braking function If brake fluid is leaking from any area of the brake there may be damage or wear and tear to the internal moving parts If the system has been contaminated with the wrong fluid there may be damage to all rubber and plastic internal parts If your brake was damaged in a crash there may be damage to the lever blade pushrod and housing assemblies Inspect and replace these parts to restore proper brake function Your product s appearance may differ from the pictures contained in this publication al BRAKE SERVICE OVERVIEW LEVER OVERHAUL LEVER EXPLODED VIEW A AA E R AR AR BR A om PRP A VVWVWVV iq G A Hose stop B Pivot bolts C Piston spring D Piston bladder pushrod assembly E Snap ring Tooled reach adjust models F Lever blade G Contact adjuster H Lever return spring Reach adjuster PARTS AND TOOLS NEEDED FOR SERVICE Safety glasses Nitrile gloves Oil pan Isopropyl alcohol Clean lint free rag Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid DOT Grease or DOT 51 or 4 compatible grease Bench vise Long tipped snap ring pliers Pick with a 90 degree bent tip 3 mm h
17. of the syringe 28 BRAKE BLEED PROCEDURE 14 Once the large bubbles at the 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 zip tie or rubber bands remove these first but keep the lever pulled in with your finger then apply pressure on the syringe plunger You will feel the pressure at your finger on the lever just let the fluid extend the lever back to ts original position Close the clamp on the caliper syringe then remove the syringe from the caliper and reinstall the bleed port screw Use a clean rag to wipe off any excess DOT fluid that spills out as you reinstall the bleed port screw 16 Open the syringe clamp on the lever 17 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 its starting position after squeezing this helps break loose the bubbles Repeat this procedure of creating a vacuum at the syringe and squeezing the brake lever ten times until large bubbles stop coming out of the lever Do 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 29 BRAKE BLEED PROCEDURE Once the large bubbles at the lever have stopp
18. om b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations For Australian customers This SRAM limited warranty is provided in Australia by SRAM LLC 133 North Kingsbury 4th floor Chicago Illinois 60642 USA To make a warranty claim please contact the retailer from whom you purchased this SRAM product Alternatively you may make a claim by contacting SRAM Australia 6 Marco Court Rowville 3178 Australia For valid claims SRAM will at its option either repair or replace your SRAM product Any expenses incurred in making the warranty claim are your responsibility The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by local 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 product
19. own lightly tap the syringe to release the bubbles sticking to the sides and c GS the bottom so that they can rise to the top of the fluid When the bubbles stop soe o forming and have all risen to the top release the plunger open the clamp ped and carefully push the air out Repeat several times You will not be able to remove all the bubbles E 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 system overfill and keep DOT fluid from contaminating your brake pads Click here for detailed brake pad removal instructions Use the T10 TORX to remove the caliper bleed port screw from the caliper body or banjo bolt Make sure the fluid in the 1 2 full syringe is pushed all the way to the tip so that there is no air gap then thread into the caliper bleed port EE 9 9 ONA V a MANS 26 BRAKE BLEED PROCEDURE For models with Contact Point Adjustment and a rotating bleed port screw located on the contact point adjuster rotate the adjuster in the direction opposite the arrow until it stops then rotate the adjuster back just enough to place the bleed screw at its highest point For models with Contact Point Adjustment and a fixed bleed port screw rotate the adjuster in the direction opposite the arrow on the adjuster knob until it stops 7 For models equipped with Reach Adjust make sure the tip of the lever blade is 75
20. s that have been incorrectly installed and or adjusted according to the respective SRAM user manual The SRAM user manuals can be found online at sram com rockshox com avidbike com truvativ com or zipp com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturers 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 when the product has been modified including but not limited to any attempt to open or repair any electronic and electronic related components including the motor controller battery packs wiring harnesses switches and chargers 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 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 Wear and tear parts are identified as e Dust seals e Stripped threads bolts and outer e Pawls Bushings aluminium titanium e Handlebar grips Transmission gears e Air sealing o rings magnesium or steel e Shifter grips e Spokes e Glide rings e Brake sleeves e Jockey wheels e Free hubs e Rubber moving parts e Brake pads e Disc brake rotors
21. s unseat Do not remove one piston if the other is still seated Remove the pistons from the caliper Repeat this process for the other caliper half Forced air will dislodge the caliper pistons rapidly which can lead to bodily injury or damage to the parts Point the caliper pistons toward a rubber surface before forcing air into the caliper Use a pick to remove the piston seals from inside each caliper body half Install new seals inside each caliper body half Do not scratch the seal gland with the pick You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant CALIPER OVERHAUL Inspect the caliper pistons for damage and replace them if necessary Apply a small amount of DOT 51 fluid to the circumference of each piston Reinstall the pistons into each half of the caliper body Wipe any excess fluid from the caliper halves There are two larger diameter pistons and two smaller diameter pistons Install one of each into each caliper half You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant E Remove the banjo port o ring from the outboard caliper half 18 Remove the o rings from the banjo bolt and banjo fitting Apply a small amount of DOT 5 1 fluid to the new o rings and install them CALIPER OVERHAUL 12 19 Reassemble the caliper halves Insert the banjo bolt through the outboard caliper half Apply a small amount of DOT 5 1 fluid to the c
22. stons D Outboard caliper body half J Pad spreader clip E Caliper body bolt K Caliper o ring F Pad retainer bolt L Banjo bolt PARTS AND TOOLS NEEDED FOR SERVICE e Safety glasses e Needle nose pliers e Nitrile gloves e Pick with a 90 degree bent tip e Oil pan e 2 5 5 mm hex wrench e Isopropyl alcohol e 2 5 mm hex bit socket e Clean lint free rag e T25 TORX e Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid T25 TORX bit socket DOT Grease or DOT 5 1 or 4 compatible grease 8mm open end wrench e Al ressor with rubber tipped blow gun chuck 0 PP 9 e 8 mm flare nut crowfoot e Soft rubber mat or small section of butyl inner tube e Torque wrench 14 CALIPER OVERHAUL TROUBLESHOOTING Sticky or slow brake pad return feel excessive lever throw Before completely disassembling your caliper it s worth trying to loosen the sticky pistons Try the following 1 Clamp the bicycle in a bicycle work stand 2 Remove the affected wheel 3 Squeeze the brake lever several times until the pads nearly contact one another 4 Push the XO Trail pad spreader clip in between the pads to spread the pads to the full width of the clip 5 Remove the clip 6 Repeat steps 3 5 several times 7 Reinstall the wheel 8 Squeeze the lever several times to position the pads at the proper distance from the rotor 9 Center the caliper on the rotor if necessary 10 Spin the wheel and check brake function All pistons should no
23. to the lever body Thread the reach adjuster onto the pushrod and turn it clockwise an additional 5 6 complete turns Tooled reach adjust models Use a 3 mm hex wrench to turn the reach adjuster 11 LEVER OVERHAUL 15 14 12 Use the angled tip of a pick to lift and fasten the eyelet of the lever return spring onto the spring anchor tab on the snap ring Use a T10 TORX wrench to install the pivot bolts into both sides of the lever Use a torque wrench with a T10 TORX bit socket to tighten the pivot bolts to 1 1 1 2 N m 10 11 in Ib 1 1 1 2 N m 10 11 in Ib LEVER OVERHAUL 15 15 Thread the compression nut into the lever body until it stops Hold the hose stop secure with an 11mm open end wrench and use a torque wrench with an 8 mm flare nut crowfoot to tighten the compression nut to 4 9 5 4 Nem 43 48 in lb Spray isopropyl alcohol on the lever and clean it with a rag Slide the hose boot onto the compression nut Reinstall the brake lever to the Discrete clamp MMX or XLoc Use a torque wrench with a T25 TORX bit socket to reinstall the brake clamp bolt into the Discrete clamp MMX or XLoc and tighten it to 5 6 N m 44 52 in Ib 11 mm 4 9 5 4 N m 43 48 in Ib 548 Wes 5 6 N m 44 52 in Ib LEVER OVERHAUL CALIPER OVERHAUL CALIPER EXPLODED VIEW A k H J A E clip G Banjo fitting B Piston seals H Inboard caliper body half C Brake pad Caliper pi
24. w be moving freely and there should not be excessive lever throw If there is no improvement continue with caliper service 15 CALIPER OVERHAUL Use a 5 mm hex wrench to remove the brake caliper from the fork or frame and remove the caliper mounting bracket and hardware from the caliper Set aside in the correct order Remove the e clip from the pad retainer bolt Use a 2 5 mm hex wrench to remove the pad retainer bolt from the caliper Es Pull on the brake pad tabs to remove the pads and pad spreader clip If the total thickness of the backing plate and pad friction material is less than 3 mm the brake pads need to be replaced 4 Use an 8 mm open end wrench to remove the banjo bolt and a T25 TORX wrench to remove the caliper body bolt Brake fluid will leak so hold the caliper over a container to catch the fluid Set the hose and banjo fitting aside Separate the caliper body halves 16 CALIPER OVERHAUL 17 Caliper Piston Removal Place one of the caliper halves piston side down on a soft rubber mat or a small section of inner tube on a flat surface Insert a rubber tipped blow gun chuck nozzle into the banjo port While firmly pushing against the caliper half and chuck nozzle squeeze the air chuck to force air into the banjo port and unseat the pistons from the caliper Place a rag over the caliper to contain any fluid that may spray Continue to force air into the caliper until both piston
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