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Technical Manual - Avid - 2010

1. ENDS OF CLIP MUST NOT PROTRUDE PAST LEVER BODY GROOVE OR EXTEND INTO LEVER SLOT GAP IN LEVER BODY GEN 000000000XXXX 20 26 27 28 29 30 LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED LEVER PUSHROD INSTALLATION Juicy 3 only Place washer onto pushrod Insert pushrod and washer into lever body so that pushrod sets ontop 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 body 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 only Line up pushrod pin with slotin coupling retainer Insert pushrod pin into coupling retainer Pushrod pin snaps into slot Insert bushings 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 snap it into place Install the pivot pin set screw into the lever blade and tighten with a 2 5mm hex wrench 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 ARE READY TO MOVE ON TO THE NEXT CHAPTER HYDRAUL
2. 12 Outboard Caliper Body Half Using an air compressor chuck insert chuck nozzle into banjo bolt hole Hold caliper in one hand pointing caliper piston 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 13 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 000000000XXXX 32 20 21 22 23 24 25 26 27 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED CALIPER ASSEMBLY Inspect caliper pistons for damage and replace if necessary Re install caliper brake pistons into each half of the caliper body Install a new banjo bolt o ring into the banjo bolt hole on outboard side of caliper body Insert and thread caliper bolt into caliper closest to banjo bolt hole Ensure new caliper banjo bolt o ring is not unseated from its position not pictured 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 Insert banjo bolt back into caliper into banjo bolt hole
3. BACK IN 2 The Elixir calipers are self adjusting the pistons need to be pushed back into the body to their original position before the new pads can be installed The safest way to do this is with the old pads still in the caliper to protectthe 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 Grab the pad tabs and pull straight out 4 nspectand 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 of the 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 000000000XXXX 52 JUICY 3 INTRODUCTION Avid brake pads should be
4. 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 either of these o rings during installation Using a T 10 Torx 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 BRAKE PAD INSTALLATION Insert spring pad clip into outer side of caliper 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 into the caliper until it clicks into place indicating it is properly secured in the caliper body 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 INSTRUCTIONS YOU HAVE DONE A GREAT JOB AND A
5. 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 000000000XXXX CODE 5 JUICY 3 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged 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 LEVER OVERHAUL SERVICE INSTRUCTIONS GETTING STARTED Remove brake lever from handlebar Remove caliper fro
6. 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 M BRAKE STYLE amp SERVICE CATEGORIES TOOLS NEEDED FOR SERVICE HYDRAULIC DISC BRAKELEVER OVERHAUL ELIXIR CR CODE 5 JUICY tete HYDRAULIC DISC BRAKEHOSE LENGTH ADJUSTMENT 8 BLEED ELIXIR 5 CR CR MAG CODE CODE 5 JUICY 3 CODE CODE 5 BB7 MOUNTAIN amp ROAD 5 DISC BRAKE PAD AND ROTOR BED IN PROGEDURE 2 t etcetera trate cisci ttc ica sd dag cede bite GEN 0000000002609 SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your Avid brakes Protect yourself Wear your safety gear GEN 0000000002609 GETTING STARTED GETTING STARTED HELPFUL HINTS 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 n
7. are aligned and push the lever pivot sleeve boltthrough the bearing Using a 4 mm hex wrench tighten sleeve boltto 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 000000000XXXX 25 LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED LEVER BLADE CAM INSTALLATION CONT 34 Squeeze the lever few times to ensure that the lever depressed and returns fully not pictured 35 Rotate the Pad Adjust Knob to the full in and the full out position to ensure full range of adjustment not pictured 36 Install the bladder reservoir cap using a T 10 Torx and tighten to 1 1 2 N m 8 7 10 4 in Ib THIS CONCLUDES THE LEVER OVERHAUL SERVICE INSTRUCTIONS YOU HAVE DONE A GREAT JOB AND ARE READY TO MOVE ON TO CODE HYDRAULIC DISC BRAKE CALIPER OVERHAUL PAGE 29 ENJOY GEN 000000000XXXX DISC BRAKE CALIPER OVERHAUL ELIXIR 5 R CR CR MAG 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged ina crash there may be damage
8. 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 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 ofthe 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 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 GEN 000000000XXXX 31 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 3 Remove the spring pad clip from the outside of the caliper NOTE IF T
9. pad handles into the pad installation tool so it holds the pads together 7 I nsertthe 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 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 8 10 in Ib 9 Removethe 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 of the guide pin THIS CONCLUDES THE DISC BRAKE PAD REPLACEMENT INSTRUCTIONS YOU DID A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY GEN 000000000XXXX 54 BB7 MOUNTAIN amp ROAD BB5 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 subject to 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 Thisis 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 surface
10. pads and pad spring clip straight out of the caliper GEN 000000000XXXX 38 CALIPER OVERHAUL DISASSEMBLY SERVICE INSTRUCTIONS CONTINUED 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 Turn the foot screw which is now exposed counter clockwise until it stops REMOVE TORQUE ARM 5 Hold the spring loaded torque arm securely in 4 y place OT SCREW 6 Removethe torque arm fixing nut using an 11 mm wrench Remove the lockwasher 7 Remove the torque arm outer body seal 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 out the drive cam outboard pressure foot assembly Be careful not to lose any of the 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 itis 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 T 25 Torx turn the inboard pressur
11. the brake lever onto the handlebar hold the lever blade between your thumb and forefinger then gently flex the lever blade from side to side Check the lever pivot action Repeat this process until the lever pivot action feels smooth Be careful notto flex the lever too far at any time otherwise damage to the lever blade or body could occur SNAP RING EYELETS 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 000000000XXXX 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged 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 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 compre
12. this disengages the pad backing plate from 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 3 Inspectand 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 4 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 GEN 000000000XXXX 53 CODE CODE5 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 subject to 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 Br
13. 6092000000000 N39 Hed SRA SRAM LLC 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 component was purchased Original proof of purchase is required 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 Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations To the extent allowed by local law except for the obligations specifically s
14. CR CR MAG ELIXIR R CR CR MAG GEN 0000000002609 48 BLEEDING PROCEDURE CONTINUED 9 10 11 12 13 14 15 ON THE LEVER Use the T 10 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 no air gap then thread into the lever bleed port NOTE 15 NOT NECESSARY TO REPOSITION THE ANGLE OF THE BRAKE LEVER ON THE HANDLEBAR YOU MAY HAVE A SMALL AMOUNT DOT rLUID 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 HOSE Hold the caliper syringe upright in your right hand and the lever syringe upright in your left hand 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 Close the red syringe clamp on the lever Pull the brake lever all the way to the bar with your finger and hold it there until instructed to release the lever 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 BLEED THE CALIPER With your right hand pull out on the caliper syringe plunger to create a vacuum then gently push in on the plunger to pressurize the system Re
15. HE 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 4 Using 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 o rings on each side of brake hose banjo and replace with new o rings 7 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 8 Loosen all three caliper body bolts with a 4mm hex wrench There are three different bolt lengths Set aside in correct order 9 Separate caliper body halves and open caliper assembly 10 Using a sharp pick remove small banjo hole body half o ring BRAKE PISTONS REMOVAL AND SERVICE 11 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
16. IC DISC BRAKE CALIPER OVERHAUL ENJOY JUICY 3 GEN 000000000XXXX JUICY 3 21 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged 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 CODE 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 Using an 8 mm open ended 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 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
17. L 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 Gently push the bevel gear out of the lever body from the backside using a pick or your thumb PISTON SPRING ASSEMBLY OVERHAUL Remove the spring from the piston spring assembly Using a small flathead screwdriver remove the spring coupling from the piston followed by the cupseal glide ring and secondary quadseal o ring Install a new quadseal o ring followed by the glide ring and a new cupseal with the open end out not pictured Install the spring coupling back onto the piston and snap the return spring back onto the spring coupling INTERNALS INSTALLATION Install the bevel gear into the gear bore and hold in place with your finger Install the detent spring and ball into the lever body Align the Pad Adjust Knob with the bevel gear and install the knob using a T 10 Torx 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 GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED INTERNALS INSTALLATION CONT 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 Whil
18. OT fluid from contaminating your brake pads 5 ELIXIR CR MAG ELIXIR CR ELIXIR R ELIXIR 5 Use the T 10 Torx to remove the caliper bleed port screw from the banjo bolt Elixir R Elixir CR Elixir CR Mag or caliper body Elixir 5 CODE CODE 5 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 to remove the caliper bleed screw from the caliper body Juicy 3 Use the T 10 Torx to remove the caliper bleed port screw from the center of the banjo bolt 6 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 7 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 bleeding the brake impossible 8 PAD CONTACT ADJUST ELIXIR For Elixir models equipped with Pad Contact Adjust rotate the adjuster until it stops in the direction opposite the arrow on the adjuster knob Then rotate the adjuster back just enough to place the bleed screw at it s highest point PAD CONTACT ADJUST CODE For Code models equipped with Pad Contact Adjust rotate the adjuster until it stops in the direction opposite the arrow on the adjuster knob 47 e ELIXIR R
19. RE READY TO MOVE ON TO THE NEXT CHAPTER HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT AND BLEEDING ENJOY GEN 000000000XXXX CODE CODE5 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged 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 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 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 a sharp pic
20. RVOIR 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 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 LEVER BLADE PUSHROD REMOVAL Code 5 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 unthread lever pivot set screw and remove completely Using a small hex wrench push lever pivot pin through lever body and remove GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED LEVER BLADE PUSHROD REMOVAL CONTINUED 15 Juicy 3 Use a 2mm hex wrench and unthread the lever pushrod completely by turning clockwise Pull lever blade away from lever body OR Code 5 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 push
21. 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 Using a T 10 Torx remove the reservoir cover screws 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 Setlever assembly down on clean towel not pictured 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 9 GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED RESERVOIR COVER BLADDER REMOVAL CONT 9 7 Insert new bladder into cover and seat 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 Usinga T 10 Torx 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 th
22. able housing cutters 3 Avid Hi Performance e Sharp pick DOT Fluid Bleed Block actual bleed block e DOT compatible grease may differ Towels Avid Bleed Kit Contents e sopropyl alcohol GEN 0000000002609 44 HOSE LENGTH ADJUSTMENT CHECK HOSE ROUTING o Take a moment and check the routing of the hoses since you can t lengthen the hose once you have cut it 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 REMOVE HOSE FROM LEVER pm CR CR MAG 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 the end of a zip tie and spray isopropyl alcohol between the boot and the lever Work the alcohol in the boot should loosen up and slide easily down the hose ELIXIR CR MAG ELIXIR CR Use an 11 mm line wrench or open ended wrench to hold the hose stop in place and use an 8 mm open ended wrench to unscrew the hose compression nut ELIXIR 5 ELIXIR R CODE JUICY 3 Use an 8 mm open ended wrench to unscrew the hose compression nut Pull the hose from the lever wiggling it if necessary 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 Slide the nut down the hose and away from th
23. ake noise can occur during the break in period as well as off and on throughout the life of the brake pads Thisis 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 Tip If you change your brake caliper pad compound from organic to metallic or vice versa you should replace the rotor with a new one to ensure maximum performace PAD REPLACEMENT REMOVE OLD BRAKE PADS AND H SPRING Remove e clip from guide pin 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 piston 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 Insertthe
24. 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 Pulland 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 000000000XXXX 28 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED ELIXIR CR ONLY BRAKE HOSE BANJO BOLT REMOVAL AND SERVICE 4 Using an8 mm open end or box wrench loosen banjo bolt Brake fluid will leak so hold over container to catch fluid 5 Pull banjo bolt completely out of caliper Dump all caliper brake fluid into container 6 Remove and replace o ring on banjo bolt and banjo CALIPER DISASSEMBLY AND SERVICE 7 Using an 8 mm and 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 escap
25. d outer Handlebar grips Shifter grips Jockey wheels Disc brake rotors Wheel braking surfaces Bottomout pads Bearings Bearing races 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 and respectively Copyright SRAM LLC 2009 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 For the latest technical information please visit our website at www sram com
26. e 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 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 GEN 000000000XXXX 29 20 21 22 23 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 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 U
27. e end where you ll be cutting Do notto engage the brake lever while the hose is removed DETERMINE PROPER HOSE LENGTH AND CUT 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 The groove in the lever nose marks the spot where you ll cut the hose Cutthe hose using hydraulic hose cutters or very sharp cable housing cutters GEN 0000000002609 45 HOSE LENGTH ADJUSTMENT CONTINUED INSTALL NEW FITTINGS Apply DOT compatible grease to the threads of a new hosebarb the compression fitting outer surfaces and compression nut threads While holding the hose firmly thread the hosebarb into the end of the hose using a T 10 Torx Slide a new compression fitting over the end of the hose with the new hosebarb RE INSTALL THE HOSE 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 ELIXIR CR MAG ELIXIR CR Hold the hose stop in place and finger tighten the compression nut until you feel it bottom out ELIXIR R ELIXIR 5 CODE Juicy 3 Finger tighten the compression nut until you feel it bottom out ELIXIR CR MAG ELIXIR While continuing to push the hos
28. e caliper body into its two halves and remove the banjo Using a 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 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 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 bolt hole Squeeze the air chuck and force air into the banjo bolt hole The compressed air will unseat the caliper piston from the piston pockets 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 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 Remove the square edge o ring from inside each piston pocket using a sharp pick and place with new o rings Remove both banjo bolt bleed screws from the top of the caliper body using a T 10 Torx Remove the o rings from the bleed scre
29. e foot clockwise until it is free from the inboard caliper body half GEN 000000000XXXX CALIPER OVERHAUL CLEANING amp INSPECTION INSTRUCTIONS 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 surfaces SMALL PART INSPECTION Check ball bearing and cam ramps for excessive wear NOTE 15 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 ke 21 22 23 24 39 CALIPER OVERHAUL ASSEMBLY SERVICE INSTRUCTIONS ASSEMBLE CALIPER Very lightly grease the inner pressure foot threads Using a T 25 Torx thread the inner pressure foot into the outboard caliper body half until the pressure foot is flush with the inner face of the 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 tig
30. e holes in the top of the pads are aligned with the guide pin holes in the top of the caliper 22 Insertthe 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 8 10 in Ib 23 Remove the pad tool The h spring will snap the pads into position 24 Using your thumb or finger install the e clip into the groove on the end of the guide pin GEN 000000000XXXX 36 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED FINISHING UP NOT PICTURED 25 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 26 Wipe assembled caliper with soapy water to remove any brake fluid 27 Re install caliper onto bicycle following the installation and torque specifications called out in the user manual THIS CONCLUDES THE CALIPER OVERHAUL SERVICE INSTRUCTIONS 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 000000000XXXX 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 o
31. e 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 compression nut to the proper torque ELIXIR ELIXIR 5 CODE Juicy 3 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 f your compression fitting is alloy tighten to 5 N m 47 in Ib f your compression fitting is steel tighten to 7 8 N m 70 in Ib Slide the boot if applicable back into place TIME TO BLEED THE BRAKES Cutting the hose introduces a small amount of air into the system so at this point itis necessary to bleed the brakes for optimal performance See the next section Bleed Guide for instructions GEN 0000000002609 BLEEDING PROCEDURE INTRODUCTION TO BLEEDING When bleeding Avid brakes 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 PROCEDURE OVERVIEW You will perform 3 basic operations when bleeding Avid brakes 1 Bleed the hose 2 Bleed the caliper 3 Bleed the lever FLUSH 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 i
32. e 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 ofthe 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 EXPLODED VIEW CODE LEVER ASSEMBLY D F H LEVER BODY QUAD SEAL SPRING GEAR COUPLING L CAM SPRING SPRING COUPLING PUSHROD M LEVER PRIMARY CUP SEAL PUSHROD COUPLING GLIDE RING J C CLIP 22 GEN 000000000XXXX 20 21 22 23 24 23 LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 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 INTERNALS REMOVAL CONT Using snap ring pliers remove the retaining ring located in the lever body at the 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 Using a T 10 Torx remove the Pad Adjust Knob Remove the detent ball bearing and spring located directly beneath the Pad Adjust Knob with a pick IMPORTANT BE CAREFU
33. e the spring is depressed insert a pin gauge a small drill bit or 1 5 mm hex will work into the compensating port to hold the assembly 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 orientthe 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 Inserta leg ofthe lever return spring into the hole on the lever 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 ata slight angle The pushrod coupling should snap firmly onto the exposed pushrod 33 Rotate the lever so that the pivot and lever body bores
34. ed 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 BED IN PROCEDURE WARNING THE BED IN PROCESS REQUIRES YOU TO PERFORM HEAVY BRAKING 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 LOSE CONTROL OF YOUR BICYCLE WHICH COULD LEAD TO A 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 THEN YOU SHOULD PRACTICE YOUR RIDING AND BRAKING TECHNIQUES ON A FLAT AND LEVEL SURFACE PRIOR TO AGGRESSIVE RIDING TO SAFELY ACHIEVE OPTIMAL RESULTS REMAIN SEATED ON THE BIKE DURING THE ENTIRE BED IN PROCEDURE 1 Accelerate the bike to a moderate speed approximately 19 kilometers or 12 miles per hour then firmly apply the brakes until you are at walking speed Repeat approximately twenty times 2 Accelerate the bike to a faster speed approximately 32 kilometers or 20 miles per hour Then very firmly and suddenly apply the brakes
35. eed 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 CODE5 BB7 Mountain and Road X x qx wu Ca up XE cp ES E pl E GEN 0000000002609 TOOLS NEEDED FOR SERVICE ALL BRAKES 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 it is 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 bra
36. embly 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 RINSE AND ALLOW TO DRY FULLY PRIOR TO REBUILDING YOU WILL ALSO NEED TO INSTALL ALL NEW SEALS AND 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 components while you service your brake 9 EXPLODED VIEW ELIXIR CR MAG LEVER ASSEMBLY 1 amp 7 1 em NU A LEVER BODY D PISTON SPRING B PIVOT BUSHINGS E LEVER BLADE C PISTON BLADDER SNAP RING REACH ADJUST PUSHROD ASSEMBLY GEN 0000000002609 LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED REMOVE LEVER EXPLODED VIEW PIVOT PIN PRESS Use the Pivot Pin Press to remove the pivot pin from the lever Prepare the tool by first installing A 1 c D E the small washer followed by the press sleeve onto the bolt Next slide the bolt through pivot pin of the lever Thread the catcher onto the bolt cop 5 until it makes contact with the lever body Insert the lever blade brace with the contoured side againstthe pivot pin into the lever blade Use a vise or 10 mm open end wrench and secure the catcher the flat edges Use a 5 mm hex UTE EET wrench and turn the bolt clockwise until the pivot pin is pushed i
37. er 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 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 FINAL TOUCH Spray isopropyl alcohol or water onto a towel and wipe off the brake lever and caliper to remove any excess DOT fluid you may have missed before Remove the Bleed Block from the caliper and re install the brake pads and spreader clip Re install your wheel according to the manufacturer 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 a good idea to test your brakes Pull on the lever extremely hard as hard as you can imagine yourself pulling the leve
38. et 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 This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM technical installation manual The SRAM installation 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 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 Brake sleeves Brake pads Chains Sprockets Cassettes Shifter and brake cables inner an
39. fo ox JAIRCOMPRESSOR WITH BLOW GUN CHUCK 1 x y soapywaren x J x jicecoupeeverace x x GEN 0000000002609 HYDRAULIC DISC BRAKE LEVER OVERHAUL ELIXIR CR MAG 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged 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 Use an 11 mm open ended wrench to hold the master cylinder head in place and 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 Allow any brake fluid to drain into a container Hold lever ass
40. hex and remove the lever bolt Carefully pull and remove the reach 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 QUT 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 OK 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 Replace the entire piston bladder snap ring assembly 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 GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED LEVER INSTALLATION Use long snap ring pliers and re install the piston bladder assembly into the lever body Slide lever blade and push rod assembly 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
41. hten GEN 000000000XXXX 40 CALIPER OVERHAUL ASSEMBLY SERVICE INSTRUCTIONS 25 26 27 28 29 30 31 32 33 34 35 36 ASSEMBLE CALIPER CONT 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 Lightly grease the ramps of the fixed cam in the outboard caliper body Place the ball bearings into the ramps of the fixed cam Insert the Drive Cam Outer Pressure Foot assembly through the hole in the outboard caliper body Rotate the cams against each other to ensure the ball bearings are seated properly in both sets of ramps 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 Hold the Drive Cam in place and re install the return spring outer seal and washer with hex shaped 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 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 against the 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
42. imple 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 at the 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 BB5 only 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 Unscrew counterclockwise the barrel adjuster on the caliper Turn the inboard pad adjustment knob clockwise Both of these adjustments move the brake pads closer to the rotor You do need to adjust both pads they wear Try different settings until the brake feels justthe way you like IMPORTANT MAKE SURE YOU TIGHTEN THE LOCKNUT ON THE BARREL ADJUSTER AFTER YOU ADJUST NOTE WHILE YOU CAN PERFORM A SIMLAR ADJUSTMENT ON THE BARREL OF YOUR BRAKE LEVER WE SUGGEST THAT YOU ADJUST FOR PAD WEAR AT THE CALIPER THAT WAY YOU LEAVE THE BRAKE LEVER FOR ON THE FLY ADJUSTMENTS THIS CONCLUDES THE DISC BRAKE PAD REPLACEMENT INSTRUCTIONS YOU HAVE DONE A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY GEN 000000000XXXX 56 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE INTRODUCTION All new brake pads and rotors should be put through a wear in process call
43. k 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 1 Remove brake caliper from fork or frame and remove caliper mounting bracket and CPS hardware from caliper Set aside in correct order not pictured GEN 000000000XXXX 34 CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 2 BRAKE PADS AND PAD H SPRING REMOVAL Remove e clip from guide pin groove on top of the caliper using a sharp pick Using 2 5 hex wrench remove the guide pin from the caliper Squeeze the pads together so they clear the pistons and pull to remove brake pads and h spring from caliper CALIPER DISASSEMBLY AND SERVICE 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 Using two 4 mm hex wrenches loosen and remove the banjo sleeve bolt and banjo shoulder bolt Completely remove all four caliper body bolts separate th
44. kes 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 JSAFETY STARTING EQUIPMENT y sareryelasses x x aeron x x x x x porran x crean work area x x wewcuseuns y x x amex x stoo y pnm x x y pnm JSMMOPENENDORBOXWRENCH x 0 y JIMMOPENENDORBOXWRENCH f XP froravewrence wenEwoseDPuRS x x SNAPRINGPLIERS INTERNAL x x 0 y x FEES sharr Pies x x jisopropyiauconoh x ewm e x x o pot JPHILLIPSHEAD screworIveR
45. m 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 Using an 8 mm open ended 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 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 REBUILD ING YOU WILL ALSO NEED TO INSTALL A NEW HOSE RESERVOIR COVER BLADDER REMOVAL Using a T 10 Torx small Phillips screwdriver for Juicy 3 remove both reservoir cover screws 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 Setlever assembly down on clean towel not pictured 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 GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 7 RESE
46. nto the catcher Remove the tool and pin from the brake lever Use a 2 mm hex wrench to turn the reach adjust pushrod clockwise until it exits the pushrod pivot pin Remove the lever lever bushings and piston spring from the lever body Clamp a 2 mm hex wrench into a vise with the long end extending upward Install the lever body onto the wrench with the wrench inserted into the lever body through the fluid flow port in the master cylinder head While applying light downward pressure to the lever body use long snap ring pliers to remove the snap ring in the lever body along with the piston bladder assembly Remove the lever body from the hex wrench NOTE THE PISTON BLADDER ASSEMBLY IS ATTACHED TO THE SNAP RING LEVER INSTALLATION Replace the entire piston bladder snap ring assembly 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 GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 10 Use long snap ring pliers to push the piston bladder snap ring assembly into the lever body and secure the snap ring in its groove with the snap ring eyelets oriented toward the lever blade opening 11 Install the piston spring with the larger diameter end first onto the reach adjust pushrod in the lever body 12 Insert a 2mm hex wrench through the non stepped side of the push rod
47. o bicycle following the installation and torque specifications called out in the user manual THIS CONCLUDES THE CALIPER OVERHAUL SERVICE INSTRUCTIONS 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 000000000XXXX 30 JUICY 3 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 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged ina 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 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
48. ou know it you ll be back on the trail note 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 Juicy 3 Hose shortening can be performed at either the lever or the caliper on Juicy 3 brakes However shortening the hose at the lever end will allow for an easier bleed HANDLING DOT FLUIDS e Avid highly recommends the use of rubber gloves when handling DOT fluids e 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 e 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 e For best results use only Avid Hi Performance DOT Fluid If Avid fluid is not available only use DOT 4 or 5 1 fluid e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e NEVER pour used DOT fluid down a sewage or drainage system or into the ground or a body of water TOOLS NEEDED P Safety glasses Compression fittings e Rubber gloves Hose barbs e Bleed Block e 2 5 and 4 hex wrenches E e 10 Torx e 8and11 mm open ended wrenches e Torque wrench e Hydraulic line cutters or very sharp c
49. peat this procedure several times until large bubbles stop coming out of the caliper NOTE DO NOT PULL THE PLUNGER PAST THE END OF THE SYRINGE 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 D 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 7 NOTE THERE WILL EXCESS DOT FLUID THAT SPILLS OUT gt AS YOU RE INSTALL THE BLEED PORT SCREW THIS IS NORMAL BE SURE WIPE THE FLUID OFF THE CALIPER WITH TOWEL AND WATER GEN 0000000002609 49 BLEEDING PROCEDURE CONTINUED 18 19 20 21 22 23 24 BLEED THE LEVER Open the red syringe clamp on the lever 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 squeezing this helps break loose the bubbles Repeat this procedure several times until large bubbles stop coming out of the lev
50. pivot pin and into the reach adjust pushrod Place the lever blade into the opening of the lever body then use the 2mm hex wrench to turn the pushrod counter clockwise and thread it into the pushrod pivot pin from the stepped side of the pin Thread the pushrod through the pin until it is flush with the non stepped side 13 Slide a pivot bushing in between each side of the lever blade and the lever body Align the holes in the lever body both bushings and the lever blade then slide the press sleeve of the Elixir CR Mag pivot pin press into the holes to maintain alignment 14 Use the Pivot Pin Press to install the pivot pin into the lever Prepare the tool by installing the washer and brake lever pivot pin onto the bolt Insert the threaded end of the bolt through the press sleeve in the lever body Thread the catcher open end first onto the bolt from the other side of the lever body Use a vise or 10 mm open end wrench to secure the flat end section ofthe catcher Insertthe lever blade brace into the lever blade with the contoured end resting against the pivot pin Use a 5 mm hex wrench to turn the bolt clockwise and press the press sleeve and pivot pin into the lever body until the press sleeve exit the lever body into the catcher and the pivot pin is centered in the lever body Remove the tool from the brake lever Note The lever blade action may feel sluggish following installation of the pivot pin To improve the feel mount
51. r 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 outboard 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 2 Turn both adjuster knobs all the way out counterclockwise then squeeze the pad tabs together and pull both
52. r while you re riding several times Make sure and look around the hose nut 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 GEN 0000000002609 DISC BRAKE PAD REPLACEMENT 51 ELIXIR R CR CR MAG 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 subject to 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 Thisis 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 Tip If you change your brake caliper pad compound from organic to metallic or vice versa you should replace the rotor with a new one to ensure maximum performace PAD REPLACEMENT REMOVE PAD RETAINER BOLT Q 1 Startby removing the E clip on the wheel side of the caliper then unscrew the retainer bolt using a 2 5 mm hex wrench Remove the retainer bolt all the way PUSH THE PISTONS
53. 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 subject to 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 Thisis 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 Tip If you change your brake caliper pad compound from organic to metallic or vice versa you should replace the rotor with a new one to ensure maximum performace PAD REPLACEMENT PUSH THE PISTONS BACK IN The Juicy 3 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 ofthe pad tabs and slide the pad toward the center of the caliper
54. rod into lever blade Pushrod unthreads and threads back into lever blade not pictured IMPORTANT REPLACE LEVER BLADE AND OR PUSHROD IF EITHER IS BENT OR DAMAGED 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 T LEVER BODY SPRING SNAP RING SPRING COUPLING WASHER PRIMARY CUP SEAL PUSHROD PISTON CROSS DOWEL LEVER BODY SPRING G COUPLING L LEVER SPRING COUPLING PRIMARY CUP SEAL COUPLING RETAINING RING PISTON J PUSHROD Juicy 3 EXPLODED VIEW JUICY 3 LEVER ASSEMBLY B D H es 6 p K SECONDARY SEAL K LEVER EXPLODED VIEW CODE 5 LEVER ASSEMBLY SECONDARY SEAL K PUSHROD DUST BOOT H COUPLING RETAINER GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED 19 20 INTERNALS REMOVAL CONTINUED 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 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 ea
55. s PAD REPLACEMENT REMOVE THE OLD PADS BB7 only 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 BB5 only Turn the inboard adjuster knob all the way out counterclockwise Pull the pad spreader clip from between the pads then remove the pads out of the caliper one at a time 2 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 3 AND FOLLOW THE PROCEDURES FOR PAD WEAR ADJUSTMENT GEN 000000000XXXX PAD REPLACEMENT CONTINUED INSTALL THE NEW PADS AND SPRING 3 BB7only 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 BB5 only Install the new pads one at a time into the caliper Slide the spreader clip into position between the pads PAD WEAR ADJUSTMENT NOT PICTURED BB7 onty 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 s
56. s very old In this case bleeding the system twice in order to completely remove the old fluid is recommended Following this procedure gives you a perfectly bled optimally performing brake Enjoy PREPARE THE SYRINGES 1 Fill one syringe 1 2 full with Avid Hi Performance 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 3 Take a moment to de gas the fluid in the 1 2 full syringe Removing as many of the gas bubbles as you can from the fluid now before pushing them into the system will make for a better bleed Leave the hose clamp shut and pull on the plunger Bubbles will appear to form and enlarge While the plunger is still pulled down lightly tap the syringe to release the bubbles sticking to the sides and the bottom so that they can rise to the top of the fluid When the bubbles stop forming and have all risen to the top release the plunger open the clamp and carefully push the air out Repeat several times NOTE YOU WILL NOT BE ABLE TO REMOVE ALL THE BUBBLES GEN 0000000002609 BLEEDING PROCEDURE CONTINUED PREPARE THE CALIPER 4 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 D
57. seated and hold firmly with your thumb 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 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 Re install the pad retainer in the outboard caliper body Apply a high strength thread lock such as Loctite 272 to the 2 caliper bolts 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 N EXTENDED 4 LEG SPRING TENSION NOTCH PAD RETAINER GEN 000000000XXXX CALIPER OVERHAUL ASSEMBLY SERVICE INSTRUCTIONS INSTALL THE NEW PADS AND SPRING 37 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 38 Push the upper and lower boots onto the integrated cable stop 39 Place the cable anchor plate the cable anchor bolt grease the bol
58. sily Hold lever body assembly upside down and drop the piston spring assembly into your hand It should slide out easily With piston spring assembly removed from lever body remove the piston from the spring Using a small flathead screwdriver remove spring coupling from piston Do not scratch any plastic parts piston or o rings If damaged you will need to replace the piston Slide piston coupling out of piston not pictured Remove and replace piston secondary seal small o ring on top of piston GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED INTERNALS REMOVAL CONT o 21 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 22 Re install spring coupling back onto piston and coupling seal into open end of seal 23 Re install spring onto coupling The coupling lightly snaps onto piston INTERNALS INSTALLATION 24 Insert spring piston assembly back into lever body spring first 25 Code 5only 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 IMPORTANT
59. sing 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 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 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 Besurethe 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 and 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 ofthe 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 ont
60. ssion nut and slide down hose not pictured 2 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 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 EXPLODED VIEW ELIXIR R CR LEVER ASSEMBLY and compression fitting from lever body A B D 3 Allow any brake fluid to drain into a container E F Hold lever assembly over container and pump lever to remove any brake fluid inside lever i assembly NOTE IF THE SYSTEM HAS BEEN CONTAMINATED WITH THE nw lt WRONG FLUID YOU WILL NEED TO FLUSH ALL THE PARTS A EX lt WITH SOAPY WATER AND ALLOW TO DRY FULLY PRIOR TO G A REBUILDING YOU WILL ALSO NEED TO INSTALL ALL NEW SEALS AND A NEW HOSE LEVER BODY PIVOT BUSHING 1 REACH ADJUST SCREW PISTON SPRING LEVER BLADE J LEVER BOLT PISTON BLADDER ASSEMBLY REACH ADJUST SPRING K PIVOT PIN LEVER ASSEMBLY SNAP RING REACH ADJUST KNOB 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 12 GEN 000000000XXXX LEVER OVERHAUL SERVICE INSTRUCTIONS CONTINUED REMOVE LEVER Use a small phillips screwdriver and remove the screw from the reach adjust knob Use a 3 mm
61. t lightly and install into the torque arm not pictured 40 Re mount the caliper onto the bike 41 Setup 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 times 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 41 GEN 000000000XXXX HYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT amp BLEED 43 ELIXIR 5 R CR CR MAG CODE CODE 5 JUICY 3 INTRODUCTION 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 following instructions will walk you through our simple bleed procedure Regardless of which Avid brake you are using the steps for hose length adjustment and bleeding are basically the same In the case where a specific model has unique features procedures so we ll show you those steps too Before y
62. 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 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 a 2 5 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
63. until you are at walking speed Repeat approximately ten times IMPORTANT DO NOT LOCK UP THE WHEELS AT ANY POINT DURING THE BED IN PROCEDURE 3 Allow the brakes to cool prior to any additional riding THIS CONCLUDES THE DISC BRAKE PAD AND ROTOR BED IN PROCEDURE YOU DID A GREAT JOB YOU ARE NOW READY TO RIDE ENJOY GEN 0000000002609 WORLD HEADQUARTERS SRAM Corporation 1333 Kingsbury St 4th FI Chicago Ill 60642 USA Phone 1 312 664 8800 Fax 1 312 664 8826 www sram com EUROPEAN HEADQUARTERS SRAM Europe Basicweg 12 d 3821 Br Amersfoort The Netherlands Phone 31 33 450 6060 Fax 31 33 457 0200 ASIAN HEADQUARTERS SRAM Taiwan No 1598 8 Chung Sahn Rd Shen Kang Hsiang Taichung County 429 Taiwan R O C Phone 886 4 2564 3678 Fax 886 4 2561 3686
64. ws and replace with new o rings GEN 000000000XXXX CALIPER OVERHAUL SERVICE INSTRUCTIONS CONTINUED CALIPER ASSEMBLY 14 14 Inspectthe 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 15 Place banjo sleeve bolt into the left half outboard side of the caliper Slide banjo onto the sleeve bolt and set the banjo angle to the desired angle 16 Align both caliper halves together and insertthe banjo shoulder bolt and the four caliper 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 17 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 18 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 19 Position the h spring between the two pads NOTE THE CODE PADS ARE SYMMETRICAL THERE IS NOT A LEFT OR RIGHT ORIENTATION 20 Locate the pad installation feature of the pad spacer tool Insertthe pad handles into the pad installation tool so it holds the pads together 21 Insertthe pads and pad tool into the caliper until th

Technical Manual - Avid - 2010

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