2012 Elixir™ 9 - Elixir 7 Service Manual
Contents
1. 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 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 www avidbike com www truvativ com or Www zipp 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 Wear and tear parts are identified as 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 alumin2. Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE Safety glasses o Torque wrench Nitrile gloves 8mm open end wrench T25 and TIO TORX wrenches o 2 5 mm hex Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid e Sharp pick DOT Grease or DOT 5 1 or 4 compatible grease o Clean lint free rags Oil pan o Needle nose pliers Flat blade screwdriver Air compressor with blow gun chuck 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 the bicycle in a bicycle work stand Spin the affected wheel Lightly squeeze the brake lever and watch the brake pads when the lever is released Determine which side of the caliper has a slow returning brake piston Remove the caliper from the bicycle If you have a caliper mounting bracket remove the bracket with the caliper attached Remove 6 6110 from the guide pin groove on top of the caliper Use a 2 5 mm hex wrench to remove the guide pin from the caliper Remove both brake pads and h spring Use a 10 mm box wrench to press the working piston into caliper body While continuing to hold the piston inside the caliper body squeeze the brake lever slowly to move the sticky piston inward Press the piston back into the caliper again Repeat these steps to correct caliper pis
3. a TIO TORX to remove the bleed screw from the banjo bolt Use a sharp pick to remove the bleed screw o ring This o ring may be a little hard to see Replace with a new bleed screw o ring Re install the banjo bolt bleed screw into the banjo bolt and tighten with a T10 TORX 5 7 16 ELIXIR 9 amp 7 BRAKE CALIPER OVERHAUL 9 Remove and replace the o rings on the banjo bolt and banjo Separate the caliper body halves and open the caliper assembly Using a sharp pick remove to replace the small banjo hole body half o ring Do not scratch the o ring gland with the pick Be sure to replace the new o ring into the hole with the recessed edge 17 ELIXIR 9 amp 7 BRAKE CALIPER OVERHAUL 1 2 Caliper Piston Removal Insert an air compressor chuck nozzle into the banjo bolt hole of one of the caliper body halves Hold the caliper in one hand and point the caliper piston in a safe direction Hold one finger covered by at least two rags over the banjo bolt through hole on the opposite side of the caliper body so air does not escape Squeeze the air chuck and force air into the banjo bolt hole The compressed air will unseat the piston from the caliper Remove the piston from the caliper Point the caliper in a safe direction Use two rags to prevent the piston from causing injury or becoming lost Repeat this process for the other caliper body half 13 Remove the square edge o ring from inside each ca
4. a small amount of air into the system so at this point it is necessary to bleed the brakes for optimal performance See the section Avid Brake Bleed Procedure for instructions ELIXIR 9 7 BRAKE CALIPER OVERHAUL AVID BRAKE HOSE LENGTH ADJUSTMENT After completing the hose length adjustment it will be necessary to bleed the brakes for optimal performance See the section Avid Brake Bleed Procedure for instructions e Avid highly recommends the use of nitrile 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 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 e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE e Safety glasses e Adjustable torque wrench e Nitrile gloves 8mm flare nut wrench e Hydraulic hose cutters or very sharp
5. banjo or bolt remove and replace the o rings and then repeat the installation process Remove the Bleed Block from the caliper and reinstall the 21 brake pads and spreader clip Reinstall your wheel according to the manufacturer s instructions e Empty the syringes into a sealed container and dispose of the fluid properly Remember DOT fluid should be recycled or disposed of in accordance to local and federal regulations e NEVER pour DOT fluid down a sewage or drainage system or into the ground or a body of water e Do not re use this fluid e Do not leave the hose clamps closed this will damage the clear tubing on the syringes 23 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 lever while you re 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 lf everything checks out YOU ARE READY TO RIDE AVID BRAKE BLEED PROCEDURE 29 INSTRUCTIONS 5 8 in 1b DISC BRAKE PAD INSTALLATION INSTRUCTIONS DISC BRAKE PAD INSTALLATION Remove pad retainer bolt Start by removing the e clip on the wheel side of the caliper then unscrew the retainer bolt using a 2 5 mm hex Remove the retainer bolt all the way Push the pistons back in Elixir calipers are self adjusting the pistons
6. 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 protect the pistons Place a flat blade screwdriver between the old pads then carefully rock it back and forth pushing the pistons back into their bores 3 Remove the old pads Grab the pad tabs and pull straight out Install the new pads and spreader Be sure the 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 5 Re install the pad retainer bolt Replace the pad retainer bolt tighten to torque specifications and replace the e clip on the wheel side of the caliper 30 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 braking You mu
7. 2012 Elixir Y 9 Elixir 7 Service Manual j r yl i ri y E 1 ia hall j a SS A J ei e _ o j e E GEN 0000000003393 Rev C 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
8. Loc 13 ELIXIR 9 7 BRAKE CALIPER OVERHAUL Avid brake lever assemblies need to be serviced periodically 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 5 1 or 4 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the housing assembly Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function e Avid highly recommends the use of nitrile 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 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 e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e
9. cable housing cutters o 11mm open end wrench e Avid DOT Grease or DOT 5 1 or 4 compatible grease e T10 TORX e Isopropyl alcohol e Clean lint free rag e Avid Bleed Kit or Avid Professional Bleed Kit e Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid Compression fittings Hose mM FA por FLUID Avid Bleed Block High Performance actual bleed block DOT Fluid may differ Avid Bleed Kit Contents AVID BRAKE HOSE LENGTH ADJUSTMENT 20 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 Pull the hose 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 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 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
10. 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 AVID BRAKE HOSE LENGTH ADJUSTMENT 2 K 4 21 AVID BRAKE HOSE LENGTH ADJUSTMENT 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 measurement because you can t go back after you cut 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 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 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 22 For models with a compression nut and a hex hose stop While continuing to push the hose into the 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 tighten the compression nu
11. de a pivot bushing in between each side of the lever blade and the lever body with the convex side of the bushings facing out Insert the pivot clip inside the lever blade Align the holes of the lever body both washers the pivot clip and the lever blade then slide the press sleeve of the press tool into the holes to maintain alignment Use the press tool 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 hold the flat end section of the catcher Insert the lever blade brace into the lever blade with the contoured end resting against the press sleeve Use a 5 mm hex to turn the bolt clockwise and press the press sleeve and pivot pin into the lever body until the press sleeve separates from the lever body and drops into the catcher and the pivot pin is centered in the lever body Remove the tool from the brake lever The lever blade action may feel sluggish following installation of the pivot pin To improve the feel mount 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 s
12. e gloves 8mm flare nut wrench T25 TORX o 11 mm open end wrench e Elixir Lever Pivot Bearing Press Tool e 2 2 5 4 and 5 mm hex wrenches e Long snap ring pliers e Bench vise or 10 mm open end wrench Oil pan e Isopropyl alcohol e Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid e Clean lint free rag DOT Grease or DOT 5 1 or 4 compatible grease ELIXIR 9 amp 7 BRAKE LEVER OVERHAUL EXPLODED VIEW ELIXIR 9 BRAKE LEVER ASSEMBLY A B A LEVER BODY E PIVOT CLIP PUSHROD SLEEVE B PIVOT BUSHINGS F LEVER BLADE J REACH ADJUST KNOB C PISTON BLADDER PUSHROD ASSEMBLY G PISTON SPRING D PIVOT PIN H SNAP RING SHOWN REMOVED Use a T25 TORX to remove the brake clamp bolt from the discrete clamp MMX or XLoc XLoc will first require the removal of the XX shifter Remove the brake lever from the handlebar Pull the hose boot off the compression nut and slide it down the hose If dirty clean the levers with soapy water and a clean rag ELIXIR 9 7 BRAKE LEVER OVERHAUL 2 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 hose compression nut Pull the brake hose and compression fitting from the brake lever body Allow any brake fluid to drain into a container Hold the lever assembly over the container and squeeze the lever to pump any brake fluid from inside the lever assembly If the system has been contaminated with the wrong flu
13. embly is attached to the snap ring Caution 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 Replace the entire piston bladder snap ring assembly with a new assembly Lubricate the piston bladder 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 Position the snap ring on the retainer of the piston with the clocked portion of the retainer seated between the two centering tabs of the snap ring 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 Orient the snap ring eyelets toward the lever blade opening You can also a long 10 mm 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 the assembly into position from inside the fluid flow port of the lever body 12 Aluminum Elixir 7 lever blade only Insert a pivot bushing into each side of the lever body 13 Align the pushrod sleeve and the pushrod Turn the reach knob clockwise by hand onto the pushrod 11 ELIXIR 9 amp 7 BRAKE LEVER OVERHAUL ELIXIR 9 7 BRAKE LEVER OVERHAUL Re install the pivot pin Carbon lever blade Sli
14. g 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 5 1 or 4 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the housing assembly Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function e Avid highly recommends the use of nitrile 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 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 e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE e Safety glasses o Torque wrench e Nitril
15. id you will need to flush all the parts with soapy water rinse and allow to dry prior to rebuilding You will also need to install all new seals and a new hose Remove the pivot pin Carbon lever blade Use the Elixir Lever Pivot Bearing Press Tool to remove the pivot pin from the lever Prepare the tool by first installing 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 until t makes contact with the lever body Insert the lever blade brace with the contoured side against the pivot pin into the lever blade Use a vise or 10 mm open end wrench to hold the flat end section of the catcher ELIXIR 9 7 BRAKE LEVER OVERHAUL Use a 5 mm hex to turn the bolt clockwise until the pivot pin is pushed into the catcher Remove the tool and pin from the brake lever The pivot bushings pivot clip and dowel may fall out of the lever blade this is ok Set them aside on a clean rag Aluminum lever blade Elixir 9 only First depress the lever blade and use a 2 mm hex to remove the set screw Elixir 9 amp 7 Open a vise 1 2 inch and place a Clean rag over the jaws of the vise Position the pivot pin over the opening of the vise Use a rubber mallet to gently tap a 5 mm hex against the pivot pin Remove the hex and pivot pin from the brake lever 5 Turn the reach adjust knob counter clockwise by hand to rem
16. iper and re install the bleed port screw Use a clean rag to wipe off any excess DOT fluid that spills out as you re install the bleed port screw 16 Open the 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 its starting position after squeezing this helos 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 14 17 28 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 There will be a small amount of excess DOT fluid that spills out as you remove the syringe and re install the bleed port screw this is normal be sure to wipe the fluid off the lever with a 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 Visually check your work Inspect the banjo bolt and banjo for 20 any protruding o rings If there are any o rings that are Squeezed beyond the outside edges of the
17. ke pad removal instructions 4 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 no air gap then thread into the caliper bleed port AVID BRAKE BLEED PROCEDURE 23 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 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 80 mm from the centerline of the handlebar If the lever 15 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 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 26 AVID BRAKE BLEED PROCEDURE Hold both syringes upright Gently pu
18. liper body half with a sharp pick Lubricate the new square edge o rings with Avid High Performance 5 1 DOT Fluid and install them inside each caliper body half Do not scratch the o ring gland with the pick You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant 14 Inspect the caliper pistons for damage and replace if necessary Re install the caliper brake pistons into each half of the caliper body Make sure the piston slots are vertical in the caliper body this keeps the fluid slots on the back side of piston lined up with fluid ports 15 Re assemble the two caliper body halves Use a T25 TORX to loosely re install the caliper body bolt to hold the assembly together 18 Use an 8 mm open end wrench to re install the banjo bolt and tighten to 8 5 10 N m 75 90 in lb 8 5 10 N m 75 90 in Ib 17 Use a T25 TORX to tighten the caliper body bolt to 8 5 10 N m 75 90 in Ib Insert the Bleed Block into the caliper in place of the brake pads You will need to bleed your brakes before re installing the brake pads Wipe the assembled caliper with alcohol and a clean rag to remove any brake fluid 20 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 Overhauling the caliper introduces
19. mooth Be careful not to flex the lever too far at any time otherwise damage to the lever blade or body could occur 12 ELIXIR 9 7 BRAKE LEVER OVERHAUL Aluminum lever blade Elixir 9 7 Confirm that the pivot bushings are still in place Insert the pivot clip into lever blade and align it with the holes in the lever body and lever blade Align the holes in the lever body both bushings and the lever blade Gently tap the pivot pin into place with a rubber mallet until it is flush with the lever body Elixir 9 only Depress the lever and use a 2 mm hex to re install and tighten the pivot set screw to 1 1 1 3 N m 10 11 in Ib The lever blade action may feel sluggish following installation of the pivot pin To improve the feel mount 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 not to flex the lever too far at any time otherwise damage to the lever blade or body could occur Use an 11 mm open end wrench to hold the hose stop in place and use an 8 mm flare nut wrench to thread the hose compression nut onto the lever body Slide the hose boot onto the compression nut Re install the brake lever into the discrete clamp MMX or XLoc Use a T25 TORX to re install the brake clamp bolt into the discreet clamp MMX or X
20. oration 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 o o ba o 0 OE CE 2 De gas the fluid in the 1 2 full syringe Leave the hose clamp are shut and pull on the plunger Bubbles will form in the brake fluid While the vato a ods O plunger is still pulled down lightly tap the syringe to release oe the bubbles sticking to the sides and the bottom so that they can rise to the top pO Soo rer of the fluid When the bubbles stop forming and have all risen to the top release Es of o8 the plunger open the clamp and carefully push the air out Repeat several times You will not be able to remove all the bubbles N 3 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 bra
21. ove the lever from the pushrod ELIXIR 9 7 BRAKE LEVER OVERHAUL To replace a damaged or lost reach adjust knob assembly Clamp a 4 mm hex into a vise with the long end extending upward Install the end of the sleeve onto the 4 mm hex Use a 2 5 mm hex to remove the reach stop screw then remove the reach knob spring cross dowel and blade from the sleeve Install the new cross dowel into the lever blade and slide the sleeve through the recessed side of the dowel Slide the new reach knob followed by the spring onto the sleeve Clamp a 4 mm hex into a vise with the long end extending upward Install the end of the sleeve onto the 4 mm hex Use a 2 5 mm hex to install and tighten the reach stop screw to 0 5 0 7 N m 4 6 in lb Remove the reach adjust blade assembly from the 4 mm hex 7 Clamp a 2 mm hex 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 Place a clean rag under the lever body to wipe up any fluid that may spill out ELIXIR 9 7 BRAKE LEVER OVERHAUL ELIXIR 9 7 BRAKE LEVER OVERHAUL Use long snap ring pliers to collapse the snap ring Then apply downward pressure to the lever body and use the pliers to remove the snap ring in the lever body along with the piston bladder assembly Remove the lever body from the hex wrench The piston bladder ass
22. 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 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 e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e NEVER pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE e Safety glasses o Avid Bleed Block e Nitrile gloves o 2 5 and 4 mm hex wrenches e T10 TORX e Sharp pick e Isopropyl alcohol e Clean lint free rag Avid Bleed Kit or Avid Professional Bleed Kit e Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid Avid Bleed Block High Performance actual bleed block DOT Fluid may differ Avid Bleed Kit Contents AVID BRAKE BLEED PROCEDURE 24 When bleeding Avid brakes keep in mind that you are simply forcing 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 discol
23. pearance 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 ELIXIR 9 amp 7 BRAKE LEVER OVERHAUL i aS O a duu eiaa 5 PARIS AND TOOLS NEEDED FRO RR SERV IE dt aE ea 5 ELIXIR 9 amp 7 BRAKE CALIPER OVERHAUL SOD DA DO as 14 PARTS AND TOOLS NEEDED FOR SERVICE ps li O RA Saees 14 AVID BRAKE HOSE LENGTH ADJUSTMENT crisol O ne aA a ea raa aa Eaua raa aeaaeae 20 PARTSAND TOOLS NEEDED FOR SER VIE a ae st E ANN oS SEA SR E AOS 20 AVID BRAKE BLEED PROCEDURE sti A eea 24 PARTS AND TOOLS NEEDED FOR SERVICE E e ere e reo o 24 DISC BRAKE PAD INSTALLATION INSTRUCTIONS 22 IA Annan nnmnnn nnan 30 n 31 220 222 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your componentry Protect yourself Wear your safety gear Important Your parts may look different from those illustrated ELIXIR 9 7 BRAKE LEVER OVERHAUL Avid brake lever assemblies need to be serviced periodically to optimize braking function If brake fluid is leakin
24. sh 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 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 of the syringe AVID BRAKE BLEED PROCEDURE AVID BRAKE BLEED PROCEDURE 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 its original position Close the clamp on the caliper syringe then remove the syringe from the cal
25. st 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 and 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 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 A Do not lock up the wheels at any point during the bed in procedure Allow the brakes to cool prior to any additional riding DISC BRAKE PAD AND ROTOR BED IN PROCEDURE 51 WWW Sfam com
26. t 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 lb If your compression fitting is steel tighten to 7 8 N m 70 in lb 9 Slide the boot back into place Cutting the hose introduces a small amount of air into the system so at this point it is necessary to bleed the brakes for optimal AVID BRAKE HOSE LENGTH ADJUSTMENT performance See the next section Avid Brake Bleed Procedure for instructions 25 AVID 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 following 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 e Avid highly recommends the use of nitrile gloves when handling DOT fluids e DOT FLUIDS WILL DAMAGE PAINTED SURFACES If any fluid comes in contact with a
27. ton inner o ring position Both pistons should now be moving freely Re install the spring pad clip h spring and pads into the caliper If there is no improvement continue with caliper service Re install the caliper Cor mounting bracket with attached caliper on the bicycle You may need to re center the caliper to the rotor If you removed the caliper without an adapter or removed it from the adapter it will need to be re centered Spin the wheel and check brake function ELIXIR 9 amp 7 BRAKE CALIPER OVERHAUL WN gt 0 14 ELIXIR 9 7 BRAKE CALIPER OVERHAUL Use a T25 TORX to remove the brake caliper from the fork or frame and remove the caliper mounting bracket and CPS hardware from the caliper Set aside in the correct order 2 Remove the e clip from the guide pin groove on top of the caliper Use a 2 5 mm hex to remove the guide pin from the caliper 3 Pull and remove both brake pads and h spring If the total thickness of the backing plate and pad friction material is less than 3 mm the brake pads need to be replaced Click here for detailed brake pad removal instructions 4 Use an 8 mm open end wrench and a T25 TORX to remove the caliper body and banjo bolts Brake fluid will leak so hold the caliper over a container to catch the fluid ELIXIR 9 amp 7 BRAKE CALIPER OVERHAUL Pull the banjo bolt completely out of caliper Pour all caliper brake fluid into a container Use
28. um titanium magnesium or steel Upper tubes stanchions Brake sleeves Brake pads Chains Sprockets Cassettes Shifter and brake cables inner and outer Handlebar grips Shifter grips Jockey wheels Disc brake rotors Wheel braking surfaces Bottom out pads Bearings Bearing Races Pawls Transmission gears Spokes Free hubs Aero bar pads Corrosion 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 brake components as well as the special tools and fluids used for service This publication includes trademarks and registered trademarks of SRAM LLC designated by the symbols and respectively Copyright SRAM LLC 2011 For exploded diagram and part number information please refer to the Spare Parts Catalog available on our web site at www sram com For order information please contact your local SRAM distributor or dealer Information contained in this publication is subject to change at any time without prior notice For the latest technical information please visit our website at www sram com Your product s ap
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