boo Z‘SRAM CORPORATION WARRANTY xv OF LIMTEDWARRANTY SHAM wort sprue rn from eet instar or esos ot pti af 2 parser orga ptcave. Tis wan any appl ote agin vant eis ecranerbie, [eis undertiswavenymastae made rough ear ete thie athe SRAM Comper nesta purchased Orga pra af purchase segue toca ‘Tiwary seen geste usta pct gel hs, The cstaner ats hear am apron eed slave ser frm cues ss worany shal be ise adie ny sane pot aso Fr expe soe stats nt Un sme garments ce the Uta Stes (alg paines Cada nay «race the danas ad itsns fis warn satameat rom nig he seta rhs {ith conser eg Une gd, Botner rest ey a mnuactuerta enforce such lanes onan Lnruarions oF uaBLTY “teens towed oy eel excepoth batons pecan his Satenent nao event hal SRAM trary spple’sbe able eee Wee indent consequent degen LUNTaTiONS OF WaRRANTY ‘Tiguan doe ct spt pradutstht have een inconetyinaled sna sdusted ce faring th raspecve SAM shes nstallsn mana The SAM Uemond canbe oan ‘nine an scam. on raclahocon arvana cm ‘Tis werany doesnt apy when the peducthas een mode, “Tiswarany does tp he thes amber aration cade es been deleretey ‘re dota eranave ‘This waranty ces apply tdemage the produ cause bya rash impact abuse tthe rads nontnpiance wt) manfacurersspectesbons of see a any aber cumstances ‘ich roduc na ean sete faces ones bayanét dean “Tiswateny oes py ta nal ar nde Weta tear gr ar abet demage fs ara efnomase, fret sniegsecrdng we SAAM recammendatins ado iin cr inten a ena or pleats aber han recomended [XAMAS OF WEAR AND TEAR: Sy i ‘Scares unvonleeere Se rena Spacaarseee fractionator ancy saeco Sng seen Sona pede baa uence Tiros ocean ced bee opt er nce. ‘wes ee amas ead he opts meen, te ‘eoraarady Shoes we Sta ange "Trey set cnr damages cela AVID BRAKE SERVICE ‘isaceomendet yubve your Andbabe serviced ya ud oye mechan, Sencig ‘nid star requtes Inwedge of brass canons wa the speci oles sed or Use at fd shold eye or posed afin seccénceo el ner epi [NEVER pura id dun a sewage or dinage stan ona he aud or aad wae ‘nspbetniye fearon ado of SBA Cain nds we 49. yp SB Sema Fre Sapam naan en fern Sn Party its nur atm Fiestas ewer SM args Fema cents sec soe ran alee Hse itera stan Sarpy i aes cn neTABLE OF CONTENTS certingsraRren. BRAKES WER: ‘OOLSNEEDEDFOR SEE HoRAUUCDISCBRAKELEVERO BBE NEVES ARGON ms DISCRRAREALPEROVERVAL—.—msesnmnnnemnvnvonn 25 SDORRLCR Fd ee 3 des % EO MONTANE RAD nn a as é 3 = HYDRAULICDISCBRAKEHOSE LENGTHADJUSTMENT & BLEED.. ELDIRR.CR -JUICY 35,7, AREON, ULTIMATE. CODE, CODES. DISCERAKEPADREPLACEMENT. CR were ARGON UCT TE SEAN R Conyigt © SRAM CORPORATION +2009 AVID TECHNICAL MANUALSAFETY FIRST! At SRAM Corporation, we care about YOU. Please, ALWAYS wear your safety glasses when servicing your Avid brakes. Protect your eyes! Wear your safety glasses! ‘GEN 0000000000382, Rew. AGETTING STARTED GETTING STARTED - HELPFUL HINTS “The Aid Tec Manual assumes yas are peamig complete aercl athe ane bang remand sears trea eee afoca sree copes brat lve avr lige sera rote as length dustment 8 bleedag ‘ake rate po elecenant ta ao at eyo ae sl Ai dese for aa uve narderta sane succes ence hen.ETN RAE Raa a COLL Leo) The following chart lists the serviceable brake models inthe 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 andor the calipers on a hydraulic dise brake system. Overhauling the levers and/or calipers introduces small amounts of ar into the system. Failure to bleed the brakes to remove this air ean degrade the performance of your brakes, which could lead to serious endior fatal injury while riding 6 BRAKE STYLE ‘SERVICE CATEGORES HYDRAULIC | MECHANICAL CAUPER |HOSEADJUST| PAD BRAKE MODELS bist bist @BLEED | REPLACEMENT ELDAR, CR x x x WICY3.5 7, CARBON UTA |X. x x (CODE, CODES x x x BT Mountain ard Road) x x 000000382, Rew. AORS Tape ala COLL e5) The following chartis alist ofthe tools needed to service on your 2009 model year Avid brakes. While this chartis intended tobe comprehensive, its stil only guide. The tools required for each step of service are detailed inthe text of each service section. Keep in mind your specific brakes may not require every tool listed a roa. OVERHAUL 'SATETYSTARTING EDUPWENT, SAFETY GASSES x ‘APRON x RUBEER GLOVES x (LEAVRAGS LNT FREE) x OILPAN x LEANWORK AREA x WRENGIE (PLERS 25MM HEX x ‘aM HEX TATORK x TITRE x Ta0TORK ‘BNIOPENEND OF BOX WRENCH 1 MMICPEN END OR BOXWFENCH TTORQLEWRENCH TNEIDLENCSED FLERS x ‘SNAP ING FLERS INTERNAL x E-CUP TOOL OPTONALD x MISCTOOL KITS: "AWD BLEED KIT x HYDRAULICLIVE CUTTERS ORVERY SHARP HOUSING CUTIERS SHARP PIO x {ISOPROPYL MOOHOL ‘SMELL ANDLARCERLATIEAD x SCREWDRIVERS. ‘PHLLIPS HEAD SCREWORVER x ‘AIR OOMIPRESSOR WITH LOW GUNCHUK 'SOAPY WATER x CE OOID BEVERAGE x Conyigt © SRAM CORPORATION +2009 AVID TECHNICAL MANUALHYDRAULIC DISC BRAKE LEVER OVERHAUL0 a a ait INTRODUCTION Avid brake lever assemblies need to be serviced in order to optimize braking function, If brake fluid is leeking from any area of ‘the brake lever assembly, there may be damage or wear and tear tothe internal moving parts. It your brake was filled with fluid OTHER than DOT 4 or5.1, damage to all rubber and plastic internal parts may exist. If your brake was damaged in a crash, there may be damage to the ever blade and pushrod assemblies, as well asthe housing assembly. Inspection and/or replacement of these parts, due to any ofthe above situations, will be necessary to restore proper brake function, eres ‘erTIe starTeD| e Remove brake lever from handlebar. Remove caliper from fork or frame. If dirty, clean with soapy water and a clean rag. Pull hose boot off compression nut and slide down hose {not pictured 2. Elixir CR: Use an 11 mm open ended wrench to hold the hose stop in place and use an 8mm open ended wrench to unscrew the hose compression nut. lxirR: Use an 8mm open ended wrench to unscrew the hose compression nut Unthread the compression nut completely by hand and slide it down the hose. Pull brake hose and compression fitting from lever body. 3. Allow any brake fluid to drain into @ container. Hold lever assembly over container and pump lever to remove any brake fluid inside lever assembly. NOTE: 1FTHESYSTEM WAS EEN CONTAMINATED WTHTHE WONG FLD, YOUWILLNEEDTOFLUSHALLTHE PARTS WITH SOAPYWATER AND ALLOWTODRYULLYPRIORTO AEBUILOINE. OU WILL ALSONEED TOINSTALL ANEW HOSE, Leven ASSEMBLY Take a few moments and familiarize yourself withthe internal components of your brake lever, This will assist you in identifying the components while you service your brake ‘PLoS EW LRT LEASSENBLY ‘s veo0oy vera exc anwstsenew ce pstoweacoerasseusty ——@ neaCNADWUSTSPAING we ote ‘GEN ooo0000000382, Rew. Aeer saiis ca eae REMOVE LEVER 0 4, Use a small phillips screwdriver and remove the serew fromthe reach adjust knob. 5. Use a 3mmhex and remove the lever bolt 6. Carefully pull and remave the reach adjust knob and attached spring IMPORTANT POINT THE REACH ADAUSTKNOB AWAYFROM ‘YOUR EVESWHEN REMOVING. THESPRING IS PRE-LOADED No MAY PoP OUT SUODENUY WTHTHEKNOB. 7. Pull back onthe lever to fully open and cisengage the push rod from the piston, Use @ small hex wrench to push the pivot pin out ofthe lever, Pull straight back on the lever blade and remove. NOTE THE PWVOT BUSHINGS MAY FAL OUTOF THELEVER BLADE TSS OK SIMPLY RESET THEMINTO THELEVER Lane, 8. Use long snap ring pliers and remove the snap ring inthe lever body along with the piston’ bladder assembly. NOTE Te PISTON ADDER ASSEMBLY IS ATTACHED TOTHE SWAPRING 9. Inspect the bladder for damage. If damaged replace the entire piston/bladder and snap ring assembly, 10. Remove the piston spring, Use a pickto remove and replace both the piston glide ring and o-ring Do NOT re-install the piston spring at this time. PORTANT: BECAREFULNOT TO OAMAGETHE PISTONGLAND WT THEPIOK IMPORTANT: DONOTREANSTALLTHEPISTONSPRING AT TAS Te 11 Lubricate the piston/bladder assembly by dipping itinto 0075.1 fluid and allow the excess ‘uid to drip oft ‘TF: YOU CAN ALSO USEDOT COMPATIBLE GREASEAS A twpnicant CCopyatt © SRAM CORPORATION 2000 AVID TECHNICAL MANUAL2 Eres eo Levenstauaron 12. Use long snap ring pliers and re-install the piston/bladder assembly into the lever body. 13. 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, 14. Align the hole in lever blade with the slot in lever body and re-install the pivot pin so it sits flush. IMPORTANT: MAKESURETHE PV BUSHINGS ARE insta, 15. Slide the reach adjust bolt through the pivot pin hole and slide the piston spring over the bolt. 16, Place the ach adjust knob ont te spring, compress the spring, and slide the reach adjust knob into place in the lever body. 17. Use a. 3mm hex to thread the lever bolt so the slotin the bolts aligned with the hole in the knob. 18. Use a small phillips screwdriver and re-install ‘the screw for the reach adjust knob. Tighten until snug. ‘THIS CONCLUDES THELEVER OVERHAULSERVICE ISTRUCTIONS. YOUHAVEDONE AGREAT JOB AND ARE [EADY TOMOVEON TOTHENEXT CHAPTER HYDEAULIC DISC DBRAKECAUPER OVERHAUL ENJOY! (GEN 0200000000382, Rew.ADISC BRAKE CALIPER OVERHAULaD ae) Me Avid caliper assemblies need to be serviced in order to optimize braking function. If caliper brake piston motion sticky’ or lacks a positive and smooth return, the caliper body/brake piston o-ring may be out of place or damaged. if your brake was filed with brake fluid other than DOT 405.1, damage to all rubber and plastic internal parts may exist. Commonly used INCORRECT ‘uid is mineral oi or DOTS, whichis silicone based. Inspection and/or replacement ofthese parts, due to any of the above situations, willbe necessary to restore proper brake Cees se ue) function ‘TROUBLESHOOTING - ‘STICKY ORSLOW BRAKEPADRETURN EEL 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 ofthe caliper has a slow returning brake piston, Remove caliper from bicycle. Ifyou have a mounting bracket, itis recommended to remove that too rust remove the caliper leaving the bracket on the fork or frame, Remove e-clip from guide pin groove on top ofthe caliper. Using a 2.5 mm hex ‘wrench remove the guide pin from the caliper. Pull and remove both brake pads and h-spring Using @ 10 mm box wrench, press working piston into caliper body. Squeeze brake lever slowly to move sticky piston inward. Press the piston back nto 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. Ifthere is no improvement, continue with caliper service. certing sraareo 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, DRAKEPAD AND H-SPRINGREMOVAL 2. Remove e-clip from guide pin groove on top of the caliper. Using a 2.5 mm hex wrench remove ‘the guide pin from the caliper. 3. Pull and remove both brake pads and h-spring NOTE FTE TOTAL THICKNESS OFTHEBACKING PLATE AND PAD FRICTION MATERIALS LSSTHANS MM, THEBRAKE PADS NEEDTOBEREPLACED (GEN 0200000000382, Rew.Aeaten isnt Cue eumerone aaevosspawonaeenoLans — @y e e senvice 4, Using an 8 mm open-end or box wrench, loosen banjo bolt. Brake fluid will leak, so hold over a container to catch fluid ‘5. Pull banjo bolt completely out of caliper. Dump all caliper brake fluid into container. 6. Remove and replace o-ring on banjo bolt and banjo cauPenoisassematy aNDseRvice 7. Using an 8mm and T 30 Torx loosen and remove the caliper body bolts. 8. Soparete caliper body halves and open caliper assembly 9. Using a sharp pick, remove small banjo hole {body hat) o-ring [BRAKE PISTONS REMOVALANDSERVICE 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 ina 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 wiile holding caliper body. Compressed air unseats the caliper piston from the caliper. Pull out completely and remove piston. IMPORTANT: POINT THECALIPERINA SAFEDIRECTION. USE A CLOTHOR A PLASTICBAG TOPREVENTTHE PISTON CAUSING INJURY of BECOMING LOST. Gutboard Caliper Body Halt: Using an air compressor chuck, insert chuck nozzle into banjo bolt hole, Hold caliper in one hand, Pointing caliper piston ina 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 wiile holding caliper body. Compressed air unseats the caliper piston from the caliper. Pull out completely and remove piston. IMPORTANT: POINT THECALIPERINA SAFEDIRECTON. USE A ‘LOTHORAPLASTICBAG TOPREVENTTHE PISTON CAUSING INJURY of BECOMING LOST. 1. Remove the square-edge o-ring from inside each caliper body half with a sharp pick and replace with new square-edge o-rings, CCopyatt © SRAM CORPORATION 2000 AVID TECHNICAL MANUALCease cunt ‘CAUPER ASSEMBLY 12. Inspect caliper pistons for damage and replace it necessary. Re-install caliper brake pistons into each hal ofthe 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) 13. Using a sharp pick, remove and replace the outboard caliper body o-ring 14. Using @ T-30 Torx and an 8 mm open ended wrench, re-install the caliper body bolts and torque to 8.5-10.2 Num (75-90 in-b). 15. Using a T-10 Torx wrench, remove bleed screw. 16. 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 17, Re-install banjo bolt bleed screw into banjo bolt and tighten with T-10 Torx wrench. BRAKEPADINSTALLATION 18. Measure the total thickness of each pad (pad backing plate and pad material). I there is less ‘than 3mm of otal width, replace both brake pads (not pictured). 19. Be sure the h-spring is oriented to the pads as, shown, Align the hole in the h-spring with the holes in the pad tabs. Squeeze the pad and spring assembly together, then insertinto the caliper as @ unit. Firmly push until the assembly is seated into place. 20. Using a 2.5 mm hex wrench, install the pad retainer bolt and tighten to 0.9-1. Nem {8-85in-b). Install the “E” clip on ‘the wheel side of the caliper making sure it sits inthe groove of the retainer bolt ANSHNG UP NOTPICTURED 21. Visually check your work. Inspect banjo bolt and banjo for any protruding o-rings.IFthere are any o-rings that are ‘squeezed! beyond the outside edges of the banjo or bol, remove and replace. Repeat installation steps. 22. Wipe assembled caliper with soapy water to remove any brake fui. 23. Re-install caliper onto bicycle following the installation and toraue specifications called out inthe user manual. ‘THIS CONCLUDES THE CALIPER OVERHAUL SERVICEINSTRUC- TIONS. YOU HAVEDONE A GREATJOB AND AREREADY TO ‘MOVEON TO THEMEXT CHAPTER, HYDRAULICDISCBRAKE ‘HOSELENGTHADJUSTMENT ANDBLEDING. EnsOV! (GEN 0200000000382, Rew.AHYDRAULIC DISC BRAKE HOSE LENGTH ADJUSTMENT & BLEEDUC SA ee ee 2) UN ee Se oy INTRODUCTION Avid brakes come with the hoses attached and bled. If you don’t need to change the hose length, then you should not need to, bleed the system again. However, it you performed a lever and/or caliper overhaul, you will nead to bleed your brakes. Bleeding is one of the most important steps in topping off the performance of any hydraulic brake system. Any ai inside a hydraulic brake system degrades the performance ofthe brake, The goal of bleeding is to remove the air tha strapped inthe hoses, caliper or lever. Crisis RE-CHECK HOSEROUTING 8 Since you can't lengthen the hose after you have cutit, take a moment and re-check the routing ofthe hoses. Be sure to account for suspension movement and check hat the bars turn freely by turning the bars all the way from side to side. Make sure the hoses are properly secured as well (not picture. AEMOVEHOSE FROMLEVER 2. Juicy, Code & ElixirR: Use an mm open ended ‘wrench to unscrew the hose compression nut Elixir R: Use an 11 mm open ended wrench to hold the hose stop in lace and use an 8 mm open ended wrench to unscrew the hose compression nt. NOTEIF YOURBEAKEHAS AHOSEBOOTPULLTHEBOOTAWAY FROM THELEVERTO ACESS THE COMPRESSION NU F THE ‘BOOT STICKS CAREFUL PRY UPA CORNERWATH SOMETHING "THAT WON'T ARM (UKE A PENCITIP)AND PRAYSOME ‘ALCOHOL BETWEENTHE BOOT AND THELEVER, WORK THE ‘ALCOHOL N; THE BOOT SHOULDLONSENUPAND SLDEEASIY DDOWNTHEHOSE, 3. Pullthe hose from the lever wiggling it if neces- sary. Be careful, DOT fui will dri from the hose. Try not to spill too much ld because any fluid ‘that drips out will create bubbles that you'll have to eliminate ater. 4,_ Slide the nut and boot ff applicable} down the hase and away from the end where you'llbe cut ting. Do not to engage the brake lever while the hse is removed inot pictured) ‘GEN ooo0000000382, Rew. Aeee) DETERMINEPROPERHOSELENGTH& CUT ‘5. Determine where you need to cut the hose by holding it up tothe lever in the position you lke Make sure to leave a gentle bend in the hose with enough length to freely turn the bars allthe ‘way from side to side. Double-check this part, because you can't go back after you cut. 6. The groove in the lever nase marks the spat where you'll cutthe hose. Cut the hose using hydraulic hase cutters or very sharp cable- housing cutters not pictured). INSTALLNEWeTTTINGS 7. While holding the hose firmly, thread a new hosebarb into the end of the hose using @ T-10, ‘Torx wrench, 8. Slide a new compression fitting over the end of ‘the hose with the new hosebarb, AE MSTALLTHEHOSE 9. Push the hose firmly into the lever unlit stops. 10. While holding the hose in place, slide the com- pression fitting and compression nut upto the lever or hose stop (not pictured), Juicy, Code & Elixir: Finger-tighten the com> pression nut until you feel it bottom out irCR: Hold the hose stop in place and fingertighten the compression nut until you feel itbottom out 11. Juicy, Code & Elixir: While continuing to push the hose into the lever body, use an 8 mm open ended wrench to tighten the compression nut to the proper torque. Elixir€R: While continuing to push the hose into the hose stop, use an 11 mm open ended wrench to hold the hose stop in place and use ‘an 8 mm open ended wrench ta tighten the com pression nut tothe proper torque. It your compression fitting is alloy tighten to 5 Nm (47 in-b). f your compression fitting is steel, tighten to 28 Nem (70in-I) 12. Side the boot if applicable} backinto place tnot pictured) IMPORTANT: CUTTING DOWN THEHOSEITRODUCES A ‘SMALLAMOUNT OF AI NTOTHE SYSTEM, WHICHGAN DDEGRADETHE PERFORMANCE OF YOUR BRAKES. ATTHIS POINT FTISNECESSARYTOBLEEDTHEBRAVES TORESTORE ‘THEMTO OPTIMAL PERFORMANCE. PLEASE CONTINUEONTO "aLEEDING PROCEDURES”. CCopyatt © SRAM CORPORATION 2000 AVID TECHNICAL MANUAL 47pena WE BLEEDING AVIO BRAKES, KEEPIN MIND THAT YOU ARESIMPLY CHASING BUBBLES OUT OFTHESYSTEML AVID ‘RECOMMENDS THAT YOU BLEED YOURBRAKES ATLEASTONCE AYEAR TOENSUREOPTIMAL PERFORMANCE. 1FYOURIDE FREQUENTLY OR IN AGGRESSIVE TERRAIN, YOUSHOULDBLEED YOUR BRAKES MORE OFTEN YOU WILLPERFORM3.BASIC ‘OPERATIONS WHEN BLEEDING AVIDERAKES: BLEED THEHOSE, BLEEDTHE CALPE, BLEED THELEVER. PREPARE THE SYRINGES Fiore singe 2 tu wih vid -Perto QD mance DOT Fluid and filthe other syringe 14 full. 2. Hold each syringe with the tip pointed up and tap the side ofthe syringe with your finger to bring any air bubbles tothe top. Place @ towel around the tp and slowly push the ar bubbles out ofthe syringe NOTE: YOUWILLNOTBEABLETOREMOVE ALLTHE BUBBLES. PREPARE THE CALIPER UY 3,5, 7, ULTIMATE & CARBONONLY 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 DOT fluid from contaminating your brake pads (not pictured) 4. Use the T-10 Torx wrench ta remove the caliper (4 bleed port screw from the center of the banjo bolt. ‘5. Make sure the fluid in the 1/2 full syringe is pushed all the way to the tip (no air gap! then ‘thread into the caliper bleed port PREPARE THE CALIPER ccovecones ony 6. Remove the wheel from your bike. Remove the J brake pads and spreader clip from the caliper and insert the appropriate Bleed Block. This will help prevent DOT fluid from contaminating your brake pads not pictured) 7. The Code caliper features two bleed port screws on either side on the banjo fitting. I's recommended that you use the bleed port on the left side of the banjo fitting during normal bleed- ing. Use the T-10 Torx wrench to remove the caliper bleed screw fram the caliper body. 8. Make sure the fluid in the 1/2 full syringe is pushed all the way to the tip (no air gap! then ‘thread into the caliper bleed port (GEN 0200000000382, Rew.APana) PREPARETHECALPER -ELOQIR PVELIXIRCR 9. Remove the wheel from your bike. Remove the brake pads and spreader clip fom the caliper and insert the appropriate Bleed Block. This will help prevent DOT fluid from contaminating your brake pads (not pictured). 10, Use the T-10 Torx wrench to remove the caliper bleed port screw from the caliper body. 11. Make sure the fluid in the 1/2 full syringe is pushed all the way to the tip (no air gapth, then ‘thread into the caliper bleed port. PREPARE THELEVER 12. Reach Adjust: For models equipped with Reach Adjust, ensure thatthe reach is nat adjusted so far out that it causes the lever blade to bottom cutan the lever body. Doing so can make bleed ing the brake impossible tnot pictured) Pad Contact Adjust: For models equipped with Pad Contact Adjust, set the adjustment so itis ‘turned all the way out (not pictured). 13. Use the T-10 Torx wrench to remove the lever bleed port screw. 14, Make sure the fluid in the 1/4full syringe is pushed all the way tothe tip {no air gap! then ‘thread into the lever bleed port NOTE: TISNOTNECESSARYTO REPOSITION THE ANGLE OF THEBRAKELEVERON THEHANDLEBAR YOUMAY HAVER SMALLAMOUNTOFDOTFUWiDDRIP FROM THEBLEED PORT ‘CREM THISIS NORMAL, JUSTHAVE A TOWEL HANDY TO WE FF ANVEXCESS AFTERTHESYRIGEISINSTALLED, BLEEDTHESYSTENE BLEED THEHOSE 15. Hold the caliper syringe upright in your right hand and the lever syringe upright in your left hand. 16. Gently push on the caliper syringe plunger to move fui from the caliper syringe into the lever syringe until the lever syringe is increased to 1/2 {ull and the caliper syringe is decreased to 1/8 full NOTE YoU SMOULDSEE BUBBLESFLLINTOTHELEVER rng 17. Close the red syringe clamp on the lever. 18. Pull the brake lever allthe way to the bar with your finger and hold itthere untilinstructed to release the leverinalater step. If you don’t want to hold the lever with your finger, have a friend hold itor you can fastenit witha toe strap or rubber bands CCopyatt © SRAM CORPORATION 2000 AVID TECHNICAL MANUALDarel BLEEDTHESYSTEME BLEEDTHE CALIPER 19. With your right hand, gently pull out on the caliper syringe plunger to create a vacuum then gently push in on the plunger to pressur izethe system. Repeat this procedure several times, until large bubbles stop coming out of the caliper. NTE: BECAREFUL NOT PULLOUTTOOHARO ON THE PLUNGER ‘ORYOUWILPULLAIR PASTTHEPLUNGERSEAL ANDYOUWILL ‘BETHERE ALLDAY TRYING To ce BUBeLESOUT 20. Once the large bubbles atthe caliper have stopped, apply @ small amount of pressure on the syringe plunger and slowly et the pressure extond te brake lever you have been holding with your finger. Ifyou fastoned the ever with atoe strap o rubber bands, remove these frst but keep the lever pulled in with your finger, then apply pressure onthe syringe plunger inot pictured) NOTE: YOUWILLFEELTHEPRESSURE AT YOUR BNGER ONTHE {Ver JUST LET THE FUND EXTEND THELEVERBACKTONTS OmcNAL POSTION, 21. Remove the syringe from te caliper and re= install he bleed part screw. NOTE: THERE WILLE EXCESSOOT LUD THATSPILS OUT AS ‘YOURE-USTALLTHE BLEED PORT SCREW, THIS 1S NOREAL ‘BESURE TO WIPE THE FLUFF THECALIPRUITH ATOWEL sano waren, BLEEDTHESYSTEME LEED THELEVER 22. Open the red syringe clamp on the lever. 23. Gently pull out on the lever syringe plunger to create a vacuum, then gently push in on plunger to pressurize the system, Squeeze and release the brake leverten times, allowing the lever to snap back t's starting position after squeez- ing this helps break loose the bubbles). Repeat ‘his procedure several times, until large bubbles stop coming out ofthe lever. NOTE|BE CAREFUL NOTPULLOUTTOOHARO ON THE PLUNGER ‘ORYOUWILLSUCK AIRPASTTHEPLUNGERSEALINTOTHE FLUID ANO CREATE MORE BUBBLES THAT YOUWLLHAVETO UMINATE 24. Once the large bubbles atthe lever have stopped, anply a small amount af pressure on the syringe plunger then remove the syringe and re-install the bleed port screw. NOTE: THERE WiLL BE ASMALL AMOUNT OF EXCESS DOT FLUID THATSPILS OUTAS YOU REMOVETHESYRINGE AND AE-NSTALLTHEBLEED PORT SCREW, THISIS NORMAL, BE ‘URETOWIPETHE FLUID OFFTHE LEVER WITHA TOWEL. © @ @ yt A L4 nN ® ® ct] (GEN 0200000000382, Rew.APana) FINAL TOUCH wor .eTURED) 25. Spray isopropyl alcohol or water onto a towel and wipe off the brake lever and caliper to re- move any excess DOT fluid you may have missed before 26. Remove the Bleed Block from the caliper and re- install the brake pads and spreader clip. 27.Re-install your wheel according to the manufac turer's instructions Empty the syringes into @ sealed container and dispose of the fluid properly, Remember, usedDOT fluid should be recycled or isposed af 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 hase clamps closed, this will damage the clear tubing on the syringes. You are almost ready to ride, but firsts 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 and look around the hose nut on the lever, and the banjo bolt on the caliper for any leaks. Make one last check ofall the bolts and fittings It everything checks out, YOU ARE READY TO RIDE! CCopyatt © SRAM CORPORATION 2000 AVID TECHNICAL MANUAL 5DISC BRAKE PAD REPLACEMENTaD ey 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 willimprove braking performance. New brake pads are subjectto a “break-in” period, Itmay take anywhere from 20 to 40 complete stopsto breakin 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 lite ofthe brake pads. Thisis rormal 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. dust, sol, and contamination of friction surfaces), Gece EMOVEPADRETANEROLT 0 Start by removing the “E” clip on the wheel side of the caliper, then unscrew the retainer bolt use ing a 2.5 mmhex wrench. Remove the retainer bolt all the way. PUSHTHEPISTONSBACKIN 2. The Bixir calipers are self adjusting, the pistons need to be pushed back into the bodyto their original position before the new pads can be in- stalled, The safest way to do this is with the old pads still in the caliper to protect the pistons. Place a flat-blade screwdriver between the cold pads, then carefully rock t back and forth, pushing the pistons back into their bores inot pictured EMOVETHEOLDPADS 3. Grab the pad tabs and pull straight out 4. Inspect and measure the total thickness of each brake pad with a ruler. ifthe total thickness is less than 3 mm, you need o replace both brake pads (not pictured), [NOTE IFTHEBACKINGPLATE AND PAD MATERIALISTHICKER ‘THAN MM YOUCANSIMPLY REANSTALLYOURBRAKEPADS ASOUTLNEDINSTEPS, STALL THENEWPADS AND SPREADER 5. Be sure the spreader clips oriented tothe pads as shown. Align the hole in the spreader clip withthe 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. Nam (80-97 in-Ib}. Install the E”cip on ‘the wheel side of the caliper making sure itsits inthe groove ofthe retainer bot. ‘THIS CONCLUDES THEDISC BRAKEPAD REPLACEMENT IWSTRUCTIONS. YOUDIDA GREAT JOBE YOU ARENOWREADY oR. eNsov! (GEN 0200000000382, Rew.A