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2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007...

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2007 AVID TECHNICAL MANUAL (ENGLISH) Part# 95-5015-004-000
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Page 1: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

2007 AVIDTECHNICAL MANUAL(ENGLISH)Part# 95-5015-004-000

Page 2: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

© SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL �

TABLE OF CONTENTS

Getting Started Information...................................................................................................................5BrakeTechnologyDesignation...............................................................................................................................6ToolsNeededforService........................................................................................................................................7

Hydraulic Disc Brake Lever Overhaul.................................................................................................................9Juicy3,5,7,Carbon,Ultimate................................................................................................................................10CODE.........................................................................................................................................................................16

Disc Brake Caliper Overhaul....................................................................................................................................21Juicy3,5,7,Carbon.................................................................................................................................................22JuicyUltimate............................................................................................................................................................25CODE.........................................................................................................................................................................29BB7.............................................................................................................................................................................33

Hydraulic Disc Brake Hose Length Adjustment & Bleeding..................................................................39Juicy3,5,7,Ultimate,Carbon-CODE..................................................................................................................40

Disc Brake Pad Change..............................................................................................................................................45Juicy3,5,7,Carbon,Ultimate................................................................................................................................46CODE.........................................................................................................................................................................47BB7.............................................................................................................................................................................48

Page 3: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

95-5015-004-000, REV. A4 © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 5

SAFETY FIRST!At SRAM Corporation, we care about YOU, our customer.

Please, ALWAYS wear your safety glasses when servicing your Avid brakes. There are just too many trails to ride, vistas to

summit and sunrises to see.Protect your eyes! Wear your safety glasses!

GETTING STARTED INFORMATION

The2007AvidTechnicalManualwascreatedtohelpyoutune,service,andtroubleshootyourAvidproducts.Forexplodeddiagramsandpartnumberinformation,pleaserefertotheAvidSparePartsCatalogavailableonourwebsiteatwww.sram.comorwww.avidbike.com.

Fororderinginformation,pleasecontactyourlocaldistributororvisitourwebsite.

Informationcontainedinthispublicationissubjecttochangeatanytimewithoutpriornotice.Forthelatesttechnicalinformation,pleasevisitourwebsite.Productnamesusedinthismanualmaybetrademarksorregisteredtrademarksofothers.

Page 4: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

95-5015-004-000, REV. A� © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 7

TOOLS NEEDED FOR SERvICE(ALL BRAkES)

Thefollowingchartisalistofthetoolsneededtoserviceonyour2007modelyearAvidbrakes.Whilethischartisintendedtobecomprehensive,itisstillonlyaguide.Thetoolsrequiredforeachstepofservicearedetailedinthetextofeach service section. Keep in mind your specific brakes may not require every tool listed.

TOOLSLEvER

OvERHAULCALIPER

OvERHAULHOSE ADJUST

& BLEEDPAD

REPLACEMENTSAFETY/STARTING EQUIPMENTSAFETYGLASSES X X X X

APRON X X X X

RUBBERGLOVES X X X X

CLEANRAGS(LINTFREE) X X X X

OILPAN X X X X

CLEANWORKAREA X X X X

WRENCHES/PLIERS2.5MMHEX X X

4MMHEX X X X

T-10TORX X X

8MMOPENENDORBOXWRENCH X

11MMBOXWRENCH X

TORQUEWRENCH X

NEEDLE-NOSEDPLIERS X X X

SNAPRINGPLIERS-INTERNAL X X

E-CLIPTOOL(OPTIONAL) X

MISC TOOLS/kITSAVIDBLEEDKIT X X X

HYDRAULICLINECUTTERSORVERYSHARPHOUSINGCUTTERS X

SHARPPICK X X X

ISOPROPYLALCOHOL X

SMALLANDLARGEFLATHEADSCREWDRIVERS X X X

AIRCOMPRESSORWITHBLOWGUNCHUCK X

SOAPYWATER X X X

ICECOLDBEVERAGE X X X X

BRAkE TECHNOLOGY DESIGNATION(ALL BRAkES)

Thefollowingchartisacompletelistofthe2007Avidbrakeline-up.Itdetailsthebrakemodelandcorrespondingtech-nologiesofeachbrake.Itisimportanttodeterminethetechnologyusedinyourbrakeinordertosuccessfullyserviceit,asthismanualissectionedbytechnology,ratherthanbrakemodels.Ifyouareunsureofthetechnologyofyourbrakes,consultyourlocalAviddealerforassistance.Thismanualassumesyouareperformingacompleteoverhauloftheentirebrakingsystem:levers,calipers,padreplacementandperformingableed(hydraulicdiscbrakesonly).

IMPORTANT:YOUMUSTBLEEDYOURBRAKESifyouoverhaultheleversand/orthecalipersonahydraulicdiscbrakesystem.Overhaulingtheleversand/orcalipersintroducessmallamountsofairintothesystem.Failuretobleedthebrakestoremovethisaircandegradetheperformanceofyourbrakes,whichcouldleadtoseriousand/orfatalinjurywhileriding.

BRAkE MODELHYDRAULIC

DISCMECHANICAL

DISCHOSE ADJUST

& BLEEDPAD

REPLACEMENTJUICY3 X X X

JUICY5 X X X

JUICY7 X X X

JUICYCARBON X X X

JUICYULTIMATE X X X

CODE X X X

BB7(MountainandRoad) X X

Page 5: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

© SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9

HYDRAULIC DISC BRAkELEvER OvERHAUL

Page 6: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

95-5015-004-000, REV. A10 © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 11

2 3 4

HYDRAULIC DISC BRAkE LEvER OvERHAUL(JUICY 3, 5, 7, CARBON, ULTIMATE)

INTRODUCTIONAvid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any areaofthebrakeleverassembly,theremaybedamageorwear-n-teartotheinternalmovingparts.Ifyourbrakewasfilled with fluid OTHER than DOT 4 or 5.1, damage to all rubber and plastic internal parts may exist. If your brake was damagedinacrash,theremaybedamagetotheleverbladeandpushrodassemblies,aswellasthereservoircap,bladderandstarwheelassemblies.Inspectionand/orreplacementoftheseparts,duetoanyoftheabovesituations,willimprovebrakefunction.

LEvER OvERHAUL SERvICE INSTRUCTIONS

getting startedRemovebrakeleverfromhandlebar.Re-movecaliperfromforkorframe.Ifdirty,cleanwithsoapywaterandacleanrag.Pullhosebootoffcompressionnutandslidedownhose(notpictured).Usingan8mmcrow’s-foot(includedinAvidBleed Kit) and socket wrench (or use a flare nut8mmwrench),loosenandremovecom-pressionnutfromleverbody.Turncounter-clockwisetoremove.Unthreadcompletelybyhandandslidecompressionnutdownhose. Pull brake hose and compression fit-tingfromleverbody.Allow any brake fluid to drain into a contain-er.Holdleverassemblyovercontainerandpump lever to remove any brake fluid inside leverassembly.note: if the system has been contaminated with the wrong fluid, you will need to flush all the parts with soapy water and allow to dry fully prior to rebuilding. you will also need to install a new hose.

reservoir cover/bladder removalUsingasmallPhillipsscrewdriver,removebothreservoircoverscrews.Removereservoircovercapandbladderfrom lever assembly. Additional brake fluid willdrainfromlever.Holdleverovercontain-er and allow fluid to drain. Set lever assem-blydownoncleantowel(notpictured).Holdingthereservoircover,removebladderfromreservoircover.Replacewithnewblad-der 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.

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LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

reservoir cover/bladder installationInsert new bladder into cover and seat flush intoundersideofreservoircover.Makesureyouhavethecorrectorientation.Placereservoircoverandbladderbackontoleverbody.Installandtightencovercapscrews(shortscrewclosesttoleverclamp).TightenbothscrewswithaPhillipsscrew-driver.

bleed screws removalUseaT-10Torxwrenchtoremovebothbleedscrews.Usingasharppick,removebotho-ringsonbleedscrewsandreplace.Installbleedscrewsbackintoleverbody.note: for juicy 3, 5 please move onto the lever blade/pushrod removal procedures.

star wheel and worm removal - juicy 7, carbon, & ultimate onlyRemoveretaininge-clipwithsharppickorsmall flathead screwdriver.Juicy7,CarbonOnly:Unthreadstarwheelandwormfromleverbody.Unthreadbyhand;pullouttoremovefromleverassembly.orJuicyUltimateOnly:Unthreadwormfromleverbodyusinga2.5mmhex.Usingapick,insertintogearhole,andpushbushingoutofleverbody.Setstarwheel/wormassemblyaside.note: do not re-install star wheel and worm gear back into lever assembly at this point.important: replace the star wheel and worm gear if it is damaged, cracked or broken, or if you are switching sides of lever body or rotating brake lever to other side of bar.

lever blade/pushrod removalJuicy5,7,Carbon,UltimateOnly:Holdingtheleverinbothhands,placeyourthumbsnearthepivotandpush.Thelevergentlysnapsintotheopenposition.Usea2.5mmhexwrenchandunthreadle-verpivotsetscrewandremovecompletely.Usingasharppick,orsmallhexwrench,pushleverpivotpinthroughleverbodyandremove.

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7 8 9

10 11 12

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OR

juicy 7, carbon juicy ultimate

Page 7: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

95-5015-004-000, REV. A12 © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 1�

LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

lever blade/pushrod removal (cont)Juicy3Only:Usea2mmhexwrenchandunthreadtheleverpushrodscrewcomplete-ly,byturningcounterclockwise.Pullleverbladeawayfromleverbody.orJuicy5,7,Carbon,UltimateOnly:Pullleverbladeawayfromleverbodyandremovepushrodpinfromwormgear.Itwillpopout.Removepushrodfromlever.Replacepushroddustbootifdamaged.Cleanifnotdamaged.Insertpushroddustbootbackontopushrodwiththeopenendfacingthepinandtheclosedendtowardthreads.Re-installpushrodintoleverblade.Pushrodunthreadsandthreadsbackintoleverblade(notpictured).important: replace lever blade and/or push-rod if either is bent or damaged.

internals removalTakeafewmomentsandfamiliarizeyourselfwiththeinternalcomponentsofyourbrakelever.Thiswillassistyouinidentifyingthecomponentswhileyouserviceyourbrake.

18. 18 19

OR

LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

internals removalJuicy3,5Only:Usingstraightinternalsnapringpliers,removecouplingretainingring.Pullretainingringfrominsidetheleverbody.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.Usingneedle-nosedpliers,carefullyremovecouplingretainer/couplingassembly.Cou-plingretainershouldslideoutfromleverbodyeasily.Holdleverbodyassemblyupsidedownanddropthepiston/springassemblyintoyourhand.Itshouldslideouteasily.orJuicy7,Carbon,UltimateOnly:Rotateworm gear retaining clip with a small flat-headscrewdriverorsharppickuntiltheendoftheclipprotrudespastthegapintheleverbody(pushendofcliptorotatewithingroove).Usingneedle-nosedpliers,graspthecliptoremovefromtheleverbody.Insert a large flathead screwdriver into wide slotintopofwormgearandturncounter-clockwise.Unthreadwormgearcompletelyandslide/pullwormgearoutofleverbodyassembly.Wormgearcouplingislocatedinsidewormgear.Thepistonspring(belowpistoninsideleverbody)shouldforcepistonassemblyoutofleverbody.Ifthespringdoesnotaidpistonremoval,useasharphookedpicktopullpistonandspringassemblyfromleverbody.Becarefulnottodamagethepiston.note: if the worm gear coupling is cracked, pull coupling out of gear and replace. cou-pling can wear out over time and crack.Withpiston/springassemblyremovedfromleverbody,removethepistonfromthespring.Using a small flathead screwdriver, remove springcouplingfrompiston.Donotscratchanyplasticparts(pistonoro-rings).Ifdam-aged,youwillneedtoreplacethepistonSlidepistoncouplingoutofpiston(notpic-tured).Removeandreplacepistonsecondaryseal(smallo-ring)ontopofpiston.

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a b d f h

c e g i

j

a. lever body f. secondary seal b. spring g. snap ring c. spring coupling h. washerd. primary cup seal i. pushrode. piston j. lever

exploded view - juicy 3 lever assembly

ab d f h j

c e g i k

l

a. lever body f. secondary seal k. pushrod dust bootb. spring g. worm gear coupling l. leverc. spring coupling h. worm geard. primary cup seal i. c-clipe. piston j. pushrod

exploded view - juicy 7, carbon, ultimate lever assembly

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ab d f h j

c e g i k

l

a. lever body f. secondary seal k. pushrod dust bootb. spring g. coupling assebmly l. leverc. spring coupling h. coupling retainerd. primary cup seal i. coupling retaining ringe. piston j. pushrod

exploded view - juicy 5 lever assembly

OR

juicy 3juicy 5, 7

carbon, ultimate juicy 3, 5 juicy 3, 5 juicy 3, 5

juicy 7, carbon ultimate

juicy 7, carbon ultimate

juicy 7, carbon ultimate

juicy 7, carbon ultimate

Page 8: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

95-5015-004-000, REV. A14 © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 15

LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

internals removal (cont)Removeprimarycupseal(lowerlargeblackseal)frompistonwithsharppickandslidenewcouplingsealontobaseofpiston.En-sure it sits flush (flat end first, flush against piston,openendout).Re-installspringcouplingbackontopistonandcouplingseal(intoopenendofseal).Re-installspringontocoupling.Thecouplinglightlysnapsontopiston.

internals installationInsertspring/pistonassemblybackintoleverbody, spring first.Juicy5Only:Insertcouplingretainerandcouplingassemblyontotopofpiston,insideleverbody.Thev-shapeoftheretainershouldbepositionedintheleverbladegroove.Usingstraightinternalsnapringpliers,insertcouplingretainingringabovecouplingre-tainerandintogrooveinleverbody.Ensureretainingringsnapsintoplacesecurely.orJuicy7,Carbon,UltimateOnly:Slidewormgear coupling (geared end first) into nar-rowendofwormgear.Thecouplingslidesdirectlyintoinnerwormgearthreads.Insertwormgearandcouplingassemblyontotopofpiston,insideleverbody.Insert large flathead screwdriver into open end (flat slot) of worm gear. Turn clockwise tothreadwormgearintoleverbody.Pressdownintowormgearwhilethegearthreadsintoleverbody.Youwillfeelspringresis-tanceasyouturn.Wormgearthreadswillengagethethreadsinleverbody.Turnclockwiseuntilwormgeariscompletelyinsideleverbody,thenbackoffthreeturns.Thisisthecorrectinstallationsetting.Usingneedle-nosedpliers,insertwormgearretainingclipabovewormgear.Positiononeendofclipintogrooveandslowlybutfirmly push down on clip with pliers until clip snaps firmly into place in groove. Rotate clipuntilendsareinsideofgroove.note: ends of clip must not protrude past lever body groove or extend into lever slot/gap in lever body.

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LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

lever/pushrod installationJuicy3Only:Lineupthepushrodwiththepushrodpinontheleverbody.Usea2mmhexwrenchandthreadtheleverpushrodscrewcompletely,byturningclockwise.orJuicy5Only:Lineuppushrodpinwithslotincouplingretainer.Insertpushrodpinintocouplingretainer.Pushrodpinsnapsintoslot.orJuicy7,Carbon,UltimateOnly:Lineuppushrodpinwithslotinwormgearcoupling(wideslotincenterofwormgearcoupling).Insertpushrodintowormgearcoupling.Pushrodpinsnapsintowormgearinnercouplingslot.Insertleverbushingsintoleverbody;oneoneachside.Thebushinglip(largerend)shouldbeoninsideofleverbody.Lineupleverpivotpinholewithbushingholes.Insertpivotpinbackintoleverandbushings.Useyourthumbtopressdownonpivotpinandsnapitintoplace.Installthepivotpinsetscrewintotheleverbladeandtightwitha2.5mmhexwrench.note: this concludes the lever overhaul ser-vice instructions for juicy 3, 5. please move onto step 37, finishing up procedures.

star wheel and worm installation - juicy 7, carbon, ultimate only.note: juicy ultimate is not equipped with a star wheel knob, however, the procedure is similar.Juicy7,CarbonOnly:Pressstarwheel/wormbushingbackintoleverbodywiththumb.Threadstarwheel/wormassemblybackintoleverbody.orJuicyUltimateOnly:Pressbushingbackintoleverbodywiththumb.Usinga2.5mmhex,threadontoworm.Usingapairofneedle-nosedpliersorare-tainingcliptool,presstheretainingclipontoendofwormtosecureleverassembly.

finishing upCleantheentireleverassemblywithsoapywaterandcleanrag(notpictured).

this concludes the lever overhaul service instructions. you have done a great job and are ready to move onto the next chapter, hy-draulic disc brake caliper overhaul. enjoy!

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juicy 5 juicy 5

juicy 5juicy 7, carbon

ultimate

juicy 7, carbon ultimate

juicy 7, carbon ultimate

juicy 7, carbon ultimate

juicy 7, carbon ultimate

juicy 3 juicy 5

juicy 7, carbon ultimate

juicy 7, carbon juicy ultimate

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95-5015-004-000, REV. A1� © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 17

2 3 4

6

HYDRAULIC DISC BRAkE LEvER OvERHAUL(CODE)

INTRODUCTIONAvid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any areaofthebrakeleverassembly,theremaybedamageorwear-n-teartotheinternalmovingparts.Ifyourbrakewasfilled with fluid OTHER than DOT 4 or 5.1, damage to all rubber and plastic internal parts may exist. If your brake was damagedinacrash,theremaybedamagetotheleverbladeandpushrodassemblies,aswellasthereservoircap,bladderandstarwheelassemblies.Inspectionand/orreplacementoftheseparts,duetoanyoftheabovesituations,willimprovebrakefunction.

LEvER OvERHAUL SERvICE INSTRUCTIONS

getting startedRemovebrakeleverfromhandlebar.Re-movecaliperfromforkorframe.Ifdirty,cleanwithsoapywaterandacleanrag.Pullhosebootoffcompressionnutandslidedownhose(notpictured).Usingan8mmcrow’s-foot(includedinAvidBleed Kit) and socket wrench (or use a flare nut8mmwrench),loosenandremovecom-pressionnutfromleverbody.Turncounter-clockwisetoremove.Unthreadcompletelybyhandandslidecompressionnutdownhose. Pull brake hose and compression fit-tingfromleverbody.Allow any brake fluid to drain into a contain-er.Holdleverassemblyovercontainerandpump lever to remove any brake fluid inside leverassembly.note: if the system has been contaminated with the wrong fluid, you will need to flush all the parts with soapy water and allow to dry fully prior to rebuilding. you will also need to install a new hose.

reservoir cover/bladder removalUsingaT-10Torxwrench,removethereser-voircoverscrews.Removereservoircovercapandbladderfrom lever assembly. Additional brake fluid willdrainfromlever.Holdleverovercontain-er and allow fluid to drain. Set lever assem-blydownoncleantowel(notpictured).Holdingthereservoircover,removebladderfromreservoircover.Replacewithnewblad-der 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.

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LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

reservoir cover/bladder removal (cont)Insert new bladder into cover and seat flush intoundersideofreservoircover.Makesureyouhavethecorrectorientation.note: do not re-install reservoir cover at this time.

bleed screws removalUsingaT-10Torxwrench,removebothbleedscrews.Usingasharppick,removebotho-ringsonbleedscrewsandreplace.Installbleedscrewsbackintoleverbody.

lever blade/cam removalUsingtwo5mmhexwrenches,loosenandremovetheleverpivotshoulderboltandleverpivotsleevebolt.note: you may need to push the shoulder bolt out with a pick or similar tool.Rotatetheleverandcamassemblytowardthehandlebarclamp.Carefullyremovetheleverbladeandreturnspringfromthecam.Slideahexwrenchthroughthebearinginthecamandpullthegentlypullthecamofftheendofthepushrod.

internals removalTakeafewmomentsandfamiliarizeyourselfwiththeinternalcomponentsofyourbrakelever.Thiswillassistyouinidentifyingthecomponentswhileyouserviceyourbrake.

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a. lever body f. quad seal k. cam springb. spring g. gear coupling l. leverc. spring coupling h. pushrodd. primary cup seal i. c-clipe. glide ring j. cam

exploded view - code lever assembly

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95-5015-004-000, REV. A18 © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 19

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LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

internals removal (cont)Usingsnapringpliers,removetheretainingringlocatedintheleverbodyatthebaseofthepushrod.Removepushrodandinternalpiston/springassembly.important: the internal piston/spring as-sembly 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.UsingaT-10Torxwrench,removethePadAdjustKnob.Removethedetentballbear-ingandspringlocateddirectlybeneaththePadAdjustKnobwithapick.important: be careful not to lose the detent ball bearing and spring when removing the pad adjust knob. you may want to hold over a clean rag while performing this step.Gentlypushthebevelgearoutoftheleverbodyfromthebacksideusingapickoryourthumb.

piston/spring assembly overhaulRemovethespringfromthepiston/springassembly.Using a small flathead screwdriver, remove thespringcouplingfromthepiston,followedbythecupseal,glideringandsecondaryquadsealo-ring.Installanewquadsealo-ring,followedbytheglideringandanewcupsealwiththeopenendout(notpictured).Installthespringcouplingbackontothepistonandsnapthereturnspringbackontothespringcoupling.

internals installationInstallthebevelgearintothegearboreandhold in place with your finger.Installthedetentspringandballintotheleverbody.AlignthePadAdjustKnobwiththebevelgearandinstalltheknobusingaT-10Torxwrench.Tightentheknobto1-1.2Nm(8.7-10.4in-lbs).Thebevelgearshouldnowbesecureandyounolongerneedtoholditinplace with your finger.

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LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

internals installation (cont)Installthepiston/springassemblyintotheleverbody.important: align the black piston key on the piston gear into the keyway on the lever body.Pushthepiston/springassemblyfarenoughintotheleverbodytocompletelydepressthespring.Whilethespringisdepressed,insertapingauge(asmalldrillbitwillwork)intothecompensatingport,toholdtheas-semblycompressedintheleverbody.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.Installthepushrodthenwasherontothetopofthepistongear.Installtheretainingringinthegrooveoftheleverbodyusingapairofsnapringpliersandorienttheringholesawayfromtheleverbodyopening.Removethegaugepinfromthecompensat-ingport.Thepistonassemblywillsnapintoplaceagainstthepushrodandwasher.

lever blade/cam installationInsertalegoftheleverreturnspringintotheholeonthelevercam.Installtheleverbladeontothecamandre-turnspring,makingsuretheexposedspringlegisseatedintotheholeontheleverblade.Withyourthumb,rollthecamonthebrakeleversothattheleverpivotholesarealigned.note: you can cut a 5mm length section of a 6mm diameter bolt as a tool to hold the cam and lever blade together as you install the assembly to the lever body.Inserttheleverbladeassemblyintotheleverbodyataslightangle.Thecamcou-pling should snap firmly onto the exposed pushrod.Rotatetheleversothatthepivotandleverbodyboresarealignedandpushtheleverpivotsleeveboltthroughthebearing.Usinga4mmhexwrench,tightensleeveboltto2-2.5Nm(17-22in-lbs).note: if you used a bolt tool in step 31, installing the pivot sleeve bolt will push out the bolt tool. be sure the bolt tool is completely removed.

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bolt tool

bolt tool

ring holes

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95-5015-004-000, REV. A20 © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 21

LEvER OvERHAUL SERvICE INSTRUCTIONS (CONT)

lever blade/cam installation (cont)Squeezetheleverafewtimestoensurethattheleverdepressedandreturnsfully(notpictured).RotatethePadAdjustKnobtothe“fullin”andthe“fullout”positiontoensurefullrangeofadjustment(notpictured).InstallthebladderreservoircapusingaT-10Torxwrenchandtightento1-1.2Nm(8.7-10.4in-lbs).

this concludes the lever overhaul service instructions. you have done a great job and are ready to move onto the next chapter, hy-draulic disc brake caliper overhaul. enjoy!

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DISC BRAkECALIPER OvERHAUL

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3HYDRAULIC DISC BRAkE CALIPER OvERHAUL

(JUICY 3, 5, 7, CARBON)

INTRODUCTIONAvidcaliperassembliesneedtobeservicedinordertooptimizebrakingfunction.Ifcaliperbrakepistonmotionis‘sticky’orlacksapositiveandsmoothreturn,thecaliperbody/brakepistono-ringmaybeoutofplaceordamaged.Ifyourbrakewas filled with brake fluid other than DOT 4 or 5.1, damage to all rubber and plastic internal parts may exist. Commonly used INCORRECT fluid is mineral oil or DOT 5, which is silicone based. Inspection and/or replacement of these parts, duetoanyoftheabovesituations,willimprovebrakefunction.

CALIPER OvERHAUL SERvICE INSTRUCTIONS

trouble-shooting -‘sticky’ or slow brake pad return feelBeforecompletelydisassemblingyourcaliper,it’sworthtryingtoloosenthestickypiston.Trythefollowing:Clampbicycleinbicycleworkstand.Spinaffectedwheel.Lightlysqueezebrakeleverandwatchbrakepadswhenleverisreleased.Determinewhichsideofthecaliperhasaslowreturn-ingbrakepiston.Removecaliperfrombicycle.Ifyouhaveamountingbracket,itisrecommendedtoremovethattooorjustre-movethecaliperleavingthebracketontheforkorframe.Usingapairofneedle-nosedpliers,removebothbrakepadsandh-spring.Removethespringpadclipfromtheoutsideofthecaliper.Usingan11mmboxwrench,pressworkingpistonintocaliperbody.Squeezebrakeleverslowlytomovestickypistoninward.Pressthepistonbackintothecaliperagain.Repeatthesestepstocorrectcaliperpistoninnero-ringposition.Bothpistonsshouldnowbemovingfreely.Re-installspringpadclip,h-spring,andpadsintocaliper.Re-installcaliperontobicycle.Spinwheelandcheckfunction.Ifthereisnoimprovement,continuewithcaliperservice.

getting startedRemovebrakecaliperfromforkorframeandremovethecalipermountingbracketandCPShardwarefromthecaliper.Setasideincorrectorder(notpictured).

brake pad and h-spring removalUsingneedle-nosedpliers,graboneofthepadtabsandslidethepadtowardthecenterofthecaliper(thisdisengagesthepadbackingplatefromthepostinthecenterofthepiston),thenpullthepadstraightout.Repeatforotherpad.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.

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

brake pad and h-spring removal (cont)Removethespringpadclipfromtheoutsideofthecaliper.

brake hose/banjo bolt removal and serviceUsingan8mmopen-endorboxwrench,loosen banjo bolt. Brake fluid will leak, so hold over a container to catch fluid.Pullbanjoboltcompletelyoutofcaliper.Dump all caliper brake fluid into container.Removeo-ringsoneachsideofbrakehosebanjoandreplacewithnewo-rings.Insertbanjoboltbackintobrakehosebanjo.Ensureoutsidebanjoo-ringisnotdamagedbybanjoboltthreads.Thismaycausealeak.Sethoseandbanjoboltaside.

caliper disassembly and serviceLoosenallthreecaliperbodyboltswitha4mmhexwrench.Therearethreedifferentboltlengths.Setasideincorrectorder.Separatecaliperbodyhalvesandopencaliperassembly.Usingasharppick,removesmallbanjohole(bodyhalf)o-ring.

brake pistons removal and serviceInboardCaliperBodyHalf:Usinganaircompressorchuck,insertchucknozzleintobanjobolthole.Holdcaliperinonehand,pointingcaliperpistoninasafedirection.Squeezetheairchuckandforceairintothebanjoboltholewhileholdingcaliperbody.Compressedairunseatsthecaliperpistonfromthecaliper.Pulloutcompletelyandremovepiston.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 causing injury or becoming lost. OutboardCaliperBodyHalf:Usinganaircompressorchuck,insertchucknozzleintobanjobolthole.Holdcaliperinonehand,pointingcaliperpistoninasafedirection.Hold one finger over the banjo bolt through-holeonoppositesideofcaliperbodysoairdoesnotescape.Squeezetheairchuckandforceairintothebanjoboltholewhileholdingcaliperbody.Compressedairun-seatsthecaliperpistonfromthecaliper.Pulloutcompletelyandremovepiston.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. Removethesquare-edgeo-ringfrominsideeachcaliperbodyhalfwithasharppickandreplacewithnewsquare-edgeo-rings.

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

caliper assemblyInspectcaliperpistonsfordamageandre-placeifnecessary.Re-installcaliperbrakepistonsintoeachhalfofthecaliperbody.Installanewbanjobolto-ringintothebanjoboltholeonoutboardsideofcaliperbody.Insertandthreadcaliperboltintocaliperclosesttobanjobolthole.Ensurenewcali-perbanjobolto-ringisnotunseatedfromitsposition(notpictured).Insertremainingtwocaliperbodyboltsandtightenallthreeboltswitha4mmhexwrenchto4.9-5.9Nm(43-52in-lb).Insertbanjoboltbackintocaliperintobanjobolthole.Hand-threadandtightenwith8mmboxwrenchto4.9-5.9Nm(43-52in-lb).Becarefulnottopincheitheroftheseo-ringsduringinstallation.UsingaT-10Torxwrench,removebanjoboltbleedscrew.Usingasharppick,removebleedscrewo-ring.Thiso-ringmaybealittlehardtosee.Replacewithanewbleedscrewo-ring.Re-installbanjoboltbleedscrewintobanjoboltandtightenwithT-10Torxwrench.

brake pad installationInsertspringpadclipintooutersideofcaliper.Measurethetotalthicknessofeachpad(padbackingplateandpadmaterial).Ifthereislessthan3mmoftotalwidth,re-placebothbrakepads(notpictured).Positiontheh-springbetweenthetwopads.Thecurvedhandleofinnerpadshouldfacetowardinboardsideofcaliper.Squeezethepadandspringassemblytogether,thenfirmly push into the caliper until it ‘clicks’ into place,indicatingitisproperlysecuredinthecaliperbody.

finishing up (not pictured)Visuallycheckyourwork.Inspectbanjoboltandbanjoforanyprotrudingo-rings.Ifthereareanyo-ringsthatare‘squeezed’beyondtheoutsideedgesofthebanjoorbolt,re-moveandreplace.Repeatinstallationsteps.Wipeassembledcaliperwithsoapywatertoremove any brake fluid.Re-installcaliperontobicyclefollowingtheinstallation and torque specifications called outintheusermanual.

this concludes the caliper overhaul service instructions. you have done a great job and are ready to move onto the next chapter, hydraulic disc brake hose length adjustment and bleeding. enjoy!

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HYDRAULIC DISC BRAkE CALIPER OvERHAUL(JUICY ULTIMATE)

INTRODUCTIONAvidcaliperassembliesneedtobeservicedinordertooptimizebrakingfunction.Ifcaliperbrakepistonmotionis‘sticky’orlacksapositiveandsmoothreturn,thecaliperbody/brakepistono-ringmaybeoutofplaceordamaged.Ifyourbrakewas filled with brake fluid other than DOT 4 or 5.1, damage to all rubber and plastic internal parts may exist. Commonly used INCORRECT fluid is mineral oil or DOT 5, which is silicone based. Inspection and/or replacement of these parts, duetoanyoftheabovesituations,willimprovebrakefunction.

CALIPER OvERHAUL SERvICE INSTRUCTIONS

trouble-shooting -‘sticky’ or slow brake pad return feelBeforecompletelydisassemblingyourcaliper,it’sworthtryingtoloosenthestickypiston.Trythefollowing:Clampbicycleinbicycleworkstand.Spinaffectedwheel.Lightlysqueezebrakeleverandwatchbrakepadswhenleverisreleased.Determinewhichsideofthecaliperhasaslowreturn-ingbrakepiston.Removecaliperfrombicycle.Ifyouhaveamountingbracket,itisrecommendedtoremovethattooorjustremovethecaliperleavingthebracketontheforkorframe.Usingapairofneedle-nosedpliers,removebothbrakepadsandh-spring.Usingan11mmboxwrench,pressworkingpistonintocaliperbody.Squeezebrakeleverslowlytomovestickypistonin-ward.Pressthepistonbackintothecaliperagain.Repeatthesestepstocorrectcaliperpistoninnero-ringposition.Bothpistonsshouldnowbemovingfreely.Re-installh-springandpadsintocaliper.Re-installcaliperontobicycle.Spinwheelandcheckfunction.Ifthereisnoimprovement,con-tinuewithcaliperservice.

getting startedRemovebrakecaliperfromforkorframeandremovethecalipermountingbracketandCPShardwarefromthecaliper.Setasideincorrectorder(notpictured).

brake pad and h-spring removalUsingneedle-nosedpliers,graboneofthepadtabsandslidethepadtowardthecenterofthecaliper(thisdisengagesthepadbackingplatefromthepostinthecenterofthepiston),thenpullthepadstraightout.Repeatforotherpad.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.

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

brake piston installationInspectcaliperpistonsfordamageandreplaceifnecessary(notpictured).Installinboardpistonthroughthepadopen-ing, pressing it flush into the caliper body withan11mmboxwrench.Installpistoncapthroughpadopening.Usingan8mmhexwrench,threadpistoncapcounterclockwiseuntilsnugintocaliperbody.Installtheoutboardpistonthroughthepadopening and press it flush into the caliper bodywithan11mmboxwrench.UsingaT-10Torx,installcaliperbodyas-semblybleedscrew.

brake hose/banjo bolt installationInsertbanjoboltbackintocaliperbanjoboltholesettingthebanjoangletothedesiredangle.Hand-threadandtightenwith8mmboxwrenchto4.9-5.9Nm(43-52in-lb).Becarefulnottopinchthebanjobolto-ringdur-inginstallation.UsingaT-10Torxwrench,removebanjoboltbleedscrew.Usingasharppick,removebleedscrewo-ring.Thiso-ringmaybealittlehardtosee.Replacewithanewbleedscrewo-ring.Re-installbanjoboltbleedscrewintobanjoboltandtightenwithT-10Torxwrench.

brake pad installationMeasurethetotalthicknessofeachpad(padbackingplateandpadmaterial).Ifthereislessthan3mmoftotalwidth,re-placebothbrakepads(notpictured).Positiontheh-springbetweenthetwopads.Thecurvedhandleofinnerpadshouldfacetowardinboardsideofcaliper.Squeezethepadandspringassemblytogether,thenfirmly push into the caliper until it ‘clicks’ into place,indicatingitisproperlysecuredinthecaliperbody.

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3CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

brake hose/banjo bolt removal and serviceUsingan8mmopen-endorboxwrench,loosen banjo bolt. Brake fluid will leak, so hold over a container to catch fluid.Pullbanjoboltcompletelyoutofcaliper.Pour all caliper brake fluid into container.Removeo-ringfrombrakehosebanjoandbanjoboltandreplacewithnewo-rings.Insertbanjoboltbackintobrakehosebanjo.Ensureoutsidebanjoo-ringisnotdamagedbybanjoboltthreads.Thismaycausealeak.Sethoseandbanjoboltaside.

brake piston removal and serviceUsingan11mmboxwrench,gentlypushoutboardpistonintocaliperbodyuntilitisflush with the inside of the caliper. Gently press a flathead screwdriver against theoutboardpistonwhilepointingthecali-perinasafedirection(youwanttoremovethe inboard piston first, so you need to hold theoutboardpistoninplace).Usinganaircompressorchuck,insertchucknozzleintobanjoboltthroughhole.Squeezetheairchuckandforceairintothebanjobolthole.Compressedairunseatstheinboardcaliperpistonfromthecaliper.Pullthepistonoutofthecaliperbodythroughpadopening.note: you may need to use a pair of needle nosed pliers to pull the piston out of the caliper body. be careful not to scratch the piston. if you scratch the piston, you will need to replace it.important: be sure to point the caliper in a safe direction. you may want to do this inside a plastic bag to prevent the piston from causing injury or becoming lost. Usingan8mmhexwrench,turnthepistoncapclockwisetopushtheoutboardpistonintoandoutofthecaliperbody.Pullthepistonoutofthecaliperbodythroughthepadopening.Pressthepistoncapintothecaliperbodyandremovethroughthepadopening.Usingasharppick,removethepistoncapo-ringandreplacewithanewo-ring.Usingasharppick,removetheinboardandoutboardquadsealo-ringsfromthecaliperbodyandreplacewithnewo-rings.note: when installing the new quad seal o-rings, use the flat side of a pick to seat the o-ring into the o-ring groove by moving it around the entire seal.UsingaT-10Torx,removecaliperbodyas-semblybleedscrew.Usingasharppick,removebleedscrewo-ringandreplacewithanewone.

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HYDRAULIC DISC BRAkE CALIPER OvERHAUL(CODE)

INTRODUCTIONAvidcaliperassembliesneedtobeservicedinordertooptimizebrakingfunction.Ifcaliperbrakepistonmotionis‘sticky’orlacksapositiveandsmoothreturn,thecaliperbody/brakepistono-ringmaybeoutofplaceordamaged.Ifyourbrakewas filled with brake fluid other than DOT 4 or 5.1, damage to all rubber and plastic internal parts may exist. Commonly used INCORRECT fluid is mineral oil or DOT 5, which is silicone based. Inspection and/or replacement of these parts, duetoanyoftheabovesituations,willimprovebrakefunction.

CALIPER OvERHAUL SERvICE INSTRUCTIONS

trouble-shooting -‘sticky’ or slow brake pad return feelBeforecompletelydisassemblingyourcaliper,it’sworthtryingtoloosenthestickypiston.Todoso,trythefollowing:Clampbicycleinbicycleworkstand.Spinaffectedwheel.Lightlysqueezebrakeleverandwatchbrakepadswhenleverisreleased.Determinewhichsideofthecaliperhasaslowreturningbrakepiston.Removecaliperfrombicycle.Ifyouhaveamountingbracket,itisrecommendedtoremovethattooorjustremovethecaliperleavingthebracketontheforkorframe.Removee-clipfromguidepingrooveontopofthecaliperusingasharppick.Usinga2.5mmhexwrenchremovetheguidepinfromthecaliper.Pullandremovebothbrakepadsandh-spring.Usinga10mmboxwrench,pressworkingpistonintocaliperbody.Squeezebrakeleverslowlytomovestickypistoninward.Pressthepistonbackintothecaliperagain.Repeatthesestepstocorrectcaliperpistoninnero-ringpistion.Bothpistonsshouldnowbemovingfreely.Re-installspringpadclip,h-spring,andpadsintocaliper.Re-in-stallcaliperontobicycle.Spinwheel,checkfunction.Ifthereisnoimprovement,con-tinuewithcaliperservice.

getting startedRemovebrakecaliperfromforkorframeandremovecalipermountingbracketandCPShardwarefromcaliper.Setasideincor-rectorder(notpictured).

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

finishing up (not pictured)Visuallycheckyourwork.Inspectbanjoboltandbanjoforanyprotrudingo-rings.Ifthereareanyo-ringsthatare‘squeezed’beyondtheoutsideedgesofthebanjoorbolt,re-moveandreplace.Repeatinstallationsteps.Wipeassembledcaliperwithsoapywatertoremove any brake fluid.Re-installcaliperontobicyclefollowingtheinstallation and torque specifications called outintheusermanual.

this concludes the caliper overhaul service instructions. you have done a great job and are ready to move onto the next chapter, hydraulic disc brake hose length adjustment and bleeding. enjoy!

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

brake pads and pad h-spring removalRemovee-clipfromguidepingrooveontopofthecaliperusingasharppick.Usinga2.5mmhexwrenchremovetheguidepinfromthecaliper.Squeezethepadstogethersotheyclearthepistons,andpulltoremovebrakepadsandh-springfromcaliper.

caliper disassembly and serviceUsinga4mmhexwrench,loosenallfourcaliperbodyboltsuntilthereisslightgapinthecaliperhalves.Thiswilleasebanjoboltremoval.Usingtwo4mmhexwrenches,loosenandremovethebanjosleeveboltandbanjoshoulderbolt.Completelyremoveallfourcaliperbodybolts,separatethecaliperbodyintoitstwohalvesandremovethebanjo.Usingasharppick,removetheo-ringsfromunderneaththeheadsofboththebanjosleeveboltandbanjoshoulderboltandreplacewithnewo-rings.Usingasharppick,removethebanjoo-ringsonboththerightandleftsideofthecaliperhalvesandreplacewithnewo-rings.

brake piston removal and serviceUsinganaircompressorchuck,insertchucknozzleintobanjobolthole.Holdcaliperinaraginonehand,usingyourthumborfinger to seal the backside of the banjo bolt hole.Squeezetheairchuckandforceairintothebanjobolthole.Thecompressedairwillunseatthecaliperpistonfromthepistonpockets.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 cal-liper 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 pis-ton pocket and seal the top of the extension with your thumb. repeat step 10 to remove the last piston.Removethesquareedgeo-ringfrominsideeachpistonpocketusingasharppickandplacewithnewo-rings.RemovebothbanjoboltbleedscrewsfromthetopofthecaliperbodyusingaT-10Torxwrench.Removetheo-ringsfromthebleedscrewsandreplacewithnewo-rings.

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

caliper assemblyInspectthecaliperpistonsfordamage,andreplaceifnecessary.Insertthecaliperbrakepistonsbackintoeachhalfofthecaliperbody.note: gently rolling the pistons clockwise as you install will help with installation.Placebanjosleeveboltintothelefthalf(outboardside)ofthecaliper.Slidebanjoontothesleeveboltandsetthebanjoangletothedesiredangle.Alignbothcaliperhalvestogetherandinsertthebanjoshoulderboltandthefourcaliperbodybolts.Usingtwo4mmhexwrench,tightenthebanjoboltto2.9-3.4Nm(26-30in-lb).Usinga4mmhexwrenchtightenthecaliperboldyboltsto5.9-6.3Nm(52-56in-lb).UsingaT-10Torx,installthetwobleedscrewsbackintothetopofthecaliperbodyandtightento.6-.7Nm(5-6in-lb).

brake pad installationInspectandmeasureeachbrakepad.Ifthereislessthan3mmoftotalpadthick-ness(padbackingandpadfrictionmaterial),replacebothbrakepads(notpictured).Positiontheh-springbetweenthetwopads.note: the code pads are symmetrical, there is not a left or right orientation.Locatethe“padinstallation”featureofthepadspacertool.Insertthepadhandlesintothe“padinstallation”toolsoitholdsthepadstogether.Insertthepadsandpadtoolintothecaliperuntiltheholesinthetopofthepadsarealignedwiththeguidepinholesinthetopofthecaliper.Inserttheguidepinthroughthecaliperbodyhalvesandthebrakepads.Usinga2.5mmhexwrench,tightentheguidepinto1.5-1.9Nm(13-17in-lb).Removethepadtool.Theh-springwillsnapthepadsintoposition.Using your thumb or finger, install the e-clip intothegrooveontheendoftheguidepin.

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CALIPER OvERHAUL SERvICE INSTRUCTIONS (CONT)

finishing up (not pictured)Visuallycheckyourwork.Inspectbanjoboltandbanjoforanyprotrudingo-rings.Ifthereareanyo-ringsthatare‘squeezed’beyondtheoutsideedgesofthebanjoorbolt,re-moveandreplace.Repeatinstallationsteps.Wipeassembledcaliperwithsoapywatertoremove any brake fluid.Re-installcaliperontobicyclefollowingtheinstallation and torque specifications called outintheusermanual.

this concludes the caliper overhaul service instructions. you have done a great job and are ready to move onto the next chapter, hydraulic disc brake hose length adjustment and bleeding. enjoy!

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BALL BEARING DISC BRAkE CALIPER OvERHAUL(BB7)

INTRODUCTIONAvidcaliperassembliesneedtobeservicedinordertooptimizebrakingfunction.Ifcaliperbrakepistonmotionis‘sticky’orlacksapositiveandsmoothreturn,thecaliperbody/brakepistono-ringmaybeoutofplaceordamaged.Inspectionand/orreplacementoftheseparts,duetoanyoftheabovesituations,willimprovebrakefunction.

important: avid’s ball bearing disc brake calipers are a one piece body that incorporate two truss bolts for strength. these bolts have tamper-proof heads and are not to be removed for any reason!

CALIPER OvERHAUL DISASSEMBLY SERvICE INSTRUCTIONS

trouble-shooting (not pictured)ThemostcommonissuewiththeBB7isthattheoutboardpressurefootcanbecomedislodgediftheoutboardadjustmentknobisturnedtoofarclockwisewithouttherotorinthecaliper(wheelofforcaliperremoved).Thebrakeisnotbroken,nordoesitrequiredisassemblytoreplacethepressurefoot.Toreplacethepressurefoot,turntheout-boardadjusterknobcounter-clockwiseuntilitstops.Iftheknobdoesn’tstop,thenthefootscrew(theendofwhichcanbeseeninthecenteroftheknob)hasbecomedisen-gagedfromtheknobandpossiblyfromthethreadsinsidethedrivecam.Inthiscase,removetheknob,thenusingapairofsmallneedle-nosedpliersoraschradervalvetool,turnthethefootscrewallthewaybackoutuntilitstops.Nowthepressurefootcanbereplaced.Relocatethepressurefootinto the bore, then give it a firm push in the center.Itwillclickbackintoplace.Ifyoure-movedtheknob,replaceitandyou’redone!

getting startedRemovethecableanchorboltandplate,thenpullthecablehousingandinnerwirefreeofthecaliper.

remove the outboard knobTurntheoutboardpadknobcounter-clock-wiseuntilitstops,thenturnbackclockwisethreefullturnstorecessthefootscrewintheknob.note: turning the outboard knob more than three full turns can dislodge the outer pressure foot from the drive cam. if this happens, proceed with removing the knob. af-ter step 4, the pressure foot can be pressed back into place.

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CALIPER OvERHAUL DISASSEMBLY SERvICE INSTRUCTIONS (CONT)

remove the outboard knob (cont)Remove the knob with a small flat-head screwdriver.Becarefulnottomarthesur-faceofthetorquearm.Turnthefootscrewwhichisnowexposedcounter-clockwiseuntilitstops.

install pad spacerTurntheinboardadjustercounter-clockwiseuntilthereisenoughclearancebetweenthepadsfora2mmpadspacer.Insertthespacer,thenturntheinboardknobclock-wiseuntilitstops.Checkthetorquearmformovement.Ifitmoves,turnthefootscrewclockwiseuntilitissecure.note: if you need to fabricate a pad spacer, use cardboard or something similar that will not damage the surface of the brake pad.

remove torque armPlaceyourthumboverthespringloadedtorquearmandholdsecurely.Remove the torque arm fixing nut using an 11mmwrench.Whilecontinuingtoholdthetorquearm,remove the indexed washer and flat washer.Removethetorquearm,springadjuster,outerbodyseal,andspringalltogether.Thenremovethehex-holewasher.Tipthebikeandallowthelockringretainertofallintoyourhand.

remove lockring and camsUsingtheAvidMDT-1LockringToolanda3/8driveratchet,breakthelockringfree.Thenusinga5mmhex,removethecaliperfromthebike.UsingtheMDT-1byhand,completelyre-movethelockring.Pulloutthecam/outboardpressurefootas-sembly.Oncethisassemblyisout,removethepadsandpadspacerfromthecaliper.

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CALIPER OvERHAUL DISASSEMBLY SERvICE INSTRUCTIONS (CONT)

remove pressure foot and inner body sealUsing a small flat-head screwdriver, remove theinboardadjusterknob.Turntheinboardpressurefootclockwiseun-tilitisfree.Removepressurefootthroughthemainbodybore.Thereisasplitinthebodysealwhichaidsininstallaionandremoval.Engagethesealatthesplitwithasmallsharptoolandcare-fullyremoveit.

cam disassemblyLift the fixed cam off the drive cam. Be carefulnottoloseanyofthethreeballbear-ings.Usesmallneedle-nosedpliersoraschradervalvecoretooltoturnthefootscrewuntilitiscompletelyunthreadedfromthedrivecam.

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CALIPER OvERHAUL CLEANING & INSPECTION INSTRUCTIONS

cleaningCleanallmetalpartsinsolvent,includingthecableanchorboltandplate.Cleanthecablesealboots,outercaliperbodyseal,andinnerbodysealinmildsoapandwater.Rinseanddryallpartscompletely(notpictured).

caliper body inspectionInspectthecaliiperbodyforanydamage;paycloseattentiontoallthreadedsurfacesandthepadretainerclipinthetopofthecaliperbody.

small part inspectionCheckballbearingandcamrampsforex-cessivewear.note: it is normal to see ball tracks in the cam ramps.Checkthethreadsofthedrivecam,footscrew,lockring,innerpressurefoot,cableanchor bolt, and torque arm fixing nut for damage.Checkthespringforanysignsofdamage.

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CALIPER OvERHAUL ASSEMBLY SERvICE INSTRUCTIONS

small part inspection (cont)Checktheinnerbodyseal,outerbodyseal,andcablesealbootsfornicks,tears,orcracking.

assemble caliperOrienttheinnerbodysealwiththegroovefacingdown.Insertthesealintothemainbodybore.Locatethesealintoitsrecessand seat it completely with your finger.Verylightly,greasetheentirebodyboreincludingthelockringthreads,theinnerpressurefootthreads,andtheinnerknobdetents.Droptheinnerpressurefootinthroughthemainbodybore,thenthreaditcounter-clockwiseuntilitbottomsout.Installtheinboardadjusterknobbylininguptherectangulartabonthebackofthepressurefootwiththeholeintheknob,thenpressing it on firmly.Re-mountthecaliperontothebike.Installthepadsandspacerintothecaliperandturntheinboardadjusterknobclock-wisetolockintoplace.

assemble camVerylightly,greasethefootscrewthreads,tipofstem-endonouterpressurefoot,andthe ramps of the drive cam and fixed cam.Usingsmallneedle-nosedpliersoraschradervalvetool,threadthefootscrewintothedrivecamcompletely,butdonottighten.Engagethestem-endoftheouterpressurefootintotheholeintheendofthedrivecamand install by firmly pressing it straight in.Placetheballbearingsintotherampsofthe drive cam, then install the fixed cam overtheshaftofthedrivecam.Rotatethecamsagainsteachothertoensuretheballbearingsareseatedproperlyinbothsetsoframps.

install cam assembly and lockringHoldthecamassemblybythedrivecamwhile keeping pressure on the fixed cam with your thumb and index finger. This serves two functions: first, it keeps the ball bearingsproperlypositionedintheirrampsandsecond,itensuresthedrivecamisnotpushedpasttheinnerbodyseal.Ifthedrivecamispushedpasttheinnerbodysealandthenpulledback,theedgeoftheinnerbodysealrollsback.Ifthisoccurs,thesealmustbereplaced.

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CALIPER OvERHAUL ASSEMBLY SERvICE INSTRUCTIONS

install cam assembly and lockringAlign the tab on the fixed cam to the corre-spondinggrooveinthecaliperbody.Installtheassembly,beingsuretopressitinbythefixed cam, not the shaft of the drive camsInstallthelockringbyhandwiththeMDT-1tool.TorquethelockringwiththeMDT-1toolto140-150in-lb.Installthelockringretainer,aligningthetabon the retainer with the cut-out in the fixed cam.

install spring adjusterPlacethehex-holewasheroverthedrivecam shaft, engaging the flats on the shaft.Applyahigh-strengththread-locksuchasLoctite272tothedrivecamthreads.Becarefulnottoallowanythread-locktoentertheareaaroundthefootscrew.Installthespringwiththelongspringtabengaging the hole in the fixed cam.Placetheouterbodysealonthespring,engagingthespringtabintotheholeintheboot.Turnthespringadjusterscrewcounter-clockwise until the bottom is flush with the bottomoftheadjuster.Theninstallthespringadjusterontopoftheouterbodyseal,engagingthespringtabintotheholeinthespringadjuster.

important: part & tool orientationtake a moment to arrange and orient the flat washer, detent washer, and torque arm fixing nut for installation. this will make them much easier to install while holding the spring-loaded torque arm in place. after the torque arm is on, the installation order will be as stated - flat washer, detent washer, then torque arm fixing nut. of these pieces, the detent washer is the only one with a “right-side up” and “up-side down” orienta-tion. look at the detent washer profile. there is a sharp edge and a rounded edge. the rounded edge goes up. this allows the outboard adjustment knob to be installed fairly easily as it is pressed on over the rounded outer edge, while the sharp inner edge keeps it firmly in place.

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CALIPER OvERHAUL ASSEMBLY SERvICE INSTRUCTIONS

install torque armInstallthetorquearm,aligningthespringadjustertabandscrewwiththerelievedareaonthebackofthetorquearm.Whenengagedcorrectly,thespringadjusterscrewwillbedrivenagainsttheshelfonthebackofthetorquearm.Pressthetorquearmonto the flats of the drive cam shaft. Make sure the arm is fully seated and hold firmly withyourthumb.Place the flat washer over the drive cam shaftandagainstthetorquearm.Placethedetentwasheroverthedrivecamshaft and against the flat washer with the roundededgeup.Thread on the torque arm fixing nut by hand, thentorqueto55-60in-lb.important: do not over tighten the torque arm fixing nut.

install outer knobInstalltheoutboardadjusterknobbyalign-ingtherectangletabofthefootscrewwiththerectangularholeinthetheknob,thenpress it on firmly.Pushtheupperandlowerbootsontotheintegratedcablestop.Placethecableanchorplateonthecableanchorbolt,greasetheboltlightlyandinstallintothetorquearmTurnbothpadadjusterknobscompletelycounter-clockwiseandremovethepadspacer.SetupthebrakebyfollowingtheproceduresintheAvidBallBearingDiskBrakeInstal-lationGuidelines.Besuretotorquetothepropervalue.

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HYDRAULIC DISC BRAkE HOSE LENGTH ADJUSTMENT

&BLEEDING

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 asyoucanimagineyourselfpullingtheleverwhileyou’reriding)severaltimes.Checkthatthecaliperclosesandreturnsproperly. Make one last check of all the bolts and fittings.

Ifeverythingchecksout,YOU ARE READY TO RIDE!

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HYDRAULIC DISC BRAkE HOSE LENGTH ADJUSTMENT & BLEEDING

(JUICY 3, 5, 7, CARBON, ULTIMATE - CODE)

INTRODUCTIONAvidbrakescomewiththehosesattachedandbled.Ifyoudon’tneedtochangethehoselength,thenyoushouldnotneedtobleedthesystemagain.Bleedingisoneofthemostimportantstepsintoppingofftheperformanceofanyhydraulicbrakesystem.Anyairinsideahydraulicbrakesystemdegradestheperformanceofthebrake.Thegoalofbleedingistoremovetheairthatistrappedinthehoses,caliperorlever.WhenyoubleedAvidbrakesyouremovemoreairthananyotherbrake’sbleedingproceduredoes.ThatisoneofthereasonswhyAvidbrakesarethemostpowerfulandprecisehydraulicbrakesonthemarket.

CHANGING HOSE LENGTHS

here are the parts that you’ll be dealing with in the hose adjustment and bleeding process. please take the time to familiarize yourself with the pictures at the right.

re-check hose routingSinceyoucan’tlengthenthehoseafteryouhavecutit,takeamomentandre-checktheroutingofthehoses.Besuretoaccountforsuspensionmovementandcheckthatthebarsturnfreelybyturningthebarsallthewayfromsidetoside.Makesurethehosesareproperlysecuredaswell.

remove hose from leverIfyourmodelhasaboot,pullitawayfromthelever,thenuseacrow’sfootwrenchtounscrewthehosecompressionnut.Ifthebootsticks,carefullypullacornerofthebootupwithsomethingthatwon’tharmit(likeapenciltip)andsprayalittlealcoholbetweenthebootandthelever.Onceyouworkthealcoholinalittle,thebootshouldloosenup.Pullthehosefromthelever.Wigglethehoseifnecessary.BecarefultospillaslittleDOTfluid as possible. Any DOT that drips out will createbubblesthatyou’llhavetoeliminatelater.Slidethenutandboot(ifapplicable)downthehoseandawayfromtheendwhereyou’llbecutting.Becarefulnottoengagetheleverwhilethehoseisremoved(notpictured).

determine proper hose length & cutDeterminewhereyouneedtocutthehosebyholdingituptotheleverinthepositionyouwouldlikeit.Thegrooveinthelevernosemarksthespotwhereyouwillcutthehose.Makesuretoleaveagentlecurveinthehose,withenoughlengthtofreelyturnthehandlebar.Double-checkthispart,be-causeyoucan’tgobackafteryoucut.

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CHANGING HOSE LENGTHS (CONT)

Cutthehoseusinghydraulichosecutters(notpicutred).note: code only - while we recommend you adjust the hose length on the lever end of the hose, you can adjust the caliper end of the hose by following the same basic proce-dure.

install new fittingsWhile holding the hose firmly, thread a new hosebarbintotheendofthehoseusinga2.5mmhexwrench.Slide a new compression fitting over the end ofthehosewiththenewhosebarb.

re-install the hosePush the hose firmly into the lever until it stops.Whileholdingthehoseinplace,slidethecompression fitting and compression nut up to the lever, then finger-tighten the nut. You mayneedtowigglethehose.Whilecontinuingtopushthehoseintotheleverbody,usethenutwrenchtotightenthecompressionnut.Whenyoufeelthecompression nut hit the compression fitting, tightenapproximatelyanother1½turns,atwhichpointyouwillfeelthecompressionnut bottom out. If your compression fitting isalloy,tightento5Nm(47in-lb).Ifyourcompression fitting is steel, tighten to 7.8Nm (70in-lb).Slidetheboot(ifapplicable)backintoplace(notpictured).

important: cutting down the hose intro-duces a small amount of air into the system, which can degrade the performance of your brakes. at this point, it is necessary to bleed the brakes to restore them to optimal per-formance. please continue onto “bleeding procedures”.

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crow’s foot 90° to torque wrench

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BLEEDING PROCEDURE

remember, when bleeding the brakes, you are simply chasing bubbles out of the system, so gravity is your friend (liquid is heavier than gas, so bubbles always tend to rise). avid’s bleeding procedure allows the isolation of the caliper so it can be bled completely air free. then, by pushing fluid from the caliper up to the lever, you remove any air in the hydraulic line. from there, it’s just a matter of purging those bubbles out of the reser-voir.

prepare the syringesFillonesyringe½fullwithAvidHi-Perfor-mance DOT fluid and close the hose clamp. Leavetheothersyringeemptyandopen.De-gas the fluid in the ½ full syringe (get-ting all the air out of the fluid now gives you theultimatebrakebleed).Todothis,leavethehoseclampclosedandpulldownontheplunger.Youwillseebubblesappearfrom nowhere in the fluid. That is all the air trapped in the fluid. Pull on the plunger severaltimes.Whenthebubblestopform-ingopentheclampandcarefullypushtheexcessairandgasout.Trytappingthesy-ringeasyoupull,toreleasemorebubbles.Repeatseveraltimes.note: be careful not to pull too hard or you will pull air past the seal of the syringe. you cannot eliminate all of the bubbles in the fluid. after you have pulled a few times and the number of bubbles decreases, you are ready to move onto step 3.

prepare the caliper and the leverUsetheT-10Torxwrenchtoremovethecaliperbleedportscrewfromthecenterofthebanjobolt.note: the code caliper features two bleed screws on either side of the banjo fitting. it is recommended that you use the bleed port on the left side of the banjo fitting during normal bleeding.Make sure the fluid in the ½ full syringe is pushedallthewaytothetip(noairgap),thenscrewthesyringeintothecaliperbleedport.important: ensure the reach adjuster is not adjusted so far out that the lever blade is bottomed out on the lever body. doing so can make bleeding the brake impossible.FormodelswithPadContact-PointAdjust-ment,turnitallthewaytotheoutposition(notpictured).note: this does not apply to juicy three or five, as they do not have this feature.

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Usinga4mmhexwrench,slightlyloosentheleverclampbolt(s)thenrotatetheleversothebodyoftheleverpointsstraightdown(perpendicular to the floor). You will need to loosenyourshiftertoallowthebrakeleverdowntothisposition(notpictured).Removethebleedportscrewandinstalltheemptysyringe,leavingtheclamponthesyringeopen.Squeezetheleverclosed(againstthebar)andfastenitwitharubberband.Thisclosesoffthemastercylinderandisolatesthecaliper,allowingtheremovalofanyairfromthecaliperonlybeforemovingontotherestofthesystem.

bleed the caliperOpenthecalipersyringeclamp(notpic-tured).Gentlypushthesyringeplungeroutwithyourthumb.Ifthereisairinthecaliper,thisdrawsitbackintothesyringe.Releasetheplungertoreplacethebubblesyoujustremoved with fluid. Tapping on the caliper withanon-marringinstrumentwhileper-formingthisprocesshelpsbubblesmoveoutintothesyringe.Repeattheprocessuntilnomorebubblesaredrawnfromthecaliper.Oncethisisaccomplished,closedthecalipersyringeclamp.note: be careful not to pull the plunger out too hard, or you will suck air past the seals.

bleed the hoseRemovetherubberbandtoreleasetheleverblade(notpictured).Whileholdingthecalipersyringeuptoprevent bubbles from floating back into the system,openthecalipersyringeclampandforce fluid from the caliper syringe up to the leversyringe.Dothisuntiltheleversyringeisapproximately¼full.Closetheleversyringeclamp,thenthecalipersyringeclamp.Atthispoint,youaredoneatthecaliperend.Removethecalipersyringeandre-installthebleedportscrew.Haveapapertowelreadytocatchany small amount of fluid that may come outoftheportwhenremovingthesyringeandre-installingthescrew.Oncethescrewisinstalled,washthecaliperwithwatertodeactivate and DOT fluid.

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BLEEDING PROCEDURE (CONT)

bleed the lever (master cylinder and reser-voir)Drawagentlevacuumontheleversyringebypullingonthesyringeplunger.Thispullsairbubblesoutofthereservoir.Releasetheplungertoreplacethebubblesyoujustremoved with fluid.Tappingontheleverwithanon-marringinstrumentwhileperformingthisprocesshelpsbubblesmoveoutintothesyringe.Youshouldalsosqueezethelever(likeyouarebraking)afewtimeswhilebleeding.Repeattheprocessuntilnomorebubblesaredrawnfromthelever.Oncetheleverisbubblefree,closethesyringeclamp(notpictured).Withthesyringestillattached,rotatetheleverup90°,sothattheleverbodyisparal-lel with the floor, and the bleed port (and sy-ringe)arepointedstraightup.Now,unscrewthesyringefromthebleedport.Place a couple drops of DOT fluid on top oftheopenportandreplacethebleedportscrew.Haveapapertowelreadytowickupany fluid that may well up in the port. Once thescrewisinstalled,washtheleverwithwater to deactivate and DOT fluid.Rotatetheleverbacktoridingpositionandre-torqueasfollows:JuicyFive/Seven/Carbon/Ultimate/CODEtorqueto2.8-3.4Nm(25-30in-lb)JuicyThreetorqueto3-5Nm(30-40in-lb)Rotateshiftersbacktoridingpositionandre-torque to manufacturer’s specifications (notpictured).

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COMPLETING HYDRAULIC DISC BRAkE HOSE ADJUSTMENT & BLEEDING

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 youcanimagineyourselfpullingtheleverwhileyou’reriding)severaltimes.Makesureandlookaroundthehosenutonthe lever, and the banjo bolt on the caliper for any leaks. Make one last check of all the bolts and fittings.

Ifeverythingchecksout,YOU ARE READY TO RIDE!

important: empty the syringes into a sealed container and dispose of the fluid properly. do not reuse this fluid! do not leave the hose clamps closed (this will damage the clear tubing on the syringes)!

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DISC BRAkEPAD REPLACEMENT

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2

DISC BRAkE PAD REPLACEMENT(JUICY 3, 5, 7, CARBON, ULTIMATE)

INTRODUCTIONAvidbrakepadsshouldbereplacedwhenthetotalthicknessofthebackingplateandpadfrictionmaterialislessthan3mm.Replacingwornbrakepadswillimprovebrakingperformance.Newbrakepadsaresubjecttoa“break-in”period.Itmaytakeanywherefrom20to40completestopstobreakinAvidpads.Youmaybegintonoticeanincreaseinbrakingpower after the first ride. Brake noise can occur during the break-in period, as well as off and on throughout the life of the brakepads.Thisisnormalandshouldnotaffectbrakingperformance.Noiseisdependentuponfactorssuchasbrakesetup,riderweight,ridingstyle,brakingstyle,andridingconditions(i.e.dust,soil,andcontaminationoffrictionsurfaces).

PAD REPLACEMENT

push the pistons back inTheJuicycalipersareselfadjusting.There-fore,thepistonsneedtobepushedbackintotheiroriginalpositioninthebodybeforethenewpadscanbeinstalled.Thebestwaytodothisiswiththeoldpadsstillinthecaliper to protect the pistons. Place a flat-bladescrewdriverbetweentheoldpadsandgentlyrockitbackandforth,pushingthepistonsbackintotheirbores(notpictured).

remove the old pads and h-springUsingneedle-nosedpliers,graboneofthepadtabsandslidethepadtowardthecenterofthecaliper(thisdisengagesthepadbackingplatefromthepostinthecenterofthepiston),thenpullthepadstraightout.Repeatforotherpad.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.Removethespringpadclipfromtheoutsideofthecaliper.Inspectandmeasurethetotalthicknessofeachbrakepadwitharuler.Ifthetotalthick-nessislessthan3mm,youneedtoreplacebothbrakepads(notpictured).note: if the backing plate and pad material is thicker than 3mm, you can simply re-install your brake pads as outlined in step 5.

install the new pads and h-springPositiontheh-springbetweenthetwopads.Thecurvedhandleofinnerpadshouldfacetowardtheinboardsideofthecaliper.Squeezethepadandspringassemblyto-gether, then firmly push into the caliper until it‘clicks’intoplace,indicatingitisproperlysecuredinthecaliperbody.

this concludes the disc brake pad replace-ment instructions. you did a great job! you are now ready to ride. enjoy!

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DISC BRAkE PAD REPLACEMENT(CODE)

INTRODUCTIONAvidbrakepadsshouldbereplacedwhenthetotalthicknessofthebackingplateandpadfrictionmaterialislessthan3mm.Replacingwornbrakepadswillimprovebrakingperformance.Newbrakepadsaresubjecttoa“break-in”period.Itmaytakeanywherefrom20to40completestopstobreakinAvidpads.Youmaybegintonoticeanincreaseinbrakingpower after the first ride. Brake noise can occur during the break-in period, as well as off and on throughout the life of the brakepads.Thisisnormalandshouldnotaffectbrakingperformance.Noiseisdependentuponfactorssuchasbrakesetup,riderweight,ridingstyle,brakingstyle,andridingconditions(i.e.dust,soil,andcontaminationoffrictionsurfaces).

PAD REPLACEMENT

remove old brake pads and h-springRemovee-clipfromguidepingrooveontopofthecaliperusingasharppick.Usinga2.5mmhexwrenchremovetheguidepinfromthecaliper.Squeezethepadstogethersotheyclearthepiston,andpulltoremovebrakepadsandh-springfromcaliper.Inspectandmeasurethetotalthicknessofeachbrakepadwitharulerorthepadthick-nessslotonthepadspacertool.Ifthetotalthickness is less than 3mm, or it fits into the slot,youneedtoreplacebothbrakepads(notpictured).note: if the backing plate and pad material is thicker than 3mm or the slot, you can simply re-install your brake pads as outlined in steps 5-10.

install the new pads and h-springPositiontheh-springbetweenthetwopads.note: the code pads are symmetrical, there is not a left or right orientation.Locatethepadinstallationfeatureofthepadspacertool.Insertthepadhandlesintothepadinstallationtoolsoitholdsthepadstogether.Insertthepadsandpadtoolintothecaliperuntiltheholesinthetopofthepadsarealignedwiththeguidepinholesinthetopofthecaliper.Inserttheguidepinthroughthecaliperbodyhalvesandthebrakepads.Usinga2.5mmhexwrench,tightentheguidepinto1.5-1.9Nm(13-17in-lb).Removethepadtool.Theh-springwillsnapthepadsintoposition.Using your thumb or finger, install the e-clip intothegrooveontheendoftheguidepin.

this concludes the disc brake pad replace-ment instructions. you did a great job! you are now ready to ride. enjoy!

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95-5015-004-000, REV. A48

DISC BRAkE PAD REPLACEMENT(BB7)

INTRODUCTIONAvidbrakepadsshouldbereplacedwhenthetotalthicknessofthebackingplateandpadfrictionmaterialislessthan3mm.Replacingwornbrakepadswillimprovebrakingperformance.Newbrakepadsaresubjecttoa“break-in”period.Itmaytakeanywherefrom20to40completestopstobreakinAvidpads.Youmaybegintonoticeanincreaseinbrakingpower after the first ride. Brake noise can occur during the break-in period, as well as off and on throughout the life of the brakepads.Thisisnormalandshouldnotaffectbrakingperformance.Noiseisdependentuponfactorssuchasbrakesetup,riderweight,ridingstyle,brakingstyle,andridingconditions(i.e.dust,soil,andcontaminationoffrictionsurfaces).

PAD REPLACEMENT

remove the old padsTurnbothadjusterknobsallthewayout(counterclockwise),thensqueezethepadtabstogetherandpullbothpadsandpadspringclipstraightoutofthecaliper.Inspectandmeasurethetotalthicknessofeachbrakepadwitharuler.Ifthetotalthick-nessislessthan3mm,youneedtoreplacebothbrakepads(notpictured).note: if the backing plate and pad material is thicker than 3mm, you can simply re-install your brake pads as outlined in step 3 and fol-low the procedures for pad wear adjustment.

install the new pads and springAssemblethespringbetweenthenewleftandrightpads.Alignthespringtothepadasshown.Squeezethebrakepadandspringclip assembly together then press firmly into thecaliperuntilit“clicks”intoplace.Thepadmarked“R”goesonthespokesideofthebrake.

pad wear adjustment (not pictured)TheBB7hasamanualpadwearadjustmentfeature.Youcanusethisfeaturetocompensateforbrakepadwearuntilthepadsneedtobereplacedwithtwoverysimpleadjustments:Turnboththeinboardandoutboardredadjustingknobsclockwiseoneortwoclicksasneededtorestoreyourbraketooptimumsettings.DoNOTuseyourbarreladjustertocompensateforpadwear.Apadwearindicatorisatthecenterofeachknob.Astheknobisturnedin,theindicatorwillretractdeeperintotheknobgivingavisualindicationofapproximatelyhowmuchthepadshaveworn.

this concludes the disc brake pad replace-ment instructions. you have done a great job! you are now ready to ride. enjoy!

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Page 27: 2007 AVID TECHNICAL MANUAL - SRAM Avid... · Disc Brake Pad Change ... © SRAM CORPORATION • 2007 AVID TECHNICAL MANUAL 9 HYDRAULIC DISC BRAkE ... exploded view - juicy 3 lever

www.sram.com www.avidbike.com

WORLD HEADQUARTERS SRAM Corporation 1333 N. Kingsbury St., 4th Floor Chicago, IL 60622 phone: +1-312-664-8800 fax: +1-312-664-8826 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 Shan Rd Shen Kang Hsiang, Taichng County 49 Taiwan R.O.C. phone: +886-4-2561-3678 fax: +886-4-2561-3686


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