technical manual avid 2009

8/3/2019 Technical Manual Avid 2009

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( e n g l i s h )te

chnicalmanual


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sram corporation warrantyExtEnt of LimitEd warranty

SRAM warrants its proucts to be ree rom eects in materials or workmanship or a perio o two

years ater original purchase. This warranty only applies to the original owner an is not transerable.

Claims uner this warranty must be mae through the retailer where the bicycle or the SRAM compo-nent was purchase. Original proo o purchase is require.

LocaL LawThis warranty statement gives the customer speciic legal rights. The customer may also have other

rights which vary rom state to state (USA), rom province to province (Canaa), an rom country to

country elsewhere in the worl.

To the extent that this warranty statement is inconsistent with the local law, this warranty shall be

eeme moiie to be consistent with such law, uner such local law, certain isclaimers an limi-tations o this warranty statement may apply to the customer. For example, some states in the Unite

States o America, as well as some governments outsie o the Unite States (incluing provinces inCanaa) may:

a. Preclue the isclaimers an limitations o this warranty statement rom limiting the statutory rightso the consumer (e.g. Unite Kingom).

b. Otherwise restrict the ability o a manuacturer to enorce such isclaimers or limitations.

Limitations of LiabiLityTo the extent allowe by local law, except or the obligations speciically set orth in this warranty

statement, In no event shall SRAM or its thir-party suppliers be liable or irect, inirect, special,

inciental, or consequential amages.

Limitations of warranty

This warraty ds t appy t prducts that ha b icrrcty istad ad/r adjustd ac -

coring to the respective SRAM technical installation manual. The SRAM user manuals can be oun

online at www.sram.com, www.rockshox.com or www.avibike.com.

This warraty ds t appy wh th prduct has b mdifid.

This warraty ds t appy wh th sria umbr r prducti cd has b dibratyaltere, eace or remove.

This warraty ds t appy t damag t th prduct causd by a crash, impact, abus f th

prouct, non-compliance with manuacturers speciications o usage or any other circumstances in

which th prduct has b subjctd t frcs r ads byd its dsig.

This warraty ds t appy t rma war ad tar. War ad tar parts ar subjct t damag

as a rsut f rma us, faiur t sric accrdig t SRAM rcmmdatis ad/r ridig r

installation in conitions or applications other than recommene.

ExampLs of wEar and tEar:

Dust sas/Bushigs/Air saig -rigs/Gid rigs/Rubbr mig parts/Fam rigs/Rar shcmutig hardwar ad mai sas/Strippd thrads ad bts (aumium,titaium, magsium r

st)/Uppr tubs (stachis)/Bra ss/Bra pads/Chais/Sprcts/Casstts/Shiftr ad

bra cabs (ir ad utr)/Hadbar grips/Shiftr grips/Jcy whs/Disc bra rtrs/Wh

braig surfacs/Bttmut pads/Barigs/Paws/Trasmissi gars/Ts

This warraty sha t cr damags causd by th us f parts f diffrt maufacturrs.

This warraty sha t cr damags causd by th us f parts that ar t cmpatib, suitab

ad/r authrizd by SRAM fr us with SRAM cmpts. This warraty sha t cr damags rsutig frm cmmrcia (rta) us.

avid brakE sErvicEW rcmmd that yu ha yur Aid bras sricd by a quaifid bicyc mchaic. Sricig

Avi brakes requires knowlege o brakes components as well as the special tools an luis use orservice.

Use brake lui shoul be recycle or ispose o in accorance to local an eeral regulations.

NEVER pour brake lui own a sewage or rainage system or into the groun or a boy o water.

This publication inclues traemarks an registere traemarks o SRAM Corporation esignate by the symbols an , respectively.

Copyright SRAM Corporation 2008

For exploe iagram an part number inormation, please reer to the Spare Parts Catalog available on our website at www.sram.com.

For orer inormation, please contact your local SRAM istributor or ealer.Ifrmati ctaid i this pubicati is subjct t chag at ay tim withut prir tic. Fr th atst tchica ifrmati, pas isit ur wbsit at www.sram.cm.

Yur prducts apparac may diffr frm th picturs/diagrams ctaid i this catag.Prouct names use in this ocument may be traemarks or registere traemarks o others.


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Copyright SRAM CORPORATION 2009 AVID TECHNICAL MANUAL 3

tabLE of contEntsGEttinG startEd ..............................................................................................................................................................................................................................5

BRAke ST Yle & SeRvICe CATeGoRIeS.............................................................................................................................................................................................................. 6ToolS neeDeD FoR SeRvICe ................................................................................................................................................................................................................................ 7

HydraULic disc brakELEvEr ovErHaUL .................................................................................................................................................................................9elIxIR R, CR............................................................................................................................................................................................................................................................... 10CoDe 5 - JUICY 3, 5, 7, CARBon, UlTIMATe ..................................................................................................................................................................................................... 13COdE ............................................................................................................................................................................................................................................................................ 19

disc brakEcaLipEr ovErHaUL ..................................................................................................................................................................................................25elIxIR R, CR...............................................................................................................................................................................................................................................................2 6

JUICY 3, 5, 7, CARBon ............................................................................................................................................................................................................................................. 29JUICY UlTIMATe...................................................................................................................................................................................................................................................... 32COdE , COdE 5 ............................................................................................................................................................................................................................................................36BB7 MoUnTAIn & RoAD .......................................................................................................................................................................................................................................4 0

HydraULic disc brakEHosE LEnGtH adJUstmEnt & bLEEd ........................................................................................................................................45elIx IR R, CR - JUICY 3, 5, 7, CARBon, UlTIMATe - CoDe, CoDe 5 .............................................................................................................................................................4 6

disc brakEpad rEpLacEmEnt ..................................................................................................................................................................................................53elIxIR R, CR...............................................................................................................................................................................................................................................................5 4JUICY 3, 5, 7, CARBon, UlTIMATe ...................................................................................................................................................................................................................... 55COdE , COdE 5 ............................................................................................................................................................................................................................................................5 6BB7 MoUnTAIn & RoAD .......................................................................................................................................................................................................................................5 7


4/58

GEN 0000000000362, Rev. A

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!


5/58

5

GEttinG startEd

GEttinG startEd - HELpfUL HintsThe Avi Technical Manual assumes you are perorming a complete overhaul o the entire brakingsystem an separates brake service into our main service categories:

1. hyraulic isc brake lever overhaul2. isc brake caliper overhaul

3. hydrauic disc bra hs gth adjustmt & bdig

4. isc brake pa replacement

You will nee to know what style o brakes you have in orer to service successully service them.Some brakes to o not use all our service categories . I you are unsure o the style o your brakes,

contact your local Avi ealer or assistance.


6/58

GEN 0000000000362, Rev. A

brakE styLE & sErvicE catEGoriEs(aLL brakEs)

The ollowing chart lists the serviceable brake moels in the 200 9 Avi prouct line. It etails each brake moel style an the

corresponing service categories.

i: Yu must bd yur bras if yu rhau th rs ad/r th caiprs a hydrauic disc bra systm.orhauig th rs ad/r caiprs itrducs sma amuts f air it th systm. Faiur t bd th bras t rm

this air ca dgrad th prfrmac f yur bras, which cud ad t srius ad/r fata ijury whi ridig.

brakE modELs

brakE styLE sErvicE catEGoriEs

HydraULicdisc

mEcHanicaLdisc

LEvErovErHaUL

caLipErovErHaUL

HosE adJUst& bLEEd

padrEpLacEmEnt

elIxIR R, CR x x x x x

JUICY 3, 5, 7, CARBon, UlTIMATe x x x x x

COdE, COdE 5 x x x x x

BB7 (Mutai ad Rad) x x x


7/58


tooLs nEEdEd for sErvicE(aLL brakEs)

Th fwig chart is a ist f th ts dd t sric yur 2009 md yar Aid bras. Whi this chart is itdd

to be comprehensive, it is still only a guie. The tools require or each step o service are etaile in the text o each service

section. Keep in min your specifc brakes may not require every tool liste.

tooLsLEvEr

ovErHaULcaLipEr

ovErHaULHosE adJUst &

bLEEdpad

rEpLacEmEnt

safEty/startinG EQUipmEnt

SAFeTY GlASSeS x x x x

APRON x x x x

RUBBeR GloveS x x x x

CleAn RAGS (lInT FRee) x x x x

oIl PAn x x x x

CleAn WoRk AReA x x x x

wrEncHEs/pLiErs

2.5 MM Hex x x4 MM Hex x x x

T-8 ToRx x

T-10 ToRx x x

T-30 ToRx x

8 MM oPen enD oR Box WRenCH x

11 MM oPen enD oR Box WRenCH x

ToRQUe WRenCH x

neeDle-noSeD PlIeRS x x x

SnAP RInG PlIeRS - InTeRnAl x x

e-ClIP Tool (oPTIonAl) x

misc tooLs/kits

AvID BleeD kIT x x x

HYDRAUlIC lIne CUTTeRS oR veRY SHARP

HoUSInG CUTTeRSx

SHARP PICk x x x

ISoPRoPYl AlCoHol x

SMAll AnD lARGe FlATHeADSCReWDRIveRS

x x x

PHIllIPS HeAD SCReWDRIveR x

AIR CoMPReSSoR WITH BloW GUn CHUCk x

SoAPY WATeR x x x

ICe ColD BeveRAGe x x x x


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9/58

9

HydraULic disc brakE

LEvEr ovErHaUL


10/58

GEN 0000000000362, Rev. A0

2 3

ELixir r, cr

introdUction

Aid bra r assmbis d t b sricd i rdr t ptimiz braig fucti. If bra uid is aig frm ay ara f

th bra r assmby, thr may b damag r war ad tar t th itra mig parts. If yur bra was d with uid

oTHeR tha DoT 4 r 5.1, damag t a rubbr ad pastic itra parts may ist. If yur bra was damagd i a crash, thrmay b damag t th r bad ad pushrd assmbis, as w as th husig assmby. Ispcti ad/r rpacmt f

these parts, ue to any o the above situations, will be necessary to restore proper brake unction.

LEvEr ovErHaUL sErvicE instrUctions

gettingstarted

Remove brake lever rom hanlebar. Remove1.

caliper rom ork or rame. I irty, clean with

soapy water an a clean rag. Pull hose boot

o compression nut an slie own hose (not

picture).

Elixir CR: Use an 11 mm open ene wrench to2.

hol the hose stop in place an use an

8 mm open ene wrench to unscrew the hose

compression nut.

Elixir R: Use an 8 mm open ene wrench to

unscrew the hose compression nut.

Unthrea the compression nut completely by

han an slie it own the hose. Pull brake hose

an compression ftting rom lever boy.

Allow any brake lui to rain into a container.3.

Hd r assmby r ctair ad pumplever to remove any brake lui insie lever

assembly.

note: ifthesystemhasbeencontaminatedwiththe

wrongfluid, youwillneedtoflushalltheparts

withsoapywaterandallowtodryfullypriorto

rebuilding. youwillalsoneedtoinstallanewhose.

leverassembly

Ta a fw mmts ad famiiariz yursf

with the internal components o your brake

lever. This will assist you in ientiy ing the

components while you service your brake.

a b cd

j

k

gh

i

f

a. leverbody e. pivotbushing i. reachadjustscrew

b. pistonspring f. leverblade j. leverbolt

c. piston/bladderassembly g. reachadjustspring k. pivotpin

d. snapring h. reachadjustknob

explodedview - elixirr/crleverassembly

e

elixircr elixirr


11/58


LEvEr ovErHaUL sErvicE instrUctions (cont)

removelever

Use a small phillips screwriver an remove the4.

scrw frm th rach adjust b.

Us a 3 mm h ad rm th r bt.5.

Carfuy pu ad rm th rach adjust b6.

an attache spring.

important: pointthereachadjustknobawayfrom

youreyeswhenremoving. thespringispre-loadedandmaypopoutsuddenlywiththeknob.

Pull back on the lever to ully open an7.

isengage the push ro rom the piston. Use a

small hex wrench to push the pivot pin out o the

lever. Pull straight back on the lever blae an

remove.

note: thepivotbushingsmayfalloutofthelever

blade, thisisok. simplyre-insertthemintothelever

blade.

Use long snap ring pliers an remove the snap8.

rig i th r bdy ag with th pist/

blaer assembly.note: thepiston/bladderassemblyisattachedtothe

snapring.

Inspect the blaer or amage. I amage9.

rpac th tir pist/baddr ad sap rig

assembly.

Remove the piston spring. Use a pick to remove10.

an replace both the piston glie ring an o-ring.

do NOT re-install the piston spring at this time.

important: becarefulnottodamagethepistongland

withthepick.

important: donotre-installthepistonspringatthis

time.

lubricat th pist/baddr assmby by11.dippig it it DoT 5 .1 uid ad aw th css

uid t drip ff.

tip: youcanalsousedotcompatiblegreaseasa

lubricant.

4 5 6

7

8 9 10

11


12/58

GEN 0000000000362, Rev. A2


leverinstallation

Use long snap ring pliers an re-install the12.

pist/baddr assmby it th r bdy.

Slie lever blae an push ro assembly straight13.

into lever boy until you hear an auible click

inicating the push ro is ully seate in the

piston.Align the hole in lever blae with the slot in lever14.

bdy ad r-ista th pit pi s it sits ush.

important: makesurethepivotbushingsare

installed.

Sid th rach adjust bt thrugh th pit pi15.

hole an slie the piston spring over the bolt.

Pac th rach adjust b t th sprig,16.

cmprss th sprig, ad sid th rach adjust

knob into place in the lever boy.

Us a 3 mm h t thrad th r bt s th17.

slot in the bolt is aligne with the hole in the

knob.Use a small phillips screwriver an re-install18.

th scrw fr th rach adjust b. Tight

until snug.

thisconcludestheleveroverhaulservice

instructions. youhavedoneagreatjobandare

readytomoveontothenextchapter, hydraulicdisc

brakecaliperoverhaul. enjoy!

12

15

18

16

17

13 14


13/58


2 3 4

codE 5 - JUicy 3, 5, 7, carbon, ULtimatE

introdUction


th bra r assmby, thr may b damag r war ad tar t th itra mig parts. If yur bra was d with uid

oTHeR tha DoT 4 r 5.1, damag t a rubbr ad pastic itra parts may ist. If yur bra was damagd i a crash, thrmay be amage to the lever blae an pushro assemblies, as well as the reservoir cap, blaer an star wheel assemblies.

Ispcti ad/r rpacmt f ths parts, du t ay f th ab situatis, wi b cssary t rstr prpr bra

unction.

LEvEr ovErHaUL sErvicE instrUctions

gettingstarted





picture).

Usig a 8 mm (r 5/16 i wrch) ad sct2.

wrench, loosen an remove compression nut

rom lever boy. Turn counterclockwise to

remove. Unthrea completely by han an slie

compression nut own hose. Pull brake hose


Aw ay bra uid t drai it a ctair.3.

Hd r assmby r ctair ad pump

r t rm ay bra uid isid r

assembly.

note: ifthesystemhasbeencontaminatedwiththe

wrongfluid, youwillneedtoflushallthepartswithsoapywaterandallowtodryfullypriorto


reservoircover/bladderremoval

Using a T-10 Torx (small Phillips screwriver or4.

Juicy 3), rm bth rsrir cr scrws.

Remove reservoir cover cap an blaer rom5.

r assmby. Additia bra uid wi drai

frm r. Hd r r ctair ad aw

uid t drai. St r assmby dw ca

towel (not picture).

Hdig th rsrir cr, rm baddr6.

rom reservoir cover. Replace with new blaer

if ctamiatd ad aig uid.

note: possiblecausesofleakingbladderand/or

reservoirinclude: brakesystemmayhavetoomuch

fluid, bladdermayhavesplit, and/orbladdermaybe

contaminated .

6


14/58

GEN 0000000000362, Rev. A4


reservoircover/bladderinstallation

Isrt w baddr it cr ad sat ush it7.

unersie o reservoir cover. Make sure you

have the correct orientation.

Place reservoir cover an blaer back onto8.

lever boy. Install an tighten cover cap screws

(short screw closest to lever clamp). Tighten

both screws with a T-10 Torx (small Phillips heascrwdrir fr Juicy 3).

bleedscrewsremoval

Use a T-10 Torx wrench to remove both blee9.

screws.

Using a sharp pick, remove both o-rings on10.

blee screws an replace.

Install blee screws back into lever boy.11.

note: forjuicy3, 5pleasemoveontotheleverblade/

pushrodremovalprocedures.

starwheelandwormremovaljuicy7, carbon, &ultimateonly

Remove retaining e-clip with sharp pick or small12.

athad scrwdrir.

Juicy 7, Carb oy :13.

Unthrea star wheel an worm rom lever boy.

Unthrea by han; pull out to remove rom lever

assembly.

or

Juicy Utimat oy:

Unthrea worm rom lever boy using a 2.5 mm

hex.

Using a pick, insert into gear hole, an push14.

bushig ut f r bdy. St star wh/ wrmassembly asie.

note: donotre-installstarwheelandwormgear

backintoleverassemblyatthispoint.

important: replacethestarwheelandwormgear

ifitisdamaged, crackedorbroken, orifyouare

switchingsidesofleverbodyorrotatingbrakelever

toothersideofbar.

leverblade/pushrodremoval

Cd 5, Juicy 5, 7, Carb, Utimat oy:15.

Hdig th r i bth hads, pac yur

thumbs near the pivot an push. The lever gentlysnaps into the open position.

Usig a 2.5mm h wrch (T-8 Tr fr Juicy16.

Carb/Utimat), uthrad r pit st

screw an remove completely.

Using a small hex wrench, push lever pivot pin17.

through lever boy an remove.

7 8 9

10 11 12

13

15 16

17

14

OR

juicy 7, carbon juicyultimate


15/58



leverblade/pushrodremoval (cont)

Juicy 3 oy: Us a 2mm h wrch ad18.

unthrea the lever pushro completely by

turning clockwise. Pull lever blae away rom

lever boy.

or

Cd 5, Juicy 5, 7, Carb, Utimat oy: Pu

lever blae away rom lever boy an removepushro pin rom worm gear. It will pop out.

Remove pushro rom lever. Replace pushro

ust boot i amage. Clean i not amage.

Insert pushro ust boot back onto pushro with

the open en acing the pin an the close en

towar threas. Re-install pushro into lever

blae. Pushro unthreas an threas back into

lever blae (not picture).

important: replaceleverbladeand/orpushrodif

eitherisbentordamaged.

internalsremovalTa a fw mmts ad famiiariz yursf

with the internal components o your brake

lever. This will assist you in ientiying the


18

a b d f h

c e g i

k

a. leverbody f. secondaryseal k. lever

b. spring g. snapring

c. springcoupling h. washer

d. primarycupseal i. pushrod

e. piston j. cross-dowel

explodedview - juicy3leverassembly

a

b d f h j

c e g i k

l

a. leverbody f. secondaryseal k. pushroddustboot

b. spring g. wormgearcoupling l. lever

c. springcoupling h. wormgear

d

.primary

cup

seal

i

.c

-clip

e. piston j. pushrod

explodedview - juicy7, carbon, ultimateleverassembly

a

b d f h j

c e g i k

l

a. leverbody f. secondaryseal k. pushroddustboot

b. spring g. couplingassebmly l. lever

c. springcoupling h. couplingretainer

d. primarycupseal i. couplingretainingring

e. piston j. pushrod

explodedview - code5, juicy5leverassembly

OR

juicy 3

juicy 5, 7carbon,ultimate

j


16/58

GEN 0000000000362, Rev. A6

19

OR


internalsremoval

Cd 5, Juicy 3, 5 oy: Usig straight itra19.

snap ring pliers, remove coupling retaining ring.

Pull retaining ring rom insie the lever boy.

important: pullretainingringoutslowly. the

couplingretainer/couplingassemblymay pop out

withtheforceofthesprings. donotlookinside

whileremovingtoavoidpotentialeyedamage.Using neele-nose pliers, careully remove

cupig rtair/cupig assmby. Cupig

retainer shoul slie out rom lever boy easily.

Hd r bdy assmby upsid dw ad drp

th pist/sprig assmby it yur had. It

shoul slie out easily.

or

Juicy 7, Carb, Utimat oy: Rtat wrm

gar rtaiig cip with a sma athad

screwriver or sharp pick until the en o theclip protrues past the gap in the lever boy

(push en o clip to rotate within groove).

Using neele-nose pliers, grasp the clip to

remove rom the lever boy.

Isrt a arg athad scrwdrir it

wie slot in top o worm gear an turn

counterclockwise. Unthrea worm gear

cmpty ad sid/pu wrm gar ut f r

bdy assmby. Wrm gar cupig is catd

insie worm gear.

The piston spring (below piston insie lever

boy) shoul orce piston assembly out o lever

boy. I the spring oes not ai piston removal,use a sharp hooke pick to pull piston an spring

assmby frm r bdy. B carfu t t

amage the piston.

note: ifthewormgearcouplingiscracked, pull

couplingoutofgearandreplace. couplingcanwear

outovertimeandcrack.

With pist/sprig assmby rmd frm20.

lever boy, remove the piston rom the spring.

Usig a sma athad scrwdrir, rm21.

spring coupling rom piston. do not scratch any

plastic parts (piston or o-rings). I amage, youwill nee to replace the piston

Slie piston coupling out o piston (not picture).22.

Remove an replace piston seconary seal23.

(small o-ring) on top o piston.

20 21

23

code5, juicy3, 5 code5, juicy3, 5 code5, juicy3, 5

juicy7, carbon,

ultimate

juicy7, carbon,

ultimate

juicy7, carbon,

ultimate

juicy7, carbon,

ultimate


17/58



internalsremoval (cont)

Remove primary cup seal (lower large black24.

seal) rom piston with sharp pick an slie new

coupling seal onto base o piston. Ensure it sits

ush (at d rst, ush agaist pist, p

en out).

Re-install spring coupling back onto piston an25.

coupling seal (into open en o seal).Re-install spring onto coupling. The coupling26.

lightly snaps onto piston.

internalsinstallation

Isrt sprig/pist assmby bac it r27.

boy, spring frst.

Cd 5, Juicy 5 oy: Isrt cupig rtair28.

an coupling assembly onto top o piston, insie

lever boy. The v-shape o the retainer shoul

be positione in the lever blae groove.

Using straight internal snap ring pliers, insert

coupling retaining ring above coupling retaineran into groove in lever boy. Ensure retaining

ring snaps into place securely.

or

Juicy 7, Carb, Utimat oy: Sid wrm gar

coupling (geare en frst) into narrow en o

worm gear. The coupling slies irectly into

inner worm gear threas.

Insert worm gear an coupling assembly onto

top o piston, insie lever boy.

Isrt arg athad scrwdrir it p

d (at st) f wrm gar. Tur ccwis t

threa worm gear into lever boy. Press own

into worm gear while the gear threas into lever

boy. You will eel spring resistance as you turn.

Wrm gar thrads wi gag th thrads i

lever boy.

Turn clockwise unt il worm gear is completely

insie lever boy, then back o three turns. This

is the correct installation setting.

Using neele-nose pliers, insert worm gear

retaining clip above worm gear. Position one

en o clip into groove an slowly but frmly

push own on clip with pliers unt il clip snaps

frmly into place in groove. Rotate clip until

ens are insie o groove.important: endsofclipmustnotprotrudepastlever

bodygrooveorextendintoleverslot/gapinlever

body.

24 25 26

27 28

OR

code5, juicy5 code5, juicy5

code5, juicy5juicy7, carbon,

ultimate

juicy7, carbon,

ultimate

juicy7, carbon,

ultimate

juicy7, carbon,

ultimate

juicy7, carbon,

ultimate


18/58

GEN 0000000000362, Rev. A8


lever/pushrodinstallation

Juicy 3 oy: Pac washr t pushrd.29.

Insert pushro an washer into lever boy so

that pushro sets on top o the piston. Using

straight internal snap ring pliers, push retaining

ring into lever boy so that piston is compresse

an retaining ring snaps into place. This hols

piston assembly an pushro insie leverbdy. li up pushrd with th thradd h

in the cross-owel o the lever. Using 2mm

hex, threa the pushro completely by turning

counter-clockwise.

or

Cd 5, Juicy 5 oy: li up pushrd pi with

slot in coupling retainer. Insert pushro pin into

coupling retainer. Pushro pin snaps into slot.

or

Juicy 7, Carb, Utimat oy: li up pushrd

pin with slot in worm gear coupling (wie slot in

center o worm gear coupling). Insert pushrointo worm gear coupling. Pushro pin snaps

into worm gear inner coupling slot.

Insert s into lever boy; one on each sie. The30.

bushing lip (larger en) shoul be on insie o

lever boy.

li up r pit pi h with bushig hs.31.

Insert pivot pin back into lever an bushings.

Use your thumb to press own on pivot pin an

snap it into place.

Install the pivot pin set screw into the lever32.

blae antighten with a 2.5mm hex wrench

note: thisconcludestheleveroverhaulservice

instructionsforcode5, juicy3, 5. pleasemoveonto

step37, finishingupprocedures.

starwheelandworminstallation - juicy7, carbon,

ultimateonly.

note: juicyultimateisnotequippedwithastarwheel

knob, however, theprocedureissimilar.

Juicy 7, Carb oy: Prss star wh/wrm33.

bushing back into lever boy with thumb.

Thrad star wh/wrm assmby bac it

lever boy.

or

Juicy Utimat oy: Prss bushig bac itlever boy with thumb.

Using a 2.5mm hex, threa onto worm.

Using a pair o neele-nose pliers or a34.

retaining clip tool, press the retaining clip onto

en o worm to secure lever assembly.

finishingup

Clean the entire lever assembly with soapy35.

water an clean rag (not picture).



readytomoveontothenextchapter, hydraulicdisc

brakecaliperoverhaul. enjoy!

29

30

31 32

OR

33

34

OR

OR

code5, juicy5

juicy7, carbon,

ultimate

juicy7, carbon

juicyultimate

juicy3 juicy3 juicy3

juicy3


19/58


2 3 4

6

codE

introdUction


th bra r assmby, thr may b damag r war--tar t th itra mig parts. If yur bra was d with uid

oTHeR tha DoT 4 r 5.1, damag t a rubbr ad pastic itra parts may ist. If yur bra was damagd i a crash, thrmay be amage to the lever blae an pushro assemblies, as well as the reservoir cap, blaer an star wheel assemblies.

Ispcti ad/r rpacmt f ths parts, du t ay f th ab situatis, wi b cssary t rstr prpr bra

unction.

codE LEvEr ovErHaUL sErvicE instrUctions

gettingstarted





picture).

Using an 8mm crows-oot (inclue in Avi2.

Bd kit) ad sct wrch (r us a ar ut

8mm wrench), loosen an remove compression

nut rom lever boy. Turn counterclockwise to

remove. Unthrea completely by han an slie

compression nut own hose. Pull brake hose


Aw ay bra uid t drai it a ctair.3.

Hd r assmby r ctair ad pump

r t rm ay bra uid isid r

assembly.

note: ifthesystemhasbeencontaminatedwiththewrongfluid, youwillneedtoflushalltheparts

withsoapywaterandallowtodryfullypriorto


reservoircover/bladderremoval

Using a T-10 Torx wrench, remove the reservoir4.

cover screws.

Remove reservoir cover cap an blaer rom5.

r assmby. Additia bra uid wi drai

frm r. Hd r r ctair ad aw

uid t drai. St r assmby dw ca

towel (not picture).Hdig th rsrir cr, rm baddr6.

rom reservoir cover. Replace with new blaer

if ctamiatd ad aig uid.

note: possiblecausesofleakingbladderand/or

reservoirinclude: brakesystemmayhavetoomuch

fluid, bladdermayhavesplit, and/orbladdermaybe

contaminated .


20/58

GEN 0000000000362, Rev. A0


reservoircover/bladderremoval (cont)

Isrt w baddr it cr ad sat ush it7.

unersie o reservoir cover. Make sure you

have the correct orientation.

note: donotre-installreservoircoveratthistime.

bleedscrewsremoval

Using a T-10 Torx wrench, remove both blee8.screws.

Using a sharp pick, remove both o-rings on9.

blee screws an replace.

Install blee screws back into lever boy.10.

leverblade/camremoval

Using two 4mm hex wrenches, loosen an11.

remove the lever pivot shouler bolt an lever

pivot sleeve bolt.

note: youmayneedtopushtheshoulderboltout

withapickorsimilartool.

Rotate the lever an cam assembly towar the12.

hanlebar clamp. Careully remove the lever

blae an return spring rom the cam.

Slie a hex wrench through the bearing in the13.

cam an pull the gently pull the cam o the en

o the pushro.

Remove the pushro coupling rom the cam14.

with neelenose pliers. I the pushro coupling

remains connecte to the pushro, pull it o

with neelenose pliers.

internalsremoval

Ta a fw mmts ad famiiariz yursf

with the internal components o your brakelever. This will assist you in ientiying the


7 8

10

9

1312

11

a b d f h k

c e g j l

m

a. leverbody f. quadseal k. cam

b. spring g. gearcoupling l. camspring

c. springcoupling h. pushrod m. lever

d. primarycupseal i. pushrodcoupling

e. glidering j. c-clip

explodedview - codeleverassembly

i

14


21/58


15

17

16


internalsremoval (cont)

Using snap ring pliers, remove the retaining ring15.

locate in the lever boy at the base o the push

rd. Rm pushrd ad itra pist/sprig

assembly.

important: theinternalpiston/springassemblyis

preloadedandwillcomeoutoftheleverbodyquickly.

besuretopointtheassemblyinasafedirection, orintoaplasticbag.

Using a T-10 Torx wrench, remove the Pa16.

Adjust kb. Rm th dtt ba barig

an spring locate irectly beneath the Pa

Adjust kb with a pic.

important: becarefulnottolosethedetentball

bearingandspringwhenremovingthepadadjust

knob. youmaywanttoholdoveracleanragwhile

performingthisstep.

Gty push th b gar ut f th r bdy17.

rom the backsie using a pick or your thumb.

piston/springassemblyoverhaul

Rm th sprig frm th pist/sprig18.

assembly.

Usig a sma athad scrwdrir, rm th19.

spring coupling rom the piston, ollowe by

the cupseal, glie ring an seconary quaseal

o-ring.

Install a new quaseal o-ring, ollowe by the20.

glie ring an a new cupseal with the open en

out (not picture).

Install the spring coupling back onto the piston21.

an snap the return spring back onto the spring

coupling.

internalsinstallation

Install the bevel gear into the gear bore an hol22.

in place with your fnger.

Install the etent spring an ball into the lever23.

boy.

Aig th Pad Adjust kb with th b gar24.

an install the knob using a T-10 Torx wrench.

Tighten the knob to 1-1.2 Nm (8.7-10.4 in-lb).

The bevel gear shoul now be secure an you no

longer nee to hol it in place with your fnger.

1918

21

24

22

23


22/58

GEN 0000000000362, Rev. A2


internalsinstallation (cont)

Ista th pist/sprig assmby it th r25.

boy.

important: aligntheblackpistonkeyonthepiston

gearintothekeywayontheleverbody.

Push th pist/sprig assmby far ugh it26.

the lever boy to completely epress the spring.

Whi th sprig is dprssd, isrt a pigauge (a small rill bit or 1.5 mm hex will work)

into the compensating port, to hol the assem-

bly compresse in the lever boy.

important: donotlookdirectlyintoleverbodywhile

performingthisstep. depressingthespringputsit

intoapreloadedconditionanditcanejectrapidly

fromtheleverbodyifthepingaugeisnotproperly

installed.

Install the pushro then washer onto the top o27.

the piston gear. Install the retaining ring in the

groove o the lever boy using a pair o snap ring

pliers an orient the ring holes away rom thelever boy opening.

Remove the gauge pin rom the compensating28.

port . The piston assembly will snap into place

against the pushro an washer.

leverblade/caminstallation

Insert a leg o the lever return spring into the29.

hole on the lever cam.

Install the lever blae onto the cam an return30.

spring, making sure the expose spring leg is

satd it th h th r bad. With

your thumb, roll the cam on the brake lever so

that the lever pivot holes are aligne.note: youcanusea5mmcableferruleasatoolto

holdthecamandleverbladetogetherasyouinstall

theassemblytotheleverbody.

Press pushro coupling back into slot in cam.31.

Insert the lever blae assembly into the lever32.

boy at a slight angle. The pushro coupling

shoul snap frmly onto the expose pushro.

Rotate the lever so that the pivot an lever33.

boy bores are aligne an push the lever pivot

sleeve bolt through the bearing. Using a 4 mm

hex wrench, tighten sleeve bolt to 2-2.5 Nm

(17-22 in-lb).note: ifyouusedaferruletoolinstep30, installing

thepivotsleeveboltwillpushouttheferruletool.

besurethebolttooliscompletelyremoved.

25 26

27

29

33

30

28

ferruletool

ferruletool

ringholes

31 32


23/58



leverblade/caminstallation (cont)

Squz th r a fw tims t sur that th33.

lever epresse an returns ully (not picture).

Rtat th Pad Adjust kb t th fu i ad34.

th fu ut psit i t sur fu rag f

adjustmt (t picturd).

Install the blaer reservoir cap using a T-1035.

Torx wrench an tighten to 1-1.2 Nm(8.7-10.4 in-lb).



readytomoveontocodehydraulicdiscbrakecaliper

overhaul, page29. enjoy!

35


24/58


25/58

25

disc brakE

caLipEr ovErHaUL


26/58

GEN 0000000000362, Rev. A6

2 3

ELixir r, cr

introdUction

Aid caipr assmbis d t b sricd i rdr t ptimiz braig fucti. If caipr bra pist mti is sticy r

acs a psiti ad smth rtur, th caipr bdy/bra pist -rig may b ut f pac r damagd. If yur bra was d

with bra uid thr tha DoT 4 r 5.1, damag t a rubbr ad pastic itra parts may ist. Cmmy usd InCoRReCTuid is mira i r DoT 5, which is siic basd. Ispcti ad/r rpacmt f ths parts, du t ay f th ab

situations, will be necessary to restore proper brake unction.

caLipEr ovErHaUL sErvicE instrUctions

troubleshooting -

sticky orslowbrakepadreturnfeel

Bfr cmpty disassmbig yur caipr,

its worth trying to loosen the sticky piston. Try

the ollowing: Clamp bicycle in bicycle work

stad. Spi affctd wh. lighty squz

brake lever an watch brake pas when lever

is release. determine which sie o the caliperhas a slow returning brake piston. Remove

caliper rom bicycle. I you have a mounting

bracket, it is recommene to remove that too

r just rm th caipr aig th bract

the ork or rame. Remove e-clip rom guie pin

groove on top o the caliper. Using a 2.5 mm hex

wrench remove the guie pin rom the caliper.

Pull an remove both brake pas an h-spring.

Using a 10 mm box wrench, press working

pist it caipr bdy. Squz bra r

slowly to move sticky piston inwar. Press

the piston back into the caliper again. Repeatthese steps to correct caliper piston inner o-ring

psiti. Bth pists shud w b mig

reely. Re-install spring pa clip, h-spring, an

pas into caliper. Re-install caliper onto bicycle.

Spin wheel, check unction. I there is no

improvement, continue with caliper service.

gettingstarted

Remove brake caliper rom ork or rame an1.

remove the caliper mounting bracket an CPS

harware rom the caliper. Set asie in correct

orer (not picture).

brakepadandh-springremoval

Remove e-clip rom guie pin groove on top o2.

the caliper. Using a 2.5 mm hex wrench remove

the guie pin rom the caliper.

Pull an remove both brake pas an h-spring.3.

note: ifthetotalthicknessofthebackingplateand

padfrictionmaterialislessthan3mm, thebrake

padsneedtobereplaced.


27/58


4

caLipEr ovErHaUL sErvicE instrUctions (cont)

eliixircronly: brakehose/banjoboltremovaland

service

Using an 8 mm open-en or box wrench, loosen4.

baj bt. Bra uid wi a, s hd r a

ctair t catch uid.

Pu baj bt cmpty ut f caipr. Dump5.

a caipr bra uid it ctair.

Rm ad rpac -rig baj bt ad6.baj.

caliperdisassemblyandservice

Usig a 8 mm ad T 30 Tr s ad rm7.

the caliper boy bolts.

Separate caliper boy halves an open caliper8.

assembly.

Usig a sharp pic, rm sma baj h9.

(boy hal) o-ring.

brakepistonsremovalandservice

Ibard Caipr Bdy Haf: Usig a air10.

cmprssr chuc, isrt chuc zz it

baj bt h. Hd caipr i had,

pitig caipr pist i a saf dircti. Hd

gr r th baj bt thrugh-h

opposite sie o caliper boy so air oes not

scap. Squz th air chuc ad frc air

it th baj bt h whi hdig caipr

boy. Compresse air unseats the caliper piston

rom the caliper. Pull out completely an remove

piston.

important: pointthecaliperinasafedirection. usea

clothoraplasticbagtopreventthepistoncausing

injuryorbecominglost.

outbard Caipr Bdy Haf: Usig a air





opposite sie o caliper boy so air oes not

scap. Squz th air chuc ad frc air




piston.

important: pointthecaliperinasafedirection. useaclothoraplasticbagtopreventthepistoncausing


Remove the square-ege o-ring rom insie11.

each caliper boy hal with a sharp pick an

replace with new square-ege o-rings.

5 6

7 8

9 10

11


28/58

GEN 0000000000362, Rev. A8


caliperassembly

Inspect caliper pistons or amage an replace12.

i necessary. Re-install caliper brake pistons

into each hal o the caliper boy. Make sure

the piston slots are vertical in caliper boy. (this

ps th uid sts th bac sid f pist

id up with uid prts).

Using a sharp pick, remove an replace the13.outboar caliper boy o-ring.

Usig a T- 30 Tr ad a 8 mm p dd14.

wrench, re-install the caliper boy bolts an

torque to 8.5-10.2 Nm (75-90 in-lb).

Using a T-10 Torx wrench, remove blee screw.15.

Using a sharp pick, remove blee screw o-ring.16.

This o-ring may be a li ttle har to see. Replace

with a new blee screw o-ring.

R-ista baj bt bd scrw it baj bt17.

an tighten with T-10 Torx wrench.

brakepadinstallationMeasure the total thickness o each pa (pa18.

backing plate an pa material). I there is less

tha 3 mm f tta width, rpac bth bra

pas (not picture).

B sur th h-sprig is ritd t th pads as19.

shown. Align the hole in the h-spring with the

hs i th pad tabs. Squz th pad ad

spring assembly together, then insert into the

caliper as a unit. Firmly push until the assembly

is seate into place.

Using a 2.5 mm hex wrench, install the pa20.

retainer bolt an tighten to

0.9-1.1 Nm (8-9.5 i-b). Ista th e cip

the wheel sie o the caliper making sure it sits

in the groove o the retainer bolt

finishingup (notpictured)

visuay chc yur wr. Ispct baj bt ad21.

baj fr ay prtrudig -rigs. If thr ar ay

-rigs that ar squzd byd th utsid

dgs f th baj r b t, rm ad rpac.

Repeat installation steps.

Wip assmbd caipr with sapy watr t22.

rm ay bra uid.

Re-install caliper onto bicycle ollowing the23.installation an torque specifcations calle out

in the user manual.

thisconcludesthecaliperoverhaulserviceinstruc-

tions. youhavedoneagreatjobandarereadyto

moveontothenextchapter, hydraulicdiscbrake

hoselengthadjustmentandbleeding. enjoy!

1312

15 1614

20

17 19


29/58


2

JUicy 3, 5, 7, carbon

introdUction






troubleshooting -







is release. determine which sie o the caliperhas a slow returning brake piston. Remove




the ork or rame. Using a pair o neele-nose

pliers, remove both brake pas an h-spring.

Remove the spring pa clip rom the outsie o

the caliper. Using an 11mm box wrench, press

wrig pist it caipr bdy. Squz bra

lever slowly to move sticky piston inwar. Press

the piston back into the caliper again. Repeat

these steps to correct caliper piston inner o-ringpsiti. Bth pists shud w b mig

reely. Re-install spring pa clip, h-spring, an

pas into caliper. Re-install caliper onto bicycle.

Spin wheel an check unction. I there is no


gettingstarted




orer (not picture).


Using neele-nose pliers, grab one o the pa2.

tabs an slie the pa towar the center o the

caliper (this isengages the pa backing plate

rom the post in the center o the piston), then

pull the pa straight out. Repeat or other pa.

note: iftheh-springdoesntcomeoutwiththe

secondpad, pushitoutfromtheopentopofthe

caliperwithapickoryourfinger.

Remove the spring pa clip rom the outsie o3.

the caliper.


30/58

GEN 0000000000362, Rev. A0

3





brakehose/banjoboltremovalandservice



ctair t catch uid.Pu baj bt cmpty ut f caipr. Dump5.


Remove o-rings on each sie o brake hose6.

baj ad rpac with w -rigs.

Isrt baj bt bac it bra hs baj.7.

esur utsid baj -rig is t damagd by

baj bt thrads. This may caus a a. St

hs ad baj bt asid.


ls a thr caipr bdy bts with a8.

4 mm hex wrench. There are three ierent boltlengths. Set asie in correct orer.

Separate caliper boy halves an open caliper9.

assembly.

Usig a sharp pic, rm sma baj h10.

(boy hal) o-ring.

brakepistonsremovalandservice

Ibard Caipr Bdy Haf: Usig a air11.



pointing caliper piston in a sae irection.

Squz th air chuc ad frc air it th

baj bt h whi hdig caipr bdy.Compresse air unseats the caliper piston rom

the caliper. Pull out completely an remove

piston.




outbard Caipr Bdy Haf: Usig a air12.





opposite sie o caliper boy so air oes notscap. Squz th air chuc ad frc air




piston.




Remove the square-ege o-ring rom insie13.

each caliper boy hal with a sharp pick an

replace with new square-ege o-rings.

4 5

13

6 7 8

9 10 11

12


31/58



caliperassembly


i necessary. Re-install caliper brake pistons

into each hal o the caliper boy.

Ista a w baj bt -rig it th baj bt15.

hole on outboar sie o caliper boy.

Insert an threa caliper bolt into caliper clos-16.

st t baj bt h. esur w caipr bajbolt o-ring is not unseate rom its posit ion (not

picture).

Insert remaining two caliper boy bolts an17.

tighten all three bolts wi th a 4 mm hex wrench to

4.9-5.9 nm (43 - 52 i-b).

Isrt baj bt bac it caipr it baj bt18.

h. Had-thrad ad tight with 8 mm b

wrch t 4.9-5.9 nm (43 - 52 i-b). B carfu

not to pinch either o these o-rings uring instal-

lation.

Usig a T-10 Tr wrch, rm baj bt19.

blee screw.Using a sharp pick, remove blee screw o-ring.20.





brakepadinstallation

Insert spring pa clip into outer sie o caliper.22.

Measure the total thickness o each pa (pa23.

backing plate an pa material). I there is less

tha 3 mm f tta width, rpac bth bra

pas (not picture).

Position the h-spring between the two pas.24.The curve hanle o inner pa shoul ace

tward ibard sid f caipr. Squz th pad

an spring assembly together, then frmly push

into the caliper until it clicks into place, inicat-

ing it is properly secure in the caliper boy.






Repeat installation steps.Wip assmbd caipr with sapy watr t25.

rm ay bra uid.

Re-install caliper onto bicycle ollowing the26.

installation an torque specifcations calle out

in the user manual.





15 1714

19 2018

2421 22


32/58

GEN 0000000000362, Rev. A2

2

JUicy ULtimatE

introdUction






troubleshooting -







is release. determine which sie o the caliper

has a slow returning brake piston. Remove




the ork or rame. Using a pair o neele-nose

pliers, remove both brake pas an h-spring.

Using an 11 mm box wrench, press working

pist it caipr bdy. Squz bra r

slowly to move sticky piston inwar. Press

the piston back into the caliper again. Repeat

these steps to correct caliper piston inner o-ringpsiti. Bth pists shud w b mig

reely. Re-install h-spring an pas into caliper.

Re-install caliper onto bicycle. Spin wheel an

check unction. I there is no improvement,

continue with caliper service.

gettingstarted




orer (not picture).


Using neele-nose pliers, grab one o the pa2.

tabs an slie the pa towar the center o the

caliper (this isengages the pa backing plate

rom the post in the center o the piston), then

pull the pa straight out. Repeat or other pa.

note: iftheh-springdoesntcomeoutwiththe

secondpad, pushitoutfromtheopentopofthe

caliperwithapickoryourfinger.





33/58


3


brakehose/banjoboltremovalandservice



ctair t catch uid.

Pu baj bt cmpty ut f caipr. Pur4.


Rm -rig frm bra hs baj ad baj5.

bolt an replace with new o-rings.Isrt baj bt bac it bra hs baj.6.

esur utsid baj -rig is t damagd by

baj bt thrads. This may caus a a. St

hs ad baj bt asid.

brakepistonremovalandservice

Using an 11 mm box wrench, gently push out-7.

bard pist it caipr bdy uti it is ush

with the insie o the caliper.

Gty prss a athad scrwdrir agaist th8.

outboar piston while pointing the caliper in a

sae irection (you want to remove the inboarpiston frst , so you nee to hol the outboar

piston in place). Using an air compressor chuck,

isrt chuc zz it baj bt thrugh h.

Squz th air chuc ad frc air it th ba-

j bt h. Cmprssd air usats th ibard

caliper piston rom the caliper. Pull the piston

out o the caliper boy through pa opening.

note: youmayneedtouseapairofneedlenosed

plierstopullthepistonoutofthecaliperbody. be

carefulnottoscratchthepiston. ifyouscratchthe

piston, youwillneedtoreplaceit.

important: besuretopointthecaliperinasafe

direction. youmaywanttodothisinsideaplastic

bagtopreventthepistonfromcausinginjuryor

becominglost.

Using an 8 mm hex wrench, turn the piston cap9.

clockwise to push the outboar piston into an

out o the caliper boy. Pull the piston out o the

caliper boy through the pa opening.

Press the piston cap into the caliper boy an10.

remove through the pa opening.

Using a sharp pick, remove the piston cap o-ring11.

an replace with a new o-ring.

Using a sharp pick, remove the inboar an out-12.

boar qua seal o-rings rom the caliper boyan replace with new o-rings.

note: wheninstallingthenewquadsealo-rings,

usetheflatsideofapicktoseattheo-ringintothe

o-ringgroovebymovingitaroundtheentireseal.

Using a T-10 Torx, remove caliper boy assembly13.

blee screw.

Using a sharp pick, remove blee screw o-ring14.

an replace with a new one.

4 5

6 7

109 11

8

1312 14


34/58

GEN 0000000000362, Rev. A4


brakepistoninstallation


i necessary (not picture).

Install inboar piston through the pa opening,16.

prssig it ush it th caipr bdy with a

11 mm box wrench.

Install piston cap through pa opening. Using17.

an 8 mm hex wrench, threa piston cap counter-clockwise until snug into caliper boy.

Install the outboar piston through the pa18.

pig ad prss it ush it th caipr bdy

with an 11 mm box wrench.

Using a T-10 Torx, install caliper boy assembly19.

blee screw.

brakehose/banjoboltinstallation

Isrt baj bt bac it caipr baj bt20.

h sttig th baj ag t th dsird ag.

Had-thrad ad tight with 8 mm b wrch

t 4.9-5.9 nm (43 - 52 i-b). B carfu t tpich th baj bt -rig durig istaati.

Usig a T-10 Tr wrch, rm baj bt21.

blee screw.

Using a sharp pick, remove blee screw o-ring.22.






Measure the total thickness o each pa (pa24.

backing plate an pa material). I there is lesstha 3 mm f tta width, rpac bth bra

pas (not picture).

Position the h-spring between the two pas.25.

The curve hanle o inner pa shoul ace

tward ibard sid f caipr. Squz th pad

an spring assembly together, then frmly push

into the caliper until it clicks into place, inicat-

ing it is properly secure in the caliper boy.

1816

2119 20

17

2522 23


35/58










rm ay bra uid.Re-install caliper onto bicycle ollowing the26.


in the user manual.






36/58

GEN 0000000000362, Rev. A6

codE, codE 5

introdUction






troubleshooting -



its worth trying to loosen the sticky piston.

To o so, try the ollowing: Clamp bicycle in

bicyc wr stad. Spi affctd wh. lighty

squz bra r ad watch bra pads

when lever is release. determine which sie

o the caliper has a slow returning brake piston.

Remove caliper rom bicycle. I you have a

mounting bracket, it is recommene to remove

that t r just rm th caipr aig th

bracket on the ork or rame. Remove e-clip

rom guie pin groove on top o the caliper

using a sharp pick. Using a 2.5 mm hex wrench

remove the guie pin rom the caliper. Pull an

remove both brake pas an h-spring. Using a

10 mm box wrench, press working piston intocaipr bdy. Squz bra r swy t

move sticky piston inwar. Press the piston

back into the caliper again. Repeat these steps

to correct caliper piston inner o-ring position.

Bth pists shud w b mig fry.

Re-install spring pa clip, h-spring, an pas

into caliper. Re-install caliper onto bicycle.

Spin wheel, check unction. I there is no


gettingstarted


remove caliper mounting bracket an CPS

harware rom caliper. Set asie in correct

orer (not picture).


37/58



brakepadsandpadh-springremoval

Remove e-clip rom guie pin groove on top o2.

the caliper using a sharp pick.

Using a 2.5 mm hex wrench remove the guie3.

pin rom the caliper.

Squz th pads tgthr s thy car th pis-4.

tons, an pull to remove brake pas an h-spring

rom caliper.


Using a 4 mm hex wrench, loosen all our caliper5.

boy bolts unt il there is slight gap in the caliper

has. This wi as baj bt rma.

Using two 4 mm hex wrenches, loosen an6.

rm th baj s bt ad baj shudr

bolt.

Completely remove all our caliper boy bolts,7.

separate the caliper boy into its t wo halves

ad rm th baj.

Using a sharp pick, remove the o-rings rom8.

udrath th hads f bth th baj s

bt ad baj shudr bt ad rpac with

new o-rings.

Usig a sharp pic, rm th baj -rigs 9.

both the r ight an let sie o the caliper halves

an replace with new o-rings.

brakepistonremovalandservice

Using an air compressor chuck, insert chuck10.

zz it baj bt h. Hd caipr i a rag

in one han, using your thumb or fnger to seal

th bacsid f th baj bt h. Squz

th air chuc ad frc air it th baj bthole. The compresse air will unseat the caliper

piston rom the piston pockets.

important: besuretopointthecaliperinasafe

direction. youmaywanttodothisinsideaplastic

bagtopreventthepistonfromcausinginjuryor

becominglost.

note: becauseofthenatureofafourpistoncaliper,

bothpistonsineachhalfofthecallipermaynot

beunseatedsimultaneously. toremovethesecond

pistonuseyourthumbtosealtheemptypistonpocket

orfindametricsocketextensionthatfitssnuglyinto

thepistonpocketandsealthetopoftheextensionwithyourthumb. repeatstep10toremovethelast

piston.

Remove the square ege o-ring rom insie each11.

piston pocket using a sharp pick an place with

new o-rings.

Rm bth baj bt bd scrws frm th12.

top o the caliper boy using a T-10 Torx wrench.

Remove the o-rings rom the blee screws an13.

replace with new o-rings.

2 43

765

10

98

11

12 13


38/58

GEN 0000000000362, Rev. A8


caliperassembly

Inspect the caliper pistons or amage, an14.

replace i necessary. Insert the caliper brake

pistons back into each hal o the caliper boy.

note: gentlyrollingthepistonsclockwiseasyou

installwillhelpwithinstallation.

Pac baj s bt it th f t haf (ut-15.

bard sid) f th caipr. Sid baj tth s bt ad st th baj ag t th

esire angle.

Align both caliper halves together an insert the16.

baj shudr bt ad th fur caipr bdy

bolts. Using two 4 mm hex wrench, tighten the

baj bt t 2.9-3.4 nm (26-30 i-b). Usig a 4

mm hex wrench tighten the caliper boly bolts

t 5.9-6.3 nm (52-56 i-b).

Using a T-10 Torx, install the two blee screws17.

back into the top o the caliper boy an tighten

to .6-.7 Nm (5-6 in-lb).


Inspect an measure each brake pa. I there18.

is ss tha 3 mm f tta pad thicss (pad

backing an pa riction material), replace both

brake pas (not picture).

Position the h-spring between the two pas.19.

note: thecodepadsaresymmetrical, thereisnota

leftorrightorientation.

lcat th pad istaati fatur f th pad20.

spacr t. Isrt th pad hads it th pad

istaati t s it hds th pads tgthr.

Insert the pas an pa tool into the caliper until21.

the holes in the top o the pas are aligne withthe guie pin holes in the top o the caliper.

Insert the guie pin through the caliper boy22.

halves an the brake pas. Using a 2.5 mm hex

wrch, tight th guid pi t 1.5-1.9 nm (13-

17 in-lb).

Remove the pa tool. The h-spring will snap the23.

pas into position.

Using your thumb or fnger, install the e-clip into24.

the groove on the en o the guie pin.

17

16

2019

14

22 23

21

24

15


39/58










rm ay bra uid.Re-install caliper onto bicycle ollowing the29.


in the user manual.






40/58

GEN 0000000000362, Rev. A0

bb7 moUntain & road

introdUction


acs a psiti ad smth rtur, th caipr bdy/bra pist -rig may b ut f pac r damagd. Ispcti ad/r

replacement o these parts, ue to any o the above situations, will be necessary to restore proper brake unction.

caLipEr ovErHaUL disassEmbLy sErvicE instrUctions

troubleshooting (notpictured)

Th mst cmm issu with th BB7 is that th

outboar pressure oot can become isloge i

th utbard adjustmt b is turd t farclockwise without the rotor in the caliper (wheel

o or caliper remove). The brake is not broken,

nor oes it require isassembly to replace the

pressure oot. To replace the pressure oot, turn

th utbard adjustr b cutr-ccwis

until it stops. I the knob oesnt stop, then the

oot screw (the en o which can be seen in the

center o the knob) has become isengage

rom the knob an possibly rom the threas

insie the rive cam. In this case, remove the

knob, then using a pair o small neele-nose

pliers or a schraer valve tool, turn the the ootscrew all the way back out until it stops. Now

the pressure oot can be replace. Relocate the

pressure oot into the bore, then give it a frm

push in the center. It will click back into place.

I you remove the knob, replace it an youre

one!

gettingstarted

Remove the cable anchor bolt an plate, then1.

pull the cable housing an inner wire ree o the

caliper. Remove the rubber cable boots.

removethebrakepads

Tur bth adjustr bs a th way ut2.

(cutrccwis), th squz th pad tabs

together an pull both pas an pa spring clip

straight out o the caliper.

21


41/58


caLipEr ovErHaUL disassEmbLy sErvicE instrUctions (cont)

removetheoutboardknob

Remove the outboar pa knob with a small3.

at-had scrwdrir. B carfu t t mar th

surace o the torque arm.

Turn the oot screw which is now expose4.

counter-clockwise until it s tops.

removetorquearmHd th sprig add trqu arm scury i5.

place.

Remove the torque arm fxing nut using an6.

11 mm wrench. Remove the lockwasher.

Remove the torque arm, outer boy seal, an7.

spring. Then remove the hex-hole washer.

removedrivecam/outboardpressurefootassembly

Using a 5 mm hex, remove the 2 caliper boy8.

bolts.

note: theboltsaredifferentlengths.

Careully remove the inboar caliper boy hal9.

an set asie.

Remove the pa retaining clip an set asie.10.

Pu ut th dri cam/utbard prssur ft11.

assmby. B carfu t t s ay f th

three ball bearings.

Use a 5mm hex to remove the outboar caliper12.

boy hal rom the bike an set asie.

drivecamdisassembly

Use small neele-nose pliers or a schraer13.

valve core tool to turn the oot screw clockwise

until it is completely unthreae rom the rive

cam. This will separate the outer pressure ootrom the cam assembly. Remove the oot screw

rom the rive cam.

removepressurefoot

Using a T-25 Torx wrench,14. turn the inboar

pressure oot clockwise until it is ree rom the

inboar caliper boy hal.

3 54

876

9 10

13

footscrew

11

14

12


42/58

GEN 0000000000362, Rev. A2

cleaning

Clean all metal parts in alcohol, incluing the15.

cable anchor bolt an plate. Clean the cable

seal boots an outer caliper boy seal in

mil soap an water. Rinse an ry all parts

completely (not picture).

caliperbodyinspection

Inspect both caliper boy halves or any16.

amage; pay close attention to all threae

suraces.

smallpartinspection

Check ball bearing an cam ramps or excessive17.

wear.

note: itisnormaltoseeballtracksinthecam

ramps.

Check the threas o the rive cam, oot screw,18.

inner pressure oot, cable anchor bolt, an

torque arm fxing nut or amage.Check the spring or any signs o amage.19.

Check the cable seal boots or nicks, tears, or20.

cracking.20

2221

18

19

1716

caLipEr ovErHaUL cLEaninG & inspEction instrUctions

caLipEr ovErHaUL assEmbLy sErvicE instrUctions

assemblecaliper

Very lightly grease the inner pressure oot21.

threas.

Using a T-25 Torx wrench, threa the inner22.

pressure oot into the outboar caliper boy hal

uti th prssur ft is ush with th ir

ace o the caliper boy.

Very lightly grease the oot screw threas, tip o23.

stem-en on outer pressure oot , an the rampso the rive cam.

Using small neele-nose pliers or a Schraer24.

valve tool, threa the oot screw into the rive

cam completely, but o not tighten. 2423

grease

grease

grease


43/58



assemblecaliper (cont)

Insert the stem-en o the outer pressure oot25.

into the hole in the en o the rive cam an

install by frmly pressing it straight in.

lighty gras th ramps f th d cam i th26.

outboar caliper boy.

Place the ball bearings into the ramps o the27.

fxe cam.Isrt th Dri Cam/outr Prssur Ft28.

assembly through the hole in the outboar

caliper boy. Rotate the cams against each

other to ensure the ball bearings are seate

properly in both sets o ramps.

Apply a high-strength threa-lock such as29.

lctit 272 t th dri cam thrads.

important: becarefulnottoallowanythread-lock

toentertheareaaroundthefootscrew.

Hd th Dri Cam i pac ad r-ista th30.

return spring, outer seal, an washer with hex-

hole.note: thespringlegthatextendsawayfromthe

springshouldpointawayfromthecaliperbody. the

notchintheoutersealshouldfaceawayfromthe

caliperbodyandbelocatedunderneaththespring

leg.

Install the torque arm, aligning the spring leg31.

with the spring tension notch on the back o the

trqu arm. Wh gagd crrcty, th sprig

adjustr scrw wi b dri agaist th sprig

leg on the back o the torque arm. Press the

trqu arm t th ats f th dri cam shaft .

Make sure the arm is ully seate an hol frmly

with your thumb.Place the lockwasher on the rive cam with the32.

roune sie towar the caliper boy. Threa on

the torque arm fxing nut by han, then torque to

55-60in-lb.

important: donotovertightenthetorquearmfixing

nut.

Ista th utbard adjustr b by aigig33.

the rectangle tab o the oot screw with the

rectangular hole in the the knob, then press it on

frmly.

Re-install the pa retainer in the outboar34.

caliper boy.Apply a high-strength threa-lock such as35.

lctit 272 t th 2 caipr bts.

Align both caliper halves together an insert36.

the caliper boy bolts. The short bolt goes in

the hole near the cable anchor, an the long bolt

goes in the hole near the housing stop. Torque

both bolts to 75-90 in-lb.

note: becarefultokeepthepadretainerinplace

whilejoiningthehalvestogether.

25 2726

30

2928

31

springtensionnotch

extended

leg

notch

spring

tension

notch

32 33 34

35

padretainer


44/58

GEN 0000000000362, Rev. A4


39

3736installthenewpadsandspring

Assemble the spring between the new let an36.

right pas. Align the spring to the pa as shown.

Squz th bra pad ad sprig cip assmby

together then press frmly into the caliper until it

cics it pac. Th pad mard R gs

the spoke sie o the brake.

Push the upper an lower boots onto the37.integrate cable stop.

Place the cable anchor plate on the cable38.

anchor bolt, grease the bolt lightly an install

into the torque arm. (not picture)

Re-mount the caliper onto the bike.39.

Set up the brake by ollowing the proceures40.

i th Aid Ba Barig Dis Bra Istaati

Guidis. B sur t trqu t th prpr

value.

compLEtinG baLL bEarinG disc brakE caLipEr ovErHaUL

You are almost reay to rie, but frst i ts a goo iea to test your brakes by pulling on the lever extremely har (as har as you

can imagine yoursel pulling the lever while youre riing) several times. Check that the caliper closes an returns properly.

Make one last check o all the bolts an ftt ings.

I everything checks out, yoU arE rEady to ridE!


45/58

45

HydraULic disc brakEHosE LEnGtH

adJUstmEnt & bLEEd


46/58

GEN 0000000000362, Rev. A6

2 3

ELixir r, cr - JUicy 3, 5, 7, carbon, ULtimatE - codE, codE 5

introdUction

Avi brakes come with the hoses at tache an ble. I you ont nee to change the hose length, then you shoul not nee to

bd th systm agai. Hwr, if yu prfrmd a r ad/r caipr rhau, yu wi d t bd yur bras. Bdig

is one o the most important steps in topping o the perormance o any hyraulic brake system. Any air insie a hyraulic brakesystem egraes the perormance o the brake. The goal o bleeing is to remove the air that is trappe in the hoses, caliper or

lever.

cHanGinG HosE LEnGtHs

re-checkhoserouting

Since you cant lengthen the hose ater you1.

have cut it, take a moment an re-check the

rutig f th hss. B sur t accut fr

suspension movement an check that the bars

turn reely by turning the bars all the way rom

sie to sie. Make sure the hoses are properlysecure as well (not picture).

removehosefromlever

Ju, ce & El r:2. Use an 8 mm open enewrench to unscrew the hose compression nut

El cr: Use an 11 mm open ene wrench tohol the hose stop in place an use an 8 mm open

ene wrench to unscrew the hose compression

nut.

note: ifyourbrakehasahoseboot, pullthebootaway

fromthelevertoaccessthecompressionnut. ifthe

bootsticks, carefullypryupacornerwithsomething

thatwontharmit (likeapenciltip) andspraysome

alcoholbetweenthebootandthelever. workthe

alcoholin; thebootshouldloosenupandslideeasily

downthehose.

Pull the hose rom the lever, wiggling it i neces-3.

sary. B carfu, DoT uid wi drip frm th hs.

Try t t spi t much uid bcaus ay uid

that rips out will create bubbles that youll have

to eliminate later.

Slie the nut an boot (i applicable) own the4.

hose an away rom the en where youll be cut-

ting. do not to engage the brake lever while the

hose is remove (not picture).

elixircr


47/58


cHanGinG HosE LEnGtHs (cont)

determineproperhoselength&cut

determine where you nee to cut the hose by5.

holing it up to the lever in the posit ion you like.

Make sure to leave a gentle ben in the hose

with enough length to reely turn the bars all the

way rom sie to sie. double-check this part,

because you cant go back ater you cut .

The groove in the lever nose marks the spot6.where youll cut the hose. Cut the hose using

hyraulic hose cutters or very sharp cable-

housing cutters (not picture).

installnewfittings

Whi hdig th hs rmy, thrad a w7.

hosebarb into the en o the hose using a T-10

Torx wrench.

Slie a new compression ftting over the en o8.

the hose with the new hosebarb.

re-installthehosePush the hose frmly into the lever until it stops.9.

Whi hdig th hs i pac, sid th cm-10.

pression ftt ing an compression nut up to the

lever or hose stop (not picture).

Ju, ce & El r: Finger-tighten the com-pression nut until you eel it bottom out.

El cr: Hd th hs stp i pac adfnger-tighten the compression nut until you eel

it bottom out.

Ju, ce & El r:11. Whi ctiuig t pushthe hose into the lever boy, use an 8 mm open

ene wrench to tighten the compression nut to

the proper torque.El cr: Whi ctiuig t push th hsinto the hose stop, use an 11 mm open ene

wrench to hol the hose stop in place an use

an 8 mm open ene wrench to tighten the com-

pression nut to the proper torque.

I your compression ftt ing is alloy, tighten to

5 Nm (47 in-lb). I your compression ftting is

steel, tighten to 7.8 Nm (70 in-lb).

Slie the boot (i applicable) back into place (not12.

picture).

important: cuttingdownthehoseintroducesa

smallamountofairintothesystem, whichcan

degradetheperformanceofyourbrakes. atthis

point, itisnecessarytobleedthebrakes torestore

themtooptimalperformance. pleasecontinueonto

bleedingprocedures.

98

11

7

5

elixircr


48/58

GEN 0000000000362, Rev. A8

bLEEdinG procEdUrE

whenbleedingavidbrakes, keepinmindthatyou

aresimplychasingbubblesoutofthesystem. avid

recommendsthatyoubleedyourbrakesatleastonce

ayeartoensureoptimalperformance. ifyouride

frequentlyorinaggressiveterrain, youshouldbleed

yourbrakesmoreoften. youwillperform3basic

operationswhenbleedingavidbrakes: bleedthehose,

bleedthecaliper, bleedthelever.

preparethesyringes

Fi syrig 1/2 fu with Aid Hi-Prfr-1.

mac DoT Fuid ad th thr syrig 1/4

ull.

Hd ach syrig with th t ip pitd up ad2.

tap the sie o the syringe with your fnger to

bring any air bubbles to the top. Place a towel

aroun the tip an slowly push the air bubbles

out o the syringe.

note: youwillnotbeabletoremoveallthebubbles.

preparethecaliper

juicy3, 5, 7, ultimate&carbononly

Remove the wheel rom your bike. Remove the3.

brake pas an spreaer clip rom the caliper

ad isrt th apprpriat Bd Bc. This wi

hp prt DoT uid frm ctamiatig yur


Use the T-10 Torx wrench to remove the caliper4.

bd prt scrw frm th ctr f th baj

bolt.

Ma sur th uid i th 1/2 fu syrig is5.

pushe all the way to the tip (no air gap!), thenthrea into the caliper blee port.

preparethecaliper

code/code5only






The Coe caliper eatures two blee port7.

scrws ithr sid th baj ttig. Its

recommene that you use the blee port on the

ft sid f th baj ttig durig rma bd-ing. Use the T-10 Torx wrench to remove the

caliper blee screw rom the caliper boy.


pushe all the way to the tip (no air gap!), then

threa into the caliper blee port.

2

4

7

5

8

1


49/58


bLEEdinG procEdUrE (cont)

preparethecaliper

elixirr/elixircr






Use the T-10 Torx wrench to remove the caliper10.blee port screw rom the caliper boy.



threa into the caliper blee port.

preparethelever

reh aju:12. For moels equippe with ReachAdjust, sur that th rach is t adjustd s

ar out that it causes the lever blae to bot tom

out on the lever boy. doing so can make blee-

ing the brake impossible (not picture).

p c aju: For moels equippe withPad Ctact Adjust, st th adjustmt s it isturne all the way out (not picture).

Use the T-10 Torx wrench to remove the lever13.

blee port screw.



threa into the lever blee port.

note: itisnotnecessarytorepositiontheangleof

thebrakeleveronthehandlebar. youmayhavea

smallamountofdotfluiddripfromthebleedport

screw, thisisnormal. justhaveatowelhandyto

wipeoffanyexcessafterthesyringeisinstalled.

bleedthesystem: bleedthehose

Hd th caipr syrig upright i yur right15.

han an the lever syringe upright in your let

han.

Gty push th caipr syrig pugr t16.

m uid frm th caipr syrig it th r

syrig uti th r syrig is icrasd t 1/2

fu ad th caipr syrig is dcrasd t 1/4

ull.

note: youshouldseebubblesfillintothelever

syringe.

Close the re syringe clamp on the lever.17.Pull the brake lever all the way to the bar with18.

your fnger an hol it there until instructe to

release the lever in a later step. I you ont

want to hol the lever with your fnger, have a

rien hol it or you can asten it with a toe strap

or rubber bans.

18

11

13 14

10

15

16

17


50/58

GEN 0000000000362, Rev. A0

bLEEdinG procEdUrE (cont)

bleedthesystem: bleedthecaliper

With yur right had, gty pu ut th19.

caliper syringe plunger to create a vacuum

then gently push in on the plunger to pressur-

iz th systm. Rpat this prcdur sra

times, until large bubbles stop coming out o the

caliper.note: becarefulnotpullouttoohardontheplunger

oryouwillpullairpasttheplungersealandyouwill

betherealldaytryingtogetbubblesout.

Once the large bubbles at the caliper have20.

stoppe, apply a small amount o pressure on

the syringe plunger an slowly let the pressure

exten the brake lever you have been holing

with your fnger. I you astene the lever with

a toe strap or rubber bans, remove these frst

but keep the lever pulle in with your fnger,

then apply pressure on the syringe plunger (not

picture).note: youwillfeelthepressureatyourfingeronthe

lever, justletthefluidextendtheleverbacktoits

originalposition.

Remove the syringe rom the caliper an re-21.

install the blee port screw.

note: therewillbeexcessdotfluidthatspillsoutas

youre-installthebleedportscrew, thisisnormal.

besuretowipethefluidoffthecaliperwithatowel

andwater.

bleedthesystem: bleedthelever

Open the re syringe clamp on the lever.22.

Gty pu ut th r syrig pugr t23.create a vacuum, then gently push in on plunger

t prssuriz th systm. Squz ad ras

the brake lever ten times, allowing the lever to

sap bac t its startig psiti aftr squz-

ing (this helps break loose the bubbles). Repeat

this proceure several times, until large bubbles

stop coming out o the lever.

note: becarefulnotpullo

technical manual avid 2009

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