Beruflich Dokumente
Kultur Dokumente
part # GEN.0000000002609
technical manual
01
We recommend that you have your Avid brakes serviced by a qualified bicycle mechanic. Servicing
Avid brakes requires knowledge of brakes components as well as the special tools and fluids used for
service.
Used brake fluid should be recycled or disposed of in accordance to local and federal regulations.
NEVER pour brake fluid down a sewage or drainage system or into the ground or a body of water.
This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols and , respectively.
Copyright SRAM LLC 2009
For exploded diagram and part number information, please refer to the Spare Parts Catalog available on our website at www.sram.com.
For order information, please contact your local SRAM distributor or dealer.
Information contained in this publication is subject to change at any time without prior notice. For the latest technical information, please visit our website at www.sram.com.
Your products appearance may differ from the pictures/diagrams contained in this catalog.
Product names used in this document may be trademarks or registered trademarks of others.
table of contents
GETTING STARTED...............................................................................................................................................................................................................................5
brake style & service categories............................................................................................................................................................................................................... 6
tools needed for service................................................................................................................................................................................................................................. 7
elixir cr mag............................................................................................................................................................................................................................................................ 9
elixir r, cr................................................................................................................................................................................................................................................................ 12
code 5 - juicy 3........................................................................................................................................................................................................................................................ 15
code............................................................................................................................................................................................................................................................................. 21
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SAFETY FIRST!
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GETTING STARTED
The following chart lists the serviceable brake models in the 2009 Avid product line. It details each brake model style and the
corresponding service categories.
Important: you must bleed your brakes if you overhaul the levers and/or the calipers on a hydraulic disc brake system.
Overhauling the levers and/or calipers introduces small amounts of air into the system. Failure to bleed the brakes to remove
this air can degrade the performance of your brakes, which could lead to serious and/or fatal injury while riding.
BRAKE STYLE
BRAKE MODELS
ELIXIR 5, R, CR, CR MAG
HYDRAULIC MECHANICAL
LEVER
CALIPER HOSE ADJUST
PAD
DISC
DISC
OVERHAUL OVERHAUL
& BLEED
REPLACEMENT
X
JUICY 3
CODE, CODE 5
SERVICE CATEGORIES
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The following chart is a list of the tools needed to service on your 2009 model year Avid brakes. While this chart is intended
to be comprehensive, it is still only a guide. The tools required for each step of service are detailed in the text of each service
section. Keep in mind your specific brakes may not require every tool listed.
LEVER
OVERHAUL
CALIPER
OVERHAUL
PAD
REPLACEMENT
SAFETY GLASSES
APRON
RUBBER GLOVES
OIL PAN
TOOLS
SAFETY/STARTING EQUIPMENT
WRENCHES/PLIERS
2.5 MM HEX
4 MM HEX
X
X
T-8 TORX
T-10 TORX
T-30 TORX
TORQUE WRENCH
NEEDLE-NOSED PLIERS
MISC TOOLS/KITS
AVID BLEED KIT
X
X
ISOPROPYL ALCOHOL
X
X
SOAPY WATER
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elixir cr mag
introduction
Avid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any area of
the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 4 or 5.1 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake
was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly.
Inspection and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake
function.
lever overhaul service instructions
getting started
exploded view
lever assembly
a . lever body
b . pivot bushings
d. piston spring
e lever blade
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exploded view
a . catcher
c . press sleeve
e . bolt
d. washer
brace
10
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10
snap ring eyelets
12
13
14
brace
11
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elixir r, cr
introduction
Avid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any area of
the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 4 or 5.1 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake
was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly.
Inspection and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake
function.
lever overhaul service instructions
getting started
elixir cr
12
elixir r
exploded view
j
g
a . lever body
e . pivot bushing
k . pivot pin
b . piston spring
d. snap ring
f. lever blade
h . reach adjust knob
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j . lever bolt
10
11
13
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13
16
15
17
18
14
14
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code 5 - juicy 3
introduction
Avid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any area of
the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 4 or 5.1 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake
was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the reservoir cap, bladder
and star wheel assemblies. Inspection and/or replacement of these parts, due to any of the above situations, will be necessary
to restore proper brake function.
lever overhaul service instructions
getting started
15
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11
12
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15
or
juicy
exploded view
internals removal
k
c
a . lever body
f. secondary seal
c . spring coupling
h . washer
b . spring
k . lever
g . snap ring
i . pushrod
e . piston
j . cross- dowel
exploded view
a
b
l
c
a . lever body
f. secondary seal
c . spring coupling
h . coupling retainer
b . spring
d. primary cup seal
e . piston
17
g . coupling assebmly
l . lever
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k
k . pushrod dust boot
16
20
18
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22
24
25
23
code 5
code 5
19
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code 5
26
juicy 3
juicy 3
juicy 3
or
OR
juicy 3
code 5
finishing up
20
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code
introduction
Avid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any area of
the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 4 or 5.1 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake
was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly.
Inspection and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake
function.
CODE lever overhaul service instructions
getting started
21
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11
12
13
14
exploded view
m
c
a . lever body
f. quad seal
k . cam
c . spring coupling
h . pushrod
m . lever
b . spring
e . glide ring
22
g . gear coupling
i . pushrod coupling
j . c - clip
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l . cam spring
15
16
17
18
19
21
22
23
24
internals installation
22. Install the bevel gear into the gear bore and hold
in place with your finger.
23. Install the detent spring and ball into the lever
body.
24. Align the Pad Adjust Knob with the bevel gear
and install the knob using a T-10 Torx. Tighten
the knob to 1-1.2 Nm (8.7-10.4 in-lb). The bevel
gear should now be secure and you no longer
need to hold it in place with your finger.
23
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26
27
28
ring holes
29
30
31
32
ferrule tool
33
ferrule tool
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25
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DISC BRAKE
CALIPER OVERHAUL
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11
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13
14
15
17
19
20
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juicy 3
introduction
Avid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any area of
the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 4 or 5.1 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake
was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly.
Inspection and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake
function.
caliper overhaul service instructions
troubleshooting sticky or slow brake pad return feel
Before completely disassembling your caliper,
its worth trying to loosen the sticky piston. Try
the following: Clamp bicycle in bicycle work
stand. Spin affected wheel. Lightly squeeze
brake lever and watch brake pads when lever
is released. Determine which side of the caliper
has a slow returning brake piston. Remove
caliper from bicycle. If you have a mounting
bracket, it is recommended to remove that too
or just remove the caliper leaving the bracket on
the fork or frame. Using a pair of needle-nosed
pliers, remove both brake pads and h-spring.
Remove the spring pad clip from the outside of
the caliper. Using an 11mm box wrench, press
working piston into caliper body. Squeeze brake
lever slowly to move sticky piston inward. Press
the piston back into the caliper again. Repeat
these steps to correct caliper piston inner o-ring
position. Both pistons should now be moving
freely. Re-install spring pad clip, h-spring, and
pads into caliper. Re-install caliper onto bicycle.
Spin wheel and check function. If there is no
improvement, continue with caliper service.
getting started
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15
17
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22
24
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CODE, CODE 5
introduction
Avid brake lever assemblies need to be serviced in order to optimize braking function. If brake fluid is leaking from any area of
the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 4 or 5.1 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake
was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly.
Inspection and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake
function.
caliper overhaul service instructions
troubleshooting sticky or slow brake pad return feel
Before completely disassembling your caliper,
its worth trying to loosen the sticky piston.
To do so, try the following: Clamp bicycle in
bicycle work stand. Spin affected wheel. Lightly
squeeze brake lever and watch brake pads
when lever is released. Determine which side
of the caliper has a slow returning brake piston.
Remove caliper from bicycle. If you have a
mounting bracket, it is recommended to remove
that too or just remove the caliper leaving the
bracket on the fork or frame. Remove e-clip
from guide pin groove on top of the caliper
using a sharp pick. Using a 2.5 mm hex wrench
remove the guide pin from the caliper. Pull and
remove both brake pads and h-spring. Using a
10 mm box wrench, press working piston into
caliper body. Squeeze brake lever slowly to
move sticky piston inward. Press the piston
back into the caliper again. Repeat these steps
to correct caliper piston inner o-ring position.
Both pistons should now be moving freely.
Re-install spring pad clip, h-spring, and pads
into caliper. Re-install caliper onto bicycle.
Spin wheel, check function. If there is no
improvement, continue with caliper service.
getting started
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11
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13
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20
21
22
23
24
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getting started
37
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foot screw
10
11
12
13
14
38
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17
16
18
19
20
21
22
23
24
grease
grease
grease
39
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25
26
28
29
27
the outer seal should face away from the caliper body
and be located underneath the spring leg.
31. Install the torque arm, aligning the spring leg
with the spring tension notch on the back of the
torque arm. When engaged correctly, the spring
adjuster screw will be driven against the spring
leg on the back of the torque arm. Press the
torque arm onto the flats of the drive cam shaft.
Make sure the arm is fully seated and hold firmly
with your thumb.
32. Place the lockwasher on the drive cam with the
rounded side toward the caliper body. Thread on
the torque arm fixing nut by hand, then torque to
55-60in-lb.
important : do not over tighten the torque arm fixing
nut.
33. Install the outboard adjuster knob by aligning the
rectangle tab of the foot screw with the
rectangular hole in the the knob, then press it on
firmly.
34. Re-install the pad retainer in the outboard
caliper body.
35. Apply a high-strength thread-lock such as
Loctite 272 to the 2 caliper bolts.
36. Align both caliper halves together and insert the
caliper body bolts. The short bolt goes in the hole
near the cable anchor, and the long bolt goes in
the hole near the housing stop. Torque both bolts
to 75-90 in-lb.
note: be careful to keep the pad retainer in place while
joining the halves together.
40
30
31
extended
leg
notch
spring
tension
notch
32
33
34
pad
retainer
35
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36
37
39
41
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42
note:
3: Hose shortening can be performed at either the lever or the caliper on Juicy 3 brakes. However, shortening the hose at the
lever end will allow for an easier bleed.
juicy
Avid highly recommends the use of rubber gloves when handling DOT fluids.
DOT FLUIDS WILL DAMAGE PAINTED SURFACES! If any fluid comes in contact with a painted surface (i.e. your frame)
or printing on the brakes, wipe it off immediately and clean with isopropyl alcohol or water. REMOVAL OF PAINT AND/OR
PRINTING BY DOT FLUID IS NOT COVERED UNDER WARRANTY!
Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be
replaced.
For best results, use only Avid Hi Performance DOT Fluid. If Avid fluid is not available, only use DOT 4 or 5.1 fluid.
Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
NEVER pour used DOT fluid down a sewage or drainage system or into the ground or a body of water.
tools needed
43
Safety glasses
Rubber gloves
Bleed Block
T-10 Torx
Torque wrench
Sharp pick
Towels
Isopropyl alcohol
Compression fittings
Torx
Hose barbs
Syringes
Avid Hi-Performance
DOT Fluid
Bleed Block
(actual bleed block
may differ)
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14
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bleeding procedure
introduction to bleeding
When bleeding Avid brakes, keep in mind that you are simply chasing bubbles out of the system. Avid recommends that you bleed
your brakes at least once a year to ensure optimal performance. If you ride frequently or in aggressive terrain, you should bleed
your brakes more often.
procedure overview
When bleeding brakes, you may notice discoloration of the old fluid as it exits the system into the syringe at the lever. If the fluid is
severely discolored, this indicates that the fluid is very old. In this case, bleeding the system twice in order to completely remove
the old fluid is recommended.
Following this procedure gives you a perfectly bled, optimally performing brake. Enjoy!
46
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7.
5
elixir r /cr /cr mag
elixir
code
juicy
6
elixir r /cr /cr mag
elixir
reach adjust
code
juicy
47
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11
13
12
14
15
17
48
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20
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DISC BRAKE
PAD REPLACEMENT
50
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JUICY 3
introduction
Avid brake pads should be replaced when the total thickness of the backing plate and pad friction material is less than 3mm.
Replacing worn brake pads will improve braking performance. New brake pads are subject to a break-in period. It may take
anywhere from 20 to 40 complete stops to break in Avid pads. You may begin to notice an increase in braking power after the
first ride. Brake noise can occur during the break-in period, as well as off and on throughout the life of the brake pads. This is
normal and should not affect braking performance. Noise is dependent upon factors such as brake setup, rider weight, riding
style, braking style, and riding conditions (i.e. dust, soil, and contamination of friction surfaces).
Tip: If you change your brake caliper pad compound from organic to metallic (or vice versa), you should replace the rotor with
a new one to ensure maximum performace.
pad replacement
push the pistons back in
44
52
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code, CODE 5
introduction
Avid brake pads should be replaced when the total thickness of the backing plate and pad friction material is less than 3mm.
Replacing worn brake pads will improve braking performance. New brake pads are subject to a break-in period. It may take
anywhere from 20 to 40 complete stops to break in Avid pads. You may begin to notice an increase in braking power after the
first ride. Brake noise can occur during the break-in period, as well as off and on throughout the life of the brake pads. This is
normal and should not affect braking performance. Noise is dependent upon factors such as brake setup, rider weight, riding
style, braking style, and riding conditions (i.e. dust, soil, and contamination of friction surfaces).
Tip: If you change your brake caliper pad compound from organic to metallic (or vice versa), you should replace the rotor with
a new one to ensure maximum performace.
pad replacement
remove old brake pads and h-spring
1. Remove e-clip from guide pin groove on top of
the caliper using a sharp pick.
2. Using a 2.5 mm hex wrench remove the guide pin
from the caliper.
3. Squeeze the pads together so they clear the
piston, and pull to remove brake pads and
h-spring from caliper.
4. Inspect and measure the total thickness of each
brake pad with a ruler or the pad thickness slot
on the pad spacer tool. If the total thickness is
less than 3 mm, or it fits into the slot, you need to
replace both brake pads (not pictured).
note: if the backing plate and pad material is thicker
than 3 mm or the slot, you can simply re-install your
brake pads as outlined in steps 5 -10.
install the new pads and h-spring
5. Position the h-spring between the two pads.
note: the code pads are symmetrical , there is not a
left or right orientation.
6. Locate the pad installation feature of the pad
spacer tool. Insert the pad handles into the pad
installation tool so it holds the pads together.
7. Insert the pads and pad tool into the caliper until
the holes in the top of the pads are aligned with
the guide pin holes in the top of the caliper.
8. Insert the guide pin through the caliper body
halves and the brake pads. Using a 2.5 mm hex
wrench, tighten the guide pin to
0.9-1.1 Nm (8-10 in-lb).
9. Remove the pad tool. The h-spring will snap the
pads into position.
10. Using your thumb or finger, install the e-clip into
the groove on the end of the guide pin.
53
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BB7
BB7
BB5
BB5
BB5
BB5
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BB7
BB7
BB5
BB5
55
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BB5
bed-in procedure
WARNING: THE BED-IN PROCESS REQUIRES YOU TO PERFORM
HEAVY BRAKING. YOU MUST BE FAMILIAR WITH THE POWER
AND OPERATION OF DISC BRAKES. BRAKING HEAVILY WHEN
NOT FAMILIAR WITH THE POWER AND OPERATION OF DISC
BRAKES COULD CAUSE YOU TO LOSE CONTROL OF YOUR BICYCLE
WHICH COULD LEAD TO A CRASH WHICH COULD LEAD TO
SERIOUS INJURY AND/OR DEATH. IF YOU ARE UNFAMILIAR WITH
THE POWER AND OPERATION OF DISC BRAKES YOU SHOULD
HAVE THE BED-IN PROCESS PERFORMED BY A QUALIFIED
BICYCLE MECHANIC. THEN YOU SHOULD [PRACTICE YOUR
RIDING AND BRAKING TECHNIQUES ON A FLAT AND LEVEL
SURFACE PRIOR TO AGGRESSIVE RIDING].
to safely achieve optimal results, remain seated on
the bike during the entire bed-in procedure.
56
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www.sram.com
WORLD HEADQUARTERS
SRAM Corporation
1333 N. Kingsbury St., 4th Fl
Chicago, Il 60642
USA
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 Sahn Rd
Shen Kang Hsiang, Taichung
County 429 Taiwan R.O.C.
Phone +886-4-2564-3678
Fax +886-4-2561-3686