Elixir™ 5 Service Manual
Contents
1. Push the pistons back in Elixir calipers are self adjusting the pistons need to be pushed back into the body to their original position before the new pads can be installed The safest way to do this is with the old pads still in the caliper to protect the pistons Place a flat blade screwdriver between the old pads then carefully rock it back and forth pushing the pistons back into their bores 0 6 0 9 N m 5 8 in Ib Remove the old pads Grab the pad tabs and pull straight out Install the new pads and spreader Be sure the spreader clip is oriented to the pads as shown Align the hole in the spreader clip with the holes in the pad tabs Squeeze the pad and clip assembly together then insert into the caliper as a unit Firmly push until the assembly is seated into place 5 Re install the pad retainer bolt Replace the pad retainer bolt tighten to torque specifications and replace the e clip on the wheel side of the caliper DISC BRAKE PAD INSTALLATION INSTRUCTIONS 2 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE All new brake pads and rotors should be put through a wear in process called bed in The bed in procedure which should be performed prior to your first ride ensures the most consistent and powerful braking feel along with the quietest braking in most riding conditions The bed in process heats up the brake pads and rotors which deposits an even layer of brake pad material transfer layer to the bra2. the pads are contaminated and must be replaced For best results use only Avid High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE DOT Grease or DOT 5 1 or 4 compatible grease Oil pan Air compressor with blow gun chuck Safety glasses 5mm hex bit socket Nitrile gloves 8mm flare nut crowfoot Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid 8mm open end wrench e 2 5mm and 5 mm hex wrenches e Sharp pick Flat blade screwdriver e Clean lint free rags Isopropyl alcohol Torque wrench TROUBLESHOOTING Sticky or slow brake pad return feel Before completely disassembling your caliper it s worth trying to loosen the sticky piston Try the following ON OO KWH Clamp the bicycle in a bicycle work stand Spin the affected wheel Lightly squeeze the brake lever and watch the brake pads when the lever is released Determine which side of the caliper has a slow returning brake piston Remove the caliper from the bicycle If you have a caliper mounting bracket remove the bracket with the caliper attached Remove e clip from the guide pin groove on top of the caliper Use a 2 5 mm
3. careful DOT fluid will drip from the hose Try not to spill too much fluid because any fluid that drips out will create bubbles that you ll have to eliminate later Slide the nut down the hose and away from the end where you ll be cutting Do not pull the brake lever while the hose is removed AVID BRAKE HOSE LENGTH ADJUSTMENT 23 Determine where you need to cut the hose by holding it up to the lever in the position you like Make sure to leave a gentle bend in the hose with enough length to freely turn the bars all the way from side to side Double check this measurement because you can t go back after you cut The groove in the lever nose marks the spot where you ll cut the hose Cut the hose using hydraulic hose cutters or very sharp cable housing cutters Apply Avid DOT Grease to the threads of a new hose barb the compression fitting outer surfaces and compression nut threads While holding the hose firmly use a T10 TORX to thread the hose barb into the end of the hose until it is flush Slide a new compression fitting over the end of the hose with the new hose barb Push the hose firmly into the lever until it stops While holding the hose in place slide the compression fitting and compression nut up to the lever or hose stop AVID BRAKE HOSE LENGTH ADJUSTMENT 24 For models with a compression nut and a hex hose stop While continuing to push the hose into the hose stop use an 11 mm open end wrenc
4. 2012 Elixir 5 Service Manual GEN OOOOO000003519 Rev B SRAM LLC WARRANTY SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase This warranty only applies to the original owner and is not transferable Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased Original proof of purchase is required This warranty statement gives the customer specific legal rights The customer may also have other rights which vary from state to state USA from province to province Canada and from country to country elsewhere in the world To the extent that this warranty statement is inconsistent with the local law this warranty shall be deemed modified to be consistent with such law under such local law certain disclaimers and limitations of this warranty statement may apply to the customer For example some states in the United States of America as well as some governments outside of the United States including provinces in Canada may a Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or i
5. ERHAUL 17 4 Use an 8 mm open end wrench to remove the compression fitting Pull the brake hose and compression fitting from the caliper body Brake fluid will leak so hold the caliper over a container to catch the fluid Use a 5 mm hex to remove the caliper body bolts Separate the caliper body halves and open the caliper assembly ELIXIR 5 BRAKE CALIPER OVERHAUL 7 Caliper Piston Removal Insert an air compressor chuck nozzle into the hole on the inside of one of the caliper body halves Hold the caliper in one hand and point the caliper piston in a safe direction Inboard caliper half only Hold one finger covered by at least two rags over the hose connection port on the top of the caliper body so air does not escape Squeeze the air chuck and force air into the hole The compressed air will unseat the piston from the caliper Remove the piston from the caliper Point the caliper in a safe direction Cover the piston with two rags to prevent the piston from causing injury or becoming lost Repeat this process for the other caliper body half Ss f N a Insert chuck nozzle y k i ow y 8 Hi 7 N 4 ry j r x p f xw wt L 7 lt ai a aye ey A Ue ELIXIR 5 BRAKE CALIPER OVERHAUL Remove the square edge o ring from inside each caliper body half with a sharp pick Lubricate the new square edge o rings with Avid High Performance 5 1 DOT Flui
6. Inspect the banjo bolt and banjo for any protruding o rings If there are any o rings that are Squeezed beyond the outside edges of the banjo or bolt remove and replace the o rings and then repeat the installation process Remove the Bleed Block from the caliper and re install the brake pads and spreader clip 22 Reinstall your wheel according to the manufacturer s instructions Empty the syringes into a sealed container and dispose of the fluid properly Remember DOT fluid should be recycled or disposed of in accordance to local and federal regulations NEVER pour DOT fluid down a sewage or drainage system or into the ground or a body of water Do not re use this fluid Do not leave the hose clamps closed this will damage the clear tubing on the syringes Z You are almost ready to ride but first its a good idea to test your brakes Pull on the lever extremely hard as hard as you can imagine yourself pulling the lever while you re riding several times Make sure to look around the compression nut on the lever and the banjo bolt on the caliper for any leaks Make one last check of all the bolts and fittings If everything checks out YOU ARE READY TO RIDE AVID BRAKE BLEED PROCEDURE DISC BRAKE PAD INSTALLATION INSTRUCTIONS Remove pad retainer bolt Start by removing the e clip on the wheel side of the caliper then unthread the retainer bolt using a 2 5 mm hex wrench Remove the retainer bolt all the way
7. VERHAUL 4 Rotate the reach adjust knob until the Phillips head screw is visible Use a small Phillips head screwdriver to turn the screw in the reach adjust knob counter clockwise and unthread it from the knob 5 Use a 3 mm hex to turn the lever bolt counter clockwise and unthread it from the lever body Use a flat blade screwdriver to carefully remove the reach adjust knob and attached spring Eye Hazard Do not look directly into the lever body while performing this step The internal reach adjust knob spring assembly is preloaded and will come out of the lever body quickly Wear safety glasses ELIXIR 5 BRAKE LEVER OVERHAUL 7 Pull the lever blade to the open position to disengage the pushrod from the piston Use your finger to push the pivot pin out of the lever body Remove the lever blade along with the pushrod The pivot bushings may fall out of the lever blade this is ok Simply re insert them into the lever blade ELIXIR 5 BRAKE LEVER OVERHAUL 1O Clamp a 2 mm hex into a vise with the long end extending upward Install the lever body onto the hex and insert the hex into the hole located in the fluid flow port Place a clean rag under the lever body to wipe up any fluid that may spill out Use long snap ring pliers to compress the snap ring located in the lever body Then apply downward pressure to the lever body and use the pliers to remove the snap ring and piston bladder assembly Remove th
8. amp must point up Use a torque wrench with a 4 mm hex bit socket to re install the brake clamp bolt and tighten the top bolt completely to 2 8 3 4 N m 25 30 in Ib so there is no gap Then tighten the bottom bolt to the same torque 4 9 5 4 N m 43 48 in Ib 2 8 3 4 N m 25 30 in Ib ELIXIR 5 BRAKE LEVER OVERHAUL 15 ELIXIR 5 BRAKE CALIPER OVERHAUL Avid brake lever assemblies need to be serviced periodically in order to optimize braking function If brake fluid is leaking from any area of the brake lever assembly there may be damage or wear and tear to the internal moving parts If your brake was filled with fluid OTHER than DOT 5 1 or 4 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the housing assembly Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function 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
9. and outer Handlebar grips Shifter grips Jockey wheels Disc brake rotors Wheel braking surfaces Bottom out pads Bearings Bearing Races Pawls Transmission gears Spokes Free hubs Aero bar pads Corrosion Tools This warranty shall not cover damages caused by the use of parts of different manufacturers This warranty shall not cover damages caused by the use of parts that are not compatible suitable and or authorized by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use AVID BRAKE SERVICE We recommend that you have your Avid brakes serviced by a qualified bicycle mechanic Servicing Avid brakes requires knowledge of brake components as well as the special tools and fluids used for service This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols and respectively Copyright SRAM LLC 2011 For exploded diagram and part number information please refer to the Spare Parts Catalog available on our web site at www sram com For order information please contact your local SRAM distributor or dealer Information contained in this publication is subject to change at any time without prior notice For the latest technical information please visit our website at www sram com Your product s appearance may differ from the pictures diagrams contained in this catalog Product names used in this document may be trademarks or reg
10. assembly there may be damage or wear and tear to the internal moving parts If your brake was filled with fluid OTHER than DOT 5 1 or 4 such as mineral oil or DOT 5 damage to all rubber and plastic internal parts may exist If your brake was damaged in a crash there may be damage to the lever blade and pushrod assemblies as well as the housing assembly Inspection and or replacement of these parts due to any of the above situations will be necessary to restore proper brake function Avid highly recommends the use of nitrile 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 High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations e Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE Safety glasses Torque wrench Nitrile gloves 4mm hex bit socket Sma
11. d and install them inside each caliper body half Do not scratch the o ring gland with the pick You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant Inspect the caliper pistons for damage and replace if necessary Re install the caliper brake pistons into each half of the caliper body Make sure the piston slots are horizontal in the caliper body this keeps the fluid slots on the back side of piston lined up with fluid ports Use a sharp pick to remove and replace the o ring located on the inside of the inboard caliper half Make sure the o ring is seated in the recessed gland Do not scratch the o ring gland with the pick Use a sharp pick to remove and replace the o ring located on the compression fitting 19 ELIXIR 5 BRAKE CALIPER OVERHAUL Re assemble the caliper body halves and re install the caliper body bolts Use a torque wrench with a 5 mm hex bit socket to tighten the caliper body bolts to 8 5 10 N m 75 90 in lb 8 5 10 N m 75 90 in Ib 12 Re install the compression fitting and brake hose onto the caliper by hand Use a torque wrench with an 8 mm flare nut crowfoot to tighten the compression fitting to 4 9 5 4 N m 43 48 in lb 4 9 5 4 N m 43 48 in Ib 13 Insert the Bleed Block into the caliper in place of the brake pads You will need to bleed your brakes before re installing the brake pads 14 Clean the assembled caliper with alcohol and a clean rag
12. d the lever back to its original position Close the clamp on the caliper syringe then remove the syringe from the caliper and re install the bleed port screw Use a clean rag to wipe off any excess DOT fluid that spills out as you re install the bleed port screw 16 Open the syringe clamp on the lever 17 Pull out on the lever syringe plunger to create a vacuum then gently push in on plunger to pressurize the system Squeeze and release the brake lever ten times allowing the lever to snap back to its starting position after squeezing this helps break loose the bubbles Repeat this procedure of creating a vacuum at the syringe and squeezing the brake lever ten times until large bubbles stop coming out of the lever Do not pull out too hard on the plunger or you will suck air past the plunger seal into the fluid and create more bubbles that you will have to eliminate AVID BRAKE BLEED PROCEDURE 0 Once the large bubbles at the lever have stopped apply a small amount of pressure on the syringe plunger then remove the syringe and re install the bleed port screw There will be a small amount of excess DOT fluid that spills out as you remove the syringe and re install the bleed port screw this is normal be sure to wipe the fluid off the lever with a clean rag Spray isopropyl alcohol or water onto a clean rag and wipe off the brake lever and caliper to remove any excess DOT fluid 2O Visually check your work
13. e Bleed Block This will help prevent system overfill and keep DOT fluid from contaminating your brake pads Click here for detailed brake pad removal instructions 4 Use the T10 TORX to remove the caliper bleed port screw from the caliper body or banjo bolt Make sure the fluid in the 1 2 full syringe is pushed all the way to the tip no air gap then thread into the caliper bleed port AVID BRAKE BLEED PROCEDURE 27 For models with Contact Point Adjustment and a rotating bleed port screw located on the contact point adjuster rotate the adjuster in the direction opposite the arrow until it stops then rotate the adjuster back just enough to place the bleed screw at its highest point For models with Contact Point Adjustment and a fixed bleed port screw rotate the adjuster in the direction opposite the arrow on the adjuster knob until it stops 7 For models equipped with Reach Adjust make sure the tip of the lever blade is 75 80 mm from the centerline of the handlebar If the lever is too far out it can make bleeding the brake impossible 8 Use the T10 TORX to remove the lever bleed port screw Make sure the fluid in the 1 4 full syringe is pushed all the way to the tip no air gap then thread into the lever bleed port It is not necessary to reposition the angle of the brake lever on the handlebar You may have a small amount of DOT fluid drip from the bleed port screw this is normal Just have a clean rag ha
14. e lever body from the hex The piston bladder assembly is attached to the snap ring Eye Hazard Do not look directly into the lever body while performing this step The internal piston spring assembly is preloaded and will come out of the lever body quickly Wear safety glasses Replace the entire piston bladder snap ring assembly with a new assembly Lubricate the new assembly by dipping it into Avid High Performance 5 1 DOT Fluid You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant ELIXIR 5 BRAKE LEVER OVERHAUL 11 12 Use long snap ring pliers to push the piston bladder snap ring assembly into the lever body and secure the snap ring in the groove of the lever body You can also use a long 10 mm socket against the snap ring to push the assembly into the lever body If you push the snap ring past its groove you can use the 2 mm hex in the vise to push on the assembly from inside the fluid flow port which will seat the snap ring into the groove Insert a pivot bushing into each side of the lever blade 14 Re install the lever blade and reach adjust pushrod into the lever body Align the ball shaped end of the pushrod with the socket in the piston Push the lever blade into the lever body to insert the pushrod into the piston You will hear a click when the pushrod is seated You can use the 2 mm hex in the vise to support the assembly from inside the fluid flow port as you push the
15. h to hold the hose stop in place and use an 8 mm flare nut wrench to tighten the compression nut to the proper torque For models with a compression nut only While continuing to push the hose into the lever body use an 8 mm flare nut wrench to tighten the compression nut to the proper torque If your compression fitting is alloy tighten to 5 N m 47 in lb If your compression fitting is steel tighten to 7 8 N m 70 in lb 9 Slide the boot back into place Cutting the hose introduces a small amount of air into the system so at this point it is necessary to bleed the brakes for optimal performance See the next section Avid Brake Bleed Procedure for instructions AVID BRAKE HOSE LENGTH ADJUSTMENT 25 AVID BRAKE BLEED PROCEDURE Avid brakes are the most powerful and precise hydraulic brakes on the market A key reason behind this is the ability to optimize brake performance with a perfect bleed The goal of bleeding is to remove any air that is trapped in the hose caliper or lever Air trapped in a hydraulic brake system degrades the performance of the brake The following instructions will walk you through our simple bleed procedure Avid brakes come with hoses attached and bled If you don t need to change the hose length you do not need to bleed the system prior to installation Supplemental video instruction is available at www sram com en service Avid highly recommends the use of nitrile gloves when handl
16. hex to remove the guide pin from the caliper Remove both brake pads and h spring Use a 10 mm box wrench to press the working piston into caliper body While continuing to hold the piston inside the caliper body squeeze the brake lever slowly to move the sticky piston inward Press the piston back into the caliper again Repeat these steps to correct caliper piston inner o ring position Both pistons should now be moving freely Re install the spring pad clip h spring and pads into the caliper If there is no improvement continue with caliper service Re install the caliper Cor mounting bracket with attached caliper on the bicycle You may need to re center the caliper to the rotor If you removed the caliper without an adapter or removed it from the adapter it will need to be re centered Spin the wheel and check brake function ELIXIR 5 BRAKE CALIPER OVERHAUL 16 Use a5 mm hex to remove the brake caliper from the fork or frame and remove the caliper mounting bracket and hardware from the caliper Set aside in the correct order not pictured 2 Remove the e clip from the guide pin groove on top of the caliper Use a 2 5 mm hex to remove the guide pin from the caliper 3 Pull and remove both brake pads and h spring If the total thickness of the backing plate and pad friction material is less than 3 mm the brake pads need to be replaced Click here for detailed brake pad removal instructions ELIXIR 5 BRAKE CALIPER OV
17. ing 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 High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE e Safety glasses Avid Bleed Block Nitrile gloves 2 5 and 4 mm hex wrenches T10 TORX e Sharp pick e Isopropyl alcohol e Clean lint free rag Avid Bleed Kit or Avid Professional Bleed Kit Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid High Performance DOT Fluid Avid Bleed Block actual bleed block may differ Avid Bleed Kit Contents AVID BRAKE BLEED PROCEDURE 26 When bleeding Avid brakes keep in mind that you are simply forcing air bubbles out of the system We recommend that you bleed your brakes at least once a year to ensure optimal performance If you ride frequently or in aggress
18. istered trademarks of others TABLE OF CONTENTS ELIXIR S BRAKE LEVER OVERIIAULL A l i i SS aaa n zo 5 PARTS AND TOOLS NEEDED POR SERVICE rd uapa eer EE E A R kapaq A A Cadets Ped rectal STEE eat 5 ELIXIR gt BRAKE CALIPER OVERHAUL issia aaaeaii Oa aaao aa a Eaa aaa a aAA aiea Ea Eaei 15 PARTS AND TOOELS NEEDED UP OR SERVICE u an A aE TE A q uu AE hana aasan 15 AVID BRAKE HOSE LENGTH ADJUSTMENT socaire a uuu L uuu s a sai asas asas asua asss 21 PARTS AND IGOESINEEPDEDTOPESERVICE unu u S naa ANNAE E cee ck sah de rece a eg mn i une era thet eee kuu akta 21 AVID BRAKE BEEEED PROGEDURE u uuu luu u done eradeaucecce Eaa aa EE aa e aea S a eea 25 PARTS AND TOOLS NEEDED FOR SERVICE oropan maana R saqma seinen tetera cea ones 25 DISC BRAKE PAD INSTALLATION INSTRUCTION S u 31 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE 32 SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your componentry Protect yourself Wear your safety gear Important Your parts may look different from those illustrated ELIXIR 5 BRAKE LEVER OVERHAUL Avid brake lever assemblies need to be serviced periodically to optimize braking function If brake fluid is leaking from any area of the brake lever
19. ive terrain you should bleed your brakes more often 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 Fill one syringe 1 2 full with Avid High Performance 5 1 DOT Fluid and fill the other syringe 1 4 full Hold each syringe with the tip pointed up and tap the side of the syringe with your finger to bring any air bubbles to the top Place a clean rag around the tip and slowly push the air bubbles out of the syringe Close the hose clamp on each syringe P o o Aa i 00 0 0 lt eae eee 2 De gas the fluid in the 1 2 full syringe Leave the hose clamp a s shut and pull on the plunger Bubbles will form in the brake fluid While the ba G I Bethe n O plunger is still pulled down lightly tap the syringe to release a oe the bubbles sticking to the sides and the bottom so that they can rise to the top pO Soo rer of the fluid When the bubbles stop forming and have all risen to the top release of o8 the plunger open the clamp and carefully push the air out Repeat several times You will not be able to remove all the bubbles N 3 Remove the wheel from your bike Remove the brake pads and spreader clip from the caliper and insert the appropriat
20. king surface of the rotor It this transfer layer that optimizes braking performance 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 and could lead to serious injury and or death If you are unfamiliar with the power and operation of disc brakes you should have the bed in process performed by a qualified bicycle mechanic To safely achieve optimal results remain seated on the bike during the entire bed in procedure Accelerate the bike to a moderate speed then firmly apply the brakes until you are at walking speed Repeat approximately twenty times 2 Accelerate the bike to a faster soeed Then very firmly apply the brakes until you are at walking speed Repeat approximately ten times A Do not lock up the wheels at any point during the bed in procedure Allow the brakes to cool prior to any additional riding DISC BRAKE PAD AND ROTOR BED IN PROCEDURE WWWwW Sram comM
21. lever blade and pushrod into the piston ELIXIR 5 BRAKE LEVER OVERHAUL 12 15 Align the holes of the lever blade bushings and lever body then use your fingers to install the pivot pin 16 Slide the lever bolt through the hole in the pivot pin 17 Hold the lever blade in the closed position to slide the piston spring over the threaded end of the bolt ELIXIR 5 BRAKE LEVER OVERHAUL 13 Place the flat side of the reach adjust knob onto the spring compress the spring and slide the reach adjust knob into place in the lever body as you slowly release the lever blade Rotate the reach adjust knob so that the chamfered hole is visible 20 a 3 mm hex to turn the lever bolt clockwise until it is snug Then turn the bolt counter clockwise 1 4 turn until the slot in the bolt is aligned with the chamfered hole in the reach adjust knob ELIXIR 5 BRAKE LEVER OVERHAUL 14 21 Use a small Phillips head screwdriver to re install the screw for the reach adjust knob into the chamfered hole and tighten until it is snug If the screw does not thread into the knob check that the chamfered hole and the slot in the bolt are aligned 22 Thread the compression nut into the lever body by hand Use 25 a torque wrench with an 8 mm flare nut crowfoot to tighten the compression nut to 4 9 5 4 Nem 43 48 in lb Slide the hose boot over the compression nut Re install the brake lever onto the handlebar Arrows on the cl
22. ll Phillips head screwdriver 8mm flare nut crowfoot Flat blade screwdriver 8mm flare nut wrench Long snap ring pliers 2 3 and 4 mm hex wrenches Oil pan Bench vise or 10 mm open end wrench Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid e Isopropyl alcohol DOT Grease or DOT 5 1 or 4 compatible grease Clean lint free rag ELIXIR 5 BRAKE LEVER OVERHAUL EXPLODED VIEW ELIXIR 5 BRAKE LEVER ASSEMBLY A LEVER BODY B LEVER SPRING C REACH ADJUST KNOB D REACH ADJUST SCREW E PIVOT PIN F LEVER BLADE PUSHROD ASSEMBLY G PISTON BLADDER ASSEMBLY H PIVOT BUSHINGS LEVER BOLT ELIXIR 5 BRAKE LEVER OVERHAUL Remove the brake lever from the handlebar Use a 4 mm hex to remove the brake clamp bolts from the clamp Pull the hose boot off the compression nut and slide it down the hose If dirty clean the levers with alcohol and a clean rag 2 Use an 8 mm flare nut wrench to unthread the hose compression nut Pull the brake hose and compression fitting from the brake lever body 3 Allow any brake fluid to drain into a container Hold the lever assembly over the container and squeeze the lever to pump any brake fluid from inside the lever assembly If the system has been contaminated with the wrong fluid you will need to flush all the parts with soapy water rinse and allow to dry prior to rebuilding You will also need to install all new seals and a new hose ELIXIR 5 BRAKE LEVER O
23. ndy to wipe off any excess after the syringe is installed AVID BRAKE BLEED PROCEDURE 28 12 15 Hold both syringes upright Gently push on the caliper syringe plunger to move fluid from the caliper syringe into the lever syringe until the lever syringe is increased to 1 2 full and the caliper syringe is decreased to 1 4 full You should see bubbles form in the lever syringe Close the syringe clamp on the lever Pull the brake lever all the way to the bar with your finger and hold it there until instructed to release the lever in a later step If you don t want to hold the lever with your finger have a friend hold it or you can fasten it with a zip tie or rubber band Pull out on the caliper syringe plunger to create a vacuum then gently push in on the plunger to pressurize the system Repeat this procedure several times until large bubbles stop coming out of the caliper Do not pull the plunger past the end of the syringe AVID BRAKE BLEED PROCEDURE 29 14 Once the large bubbles at the caliper have stopped apply a small amount of pressure on the syringe plunger and slowly let the pressure extend the brake lever you have been holding with your finger If you fastened the lever with a zip tie or rubber bands remove these first but keep the lever pulled in with your finger then apply pressure on the syringe plunger You will feel the pressure at your finger on the lever just let the fluid exten
24. to remove any brake fluid Overhauling the caliper introduces a small amount of air into the system so at this point it is necessary to bleed the brakes for optimal performance See the section Avid Brake Bleed Procedure for instructions 20 ELIXIR 5 BRAKE CALIPER OVERHAUL 21 AVID BRAKE HOSE LENGTH ADJUSTMENT After completing the hose length adjustment it will be necessary to bleed the brakes for optimal performance See the section Avid Brake Bleed Procedure for instructions Avid highly recommends the use of nitrile 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 High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid e Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water PARTS AND TOOLS NEEDED FOR SERVICE e Safety glasses Nitrile gloves H
25. ts third party suppliers be liable for direct indirect special incidental or consequential damages This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM technical installation manual The SRAM installation manuals can be found online at www sram com www rockshox com www avidbike com www truvativ com or Www zipp com This warranty does not apply when the product has been modified This warranty does not apply when the serial number or production code has been deliberately altered defaced or removed This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturer s specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not apply to normal wear and tear Wear and tear parts are subject to damage as a result of normal use failure to service according to SRAM recommendations and or riding or installation in conditions or applications other than recommended Wear and tear parts are identified as Dust seals Bushings Air sealing o rings Glide rings Rubber moving parts Foam rings Rear shock mounting hardware and main seals Stripped threads and bolts aluminum titanium magnesium or steel Upper tubes stanchions Brake sleeves Brake pads Chains Sprockets Cassettes Shifter and brake cables inner
26. ydraulic hose cutters or very sharp cable housing cutters Avid DOT Grease or DOT 5 1 or 4 compatible grease Isopropyl alcohol Avid Bleed Kit or Avid Professional Bleed Kit Compression fittings Hose ANS SIM FA por FLUID Adjustable torque wrench 8 mm flare nut wrench 11 mm open end wrench T10 TORX Clean lint free rag Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid Avid Bleed Block High Performance actual bleed block DOT Fluid Avid Bleed Kit Contents may differ AVID BRAKE HOSE LENGTH ADJUSTMENT 22 2 K 4 Make sure the hoses are properly secured to the bicycle and check the routing of each hose Account for suspension movement and be sure the handlebars can move freely by turning the bars all the way from side to side Pull the hose boot away from the lever to access the compression nut If the boot sticks carefully pry up a corner with something that won t harm it like the end of a zip tie and spray isopropyl alcohol between the boot and the lever Work the alcohol in the boot should loosen up and slide easily down the hose For models with a compression nut and a hex hose stop Use an 11 mm open end wrench to hold the hose stop in place and use an 8 mm flare nut wrench to unthread the compression nut For models with a compression nut only Use an 8 mm flare nut wrench to unthread the compression nut Compression nut Pull the hose from the lever Be
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