Avid Technology AVID DISC BRAKES Instruction sheet

Only levers designated for side-pull brakes, such as
Avid’s Speed Dial Series and AD 3 levers, can be
used the Mountain Ball Bearing Disc Brake. For
best operation and performance Avid highly recom-
mends that you use an Avid Speed Dial lever and
premium quality brake cable and housing. Failure
to do so will reduce the performance of the sys-
tem.
Avid Disc brakes are compatible with 44mm, 6-bolt,
International Standard hubs.
We recommend 32 or 36 spoke wheels with a 3 or
4 cross spoke lacing pattern.
DO NOT USE RADIALLY SPOKED WHEELS.
DO NOT TOUCH THE BRAKING SURFACE OF
THE ROTOR WITH YOUR BARE HANDS.
WEAR GLOVES, OR HANDLE THE ROTOR BY THE SPOKES. OILS
FROM YOUR FINGERS WILL DEGRADE THE PERFORMANCE OF
ANY DISC BRAKE. DISC BRAKES BECOME VERY HOT DURING
USE. DO NOT TOUCH THE CALIPER OR ROTOR IMMEDIATELY
AFTER USE. MAKE SURE THE BRAKE HAS COOLED DOWN
BEFORE MAKING ANY ADJUSTMENTS.
1
TOOLS NEEDED: 2.5mm & 5mm hex wrenches, T-25 TORX®wrench, adjustable
torque wrench [5-10Nm (40-90 IN-Lbs) range,] and cable cutters.
Mount rotor to hub using supplied
T-25 TORX
®
bolts and tighten to
the specified torque.
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MMUUSSTTffaacceeoouutt..Install wheel into
fork or frame.
IF YOU ARE USING A HUB WITH
A REMOVABLE SHIM - YOU MAY
NEED LONGER ROTOR MOUNTING BOLTS.
CONTACT THE HUB MANUFACTURER FOR THE
RECOMMENDED BOLTS.
WWAARRNNIINNGG
2
For International Standard Mount, bolt the
caliper assembly and mounting bracket
(“AVID” facing OUT) to the I.S. mounting
tabs using the M6 bolts provided. Tighten
to the specified torque value. Loosen
slightly the two CPS bolts that attach the
caliper to the mounting bracket.
For Manitou forks, remove the mounting
bracket, leaving the CPS bolts & washer
stacks intact. Discard the bracket and
install the caliper on the fork.
DDoonnoottttiigghhtteenntthheeCCPPSSbboollttssyyeett..
3
WWAARRNNIINNGG
TTOORRQQUUEE::
99-1100NNmm((8800-9900IInn-LLbbss))
Install the rotor Mount the caliper
Align the Caliper
FRONT
REAR CPS BOLT
BRACKETS CPS HARDWARE
DDOONNOOTTTTIIGGHHTTEENNYYEETT!!
BBRRAAKKEEIINNSSTTAALLLLAATTIIOONN
Rotor should be offset to the outboard
side of the rotor slot. Ideal ratio is
1/3 to 2/3.
2002 Mountain Ball Bearing Disc Brake
Installation Guidelines
11//3322//33
IMPORTANT
Brakes are a safety-critical item on a bicycle. Improper set-up or use of brakes can result
in loss of control or an accident, which could lead to a severe injury.
AAvviiddbbrraakkeessaarreeaappeerrffoorrmmaanncceepprroodduucctttthhaattooffffeerriinnccrreeaasseeddssttooppppiinngg
ppoowweerroovveerrssttaannddaarrddbbrraakkeess..It’s your responsibility to learn and understand prop-
er braking techniques. Consult the owner’s manual for your bicycle and a professional
bike dealer. Practice your riding and braking techniques on a flat and level surface prior
to aggressive riding.
The effectiveness of braking is dependent on many conditions over which Avid has no
control. These include the speed of the bicycle, type and condition of the riding surface,
braking lever force, proper installation and maintenance of brakes, cables, levers, brake
pads, the condition of the bike, weight of the rider, proper braking techniques, weather,
terrain, and a variety of other factors.
Avid brakes and levers are not intended for use on any motorized bicycle or vehicle. Any
such use could result in a serious personal injury.
ALWAYS RIDE UNDER CONTROL.
Remember, it takes longer to stop in wet conditions. To reduce the possibility of an
accident and minimize trail erosion, you should avoid locking-up your wheels.
FOLLOW THESE INSTRUCTIONS CAREFULLY.
IF YOU DO NOT UNDERSTAND THE INSTRUC-
TIONS, HAVE THE INSTALLATION DONE BY A
PROFESSIONAL BIKE MECHANIC.
ii
Rotor
Caliper
Turn the inboard (closest to the wheel) knob clockwise
until the rotor is properly positioned in the caliper body.
A. B.
True the Caliper
Turn the outboard pad adjustment knob in until it is firmly squeezing
the rotor against the inboard pad - thus immobilizing the actuating
arm.
Pad
IMPORTANT:
If uusing rracks, ppanniers, oorffenders, tthis iisaaggood ttime
to eensure tthere iiscclearance ffor tthe ccaliper ttorque aarm
to mmove tthrough iits ccomplete rrange oofmmotion.
IMPORTANT:
The ssupplied TORX®wrench
is ffor eemergencies oonly.
Use aattorque wwrench tto
ensure pproper ttorque
value.
TTOORRQQUUEE::
66..22NNmm((5555IInn-LLbbss))
Tip:
If the adjuster knobs are difficult
to turn, turn them back and forth a
few times until they feel smooth.

LIMITED WARRANTY
Avid, LLC (Avid) warrants to the original consumer purchaser of everyAvid product that the product shall be free from defects in workman-
ship and materials for a period of one (1) year from the original date of purchase. The sole remedy under this warranty is limited to, atAvid's
sole discretion, repair or replacement of the defective product. Labor and shipping costs are excluded from this warranty. This warranty only
applies to the original consumer purchaser and is not transferable.
THIS WARRANTY DOES NOT COVER normal wear and tear (including, without limitation, brake pad wear), or defects or failures that are
related in any way to improper installation or follow-up maintenance, accident, abuse or neglect (including, without limitation, thread damage).
Since Avid has no control over the product's final use, Avid also does not warrant the suitability of the product for specific riders and/or uses.
IN NO EVENT SHALL AVID BE RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER BASED ON CON-
TRACT, WARRANTY, NEGLIGENCE, OR STRICT OR PRODUCTS LIABILITY, INCLUDING WITHOUT LIMITATION, PERSONAL INJURY
DAMAGES, PROPERTY DAMAGE OR ECONOMIC LOSSES. Some states do not allow the exclusion or limitation of incidental or conse-
quential damages, so the above limitation or exclusion may not apply to you.
AVID MAKES NO OTHER EXPRESS WARRANTIES. ALL IMPLIED WARRANTIES, INCLUDING ANY WARRANTIES OF MER-
CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE ONE (1) YEAR DURATION OF THIS
WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
Claims under this warranty may be initiated with any Avid dealer. If this is not practical, you may contact Avid in writing at the address listed
below. Dated proof of purchase must accompany all warranty claims.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Spring tension adjustment
If necessary, spring tension can be adjusted by turning
the spring tension adjustment screw with a 2.5mm hex
wrench. Turning the screw clockwise increases spring
tension, which equals harder lever pull.
Cable slack adjustment
Use the barrel adjuster on the brake lever to
remove any cable slack from the system.
Turn the adjuster out until there is no free
play in the lever, but not so far that the
torque arm on the caliper is advanced. The
torque arm should return completely when
the brake lever is released.
Pad wear adjustment
As with any brake, you will need to compensate for brake pad wear over time. To do this, turn
both inboard and outboard red adjusting knobs CLOCKWISE 1 or 2 clicks as needed to restore
your brake to optimum settings. DO NNOT uuse yyour bbarrel aadjuster ttoccompensate ffor ppad wwear.
A pad wear indicator is at the center of each knob. As the knob is turned in, the indicator will
retract deeper into the knob giving a visual indication of approximately how much the pads have
worn.
Care and cleaning
Pad replacement
A pad should be replaced when it’s total thickness (backing plate & friction
material) is less than 3mm.
To remove the pads, back both adjuster knobs all the way out (counter-clockwise,)
then squeeze the pad tabs together and pull both pads straight out of the caliper.
Reverse the process for installation of the new pads. Squeeze the brake pad/spring
clip assembly together then press firmly into the caliper until it “clicks” into place.
Before each ride
Extreme care must be taken when cleaning both the bicycle and
its new disc brakes. Under normal use, it is not necessary to
clean the caliper rotor or pads. If necessary, use only water and
dish detergent to wash the caliper and rotor - being sure to thor-
oughly rinse all soap residue from the rotor. Dry with a clean
paper towel.
- Check cables for signs of wear or fraying.
- Squeeze the brake lever firmly and check for proper brake
function. Adjust for pad wear if necessary.
- Check pads for wear and replace if necessary.
- Make sure rotors are free of foreign substances and oils.
DISC BRAKES ARE OIL SENSITIVE! DO NOT SPRAY ANY SOL-
VENTS OR LUBRICANTS IN THE VICINITY OF THE ROTORS OR
BRAKE PADS. NEVER TOUCH THE PAD SURFACE OR ROTOR
SURFACE WITH YOUR FINGERS. DOING SO WILL SIGNIFICANT-
LY DEGRADE BRAKING PERFORMANCE.
WARNING
Tighten the two
CPS bolts that
attach the caliper
to the mounting
bracket. Tighten
one and then the
other, repeating
until they are at the
specified torque.
4Tighten the caliper 5Install the cable
6Turn both pad adjustment knobs counterclockwise until desired
pad/rotor clearance is achieved (approximately 2 or 3 clicks
each).
IIMMPPOORRTTAANNTT::
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bbrraakkeeppaaddwweeaarraaddjjuussttmmeenntt,,uusseebbootthhtthheeiinnbbooaarrddAANNDDoouuttbbooaarrdd
kknnoobbss..Outboard pad adjustment knob Inboard pad adjustment knob
Adjust brake pads
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Avid, LLC. 2875 W. Oxford Ave, Englewood, CO 80111 USA - 303-762-9353 - www.avidbike.com
Brake pad 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 not only during the break-in period, but off and on though out the life of the brake pads. Noise is dependent upon factors such as brake set-up,
rider weight, riding style, braking style, and riding conditions (i.e. dust, soil, etc. contamination of friction surfaces).
Pad Wear
Indicators
Pass the brake wire through the anchor
bolt on the actuating arm. Cable slack
may be removed with a fourth-hand tool.
Tighten cable anchor bolt to the specified
torque. Use the barrel adjuster at the
brake lever to remove any remaining
cable slack.
IIMMPPOORRTTAANNTT::
AAfftteerrtthheeccaabblleeiissaanncchhoorreedd,,cchheecckkttoobbee
ssuurreetthheerreeiissnnoommoorreetthhaann2200mmmm((33//44iinn..))
ooffeexxcceessssccaabblleebbeeyyoonnddtthheeaanncchhoorrbboolltt..
TTrriimmaassnneecceessssaarryy..TTOORRQQUUEE::
55-77NNmm((4400-6600IInn-LLbbss))
Tip:
After anchoring the cable,
slide the lower boot down
and place one small dot
of light grease inside.
Return the boot to its
proper position.
TTOORRQQUUEE::
88-1100NNmm((7700-9900IInn-LLbbss))