GUIDE DB5, R & RS
Contents
1. Piston Assembly Removal 13 Piston Assembly Installation NOTICE DOT fluid 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT fluid is not covered under warranty Submerge a new piston assembly by hand into Avid High Performance 5 1 DOT fluid to lubricate the piston assembly You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant Avid High Performance DOT 5 1 fluid Install the new piston assembly Spray isopropyl alcohol on the lever body and both of your gloves and clean the lever body and your gloves with a rag oa vz ee Acree x k aig y Internal snap ring pliers Install the washer on the piston assembly Use long tipped internal snap ring pliers to push the piston assembly into the lever body and secure the snap ring in its groove Orient the snap ring eyelets opposite the opening in the lever body You can also use a 10 mm deep socket against the snap ring to push the piston bladder snap ring assembly into the lever body Piston Assembly Installation 14 Lever Blade Installation RS only Use needle nose pliers to install the SwingLink bushings If the SwingLink bushings fall out easily apply a small amount of grease 2 Insert the lever blade bushings into2. on a soft rubber mat or a small section of inner tube on a flat surface Insert a rubber tipped blow gun chuck nozzle into the caliper hose port Wear safety glasses The caliper piston may dislodge rapidly from the caliper which can lead to bodily injury or damage to the parts Point the caliper piston toward a rubber surface before forcing air into the caliper Rubber Rubber tipped blow gun chuck nozzle While firmly pushing against the caliper half and chuck nozzle squeeze the air chuck to force air into the caliper hose port and dislodge the piston from the caliper Continue to force air into the caliper until the piston is dislodged Remove the piston from the caliper 6 Place the outboard caliper body half piston side down on a soft rubber mat or a small section of inner tube on a flat surface Insert a rubber tipped blow gun chuck nozzle into the bleed screw opening Wear safety glasses The caliper piston may dislodge rapidly from the caliper which can lead to bodily injury or damage to the parts Point the caliper piston toward a rubber surface before forcing air into the caliper Rubber Rubber tipped blow gun chuck nozzle While firmly pushing against the caliper half and chuck nozzle squeeze the air chuck to force air into the bleed screw opening and dislodge the piston from the caliper Continue to force air into the caliper until the piston is dislodged Remove the piston from the calipe
3. an even layer of brake pad material transfer layer to the braking surface of the rotor This transfer layer 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 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 To safely achieve optimal results remain seated on the bike during the entire bed in procedure Do not lock up the wheels at any point during the bed in procedure e Accelerate the bike to a moderate speed then firmly apply the brakes until you are at walking speed Repeat approximately twenty times Accelerate the bike to a faster speed Then very firmly apply the brakes until you are at walking speed Repeat approximately ten times Allow the brakes to cool prior to any additional riding Disc Brake Pad and Rotor Bed in Procedure 37 This publication includes trademarks and registered trademarks of the following companies TORX is a registered trademark of Acument Intellectual Properties LLC Loctite and 242 are registered trademarks of Henkel Corporation Disc Brake Pad and Rotor Bed in Procedure 38 DORAIN www sram com GEN 0000000004801 Rev A 2014 SRAM LLC
4. the banjo bolt to 9 7 11 7 Nem 86 104 in Ib 9 7 11 7 Nem 86 104 in lb 9 Insert the bleed block into the caliper NOTICE You must bleed your brakes before reinstalling the brake pads Bleed block Spray isopropyl alcohol on the caliper and clean it with a rag Visually check your work If any of the o rings protrude from the banjo fitting or banjo bolt remove and replace the o rings then repeat the installation process NOTICE Overhauling the caliper removes all of the fluid from the caliper You must bleed the brakes for optimal performance For brake bleed brake hose shortening and brake pad replacement instructions visit www sram com service Caliper Piston Installation 27 SRAM DB5 Caliper Service Parts and Tools Needed for Service e Safety glasses e 5mm hex bit socket e Nitrile gloves e 8mm line wrench e Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or 2 5mm and 5 mm hex wrenches Avid DOT Grease or DOT 5 1 or 4 compatible grease e Sharp pick e Oil pan e Clean lint free rag e Flat blade screwdriver e Isopropyl alcohol e Air compressor with blow gun chuck e Soft rubber or piece of inner tube e Torque wrench SRAM DB5 Caliper Exploded View Crimped hose fitting Caliper body bolt Bleed screw Caliper o ring Pad Spreader Piston seal Caliper Caliper hose port piston 00 Caliper piston Brake pad E clip J Piston seal Outboard caliper body Inboard cal
5. 2015 GUIDE DB5 R amp RS Service Manual o Y lA SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein 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 all warranties including any implied warranties of reasonable care merchantibility or fitness for a particular purpose are hereb disclaimed LOCAL LAW 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
6. E R amp GUIDE RS CALIPER SERVICE tica 18 PARTS AND PODES NBEDED FOR SERIES ee a a is 18 SALER EXPLODEO MENS a late nee 18 TROVBLE OO UN a E 19 CALCIPER BRAKE PADRE MONA Lp ii ad ocio caso 20 CAPES PS TON RENO on a is EA 21 CALIBRE RPI PON ACCA TIO asalta oia iaa iia dai ciao ai caio ces 25 SKRAM DBS GCALIPER SERVICE datan 26 PARES AND TOOES NEEDEELPOR SERVICE Ga re errr rr 26 SRAM DBO CALIPER EXPO DEEE it ego eee nee ee eee did 26 TROVBEE EAT cioon 27 CALIPER BRARE PAD REMOVAL iia 28 CALIPER PL TON REMOVAL mron a E ee re eer er 29 GALIPER PIS FORING PR ATIONSS a GR no ea A A A 52 DISC BRAKE PAD AND ROTOR BED IN PROCEDURE siii ais 35 SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing SRAM products Protect yourself Wear your safety gear SAFETY INSTRUCTIONS Always wear safety glasses and nitrile gloves when working with DOT fluid Place an oil pan on the floor underneath the area where you will be working on the brake 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 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT flui
7. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations For Australian customers This SRAM limited warranty is provided in Australia by SRAM LLC 1333 North Kingsbury 4th floor Chicago Illinois 60642 USA To make a warranty claim please contact the retailer from whom you purchased this SRAM product Alternatively you may make a claim by contacting SRAM Australia 6 Marco Court Rowville 3178 Australia For valid claims SRAM will at its option either repair or replace your SRAM product Any expenses incurred in making the warranty claim are your responsibility The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party suppliers be liable for direct indirect special incidental or consequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that hav
8. both sides of the lever by hand RS only Use your hand to set the SwingLink into place 4 RS only Line up the hole in the SwingLink with the hole in the bushings then push the pivot pin into the hole until it stops Needle nose pliers Lever Blade Installation 15 5 RS only Apply a small amount of 242 Blue Loctite onto the threads of the SwingLink pivot pinch bolt Use a T8 TORX wrench to thread the SwingLink pivot pinch bolt into the SwingLink T8 TORX wrench 242 Blue Loctite Lever Blade Installation 16 DB5 and R only Use your hand to insert the lever assembly into the lever body placing the push rod into the piston and lever return spring on the lever body Make sure your lever return spring is seated in the lever properly as seen in the picture The reach adjuster must be seated in the cam hole if it is not set properly you will be unable to adjust your reach RS only Use your hand to insert the lever assembly into the lever body placing the push rod into the piston and lever return spring on the lever body Make sure your lever return spring is seated in the lever properly as seen in the picture The end of the spring that points outward must be placed against the lever blade while the end of the spring that points inward rests against the lever body The reach adjuster must be seated in the cam hole if it is not set properly you will be unable to adjust your reach Lever Blade Instal
9. d 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 DOT 5 1 fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid Brake Service Overview SRAM brake systems need to be serviced periodically to optimize braking function If brake fluid is leaking from any area of the brake there may be damage or wear and tear to the internal moving parts If the system has been contaminated with the wrong fluid there may be damage to all rubber and plastic internal parts If your brake was damaged in a crash there may be damage to the lever blade pushrod and housing assemblies Inspect and replace these parts to restore proper brake function Your product s appearance may differ from the pictures contained in this publication SAFETY INSTRUCTIONS 5 Lever Service Parts and Tools Needed for Service e Safety glasses e Long tipped snap ring pliers e Nitrile gloves e Pick with a 90 bent tip e Oil pan e T8 710 amp T25 TORX wrench e Isopropyl alcohol e T8 amp T10 TORX bit socket e Clean lint free rag e 8mm flare nut wrench e Avid High Performance DOT 51 fluid or DOT 4 fluid or e 4mm hex wrench Avid DOT Grease e Torque wrench e Needle nose pliers e 242 Blue Loctite Guide RS Lever Exploded View Reservoir bolt Y N Swingli
10. e been incorrectly installed and or adjusted according to the respective SRAM user manual The SRAM user manuals can be found online at sram com rockshox com avidbike com truvativ com or zipp com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturers 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 when the product has been modified including but not limited to any attempt to open or repair any electronic and electronic related components including the motor controller battery packs wiring harnesses switches and chargers 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 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 e Dust seals e Stripped threads bolts e Handlebar grips e Spokes e Bushings aluminium titanium e Shifter grips e Free hubs e Air sealing o rings magnesium or steel e Jockey wheels e Aero bar pads e Glide rings e Brake sleeves e Disc brake rotors e Corrosion e Rubber moving parts e Brake pads e Wheel braking surface
11. el and check the brake function The pistons should move freely and there should not be excessive brake lever throw If there is no improvement in the brake function proceed with caliper service Troubleshooting 21 Caliper Brake Pad Removal Use a 5 mm hex wrench to remove the brake caliper from the fork or frame Remove the caliper mounting bracket and hardware from the caliper then set the parts aside in the order they were removed Use needle nose pliers to remove the E clip from the pad retainer Pee eee bolt Use a 2 5 mm hex wrench to remove the pad pin from the caliper Needle nose pliers Push the brake pads out of the caliper NOTICE Brake pads must be replaced if the total thickness of the backing plate and pad friction material is less than 3 mm Caliper Caliper Brake Pad Removal 22 Caliper Piston Removal NOTICE DOT fluid 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT fluid is not covered under warranty Use an 8 mm open end wrench to remove the banjo bolt Set the hose and banjo fitting aside 8 mm open end wrench Use a T25 TORX wrench to remove the caliper body bolt 125 TORX wrench Separate the caliper body halves Caliper Piston Removal 25 Remove the internal caliper o ring
12. fluid is not covered under warranty Use a5 mm hex wrench to remove the brake caliper from the fork or frame Remove the caliper mounting bracket and hardware from the caliper then set the bracket and hardware aside in the order they were removed 2 5 mm hex wrench 2 Use needle nose pliers to remove the E clip from the pad pin Use a 2 5 mm hex wrench to remove the pad pin from the caliper y Needle nose pliers Pull the brake pads out of the caliper NOTICE Brake pads must be replaced if the total thickness of the backing plate and pad friction material is less than 3 mm Caliper Brake Pad Removal 30 Caliper Piston Removal NOTICE DOT fluid 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT fluid is not covered under warranty Use an 8 mm line wrench to remove the crimped hose fitting E Pull the brake hose and crimped hose fitting from the caliper hose J port i Brake fluid will leak so hold the caliper over a container to catch the fluid 8 mm line wrench Use a 5 mm hex wrench to remove the caliper body bolts Separate the caliper body halves Use a T10 TORX wrench to remove the bleed screw T10 TORX wrench Caliper Piston Removal 31 5 Place the inboard caliper half piston side down
13. from the outboard caliper half 5 Place one of the caliper halves piston side down on a soft rubber mat or a small section of inner tube on a flat surface Insert a rubber tipped blow gun chuck nozzle into the banjo port Wear safety glasses The caliper pistons may dislodge rapidly from the caliper which can lead to bodily injury or damage to the parts Point the caliper pistons toward a rubber surface before forcing air into the caliper Rubber Rubber tipped blow gun chuck nozzle While firmly pushing against the caliper half and chuck nozzle squeeze the air chuck to force air into the banjo port and dislodge the pistons from the caliper Place a rag over the caliper to contain any fluid that may spray Continue to force air into the caliper until both pistons dislodge Do not remove one piston if the other is still seated Remove the pistons from the caliper Repeat this process for the other caliper half Use a pick to remove the piston seals from inside each caliper body half Install new seals inside each caliper body half Do not scratch the seal gland with a pick It could result in a slow fluid leak when the brake is applied Caliper Piston Removal 24 Caliper Piston Installation NOTICE DOT fluid 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 it with isopropyl alcohol o
14. id is not covered under warranty Use a T25 TORX wrench or a 4 mm hex wrench to remove the brake clamp bolt from the discrete clamp MMX or XLoc XLoc requires removal of the shifter and remove the brake lever from the handlebar Pull the hose boot off the compression nut and slide it down the hose Use an 8 mm flare nut wrench to remove the hose compression nut Pull the brake hose and compression fitting from the brake lever body 8 mm flare nut wrench 4 Pour the brake fluid into an oil pan Squeeze the lever blade to pump out excess brake fluid from inside the lever body NOTICE If the system has been contaminated with mineral oil or DOT 5 fluid flush all the parts with soapy water rinse and allow all parts to dry prior to rebuilding Install all new seals and a new hose For best results use only Avid High Performance DOT 5 1 fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Lever Blade Removal 9 5 Use a T10 TORX wrench to remove the reservoir cap bolts from the reservoir cap T10 TORX wrench 6 Remove the reservoir cover and bladder from the lever body EJ Pour the fluid from the brake lever body into a pan Separate the bladder from the reservoir cover Spray isopropyl alcohol on the bladder and the reservoir cover and clean them with a rag NOTICE All components must be completely dry before reinstalling them Moisture residue from cleaning the bladder can leak ou
15. iper body SRAM DB5 Caliper Service 28 Troubleshooting Sticky or slow brake pad return feel excessive lever throw If your brakes feel sticky and exhibit slow brake pad return and or excessive brake lever throw it may be a result of the pistons sticking in the caliper Before completely disassembling your caliper you can try to loosen the sticky piston by performing the following steps l Clamp the bicycle into a bicycle work stand Remove the wheel from the affected caliper Squeeze the brake lever several times until the brake pads nearly contact one another Insert the Guide Pad Spreader Clip between the brake pads to spread the pads to the full width of the clip Remove the Guide Pad Spreader Clip Repeat steps 3 5 several times Reinstall the wheel Squeeze the brake lever several times to position the brake pads to the proper distance from the rotor O ON O U RS NN Center the caliper on the rotor if necessary O Spin the wheel and check the brake function The pistons should move freely and there should not be excessive brake lever throw If there is no improvement in the brake function proceed with caliper service Troubleshooting 29 Caliper Brake Pad Removal NOTICE DOT fluid 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT
16. lation 17 7 Line up the cam and lever blade with the holes in the lever body then press the pivot pin through the holes EJ Apply a small amount of blue Loctite onto the pinch bolt Use a T8 TORX wrench to thread the pinch bolt into the lever body Use a torque wrench and a T8 TORX wrench to tighten the bolt to 2 7 3 2 N m 24 28 in lb Blue Loctite 2 7 3 2 Nem 24 28 in lb 9 Use a T8 TORX wrench to install a new binder bolt plug T8 TORX wrench Lever Blade Installation 18 Press the bladder into the reservoir cap make sure the bladder is properly seated into the reservoir cap The bladder should be flush with the cap Insert the reservoir cap bladder assembly onto the lever body Use a torque wrench with a T10 TORX bit to tighten each reservoir cap bolt to 2 7 3 2 N m 24 28 in lb TIO TORX 2 7 3 2 Nem 24 28 in Ib Spray isopropyl alcohol on the lever body and clean it with a rag Lever Blade Installation 19 Guide R amp Guide RS Caliper Service Parts and Tools Needed for Service e Safety glasses e Nitrile gloves e Oil pan e Isopropyl alcohol e Clean lint free rag e Avid High Performance DOT 51 fluid or DOT 4 fluid or Avid DOT Grease or DOT 5 1 or 4 compatible grease e Air compressor with rubber tipped blow gun chuck nozzle e Soft rubber mat or small section of butyl inner tube e Bleed block Needle nose pliers Pick with a 90 degree bent tip 2 5 mm 5 mm hex wre
17. nch 2 5 mm hex bit socket T25 TORX wrench T25 TORX bit socket 8 mm open end wrench 8 mm flare nut crowfoot Torque wrench Guide R RS Caliper Exploded View Bleed screw o ring Banjo bolt o ring Banjo bolt o Bleed screw 0 Caliper pistons Caliper body bolt Caliper body Internal caliper o ring 4 Brake pads Piston seals Banjo fitting Spreader clip Piston seals ele org Caliper pistons 0 a E clip Caliper body Guide R Guide RS Caliper Service 20 Troubleshooting Sticky or slow brake pad return feel excessive lever throw If your brakes feel sticky and exhibit slow brake pad return and or excessive brake lever throw it may be a result of the pistons sticking in the caliper Before completely disassembling your caliper you can try to loosen the sticky piston by performing the following steps l Clamp the bicycle into a bicycle work stand Remove the wheel from the affected caliper Squeeze the brake lever several times until the brake pads nearly contact one another Insert the Guide Pad Spreader Clip between the brake pads to spread the pads to the full width of the clip Remove the Guide Pad Spreader Clip Repeat steps 3 5 several times Reinstall the wheel Squeeze the brake lever several times to position the brake pads to the proper distance from the rotor O ON O U RS NN Center the caliper on the rotor if necessary O Spin the whe
18. nk bushings Reservoir a SwingLink push rod eo Snap ring pivot pinch bolt Bladder SwingLink Washer AO S winglink pivot pin A Pinch bolt Hose boot Compression nut Lever return Binder plug Lever body spring Bleed port screws Pivot pin Reach adjuster Lever blade bushings Lever blade Guide RS Lever Exploded View 6 Guide R Lever Exploded View Reservoir bolt Reservoir cap T SwingLink AAA Piston assembly SwingLink push rod Snap rin de Binder plug Washer e PANNY aa he 2 00 amp Lever return spring Lever body Y O Bleed port screws PA S Lever blade bushings Bladder Pinch bolt O Washer Reach adjuster Lever blade Guide R Lever Exploded View 7 SRAM DB5 Exploded View AN T T Reservoir cap SwingLink Ti oi push rod Bladder Piston assembly Snap ring Washer Binder plug creamy 0 4 o Se oe Lever return spring Compression nut O Lever body O Bleed port screws va va Reach adjuster Pivot pin Lever blade bushings Lever blade SRAM DB5 Exploded View 8 Lever Blade Removal NOTICE DOT fluid 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT flu
19. o ring and install it 5 Align the caliper body halves together Thread the caliper body bolts into the caliper by hand Use a torque wrench with a 5 mm hex bit socket to tighten each bolt to 9 8 11 8 N m 87 104 in lb Use a T10 TORX wrench to install the bleed screw T10 TORX wrench 9 8 11 8 N m 87 104 in lb crimped hose fitting 59 Use an 8 mm line wrench to install the crimped hose fitting into the caliper hose port 8 mm line wrench 9 Insert the bleed block into the caliper NOTICE You will need to bleed your brakes before reinstalling the brake pads Spray isopropyl alcohol on the caliper and clean it with a rag Visually check your work If an o ring protrudes from the crimped hose fitting remove and replace the o ring then repeat the installation process NOTICE Overhauling the caliper removes all of the fluid from the caliper You must bleed the brakes for optimal performance For brake bleed brake hose shortening and brake pad replacement instructions visit www sram com service crimped hose fitting 36 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
20. r Caliper Piston Removal 32 7 Use a pick to remove the piston seal from inside both the inboard and outboard half of the caliper body and install a new seal inside each caliper body half NOTICE Do not scratch the seal gland with a pick It could result in a slow fluid leak when the brake is applied Caliper Piston Removal SS Caliper Piston Installation NOTICE DOT fluid 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 it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT fluid is not covered under warranty Inspect the caliper pistons for damage and replace the pistons if Avid ish Batommance Bi DOT EUR necessary To install the pistons use your gloved finger to apply a small amount of DOT 5 1 fluid to the circumference of each piston Install a piston into each of the caliper body halves so that the piston runs horizontal in the caliper You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant Spray isopropyl alcohol on the caliper halves and both of your gloves and clean them with a rag 3 Use a pick to remove the caliper o ring from the inboard caliper half and install a new o ring Caliper Piston Installation 34 4 Use a pick to remove the o ring from the crimped hose fitting Apply a small amount of DOT 5 1 fluid to the new
21. r water Damage to painted and or printed surfaces by DOT fluid is not covered under warranty Inspect the caliper pistons for damage and replace the pistons if necessary Avid High Performance 5 1 DOT Fluid To install the pistons use your gloved finger to apply a small amount of DOT 5 1 fluid to the circumference of each piston Reinstall the pistons into each half of the caliper body You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant Spray isopropyl alcohol on the caliper halves and both of your gloves and wipe with a rag 3 Install a new internal caliper o ring on the outboard facing caliper half Caliper Piston Installation 25 4 Remove the o rings from the banjo bolt and banjo fitting Apply a small amount of DOT 5 1 fluid to the new o rings and install them 5 Insert the banjo bolt through the outboard caliper half Apply a small amount of DOT 5 1 fluid to the caliper o ring and install it onto the banjo bolt Align the banjo fitting with the banjo bolt and thread the bolt by hand into the banjo fitting until it stops Do not tighten the banjo bolt yet 7 Install the caliper body bolt and use a torque wrench with a T25 TORX bit socket to tighten the bolt to 9 7 11 7 Nem 86 104 in Ib T25 TORX 9 7 11 7 N m 86 104 in lb Caliper Piston Installation 26 Hold the banjo fitting at the desired angle Use a torque wrench with an 8 mm flare nut crowfoot to tighten
22. s e Tools e Foam rings e Chains e Bottomout pads e Motors e Rear shock mounting hardware Sprockets e Bearings e Batteries and main seals e Cassettes e Bearing races e Upper tubes stanchions e Shifter and brake cables inner Pawls and outer Transmission gears Notwithstanding anything else set forth herein this warranty is limited to one year for all electronic and electronic related components including motors controllers battery packs wiring harnesses switches and chargers The battery pack and charger warranty does not include damage from power surges use of improper charger improper maintenance or such other misuse 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 authorised by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use TABLE OF CONTENTS BRAKE SERVICE OVERVIE Wi A A anus den eue tenu sde ends 5 LEVER SERVICE Eana iieiea iaaii aaae Sinera 6 PAR TSAND TJQOLS NEEDED F R SERVICE A a E E EE E E 6 D S EXPEODED VIE Yieee E wp gars cae E E ee A led 6 RLEVER EA PLCODED y IE Yoi N E E E sneer eet 7 RS LEVER EA PEO DEC RENNES N piloto pp 7 ELEVERBLADE REMOVAL iaie E N 8 POTON A EPB REMOVAL crror aea a A E E E eaten 11 PISTON ASSEMBLY INSTALLATION perosi dada EE E 13 EEVERBEADE INSTAELATI ON sisas iia 14 GUID
23. t of the bladder as it dries which can be misinterpreted as a system leak when it is not Lever Blade Removal 10 Use a pick to remove the binder plug Use a T8 TORX wrench to remove the pinch bolt T8 TORX wrench Use the T8 TORX wrench to push out the pivot pin T8 TORX wrench Remove the lever blade from the lever body Lever Blade Removal 11 Piston Assembly Removal Use a pick to remove the lever blade bushings from both sides of the lever RS only Use a T8 TORX wrench to remove the SwingLink pivot 2 pinch bolt 3 RS only Use a T8 TORX wrench to push out the SwingLink pivot pin The SwingLink will fall out easily Remove the SwingLink bushings from both sides of the lever T8 TORX wrench T8 TORX wrench Piston Assembly Removal 12 Use long tipped internal snap ring pliers to apply downward pressure to the lever body and remove the snap ring Turn the lever body upside down to allow the washer to fall out of the body Internal snap ring pliers 6 Use needle nose pliers to remove the piston assembly o CAUTION EYE HAZARD gt Pb Wear safety glasses 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 which can result in injury Needle nose pliers 7 Spray isopropyl alcohol on the lever body and the lever blade and clean them with a rag
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