2015
GUIDE DB5, R & RS
Service Manual
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.
where the bicycle or the SRAM component was purchased. Original proof of purchase is required. Except as described herein, SRAM makes no other
warranties, guaranties, or representations of any type (express or implied), and all warranties (including any implied warranties of reasonable care,
merchantability, or fitness for a particular purpose) are hereby 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:
Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer
(e.g. United Kingdom).
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, 1000 W. Fulton Market, 4th Floor, Chicago, IL, 60607, 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 have 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:
Dust seals
Bushings
Air sealing o-rings
Glide rings
Rubber moving parts
Foam rings
Rear shock mounting hardware and
main seals
Upper tubes (stanchions)
This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the retailer
Stripped threads/bolts (aluminium,
titanium, magnesium or steel)
Brake sleeves
Brake pads
Chains
Sprockets
Cassettes
Shifter and brake cables (inner and
outer)
Handlebar grips
Shifter grips
Jockey wheels
Disc brake rotors
Wheel braking surfaces
Bottomout pads
Bearings
Bearing races
Pawls
Transmission gears
Spokes
Free hubs
Aero bar pads
Corrosion
Tools
Motors
Batteries
Notwithstanding anything else set forth herein, 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 dierent 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 OVERVIEW ........................................................................................................................................................... 5
LEVER SERVICE ................................................................................................................................................................................. 6
PARTS AND TOOLS NEEDED FOR SERVICE ........................................................................................................................................................................... 6
DB5 EXPLODED VIEW ....................................................................................................................................................................................................................... 6
R LEVER EXPLODED VIEW ...............................................................................................................................................................................................................7
RS LEVER EXPLODED VIEW ............................................................................................................................................................................................................7
LEVER BLADE REMOVAL ................................................................................................................................................................................................................. 8
PISTON ASSEMBLY REMOVAL ....................................................................................................................................................................................................... 11
PISTON ASSEMBLY INSTALLATION ...........................................................................................................................................................................................13
LEVER BLADE INSTALLATION .....................................................................................................................................................................................................14
GUIDE R & GUIDE RS CALIPER SERVICE .....................................................................................................................................18
PARTS AND TOOLS NEEDED FOR SERVICE .......................................................................................................................................................................... 18
CALIPER EXPLODED VIEW ............................................................................................................................................................................................................18
TROUBLESHOOTING .........................................................................................................................................................................................................................19
CALIPER BRAKE PAD REMOVAL ................................................................................................................................................................................................20
CALIPER PISTON REMOVAL ..........................................................................................................................................................................................................21
CALIPER PISTON INSTALLATION ............................................................................................................................................................................................... 23
SRAM DB5 CALIPER SERVICE ....................................................................................................................................................... 26
PARTS AND TOOLS NEEDED FOR SERVICE ......................................................................................................................................................................... 26
SRAM DB5 CALIPER EXPLODED VIEW ...................................................................................................................................................................................26
TROUBLESHOOTING ........................................................................................................................................................................................................................ 27
CALIPER BRAKE PAD REMOVAL ................................................................................................................................................................................................28
CALIPER PISTON REMOVAL .........................................................................................................................................................................................................29
CALIPER PISTON INSTALLATION ............................................................................................................................................................................................... 32
DISC BRAKE PAD AND ROTOR BED-IN PROCEDURE .............................................................................................................. 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 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 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.
5SAFETY INSTRUCTIONS
Lever Service
Parts and Tools Needed for Service
• Safety glasses
• Nitrile gloves
• Oil pan
• Isopropyl alcohol
• Clean, lint-free rag
• Avid High-Performance DOT 5.1 fluid or DOT 4 fluid, or
Avid DOT Grease
• Needle nose pliers
Guide RS Lever Exploded View
Reservoir bolt
• Long-tipped snap ring pliers
• Pick with a 90˚ bent tip
• T8 , T10, & T25 TORX® wrench
• T8 & T10 TORX® bit socket
• 8 mm flare nut wrench
• 4 mm hex wrench
• Torque wrench
• Loctite® Threadlocker Blue 242®
Reservoir cap
Bladder
Hose boot
Compression nut
Lever body
Bleed port screws
Lever blade bushings
Piston assembly
Pivot pin
Lever return
spring
Reach adjuster
Washer
Snap ring
Lever blade
SwingLink bushings
SwingLink
SwingLink
push rod
SwingLink pivot pin
Pinch bolt
SwingLink
pivot
pinch bolt
Binder plug
6Guide RS Lever Exploded View
Guide R Lever Exploded View
Reservoir bolt
Reservoir cap
Bladder
Hose boot
Compression nut
Lever body
Bleed port screws
Lever blade bushings
Pivot pin
Piston assembly
Lever return spring
Snap ring
Washer
Reach adjuster
Lever blade
SwingLink
SwingLink™
push rod
Binder plug
Pinch bolt
Washer
7Guide R Lever Exploded View
SRAM DB5 Exploded View
Reservoir bolt
Reservoir cap
Bladder
Hose boot
Compression nut
Lever body
Bleed port screws
Lever blade bushings
Pivot pin
Piston assembly
Reach adjuster
Washer
Lever blade
Snap ring
SwingLink
push rod
Lever return spring
SwingLink™
Binder plug
Washer
Pinch
bolt
8SRAM DB5 Exploded View
L ever Blade Removal
8 mm flare nut wrench 15 N•m (133 in-lb) 22 mm
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 a T25 TORX® wrench or a 4 mm hex wrench to remove the
1
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 o the compression nut and slide it down the
2
hose.
Use an 8 mm flare nut wrench to remove the hose compression
3
nut.
Pull the brake hose and compression fitting from the brake lever
body.
Pour the brake fluid into an oil pan. Squeeze the lever blade to
4
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.
9Lever Blade Removal
Use a T10 TORX® wrench to remove the reservoir cap bolts from
T10 TORX wrench 15 N•m (133 in-lb) 22 mm
5
the reservoir cap.
Remove the reservoir cover and bladder from the lever body.
6
Pour the fluid from the brake lever body into a pan.
7 7
Separate the bladder from the reservoir cover.
8
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 out of the
bladder as it dries, which can be misinterpreted as a system leak
when it is not.
10Lever Blade Removal
Use a pick to remove the binder plug.
Pick 15 N•m (133 in-lb) 22 mm
T8 TORX wrench 15 N•m (133 in-lb) 22 mm
T8 TORX wrench 15 N•m (133 in-lb) 22 mm
9
Use a T8 TORX® wrench to remove the pinch bolt.
10
Use the T8 TORX® wrench to push out the pivot pin.
11
Remove the lever blade from the lever body.
12 13
The lever blade has four pieces, the lever blade, the cam/push rod
assembly, a washer, and the lever return spring. To hold all pieces
together you may reinstall the lever pivot pin and gently set aside.
11Lever Blade Removal
Piston Assembly Removal
T8 TORX wrench 15 N•m (133 in-lb) 22 mm
T8 TORX wrench 15 N•m (133 in-lb) 22 mm
Use a pick to remove the lever blade bushings from both sides of
1
the lever.
RS only: Use a T8 TORX® wrench to remove the SwingLink™ pivot
2
pinch bolt.
RS only: Use a T8 TORX® wrench to push out the SwingLink pivot
3
pin. The SwingLink will fall out easily.
Remove the SwingLink bushings from both sides of the lever.
4
12Piston Assembly Removal
Use long-tipped internal snap ring pliers to apply downward
Internal snap ring pliers 20 mm or 15 mm Thru Axle
Needle nose pliers 15 N•m (133 in-lb) 22 mm
5
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.
Use needle nose pliers to remove the piston assembly.
6
CAUTION - EYE HAZARD
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.
Spray isopropyl alcohol on the lever body and the lever blade and
7
clean them with a rag.
13Piston Assembly Removal
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