Page 1
2015
GUIDE DB5, R & RS
Service Manual
Page 2
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.
Page 3
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
Page 4
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!
Page 5
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
Page 6
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
Page 7
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
Page 8
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
Page 9
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
Page 10
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
Page 11
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
Page 12
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
Page 13
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
Page 14
P iston Assembly Installation
Avid High Performance DOT 5.1 fluid 15 N•m (133 in-lb) 22 mm
Internal snap ring pliers
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-
1
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.
Install the new piston assembly.
2
Spray isopropyl alcohol on the lever body and both of your gloves
and clean the lever body and your gloves with a rag.
lnstall the washer on the piston assembly.
3
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.
14Piston Assembly Installation
Page 15
Lever Blade Installation
Needle nose pliers 2.7-3.2 N•m (24-28 in-lb) 22 mm
RS only: Use needle nose pliers to install the SwingLink™ bushings.
1 1
If the SwingLink bushings fall out easily, apply a small amount of
grease.
Insert the lever blade bushings into both sides of the lever by
2
hand.
RS only: Use your hand to set the SwingLink into place.
3
RS only: Line up the hole in the SwingLink with the hole in the
4
bushings, then push the pivot pin into the hole until it stops.
15Lever Blade Installation
Page 16
RS only: Apply a small amount of Loctite® Threadlocker Blue 242®
Loctite® Threadlocker Blue 242® 20 mm or 15 mm Thru Axle
T8 TORX wrench QR
5
onto the threads of the SwingLink™ pivot pinch bolt.
Use a T8 TORX® wrench to thread the SwingLink pivot pinch bolt
into the SwingLink.
16Lever Blade Installation
Page 17
DB5 and R only: Use your hand to insert the lever assembly into
6
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.
17Lever Blade Installation
Page 18
Line up the cam and lever blade with the holes in the lever body,
Loctite® Threadlocker Blue 242® 20 mm or 15 mm Thru Axle
T8 TORX wrench QR
22 mm 2.7-3.2 N•m (24-28 in-lb) 22 mm
T8 TORX wrench 2.7-3.2 N•m (24-28 in-lb) 22 mm
7
then press the pivot pin through the holes.
Apply a small amount of Loctite® Threadlocker Blue 242® onto the
8
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).
Use a T8 TORX® wrench to install a new binder bolt plug.
9
18Lever Blade Installation
Page 19
Press the bladder into the reservoir cap, make sure the bladder is
T10 TORX® 2.7-3.2 N•m (24-28 in-lb) T10 TORX®
10
properly seated into the reservoir cap. The bladder should be flush
with the cap.
Insert the reservoir cap/bladder assembly onto the lever body.
11
Use a torque wrench with a T10 TORX® bit to tighten each
12
reservoir cap bolt to 2.7-3.2 N·m (24-28 in-lb).
Spray isopropyl alcohol on the lever body and clean it with a rag.
13
19Lever Blade Installation
Page 20
Cut the hose to install a new barb and compression fitting.
SRAM Hydraulic Hose Cutter 2.7 - 3.2 N·m (24-28 in-lbs) 22 mm
T8 DOT Grease
T8
DOT Grease
14
Apply DOT grease to the hose barb threads. Thread the hose barb
15
into the hose until it is flush with the end of the hose.
NOTICE
Do not overtighten the hose barb. Overtightening may cause
damage to the hose liner.
16
17
Install the compression nut onto the hose.
Thread the compression fitting over the hose barb, counterclockwise, until it is flush or slightly lower than the hose barb.
The compression fitting is reverse threaded.
Apply DOT grease to the outside of the compression fitting and
the threads of the compression nut.
20Lever Blade Installation
Page 21
Apply SRAM® DOT grease onto the compression nut and install the
8 mm flare nut crowfoot 8 N·m (71 in-lb) 22 mm
18 14
compression fitting and nut into the lever.
Use a flare nut crowfoot with a torque wrench to tighten the
15
compression nut to 8 N·m (71 in-lb).
Spray isopropyl alcohol on the lever body and clean it with a rag.
⚠ CAUTION
Servicing your brakes removes all of the fluid from the system. You must bleed the brakes after you service the brake caliper and/or lever.
For brake bleed, brake hose shortening, and brake pad replacement instructions, visit www.sram.com/service.
21Lever Blade Installation
Page 22
Guide R & Guide RS Caliper 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 or DOT 5.1 or 4 compatible grease
• Air compressor with rubber-tipped blow gun chuck nozzle
• Soft rubber mat or small section of butyl inner tube
• Bleed block
• Needle nose pliers
• Pick with a 90 degree bent tip
• 2.5 mm & 5 mm hex wrench
• 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
Internal caliper o-ring
Bleed screw
Pad retainer bolt
Caliper body bolt
Caliper body
Caliper pistons
Piston seals
Spreader clip
Brake pads
Piston seals
Caliper pistons
Banjo fitting
Caliper o-ring
E-clip
Caliper body
22Guide R & Guide RS Caliper Service
Page 23
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:
1. Clamp the bicycle into a bicycle work stand.
2. Remove the wheel from the affected caliper.
3. Squeeze the brake lever several times until the brake pads nearly contact one another.
4. Insert the Guide Pad Spreader Clip between the brake pads to spread the pads to the full width of the clip.
5. Remove the Guide Pad Spreader Clip.
6. Repeat steps 3-5 several times.
7. Reinstall the wheel.
8. Squeeze the brake lever several times to position the brake pads to the proper distance from the rotor.
9. Center the caliper on the rotor if necessary.
10. 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.
23Troubleshooting
Page 24
Caliper Brake Pad Removal
Needle nose pliers 20 mm or 15 mm Thru Axle
2.5 mm hex wrench QR
Caliper 2.7-3.2 N•m (24-28 in-lb) 22 mm
Use a 5 mm hex wrench to remove the brake caliper from the fork
1
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
2
bolt. Use a 2.5 mm hex wrench to remove the pad pin from the
caliper.
Push the brake pads out of the caliper.
3
NOTICE
Brake pads must be replaced if the total thickness of the backing
plate and pad friction material is less than 3 mm.
24Caliper Brake Pad Removal
Page 25
Caliper Piston Removal
8 mm open end wrench Rubber-tipped blow gun chuck nozzle 22 mm
T25 TORX wrench Rubber-tipped blow gun chuck nozzle 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 an 8 mm open end wrench to remove the banjo bolt.
1
Set the hose and banjo fitting aside.
Use a T25 TORX® wrench to remove the caliper body bolt.
2
Separate the caliper body halves.
3
25Caliper Piston Removal
Page 26
Remove the internal caliper o-ring from the outboard caliper half.
Rubber Rubber-tipped blow gun chuck nozzle 22 mm
4
Place one of the caliper halves, piston side down, on a soft rubber
5
mat or a small section of inner tube on a flat surface.
Insert a rubber-tipped blow gun chuck nozzle into the banjo port.
CAUTION - EYE HAZARD
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.
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
6
body half. Install new seals 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.
26Caliper Piston Removal
Page 27
Caliper Piston Installation
Avid High Performance 5.1 DOT Fluid
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
1
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.
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
2
gloves, and wipe with a rag.
Install a new internal caliper o-ring on the outboard facing caliper
3
half.
27Caliper Piston Installation
Page 28
Remove the o-rings from the banjo bolt and banjo fitting.
T25 TORX 9.7-11.7 N·m (86-104 in-lb) T25 TORX®
4
Apply a small amount of DOT 5.1 fluid to the new o-rings and
install them.
Insert the banjo bolt through the outboard caliper half.
5
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
6
hand, into the banjo fitting until it stops. Do not tighten the banjo
bolt yet.
Install the caliper body bolt and use a torque wrench with a
7
T25 TORX® bit socket to tighten the bolt to
9.7-11.7 N·m (86-104 in-lb).
28Caliper Piston Installation
Page 29
Hold the banjo fitting at the desired angle. Use a torque wrench
8 mm 9.7-11.7 N•m (86-104 in-lb) 22 mm
Bleed block 15 N•m (133 in-lb) 22 mm
8
with an 8 mm flare nut crowfoot to tighten the banjo bolt to
9.7-11.7 N·m (86-104 in-lb).
Insert the bleed block into the caliper.
9
NOTICE
You must bleed your brakes before reinstalling the brake pads.
Spray isopropyl alcohol on the caliper and clean it with a rag.
10
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.
⚠ CAUTION
Servicing your brakes removes all of the fluid from the system. You must bleed the brakes after you service the brake caliper and/or lever.
For brake bleed, brake hose shortening, and brake pad replacement instructions, visit www.sram.com/service.
29Caliper Piston Installation
Page 30
SRAM DB5 Caliper Service
Parts and Tools Needed for Service
• Safety glasses
• Nitrile gloves
• Avid High-Performance 5.1 DOT Fluid or DOT 4 Fluid, or
Avid DOT Grease or DOT 5.1 or 4 compatible grease
• Oil pan
• Flat blade screwdriver
• Air compressor with blow gun chuck
• Torque wrench
SRAM DB5 Caliper Exploded View
• 5 mm hex bit socket
• 8 mm line wrench
• 2.5 mm and 5 mm hex wrenches
• Sharp pick
• Clean, lint-free rag
• Isopropyl alcohol
• Soft rubber or piece of inner tube
Caliper body bolt
Pad pin
Bleed screw
Caliper piston
Outboard caliper body
Caliper o-ring
Piston seal
Brake pad
Pad Spreader
Piston seal
Crimped hose fitting
Caliper
piston
Inboard caliper body
Caliper hose
port
E-clip
30SRAM DB5 Caliper Service
Page 31
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:
1. Clamp the bicycle into a bicycle work stand.
2. Remove the wheel from the affected caliper.
3. Squeeze the brake lever several times until the brake pads nearly contact one another.
4. Insert the Guide Pad Spreader Clip between the brake pads to spread the pads to the full width of the clip.
5. Remove the Guide Pad Spreader Clip.
6. Repeat steps 3-5 several times.
7. Reinstall the wheel.
8. Squeeze the brake lever several times to position the brake pads to the proper distance from the rotor.
9. Center the caliper on the rotor if necessary.
10. 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.
31Troubleshooting
Page 32
Caliper Brake Pad Removal
Needle nose pliers 20 mm or 15 mm Thru Axle
2.5 mm hex wrench QR
Caliper 2.7-3.2 N•m (24-28 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 5 mm hex wrench to remove the brake caliper from the fork
1
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.
Use needle nose pliers to remove the E-clip from the pad pin.
2
Use a 2.5 mm hex wrench to remove the pad pin from the caliper.
Pull the brake pads out of the caliper.
3
NOTICE
Brake pads must be replaced if the total thickness of the backing
plate and pad friction material is less than 3 mm.
32Caliper Brake Pad Removal
Page 33
Caliper Piston Removal
8 mm line wrench 2.7-3.2 N•m (24-28 in-lb) 22 mm
5 mm hex wrench 2.7-3.2 N•m (24-28 in-lb) 22 mm
T10 TORX wrench 2.7-3.2 N•m (24-28 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 an 8 mm line wrench to remove the crimped hose fitting.
1
Pull the brake hose and crimped hose fitting from the caliper hose
port.
Brake fluid will leak, so hold the caliper over a container to catch
the fluid.
Use a 5 mm hex wrench to remove the caliper body bolts.
2
Separate the caliper body halves.
3
Use a T10 TORX® wrench to remove the bleed screw.
4
33Caliper Piston Removal
Page 34
Place the inboard caliper half, piston side down, on a soft rubber
Rubber Rubber-tipped blow gun chuck nozzle 22 mm
Rubber Rubber-tipped blow gun chuck nozzle 22 mm
5
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.
CAUTION - EYE HAZARD
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.
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.
Place the outboard caliper body half, piston side down, on a soft
6
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.
CAUTION - EYE HAZARD
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.
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 caliper.
34Caliper Piston Removal
Page 35
Use a pick to remove the piston seal from inside both the inboard
7
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.
35Caliper Piston Removal
Page 36
Caliper Piston Installation
Avid High Performance 5.1 DOT Fluid
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
1
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
2
gloves, and clean them with a rag.
Use a pick to remove the caliper o-ring from the inboard caliper
3
half and install a new o-ring.
36Caliper Piston Installation
Page 37
Use a pick to remove the o-ring from the crimped hose fitting.
5 mm hex 9.8-11.8 N·m (87-104 in-lb) T25 TORX®
T10 TORX wrench 9.8-11.8 N·m (87-104 in-lb) T25 TORX®
4
Apply a small amount of DOT 5.1 fluid to the new o-ring and install
it.
Align the caliper body halves together.
5
Thread the caliper body bolts into the caliper by hand.
Use a torque wrench with a 5 mm hex bit socket to tighten each
6
bolt to 9.8-11.8 N·m (87-104 in-lb).
Use a T10 TORX® wrench to install the bleed screw.
7
37crimped hose fitting
Page 38
Use an 8 mm line wrench to install the crimped hose fitting into
8 mm line wrench 9.7-11.7 N·m (86-104 in-lb) T25 TORX®
8
the caliper hose port.
Insert the bleed block into the caliper.
9
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.
10
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.
⚠ CAUTION
Servicing your brakes removes all of the fluid from the system. You must bleed the brakes after you service the brake caliper and/or lever.
For brake bleed, brake hose shortening, and brake pad replacement instructions, visit www.sram.com/service.
38crimped hose fitting
Page 39
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 braking surface of the rotor. This transfer layer optimizes braking performance.
WARNING - CRASH HAZARD
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.
• 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.
39Disc Brake Pad and Rotor Bed-in Procedure
Page 40
This publication includes trademarks and registered trademarks of the following companies:
TORX® is a registered trademark of Acument Intellectual Properties, LLC.
Loctite® and Threadlocker Blue 242® are registered trademarks of Henkel Corporation
40Disc Brake Pad and Rotor Bed-in Procedure
Page 41
www.sram.com
GEN.0000000004801 Rev B © 2017 SRAM, LLC
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