SRAM Guide Ultimate Service Manual

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GEN.0000000004961 Rev C

Guide Ultimate

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.

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. 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)

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 dierent 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

TROUBLESHOOTING .....................................................................................................................................................................................................................................6

CALIPER SERVICE ..............................................................................................................................................................................................7

PARTS AND TOOLS NEEDED FOR SERVICE..........................................................................................................................................................................................7

CALIPER EXPLODED VIEW .......................................................................................................................................................................................................................... 7

CALIPER BRAKE PAD REMOVAL ................................................................................................................................................................................................................8

CALIPER PISTON REMOVAL ........................................................................................................................................................................................................................9

CALIPER PISTON INSTALLATION ............................................................................................................................................................................................................ 12

LEVER SERVICE ................................................................................................................................................................................................15

GUIDE ULTIMATE EXPLODED VIEW ....................................................................................................................................................................................................... 15

LEVER BLADE REMOVAL............................................................................................................................................................................................................................ 16

PISTON ASSEMBLY REMOVAL ................................................................................................................................................................................................................. 19

PISTON ASSEMBLY INSTALLATION .......................................................................................................................................................................................................22

LEVER BLADE INSTALLATION .................................................................................................................................................................................................................26

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!

5Brake Service Overview

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

• Servicing your brakes removes all of the brake fluid from the system. You must bleed your brakes after you service the brake caliper and/or lever.

• Always wear safety glasses and nitrile gloves when working with DOT fluid.

• Place an oil pan on the floor 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 SRAM High-Performance 5.1 DO fluid. If SRAM fluid is not available, only use DOT 5.1 or 4 fluid.

Do not use mineral oil or DOT 5 fluid.

NOTICE

SRAM Guide Ultimate™ Brakes are a unique product. The Guide Ultimate caliper must be serviced before the lever. The lever must be connected to the caliper and the brakes must still have fluid in them in order to advance the pistons and service the caliper. Once the lever has been disconnected and the fluid drained it is not possible to advance the pistons.

6Troubleshooting

Troubleshooting

'Sticky' or slow brake pad return 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 Ultimate pad spreader between the brake pads to spread the pads to the full width of the clip.

5. Remove the Guide Ultimate pad spreader.

6. Repeat steps 3-5.

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.

7Caliper Service

Caliper Service

We recommend that you have your SRAM® Guide Ultimate™ brakes serviced by a qualiﬁed bicycle mechanic. Servicing SRAM brakes knowledge of brake components as well as the special tools and oils used for service.

For exploded diagram and part number information, please refer to the Spare Parts Catalog available on our website at sram.com/service. For order information, please contact your local SRAM distributor or dealer.

Information contained in this publication is subject to change at any time without prior notice. For the latest technical information, please visit our website at sram.com/service.

Your product's appearance may dier from the pictures contained in this publication

P arts and Tools Needed for Service

• Safety glasses

• Nitrile gloves

• Oil pan

• Isopropyl alcohol

• Clean, lint-free shop towel

• Bleed block

• Guide Ultimate pad spreader

• Pick with a 90 degree bent tip

• T25 TORX® wrench

• T25 TORX bit socket

• Torque wrench

• SRAM High-Performance 5.1 DOT fluid

• DOT compatible grease

C aliper Exploded View

E-clip

Banjo fitting

Banjo bolt

Caliper body bolt

Caliper o-ring

Pad retention bolt

Inboard caliper body

Outboard caliper body

Caliper pistons

Piston seals

Brake pads

H-spring

Bleed screw port

Caliper body bolt

Heat shield

Guide Ultimate pad spreader

Banjo

8Caliper Brake Pad Removal

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 fluid is not covered under warranty.

Use a T25 TORX

wrench to remove the brake caliper from the fork or

frame.

Remove the caliper mounting bracket and hardware from the caliper then set them aside in the order that they were removed.

Use needle nose pliers to remove the E-clip from the pad retention bolt. Remove the Guide Ultimate™ pad spreader. Use a 2.5 mm hex wrench to remove the pad retention bolt from the caliper.

Remove the brake pads from 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.

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

space between frames

space between steps

9Caliper Piston Removal

Caliper Piston Removal

NOTICE

Use a 2.5 mm hex wrench to install the pad retention bolt.

Insert the Guide Ultimate™ pad spreader so that it snaps onto the pad retention bolt.

Squeeze the brake lever to advance the pistons until they contact the pad spreader.

2.5 mm hex wrench 20 mm or 15 mm Thru Axle

space between frames

space between steps

10Caliper Piston Removal

Use a T25 TORX

wrench to remove the banjo bolt. Remove the Guide

Ultimate pad spreader.

Use a 2.5 mm hex wrench to remove the pad retention bolt.

Use a T25 TORX

wrench to remove each caliper body bolt.

Separate the caliper body halves.

Set the heat shield aside.

T25 TORX wrench Rubber-tipped blow gun chuck nozzle 22 mm

2.5 mm hex wrench QR

T25 TORX wrench Rubber-tipped blow gun chuck nozzle 22 mm

+ 21 hidden pages

SRAM Guide Ultimate Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual