Service Manual 2015 Guide Ultimate English
Contents
1. 27 Use a torque wrench and a T10 TORX bit socket to tighten each reservoir cap bolt to 1 1 3 Nem 10 11 in Ib T10 TORX bit 1 1 3 Nem 10 11 in lb Spray isopropyl alcohol on the lever body and clean it with a rag This concludes the Guide Ultimate Brake Service NOTICE You must bleed the brakes for optimal performance For brake bleed brake hose shortening and brake pad replacement instructions visit www sram com service Lever Blade Installation 28 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 S RIE www sram com service We will revolutionize the relationship that our users have with SRAM products cultivating a bond between the rider and bicycle Our technical communication will be delivered in innovative and exciting ways with deliberation and accuracy that inspires loyalty and trust across the globe SRAM TechCom Vision Statement WORLD HEADQUARTERS ASIAN HEADQUARTERS SRAM LLC SRAM Taiwan SRAM Europe EUROPEAN HEADQUARTERS 1333 North Kingsbury 4th Fir No 1598 8 Chung Shan Road Paasbosweg 14 16 Chicago Illinois 60642 Shen Kang Hsiang Taichung City 3862ZS Nijkerk USA Taiwan R O C The Netherlands2. Use a torque wrench and a T8 TORX bit socket to tighten the bolt to 1 1 3 Nem 10 11 in lb AO a a T8 TORX bit 1 1 3 Nem 10 11 in lb Piston Assembly Installation 25 Lever Blade Installation Insert the lever blade into the lever body with the inboard spring pressing against the lever body Align the pivot holes of the lever blade and the lever body Make sure the lever return spring is seated properly in the lever The outboard end of the spring must press against the lever blade while the inboard end of the spring must press against the lever body If the return spring is not seated properly the reach adjustment feature of the lever blade will be inoperable 2 Apply a small amount of Loctite 242 onto the threads of each pivot bolt Z Use a T10 TORX wrench to thread each pivot bolt into the bearings on each side of the lever body Inboard spring Loctite 242 T10 TORX wrench Lever Blade Installation 26 4 Use a torque wrench and a T10 TORX bit socket to tighten each pivot bolt to 1 1 3 Nm 10 11 in lD 5 Press the bladder into the reservoir cap the bladder must be flush with the cap to be properly installed 6 Insert the reservoir cap bladder assembly onto the lever body 7 Use your fingers to insert the detent ball followed by the detent spring into the lever body reservoir hole closest to the lever blade T10 TORX bit 1 1 5 Nem 10 11 in lb Lever Blade Installation
3. GEN OOOOOO00004961 Rev B 2015 SRAM LLC 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 merchantibility 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 a Preclude the disclaimers and limitations of
4. T25 TORX wrench 2 5 mm hex wrench Caliper Piston Removal 10 EJ Remove the pistons from each caliper body half Use a pick to remove the piston seals from each caliper body half Install new seals inside each caliper body half Do not scratch the seal gland with the pick Scratches could cause fluid to leak when the brake is applied which will contaminate the brake pads and could lead to a brake failure Ets Caliper Piston Removal 11 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 necessary SRAM High Performance DOT 5 1 fluid Use your gloved finger to apply a small amount of SRAM High Performance 5 1 DOT fluid to the circumference of each piston Install the pistons into each half of the caliper body For the best braking performance use only SRAM High Performance 5 1 DOT fluid If SRAM fluid is not available use only DOT 5 1 or 4 fluid Do not use grease Grease will prevent the pistons from fully retracting into the caliper bores which will reduce braking performance Spray isopropyl alcohol on the caliper halves and both of your gloves and clean
5. 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 Brake Service Overview 5 Troubleshooting Sticky or slow brake pad return excessive lever throw If your brakes feel sticky and exhibit slow brake pad r
6. 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 e Dust seals e Stripped threads bolts aluminium Handlebar grips e Transmission gears e Bushings titanium magnesium or steel e Shifter grips e Spokes e Air sealing o rings e Brake sleeves e Jockey wheels e Free hub
7. them with a rag Install new caliper o rings onto the outboard caliper half Add a small amount of DOT compatible grease onto the installed o rings to help them stay in place or to prevent them from falling out as you assemble the caliper Caliper Piston Installation 12 4 Align the caliper body halves then use a T25 TORX wrench to thread each body bolt into the caliper two full turns Install the heat shield T25 TORX Use a T25 TORX bit socket with a torque wrench to tighten each 5 bolt to 4 4 5 4 Nem 39 48 in lb T25 TORX 4 4 5 4 Nem 39 48 in lb Remove the o rings from the banjo bolt and banjo fitting Apply a small amount of SRAM High Performance 5 1 DOT fluid to the new o rings and install them Caliper Piston Installation 13 Hold the banjo at the desired angle Use a torque wrench with a T25 TORX bit socket to tighten the bolt to 4 4 5 4 Nem 39 48 in lb T25 Torx bit 4 4 5 4 Nem 39 48 in lb EJ Insert the Guide Ultimate bleed block into the caliper You must bleed your brakes before reinstalling the brake pads Installing the brake pads prior to bleeding the brakes could contaminate the brake pads and could lead to a brake failure Bleed block 9 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 S
8. 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 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 away from the brake body to expose the compression nut then slide the boot down the brake hose Z Use an 8 mm flare nut wrench to unthread the hose compression nut then pull the brake hose and compression fitting from the brake lever body 8 mm flare nut wrench Pour the brake fluid into an oil pan Squeeze the lever blade to force any remaining brake fluid out of 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 the best braking performance use only SRAM High Performance 5 1 DOT fluid If SRAM fluid is not available use only High Performance 5 1 DOT fluid or 4 fluid Lever Blade Removal 16 5 Use a T10 TORX wrench to remove the reservoir cap bolt nearest to the lever blade Carefully turn the lever body upside down so that the detent spring a
9. AFETY INSTRUCTIONS 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 Caliper Piston Installation 14 Lever Service Parts and Tools Needed for Service e Safety glasses e Pick with a 90 degree bent tip e Nitrile gloves e T8 T10 amp T25 TORX wrench e Oil pan e T8 amp T10 TORX bit socket e Isopropyl alcohol 8mm flare nut wrench e Clean lint free rag e 2mm amp 4mm hex wrench SRAM High Performance 5 1 DOT fluid or DOT 4 Fluid or e Torque wrench SRAM DOT Grease e SRAM Guide Lever Internals Assembly Tool e DOT compatible grease install internals e Loctite 242 e Needle nose pliers e Lever Internals Kit SRAM Guide Lever Internals Assembly Tool Guide Ultimate Exploded View Reservoir bolts 2 N a SwingLink pivot hole 2 E SwingLink Lever body Pinch Detent spring es Deten Piston assembly INC ball Sleeve Pivot pin bolt Coupler N i d ro Lever return spring Lever pivot hole 2 SwingLink bushings 2 a A XswingLink Bleed port push rod Compression nut Lever pivot Hose boot bolts 2 Bleed port screws 2 Lever blade Contact Point Adjustment dial Guide Ultimate Exploded View 15 Lever Blade Removal NOTICE DOT fluid
10. e and coupler 5 Insert the SRAM Guide Lever Internals Assembly Tool into the lever body and align the keyslot of the tool with the piston sleeve Use the tool to unthread the sleeve then remove the sleeve and coupler from the lever body If the piston sleeve and coupler become stuck in the lever body after unthreading the piston sleeve use a pair of need e nose pliers to gently grip the piston sleeve and remove it from the lever body SRAM Guide Lever Internals Assembly Tool Remove the sleeve from the coupler from the SRAM tool then separate the sleeve and coupler by hand Spray isopropyl alcohol on both the sleeve and the coupler and clean them with a rag Piston Assembly Removal 20 7 Place a rag over the open end of the lever body near the Contact Point Adjustment dial Use your fingers to slide the Contact Point Adjustment dial out of the lever body Wear safety glasses The piston assembly is spring loaded and will forcefully eject from the lever body when the Contact Point Adjustment dial is removed Be sure to cover the end of the lever body with a rag to capture the piston assembly and prevent it from becoming a projectile 8 Remove the piston assembly from the lever body Spray isopropyl alcohol on the lever body and the lever blade then Le clean them with a rag i Piston Assembly Removal 21 Piston Assembly Installation NOTICE DOT fluid will damage painted surfaces If any fluid c
11. eturn 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 Remove the wheel from the affected caliper Squeeze the brake lever several times until the brake pads nearly contact one another Insert the Guide Ultimate pad spreader between the brake pads to spread the pads to the full width of the clip Remove the Guide Ultimate pad spreader Repeat steps 3 5 Reinstall the wheel Squeeze the brake lever several times to position the brake pads to the proper distance from the rotor O ONO RAN 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 6 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
12. gk we sd Dea ERK IE ie is eR ee ee lee Peer bi ee aE ene eae er ee reer ren eee 15 GUIBDE LETIMAIE meg URL ED AE AE er N ee De ee ee Ge oC oO Ge ee ee ee eo Gee Ge en rte 15 LE EF BULALE RENI AL is E ee es ee ei mtr es ed Do ee ee Ee ee Ee ee EE eg EE ge 16 PE TONA EMEL F EMO Hs onse Serie ae E ee ed ee ee EP ee Se EE ee SE ee ar 19 Pi TANA EMEL IN TALLAT EN ss ee de ee oe ee Oe ee AE emcee aca ce etc cer eae cece eee eric ee 22 LE EF BLADE HE TALLE LIE N sa n Ee oe nese cee tegen cree E ee ne Ie RE Ee oe N EE Ee eee 26 SAFETY FIRST We care about YOU Please always wear your safety glasses and orotective gloves when servicing SRAM products Protect yourself Wear your safety gear 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 e Servicing your brakes removes all of the brake fluid from the system You must bleed your brakes after you service the brake caliper
13. l and insert the SRAM tool into the lever body until you feel the sleeve and contact adjust dial engage Thread the sleeve into the lever body until it stops then remove the SRAM tool from the lever body Guide Lever Internals Assembly Tool Piston Assembly Installation 23 Use needle nose pliers to install the SwingLink bushings into the lever SwingLink pivot holes so that the lip of the bushing is flush on the inside of the lever body If the SwingLink bushings fall out easily apply a small amount of grease to the bushings to helo hold them in place a D Ed Pa ad s Needle nose pliers Bushing lip gt 7 Use a caliper to verify that the push rod lenth in the SwingLink is 26 3 mm Turn the push rod counter clockwise by hand to extend the pushrod length Turn the push rod clockwise by hand to decrease the pushrod length NOTICE The push rod length must be set to exactly 26 3 mm Any other length will reduce brake performance Place the SwingLink onto a 2 mm hex wrench then insert the pushrod into the coupler sleeve 2 mm hex wrench Piston Assembly Installation 24 Align the SwingLink pivot holes and the SwingLink bushings then press the pivot pin into the SwingLink pivot hole until it is flush with the lever body on both sides Apply a small amount of Loctite 242 onto the pinch bolt T8 TORX wrench Use a T8 TORX wrench to thread the SwingLink pinch bolt into the lever body
14. nd ball fall out of the lever body If they do not initially fall out gently tap the lever against a clean rag Use a T10 TORX wrench to remove the other reservoir cap bolt 8 Remove the reservoir cover and bladder from the lever body T10 TORX wrench T10 TORX wrench t Lever Blade Removal 17 9 Pour the fluid from the brake lever body into a pan 10 Separate the bladder from the reservoir cover Spray isopropyl alcohol on the bladder and the reservoir cover then 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 Use a T10 TORX wrench to remove the lever pivot bolts T10 TORX wrench 12 Remove the lever blade Lever Blade Removal 18 Piston Assembly Removal Use a T8 TORX wrench to unthread then remove the SwingLink pinch bolt from the lever body 2 Use the end of a T8 TORX wrench to push the SwingLink pivot pin out of the lever body Z Slide the end of a T8 TORX wrench through the hole in the SwingLink then pull the SwingLink out of the lever body T8 TORX wrench T8 TORX wrench T8 TORX wrench T8 TORX wrench Piston Assembly Removal 19 Remove the SwingLink bushings by hand SwingLink bushing F SRAM Guide Lever Internals Assembly Tool af Sleev
15. omes 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 the new piston assembly in SRAM High Performance 5 1 DOT fluid You can also use SRAM High Performance 5 1 DOT fluid or 4 compatible grease as a lubricant SRAM High Performance 5 1 DOT fluid 2 Insert the piston assembly into the lever body Spray isopropyl alcohol on the lever body and both of your gloves then clean them with a rag Use the SRAM Guide Lever Internals Assembly Tool to press the piston into the lever body While pressing down on the piston with the half moon shape of the tool turned toward the lever opening insert the contact adjust dial half way into the lever then remove the tool Continue to insert the dial so that it is fully seated into the lever body You should hear a pop sound when the contact knob is fully seated in place SRAM Guide Lever Internals Assembly Tool T SRAM Guide Lever Internals Assembly Tool Piston Assembly Installation 22 4 Insert the sleeve into the coupler by hand The sleeve threads must be oriented away from the base of the coupler 5 Insert the sleeve and coupler into the keyslot of the SRAM Guide Lever Internals Assembly Tool Use the SRAM tool to align the slots on the sleeve with the slots on the contact adjust dia
16. 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 differ from the pictures contained in this publication Parts and Tools Needed for Service e Safety glasses e Pick with a 90 degree bent tip e Nitrile gloves e T25 TORX wrench e Oil pan e T25 TORX bit socket e Isopropyl alcohol e Torque wrench e Clean lint free rag e SRAM High Performance 5 1 DOT fluid e Bleed block e DOT compatible grease e Guide Ultimate pad spreader Caliper Exploded View Outboard caliper body Caliper body Guide Ultimate pad spreader bolt Caliper o ring Piston seals Banjo Pad retention bolt Banjo Caliper pistons es Banjo bolt Piston seals Caliper body bolt Caliper o ring Brake pads Caliper pistons H spring E clip Bleed screw port Inboard caliper body Caliper Service 7 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 orde
17. r that they were removed 2 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 2 5 mm hex wrench Needle nose pliers 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 Caliper Brake Pad Removal 8 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 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 2 5 mm hex wrench Squeeze the brake lever to advance the pistons until they contact the pad spreader Use a T25 TORX wrench to remove the banjo bolt T25 TORX wrench Caliper Piston Removal 9 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 7 Remove both of the caliper o rings from the outboard side of the caliper
18. s e Glide rings e Brake pads e Disc brake rotors e Aero bar pads e Rubber moving parts e Chains e Wheel braking surfaces e Corrosion e Foam rings e Sprockets e Bottomout pads e Tools e Rear shock mounting hardware e Cassettes e Bearings e Motors and main seals e Shifter and brake cables inner e Bearing races e Batteries e Upper tubes stanchions and outer e Pawls 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 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 OV ER V UE Voges dees essens iese ee ee dee diges ed dee vs ve ee ee ee ei eN we ee ge se we neue dessein nee denied 5 1OUELE OO EE Ee E ee ee DE Ee RE ED ee Ee ER Re ee Ee 6 CALIPER SERVICE EEN RE ER N EE EE OE N EE EE N N RE N 7 PARTS AND TOOLS NEEDED FOR SERVICE is a AE ee Rea se Ge Rees Gees 7 AB sd dek SR N S A RA RR RR N 7 CALIPER BRAKE FAD IS ie MA RR E AO nana RE ie a 8 CALIPER PS RIe Hie ARE AA N ER AR OR N tearm cance 9 CALIPER aie N or EE vide MR OR RE KA RE EE N AE N 12 ELEVER SERVICE EE EA EE EE LO OE EE 15 FAR AND a MB
19. this warranty statement from limiting the statutory rights of the consumer e g United Kingdom b 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
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