SRAM HydroR Service Manual
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SRAM HydroR Service Manual

Disc brake
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See also: User Manual
HydroR™ Disc Brake
Caliper/Master Piston/
Hose Replacement
s e r v i c e
m a n u a l
GEN0000000005217 Rev D
© 2018 SRAM, LLC

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Summary of Contents for SRAM HydroR

  • Page 1 HydroR™ Disc Brake s e r v i c e Caliper/Master Piston/ m a n u a l Hose Replacement GEN0000000005217 Rev D © 2018 SRAM, LLC...
  • Page 2 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.
  • Page 3 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 4: Table Of Contents

    TABLE OF CONTENTS SRAM® HYDROR™ BRAKE SYSTEMS ................................5 TROUBLESHOOTING ......................................6 DISC BRAKE PAD ADVANCEMENT PROCEDURE ....................................6 SRAM® HYDROR™ BRAKE CALIPER SERVICE ..............................8 PARTS, TOOLS, AND SUPPLIES ..........................................8 EXPLODED VIEW ................................................8 CALIPER BRAKE PAD REMOVAL ..........................................9 CALIPER PISTON REMOVAL ............................................10 CALIPER PISTON INSTALLATION ..........................................

  • Page 5: Sram® Hydror™ Brake Systems

    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.

  • Page 6: Troubleshooting

    T r o u b l e s h o o t i n g D i s c B r a k e P a d A d v a n c e m e n t P r o c e d u r e If your brakes have excessive brake lever throw, it may be a result of the pistons sticking in the caliper.
  • Page 7 Repeat steps 2-4 several times. Tire lever If one piston is moving and the other piston remains stuck, then remove the brake pads and use a plastic tire lever to hold back the piston that is moving. Squeeze the brake lever until the stuck piston begins to move.

  • Page 8: Sram® Hydror™ Brake Caliper Service

    Lubricants and Fluids • Hex bit socket: 2.5 mm • Isopropyl alcohol • Needle nose pliers • SRAM DOT 5.1 hydraulic brake fluid • Open end wrench: 6 mm, 10 mm • SRAM DOT assembly grease • Pick SRAM Tools •...

  • Page 9: Caliper Brake Pad Removal

    C a l i p e r B r a k e P a d R e m o v a l Remove the caliper mounting hardware from the caliper, then set them aside in the order that they were removed. Flat mount: Leave the mounting bracket installed.

  • Page 10: Caliper Piston Removal

    C a l i p e r P i s t o n R e m o v a l N OT ICE DOT fluid will damage painted surfaces. If any fluid comes in contact with a painted surface (e.g. your frame) or printing on the brakes, wipe it off immediately and clean it with isopropyl alcohol or water.
  • Page 11 Install new seals, a new bladder, and replace the hose. For the best braking performance, use only SRAM® DOT 5.1 fluid. If SRAM fluid is not available, use only DOT 5.1 fluid or 4 fluid. Caliper Piston Removal...

  • Page 12: Caliper Piston Installation

    NOTI CE 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.
  • Page 13 Tighten the caliper body bolt. 9.8-11.8 N·m (86-104 in-lb) Post and Flat Post mount only: Remove the banjo bolt o-ring. Apply grease to the Post Mount new o-ring and install it on the bolt. Install the bolt into the caliper. DOT grease Post Mount Flat mount only: Remove the o-rings from the banjo bolt.
  • Page 14 Bleed block Cut the hose to install a new barb and compression fitting. NOTI CE You must install a new hose barb and compression fitting before reconnecting the brake lever to the hose. SRAM Hydraulic Hose Cutter Caliper Piston Installation...
  • Page 15 Servicing your brake caliper removes fluid from the system. You must bleed the brakes before reinstalling the brake pads. Installing the brake pads prior to bleeding the brakes could contaminate the brake pads and lead to a brake failure. For brake bleed and brake pad replacement instructions, consult the HydroR™ Hose Shortening and Bleed Manual at www.sram.com/service. Caliper Piston Installation...

  • Page 16: Sram® Hydror™ Lever Service

    Lubricants and Fluids • Pin removal punch: 2 mm x 1.5 in • Isopropyl alcohol • Rubber mallet • SRAM DOT 5.1 hydraulic brake fluid • Torque wrench • SRAM DOT assembly grease SRAM Tools • SRAM brake bleed syringe...

  • Page 17: Master Cylinder Piston Removal

    DOT fluid will damage painted surfaces. If any fluid comes in contact with a painted surface (e.g. 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. There are two stop plate types for HydroR disc brakes: stop plate Stop plate gen. 2 generation 1, and stop plate generation 2.
  • Page 18 Push the pivot pin out of the lever blade. Remove the lever bias spring. ⚠WA RNI NG- EYE HAZARD Wear safety glasses. The lever bias spring may eject from the lever. Small hex wrench Turn the reach adjust pushrod clockwise to release the pivot barrel(s) 2.5 mm Brake lever and lever blade from the hood.
  • Page 19 Thread the bleed syringe into the bleed port. Fluid may drip from the bleed port. Clean the brake assembly with water and a shop towel to remove any DOT fluid that drips from the bleed port. Stop Plate Gen. 1: Remove the thread forming screw from the stop plate in the hood.
  • Page 20 Stop Plate Gen. 2: Use a mallet and a pin-removal punch to gently tap Roll pin out the roll pin. Remove the thread forming screw from the stop plate in the hood, then remove the stop plate and reach adjust pushrod. Pin removal punch Mallet Pick...
  • Page 21 Use a shop towel to remove excessive DOT fluid from the brake assembly. Unthread the bleed syringe from the bleed port. 1.5-1.7 N·m NOTI CE Place a shop towel below the brake assembly to catch any spilled DOT fluid. Clean DOT fluid from all painted surfaces. Install the bleed screw into the bleed port.

  • Page 22: Master Cylinder Piston Installation

    M a s t e r C y l i n d e r P i s t o n I n s t a l l a t i o n Apply grease to the piston seal and o-rings on a new master cylinder piston assembly.
  • Page 23 Stop Plate Gen 1: Use a 2.5 mm hex wrench to depress the reach 2.5 mm Stop plate gen. 1 adjust pushrod so it pushes against the master cylinder piston head and use a pick to seat the piston stop plate underneath the bar in the hood.
  • Page 24 Shift-brake lever: Install the inner pivot barrel into the outer pivot 2.5 mm Shift-brake lever barrel in the lever so the holes in the pivot barrels align with the reach adjust pushrod in the hood. Shift-brake lever Brake lever: Install the inner pivot barrel into the lever so the hole in 2.5 mm Brake lever the pivot barrel aligns with the reach adjust pushrod in the hood.
  • Page 25 Use needle nose pliers or a flat blade screwdriver to install the circlip Flat blade screwdriver or pliers onto the pivot pin with the rounded side facing outward. NOTI CE Inspect the circlip to make sure it is installed properly. If the circlip is missing or not installed properly, it could cause the pivot pin to fall out of the brake.

  • Page 26: Sram® Hydraulic Hose Replacement

    S R A M ® H y d r a u l i c H o s e R e p l a c e m e n t Perform the hose replacement service if the hose needs to be replaced. For hose shortening instructions, consult the HydroR™ Hose Shortening and Bleed Manual at www.sram.com/service.

  • Page 27: Exploded View

    E x p l o d e d V i e w Reservoir cover and bolts Hood cover Banjo bolt Bladder Banjo O-ring Hood Hydraulic hose Compression Hatch cover and screws Boot Compression fitting and Hose barb Banjo Exploded View...

  • Page 28: Hose Removal

    H o s e R e m o v a l Remove the wheel from the bicycle according to the manufacturer's instructions. Remove the E-clip from the pad retention bolt. 2.5 mm Remove the pad retention bolt from the caliper. Needle nose pliers Remove the brake pads.
  • Page 29 NOTI CE Fluid will drip. Place an oil pan and/or rag under the hose. Hydraulic hose cutter Remove the shifter cable from the derailleur cable anchor points according to the user manual on www.sram.com/service, if applicable. 5 mm Hose Removal...
  • Page 30 Remove the handlebar tape. Loosen the handlebar clamp and remove the brake lever from the bicycle. Remove the hood cover from the hood. Replace the shifter cable, if needed. Remove the three hatch cover screws. Remove the hatch cover. Phillips #1 Phillips #1 Hose Removal...

  • Page 31: Hose Installation

    Remove the four reservoir cover bolts. Use a rag to remove the reservoir cover and bladder assembly. Discard the fluid into an oil pan. Remove the banjo bolt and discard the hose. 4 mm H o s e I n s t a l l a t i o n Spray isopropyl alcohol on the reservoir, bladder, and reservoir cover and clean them with a rag.
  • Page 32 Apply grease to the new o-rings and install them onto both sides of the DOT grease new banjo. DOT grease Install the banjo and hose into the hood. 4 mm 3.9-4.4 N·m (35-39 in-lb) Align the bladder assembly in the reservoir cover with the reservoir in the hood.
  • Page 33 cover screws. Spray isopropyl alcohol on the hood and clean it with a rag. Hose Installation...
  • Page 34 Route the new hose through or onto the frame according to the frame manufacturer's instructions. Install the shifter cable to the derailleur(s) according to the user manual at www.sram.com/service. To shorten the hose, hold the hose at the caliper with a length that Hydraulic hose cutter creates a gentle bend in the hose and allows the handlebar to freely turn from side to side.
  • Page 35 Apply grease to the hose barb threads. Thread the hose barb into the hose until it is flush with the end of the hose. NOTI CE Do not overtighten the hose barb. Overtightening may cause damage to the hose liner. DOT grease Install the banjo boot and compression nut onto the hose.
  • Page 36 Connectamajig™ only: Calipers with a Connectamajig at the banjo must DOT grease replace the banjo when replacing the hose. The caliper can be removed or remain installed on the frame or fork. Remove the Connectamajig banjo. Apply grease to the new banjo bolt o-ring(s) and install on the bolt.
  • Page 37 Replacing the hose removes all of the fluid from the system. You must bleed the brakes before reinstalling the brake pads. Installing the brake pads prior to bleeding the brakes could contaminate the brake pads and lead to a brake failure. For brake bleed and brake pad replacement instructions, visit www.sram.com/service. This publication includes trademarks and registered trademarks of the following companies: TORX®...
  • Page 38 ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No. 1598-8 Chung Shan Road 1000 W. Fulton Market, 4th Floor Paasbosweg 14-16 Shen Kang Hsiang, Taichung City Chicago, Illinois 60607 3862ZS Nijkerk Taiwan R.O.C. The Netherlands...

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