SRAM DB-G2 RE-A2 Service Manual Download Page 12 | Manualshive

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12

Caliper Piston Removal

Remove the caliper body bolts.

Remove the caliper body bolts.

Separate the caliper halves and remove the banjo.

Separate the caliper halves and remove the banjo.
Set the banjo aside.

Set the banjo aside.

Remove the banjo o-rings and discard them.

Remove the banjo o-rings and discard them.

2

5 mm

5 mm

3

Pick

Pick

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Summary of Contents for DB-G2 RE-A2

Page 1: ...SERVICE MANUAL GEN 0000000007229 Rev A 2022 SRAM LLC 2023 G2 RE...

Page 2: ...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 3: ...IPER BRAKE PAD REMOVAL 10 CALIPER PISTON REMOVAL 11 CALIPER PISTON INSTALLATION 17 LEVER SERVICE 24 PARTS AND TOOLS NEEDED FOR SERVICE 24 LEVER EXPLODED VIEW 24 LEVER FLUID REMOVAL 25 LEVER BLADE REMO...

Page 4: ...oil or DOT 5 fluid flush all of the parts with soapy water rinse them with clean water then allow all the parts to dry prior to rebuilding Install new seals a new bladder and replace the hose For best...

Page 5: ...o ring when instructed Apply DOT grease to the new seal or o ring when instructed NOTICE Do not scratch any sealing surfaces when servicing the product Scratches can cause leaks Consult the spare par...

Page 6: ...G2 disc brakes Clamp the bicycle into a bicycle work stand Clamp the bicycle into a bicycle work stand Remove the wheel from the affected caliper Remove the wheel from the affected caliper Remove the...

Page 7: ...y press the pistons back into the Use a plastic tire lever to carefully press the pistons back into the caliper caliper Repeat steps 4 6 one more time Repeat steps 4 6 one more time With the pistons p...

Page 8: ...enter the caliper on the rotor if necessary Spin the wheel and check the brake function The pistons should move Spin the wheel and check the brake function The pistons should move freely and there sho...

Page 9: ...f SRAM or AVID DOT grease is not available only use a DOT compatible grease Common Tools Air compressor with a rubber tipped blow chuck Digital caliper Flare nut crowfoot 8 mm Flare nut wrench 8 mm He...

Page 10: ...e order that they were removed Remove the E clip from the pad retention bolt Remove the E clip from the pad retention bolt Remove the pad retention bolt from the caliper Remove the pad retention bolt...

Page 11: ...e it off immediately and clean it with isopropyl alcohol or water Damage to painted and or printed surfaces by DOT brake fluid is not covered under warranty Remove the hose boot from the compression n...

Page 12: ...caliper body bolts Separate the caliper halves and remove the banjo Separate the caliper halves and remove the banjo Set the banjo aside Set the banjo aside Remove the banjo o rings and discard them...

Page 13: ...iper body port with one quick burst The largest piston closest to the port should with one quick burst The largest piston closest to the port should dislodge from the caliper An audible pop sound may...

Page 14: ...pop sound may be heard when the small piston Again an audible pop sound may be heard when the small piston dislodges from the caliper dislodges from the caliper The small piston should be in the pisto...

Page 15: ...on seals Discard the piston seals NOTICE Do not scratch the seal gland with a pick It could result in a slow fluid leak when the brake is applied Spray isopropyl alcohol into each caliper body half an...

Page 16: ...each caliper body half piston seal into the piston bore seal grooves in each caliper body half Use the curved end of a non metallic pick or equivalent to help guide Use the curved end of a non metall...

Page 17: ...rake fluid Apply a small amount of SRAM High Performance DOT 5 1 brake fluid to the circumference of each piston to the circumference of each piston Install the piston into the piston bore squarely an...

Page 18: ...DOT 5 1 brake fluid onto each new caliper o ring and install each o ring into each caliper body half o ring into each caliper body half Clean the banjo Clean the banjo Clean each caliper bolt Clean ea...

Page 19: ...o full Align the caliper body halves and install the caliper body bolts two full turns turns Align the banjo hole with the fluid port step install the banjo and pinch Align the banjo hole with the flu...

Page 20: ...t the hose to install a new barb and compression fitting WARNING All SRAM brakes that use a compression fitting and hose barb must use a new SJ Stealth a majig hose barb and a new red SJ compression f...

Page 21: ...d onto the brake hose and press the compression fitting onto the hose until it stops the hose until it stops Thread the compression fitting onto the hose barb counter clockwise Thread the compression...

Page 22: ...hand until it stops stops Tighten the compression nut and compression fitting to 8 N m 71 in lb Tighten the compression nut and compression fitting to 8 N m 71 in lb Install a crowfoot socket at 90 d...

Page 23: ...it with a shop towel Spray isopropyl alcohol on the caliper and clean it with a shop towel Visually check your work If any of the o rings protrude from the banjo fitting or banjo bolt remove and repl...

Page 24: ...use a DOT compatible grease Common Tools Flare nut crowfoot wrench 8 mm Flare nut wrench 8 mm Hammer Hex wrenches 2 5 3 4 6 mm Internal snap ring pliers Needle nose pliers Pick metallic Pick non meta...

Page 25: ...andlebar Pull the hose boot off the compression nut and slide it away from the Pull the hose boot off the compression nut and slide it away from the lever lever Remove the hose compression nut Remove...

Page 26: ...from the lever body Remove the reservoir cover and bladder from the lever body Pour the remaining brake fluid from the brake lever body into an oil Pour the remaining brake fluid from the brake lever...

Page 27: ...ver Separate the bladder from the reservoir cover Spray isopropyl alcohol on the bladder and the reservoir cover and Spray isopropyl alcohol on the bladder and the reservoir cover and clean them with...

Page 28: ...ever blade assembly The lever blade assembly will separate into four pieces when removed The lever blade assembly will separate into four pieces when removed from the lever body SwingLink cam lever bi...

Page 29: ...washer to fall out of the Turn the lever body upside down to allow the washer to fall out of the body body CAUTION EYE HAZARD Wear safety glasses Do not look directly into the lever body while perform...

Page 30: ...under warranty Submerge the new piston assembly in SRAM High Performance Submerge the new piston assembly in SRAM High Performance DOT 5 1 brake fluid to lubricate the seals DOT 5 1 brake fluid to lu...

Page 31: ...push the piston washer and Use long tipped internal snap ring pliers to push the piston washer and piston assembly into the lever body and seat the snap ring into the piston assembly into the lever bo...

Page 32: ...clip in place while installing the lever Hold the spring and main pivot clip in place while installing the lever blade blade Insert the Reach Adjust Screw pin into the cam hole Insert the Reach Adjust...

Page 33: ...ssembly until it is centered in the lever body cam assembly until it is centered in the lever body Confirm the lever return spring is seated properly in the lever The Confirm the lever return spring i...

Page 34: ...flush with the cap with each hole centered and seated over the bolt holes in the cap holes in the cap Insert the reservoir cap bladder assembly onto the lever body Insert the reservoir cap bladder ass...

Page 35: ...tting upon reassembly The factory may have installed a non red SJ compression fitting which functioned properly prior to disconnection Upon reconnection you must install a new SJ hose barb and a new r...

Page 36: ...l it is flush or slightly lower than the hose barb The compression fitting is reverse threaded The compression fitting is reverse threaded Slide the compression nut to the compression fitting Slide th...

Page 37: ...he hose boot onto the lever Spray isopropyl alcohol on the lever body and clean it with a shop Spray isopropyl alcohol on the lever body and clean it with a shop towel towel CAUTION Servicing your bra...

Page 38: ...g 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 in...

Page 39: ...598 8 Chung Shan Road Shen Kang Hsiang Taichung City Taiwan R O C WORLD HEADQUARTERS SRAM LLC 1000 W Fulton Market 4th Floor Chicago Illinois 60607 U S A EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 1...

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