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SRAM G2 R, Service Manual, Page: 20 / 37

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SRAM G2 R Service Manual Download Page 20

20

Lever Service

L e v e r   S e r v i c e

P a r t s   a n d   T o o l s   N e e d e d   f o r   S e r v i c e

Parts

•  Lever Internals Guide™ RS or Lever Internals Guide R/RE / DB5™ / 

Code™ R

Safety and Protection Supplies

•  Safety glasses
•  Nitrile gloves
•  Oil pan
•  Clean, lint-free shop towels

Lubricants and Fluids

•  Isopropyl alcohol
•  SRAM High-Performance DOT 5.1 brake fluid. If SRAM fluid is not 

available, only use DOT 5.1 or 4 brake fluid.

•  SRAM or AVID DOT grease. If SRAM or AVID DOT grease is not 

available only use a DOT compatible grease.

Common Tools

•  Needle nose pliers
•  Pick with a 90 degree bent tip
•  Internal snap ring pliers
•  T8, T10, & T25 TORX wrench
•  T10 TORX bit socket
•  8 mm flare nut crowfoot wrench
•  2.5, 3, 4, & 6 mm hex wrenches
•  6 mm socket
•  Torque wrench
•  Hammer

G 2   R S   L e v e r   E x p l o d e d   V i e w

G 2   R   L e v e r   E x p l o d e d   V i e w

Reservoir bolts (2)

Reservoir bolts (2)

Bladder

Bladder

Reservoir cap

Reservoir cap

Piston assembly

Piston assembly

Lever bias spring

Lever bias spring

Pushrod

Cam bushing

Cam bushing

Main pivot clip

Main pivot clip

SwingLink

SwingLink push rod

Lever pivot pin

Lever pivot pin

Snap ring

Snap ring

Washer

Washer

Lever pivot bushings (2)

Lever pivot bushings (2)

Bleed 

port (2)

Bleed 

port (2)

Lever 

assembly

Lever 

assembly

SwingLink 

pivot hole

Lever 

pivot hole

Lever 

pivot hole

Lever body

Lever body

Compression fitting

Compression fitting

Compression nut

Compression nut

Hose boot

Hose boot

Hose barb

Hose barb

Hose

Hose

SwingLink bushings (2)

Bleed port screw (2)

Bleed port screw (2)

Bleed port screw o-ring (2)

Bleed port screw o-ring (2)

SwingLink pivot pin

Summary of Contents for G2 R

Page 1: ...SERVICE MANUAL G2 RS G2 R GEN 0000000006205 Rev A 2020 SRAM LLC...

Page 2: ...ntal or consequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed adjusted and or maintained according to the respective SRAM user man...

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: ...N INSTALLATION 16 CALIPER BRAKE HOSE INSTALLATION 18 LEVER SERVICE 20 PARTS AND TOOLS NEEDED FOR SERVICE 20 G2 RS LEVER EXPLODED VIEW 20 G2 R LEVER EXPLODED VIEW 20 LEVER FLUID REMOVAL 21 LEVER BLADE...

Page 5: ...hem 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 results use only SRAM High Performance DOT 5 1 brake fluid If SRA...

Page 6: ...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 7: ...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 E clip from the pad retention bolt Remo...

Page 8: ...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 9: ...er 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 should...

Page 10: ...compatible grease Common Tools 2 5 mm hex wrench Needle nose pliers Pick with a 90 degree bent tip T25 TORX wrench T25 TORX bit socket Torque wrench Digital caliper SRAM Tools SRAM Brake Bleed Kit inc...

Page 11: ...hem aside in the order that they were removed Use needle nose pliers to remove the E clip from the pad retention Use needle nose pliers to remove the E clip from the pad retention bolt bolt Remove the...

Page 12: ...f 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 surfa...

Page 13: ...he pad spacer so that it snaps onto the pad retention bolt Squeeze the brake lever to advance the pistons until they contact the Squeeze the brake lever to advance the pistons until they contact the p...

Page 14: ...boot from the compression nut Disconnect the brake hose from the caliper body Disconnect the brake hose from the caliper body Remove each caliper body bolt Remove each caliper body bolt Separate the...

Page 15: ...istons Remove the piston seals from each caliper body half Install new seals Remove the piston seals from each caliper body half Install new seals inside each caliper body half inside each caliper bod...

Page 16: ...ody NOTICE For the best braking performance use only SRAM High Performance DOT 5 1 brake fluid If SRAM fluid is not available use only DOT 5 1 or 4 brake fluid Do not apply grease to the caliper pisto...

Page 17: ...ck into the caliper Install the pad retention bolt Install the pad retention bolt WARNING You must bleed your brakes before reinstalling the brake pads Installing the brake pads prior to bleeding the...

Page 18: ...the hose barb threads Thread the hose barb into the hose until it is flush with the end of the hose the hose until it is flush with the end of the hose NOTICE Do not overtighten the hose barb Overtigh...

Page 19: ...tall the rubber boot onto the compression nut Spray isopropyl alcohol on the caliper and clean it with a shop towel Spray isopropyl alcohol on the caliper and clean it with a shop towel CAUTION Servic...

Page 20: ...2 5 3 4 6 mm hex wrenches 6 mm socket Torque wrench Hammer G 2 R S L e v e r E x p l o d e d V i e w G 2 R L e v e r E x p l o d e d V i e w Reservoir bolts 2 Reservoir bolts 2 Bladder Bladder Reservo...

Page 21: ...ndlebar Pull the hose boot off the compression nut and slide it down the hose Pull the hose boot off the compression nut and slide it down the hose Remove the hose compression nut Remove the hose comp...

Page 22: ...voir cover and bladder from the lever body Pour the fluid from the brake lever body into a pan Pour the fluid from the brake lever body into a pan Remove the two bleed screws Remove the two bleed scre...

Page 23: ...and the reservoir cover and Spray isopropyl alcohol on the bladder and the reservoir cover and clean them with a shop towel clean them with a shop towel NOTICE All components must be completely dry b...

Page 24: ...e lever assembly will separate into four pieces when removed from The lever assembly will separate into four pieces when removed from the lever body SwingLink cam lever bias spring main pivot clip and...

Page 25: ...ernal snap ring pliers to apply downward pressure to the lever body and remove the snap ring to the lever body and remove the snap ring Turn the lever body upside down to allow the washer to fall out...

Page 26: ...26 Piston Assembly Removal Use needle nose pliers to remove the piston assembly Use needle nose pliers to remove the piston assembly 5 Needle nose pliers...

Page 27: ...You can also use SRAM DOT Assembly Grease or DOT 5 1 or 4 compatible grease as a lubricant compatible grease as a lubricant Install the new lubricated piston assembly into the lever body Install the...

Page 28: ...ll out easily apply a small amount of DOT grease to the bushings to help hold them in place grease to the bushings to help hold them in place Place the SwingLink pushrod into the piston Place the Swin...

Page 29: ...ently tap the pivot pin into the pivot hole Use a hammer to gently tap the pivot pin into the pivot hole Make sure the lever bias spring is seated properly in the lever The Make sure the lever bias sp...

Page 30: ...t clip in place while installing the lever Hold the spring and main pivot clip in place while installing the lever blade Insert the Reach Adjust Screw pin into the cam hole blade Insert the Reach Adju...

Page 31: ...spring is seated properly in the lever The 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 outboard end of th...

Page 32: ...uld be flush properly seated into the reservoir cap The bladder should be flush with the cap with the cap Insert the reservoir cap bladder assembly onto the lever body Insert the reservoir cap bladder...

Page 33: ...of the hose 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 Thread the compression fitting over the hose b...

Page 34: ...and clean it with a shop Spray isopropyl alcohol on the lever body and clean it with a shop towel towel Slide the hose boot onto the lever Slide the hose boot onto the lever CAUTION Servicing your br...

Page 35: ...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 36: ...t Kage Komfy Level Lyrik MatchMaker Maxle Maxle 360 Maxle DH Maxle Lite Maxle Lite DH Maxle Stealth Maxle Ultimate Micro Gear System Mini Block Mini Cluster Monarch Monarch Plus Motion Control Motion...

Page 37: ...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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