SRAM G2 RSC Service Manual Download Page 4

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TABLE OF CONTENTS

SRAM G2 BRAKE SYSTEMS SERVICE ..............................................................................................................................................................5

SERVICE PROCEDURES .................................................................................................................................................................................................................................6

TROUBLESHOOTING ..........................................................................................................................................................................................7

CALIPER SERVICE .............................................................................................................................................................................................10

PARTS AND TOOLS NEEDED FOR SERVICE.........................................................................................................................................................................................10

CALIPER EXPLODED VIEW .........................................................................................................................................................................................................................10

CALIPER BRAKE PAD REMOVAL ................................................................................................................................................................................................................ 11

CALIPER PISTON REMOVAL ....................................................................................................................................................................................................................... 12

CALIPER PISTON INSTALLATION .............................................................................................................................................................................................................16

LEVER SERVICE .................................................................................................................................................................................................19

G2 ULTIMATE LEVER EXPLODED VIEW ................................................................................................................................................................................................20

G2 RSC LEVER EXPLODED VIEW ............................................................................................................................................................................................................20

LEVER FLUID REMOVAL ..............................................................................................................................................................................................................................21

LEVER BLADE REMOVAL............................................................................................................................................................................................................................ 24

PISTON ASSEMBLY REMOVAL .................................................................................................................................................................................................................26

PISTON ASSEMBLY INSTALLATION ........................................................................................................................................................................................................29

LEVER BLADE INSTALLATION .................................................................................................................................................................................................................. 33

RESERVOIR CAP INSTALLATION ............................................................................................................................................................................................................. 35

BRAKE HOSE INSTALLATION ...................................................................................................................................................................................................................36

DISC BRAKE PAD AND ROTOR BED-IN PROCEDURE ............................................................................................................................... 38

G2 ULTIMATE LEVER BEARING REPLACEMENT ......................................................................................................................................... 39

Summary of Contents for G2 RSC

Page 1: ...SERVICE MANUAL GEN 0000000005960 Rev F 2022 SRAM LLC G2 Ultimate and RSC...

Page 2: ...Y NOT APPLY TO YOU 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 manual The SRA...

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: ...CALIPER PISTON INSTALLATION 16 LEVER SERVICE 19 PARTS AND TOOLS NEEDED FOR SERVICE 19 G2 ULTIMATE LEVER EXPLODED VIEW 20 G2 RSC LEVER EXPLODED VIEW 20 LEVER FLUID REMOVAL 21 LEVER BLADE REMOVAL 24 PIS...

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: ...he 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 parts catalog to replace the damaged part Do not...

Page 7: ...brakes exhibit excessive lever throw or spongy feel perform the following steps before bleeding the system Clamp the bicycle into a bicycle work stand Remove the wheel from the affected caliper Remove...

Page 8: ...tact the rotors Remove the rotors Use a plastic tire lever to carefully press the pistons back into the caliper Repeat steps 4 6 one more time With the pistons pressed back into the caliper install th...

Page 9: ...lever throw is acceptable Center the caliper on the rotor if necessary Spin the wheel and check the brake function The pistons should move freely and there should not be excessive brake lever throw If...

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: ...in the order that they were removed Use needle nose pliers to remove the E clip from the pad retention bolt Remove the pad retention bolt from the caliper Remove the brake pads and pad h spring from t...

Page 12: ...ces 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...

Page 13: ...Squeeze the brake lever to advance the pistons until they contact the pad spacer Use a T25 TORX wrench to remove the banjo bolt Remove the pad spacer Remove the pad retention bolt 4 5 2 5 mm 20 mm or...

Page 14: ...liper body halves Remove both of the caliper o rings from the inboard side of the caliper Remove the pistons from each caliper body half NOTICE If it is not possible to remove the pistions by hand sof...

Page 15: ...land 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 NOTICE Do not apply grease to the caliper pisto...

Page 16: ...o each half of the caliper body 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...

Page 17: ...the desired angle Tighten the banjo bolt to 5 N m 44 2 in lb Insert the bleed block into the caliper Install the pad retention bolt WARNING You must bleed your brakes before reinstalling the brake pad...

Page 18: ...s protrude from the banjo fitting or banjo bolt remove and replace the o rings then repeat the installation process CAUTION Servicing your brakes removes all of the fluid from the system You must blee...

Page 19: ...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 grea...

Page 20: ...screws 2 Detent ball SwingLink Pivot pin SwingLink push rod SwingLink Lever pivot Lever pivot bushings 2 Bleed port Lever assembly SwingLink pivot hole Hose Reservoir bolts 2 Bladder Reservoir cap Det...

Page 21: ...ench 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 off the compression nut an...

Page 22: ...turn the lever body upside down so that the detent spring and ball fall out of the lever body If they do not initially fall out gently tap the lever against a clean shop towel Remove the remaining res...

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

Page 24: ...ring Service page 37 If bearing service is not required continue with Piston Assembly Removal page 24 G2 RSC The reach adjust assembly will separate into four pieces when removed from the lever body S...

Page 25: ...25 Lever Blade Removal G2 RSC Use a small flat blade screwdriver to carefully remove the pivot bushings Clean the bushings and install them into the lever body G2 RSC G2 RSC 3...

Page 26: ...the SwingLink pinch bolt Note The red SwingLink does not have a pinch bolt Use a T8 TORX wrench to push the SwingLink pivot pin out of the lever body Black SwingLink Use a T8 TORX wrench to remove th...

Page 27: ...slot of the tool with the piston sleeve Use the tool to unthread the sleeve and remove the sleeve and coupler If the piston sleeve and coupler are stuck in the lever body use needle nose pliers to gen...

Page 28: ...ut the contact adjust knob CAUTION EYE HAZARD Use safety glasses The piston assembly is spring loaded and will forcefully eject from the lever body when the contact knob is removed Remove the piston a...

Page 29: ...can also use SRAM DOT Assembly Grease or DOT 5 1 or 4 compatible grease as a lubricant Install the new lubricated piston assembly into the lever body Spray isopropyl alcohol on the lever body and bot...

Page 30: ...to the piston assembly Engage the slots on the sleeve with the contact adjust knob and continue to thread the SRAM Lever Internals Assembly Tool tool in a clockwise rotation until it stops Use needle...

Page 31: ...is extended as far as possible Use a 2 mm hex wrench to place the pushrod into the coupler sleeve Red SwingLink Place the SwingLink pushrod into the piston Align the holes of the SwingLink and the Sw...

Page 32: ...ue 242 onto the pinch bolt Black SwingLink only Use a T8 TORX wrench to thread the SwingLink pinch bolt into the lever body Use a torque wrench and a T8 TORX bit socket to torque the bolt to 1 2 N m 1...

Page 33: ...the lever body Make sure your lever bias 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...

Page 34: ...locker Blue 242 onto each pivot bolt Use a torque wrench and a T10 TORX bit socket to tighten each pivot bolt to 1 2 N m 10 5 in lb G2 RSC Use a hammer to gently tap the pivot pin into the pivot hole...

Page 35: ...eservoir cap The bladder should be flush with the cap Insert the reservoir cap bladder assembly onto the lever body Install the detent ball followed by the detent spring into the lever body reservoir...

Page 36: ...fitting Brake hoses assembled with non Stealth a majig hose barbs and compression fittings will not function Apply DOT grease to the hose barb threads Thread the hose barb into the hose until it is f...

Page 37: ...n lb Spray isopropyl alcohol on the lever body and clean it with a shop towel CAUTION Servicing your brakes removes all of the fluid from the system You must bleed the brakes after you service the 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: ...g the bearing to be removed Install the bearing press onto the bearing press bolt and thread into the threaded bearing press Tighten the bearing press bolt until the bearing is pressed through the lev...

Page 40: ...ed bearing press Do not reuse bearings that have been removed Tighten the bearing press bolt until the bearing is pressed into the lever body Unthread the bearing press bolt to remove the tools from t...

Page 41: ...DH Maxle Lite Maxle Lite DH Maxle Stealth Maxle Ultimate MicroAdjust Micro Gear System Mini Block Mini Cluster Monarch Monarch Plus Motion Control Motion Control DNA MRX MX Noir NX OCT OmniCal OneLoc...

Page 42: ...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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