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Lever Brake Hose Installation

L e v e r B r a k e H o s e I n s t a l l a t i o n

Slide the lever hose boot and compression nut away from the

compression fitting.

Cut 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 fitting 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, red SJ

compression 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 flush with the end of the hose.

NOTICE

Do not overtighten the hose barb. Overtightening may cause

damage to the hose liner.

SRAM Hydraulic Hose Cutter

DOT grease

Содержание DB-G2 RE-A2

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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