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27

Piston Assembly Installation

P i s t o n   A s s e m b l y   I n s t a l l a t i o n

NOTICE

DOT brake fluid will damage painted surfaces. 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 surfaces by DOT brake fluid is not covered 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.

DOT 5.1 brake fluid.
You can also use SRAM DOT Assembly Grease, or DOT 5.1 or 4 

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 new lubricated piston assembly into the lever body.

lnstall the washer on the piston assembly.

lnstall the washer on the piston assembly.
Use long-tipped internal snap ring pliers to push the piston assembly 

Use long-tipped internal snap ring pliers to push the piston assembly 

into the lever body, and secure the snap ring in its groove. Orient the 

into the lever body, and secure the snap ring in its groove. Orient the 

snap ring eyelets opposite the opening in the lever body.

snap ring eyelets opposite the opening in the lever body.

1 

SRAM High-Performance DOT 5.1 brake fluid

2 

3 

internal snap ring pliers

Содержание G2 R

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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