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SRAM G2 Brake Systems Service

S R A M   G 2   B r a k e   S y s t e m s   S e r v i c e

We recommend that you have your SRAM G2 components serviced by a qualified bicycle mechanic. Servicing SRAM components requires knowledge 

of bicycle mechanics as well as the special tools and lubricants/fluids used for service.
SRAM brake systems need to be serviced periodically to optimize braking function. If brake fluid is leaking from any area of the brake there may be 

damage or wear and tear to the internal moving parts. If the system has been contaminated with the wrong fluid there may be damage to all rubber 

and plastic internal parts. If your brake was damaged in a crash there may be damage to the lever blade, pushrod, and housing assemblies. Inspect 

and replace these parts to restore proper brake function.
Visit 

www.sram.com/service

 for the latest SRAM Spare Parts catalog and technical information. For order information, please contact your local SRAM 

distributor or dealer.
          For recycling and environmental compliance information, please visit 

www.sram.com/company/environment

.

Information contained in this publication is subject to change at any time without prior notice. Your product's appearance may differ from the pictures 

contained in this publication.

SAFETY INSTRUCTIONS

Do not use mineral oil or DOT 5 fluid.
If the brake system has been contaminated with mineral 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 results, use only SRAM High-Performance DOT 5.1 brake fluid. If SRAM brake fluid is not available, only use DOT 5.1 or 4 brake fluid.
Use only DOT compatible grease.
Always wear safety glasses and nitrile gloves when working with DOT brake fluid.
Used DOT brake fluid should be recycled or disposed of in accordance to local and federal regulations.
Never pour DOT brake fluid down a sewage or drainage system or into the ground or a body of water.
Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be replaced.
Place an oil pan on the floor underneath the area where you will be working on the brake.
Servicing your brakes removes all of the brake fluid from the system. You must bleed your brakes after you service the brake system. Consult the 

SRAM MTB Disc Brake Hose Shortening and Bleed Manual

 at 

www.sram.com/service

.

CAUTION

Do not use mineral oil or DOT 5 fluid. Do not use tools, rags, or syringes that are contaminated with mineral oil or DOT 5 fluid. Using contaminated 

materials will result in permanent damage to the seals and reduce braking performance. Brakes must be replaced if contaminated with mineral oil 

or DOT 5 fluid.

NOTICE

The G2 caliper must be serviced before the lever. The lever must be connected to the caliper and the brakes must still have fluid in them in order to 

advance the pistons and service the caliper. Once the lever has been disconnected and the fluid drained it is not possible to advance the pistons. 

Содержание G2 RSC

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

Страница 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...

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: ...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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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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