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Related Manuals for SRAM G2 RE
Summary of Contents for SRAM G2 RE
- Page 1 2023 G2 RE SERVICE MANUAL GEN.0000000007229 Rev A © 2022 SRAM, LLC...
- Page 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!
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Page 3: Table Of Contents
TABLE OF CONTENTS SRAM G2 BRAKE SYSTEMS SERVICE ................................4 WARRANTY AND TRADEMARK ...........................................4 SERVICE PROCEDURES ..............................................5 BRAKE PAD ADVANCEMENT ....................................6 CALIPER SERVICE .......................................9 PARTS AND TOOLS NEEDED FOR SERVICE......................................9 CALIPER EXPLODED VIEW ............................................9 CALIPER BRAKE PAD REMOVAL ..........................................10 CALIPER PISTON REMOVAL ............................................11 CALIPER PISTON INSTALLATION .......................................... -
Page 4: Sram G2 Brake Systems 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. -
Page 5: Service Procedures
S e r v i c e P r o c e d u r e s The following procedures should be performed throughout service, unless otherwise specified. Clean the part with isopropyl alcohol and a clean, lint-free shop towel. Clean the part with isopropyl alcohol and a clean, lint-free shop towel. -
Page 6: Brake Pad Advancement
B r a k e P a d A d v a n c e m e n t NOTICE Do not apply DOT brake fluid or grease to caliper pistons when performing troubleshooting procedures. Use of DOT brake fluid or grease can diminish braking performance and cause rotor rubbing. - Page 7 Squeeze the brake lever to advance the pistons until they contact the Squeeze the brake lever to advance the pistons until they contact the rotors. rotors. Remove the rotors. Remove the rotors. Use a plastic tire lever to carefully press the pistons back into the Use a plastic tire lever to carefully press the pistons back into the caliper.
- Page 8 Squeeze the brake lever until the contact point is firm and lever throw Squeeze the brake lever until the contact point is firm and lever throw is acceptable. is acceptable. Center the caliper on the rotor if necessary. Center the caliper on the rotor if necessary. Spin the wheel and check the brake function.
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Page 9: Caliper Service
DOT 5.1 or 4 brake fluid. • Pad spreader (2.8 mm width) • SRAM or AVID DOT grease. If SRAM or AVID DOT grease is not available, only use a DOT compatible grease. C a l i p e r E x p l o d e d V i e w... -
Page 10: Caliper Brake Pad Removal
C a l i p e r B r a k e P a d R e m o v a l Remove the brake caliper from the fork or frame. Remove the brake caliper from the fork or frame. Remove the caliper mounting bracket and hardware from the caliper Remove the caliper mounting bracket and hardware from the caliper then set them aside in the order that they were removed. -
Page 11: Caliper Piston Removal
C a l i p e r P i s t o n R e m o v a l N OT ICE 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. - Page 12 Remove the caliper body bolts. Remove the caliper body bolts. 5 mm 5 mm 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. Remove the banjo o-rings and discard them.
- Page 13 Secure a piece of rubber mat on a bench vise, or similar flat secure Secure a piece of rubber mat on a bench vise, or similar flat secure surface. surface. Position one caliper half flat and firmly with the caliper body fluid port Position one caliper half flat and firmly with the caliper body fluid port over the edge of the vise.
- Page 14 Position the caliper half again flat on the vise and mat, with the caliper Position the caliper half again flat on the vise and mat, with the caliper body fluid port over the edge of the vise. body fluid port over the edge of the vise. Align the blow chuck nozzle with the caliper body fluid port again.
- Page 15 Pierce each piston seal with a pick, and remove each piston seal from Pierce each piston seal with a pick, and remove each piston seal from inside both caliper body halves. inside both caliper body halves. Discard the piston seals. Discard the piston seals.
- Page 16 Use the curved end of a non-metallic pick, or equivalent, to help guide Use the curved end of a non-metallic pick, or equivalent, to help guide each seal into the piston bore groove. each seal into the piston bore groove. SRAM High-Performance DOT 5.1 Pick brake fluid SRAM High-Performance DOT 5.1...
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Page 17: Caliper Piston Installation
NOTICE For the best braking performance, use only SRAM High-Performance 5.1 DOT brake fluid. If SRAM fluid is not available, use only DOT 5.1 or 4 brake fluid. Do not use grease. Grease will prevent the pistons SRAM High-Performance DOT 5.1... - Page 18 Apply DOT 5.1 brake fluid onto each new caliper o-ring and install each Apply 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. SRAM High-Performance DOT 5.1 brake fluid Clean the banjo. Clean the banjo.
- Page 19 Align the caliper body halves and install the caliper body bolts two 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 fluid port step, install the banjo, and pinch each caliper half together.
- Page 20 Cut the hose to install a new barb and compression fitting. ⚠ WARNI NG 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.
- Page 21 Apply DOT grease to the hose barb threads. Thread the hose barb into 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. the hose until it is flush with the end of the hose. NOTICE Do not overtighten the hose barb.
- Page 22 Insert the compression fitting into the banjo and hold it firmly into the Insert the compression fitting into the banjo and hold it firmly into the banjo. Thread the compression fitting into the banjo by hand until it banjo. Thread the compression fitting into the banjo by hand until it stops.
- Page 23 Servicing your brakes removes all of the fluid from the system. You must bleed the brakes after you service the brake caliper and/or lever. For brake bleed, brake hose shortening, and brake pad replacement instructions, visit www.sram.com/service. Caliper Piston Installation...
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Page 24: Lever Service
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 Common Tools • Lever Internals V2 Guide R / G2 R / Guide RE / G2 RE / CODE R / DB5 • Flare nut crowfoot wrench: 8 mm • Flare nut wrench: 8 mm Safety and Protection Supplies •... -
Page 25: Lever Fluid Removal
Install new seals and a new hose. For best results, use only SRAM High-Performance DOT 5.1 brake fluid. If SRAM fluid is not available, only use DOT 5.1 or 4 brake fluid. Oil pan Lever Fluid Removal... - Page 26 Remove the reservoir cap bolts. Remove the reservoir cap bolts. Remove the reservoir cover and bladder 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 body into an oil pan.
- Page 27 Remove each o-ring from each bleed screw, and discard the o-rings. Remove each o-ring from each bleed screw, and discard the o-rings. Install new o-rings onto each bleed screw. Install new o-rings onto each bleed screw. Pick Install each bleed screw into the lever body. Install each bleed screw into the lever body.
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Page 28: Lever Blade Removal
L e v e r B l a d e R e m o v a l Place the lever pivot on top of a 6 mm socket. Tap a 4 mm hex wrench Place the lever pivot on top of a 6 mm socket. Tap a 4 mm hex wrench with a hammer to remove the pivot pin. -
Page 29: Piston Assembly Removal
P i s t o n A s s e m b l y R e m o v a l Use long-tipped internal snap ring pliers to apply downward pressure Use long-tipped internal snap ring pliers to apply downward pressure to the lever body and remove the snap ring. -
Page 30: Piston Assembly Installation
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 to lubricate the seals. - Page 31 Use long-tipped internal snap ring pliers to 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 body, and seat the snap ring into the groove.
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Page 32: Lever Blade Installation
L e v e r B l a d e I n s t a l l a t i o n Hold the spring and main pivot clip in place while installing the lever Hold the spring and main pivot clip in place while installing the lever blade. - Page 33 Align the pushrod cam and lever blade with the lever pivot holes in the Align the pushrod cam and lever blade with the lever pivot holes in the lever body, then insert the pivot pin through one pivot hole and use it lever body, then insert the pivot pin through one pivot hole and use it to align the pushrod cam assembly with the lever pivot hole.
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Page 34: Reservoir Cap Installation
R e s e r v o i r C a p I n s t a l l a t i o n Insert and seat the bladder into the reservoir cap. The bladder should Insert and seat the bladder into the reservoir cap. The bladder should be flush with the cap with each hole centered and seated over the bolt be flush with the cap with each hole centered and seated over the bolt holes in the cap. -
Page 35: Lever Brake Hose Installation
Cut the hose to install a new barb and compression fitting. ⚠ WARNI NG 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. - Page 36 Insert the non-threaded end of a new compression fitting over the hose Insert the non-threaded end of a new compression fitting over the hose barb and onto the brake hose and press the compression fitting onto barb and onto the brake hose and press the compression fitting onto the hose until it stops.
- Page 37 Servicing your brakes removes all of the fluid from the system. You must bleed the brakes after you service the brake caliper and/or lever. For brake bleed, brake hose shortening, and brake pad replacement instructions, visit www.sram.com/service. Lever Brake Hose Installation...
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Page 38: Disc Brake Pad And Rotor Bed-In Procedure
(transfer layer) to the braking surface of the rotor. This transfer layer optimizes braking performance. To watch a video of the bed-in procedure, visit www.sram.com/service. - Page 39 ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No. 1598-8 Chung Shan Road 1000 W. Fulton Market, 4th Floor Paasbosweg 14-16 Shen Kang Hsiang, Taichung City Chicago, Illinois 60607 3862ZS Nijkerk Taiwan R.O.C. U.S.A. The Netherlands...