l a u n a m l a c i n h c e t ) 0 0 0 6 1 0 5 1 0 4 5 9 # t r a p
h s i l g n e (
SRAM oRiginAl PARtS CAutIon: the SRAM Warray plicy des cver damages cased by he se -SRAM pars. use ly SRAM pars wih SRAM cmpes. Isallai pars ad accessries rigially ieded cld resl i less ha pimal perrmace ad/r ijry. Fr i-deph service irmai SRAM prdcs, reer r websie a www.sram.cm. Cac yr lcal SRAM disribr r dealer r rderig irmai. Irmai caied i his pblicai is sbjec chage a ay ime wih prir ice. Yr prdc‘s appearace appearace may vary rm he diagrams caied i his caalg.
© Cpyrigh SRAM Crprai 2007 Irmai may be ehaced wih prir ice. Released 2007
tABlE oF ContEntS ContEnt S ge Sared ................................................................................ ........................................................................................................................ .................................................................................. .................................................... ..........55 Frk techlgy Desigai ad oil Vlmes ................................................................................................................6 tls needed r Service Ser vice ............................................ ..................................................................................... .................................................................................. ................................................................8 .......................8
lwer le Rema (A Frs) ................................................................................... ........................................................................................................................... ................................................ ........ 11 Bus Serce (A Frs) ...........................................................................................................................................13 ....................................................................................................................... .................................................................................. .................................................2 ........233 Damper Serce .............................................................................. Rebud & turey (Argyle 302 - Dar 2, 2 wih trkey, 3 - Dmai 302 - Pike 327 - Rec 327/XC, 335/SL - tra 289, 302) ........24
M Cr (Argyle 318, 409 - Dmai 318 - Lyrik IS - tra 318 - tem IS) ...................................................................................27
M Cr (BX Xer Race, team, team, WC Pike 351, 409, 42 6, 45 4 - Reba SL, Race, team, team, WC - Rec 351 -Revelai 409, 426) ...........................................................................................................................................................30
M Cr (SID team, WC) .................................................................... .............................................................................................................. .................................................................................. .......................................................33 ...............33
Pure Dee (SID Race) ......................................................................................................... .................................................................................................................................................. .....................................................................37 ............................37
Mss Cr (Lyrik - tem) ....................................................... ................................................................................................. ................................................................................... .....................................................................39 ............................39
Spr Serce ................................................................................. ........................................................................................................................... ................................................................................... ................................................4 .......433 C (Argy le 30 2, 318 - Dar 1, 2, 2 (wih trkey), trkey), 3 - Dmai 30 2, 318 - tra 28 9, 30 2, 318) ........... ................ .......... .......... ........... ........... ........44 ...44
C (BXXer Race, team - Rec 327, 335, 351 - tem) ....................................................................................................45
C U-tur (Dmai 302, 318 - tra 289, 302, 318) .............................................................................................................................46
C U-tur (Lyrik, Lyrik IS - Pike 409, 426, 454 - Rec 327, 351 - Revelai 426) .....................................................................47
S Ar (Argyle 409, Rec 335, 351 - tra 318) ...........................................................................................................................48
S Ar (BXXer WC - Lyrik, Lyrik IS - Rec 327, 335, 351 - tem) .......................................................................................51
Dua Ar (Pike 409, 426, 454 - Reba SL, Race, team, WC - Revelai 409, 426) .....................................................................54
Dua Ar (SID Race, team, WC) ......................................................................................................... ................................................................................................................................................. ................................................5 ........566
Ar U-tur (Pike 409, 429, 454 - Reba Race, team - Revelai 409, 429) ....................................................................................58
2-Sep Ar (Lyrik, Lyrik IS - tem, tem IS) .....................................................................................................................................62
lwer le isaa (A Frs) ............................................................................................................................65 -Rde Spr Serce............................................................................... ........................................................................................................................ ............................................................................69 ...................................69 Rear Sc Serce ................................................................................... ............................................................................................................................ ............................................................................75 ...................................75 tls needed r Service Ser vice ............................................ ..................................................................................... .................................................................................. ..............................................................76 .....................76 Ari, Ari , Bar, MC, Pearl .................................................................... ............................................................................................................. ................................................................................... ................................................7 ......777 March ................................................................................ .......................................................................................................................... ................................................................................... .......................................................79 ..............79 Viv id ................................................................................. ......................................................................................................................... .................................................................................. ...............................................................82 .....................82 © SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
SAFEtY FiRSt!
A SRAM Crprai, we care ab You, r csmer. Please, ALWAYS wear yr saey glasses whe servicig yr RckShx rk. Prec yr eyes! Wear yr saey glasses!
4
95-4015-016-000 REV A
gEtting StARtED
Fr explded diagrams ad par mber irma i, please reer he Spare Par s Caalg, which is available r websie a www.sram.cm Fr rderig irmai, please cac yr lcal disribr r v isi r websie a www.sram.cm. Irmai caied i his pblicai is sbjec chage a ayime wi h prir ice. Fr he laes echical irmai, please visi r websie a www.sram.cm. Prdc ames sed i his maal may be rademarks r regis ered rademarks hers. © SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
5
FoRk tEChnologY DESignAtion AnD oil volUMES (All FoRkS) the llwig char is a cmplee lis he 200 8 RckShx rk lie-p. I deails he rk mdel ad crrespdig damper ad sprig echlgy specic each rk, ad he il vlme ad weigh r each rk leg. I is impra deer mie he echlgy sed i yr rk i rder sccesslly service i, as his maal is secied by echlgy, raher ha rks. I y are sre he echlgy sed i yr rk, csl yr lcal RckShx dealer r assisace.
damper technology
(right leg )
oil wt
upper leg
volume
(cc /ml )
oil wt
spring technology
(left leg )
lower leg
volume
(cc /ml )
oil wt
upper leg
volume
(cc /ml )
oil wt
lower leg
argyle 30 2
rebound only
130
5
10
15
coil
-
-
30
15
argyle 318
motion control
130
5
10
15
coil
-
-
30
15
argyle 40 9
motion control
130
5
10
15
solo air
6
15
15
15
/ team
motion control
150
5
15
15
coil
30
15
-
-
bo XX er world cup
motion control
150
5
15
15
solo air
6
15
15
15
none
-
-
20
15
coil
-
-
20
15
turnkey
93
5
10
15
coil
-
-
20
15
dart 2
rebound only
150
5
-
-
coil
-
-
20
15
dart 3
turnkey
93
5
10
15
coil
-
-
20
15
dart 29 r
turnkey
93
5
10
15
coil
-
-
20
15
domain 30 2
rebound only
200
5
10
15
coil
-
-
15
15
domain 30 2 coil u -turn
rebound only
200
5
10
15
coil u -turn
-
-
15
15
domain 318
motion control
200
5
10
15
coil
-
-
15
15
domain 318 coil u -turn
motion control
200
5
10
15
coil u -turn
-
-
15
15
lyrik coil u -turn
mission control
112
5
15
15
u -turn
-
-
15
15
lyrik solo air
mission control
112
5
15
15
solo air
6
15
15
15
lyrik 2 -step
mission control
112
5
15
15
2 -step
35
2.5
10
15
lyrik is coil u -turn
motion control is
112
5
15
15
u -turn
-
-
15
15
lyrik is solo air
motion control is
112
5
15
15
solo air
6
15
15
15
lyrik is 2 -step
motion control is
112
5
15
15
2 -step
35
2.5
10
15
rebound only
120
5
15
15
coil u -turn
-
-
15
15
coil u -turn
motion control
120
5
15
15
coil u -turn
-
-
15
15
pike 40 9 coil u -turn
motion control
120
5
15
15
coil u -turn
-
-
15
15
pike 40 9 air u -turn
motion control
120
5
15
15
air u -turn
6
15
15
15
pike 40 9 dual air
motion control
120
5
15
15
dual air
6
15
15
15
pike 42 6 coil u -turn
motion control
120
5
15
15
coil u -turn
-
-
15
15
pike 42 6 air u -turn
motion control
120
5
15
15
air u -turn
6
15
15
15
pike 42 6 dual air
motion control
120
5
15
15
dual air
6
15
15
15
pike 45 4 coil u -turn
motion control
120
5
15
15
coil u -turn
6
15
15
15
pike 45 4 air u -turn
motion control
120
5
15
15
air u -turn
-
-
15
15
pike 45 4 dual air
motion control
120
5
15
15
dual air
6
15
15
15
reba sl
motion control
110
5
15
15
dual air
6
15
15
15
reba race
motion control
110
5
15
15
dual air
6
15
15
15
reba race air u -turn
motion control
110
5
15
15
air u -turn
6
15
15
15
reba team
motion control
110
5
15
15
dual air
6
15
15
15
reba team air u -turn
motion control
110
5
15
15
air u -turn
6
15
15
15
reba world cup (wc )
motion control
110
5
15
15
dual air
6
15
15
15
bo XX er race
dart 1 dart 2
(w / turnkey)
pike 32 7 coil u -turn pike
6
volume
(cc /ml )
351
95-4015-016-000 REV A
FoRk tEChnologY DESignAtion AnD oil volUMES (Cont)
damper technology
(right leg ) recon 32 7 / Xc solo air
volume
(cc /ml )
oil wt
upper leg
volume
(cc /ml )
oil wt
lower leg
spring technology
(left leg )
volume
(cc /ml )
oil wt
upper leg
volume
(cc /ml )
oil wt
lower leg
rebound only
120
5
15
15
solo air
6
15
15
15
recon 33 5 /sl
turnkey
120
5
15
15
coil
-
-
30
15
recon 33 5 /sl solo air
turnkey
120
5
15
15
solo air
6
15
15
15
recon 351 / race
motion control
18
5
15
15
coil
-
-
30
15
recon 351 / race coil u -turn
motion control
118
5
15
15
coil u -turn
-
-
30
15
recon 351 / race solo air
motion control
118
5
15
15
solo air
6
15
15
15
revelation 40 9 coil u -turn
motion control
115
5
15
15
coil u -turn
6
15
15
15
revelation 40 9 air u -turn
motion control
115
5
15
15
air u -turn
6
15
15
15
revelation 42 6 dual air
motion control
115
5
15
15
dual air
6
15
15
15
revelation 42 6 coil u -turn
motion control
115
5
15
15
coil u -turn
-
-
30
15
revelation 426 air u -turn
motion control
115
5
15
15
air u -turn
6
15
15
15
sid race
pure delite
5
15
10
15
dual air
6
15
10
15
sid team
motion control
-
-
10
15
dual air
6
15
10
15
sid world cup (wc )
motion control
-
-
10
15
dual air
6
15
10
15
totem coil
mission control
137
5
20
15
coil
-
-
20
15
totem solo air
mission control
137
5
20
15
solo air
6
15
20
15
totem 2 -step
mission control
137
5
20
15
2 -step
135
2.5
20
15
totem is coil
motion control is
137
5
20
15
coil
-
-
20
15
tora 28 9
rebound only
145
5
15
15
coil
-
-
20
15
tora 28 9
rebound only
145
5
15
15
coil u -turn
-
-
30
15
tora 30 2
turnkey
145
5
15
15
coil
-
-
20
15
tora 30 2
turnkey
145
5
15
15
coil u -turn
-
-
30
15
tora 318
motion control
145
5
15
15
coil
-
-
20
15
tora 318
motion control
145
5
15
15
coil u -turn
-
-
20
15
tora 318
motion control
130
5
15
15
solo air
6
15
15
15
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
toolS nEEDED FoR SERviCE (All FoRkS) the llwig char is a lis he mdel year 2008 ls eeded r service yr RckShx rk. While his char is ieded be cmprehesive, i is sill ly a gide. the ls reqired r each sep service are deailed i he ex each service seci. Keep i mid yr specic rk may reqire every l lised.
loWER lEg REMovAl
BUShing SERviCE
DAMPER SERviCE
SPRing SERviCE
loWER lEg inStAllAtion
SAFEtY GLASSES
X
X
X
X
X
APRon
X
X
X
X
X
RuBBER GLoVES
X
X
X
X
X
CLEAn RAGS (LInt FREE)
X
X
X
X
X
oIL PAn
X
X
X
X
X
CLEAn WoRK AREA
X
X
X
X
X
BICYCLE StAnD
X
X
X
X
toolS SAFEtY/StARting EQUiPMEnt
BEnCH VISE
X
WREnChES/PliERS 1.5 MM HEX
X
2 MM HEX
X
2.5 MM HEX
X
4 MM HEX
X¹
5 MM HEX
X
X
X²
X¹ X
6 MM HEX
X
8 MM HEX
X6
10 MM SoCKEt oR oPEn EnDED WREnCH
X
5
X
X
14 MM SoCKEt
X,X
15 MM SoCKEt
X
5
24 MM SoCKEt
X
SoCKEt EXtEnSIon
6
X X5, X6
24 MM tHIn WREnCH
X²
MISSIon ContRoL WREnCH
X²
toRQuE WREnCH
X
SLIP JoInt PLIERS
X²
SnAP RInG PLIERS - IntERnAL
X
X
SnAP RInG PLIERS - EXtERnAL
X
X
X
X
X
X
X
X
X
MiSC toolS PLAStIC MALLEt
X
MALLEt DRIFt tooL LonG DoWEL RoD (PLAStIC oR WooD) FLAtHEAD SCREWDRIVER
X X
X
X X
X
SHARP PICK
X
X
SHoCK PuMP
X³
X
SHRADER VALVE CoRE tooL
X
X7
BoXXer Only ²Mission Control Only ³SID Race Only 4 SID Models Only 5 i-Ride Only 6 i-Ride with M-10 Star Nut Only 7 2-Step Air Only ¹
8
95-4015-016-000 REV A
toolS nEEDED FoR SERviCE (Cont)
toolS
loWER lEg REMovAl
BUShing SERviCE
DAMPER SERviCE
MAGnEt
SPRing SERviCE
loWER lEg inStAllAtion
X
RuLER
X³
SID DuAL AIR uPPER tuBE REtAInER tooL
X¹ X
BuSHInG REMoVAL tooL/PLAtE
4
X
oil/liQUiDS 2.5, 5, 10 oR 15 Wt SuSPEnSIon oIL
X
X
X
X
GREASE
X
X
X
X
i-RIDE GREASE (Maxima SG-920)
X
oIL MEASuRInG DEVICE
X
X
X
X
ISoPRoPYL ALCoHoL
X
X
X
X
X
FRoStY CoLD BEVERAGE
X
X
X
X
X
BoXXer Only ²Mission Control Only ³SID Race Only 4 SID Models Only 5 i-Ride Only 6 i-Ride with M-10 Star Nut Only 7 2-Step Air Only ¹
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
9
10
95-4015-016-000 REV A
loWER lEg REMovAl
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
11
loWER lEg REMovAl (All FoRkS)
intRoDUCtion Remvig he lwer legs yr rk is he rs sep i servicig yr rk. I allws y access yr rk bshigs, damper sysem ad sprig sysem. oce y have remved yr rk lwer legs, y'll be ready mve he ex seci.
loWER lEg REMovAl inStRUCtionS note : boXX er only a
- loosen
upper crown bolts with
4 m m heX wrench and remove upper crown.
spray
isopropyl alcohol on upper tubes and under frame bumpers. twist and pull up to remove bumpers. finally, use a
4 mm heX wrench to loosen lower crown
bolts and remove uppers from crown by twisting and sliding each upper down and out of crown.
1.
2.
3. 4.
5.
6.
7. 8.
12
Remve he air chamber valve cver cap rm he le rk leg p cap. I rk has a egaive air chamber, remve he egaive air chamber valve cver cap rm he b m he le r k leg. Depress schrader valve ad release all air rm he air chamber. I rk has a egaive air chamber, sar wih he egaive air chamber rs, he prceed he psiive air chamber. Pll exeral rebd adjser kb ad remve rm he righ sha bl. use a 5 mm hex wrech lse bh sha bls 3 4 rs. Fr Dal Air eqipped rks, se a 10 mm scke (r pe ed) wrech lse ad hread he Dal Air sha js pas he hreaded sha ed. use a plasic malle gely ap each sha bl ree rm i s press- he lwer leg ad se yr gers remve sha bls/ cmpleely. Remve he lwer leg assembly rm rk by rmly pllig i dwward, hldig bh legs r he brake arch. use il pa drai excess il rm lwer leg assembly. Spray isprpyl alchl ad i he lwer leg assembly. Wipe he lwer legs clea, he wrap a clea rag ard a dwel ad clea he iside each lwer leg ( picred).
boXX er only
boXX er only
boXX er only
1
2
3
4
5
6
7
95-4015-016-000 REV A
BUShing SERviCE
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
1
BUShing SERviCE (All FoRkS)
intRoDUCtion Sspesi rk bshigs are csidered "wear ad ear" par s ad reqire reglar maieace, depedig he reqecy ridig, ridig errai, rider bdy weigh, ad ype rk. the mre y ride, he mre reqely yr bshigs eed be replaced. the llwig chaper cvers Ds & oil Seal remval, Bshig remval, Bshig isallai, ad Ds & oil Seal isallai. A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers. SYMPtoMS oF WoRn BUShingS Sympms wr bshigs ha eed be replaced iclde, a "kckig" sd rm he rk w he ridig, ad/r he headse may eel lse whe i is'.
tWo MEthoDS oF ChECking FoR looSE BUShingS Med 1: o-Be cec 1.
Cmpress rk 5 imes circlae lwer leg lbe ( picred). 2. Hld he r brake lever igh ad rck he bike back ad rh. I he rk eels like i's "kckig", r he headse eels lse, prceed seps 2 ad 3. 3. Check he rk: wrap yr gers ard he ds seal ad pper be area. Rck he bike back ad rh agai. Lise ad eel i here is ay play bewee he pper be ad he ds seal. I s, he bshigs are lse. 4. Check he headse: wrap yr gers ard he headse pper cp r lwer cp/race areas. Hldig he brake, rck he bike back ad r h ad eel i he headse is lse. I s, ighe he headse ad check agai.
Med 2: off-Be cec 1. 2.
2
3
4
2
Cmpress rk 5 imes circlae lwer leg lbe ( picred). Hld he rk crw igh i e had ad he brake arch i he her had. try ad mve he brake arch back ad rh . I y ca eel ay play, r i he rk eels like i's "kckig", he bshigs are lse. note : you may wish to brace the fork on a table or on the floor to steady it.
14
95-4015-016-000 REV A
DUSt & oil SEAl REMovAl (All FoRkS) 1.
Remve he ds seal sig a medim large fa-head screwdriver carelly pry i rm he lwer leg.
1
2
3
note : not all forks contain a foam ring . if your fork does not have a foam ring , please move onto step
2.
3.
Remve he il am rig wih yr gers. note : not all forks contain an inner oil seal . if your fork does not have an inner oil seal , please move onto the neXt section, bushing removal .
3.
Remve he ier il seal, lcaed js belw he ds seal sig a fa head screwdriver. t prec he lwer leg pai, place a rag i bewee he lwer leg ad he screwdriver. note : the dust seal eliminates the need to replace the oil seal . note : all dart forks and tora
289, 302 do not have serviceable bushings , please move on to dust & oil seal installation.
BUShing REMovAl (All ARgYlE - Boxx ER - DoMAin - lYRik - PikE - REBA - RECon - REv ElAtion - SiD - totEM & toRA 318) 1.
Clamp bshig remval hadle/pller l i bech vise ighly. 2. Isall he crrec bshig remval plae hadle ed ad secre wih hadle plae screw. • 28 mm plae (SID) • 32 mm plae (Arg yle, BXXer, Pike, Reba, Rec, Revelai, tra) • 35 mm plae (Dmai, Lyrik) • 40 mm plae (tem) 3. Slide he remval plae i he lwer leg pas he pper bshig. the remval plae pivs whe isered. Pll lwer leg away rm pller l ad hk he fa ed he plae secre der he bshig. Whe he plae is secre der bshig, begi remve. 4. use a plasic malle rmly ad sqarely hi he p he lwer leg he fa ds seal srace area il pper bshig plls ree.
1
2
3
28, 32, 35, or 40 mm plate
4
5
important: do not hit the brake arch to remove the bushing . this can damage your fork .
5.
6. 7.
t pll he lwer bshig ree rm he lwer leg, slide he remval plae pas he lwer bshig ad hk he fa ed he plae secre der he bshig. Agai, rmly ad sqarely hi he p he lwer leg he fa ds seal srace area il he lwer bshig plls ree. Lger lwer bshigs may reqire mre rce. Rer S ep 3 ad repea r he her rk leg. Spray isprpyl alchl iside lwer legs. Wrap a clea rag ard a dwel ad clea he iside he lwer legs ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
15
BUShing inStAllAtion - 28 MM UPPER tUBE DiAMEt ER (SiD) lower bushing installation with bushing size :
28
1. 2.
3. 4. 5.
6.
7.
mm X
20 mm (sid)
Clamp 28 mm bshig isallai l i bech med vise, allwig 1" verhag. Slide he lwer bshig sleeve (131.25 mm lg, brshed almim) bshig isallai ps. Slide lwer bshig p lwer bshig isallai sleeve. Slide lwer leg ver isallai ps ad res p lwer bshig. Iser he malle dri l i he lwer leg sha hle ad hld i place wih e had. usig a plasic malle, hi he malle dri l press he bshig i he lwer leg. Cie hi he malle dri l il he lwer leg ds seal ridge is level wih he p he isallai ps spacer. Remve lwer leg rm l ad ispec he he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg hrizally ad release. Lwer leg shld swig 90° dw ad sp ( picred). note: if lower leg feels tight or does not move at all , slide lower leg back onto bushing installation post
1
2
3
bushing sleeve
4
5
6
9
10
11
and rock side to side to loosen fit .
8.
Rer sep 1 ad repea r her leg. 5 mm spacer
upper bushing installation with bushing size :
10 mm bushing
28 mm X 10 mm (sid)
9. 10.
11. 12. 13.
14. 15.
Remve lwer bshig isallai sleeve rm bshig isallai ps. Slide 10 mm he 5 mm pper bshig isallai spacers bshig isallai ps. Slide pper bshig bshig isallai ps, p he 5 mm spacer. Slide lwer leg ver isallai ps ad res p pper bshig. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l press he bshig i he lwer leg. Cie hi he malle dri l il he lwer leg sps mvig. Remve lwer leg rm l ad ispec he i he pper bshig by slidig e pper be i he lwer leg. Hld lwer leg hrizally ad release. Lwer leg shld swig 90° dw ad sp ( picred).
10 mm spacer
12
13
14
note: do not press bushing below bore step. note: if lower leg feels tight or does not move at all , slide lower leg back onto bushing installation post and rock side to side to loosen fit .
16. Rer S ep 9 ad repea r her leg.
16
95-4015-016-000 REV A
BUShing inStAllAtion 32 MM UPPER tUBE DiAMEtER (ARgYlE - PikE - REBA - RECon - REvElAtion - toRA 318) 32 MM UPPER tUBE DiAMEtER (BoxxER) lower bushing installation with bushing size :
32
30 mm - slotted (argyle, pike, reba, recon , revelation , tora 318) 32 mm X 76 mm - non-slotted (boXX er)
1. 2.
mm X
1
2 lower spacer
Clamp 32 mm bshig isallai l i bech med vise. Slide lwer bshig isallai spacer bshig isallai ps. note : recon , revelation , and tora
3 bushing sleeve
(short)
318 use the short
spacer in this step.
3.
Slide he lwer bshig sleeve bshig isallai ps. 4. Rec, Revelai, tra 318 oly: Slide he all lwer bshig spacer he bshig isallai ps. 5. Slide lwer bshig he p he lwer isallai sleeve.
4
5
6
lower spacer
(tall)
note : boXX er lower bushing is not slotted .
6.
Slide lwer leg ver isallai ps ad res p lwer bshig. 7. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l press he bshig i he lwer leg. 8. Cie hi he malle dri l, il he lwer leg ds seal ridge is level wih he p he isallai ps spacer. Y will eel i sp as he bshig is "se" i he lwer leg. 9. Remve lwer leg rm l ad ispec he i he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). note : if lower leg swings too freely, repeat step
lower bushing
7
8
8.
if lower leg feels tight or does not move at all , slide lower leg back onto bushing installation post and rock side to side to loosen fit .
10. Rer S ep 1 ad repea r her leg.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
1
BUShing inStAllAtion (Cont) 32 MM UPPER tUBE DiAMEtER (ARgYlE - PikE - REBA - RECon - REvElAtion - toRA 318) 32 MM UPPER tUBE DiAMEtER (BoxxER) upper bushing installation with bushing size :
11
32 mm X 30 mm non-slotted (argyle , pike , reba, recon , revelation , tora 318) 32 mm X 10 mm - non-slotted (boXX er)
11. Remve lwer bshig sleeve (ad all lwer bshig spacer r Rec, Revelai, ad tra 318). Leave ly he lwer bshig spacer bshig isallai l. 12. Slide pper bshig bshig isallai ps. 13. Slide lwer leg ver isallai ps, ad res p he pper bshig. 14. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l press he pper bshig i lwer leg. 15. Cie hi he malle dri l il he lwer leg ress lsh p he isall spacer. Y will eel i sp as he bshig is "se " i he lwer leg. the p he bshig shld be lsh/level wih il seal sep i he lwer leg. 16. Remve lwer leg rm l ad ispec he i he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). note: if lower leg swings too freely, repeat step
12
13 upper bushing
lower spacer
(short)
14
15
15.
if lower leg feels tight or does not move at all , slide lower leg back onto bushing installation post and rock side to side to loosen fit .
17. Rer S ep 11 ad repea r her leg.
18
95-4015-016-000 REV A
BUShing inStAllAtion 35 MM UPPER tUBE DiAMEtER (DoMAin - lYRik) 40 MM UPPER tUBE DiAMEtER (totEM) lower bushing installation with bushing size :
1
3 5 mm X 30 mm - slotted (domain, lyrik ) 40 mm X 30 mm - slotted (totem)
1. 2. 3. 4. 5. 6.
7.
8.
Clamp 32 mm bshig isallai l i bech med vise. Slide bshig isallai l adaper ver bshig isallai ps. Slide lwer bshig sleeve he adaper. Slide lwer bshig he adaper. Slide lwer leg ver isallai ps ad res p lwer bshig. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l press he bshig i he lwer leg. Cie hi he malle dri l, il he lwer leg ds seal ridge is level wih he p he isallai ps spacer. Y will eel he sppig pi as he bshig is "se" i he lwer leg. Remve lwer leg rm l ad ispec he i he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). note : if lower leg swings too freely, repeat step
7.
2
3 sleeve
4
5
6
10
11
lower bushing
7
if
lower leg feels tight or does not move at all , slide lower leg back onto bushing installation post and
upper
rock side to side to loosen fit .
9.
bushing
Rer S ep 1 ad repea r her leg. upper bushing installation with bushing size :
35 mm X 30 mm - non slotted (domain, lyrik ) 40 mm X 30 mm - non slotted (totem)
10. Remve lwer bshig sleeve rm he adaper ad slide pper bshig he adaper. 11. Slide lwer leg ver isallai ps, ad res p he pper bshig. 12. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l press he pper bshig i lwer leg. 13. Cie hi he malle dri l il he lwer leg ress lsh p he isall spacer. Y will eel i sp as he bshig is "se " i he lwer leg. the p he bshig shld be lsh/level wi h il seal sep i he lwer leg.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
12
13
19
BUShing inStAllAtion (Cont) 35 MM UPPER tUBE DiAMEtER (DoMAin - lYRik) 40 MM UPPER tUBE DiAMEtER (totEM) upper bushing installation with bushing size :
35 mm X 30 mm - non slotted (domain, lyrik ) 40 mm X 30 mm - non slotted (totem)
14. Remve lwer leg rm l ad ispec he i he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). note: if lower leg swings too freely, repeat step
8.
if lower leg feels tight or does not move at all , slide lower leg back onto bushing installation post and rock side to side to loosen fit .
15. Rer S ep 10 ad repea r her leg.
20
95-4015-016-000 REV A
FoAM Ring & DUSt SE Al inStAllAtion (SiD) foam ring and dust seal installation
1. 2.
Sak ew am rigs i sspesi il. Slide ds seal isallai l ver he 2 8 mm bshig isallai l. I shld si fsh wih he base he isallai l. 3. Slide ew ds seal ver bshig isallai l ad p ds seal isallai l.
1
2
3
4
5
6
note : dust seal should be installed energizer spring side down.
4.
Slide il-saraed am rig ver bshig isallai l ad p ds seal. Sea he am rig iside he der caviy he ds seal. Wipe excess il he ds seal wih a clea rag. 5. Slide lwer leg bshig isallai l, p ew ds seal. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l il ds seal seas iside lwer leg, fsh wih he p he lwer leg ds seal sep. 6. Ds seal shld be press- sg i he lwer leg, wih li le gap shwig. 7. Rer S ep 1 ad repea r her leg.
FoAM Ring & DUSt SEAl inStAll Ation (REBA - RECon - REvElAtion - toRA 318) foam ring installation
1. 2.
Sak ew am rigs i sspesi il. Iser ew il-saraed am rig i lwer leg.
1
2
3
4
dust seal installation
3. 4. 5.
Iser ew ds seal i he wide ed he ds seal isallai l. Iser ds seal i lwer leg ad press s raigh dw ad evely sea i lwer leg. Ds seal shld be press- sg ad fsh i lwer leg. note : check foam ring under dust seal . foam ring should not protrude from dust seal . if so , adjust
5
foam ring inside lower leg , flush on all sides.
6.
Rer S ep 1 ad repea r her leg.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
21
FoAM Ring, DUSt SEAl & oil SEAl inS tAllAtion (ARgYlE - BoxxER - DoM Ain - lYRik - PikE - REBA - totEM) oil seal installation
1.
Apply grease r sspesi il he iside he lwer leg il seal cer-bre. 2. Iser he ew il seal he sepped ed he il/ds seal isallai l. 3. usig he il/ds seal isallai l, iser he il seal dw ad i he il sep i he lwer leg. Apply pressre all sides he il seal sea i i place.
1
2
3
4
5
6
7
8
foam ring installation note : for domain, lyrik , and totem, please move onto dust seal installation, step
4. 5.
6.
Sak ew am rigs i sspesi il. Iser ew il-saraed am rig i lwer leg p il seal. dust seal installation
6.
Iser ew ds seal i he pckeed ed he il/ds seal isallai l. 7. usig he il/ds isallai l, iser ds seal i lwer leg. Apply pressre all sides he ds seal sea i i place. 8. Ds seal shld be press- sg ad fsh i lwer leg. note: check foam ring under dust seal . foam ring should not protrude from dust seal . if so , adjust foam ring inside lower leg , flush on all sides.
9.
Rer S ep 1 ad repea r her leg.
CoMPlEting BUShing SERviCE (All FoRkS) Cmplee he bshig service yr rk by deailig he lwer legs. Spray isprpyl alchl eire lwer leg assembly ad wipe wih a clea rag. Check he decals yr rk ad replace i ecessary. this concludes the bushing service for your fork . you did a great job! you are now ready to move on to the neXt section: damper service. enjoy!
22
95-4015-016-000 REV A
DAMPER SERviCE
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
2
REBoUnD & tURnkEY DAMPER SERviCE (ARgYlE 302 - DARt 2, 3 - DoMAin 302 - PikE 327 - RECon 327, 335, Sl, xC - toRA 289, 302)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DAMPER REMovAl/SERviCE inStRUCtionS note : for dart move to step
1.
2, and tora 289 please skip step 1 and
2.
1
Remve exeral sap rig rm cmpressi adjser kb sig exeral sap rig pliers ad remve cmpressi adjser kb ad -rig.
oR
or
2.
I rk is eqipped wih a reme cmpressi lck eare, remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad whie p cap shield. uhread cmpressi damper p cap wih a 24 mm scke wrech. note : for argyle
289
3.
4.
5.
2
3
5
6
4
302, dart 2, domain 302, and tora 5.
please move to step
Remve cmpressi damper by pllig p ad gely rckig side side. I rk is eqipped wih a reme lck eare, be sre remve he reme cmpressi damper cable-sp clamp; which is lcaed der he cmpressi damper p cap. oce remved, clea pper be hreads wih a rag. Replace cmpressi damper p cap -rig by gely pichig -rig remve. Apply a ew drps sspesi il ew -rig ad re-isall. Remve rk rm bicycle sad ad pr remaiig il i pa. note : for dart
2, this completes the removal procedures, please move to step 10.
6.
7.
tr rk pside dw ad psh rebd damper sha hrgh sha gide. use a lg dwel rd help psh damper pis pas pper be hreads ad remve rm pper be. Remve rebd damper -rig ad damper ier seal-head -rig (lcaed i he b m he pper be). Apply resh grease ew -rigs ad re-isall.
7
important: if using a pick to remove inner seal head o- ring , do not scratch o- ring gland. scratches may cause oil to leak.
24
95-4015-016-000 REV A
oPtionAl - CoMPRESSion DAMPER UPgRADE: non-REMotE to REMotE ADjUSt upgradig rm a -reme cmpressi adjs rk a reme cmpressi adjs (rm a crw med adjser kb a reme PpL c r PshLc lever adjser), reqires replacig he -reme cmpressi damper wih a rem e cmpressi damper ad cable-sp clamp. the reme rer sprig is iegraed i he cmpressi damper ad is reqired r se wih he PpLc ad PshLc reme lever assembly.
DAMPER inStAllAtion inStRUCtionS 8.
Clamp rk back i bicycle sad ad apply a ligh lm grease pper be hreads. Iser rebd damper back i righ side pper be, sha rs ad press pis i pper be pas be hreads. 9. Psh rebd damper i pper be sig a lg dwel rd. Gide rebd damper sha hrgh damper seal head a he b m he pper be ad pll sha hrgh by had i he lly exeded psii. 10. Measre ad pr 5w sspesi il i he pper be sig he vlmes lised i he char a righ. note : for dart
8
9
10
11
12
2 and tora 289 please move to step
12. important: oil volume is critical . too much oil reduces available travel , which can lead to fork damage from compression bottom out. too little oil decreases damping performance .
11. Reme oly: Psii cable-sp clamp i he 10 'clck psii ard he pper be hle he crw prir iserig cmpressi damper. Grease pper be hreads liberally he iser cmpressi damper i pper be. Press dw ad wis wrk damper i pper be. Be carel damage -rig seals pper be hreads. 12. Press p cap dw i pper be hreads ad had ighe. usig a 24 mm scke wrech, ighe 60 i/lbs. note : for dart
2 and tora 289, this completes the installation instructions . you are ready to move on to the neXt section in the manual : spring service.
oil volume
argyle
302
130cc /ml
dart
2
150cc /ml
dart
2 (with turnkey)
93 cc /ml
dart
3
93 cc /ml
domain pike
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
(±5 cc /ml )
fork
302
327
200cc /ml 120 cc /ml
recon
327, Xc
120 cc /ml
recon
335, sl
120 cc /ml
tora
289
145cc /ml
tora
302
145cc /ml
25
DAMPER inStAllAtion inStRUCtionS (Cont) note : turn compression adjuster heX counterclockwise to the open position.
13. Place cmpressi adjser kb cmpressi damper p cap wih he kb dial se i he 3 'clck psii. usig exeral sap rig pliers, secre he cmpressi adjser kb wih a ew sap rig.
13
oR
or
I rk is eqipped wih a reme cmpressi lck eare, place reme spl cmpressi damper p cap wih he cable se screw i he 3 'clck psii. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig. this concludes the damper service for your fork . you did a great job! you are now ready to move on to the neXt section: spring service . enjoy!
26
95-4015-016-000 REV A
Motion ContRol DAMPER SERviCE (ARgYlE 318, 409- DoMAin 318 - lYRik iS - toRA 318 - totEM iS)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DAMPER REMovAl/SERviCE inStRUCtionS note : for argyle
318 and 409, it is not necessary to remove the motion control knob, please skip step one and move to step 2.
1.
1
Remve exeral sap rig rm cmpressi adjser kb sig exeral sap rig pliers ad remve cmpressi adjser kb ad -rig seal.
oR
or
I rk is eqipped wih a reme cmpressi lck eare, remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad whie p cap seal.
2
3
5
6
4
or
I rk is eqipped wih Mi Cr l IS, se a 2 mm hex remve screw rm cmpressi he adjser kb. Remve cmpressi adjser kb ( picred). 2. uhread cmpressi damper p cap wih a 24 mm scke wrech. 3. Remve cmpressi damper rm pper be/ crw by pllig p ad gely wisig side side. I rk is eqipped, be sre remve he reme cmpressi damper cable-sp clamp; which is lcaed der he cmpressi damper p cap. oce remved, clea pper be hreads wih a rag. 4. Wih a sharp pick, remve he cmpressi damper p cap -rig (lcaed a he p he damper) ad he cmpressi damper seal (lcaed a he bm he damper). Apply a ew drps sspesi il he ew -rig ad seal ad isall. important: if using a pick to remove inner seal head o- ring , do not scratch o- ring gland. scratches may cause oil to leak.
5. 6.
7.
7
Remve rk rm bicycle sad ad pr remaiig il i pa. tr rk pside dw. Psh rebd damper sha i pper be/seal head ad remve rebd damper rm pper be. Remve rebd damper glide rig ad ier seal head -rig. Apply resh grease ew -rigs ad re-isall.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
2
oPtionAl - CoMPRESSion DAMPER UPgRADE: non-REMotE to REMotE ADjUSt (toRA 318 onlY) upgradig rm a -reme cmpressi adjs rk a reme cmpressi adjs (rm a crw med adjser kb a reme PpL c r PshLc lever adjser), reqires replacig he -reme cmpressi damper wih a rem e cmpressi damper ad cable-sp clamp. the reme re r sprig is desiged i he cmpressi damper ad is reqired r se wih he PpLc ad PshLc reme lever assembly.
DAMPER inStAllAtion inStRUCtionS 8.
Clamp rk back i bicycle sad. Iser rebd damper back i righ side pper be, sha rs. Gide rebd damper hrgh damper seal head a b m pper be ad pll hrgh. 9. thread sha bl i rebd damper sha ed ad pll rebd damper sha dw hrgh seal head i lly exeded psii. 10. Measre ad pr 5w sspesi il i he pper be, hrgh he crw sig he llwig vlmes: oil volume
9
10
11
(±5 cc /ml )
fork argyle
318
130cc /ml
argyle
409
130 cc /ml
domain 318
200 cc /ml
tora
8
318
145 cc /ml
important: oil volume is critical . too much oil reduces available travel , which can lead to fork damage from compression bottom out. too little oil decreases damping performance .
12
11. Reme oly: Slide cmpressi damper hrgh cable-sp clamp prir iseri. Psii he cable-sp clamp i he 10 'clck psii he crw. Grease pper be hreads liberally, he iser cmpressi damper i pper be. Press dw ad wis wrk damper i pper be. 12. As s as he damper seal passes hrgh he pper be hreads, pll he damper p slighly, he psh back dw. the cmpressi damper shld slide p ad dw easily, idicaig he seal i he prper psii, ad lded ver. Repea prcedre il he cmpressi damper slides p ad dw easily. the press he cmpressi damper dw il he pper -rig cacs he pper be hreads.
28
95-4015-016-000 REV A
DAMPER inStAllAtion inStRUCtionS (Cont) 13. tr he damper clckwise ad hread i he pper be. Be carel damage he pper damper -rig. Cie hread p cap dw i pper be hreads ad had ighe. usig a 24 mm scke wrech, ighe 60 i/lbs.
13
note : for argyle
318 and 409 this completes the installation process. note : turn compression adjuster heX counterclockwise to the open position.
14. Place cmpressi adjser kb cmpressi damper p cap wih he kb dial se i he 3 'clck psii. usig exeral sap rig pliers, secre he cmpressi adjser kb wih a ew sap rig.
14
or
I rk is eqipped wih a reme cmpressi lck eare, place reme spl cmpressi damper p cap wih he cable se screw i he 3 'clck psii. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig.
oR
this concludes the damper service for your fork . you did a great job! you are now ready to move on to the neXt section: spring service . enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
29
Motion ContRol DAMPER SERviCE (BoxxER RACE, tEAM, WC - PikE 409, 426, 454 - REBA Sl, RACE, tEAM, WC - RECon 351 - REvElAtion 409, 426)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DAMPER REMovAl/SERviCE inStRUCtionS note :
boXX er only, it is not necessary to remove the motion control adjuster knob. please skip step 1 and move to step 2.
1.
1
Remve exeral sap rig rm cmpressi adjser kb sig exeral sap rig pliers ad remve cmpressi adjser kb ad -rig seal.
oR
or
2. 3.
4.
5. 6.
7.
8. 9.
10.
0
I rk is eqipped wih a reme cmpressi lck eare, remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad whie p cap seal. uhread cmpressi damper p cap wih a 24 mm scke wrech. Remve cmpressi damper rm pper be/ crw by pllig p ad wis ig side side. oce remved, clea pper be hreads wih a rag. Wih a sharp pick, remve cmpressi damper -rigs (lcaed a he p ad bm he damper). Apply a ew drps sspesi il ew -rigs ad re-isall. Remve rk rm bicycle sad ad pr remaiig il i pa. Remve rebd damper seal head reaiig rig (lcaed iside he bm he righ pper be), sig exeral sap rig pliers. Pll dw ad remve he rebd damper ad seal head assembly rm he pper be. Slide seal head damper sha ad remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew -rigs ad reisall. Spray isprpyl alchl r ebd damper sha, ad clea wih a rag ( picred). I damaged, replace rebd damper pis glide rig. Psii pper be base rig p seal head sep ad slide rebd seal head assembly rebd damper sha. Spray isprpyl alchl i he pper be. Wrap a clea rag ard a dwel ad clea he iside he pper be ( picred).
2
3
5
6
7
4
9
95-4015-016-000 REV A
oPtionAl - CoMPRESSion DAMPER UPgRADE: non-REMotE to REMotE ADjUSt (ExClUDES BoxxER) upgradig rm a -reme cmpressi adjs rk a reme cmpressi adjs (rm a crw med adjser kb a reme PpL c r PshLc lever adjser), reqires replacig he -reme cmpressi damper wih a rem e cmpressi damper ad cable-sp clamp. the reme re r sprig is desiged i he cmpressi damper ad is reqired r se wih he PpLc ad PshLc reme lever assembly.
DAMPER inStAllAtion inStRUCtionS 11. Iser rebd damper pis i he bm he pper be a a agle, wih he pe-eded side he glide rig ace ward. Cie agle ad rae il glide rig is i he pper be. Psii he pper be base rig seal ad seal head i he pper be. 12. Psii he pper be base rig seal ad seal head i he pper be ad press i he pper be wih yr hmb. 13. use ieral sap rig pliers secre seal head i pper be wih reaiig rig. important: make sure the retaining ring is securely fastened in the upper tube groove. you can check this
12
11
13
14
by using the snap ring pliers to rotate the retaining ring in the shaft one complete revolution .
14. Pll rebd damper sha dw, i he lly exeded psii. Measre ad pr 5w sspesi il i he pper be, hrgh he crw, sig he vlmes lised i he char a righ. *boXX er only optional procedure :
bo XX er only
you can use a
bo XX er only
suspension oil height tool to measure oil volume . measure and set syringe needle stop to
205
mm . pour
5 wt oil into upper tube. insert syringe needle into the upper tube , resting the stop flat on upper tube. pull out any eXcess oil with syringe plunger. remove oil height tool from upper tube. important: oil volume is critical . too much oil reduces available travel , which can lead to fork damage from compression bottom out. too little oil decreases damping performance .
oil volume fork
(± 5cc /ml )
bo XX er race , team, wc
150 cc /ml*
pike
351, 409, 426, 454
reba sl , race , team, wc recon
351
revelation
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
120cc /ml 110cc /ml 118cc /ml
409, 426
114cc /ml
1
DAMPER inStAllAtion inStRUCtionS (Cont) 15. Iser cmpressi damper i pper be. Press dw ad wis wrk damper i pper be. 16. tr he damper clckwise hread i he pper be. Be carel damage he pper damper -rig. Cie hread p cap dw i pper be hreads ad had ighe. usig a 24 mm scke wrech, ighe 60 i/lbs.
15
16
note : for boXX er , this completes the installation procedures. note : turn compression adjuster heX counterclockwise to the open position.
17. Place cmpressi adjser kb cmpressi damper p cap wih he kb dial se i he 3 'clck psii. usig exeral sap rig pliers, secre he cmpressi adjser kb wih a ew sap rig. or
17
oR
I rk is eqipped wih a reme cmpressi lck eare, place reme spl cmpressi damper p cap wih he cable se screw i he 3 'clck psii. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig. this concludes the damper service for your fork . you did a great job! you are now ready to move on to the neXt section: spring service . enjoy!
2
95-4015-016-000 REV A
Motion ContRol DAMPER SERviCE (SiD tEAM, WoRlD CUP)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DAMPER REMovAl/SERviCE inStRUCtionS 1. 2. 3.
4. 5.
Remve reme cable sp clamp sig a 2 mm hex wrech. Remve Fldgae adjser kb sig a 1.5 mm hex wrech. Remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad rer sprig. uhread cmpressi damper p cap wih a 24 mm scke wrech. Remve cmpressi damper, damper be ad rebd damper assembly rm pper be/ crw by pllig p ad wis ig side side. Clea pper be hreads wih a rag.
1
2
3
4
5
7
9
11
12
note : leave the threaded base retainer inside the bottom of the upper tube .
6.
7.
8.
9.
10. 11.
12.
Pll he rebd damper/seal head assembly rm he bm he dampig be. Be sre wrap a rag ard he damper be, as il will drai rm he assembly. Pr remaiig il rm damper be i il pa. Remve cmpressi damper rm damper be by pllig p gely. Allw ay excess il drai i il pa. Pll sraigh ; d' wis. Spray cmpressi damper assembly ad damper be (iside ad ) wih isprpyl alchl. Wipe grease ad il rm damper assembly ad side damper be. Wrap a clea rag ard a dwel ad clea he iside he damper be ( picred). Slide seal head rebd damper sha ad remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew -rigs ad isall. Spray rebd damper sha wih isprpyl alchl, ad clea wih a rag ( picred). Ispec rebd damper pis glide rig ad damper sha. Replace eiher, i damaged. Slide rebd damper seal head back rebd damper sha. Iser a 2 .5 mm hex wrech (r rebd adjser kb) i rebd damper adjser a he bm he sha, ad r cer-clckwise pe he rebd damper valve. this allws il fw i he damper valve whe re-llig damper be wih il.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
6
DAMPER REMovAl/SERviCE inStRUCtionS (Cont) 13. Lbricae rebd damper ad seal head by sbmergig i a caier sspesi il. 14. Remve cmpressi damper -rigs (lwer, ieral faig pis - IFP, ad primary). Apply a ew drps sspesi il ew rigs ad isall.
13
14
DAMPER inStAllAtion inStRUCtionS 15. Place gld Fldgae adjser kb back he cmpressi damper ad ighe wih a 1.5 mm hex wrech. 16. tr he cmpressi spl adjser hex cer-clckwise il i sps. this is he ll pe psii. 17. Apply sspesi il bh he mai pis ad IFP - rigs he cmpressi damper. 18. Iser he cmpressi damper back i he damper be ad slide eire damper assembly i he be. Press p cap rmly i place. 19. Hldig damper be wih he pe ed p, pr 5w sspesi il i he damper be il be is apprximaely hal-ll. tap he cmpressi damper be lighly a fa srace release ay air bbbles rapped iside he damper. 20. Pr addiial 5w sspesi il i damper be il cmpleely ll. 21. Remve rebd damper ad seal head rm he il caier i which i was sbmerged. Wrap a rag ard he damper be cach displaced il. Wih he seal head bmed , slwly iser rebd pis i he damper be, by pshig he seal head, il i is lly seaed. Wipe all il rm damper be.
15
16
compression closed
compression open
17
19
18
20
important: do not cycle the rebound damper into the damper tube. the compression damper is not secure in the damper tube until threaded into the upper and tightened with a socket wrench.
21
4
95-4015-016-000 REV A
DAMPER inStAllAtion inStRUCtionS (Cont) 22. Iside he damper pper be is a -rig ha sis be wee he damper be/rebd seal head assembly ad he pper be hread base reaier. Esre he -rig is psiied fa he hreaded pper be base reaier. I he -rig came wi h he damper be assembly, apply a small am grease he -rig ad re-psii i he b m he rebd damper seal head. 23. Iser he damper assembly back i he pper be, rebd sha rs . Gide he ed he rebd damper hrgh he ceer he hreaded base re aier, slidig he damper cmpleely i he pper be. 24. Had hread he cmpressi damper p cap i he pper be. use a 24 mm scke wrech ad ighe p cap 60 i-lb.
22
23
24
25
important: do not allow rebound damper shaft to scrape the retainer upon insertion.
25. Iser he rebd damper exeral adjser kb i he b m he rebd damper sha ad r clckwise il damper is i he ll clsed psii. this will prec he damper rd whe isallig he lwer leg sha bl.
oPtionAl - REMotE ADjUSt to non-REMotE Swichig rm a rem e cmpressi adjs a crw med cmpressi adjs reqires ly he remval he reme spl ad cable sp clamp assemblies, ad isallai he s adard cmpressi adjser kb. ulike sadard Mi Crl cmpressi dampers, he 07 SID Mi Crl cmpressi damper reme rer sprig is not iegraed i he damper assembly. the reme PpLc r P shLc lever adjser ca eiher be remved rm he hadlebar, r simply remve he cable/cable hsig ad leave he PpLc r PshLc lever yr hadlebar, i case y chse re-isall he reme spl i he re.
DAMPER inStAllAtion inStRUCtionS (Cont) 26. Remve Fldgae adjser kb agai, sig a 1.5 mm hex wrech ( picred) 27. Place cable sp clamp he p cap wih he cable sp psiied a apprximaely 90° r ward rm he seerer be. tr he cmpressi spl adjser sha (hex shaped) cer-clckwise il i s ps, esre i is i he pe (lcked) psii. 28. Place he reme spl he cmpressi spl adjser sha ad r clckwise il i sps, i he clsed (lck) psii. Hld he reme spl i he clsed psii ad se yr ree had ra e he cable sp clamp cer-clckwise il i ches he reme spl sp. 29. tighe cable sp clamp wih a 2.5 mm hex wrech. Check he psii he reme spl by raig i cer-clckwise he ll pe (lcked) psii. the se screw shld be i lie wih he pe mark he cable sp clamp.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
27
28
29 cable set-screw
open mark
5
DAMPER inStAllAtion inStRUCtionS (Cont) 30. Remve he reme spl w hile he cmpressi adjser is i he pe (lck) psii. Apply a small am grease he reme spl rer sprig (grease will hld he re r sprig i he reme spl drig isallai). Iser he rer sprig i he derside he reme spl, wih he lg sprig leg acig . 31. Place he reme spl ad rer sprig he cmpressi damper adjser hex by aligig he lg leg he rer sprig i e dee hle i he p cap, a he same ime as aligig he cable se screw wih he pe mark he cable sp clamp. 32. tr he reme spl clckwise il splsp res s i he clsed psii agais he cable sp clamp sp. I he sp he reme spl des ch he sp he cable sp clamp, lse cable sp clamp ad rae i cer-clckwise il he w s ps ch ad reighe cable sp clamp. Release he spl rm he clse psii ad es he rer he pe psii. 33. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig. 34. Place he Fldgae adjser kb back he cmpressi damper spl sha . tighe he Fldgae adjser kb se screw he fa srace he black adjser rd wih a 1.5 mm hex wrech.
30
31
insert spring leg into detent hole
32
33
34
this concludes the damper service for your fork . you did a great job! you are now ready to move on to the neXt section: spring service . enjoy!
6
95-4015-016-000 REV A
PURE DElitE DAMPER SERviCE (SiD RACE)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DAMPER REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the pure delite air chamber before proceeding . remove
1
2
4
5
air valve cover cap and depress schrader valve to release any air pressure.
1.
uhread cmpressi damper p cap wih a 24 mm scke wrech. 2. Pll p ad remve he eire Pre Deli e damper assembly rm he pper be. Remve he p cap by pllig he Pre Deli e damper be. 3. Iver he damper assembly ad gely, b rmly, pll he rebd damper seal head assembly rm he Pre be. Hld a rag ard be while pllig, cach ay il ha may spill. Pr ay remaiig il rm he Pre be i il pa. 4. Remve he Ieral Flaig Pis (IFP), which is lcaed iside he Pre damper be, i he ceer he be. the IFP is he seal ha separaes he il rm he air i he Delie air chamber. t remve he IFP, iser a lg dwel rd (plasic r wd) i he Pre be il he rd ches he derside he IFP. Psh rmly he rd release he IFP rm he Pre be.
3
top cap pure tube
ifp
damper
7
important: be careful not to scratch the inside of the pure tube with the dowel rod . scratches will cause oil / air to leak and the pure delite damper system will not function properly.
5. 6.
7.
Review he Pre Delie Damper assembly cmpes. Remve IFP ier ad er -rigs. Apply a ew drps sspesi il ew -rig ad re-isall ( picred). Slide seal head rebd damper sha ad remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew -rigs ad re-isall. Ispec damper sha r scraches ad replace i damaged. Place seal head back rebd damper sha.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
DAMPER inStAllAtion inStRUCtionS 9.
Iser IFP i he Pre be a a deph 6 iches. t d his, m a lg dwel rd (plasic r wd) i a bicycle sad clamp r bech vise wih 6 iches expsed rd. Place he IFP he ed he dwel, pckeed side dw. Place e ed he Pre tbe ver he IFP ad press rmly dw il he IFP is seaed iside he be. note : be careful not to damage
9
10
ifp o-ring or your
hands on the sharp edges of the pure tube. use a rag to protect your hands.
10. Cie press he IFP i he Pre be il he be ed is fsh agais he bicycle clamp r vise. the IFP is w seaed rmly iside he Pre be a a 6 ich deph. Pll he Pre be he dwel. 11. Hld he Pre be ver il pa, wih he pckeed side he IF P acig dw (rded side acig p) ad ll he be cmpleely wi h 15w sspesi il. 12. Make sre he rebd damper is i he pe psii.
11
12
13
14
15
16
note : be sure piston seal head is topped against rebound piston.
Gely ad slwly iser he rebd damper pis head i he il lled Pre be. the il will slwly ll he damper valves (sme il will spill). Allw egh il ll he damper valve caviies ad p il vlme i ecessary. Wih he seal head bmed , gely press dw he seal head il i saps i he Pre be secrely. Yr damper is w sealed. important: do not cycle the damper shaft until the delite air top cap has been installed and pressurized.
13. Iser he Pre Delie damper assembly i he pper be hrgh he crw. 14. Add 6cc/ml 15w sspesi il he p chamber he damper. this will lbricae he IFP -rig. 15. Had hread he damper p cap i he pper be. use a 24 mm scke wrech ad ighe p cap 60 i-lb. Pressrize he air chamber wih yr shck pmp 20-6 0psi. the IFP is w pressre se ad yr damper sealed. 16. Iser he rebd damper exeral adjser kb i he b m he rebd damper sha ad r clckwise il damper is i he ll clsed psii. this will prec he damper rd whe isallig he lwer leg sha bl. this concludes the damper service for your fork . you did a great job! you are now ready to move on to the neXt section: spring service . enjoy!
8
95-4015-016-000 REV A
MiSSion ContRol DAMPER SERviCE (lYRik - totEM)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DAMPER REMovAl/SERviCE inStRUCtionS 1.
tr ble high speed cmpressi kb clckwise, se i he maximm cmpressi psii. ( picred) 2. tr Fldgae " " psii by pshig lw speed cmpressi adjser dw ad r aig cer-clckwise 9 0°. 3. uhread cmpressi damper p cap wih a hi 24 mm wrech. Access he p cap is der he high speed cmpressi kb.
2
3
floodgate in off position
oR
or
4.
5.
6.
7.
8. 9.
Iser a 2.5 mm hex wrech i he gld lw speed cmpressi kb ad r i cerclckwise il i sps ( picred). this allws maximm iseri deph r he 4 mm wrech. Gely grasp he lw speed cmpressi kb wih he slip ji pliers, sig a 4 mm hex wrech remve lw speed cmpressi screw. Li ad remve he lw speed cmpressi kb. the, sig a 1.5 mm hex wrech, lse bh reaiig bls he high speed cmpressi kb. Remve he high speed cmpressi kb. this allws access he p cap. uhread cmpressi damper p cap sig a 24 mm scke wrech. Remve cmpressi damper rm pper be/ crw by pllig p ad wis ig side side. oce remved, clea pper be hreads wih a rag. Remve glide rig rm cmpressi damper pis assembly. Apply a ew drps sspesi il ew glide rig ad re-isall. Remve rk rm bicycle sad ad pr remaiig il i pa. Rer rk bicycle sad. Remve rebd damper seal head reaiig rig (lcaed iside he bm he righ pper be), sig ieral sap rig pliers. Pll dw ad remve he rebd damper assembly rm he pper be. Psh pward rebd sha separae rebd pis assembly rm rebd be. Spray rebd damper sha wih isprpyl alchl, ad clea wih a rag ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
4
7
5
6
8
9
DAMPER REMovAl/SERviCE inStRUCtionS (Cont) 10. Remve ier ad er -rigs rm rebd seal head. Apply a ew drps sspesi il ew -rigs ad re-isall.
10
11
important: if using a pick to remove inner seal head o- ring , do not scratch o- ring gland. scratches may cause oil to leak.
11. Remve glide rig rm rebd sha assembly. Apply a ew drps sspesi il ew glide rig ad re-isall.
DAMPER inStAllAtion inStRUCtionS 12. Isall rebd sha assembly i rebd be.
12
13
14
note : be sure not to damage rebound tube inner o- ring .
13. Isall rebd assembly i pper be ad secre wih reaiig rig sig ieral sap rig pliers. important: make sure the retaining ring is securely fastened in the upper tube groove. you can check this by using the snap ring pliers to rotate the retaining ring in the shaft one complete revolution .
14. Pll rebd damper sha dw i he ll y exeded psii. 15. Measre ad pr 5w sspesi il i he pper be, hrgh he crw, sig he llwig vlmes:
15
oil volume fork
(± 3cc /ml )
lyrik
112cc /ml
totem
137cc /ml
important: oil volume is critical . too much oil reduces available travel , which can lead to fork damage from compression bottom out. too little oil decreases damping performance .
40
95-4015-016-000 REV A
DAMPER inStAllAtion inStRUCtionS (Cont) 16. Dble check he Fldgae esre i is i he " " psii. Isall Missi Crl damper assembly i pper be hrgh he crw. Had hread he cmpressi damper p cap i he pper be. use a hi 24 mm scke wrech ad ighe p cap 60 i -lb.
16
oR
or
Dble check he Fldgae esre i is i he " " psii. Iser Missi Crl damper assembly i pper be hrgh he crw. Had hread he cmpressi damper p i he pper be. use a 24 mm scke wrech ad ighe p cap 60 i-lb. Isall high speed cmpressi kb sig a 1.5 mm hex wr ech ighe screws. Isall lw speed cmpressi kb by gely graspig he kb wih slip ji pliers ad sig a 4 mm hex wrech ighe screw. this concludes the damper service for your fork . you did a great job! you are now ready to move on to the neXt section: spring service. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
41
42
95-4015-016-000 REV A
SPRing SERviCE
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
4
Coil SPRing SERviCE (ARgYlE 302, 318 - DARt 1, 2, 2 (With tURnkEY), 3 - DoMAin 302, 318 - toRA 289, 302, 318)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
Coil SPRing REMovAl/SERviCE inStRUCtionS 1.
uhread ad remve sprig p cap wih a 24 mm scke wrech.
1
2
important: press down firmly when loosening top
pre -load spacer
cap.
Argyle 302 , 318 oly: Remve sprig pre-lad spacer(s). 3. Psh sprig sha pward, rm he b m he pper be, he remve sprig ad sprig spacers rm pper be. 4. tr rk pside dw ad slide he sprig sha assembly he pper be. Remve sprig sha assembly ad ispec r damage. 5. Spray isprpyl alchl sprig, sprig sha assembly ad he iside ad side he pper be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred).
3
2.
4
Coil SPRing inStAllAtion inStRUCtionS 5.
6. 7. 8. 9.
Iser ad drp sprig sha assembly i pper be hrgh he crw. Gide he hreaded ed hrgh he sha gide a he bm he pper be ad gely pll sha hrgh ll exesi. Apply resh grease liberally sprig/sprig spacer assembly. Iser ad drp sprig assembly i pper be hrgh he crw. Argyle 302 , 318 oly: Isall sprig pre-lad spacers. Clea p cap, he apply a small am grease p cap hreads. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe 60 i-lb.
5
6
8
9
7
pre -load spacer
this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
44
95-4015-016-000 REV A
Coil SPRing SERviCE (BoxxER RACE, tEAM - RECon 335, 351, RACE, Sl - totEM)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
SPRing REMovAl/SERviCE inStRUCtionS 1.
uhread ad remve sprig p cap wih a 24 mm scke wrech.
1
2
important: press down firmly when loosening top
pre -load spacer
cap.
Remve sprig pre-lad spacer(s) ad pll sprig rm pper be. 3. Remve he sprig sha base plae re aiig rig sig ieral sap rig pliers. 4. Pll sprig sha ad base plae rm pper be. Ispec assembly r damage ad replace eire assembly i ecessary. 5. Spray isprpyl alchl sprig, sprig islars (islars are BXXer ly), sprig sha ad he iside ad side he pper be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred).
3
2.
4
note : you can secure the spring isolators to the spring (bo XX er only) by using a heat gun or hair dryer to shrink them around the spring.
Coil SPRing inStAllAtion inStRUCtionS 6.
Iser sprig sha assembly back i bm pper be s he base plae assembly is seaed i he pper be sep. Secre sprig sha assembly wih re aiig rig, sig ieral sap rig pliers. 7. Apply resh grease liberally sprig ad sprig islars (islars are BXXer ly). 8. Iser sprig back i pper be ad place sprig prelad spacer(s) p sprig iside pper be. 9. Clea p cap, he apply a small am grease p cap hreads. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe 60 i-lb.
6
7
8
9
this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
45
Coil U-tURn SPRing SERviCE (DoMAin 302, 318 - toRA 289, 302, 318)
intRoDUCtion A his pi y shld already have have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers. Coil U-tURn SPRing REMovAl/SERviCE inStRUCtionS 1.
Remve u-tr u-tr kb screw wih a 2.5 mm hex wrech ad remve u -tr -tr adjser kb. 2. Remve dee ball bearigs ad dee sprigs rm p cap sig a mage. 3. uhread ad remve sprig p cap wih a 24 mm scke wrech. wrech. the sprig is aached he p cap cap ad sprig sha. Pll ad li eire sprig assembly rm pper be.
1
2
3
important: press down firmly when loosening top cap.
4.
5.
Remve u-tr u-tr egaive sprig assembly rm pper be, y may eed r rk pside dw remve. Spray isprpyl alchl eire sprig assembly, egaive sprig, ad he iside ad side he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred).
4
Coil U-tURn SPRing inStAllAtion inStRUCtionS 6. 7. 8.
9.
10.
11.
Apply resh grease liberally egaive sprig, he eire sprig assembly, ad p cap hreads. Iser ad drp egaive sprig i pper be hrgh he crw. Iser u-tr sprig assembly i pper be hrgh crw, sha sha ed rs. Alig ad sea sea he sprig sha hrgh he sha gide/base plae. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke scke wrech, ighe 60 i-lb. usig a mage, iser each dee sprig i p cap dee dee hles, evely spaced. spaced. Place each dee ball bearig p each dee sprig. Place u-tr adjser kb p hex. tighe u-tr kb screw wih a 2.5 mm hex wrech.
6
7
8
9
10
11
this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
46
95-4015-016-000 95-4015-016-000 REV A
Coil U-tURn SPRing SERviCE (lYRik - PikE 327, 351, 409, 426, 454 - RECon 351, RACE - REvElAtion 426)
intRoDUCtion A his pi y shld already have have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers. Coil U-tURn SPRing REMovAl/SERviCE inStRUCtionS 1.
Remve u-tr u-tr kb screw wih a 2.5 mm hex wrech ad remve u -tr -tr adjser kb. 2. Remve dee ball bearigs ad dee sprigs rm p cap sig a mage. 3. uhread ad remve sprig p cap wih a 24 mm scke wrech. wrech. the sprig is aached he p cap cap ad sprig sha. Pll ad li eire sprig assembly rm pper be.
1
2
3
important: press down firmly when loosening top cap.
4.
Spray isprpyl alchl eire sprig assembly ad he iside ad side he pper be ad wipe wih a clea rag. rag. Wrap a clea rag ard a lg dwel ad iser iser i he pper be clea iside he pper be ( picred).
Coil U-tURn SPRing inStAllAtion inStRUCtionS 5. 6.
7.
8.
9.
Apply resh grease liberally he e ire sprig assembly, ad p cap hreads. Iser u-tr sprig assembly i pper be hrgh crw, sha sha ed rs. Alig ad sea sea he sprig sha hrgh he sha gide/base plae. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke scke wrech, ighe 60 i-lb. usig a mage, iser each dee sprig i p cap dee dee hles, evely spaced. spaced. Place each dee ball bearig p each dee sprig. Place u-tr adjser kb p hex. tighe u-tr kb screw wih a 2.5 mm hex wrech.
5
6
8
9
7
this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
4
Solo AiR SPRing SERviCE (ARgYlE 409 - toRA 302, 318)
intRoDUCtion A his pi y shld already have have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
Solo AiR SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress schrader
1
2
valve again to remove any remaining air pressure.
1.
2. 3.
4.
5.
6. 7.
uhread air sprig p cap wih a 2 4 mm scke wrech. the air sprig sprig assembly is aached he p cap. Pll ad li eire air sprig assembly rm pper be. Pll p cap air be assembly ad pr ay air seal lbrica i il pa. Remve air sha ad air seal head rm he b m he air be by pllig sha sha dw ad wis ig side side. Spray isprpyl alchl he iside ad side he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred). Remve air pis reaier rig sig exeral sap rig pliers. the remve air air pis wavy sprig washer ad pis pis rm air sha . Slide air sleeve seal head assembly rm air sha. Remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew rigs ad re-isall.
3
5
7
9
6
important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.
8.
Spray air sha wi h isprpyl alchl ad wipe clea wih a rag ( picred). 9. Iser air pis back air sha head. Isall sprig wavy washer air sha ed ad secre i place place wih air pis reaier rig, sig exeral sap rig pliers. Check reaiig rig make sre i secres he air pis air sha sha head. the pis shld cmpress slighly wih sprig resis ace agais agais wavy sprig washer ad reaiig rig.
48
95-4015-016-000 95-4015-016-000 REV A
Solo AiR SPRing REMovAl/SERviCE inStRUCtionS (Cont) 10. Remve bm- bmper ad kick plae rm egaive air sleeve/seal head. 11. Remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew rigs ad re-isall.
11
10
important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.
oPtionAl - All tRAvEl ConFigURAtionS (toRA 318) All ravel spacers are lcaed js abve he air seal head. I y wa chage he ravel yr rk , sap he ravel spacer seal head decrease ravel, r remve icrease ravel.
30 mm
50 mm
no spacer
spacer
spacer
80 mm
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
100
mm
130 mm
49
Solo AiR SPRing inStAllAtion inStRUCtionS 12. Iser b m- bmper ad pad back air seal head. Slide air seal head/sleeve assembly back i air sha, bmpers rs. 13. Iser lbricaed air assembly, bh piss ad air sleeve i e ed air be. Psh air seal head i air be il rmly seaed. 14. Iser air sha i p pper be, hrgh crw. Gide he bm he air sha hrgh he sha gide i he bm he pper be. Iser air be assembly i pper be il i ress iside pper be. 15. Measre ad pr 6cc/ml 15w sspesi il i pper be hrgh he crw. Sspesi il i he air chamber lbricaes he air seal rig drig se ad maiais he air seal. 16. Psh air sha li air be pper be a cple iches. Iser he air p cap i air be ad press igh i air be. 17. Drp air be/p cap assembly i pper be. Check bm pper be ad make sre air sha gide is seaed i pper be sha gide. 18. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe 60 i-lb.
12
13
14
15
16
17
18
this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
50
95-4015-016-000 REV A
Solo AiR SPRing SERviCE (BoxxER WC - lYRik - RECon - totEM)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
Solo AiR SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress schrader
1
2
3
5
6
valve again to remove any remaining air pressure.
1.
uhread ad remve air sprig p cap wih a 24 mm scke wrech. Remve rk rm sad ad pr ay air seal lbrica i il pa. 2. use yr ger press he air seal head i he pper be. Y will eel i break ree ad slide i he be ab 3 mm. 3. Remve he air assembly sha gide reaiig rig rm he b m he le pper be, sig exeral sap rig pliers. Pll air sha dw remve air sprig assembly ad sha gide rm pper be. 4. Spray isprpyl alchl he iside ad side he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred). note : for lyrik , and totem it is not necessary to
5, 6, 7 or 9. simply inspect retainer ring and wavy washer (and cushion on lyrik and totem). if damaged, you will need to replace the air piston head assembly. otherwise please complete step 8, then move to step 11. perform steps
5.
6. 7.
7
Remve air pis reaier rig sig exeral sap rig pliers. the remve air pis wavy sprig washer ad pis rm air sha . Slide air sleeve/seal head assembly rm air sha. Remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew rigs ad re-isall. important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.
8.
Spray air sha wi h isprpyl alchl ad wipe clea wih a rag ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
51
Solo AiR SPRing REMovAl/SERviCE inStRUCtionS (Cont) 9.
Iser air pis back air sha head. Isall sprig wavy washer air sha ed ad secre i place wih air pis re aier rig, sig exeral sap rig pliers. Check reaiig rig make sre i secres he air pis air sha head. the pis shld cmpress slighly wih sprig resis ace agais wavy sprig washer ad reaiig rig. 10. Remve bm- bmper ad kick plae rm egaive air sleeve/seal head. 11. Remve ier ad er seal head -rigs. Apply a ew drps sspesi il ew rigs ad re-isall.
9
10
11
important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.
oPtionAl - All tRAvEl ConFigURAtionS (RECon 327, 335, 351) All ravel spacers are lcaed js abve he air seal head. I y wa chage he ravel yr rk , sap he ravel spacer seal head decrease ravel, r remve icrease ravel.
50
30 mm mm
no spacer
spacer
spacer
80 mm
52
100
mm
130 mm
95-4015-016-000 REV A
Solo AiR SPRing inStAllAtion inStRUCtionS 12. Iser b m- bmper ad kick plae back air seal head. Slide air seal head/sleeve assembly back i air sha, bmpers rs . 13. Iser lbricaed air pis i b m pper be ad slide he lwer air pis /sleeve assembly i pper be. 14. Sea he sha gide rig ad wavy washer i pper be sep, he slide egaive air sleeve i pper be ad sea sha gide base i pper be sep. 15. Secre reaiig rig i pper be reaiig rig grve sig exeral sap rig pliers. Psii reaiig rig hles ard reaiig rig psiier base plae. Veriy reaiig rig is secre i pper be. 16. Measre ad pr 6cc/ml 15w sspesi il i air be hrgh he crw. Sspesi il i he air chamber lbricaes he air seal -rig drig se ad maiais he air seal. 17. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe 60 i-lb. this concludes the spring service for your fork . you did a great job! you are now ready to move on to the
12
13
15
14
16 base plate retaining ring positioner
retaining ring holes
17
neXt section: lower leg installation. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
5
DUAl AiR SPRing SERviCE (PikE 409, 426, 45 4 - REBA Sl, RACE, tEAM, WC - REvEl Ation 409, 426)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DUAl AiR SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress positive
1
2
3
4
5
6
8
9
10
and negative schrader valves again to remove any remaining air pressure.
1. 2. 3. 4.
uhread ad remve Dal Air p cap wih a 24 mm scke wrech. Remve rk rm s ad ad pr ay air seal lbrica i il pa. Clamp rk back i bicycle sad ad w ipe sha ad base plae wih a rag. Psh egaive air sha p ad i base plae, leavig ly he ip he hreaded sha ed prrdig rm base valve. note : you may need to depress the schrader valve as you push the shaft, to prevent a vacuum .
5.
6.
7.
8. 9.
Slide a 15 mm scke l (r similar hllw l) ver he air sha ed ad press r mly agais he base plae. While pressig he air base plae p ad i he pper be, remve he reaiig rig sig exeral sap rig pliers. oce reaiig rig is remved, gel y pll air sha dw remve air sprig assembly ad base plae rm pper be. Spray isprpyl alchl he iside ad side he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred). Remve base plae, base plae -r ig/bmper, ad egaive air pis rm he Dal Air sha. Remve er ad ier egaive air pis -rigs. Apply a ew drps sspesi il ew -rigs ad re-isall.
air piston o - ring base plate
important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.
10. Remve er psiive air pis -rig. Apply a ew drps sspesi il ew -rig ad re-isall. important: if using a pick to remove o-ring, do not scratch seal head . scratches may cause oil to leak.
54
95-4015-016-000 REV A
oPtionAl - All tRAvEl ConFigURAtionS All ravel spacers are lcaed js abve he bm bmper washer. I y wa chage he ravel yr rk, sap he ravel spacer he Dal Air sha decrease ravel, r remve icrease ravel.
pike :
10 mm revelation : 15 mm reba : 15 mm
no spacer
spacer
(above washer)
pike :
pike :
reba:
140 mm 115 mm revelation : 130 mm
reba :
130 mm 100 mm revelation: 115 mm
DUAl AiR SPRing inStAllAtion inStRUCtionS 11. Re-isall he egaive air pis, base plae -rig/ bmper ad base plae he Dal Air sha ad re-apply sspesi il -rigs. 12. Iser Dal Air assembly i pper be, psiive air pis rs , llwed by he egaive air pis. Iser base plae assembly i pper be sep ad press i rmly. 13. usig yr hmb, press base plae i pper be. While pressig base plae, isall exeral reaiig rig sig exeral sap rig pliers. Veriy re aiig rig is secre i pper be grve. Alig reaiig rig accrdig he rieai he base plae reaiig rig grve. 14. Measre ad pr 6cc/ml 15w sspesi il i air be hrgh crw. Sspesi il i he air chamber lbricaes he air seal -rig drig se ad maiais he air seal. 15. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe 60 i-lb.
11
12
14
15
13
this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
55
DUAl AiR SPRing SERviCE (SiD RACE, tEAM, WC)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
DUAl AiR SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress positive
1
2
3
and negative schrader valves again to remove any remaining air pressure.
1.
uhread ad remve Dal Air sprig p cap wih a 24 mm scke wrech. 2. Remve rk rm s ad ad pr ay il rm psiive air chamber i il pa. 3. Remve hreaded pper be reaier sig he SID Dal Air pper be reaier l ad a scke wrech. important: the retainer is reverse threaded. turn the wrench
4.
clockwise to unthread.
Pll Dal Air sprig sha assembly r m pper be.
4
6
8
9
note : you may need to depress the negative schrader valve as you pull the dual air shaft; pressure builds up as you pull .
5.
Spray isprpyl alchl he iside ad side he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred). important: look inside the upper tube using a light and check for scratches. if the inside surface of the upper tube is scratched, replace the assembly. scratches can cause air bypass and effect the performance of your fork .
6. 7. 8.
Slide he egaive air pis sleeve rm air sprig sha. Spray isprpyl alchl he air sha ad wipe wih a clea rag ( picred). Remve he er ad ier egaive air pis -rigs as well as he er psiive air pis -rig. Apply a ew drps sspesi il ew -rigs ad re-isall. important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.
9.
56
Slide egaive air sprig sleeve back air sprig sha.
95-4015-016-000 REV A
oPtionAl - All tRAvEl ConFigURAtionS All ravel spacers are lcaed js abve he egaive sleeve p bmper. t chage he ravel yr rk, slide egaive sleeve dw ad sap he ravel spacer seal head decrease ravel, r remve icrease ravel.
20 mm spacer
60
no spacer
80 mm
mm
DUAl AiR SPRing inStAllAtion inStRUCtionS 10. Re-apply resh sspesi il ew psiive ad egaive air pis -rigs. 11. Iser psiive air pis i bm pper be ad psh air pis/sha assembly i pper be. 12. Slide he egaive air pis sleeve dw air sprig sha ad i he b m he pper be. Cie slide eire egaive air sprig sleeve i pper be.
10
11
12
13
14
15
note : you may need to depress the negative schrader air valve as you push the negative sleeve into the upper tube to release the air pressure build up and aid in installation.
13. thread Dal Air sprig assembly hreaded base reaier i he pper be by had. usig he SID Dal Air pper be reaier l ad a scke wrech, press i reaier rmly ad ighe he hreaded pper be/base reaier 30 i-lb. important: the retainer is reverse threaded. turn by hand and wrench
counter-clockwise to
thread .
14. Make sre rk is psiied prigh i wrksad. Measre ad pr 6cc/ml 15w sspesi il i psi ive air chamber, hrgh he crw. note : suspension oil on top of the positive air piston o- ring is critical to lubrication and maintenance of the air seal .
15. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe 60 i-lb. this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
5
AiR U-tURn SPRing SERviCE (PikE 409, 429, 454 - REBA RACE, tEAM - REvElAtion 409, 429)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
AiR U-tURn SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress positive
1
2
and negative schrader valves again to remove any remaining air pressure.
1.
2.
Adjs ravel seig max (ll) ravel. Psh exeral re aiig clip rm abve u-tr kb wih a pick r screwdriver ad remve adjser kb. Remve dee ball bearigs ad dee sprigs rm p cap sig a mage. important: it is
not necessary to remove the u-turn
top cap to service the air u-turn spring assembly. in the event the top cap must be removed, unthread with
24 mm socket wrench. before re-installing top cap, clean old thread - lock off top cap. then add a few drops of blue thread -lock to the top cap threads and tighten with socket wrench to 60 in-lb .
3
4
5
6
a
3.
4.
5.
6.
7.
tr Air u-tr ravel adjs sha , which prrdes rm bh he ceer he p cap ad he bm he air sha, CloCkWiSE hread he air sprig assembly rm he A ir u-tr p cap (p cap shld be igh iside crw/pper be). Pll dw he A ir u-tr sha ad remve he eire sprig assembly rm he bm he pper be. Remve ef washer rm iside p cap. t remve, psh dw wih a pick r fa-head screwdriver. Washer will exi bm he pper be. Remve small exeral reaiig rig lcaed a he b m he air chamber sig exeral sap rig pliers, he remve gide plae. Psh dw seal head wih a fa-head screwdriver (psii screwdriver head agais sep, away rm sha) ad ree he re aiig rig rm he seal head. oce seal head slides i air be, remve seal head reaiig rig, sig sap rig pliers.
7
important: do not scratch air shaft. scratches with cause air to leak and effect the performance of your fork .
58
95-4015-016-000 REV A
AiR U-tURn SPRing REMovAl/SERviCE inStRUCtionS (Cont) 8.
Pll air sha, egaive air seal head ad psiive air pis assemblies air be. Slide ad remve almim seal head rm air sha . 9. Spray isprpyl alchl air sha ad wipe wih a clea rag ( picred). 10. Remve seal head rm air pis sha . Remve he ier ad er seal head -rigs as well as he small er -rig lcaed he air pis sha grve. Apply a ew drps sspesi il ew -rigs ad re-isall.
8
10
11
12
important: if using a pick to remove o-rings, do not scratch seal head or o- rings. scratches will cause permanent air leak .
11. Hldig he air be, place pper chke assembly ed fa srace. Firmly press be dw fa sr ace break he seal ad psh chke assembly hrgh be. note : the choke assembly will feel tight inside tube
push down
while pushing choke out of air tube. you may need to
with dowel
tap the end of the air shaft on a flat working surface to free the upper air spring assembly from the air tube.
12. use a -meallic dwel cie psh he assembly hrgh ad he air be. Remve assembly cmpleely rm air be.
14
15
16
important: using a non - metallic dowel helps to ensure the inside of the air tube does not get scratched.
13. Spray isprpyl alchl he iside ad side he air be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be ( picred). 14. Remve exeral chke reaiig rig rm ravel adjsme sha, sig exer al sap rig pliers. Remve chke pis ad chke/sha washer. 15. Remve exeral chke -rig. Apply a ew drps sspesi il ew -rig ad reisall.
17
important: if using a pick to remove o-ring, do not scratch choke piston. scratches may cause air leak .
16. Remve pper seal head rm adjser sha . 17. use a fa head screwdriver ad remve ier rig reaiig rig. the remve bh he ier ad er seal head -rigs. Apply a ew drps sspesi il ew -rigs ad re-isall. use a fa head screwdriver re-is all ier -rig reaiig rig.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
59
AiR U-tURn SPRing REMovAl/SERviCE inStRUCtionS (Cont) 18. Re-isall pper seal head ravel adjsme sha ad apply sspesi il adjser sha ad ier seal head -rig. 19. Isall chke pis ad secre wih a nE W 10 mm exeral re aiig rig, sig exeral sap rig pliers. 20. Apply sspesi il bh pis -rigs.
18
19
20
AiR U-tURn SPRing inStAllAtion inStRUCtionS 21. Apply a hi lm grease he iside grve he pe ed he air sprig be. Iser he pper chke assembly i pe ed air sprig be, schrader valve rs, ad press cmpleely i air be. 22. usig a lg -meallic dwel, psh assembly p i he air be il seaed fsh agais he rlled ed he air be. 23. Hld air be wih pe ed p. Measre ad pr 6cc/ml 15w sspesi il i air be/psiive air chamber, p he pper chke assembly. this will lbricae he chke -rig ad psiive air pis -rig whe rk is cmpressed. Se aside air be, prigh, s il des spill. 24. Re-apply sspesi il ier seal head rig ad slide egaive air seal head Dal Air sha, fa ed rs. Slide p bm bmper. 25. Re-apply sspesi il psiive ad egaive air pis -rigs ad iser psiive air pis i pe ed air sprig. Psh air sha assembly i air be. 26. usig a small fahead screwdriver, press dw seal head sha sep sea i place iside air be. Secre seal head i air be wih reaiig rig, sig ieral sap rig pliers.
21
22
24
25
26
23
27
important: retaining ring must be fully seated in upper tube groove . check retaining ring closely to ensure secure fit .
27. Add air he psiive air chamber (40-6 0psi) esre assembly cmpes are seaed prperly iside air be.
60
95-4015-016-000 REV A
AiR U-tURn SPRing inStAllAtion inStRUCtionS (Cont) 28. Iser air be gide plae i he ed air be. Secre ard small seal head grve wih a ew 13 mm exeral reaiig rig, sig exeral sap rig pliers. Veriy reaiig rig is seaed agais gide plae s i ca mve reely.
28
29
important: eXternal retaining rings may deform when removed and installed. pinch ends tight with pliers, to ensure correct fit . note : the u-turn air assembly is now assembled and ready to be installed into fork upper tube / crown.
29. Place tef washer ver hreaded sha ed, fa agais ravel sha. Iser Air u-tr assembly i bm le rk pper be, adjser ed rs. 30. Slide i pper be il pper assembly egages p cap. thread assembly i p cap by hldig he bm he air sha ad rig Cuer-ccwse il i sps. 31. Iser each dee sprig i p cap dee hles, evely spaced. Place each dee ball bearig p each dee sprig. 32. Place Air u-tr adjser kb hex sha ed. Secre kb air sha wi h exeral reaiig rig, sig exeral sap rig pliers. Make sre reaiig rig is isered i grve, air sha hreads. important: air u-turn fork
30
31
32
must be set to full
travel setting before installing lower legs. turn air u-turn knob counter- clockwise to set to full travel . this concludes the spring service for your fork . you did a great job! you are now ready to move on to the neXt section: lower leg installation. enjoy!
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
61
2-StEP AiR SPRing SERviCE (lYRik - totEM)
intRoDUCtion A his pi y shld already have he lwers remved rm yr rk. I , y will eed rer he Lwer Leg Remval seci his maal ad llw he isrcis r remvig yr rk lwers.
2-StEP AiR SPRing REMovAl/SERviCE inStRUCtionS 1.
Remve all air pressre rm he sysem by depressig air valve a he b m he le leg, ad he remve he 2-S ep schrader valve sig a Schrader valve l.
1
2
3
4
5
6
7
8
9
10
warning : verify all pressure is removed from the air chamber before proceeding .
2. 3.
4.
5. 6. 7. 8.
usig a 2 mm hex wrech remve 2-Sep adjser xig screw ad crl kb. usig a 24 mm scke wrech, hread ad remve he 2-Sep p cap. Ispec 2-Sep p cap -rig r damage. Replace i ecessar y. Remve rk rm bicycle sad ad pr ay remaiig il i il pa. Rer rk bicycle sad. usig exeral sap rig pliers, remve reaiig rig rm he bm he le pper be. Gely pll dw he air sha remve he eire 2-Sep assembly. Remve lwer seal head rm sha assembly ad se aside. Separae he 2-Sep assembly i 3 pars: sha assembly, air be, ad pis hsig (i rder i picre). important: avoid pulling the shaft past the bleed holes on the air tube as this may damage the o-rings. remove shaft out of the top of air tube opposite the bleed holes.
9.
Remve pis rm he IFP pis hsig. Ispec IFP pis hsig r damage r scraches, payig clse aei he iside srace he IFP pis hsig. I damaged r scrached, replace he IF P pis hsig. 10. Remve pis -rig. Clea pis wih isprpyl alchl. Apply a ew drps sspesi il ew -rig ad re-isall. important: if using a pick to remove o-rings, do not scratch lower seal head or o- rings. scratches will cause permanent air leak .
62
95-4015-016-000 REV A
2-StEP AiR SPRing REMovAl/SERviCE inStRUCtionS (Cont) 11. Ispec IFP pis hsig -rig r damage. Replace i ecessary. Re-assemble IFP ad IFP pis hsig. the IFP shld be isered i he hsig wih he -r ig side dw. Press he IFP i he IFP pis hsig il i bms cmpleely.
11
13
14
15
note : improper installation of the ifp will change
2-step air spring performance and / or affect the system ’s ability to achieve full travel adjustment range .
12. Spray isprpyl alchl he iside ad side he air be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be clea iside he pper be. Ispec he air be r damage ad scraches . Replace i damaged r scrached ( picred). 13. Rer lwer seal head. Remve ier ad er lwer seal head -rigs. Apply a ew drps sspesi il ew -rigs ad reisall. important: if using a pick to remove o-rings, do not scratch lower seal head or o- rings. scratches will cause permanent air leak .
14. Remve lwer faig pis rm he air sha assembly. Remve lwer faig pis ier ad er -rigs. Spray lwer faig pis wih isprpyl alchl ad wipe wih a clea rag. Apply a ew drps sspesi il ew -rigs ad re-isall. 15. Remve rbber cshi ad sig a fa head screw driver, carelly remve p sprig assembly rm he air sha. Spray wih isprpyl alchl ad wipe wih a clea rag. 16. usig exeral sap rig pliers, remve he reaiig rig ad wavy sprig washer lcaed p he mai pis. 17. Remve he ier ad er pis -rigs. Spray he mai pis wi h isprpyl alchl ad wipe wih a clea rag. Apply a ew drps sspesi il ew -rigs ad re-isall.
16
17
2-StEP AiR SPRing inStAllAtion inStRUCtionS 18. Ispec he ace seal -rig, makig sre i is seaed prperly. A prperly seaed -rig will have ay disri i is shape ( picred). 19. Spray air sha wi h isprpyl alchl ad wipe wih a clea rag. Ispec air sha r damage r scraches. Replace i damaged r scrached ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
6
2-StEP AiR SPRing inStAllAtion inStRUCtionS (Cont) 20. Reassemble mai pis ad kick plae ad isall air sha. Slide wavy washer p mai pis ad secre i place wih sap rig. 21. Isall p sprig assembly, rbber cshi, ad lwer faig pis air sha. D isall lwer seal head a his ime. 22. Isall sha assembly i air be, air valve rs, i he side ppsie he w hles he air be. Isall lwer seal head sha assembly. 23. Measre ad pr 5cc/ml 15w sspesi il i he p he air be assembly. 24. Iser he IFP pis hsig i he air be assembly, beig carel spill he il already i air be. 25. Iser he 2-Sep assembly i he bm he pper be. Secre wih re aiig rig.
20
21
22
23
24
25
26
27
28
29
30
important: retaining ring must be fully seated in upper tube groove . check retaining ring closely to ensure secure fit .
26. Gely pll dw air sha exed maximm legh. 27. Lyrik oly: Measre ad pr 35cc/ml 2.5w sspesi il i he p he pper be. tem oly: Measre ad pr 135cc/ml 2.5w sspesi il i he p he pper be. tip : tap the side of the upper tube with your hand, then gently wiggle the shaft side to side to bring any trapped air bubbles to the top. gently pull down on air shaft again to make sure it is at full eXtension . note : the oil will just reach the bottom of the upper tube threads , remove any eXcess oil . important: as little as
2 cc / ml can make a difference in the travel adjustment performance . too little oil will result in limited travel adjustment range . too much oil will change fork height.
28. Iser p cap i pper be/crw ad had hread i pper be. usig he 2-Sep adjser kb, r he adjser he mimm ravel seig. Remve he adjser kb ad sig a 24 mm scke wrech, ighe p cap 60 i-lb. 29. Isall 2-S ep adjser kb ad secre xig screw wih a 2 mm hex wr ech. 30. Isall schrader valve i b m air sha, sig schrader valve l. 31. Add 100psi he 2-Sep sysem. Rae adjser kb miimm ravel psii ad cmpress air sha esre prper ci. Rae adjser kb ll ravel psii ad veriy rer ll exesi.
31
this concludes the spring service for your fork .
64
95-4015-016-000 REV A
loWER lEg inStAllAtion
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
65
loWER lEg inStAllAtion (All FoRkS)
intRoDUCtion A his pi y shld already have already servised yr rk bshigs, damper sysem, ad sprig sysem. oce y have re-isalled yr rk lwers, y will have sccesslly serv ised yr rk ad y will be ready ride!
loWER lEg inStAllAtion inStRUCtionS 1.
Spray pper bes wi h isprpyl alchl ad wipe wih a clea rag ( picred). 2. Pr r ijec 15w sspesi il ew r clea am rigs, js der ds seals iside each lwer leg. 3. Slide lwer leg assembly he pper bes il y eel he lwer bshig ch he ed he pper bes.
2
3
4
important: make sure both dust seals slide onto the tubes correctly and do not fold under .
4.
Iver rk ab 4 5°, rk legs piig pward. Measre ad ijec sspesi il i lwer legs hrgh each sha bl hle, accrdig he bm vlme vales d i he oil Vlme char lcaed i he Ge ig Sared Irmai seci his maal. Wipe all excess il rm lwer legs. note : boXX er only
6
- slide damper side fork leg back
onto upper tube until the lower bushing touches the end of the upper tube after injecting oil .
4.
Ispec ad clea air sprig sha bl s, black yl crsh washers ad crsh wash reaiers. Replace crsh washers ad crsh washer reaiers i damaged ( picred). note : damaged or dirty crush washers can cause oil to leak.
6.
66
Iser rebd damper ad air sprig sha bls i hreaded sha eds, hrgh lwer leg sha hles ad ighe w ih a 5 mm hex r 10 mm scke wrech 60i-lb.
95-4015-016-000 REV A
loWER lEg inStAllAtion inStRUCtionS (Cont) note : boXX er only
- insert each upper tube evenly into the lower crown. pull upper tubes up and into the crown, twisting gently as the upper tubes ease into the holes. pull left (damper side ) upper tube up to the fully eXtended position (do not over eXtend!). measure 205 mm from the dust / lower leg to the bottom of the lower crown hole and tighten the crown bolt with a
4 mm heX to 65 in / lb .
pull
the right (spring side) upper tube even with the left and tighten the crown bolt to
65 in / lb .
make sure
bo XX er only
the upper tubes are positioned at an even height!
boXX er only
boXX er only
refer to the diagram for crown measurements . slide bo XX er crown heights
each upper tube / frame bumper onto each upper tube. install upper crown on upper tubes and steerer tube. refer to the diagram for appropriate measurements . tighten upper crown with a
4 mm heX wrench to 65
short upper crown
in -lb .
152 mm (± 2 mm)
7.
Iser ex eral rebd damper kb i rebd damper sha bl. Psh i il secre. Adjs as desired. 8. Fr air sprig rks, reer he air char yr rk ad ifae psi ive ad egaive air chambers apprpriae psi. Fr cil rks, mve Sep 9. 9. Spray isprpyl alchl eire rk ad wipe wih a clea rag ( picred). 10. thread psiive ad egaive air valve cap cvers air p cap.
tall upper crown frame / upper tube
182
mm
( ± 2 mm)
bumper
lower crown
20 5 mm (± 2 mm)
this concludes the service for your fork . you did a great job! you are now ready to install your fork on your bike and go for a ride!
7
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
8
10
6
68
95-4015-016-000 REV A
-RiDE SPRing SERviCE
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
69
-RiDE SPRing SERviCE intRoDUCtion t maiai he high perr mace, saey, ad lg lie yr i-Ride rk , peridic maieace is reqired. I y ride i exreme cdiis, maieace shld be perrmed mre reqely.
SERviCE inStRUCtionS remove
1. 2. 3.
4. 5.
-ride
fork from the bike (not pictured)
Remve he r wheel. Remve he r brake. -Rde: usig a 5 mm hex, remve he headse bl, he remve he headse cap. -Rde w M10 sar u : usig a 8 mm hex, remve he headse bl, he remve he headse cap. Lse he sem bl(s) ad remve he sem wih he hadlebar iac. Carelly pll he rk dw he headbe. Reai spacers ad headse pars as y g.
a b
c
d
e
f
g
h
i
j
k
l
disassemble steerer assembly
6.
Wih he r side he i-Ride rk acig y, lcae he p he seerer be ad wrie he wrd 'r ' he seerer be i permae marker. 7. usig eiher a 14 mm scke he ed a scke exesi r a lg 6 mm hex, lse ad remve he reaiig . Iver he rk ad le he lck washer all i yr had.
m
n
a . retaining nut
f. threaded insert
k . bottom out bumper
b . lock washer
g . compression shaft
l . boot
c . c- clip
h . top spring guide
m. inner steerer
d. compression washer
i.
n. outer steerer
e . top out spring
j . bottom spring guide
compression spring
note : if the lock washer doesn’t fall out, use a pick to pull the lock washer off of the threaded insert and out of the steerer .
-Rde w M10 sar u : usig a lg 6 mm hex hrgh he ceer he sar , lse he reaiig . usig a pick, pll he lck washer he hreaded iser.
6
note : the nut and the washer will remain in the steerer tube between the star nut and the baseplate, located inside the outer steerer . tip : leave the long
6 mm heX wrench in the retaining
nut and lock washer to keep them aligned within the steerer tube. this will ease re -assembly later .
-Rde: Clea he reaiig wih isprpyl alchl ad wipe wih a clea rag. Apply ble hreadlck (Lcie 244 0) he hreads per maacrer's isrcis ( picred). this will allw ime r he hreadlck dry. 9. Carelly c he zip ie secrig he b he er seerer, ad pll he bm he b ver he lwer leg crw fage. 8.
7
9
i- ride with m10 star nut
0
95-4015-016-000 REV A
SERviCE inStRUCtionS (Cont) 10. Pll he er seerer pwards il i clears he ier seerer ad remve.
10
11
12
13
15
17
18
19
note : if the outer steerer does not easily separate from the inner steerer , place a dowel rod on top of the threaded insert and firmly strike the rod with a mallet to loosen the outer steerer .
11. Remve he b ad he b m bmper. remove coil spring, clean and lubricate
12. usig a clh prec he palm yr had, cmpress he cil sprig by pressig dw he hreaded hreaded iser. I is ecessary ecessary lly cmpress he sprig, js press egh relieve pressre he reaiig c-clip.
14
note : you may want may want to place the fork between your feet to stabilize the fork during this process.
13. usig sap rig pliers while he sprig is cmpressed, remve he reaiig c-clip rm wihi he ier seerer. seerer. the sprig assembly assembly will decmpress ad rise he ier seerer. important: maintain control of the spring assembly as it rises out of the inner steerer so it does not rapidly eject and harm you or your surroundings .
14. Separae he cmpressi washer, p sprig, cmpressi sha, p sprig gide, ad cmpressi sprig. 15. Lcae he derside derside he rk crw. usig a lg, 7 mm (1/4”) diameer dwel psh he b m sprig gide he ier seerer. 16. Spray all pars wi h isprpyl alchl ad wipe wih a clea rag. Ispec all pars r wear ( picred). 17. Geersly apply grease cmpressi ad p sprigs. 18. Iser he sprig gides i he cmpressi sprig. Slide he cmpressi cmpressi sprig assembly assembly i he ier s eerer. 19. Slide he p- sprig, washer, ad c-clip ver he cmpressi cmpressi sha assembly. Slide he cmpressi sha assembly i ier seerer. 20. usig a clh prec he palm yr had, cmpress he cmpressi sprig by pressig dw he hreaded hreaded iser iser . usig sap sap rig pliers, re-isall he c-clip. important: verify the c- clip is fully seated before
20
decompressing the spring. note : the c- clip profile has a rounded edge and a sharp edge . make sure the sharp edge of the c- clip is facing up, away from the fork .
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
1
SERviCE inStRUCtionS inspect, clean , and grease steerer assembly
21
23 11
24 11
25
outer steerer
21. Spray isprpyl alchl iside he er s eerer. Wrap a clea rag ard a dwel ad clea he iside he er s eerer. 22. Ispec he bshigs ad iside seerer srace r excessive wear. ( picred) 23. usig a grease brsh, apply a medim ca grease (Maxima SG-920) he bshigs ad ad D-sl fas. inner steerer
24. Spray isprpyl alchl he iside ad side he ier seerer be. Wrap a clea clea rag ard a dwel ad clea he iside he ier seerer. Clea he side he ier ier seerer be wih a rag. 25. Spray isprpyl alchl alchl he bm- bmper ad clea clea wih a rag. Ispec he b m- bmper r damage ad replace i ecessary ( picred). 26. Ispec he seerer sr ace r excessive wear ( picred). 27. Re-isall he b m bmper by slidig i he base he seerer. 28. usig a grease brsh, apply a liberal caig grease (Maxima SG-920) he ier seerer.
28
29
boot
29. Clea he b wih sapy waer. Ispec r cs r damage, ad replace i ecessary. note : the flat notch on the boot flange is a design
flat notch
feature and is not a sign of damage.
assemble the steerer assembly
30. Alig he seerer s he wrd ‘ r’ is acig y. Slide he er er seerer ver he ier seerer, wachig hrgh he p r he hreaded iser alig ad pass hrgh he baseplae. Wipe ay excess excess grease. grease. tip : use the pick to guide the threaded insert through the baseplate if necessary.
31. We a small pach a clea clh wih isprpyl alchl. usig a dwel rd wrk he clh i he s eerer clea ay grease rm he hreaded iser ( picred). 32. usig a 6 mm hex, psii he lck washer ad reaiig he hreaded iser. -Rde w M10 sar u : usig a pick r 6 mm hex wrech, alig he lck washer ver he hreaded iser as y brig he seerers i psii ad psii he reaiig p he hreaded iser iser.. Pass a lg 6 mm hex hrgh he ceer he sar ad ighe he reaiig . D ver ighe.
2
30
32
i-ride with ride with m10 star nut
95-4015-016-000 95-4015-016-000 REV A
SERviCE inStRUCtionS 33. usig a rqe wrech wih a 14 mm scke exesi ighe he reaiig 120i-lb (13.6 nm). 34. Place he p he b ver he fage he er seerer s ha he fa ch he b is he back side he rk.
33
34
35
note : the top of the boot flange has a flat area on the circumference. this is the 'back' of the boot.
35. Pll he bm he b ver he lwer leg crw fage, he alig a zip ie i he grve a he p he b s ha he aseer is i he middle he fa ch he p b fage. tighe he zip ie he back he b ad c he excess. 36. Check he ci he rk. Re-isall rk ad brake caliper accrdig maacrer's isrcis ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
flat notch
4
95-4015-016-000 REV A
REAR ShoCk SERviCE
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
5
toolS nEEDED FoR SERviCE (REAR ShoCkS) the llwig char is a lis he mdel year 2008 ls eeded r service yr RckShx rear shck. While his char is ieded be cmprehesive, i is sill ly a gide. the ls reqired r each sep service are deailed i he ex each service seci. Keep i mid yr specic shck may reqire every l lised. ARio - BAR MC - PEARl
Marc
vd
SAFEtY GLASSES
X
X
X
APRon
X
X
X
RuBBER GLoVES
X
X
X
CLEAn RAGS (LInt FREE)
X
X
X
oIL PAn
X
X
X
CLEAn WoRK AREA
X
X
X
BEnCH VICE
X
X
X
SoFt JAWS
X
X
X
toolS SAFEtY/StARting EQUiPMEnt
SHAFt CLAMP
X
WREnChES/PliERS 1.5 mm HEX
X
2 mm HEX
X
X
2.5 mm HEX
X
X
13 mm WREnCH
X
30 mm tHIn WREnCH
X
ADJuStABLE WREnCH
X
CRoW'S Foot WREnCH
X
toRQuE WREnCH
X
X
X
t-10 toRX® WREnCH
X
24 mm PIn SPAnnER
X
SLIP JoInt PLIERS
X
MiSC toolS AIR CoMPRESSoR WItH BLoW Gun CHuCK
X
GAuGED AIR PuMP
X
X
X
SHARP PICK
X
X
X
SHoCK PuMP
X
X
X
SCHRADER VALVE CoRE REMoVAL tooL
X
StRAP WREnCH
X
oil/liQUiDS 2.5 , 3, oR 5Wt SuSPEnSIon oIL
X
GREASE
X
X
X
X
oIL MEASuRInG DEVICE
X
X
X
ISoPRoPYL ALCoHoL
X
X
X
BLuE tHREADLoCK
X
RED tHREADLoCK FRoStY CoLD BEVERAGE
6
X X
X
X
95-4015-016-000 REV A
REAR ShoCk SERviCE (ARio - BAR - MC - PEARl)
intRoDUCtion Prir ser vicig yr rear shck, y will rs eed remve i rm yr bicycle rame accrdig yr bicycle maacre's isrcis. oce yr shck is yr bicycle, be sre remve he shck m hardware.
AiR CAn REMovAl/SERviCE inStRUCtionS getting started
usig eiher yr gers r a pair pliers, be sre remve shck mig hardware. Spray isprpyl alchl eire shck ad wipe wih a clea rag ( picred). air can removal
1.
Remve air valve cver cap. usig a small hex wrech r pick, depress schrader valve ad release all air rm shck. use a Schrader valve l remve he valve cre. important: to avoid injury, all air pressure must be released from shock prior to removing the air can .
2.
1
2
3
4
5
Gely secre air ca shck eyele i bech vise. note : use aluminum vise " soft- jaws " to protect the shock eyelet when clamped .
3.
Grip he air ca by had ad r rmly cerclckwise. Pll he air ca p shck damper bdy slwly remve. note : air pressure may release , so hold air can tightly while pulling up.
4.
Remve egaive sprig spacer ad egaive sprig bmper. Spray bh wih isprpyl alchl ad wipe wih a clea rag. important: do not attempt to disassemble shock damper and / or shock eyelet assembly. they are not serviceable .
5. 6.
usig a sharp pick, remve he black rbber ds seal rm he air ca. Hld air ca, arrw ed dw ad remve ble air ca glide rig wih a sharp pick. important: do not scratch the inside of the air can with pick . scratches can cause permanent air bypass .
7.
Spray isprpyl alchl iside air ca ad wipe wih a clea rag. Ispec he iside he air ca r ay rgh sraces r scraches. R yr ger alg he iside srace he air ca eel r rgh sraces r scraches as well. Replace air ca i scrached r damaged ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
6
AiR CAn REMovAl/SERviCE inStRUCtionS 8.
Remve large xed air pis -rig. Apply a ew drps sspesi il ew -rig ad re-isall.
8
9
11
12
13
14
important: the fiXed air piston o- ring is the main air seal . be sure to replace this o-ring.
9.
Isall ew air ca glide rig ad ew air ca ds seal. 10. Spray isprpyl alchl air ca hreads ad eyele bdy hreads ad wipe wih a clea rag ( picred). 11. Apply 2-3 drps ble hreadlck eyele bdy hreads, evely spaced. Spread evely hreads ad wipe away excess hreadlck wih a clea rag. 12. Apply a small am 5w sspesi il he iside he air ca. usig yr ger, spread ad ca he eire ier air ca srace wih he il. Re-apply a ew drps sspesi il he glide rig ad rbber ds seal. important: coating the inside the air can with suspension oil ensures lubrication of the fiXed air piston o-ring, which reduces friction and o-ring wear .
13. Isall egaive sprig bmper ad egaive sprig spacer. 14. Psii air ca ver shck eyele ad slide dw shck bdy. Press air ca dw rmly ad hread clckwise ighe i eyele bdy as ighly as pssible by had. note : ensure the outside of the air can is free from oil . this allows more leverage when tightening air can onto shock eyelet body.
15. use a Schrader valve l re-isall he valve cre. ( picred) 16. usig a shck pmp, ifae shck desired air pressre ad isall valve cver cap ( picred). 17. Spray isprpyl alchl eire shck ad wipe wih a clea rag ( picred). 18. Iser mig hardware i bh eyeles ( picred). this concludes the spring service for your shock. you did a great job! you are now ready to re - install your shock onto your bike and go for a ride!
8
95-4015-016-000 REV A
REAR ShoCk SERviCE (MonARCh)
intRoDUCtion Prir ser vicig yr rear shck, y will rs eed remve i rm yr bicycle rame accrdig yr bicycle maacre's isrcis. oce yr shck is yr bicycle, be sre remve he shck m hardware.
SERviCE inStRUCtionS getting started
usig eiher yr gers r a pair pliers, be sre remve shck mig hardware ( picred). Place a il pa he fr dereah he area he shck. Place a large il absrbig rag direcly dereah he vise where he shck will be clamped cach all il ha will spill rm he shck drig service ( picred). tr Rebd Adjser lly cer-clckwise, ward he rabbi. Swich Gae (i applicable) he ll pe, lcked, psii.
1
2
3
air can removal
1. 2.
Remve swivel air valve cap. usig a pick, depressrize air ca by depressig valve. usig a Schrader valve l, remve i rge pr cap. usig a pick, depressrize irge by depressig valve. usig Schrader valve l, remve he irge valve cre. important: to avoid injury, all air and nitrogen pressure must be released from shock prior to servicing.
3.
4
5
Secre shck sideways, by air ca sha eyele, i bech vise. note : use aluminum vise " soft- jaws " to protect the shaft eyelet when clamped .
4.
Grip air ca ad r cer-clckwise hread. Remve air ca. tip : spray isopropyl alcohol on air can and wipe with a clean rag . this will help with grip. note : you may need to use a strap wrench to help unthread the air can . if possible, avoid placing strap wrench on logo sticker .
5.
6
Remve he egaive sprig bmper r m iside he air ca. shaft assembly service
6.
Secre bdy eyele i vise. note : use aluminum vise " soft- jaws " to protect the body eyelet when clamped .
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
9
SERviCE inStRUCtionS 7.
usig a 2 mm hex, hread ad remve bleed screw.
7
8
9
10
12
note : the white compression ball may float up through bleed hole, this is ok . simply remove ball from bleed hole . you will be able to skip step 10.
8.
usig a adjsable wrech, lse ad remve sha assembly rm shck bdy. note : oil will spill from the shock body and / or shaft assembly.
9.
Hld he sha eyele wih e had, ad psh seal head ward air ca cap wih yr her had expse bleed hle derside seal head. note : be careful not to pinch your fingers as you slide the seal head .
10. usig a pick, psh ad remve he whie cmpressi ball he backside seal head hrgh bleed hle. 11. Spray eire sha assembly wih isprpyl alchl ad wipe wih a clea rag ( picred). 12. usig a pick, remve seal head er glide r ig ad er seal. usig a pick remve pis glide rig. Apply a small am grease ew seal head er glide rig ad er seal ad pis glide rig ad re-isall.
seal head outer glide ring
13
seal head outer seal
14
ifp and shock body service
13. Remve shck bdy rm vise, ad pr remaiig il i il pa. 14. Wrap a rag ard ed shck bdy, iser air cmpressr chck i irge ll hle, ad rce air i bdy remve IFP. important: use the rag to catch the ifp as it leaves
piston glide ring
the shock body. do not hold your hand over opening wrapped with rag ; it will hurt.
15. Spray isprpyl alchl he iside ad side shck bdy ad wipe wih a clea rag. Ispec he iside he shck bdy r scraches. ( picred) 16. Spray IFP wih isprpyl alchl ad wipe wih a clea rag. usig a pick, carelly remve IFP -rig. Apply a small am grease ew -rig ad re-isall. 17. usig a gage l, iser IFP i shck bdy wih he sepped side visible. Se IFP heigh vale idicaed i he able belw.
16
17
important: measure ifp height from the bottom of the step on the ifp.
80
shock body dimensions
ifp insertion depth
152 X 31
51 mm
165 X 38
56 mm
190 X 51
61 mm
200 X 51
61 mm
200 X 57
67 mm
216 X 63
73 mm
222 X 66
76 mm 95-4015-016-000 REV A
SERviCE inStRUCtionS shock reassembly
18. usig a Schrader valve cre l, isall irge valve. 19. Clamp shck by sha eyele back i vise. 20. Pr ew il il i is level wih he p he shck bdy. 21. Slide seal head dw agais pis.
18
19
20
21
22
23
24
25
26
28
29
note : be sure gate is in full open (unlocked) position.
22. usig a 1.5 mm hex wr ech, depress he ppe valve a he bm sha assembly. this will esre il ery he sha. note : the popet should not remain open .
23. Hldig he seal head, place i he shck bdy. thread sha assembly shck bdy. important: do not hold on to the shaft eyelet or air can cap while inserting. it will move and displace too much oil . note : oil will displace out of the bleed hole.
24. usig a rqe wrech wih crw's , rqe sha assembly 250 i/lb. important: install crow 's foot at
90°
to torque
wrench
25. Iser ew whie cmpressi ball i bleed hle. 26. usig a 2.5 mm hex, gely hread bleed screw i bleed hle il y eel i ch he whie cmpressi ball. tighe a addiial ½ r. 27. Spray assembly wih isprpyl alchl ad wipe wih a clea rag ( picred). 28. Remve shck rm vise. usig a gaged pmp, pressrize shck bdy 250-300psi. usig a Schrader valve l re-isall irge pr cap. 29. usig a pick, remve ier al glide rig air ca. Apply a small am grease ew glide rig ad re-isall. 30. Grease he seal head er glide rig, er seal, ad egaive sprig bmper ( picred). 31. Slide egaive sprig bmper, chamered side rs, shck bdy. 32. Re-clamp shck by sha eyele ad isall air ca, wis clckwise while pshig. 33. Isall red ravel idicar -rig. ( picred) 34. Isall swivel air valve cap. ( picred)
31
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
32
81
REAR ShoCk SERviCE (viviD)
intRoDUCtion Prir ser vicig yr rear shck, y will rs eed remve i rm yr bicycle rame accrdig yr bicycle maacre's isrcis. oce yr shck is yr bicycle, be sre remve he shck m hardware.
SERviCE inStRUCtionS getting started (not pictured)
eXploded view
usig eiher yr gers r a pair pliers, be sre remve shck mig hardware.
b
a
- vivid rear shock assembly
d
c
e
f
Place a il pa he fr dereah he area he shck. Place a large il absrbig rag direcly dereah he vise where he shck will be clamped cach all il ha will spill rm he shck drig service.
h
Recrd he adjsme seigs r ps-service se-p. tr he Begiig Srke Rebd ad Edig Srke Rebd adjsmes he ll pe psii, ward he rabbi. tr he Lw Speed Cmpressi adjsme he ll clsed psii, ward he rle.
g
i
j
k
l
m
a . body eyelet
f. seal head
k . ifp bleed screw
b . shock body
g . shaft eyelet
l . ifp sealhead cap
c . centering ring & o -ring
h . shaft assebmly
m. ifp cap
d. inner tube
i.
e . piston
j . ifp
1
ifp resevoir
2
3
spring removal
1. 2.
tr pre-lad cllar cer-clckwise il i sps. Remve sprig reaier, sprig ad drp sp. Se aside pars il Shck Bleed & Reassembly seci.
drop stop
spring
note : the drop stop houses a bumper which will not spring retainer
be removed from the shock .
shock body disassembly
3.
Clamp shck by bdy eyele i vise. note : use aluminum vise " soft jaws " to protect the shaft eyelet when clamped .
4.
usig a t-10 trx, remve he I FP cap rm he IFP reser vir ad discharge air by depressig he valve. usig a Schrader valve l, remve he Schrader valve cre.
4
5 hold pin spanner in place
important: be sure to completely discharge the ifp reservoir to avoid personal injury during disassembly .
5.
usig he RckShx 24 mm pi spaer, hread he seal head. important: hold the pin spanner head in place with your opposite hand during use to avoid damaging the seal head pin holes.
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SERviCE inStRUCtionS (Cont) 6.
Pll p seal head ad remve eire sha assembly.
6
7
10
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note : the shock body inner tube may become dislodged with the shaft assembly ; this is ok . if this occurs, simply separate the shaft assembly from the inner tube and remove the inner tube from the shock body.
7. 8. 9.
usig yr gers, remve ier be rm shck bdy. Remve shck rm vise ad pr all il rm shck i il pa ( picred). Crm ha he ceerig rig, lcaed i he bm he shck bdy, is sill i place ( picred). note : the centering ring may become dislodged when removing the inner tube , this is ok . if this occurs, simply separate centering ring from the inner tube and remove from the shock body.
10. Clamp pick i vise. Slide he shck bdy ver pick. usig he pick as a hk, gely cach he bm he ceerig rig ad pll back he shck bdy disldge he ceerig rig. Y may have hk he pick ard he ceerig rig i several places i rder disldge. important: do not to scratch the bottom of the shock body with the pick ; this is the sealing surface.
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14
15
16
damage to this surface will interfere with the performance of the shock.
shock body shaft assembly service
11. Spray sha assembly wi h isprpyl alchl ad wipe wih a clea li-ree rag ( picred). 12. usig he RckShx sha clamp l, clamp he sha assembly i he vise. note : spray isopropyl alcohol on shaft clamp and wipe with a clean rag prior to use .
13. usig a pick, remve glide rig he mai pis. Apply a small am grease ew glide rig ad re-isall. 14. usig a 13 mm wrech, hread pis bl. Carelly remve mai pis assembly (pis bl, mai pis, ad shim sack washers), keepig all pars geher ad se aside. 15. Firmly pll p seal head ad remve. 16. usig a pick, remve he sha w iper seal ad mai sha -rig lcaed i he ierir he seal head. Remve he qad rig p pad lcaed he backside he side head. Apply a small am grease ew sha wiper seal, mai sha -rig ad qad rig p pad ad re-isall. 17. Ispec he bdy seal -rig lcaed he derside lip he seal head r wear r damage. Replace i ecessar y. 18. Se aside seal head ad mai pis assembly ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
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SERviCE inStRUCtionS (Cont) 19. Flip sha assembly i sha clamp s sha eyele is accessible. usig 13 mm wrech, hread he eyele ad remve. 20. Clea Lcie rm hreads sha eyele ( picred). 21. usig a pick, carelly psh he red Begiig Srke Rebd Adjser kb he sha eyele.
19
21
22
23
24
25
26
27
note : the beginning stroke rebound adjuster knob houses the detent ball and spring . be careful not to lose these parts.
22. usig a pick, remve he Begiig Srke Rebd Adjser kb -rig. Apply a small am grease ew -rig ad re-isall. 23. usig a cresce wrech, hread he rebd eedle ad remve. important: be very careful not to damage the heX on the rebound needle with the crescent wrench.
24. usig a pick, remve he rebd eedle -rig. Apply a small am grease ew -r ig ad re-isall. Se aside rebd eedle. 25. Carelly iser dee sprig llwed by dee ball i he se hle i he sha eyele. Slide rebd kb, wih dee eares ieracig wih he dee ball, back i sha eyele. Se aside sha eyele. 26. Flip sha assembly i sha clamp s rebd bleed pr is accessible. Grease ierir seal head ad isall sha assembly wi h seal head hreads rieed p ward y. important: make sure the shaft wiper seal does not fold over when installing seal head.
27. usig a 13 mm wrech, hread pis assembly back sha assembly ad rqe 70 i-lbs. 28. Flip sha assembly i sha clamp s sha eyele hreads are expsed. While pshig dw, hread rebd eedle i sha by had il i sps. 29. Clea sha assembly hreads wih alchl. Place a cple drps red Lcie hreads. important: be sure loctite does not get between rebound needle and shaft. it will prevent the needle
piston assembly
from moving .
30. Clea sha eyele hreads wih alchl ( picred). 31. Hldig he sha eyele assembly by he eyele, hread sha eyele assembly sha.
28
29
31
important: do not hold the beginning stroke rebound knob while threading the shaft eyelet assembly.
Aer apprximaely 4 ll rs, y will hear a adible clickig sd, idicaig he rebd eedle has egaged he adjser k b. Cie hread sha eyele assembly by had il igh. usig a 13 mm wrech 130 i-lbs.
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95-4015-016-000 REV A
SERviCE inStRUCtionS (Cont) 32. Remve sha assembly rm vise ad se aside il Shck Bleed & Reassembly seci ( picred).
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34
35
36
37
ifp reservoir & low speed compression valve service ifp reservoir service
33. Clamp shck bdy by he bdy eyele i vise. usig a 30 mm fa wrech a he base IFP reservir ( keep he reser vir rm spiig) ad a 24 mm pi spaer wrech he p he reservir, hread he IF P seal head cap ad remve. important: hold the pin spanner head flat against the seal head cap during use to avoid damaging the pin holes.
main seal o-ring
34. Ispec IFP seal head -rig r damage. Replace i ecessary. 35. usig a 30 mm fa w rech a he base he IFP reservir, hread ad remve he IFP reservir. note : the ifp may become dislodged from the ifp
glide ring
reservoir; this is ok . if this occurs, simply remove the ifp from the ifp reservoir.
36. usig yr ger, psh he IFP he IFP reservir rm he backside. 37. usig a pick, remve ble glide rig ad mai seal -rig rm he IFP. Apply a small am grease ew glide rig ad -rig ad reisall. 38. usig a t-10 trx, remve IFP bleed screw. usig a pick, remve IFP bleed screw -rig. Apply a small am grease ew -r ig ad re-isall. 39. Se aside IFP reservir, IFP, ad IFP bleed screw il Shck Bleed & Reassembly seci ( picred).
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40
41
42
43
low speed compression valve service
40. usig a 2 mm hex, remve he lw speed cmpressi kb. tip : you do not need to completely remove the retaining screw to remove the knob.
41. Sqeeze he Lw Speed C mpressi valve assembly bewee yr gers, ad carelly psh i p ad he bdy side IFP reservir. note : continue to squeeze the compression valve assembly together as you remove ; it houses the detent ball and spring . be careful not to lose these parts.
42. Ispec bdy side IFP reservir -rig r damage. Apply grease ew -rig ad replace i ecessary. 43. Separae ier kb ad dee ball ad sprig, rm Lw Speed Cmpressi valve assembly. Slide shim check sprig valve assembly.
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
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SERviCE inStRUCtionS (Cont) 44. usig yr gers, hread cmpressi eedle rm he back he Lw Speed Cmpressi valve assembly. 45. Ispec check shim r damage ad replace i ecessary.
44
45
46
important: if the check shim needs to be replaced, do not use a pick to remove. instead , use your fingernail to remove to avoid damaging the valve sealing surface.
46. Remve he Lw Speed Cmpressi valve mai -rig, cmpressi pis -rig, ad cmpressi eedle -rig. Apply grease ew mai, cmpressi, ad eedle -rigs ad re-isall. 47. Remve shck rm vise ad pr ay remaiig il. Clamp shck by bdy eyele back i vise ( picred). 48. usig yr gers, hread cmpressi eedle back i Lw Speed C mpressi valve assembly. 49. Slide shim check sprig assembly. usig a dab grease hld pars geher, iser dee sprig llwed by dee ball i ier kb. 50. Isall ier kb cmpressi eedle ad hld eire assembly geher by sqeezig i bewee yr gers. 51. Carelly iser lw speed cmpressi valve assembly i shck bdy, ier kb rs.
48
49
50
51
52
53
tip : use your little finger to help guide the low speed compression valve assembly into place . important: make sure the low speed compression valve assembly is fully seated. be careful not to damage the main o-ring.
52. Had hread IFP reservir shck bdy il i is igh. important: make sure there is no gap between the ifp reservoir and shock body.
53. usig a 2 mm hex, re-is all lw speed cmpressi kb. ending stroke rebound service
54. Clamp shck i vise sideways by bdy eyele s he Edig S rke Rebd adjser is easily accessible. usig a 2.5 mm hex, r he Edig Srke Rebd adjser 5 clicks rm lly pe. 55. usig a pick, remve Edig Srke Rebd reaiig rig.
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54
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95-4015-016-000 REV A
SERviCE inStRUCtionS (Cont) 56. usig a 2.5 mm hex hread he Edig Srke Rebd adjser screw ad remve.
56
57
important: the ending stroke rebound adjuster houses two detent balls , the detent spring, high speed rebound coil spring and plug, and two shims . be careful not to loose these parts .
57. Remve Edig Srke Rebd adjser screw -rig. Apply grease ew -rig ad reisall. 58. Replace rebd shims. 59. usig a dab grease hld pars ge her, sack he 6 mm shim (arrw shim) rebd plg, llwed by 7 mm shim (wider shim). Carelly drp rebd plg, shims rs, i rebd hle. Iser High Speed Rebd cil sprig p rebd plg.
58
6 mm shim
tip : gently seat the rebound plug into place with a pick .
60. Grease Edig Srke Rebd adjser screw. Iser dee sprig i hle, llwed by dee balls i hles eiher side. use a dab grease keep he dee balls i place. 61. Carelly iser Edig Sr ke Rebd adjser screw i Edig Srke Rebd hsig. usig a 2.5 mm hex, hread il i sps. All pars are prperly seaed whe y hear 'clickig' sds.
59
7 mm shim
60
61
62
63
64
65
important: you don' t want to feel the parts binding as you thread adjuster screw into place . it should remain smooth until it starts to click . if the parts bind, it means one of the detent balls came unseated and you will need to re -do this step.
62. usig yr gers, re-isall Edig Srke Rebd reaiig rig. 63. usig a 2.5 mm hex, r he Edig Sr ke Rebd adjser lly cer-clckwise, ward he rabbi esre he re aiig rig is lly seaed. shock bleed & re -assembly procedures
64. Clamp shck by bdy eyele s he shck bdy ad IFP reser vir are accessible. 65. Grease he -rig grve he Ceerig Rig ad re-isall he ace seal -rig, smhig grease ver he -rig keep i i place. usig he ier be as a psh rd, press he Ceerig Rig, -rig side dw, i he bm he shck bdy. 66. usig a 2.5 mm hex, esre he Edig Srke Rebd Adjser is red lly cerclckwise, ward he rabbi ( picred). 67. 5.1 onLY: tr he Lw Speed Cmpressi Kb lly cer-clckwise, away rm “+” sig ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
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SERviCE inStRUCtionS (Cont) 68. usig 3w il (r high grade 2.5w), ll he IFP reservir he p. oil will gradally fw rm he IFP reser vir i he shck bdy hrgh he small pr lcaed a he bm he IFP reservir. Cie ll IFP reservir il he il level i he shck bdy reaches apprximaely 25 mm i deph. 69. Begi he reverse prcess prig il i he shck bdy. Cie il il sar s verfw he IFP reservir. this prcedre eec ively disldges air bbbles rm he sysem. tp he il i he shck bdy i rder cie il fw rm he shck bdy he IFP reservir. 70. Gely slide he IFP, sep side dw, p he IFP reservir. Le he IFP 'fa' p he il i IFP reser vir. 71. Cver he bleed hle he IFP wih yr hmb creae a seal ad rmly psh he IFP dw i he IFP reser vir apprximaely 12 mm.
68
69
70
71
note : you will feel the ifp o-ring 'engage' the wall of the ifp reservoir once it is past the threads .
72. tp he il i he shck bdy agai i rder cie il fw rm he shck bdy he IFP reservir.
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73
74
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77
important: wait for the oil to overflow from the ifp reservoir before continuing.
73. usig he t-10 trx, isall he IFP bleed screw. tighe il he IFP spis. 74. usig he t-10 trx as a psh rd, rmly psh he IFP dw i IFP reservir il i sps, apprximaely 45.5 mm rm p IFP reservir. 75. Iser he shck bdy ier be i he shck bdy wih he crss hles p ward he peig. important: it is critical that the cross holes are facing up toward the shock body opening.
76. Gely wiggle he ier be side side agais he shck bdy wih yr ger disldge ay air bbbles bewee he w walls. 77. tp il i he shck bdy e las ime. 78. Sea he seal head lly agais he pis he sha assembly. Place he pis i il p he shck bdy a a 4 5 degree agle. Rae he sha assembly 2-3 imes cver he pis assembly i il. Cie rae he sha assembly as y alig i ver ically, ad gely iser he assembly i he shck bdy. this prcess miimizes rapped air drig he assembly prcess.
88
cross holes
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95-4015-016-000 REV A
SERviCE inStRUCtionS (Cont) 79. Hld he sha assembly by he seal head ad swy hread he seal head he shck wih yr gers. trapped air ad il shld escape hr he ch i he seal head hreads.
79
80
81
82
important: do not thread or push on the shaft assembly from the shaft eyelet. this could displace more oil than is necessary at this time. important: be sure to perform this step slowly, allowing oil and air to escape thru the notch.
80. Cie hread he seal head dw il he seal head -rig is egaged. usig he 24 mm pi spaer l, rqe he seal head 250 i-lbs.
83
note : firmly hold the 24 mm pin spanner in place with one hand while torquing with the other. important: the torque wrench should be attached at a 90 degree angle to the 24 mm pin spanner tool in order to obtain an accurate torque measurement.
81. Remve he shck rm he vise ad pr ay excess il ha is remaiig abve he IFP. important: failure to remove this eXcess oil will reduce the ifp volume and limit shock travel .
82. Clamp he shck back i he v ise a he Bdy Eyele ad isall he IF P reservir seal head. usig he 24 mm pi spaer l, rqe 100 i-lbs.
84
important: the torque wrench should be attached at a 90 degree angle to the 24 mm pin spanner tool in order to obtain an accurate torque measurement.
83. Isall he Vi vid air adaper a gaged pmp, ad charge he IFP chamber : Shck Mdel
Pressre
Vivid 5.1
200psi (13.8 bar)
Vivid 4.1
230psi (15.9 bar)
84. usig a t-10 trx®, isall he IFP ed cap he reservir. 85. Spray he eire shck wih alchl ad wipe clea wih a li r ee rag ( picred).
© SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL
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CoPYRight All ce iclded i his caalg, icldig b limied ex, graphics r images is cpyrighed as a cllecive wrk der he uied Saes ad her cpyrigh laws, ad is he prpery SRAM Crprai. Cpyrigh 2007, SRAM Crprai. ALL RIGHtS RESERVED. Ay her se, icldig b limied he reprdci, disribi, display r rasmissi his ce his caalg is sricly prhibied. oher ames prdcs ad cmpaies meied i his caalg may be he rademarks heir respecive wers. All irmai ad specicais i his caalg are sbjec chage wih ice. the llwig are rademarks r regisered rademarks SRAM Crprai i he uied Saes ad her cries: SRAM, RckShx, Avid, trvaiv, 1:1, Grip Shi, trped, u-tr, Bar, BXXer, Pike, SID, Reba, BlackBx, Climb I Crl, tlli, Jicy, Sigle Digi, Speed Dial, Arch Rival, Black ops, Flak Jacke, Fll Meal Jacke, Hsseel, Hlzeller, Lalarm, Syl, Firex, IsFlw, tr, Giga Pipe, FiveD, Isis Drive (desig), Wav, X.0, X.9, X.7, 5.0, 4.0, 3.0, SX4, SX5, 1:1 Acai Rai, tRX, Aack, Rcke, SRAM Rcke, Ceera, MRX, PwerChai, PwerGlide, PwerLik, PwerLck, SalShaker, Implse techlgy, thmbs up, Zer Lss travel, C3 Cmpsie, Zer Lss travel, Cable Cradle, SraighSh, ui-Lever, Qick View, i-LIGHt, i-BRAKE, i-MotIon, i-MotIon 3, i-MotIon 9, Sparc, S7, P5, t3, DalDrive, twiDrive, Badix, Frce, Rival, Dbletap, HCt, oCt, Exac Acai, Missi Crl, 2-Sep, Maxle, Maxle 360, Sl Air, Dal Air, trKey, IsLie, IsLie Cshi, Air u-tr, Rear Maxle, PpLc, PpLc Dal, PpLc Adjs, PshLc, Ari, Pearl, MC, Argyle, Dmai, tem, Lyrik, revelai, Rec, tra, Dar, Cde, ulimae, Shry, Frce Vecr Aligme, BB5, BB7, FR5, Bxgide, Shigide, Egieerig he shi, XR, team, LE, 3D, XR 3D, team 3D, Rler, team BMX, Racig XR, Racig team, Racig Jir, Rki, nir, Blaze, 5D, X-Flw, Elia, Pwer Splie, GXP, Giga X Pipe, ISIS, overdrive, Sqare LE, Hwizer, Beyd Perrmace ad Ivaive Bicycle Cmpes.
WoRlD hEADQUARtERS SRAM Crprai 1333 n. Kigsbry, 4h Flr Chicag, Illiis 60622 uied Saes America Phe: +1-312-664-8800 Fax: +1-312-664-8826 E-mail: sram
[email protected]m ASiAn hEADQUARtERS SRAM taiwa n. 1598-8 Chg Sha Rad She Kag Hsiag, taichg Cy 429 taiwa R.o.C. Phe: +886-4-2561-3678 Fax: +886-4-2561-3686 E-mail:
[email protected]m EURoPEAn hEADQUARtERS SRAM Erpe Basicweg 12-D 3821 BR Amersr the neherlads Phe: +31-33-450-6060 Fax: +31-33-457-0200 E-mail: sramer
[email protected]m
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