Rockshox Service Manuals 2009

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 Warray plicy des  cver damages cased by he se  -SRAM pars. use ly SRAM pars wih SRAM cmpes. Isallai  pars ad accessries  rigially ieded cld resl i less ha pimal perrmace ad/r ijry. Fr i-deph service irmai  SRAM prdcs, reer  r websie a www.sram.cm. Cac yr lcal SRAM disribr r dealer r rderig irmai. Irmai caied i his pblicai is sbjec  chage a ay ime wih prir ice. Yr prdc‘s appearace appearace may vary rm he diagrams caied i his caalg.

© Cpyrigh SRAM Crprai 2007 Irmai may be ehaced wih prir ice. Released 2007

tABlE oF ContEntS ContEnt S ge Sared ................................................................................ ........................................................................................................................ .................................................................................. .................................................... ..........55 Frk techlgy Desigai ad oil Vlmes ................................................................................................................6 tls needed r Service Ser vice ............................................ ..................................................................................... .................................................................................. ................................................................8 .......................8

lwer le Rema (A Frs) ................................................................................... ........................................................................................................................... ................................................ ........ 11 Bus Serce (A Frs) ...........................................................................................................................................13 ....................................................................................................................... .................................................................................. .................................................2 ........233 Damper Serce .............................................................................. Rebud & turey (Argyle 302 - Dar 2, 2 wih trkey, 3 - Dmai 302 - Pike 327 - Rec 327/XC, 335/SL - tra 289, 302) ........24

M Cr (Argyle 318, 409 - Dmai 318 - Lyrik IS - tra 318 - tem IS) ...................................................................................27

M Cr (BX Xer Race, team, team, WC Pike 351, 409, 42 6, 45 4 - Reba SL, Race, team, team, WC - Rec 351 -Revelai 409, 426) ...........................................................................................................................................................30

M Cr (SID team, WC) .................................................................... .............................................................................................................. .................................................................................. .......................................................33 ...............33

Pure Dee (SID Race) ......................................................................................................... .................................................................................................................................................. .....................................................................37 ............................37

Mss Cr (Lyrik - tem) ....................................................... ................................................................................................. ................................................................................... .....................................................................39 ............................39

Spr Serce ................................................................................. ........................................................................................................................... ................................................................................... ................................................4 .......433 C (Argy le 30 2, 318 - Dar 1, 2, 2 (wih trkey), trkey), 3 - Dmai 30 2, 318 - tra 28 9, 30 2, 318) ........... ................ .......... .......... ........... ........... ........44 ...44

C (BXXer Race, team - Rec 327, 335, 351 - tem) ....................................................................................................45

C U-tur (Dmai 302, 318 - tra 289, 302, 318) .............................................................................................................................46

C U-tur (Lyrik, Lyrik IS - Pike 409, 426, 454 - Rec 327, 351 - Revelai 426) .....................................................................47

S Ar (Argyle 409, Rec 335, 351 - tra 318) ...........................................................................................................................48

S Ar (BXXer WC - Lyrik, Lyrik IS - Rec 327, 335, 351 - tem) .......................................................................................51

Dua Ar (Pike 409, 426, 454 - Reba SL, Race, team, WC - Revelai 409, 426) .....................................................................54

Dua Ar (SID Race, team, WC) ......................................................................................................... ................................................................................................................................................. ................................................5 ........566

Ar U-tur (Pike 409, 429, 454 - Reba Race, team - Revelai 409, 429) ....................................................................................58

2-Sep Ar (Lyrik, Lyrik IS - tem, tem IS) .....................................................................................................................................62

lwer le isaa (A Frs) ............................................................................................................................65 -Rde Spr Serce............................................................................... ........................................................................................................................ ............................................................................69 ...................................69 Rear Sc Serce ................................................................................... ............................................................................................................................ ............................................................................75 ...................................75 tls needed r Service Ser vice ............................................ ..................................................................................... .................................................................................. ..............................................................76 .....................76 Ari, Ari , Bar, MC, Pearl .................................................................... ............................................................................................................. ................................................................................... ................................................7 ......777 March ................................................................................ .......................................................................................................................... ................................................................................... .......................................................79 ..............79 Viv id ................................................................................. ......................................................................................................................... .................................................................................. ...............................................................82 .....................82 © SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL



SAFEtY FiRSt!

A SRAM Crprai, we care ab You, r csmer. Please, ALWAYS wear yr saey glasses whe servicig yr RckShx rk. Prec yr eyes! Wear yr saey glasses!

4

95-4015-016-000 REV A

gEtting StARtED

Fr explded diagrams ad par mber irma i, please reer  he Spare Par s Caalg, which is available  r websie a www.sram.cm Fr rderig irmai, please cac yr lcal disribr r v isi r websie a www.sram.cm. Irmai caied i his pblicai is sbjec  chage a ayime wi h prir ice. Fr he laes echical irmai, please visi r websie a www.sram.cm. Prdc ames sed i his maal may be rademarks r regis ered rademarks  hers. © SRAM CORPORATION • 2008 ROCKSHOX TECHNICAL MANUAL

5

FoRk tEChnologY DESignAtion AnD oil volUMES (All FoRkS) the llwig char is a cmplee lis  he 200 8 RckShx rk lie-p. I deails he rk mdel ad crrespdig damper ad sprig echlgy specic  each rk, ad he il vlme ad weigh r each rk leg. I is impra  deer mie he echlgy sed i yr rk i rder  sccesslly service i, as his maal is secied by echlgy, raher ha rks. I y are sre   he echlgy sed i yr rk, csl yr lcal RckShx dealer r assisace.

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


motion control

120

5

15

15

coil u -turn

-

-

15

15


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


motion control

120

5

15

15

coil u -turn

6

15

15

15


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 llwig char is a lis  he mdel year 2008 ls eeded r service  yr RckShx rk. While his char is ieded  be cmprehesive, i is sill ly a gide. the ls reqired r each sep  service are deailed i he ex  each service seci. Keep i mid yr specic rk may  reqire every l lised.

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


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


9

10

95-4015-016-000 REV A

loWER lEg REMovAl


11

loWER lEg REMovAl (All FoRkS)

intRoDUCtion Remvig he lwer legs  yr rk is he rs sep i servicig yr rk. I allws y access  yr rk bshigs, damper sysem ad sprig sysem. oce y have remved yr rk lwer legs, y'll be ready  mve  he ex seci.

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

Remve he air chamber valve cver cap rm he le rk leg p cap. I rk has a egaive air chamber, remve he egaive air chamber valve cver cap rm he b m  he le r k leg. Depress schrader valve ad release all air rm he air chamber. I rk has a egaive air chamber, sar  wih  he egaive air chamber rs, he prceed  he psiive air chamber. Pll exeral rebd adjser kb ad remve rm he righ sha bl. use a 5 mm hex wrech  lse bh sha  bls 3  4 rs. Fr Dal Air eqipped rks, se a 10 mm scke (r pe ed) wrech  lse ad hread he Dal Air sha  js pas he hreaded sha ed. use a plasic malle  gely ap each sha bl ree rm i s press-  he lwer leg ad se yr gers  remve sha bls/ cmpleely. Remve he lwer leg assembly rm rk by rmly pllig i dwward, hldig  bh legs r he brake arch. use il pa  drai excess il rm lwer leg assembly. Spray isprpyl alchl  ad i he lwer leg assembly. Wipe he lwer legs clea, he wrap a clea rag ard a dwel ad clea he iside  each lwer leg ( picred).

boXX er only

boXX er only

boXX er only

1

2

3

4

5

6

7

95-4015-016-000 REV A

BUShing SERviCE


1

BUShing SERviCE (All FoRkS)

intRoDUCtion Sspesi rk bshigs are csidered "wear ad ear" par s ad reqire reglar maieace, depedig  he reqecy  ridig, ridig errai, rider bdy weigh, ad ype  rk. the mre y ride, he mre reqely yr bshigs eed  be replaced. the llwig chaper cvers Ds & oil Seal remval, Bshig remval, Bshig isallai, ad Ds & oil Seal isallai. A his pi y shld already have he lwers remved rm yr rk. I , y will eed  rer   he Lwer Leg Remval seci  his maal ad llw he isrcis r remvig yr rk lwers. SYMPtoMS oF WoRn BUShingS Sympms  wr  bshigs ha eed  be replaced iclde, a "kckig" sd rm he rk w he ridig, ad/r he headse may eel lse whe i is'.

tWo MEthoDS oF ChECking FoR looSE BUShingS Med 1: o-Be cec 1.

Cmpress rk 5 imes  circlae lwer leg lbe ( picred). 2. Hld he r brake lever igh ad rck he bike back ad rh. I he rk eels like i's "kckig", r he headse eels lse, prceed  seps 2 ad 3. 3. Check he rk: wrap yr gers ard he ds seal ad pper be area. Rck he bike back ad rh agai. Lise ad eel i here is ay play bewee he pper be ad he ds seal. I s, he bshigs are lse. 4. Check he headse: wrap yr gers ard he headse pper cp r lwer cp/race areas. Hldig he brake, rck he bike back ad r h ad eel i he headse is lse. I s, ighe he headse ad check agai.

Med 2: off-Be cec 1. 2.

2

3

4

2

Cmpress rk 5 imes  circlae lwer leg lbe ( picred). Hld he rk crw  igh i e had ad he brake arch i he her had. try ad mve he brake arch back ad rh . I y ca eel ay play, r i he rk eels like i's "kckig", he bshigs are lse. 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.

Remve he ds seal sig a medim  large fa-head screwdriver  carelly pry i rm he lwer 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.

Remve he il am rig wih yr 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.

Remve he ier il seal, lcaed js belw he ds seal sig a fa  head screwdriver. t prec he lwer leg pai, place a rag i bewee he lwer leg ad  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 bshig remval hadle/pller l i  bech vise ighly. 2. Isall he crrec bshig remval plae  hadle ed ad secre wih hadle plae screw. • 28 mm plae (SID) • 32 mm plae (Arg yle, BXXer, Pike, Reba, Rec, Revelai, tra) • 35 mm plae (Dmai, Lyrik) • 40 mm plae (tem) 3. Slide he remval plae i he lwer leg pas he pper bshig. the remval plae pivs whe isered. Pll lwer leg away rm pller l ad hk he fa ed  he plae secre der he bshig. Whe he plae is secre der bshig, begi  remve. 4. use a plasic malle  rmly ad sqarely hi he p  he lwer leg  he fa  ds seal srace area il pper bshig plls 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 pll he lwer bshig ree rm he lwer leg, slide he remval plae pas he lwer bshig ad hk he fa ed  he plae secre der he bshig. Agai, rmly ad sqarely hi he p   he lwer leg  he fa ds seal srace area il he lwer bshig plls ree. Lger lwer bshigs may reqire mre rce. Rer  S ep 3 ad repea r he her rk leg. Spray isprpyl alchl iside lwer legs. Wrap a clea rag ard a dwel ad clea he iside  he lwer legs ( picred).


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 bshig isallai l i bech med vise, allwig 1"  verhag. Slide he lwer bshig sleeve (131.25 mm lg, brshed almim)  bshig isallai ps. Slide lwer bshig  p   lwer bshig isallai sleeve. Slide lwer leg ver isallai ps ad res  p  lwer bshig. Iser he malle dri  l i he lwer leg sha hle ad hld i place wih e had. usig a plasic malle, hi he malle dri l  press he bshig i he lwer leg. Cie  hi he malle dri l il he lwer leg ds seal ridge is level wih he p  he isallai ps spacer. Remve lwer leg rm l ad ispec he   he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg hrizally ad release. Lwer leg shld swig 90° dw ad sp ( picred). 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.

Rer  sep 1 ad 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.

Remve lwer bshig isallai sleeve rm bshig isallai ps. Slide 10 mm he 5 mm pper bshig isallai spacers  bshig isallai ps. Slide pper bshig  bshig isallai ps,  p   he 5 mm spacer. Slide lwer leg ver isallai ps ad res  p  pper bshig. Iser malle dri l i  he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l  press he bshig i he lwer leg. Cie  hi he malle dri l il he lwer leg sps mvig. Remve lwer leg rm l ad ispec he i  he pper bshig by slidig e pper be i he lwer leg. Hld lwer leg hrizally ad release. Lwer leg shld swig 90° dw ad sp ( picred).

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. Rer  S ep 9 ad 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 bshig isallai l i bech med vise. Slide lwer bshig isallai spacer  bshig isallai ps. note : recon , revelation , and tora

3 bushing sleeve

(short)

318 use the short

spacer in this step.

3.

Slide he lwer bshig sleeve  bshig isallai ps. 4. Rec, Revelai, tra 318 oly: Slide he all lwer bshig spacer  he bshig isallai ps. 5. Slide lwer bshig  he p   he lwer isallai sleeve.

4

5

6

lower spacer

(tall)

note : boXX er lower bushing is not slotted .

6.

Slide lwer leg ver isallai ps ad res  p  lwer bshig. 7. Iser malle dri  l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l  press he bshig i he lwer leg. 8. Cie  hi he malle dri l, il he lwer leg ds seal ridge is level wih he p   he isallai ps spacer. Y will eel i sp as he bshig is "se" i  he lwer leg. 9. Remve lwer leg rm l ad ispec he i  he lwer bshig by slidig e pper be i  he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). 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. Rer  S ep 1 ad repea r her leg.


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. Remve lwer bshig sleeve (ad all lwer bshig spacer r Rec, Revelai, ad tra 318). Leave ly he lwer bshig spacer  bshig isallai l. 12. Slide pper bshig  bshig isallai ps. 13. Slide lwer leg ver isallai ps, ad res  p  he pper bshig. 14. Iser malle dri l i  he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri  l  press he pper bshig i lwer leg. 15. Cie  hi he malle dri l il he lwer leg ress lsh  p   he isall spacer. Y will eel i sp as he bshig is "se " i he lwer leg. the p  he bshig shld be lsh/level wih il seal sep i he lwer leg. 16. Remve lwer leg rm l ad ispec he i  he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). note: if lower leg swings too freely, repeat step

12

13 upper bushing

lower spacer

(short)

14

15

15.


17. Rer  S ep 11 ad 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 bshig isallai l i bech med vise. Slide bshig isallai l adaper ver bshig isallai ps. Slide lwer bshig sleeve  he adaper. Slide lwer bshig   he adaper. Slide lwer leg ver isallai ps ad res  p  lwer bshig. Iser malle dri  l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l  press he bshig i he lwer leg. Cie  hi he malle dri l, il he lwer leg ds seal ridge is level wih he p   he isallai ps spacer. Y will eel he sppig pi as he bshig is "se" i he lwer leg. Remve lwer leg rm l ad ispec he i  he lwer bshig by slidig e pper be i  he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). 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

Rer  S ep 1 ad 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. Remve lwer bshig sleeve rm he adaper ad slide pper bshig  he adaper. 11. Slide lwer leg ver isallai ps, ad res   p  he pper bshig. 12. Iser malle dri  l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri l  press he pper bshig i lwer leg. 13. Cie  hi he malle dri l il he lwer leg ress lsh   p  he isall spacer. Y will eel i sp as he bshig is "se " i he lwer leg. the p  he bshig shld be lsh/level wi h il seal sep i he lwer leg.


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. Remve lwer leg rm l ad ispec he i  he lwer bshig by slidig e pper be i he lwer leg. Hld lwer leg 90° hrizally ad release. Lwer leg shld swig 45° dw ad sp ( picred). note: if lower leg swings too freely, repeat step

8.


15. Rer  S ep 10 ad 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.

Sak ew am rigs i sspesi il. Slide ds seal isallai l ver he 2 8 mm bshig isallai l. I shld si fsh wih he base  he isallai l. 3. Slide ew ds seal ver bshig isallai l ad   p  ds seal isallai l.

1

2

3

4

5

6

note : dust seal should be installed energizer spring side down.

4.

Slide il-saraed am rig ver bshig isallai l ad   p  ds seal. Sea he am rig iside he der caviy  he ds seal. Wipe excess il  he ds seal wih a clea rag. 5. Slide lwer leg  bshig isallai l,  p  ew ds seal. Iser malle dri l i he lwer leg sha hle ad hld i place. usig a plasic malle, hi he malle dri  l il ds seal seas iside lwer leg, fsh wih he p   he lwer leg ds seal sep. 6. Ds seal shld be press- sg i he lwer leg, wih li le   gap shwig. 7. Rer  S ep 1 ad repea r her leg.

FoAM Ring & DUSt SEAl inStAll Ation (REBA - RECon - REvElAtion - toRA 318) foam ring installation

1. 2.

Sak ew am rigs i sspesi il. Iser ew il-saraed am rig i lwer leg.

1

2

3

4

dust seal installation

3. 4. 5.

Iser ew ds seal i he wide ed  he ds seal isallai l. Iser ds seal i lwer leg ad press s raigh dw ad evely  sea i lwer leg. Ds seal shld be press- sg ad fsh i lwer 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.

Rer  S ep 1 ad repea r her leg.


21

FoAM Ring, DUSt SEAl & oil SEAl inS tAllAtion (ARgYlE - BoxxER - DoM Ain - lYRik - PikE - REBA - totEM) oil seal installation

1.

Apply grease r sspesi il   he iside  he lwer leg il seal cer-bre. 2. Iser he ew il seal   he sepped ed  he il/ds seal isallai l. 3. usig he il/ds seal isallai l, iser he il seal dw ad i he il sep i he lwer leg. Apply pressre  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.

Sak ew am rigs i sspesi il. Iser ew il-saraed am rig i lwer leg  p  il seal. dust seal installation

6.

Iser ew ds seal i  he pckeed ed  he il/ds seal isallai l. 7. usig he il/ds isallai l, iser ds seal i lwer leg. Apply pressre  all sides  he ds seal  sea i i place. 8. Ds seal shld be press- sg ad fsh i lwer 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.

Rer  S ep 1 ad repea r her leg.

CoMPlEting BUShing SERviCE (All FoRkS) Cmplee he bshig service  yr rk by deailig he lwer legs. Spray isprpyl alchl  eire lwer leg assembly ad wipe wih a clea rag. Check he decals  yr rk ad 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


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 pi y shld already have he lwers remved rm yr rk. I , y will eed  rer   he Lwer Leg Remval seci  his maal ad llw he isrcis r remvig yr rk lwers.

DAMPER REMovAl/SERviCE inStRUCtionS note : for dart move to step

1.

2, and tora 289 please skip step 1 and

2.

1

Remve exeral sap rig  rm cmpressi adjser kb sig exeral sap rig pliers ad remve cmpressi adjser kb ad -rig.

oR

or

2.

I rk is eqipped wih a reme cmpressi lck eare, remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad whie p cap shield. uhread cmpressi damper p cap wih a 24 mm scke wrech. note : for argyle

289

3.

4.

5.

2

3

5

6

4

302, dart 2, domain 302, and tora 5.

please move to step

Remve cmpressi damper by pllig p ad gely rckig side  side. I rk is eqipped wih a reme lck eare, be sre  remve  he reme cmpressi damper cable-sp clamp; which is lcaed der he cmpressi damper p cap. oce remved, clea pper be hreads wih a rag. Replace cmpressi damper p cap -rig by gely pichig -rig  remve. Apply a ew drps  sspesi il  ew -rig ad re-isall. Remve rk rm bicycle sad ad pr remaiig il i pa. note : for dart

2, this completes the removal procedures, please move to step 10.

6.

7.

tr rk pside dw ad psh rebd damper sha hrgh sha gide. use a lg dwel rd  help psh damper pis pas pper be hreads ad remve rm pper be. Remve rebd damper -rig ad damper ier seal-head -rig (lcaed i he b m  he pper be). Apply resh grease  ew -rigs ad re-isall.

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 upgradig rm a -reme cmpressi adjs rk  a reme cmpressi adjs (rm a crw med adjser kb  a reme PpL c r PshLc lever adjser), reqires replacig he -reme cmpressi damper wih a rem e cmpressi damper ad cable-sp clamp. the reme rer sprig is iegraed i  he cmpressi damper ad is reqired r se wih  he PpLc ad PshLc reme lever assembly.

DAMPER inStAllAtion inStRUCtionS 8.

Clamp rk back i bicycle sad ad apply a ligh lm  grease  pper be hreads. Iser rebd damper back i righ side  pper be, sha rs ad press pis i pper be pas be hreads. 9. Psh rebd damper i pper be sig a lg dwel rd. Gide rebd damper sha hrgh damper seal head a he b m  he pper be ad pll sha hrgh by had i he lly exeded psii. 10. Measre ad pr 5w sspesi il i he pper be sig he vlmes lised 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. Reme oly: Psii cable-sp clamp i he 10 'clck psii ard he pper be hle  he crw prir  iserig cmpressi damper. Grease pper be hreads liberally he iser cmpressi damper i pper be. Press dw ad wis  wrk damper i pper be. Be carel   damage -rig seals  pper be hreads. 12. Press p cap dw i pper be  hreads ad had ighe. usig a 24 mm scke wrech, ighe  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


(±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 cmpressi adjser kb  cmpressi damper p cap wih  he kb dial se i he 3 'clck psii. usig exeral sap rig pliers, secre he cmpressi adjser kb wih a ew sap rig.

13

oR

or

I rk is eqipped wih a reme cmpressi lck eare, place reme spl  cmpressi damper p cap wih he cable se screw i he 3 'clck psii. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig. 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)


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

Remve exeral sap rig  rm cmpressi adjser kb sig exeral sap rig pliers ad remve cmpressi adjser kb ad -rig seal.

oR

or

I rk is eqipped wih a reme cmpressi lck eare, remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad whie p cap seal.

2

3

5

6

4

or

I rk is eqipped wih Mi Cr l IS, se a 2 mm hex  remve screw rm cmpressi he adjser kb. Remve cmpressi adjser kb ( picred). 2. uhread cmpressi damper p cap wih a 24 mm scke wrech. 3. Remve cmpressi damper rm pper be/ crw by pllig p ad gely  wisig side  side. I rk is eqipped, be sre  remve he reme cmpressi damper cable-sp clamp; which is lcaed der  he cmpressi damper p cap. oce remved, clea pper be hreads wih a rag. 4. Wih a sharp pick, remve he cmpressi damper p cap -rig (lcaed a he p  he damper) ad he cmpressi damper seal (lcaed a he bm  he damper). Apply a ew drps  sspesi il  he ew -rig ad seal ad isall. 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

Remve rk rm bicycle sad ad pr remaiig il i pa. tr rk pside dw. Psh rebd damper sha i  pper be/seal head ad remve rebd damper rm pper be. Remve rebd damper glide rig ad ier seal head -rig. Apply resh grease  ew -rigs ad re-isall.


2

oPtionAl - CoMPRESSion DAMPER UPgRADE: non-REMotE to REMotE ADjUSt (toRA 318 onlY) upgradig rm a -reme cmpressi adjs rk  a reme cmpressi adjs (rm a crw med adjser kb  a reme PpL c r PshLc lever adjser), reqires replacig he -reme cmpressi damper wih a rem e cmpressi damper ad cable-sp clamp. the reme re r sprig is desiged i he cmpressi damper ad is reqired r se wih  he PpLc ad PshLc reme lever assembly.


Clamp rk back i bicycle sad. Iser rebd damper back i righ side  pper be, sha rs. Gide rebd damper hrgh damper seal head a b m  pper be ad pll hrgh. 9. thread sha bl i rebd damper sha ed ad pll rebd damper sha dw  hrgh seal head i lly exeded psii. 10. Measre ad pr 5w sspesi il i he pper be, hrgh he crw sig he llwig vlmes: 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. Reme oly: Slide cmpressi damper hrgh cable-sp clamp prir  iseri. Psii he cable-sp clamp i he 10 'clck psii  he crw. Grease pper be hreads liberally, he iser cmpressi damper i pper be. Press dw ad wis   wrk damper i pper be. 12. As s as  he damper seal passes hrgh he pper be hreads, pll he damper p slighly, he psh back dw. the cmpressi damper shld slide p ad dw easily, idicaig he seal i he prper psii, ad  lded ver. Repea prcedre il he cmpressi damper slides p ad dw easily. the press he cmpressi damper dw il  he pper -rig cacs he pper be hreads.

28

95-4015-016-000 REV A

DAMPER inStAllAtion inStRUCtionS (Cont) 13. tr he damper clckwise ad hread i he pper be. Be carel   damage he pper damper -rig. Cie  hread p cap dw i pper be hreads ad had ighe. usig a 24 mm scke wrech, ighe  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 cmpressi adjser kb  cmpressi damper p cap wih  he kb dial se i he 3 'clck psii. usig exeral sap rig pliers, secre he cmpressi adjser kb wih a ew sap rig.

14

or

I rk is eqipped wih a reme cmpressi lck eare, place reme spl  cmpressi damper p cap wih he cable se screw i he 3 'clck psii. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig.

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!


29

Motion ContRol DAMPER SERviCE (BoxxER RACE, tEAM, WC - PikE 409, 426, 454 - REBA Sl, RACE, tEAM, WC - RECon 351 - REvElAtion 409, 426)


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

Remve exeral sap rig  rm cmpressi adjser kb sig exeral sap rig pliers ad remve cmpressi adjser kb ad -rig seal.

oR

or

2. 3.

4.

5. 6.

7.

8. 9.

10.

0

I rk is eqipped wih a reme cmpressi lck eare, remve exeral sap rig rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad whie p cap seal. uhread cmpressi damper p cap wih a 24 mm scke wrech. Remve cmpressi damper rm pper be/ crw by pllig p ad wis ig side  side. oce remved, clea pper be hreads wih a rag. Wih a sharp pick, remve cmpressi damper -rigs (lcaed a he p ad bm  he damper). Apply a ew drps  sspesi il  ew -rigs ad re-isall. Remve rk rm bicycle sad ad pr remaiig il i pa. Remve rebd damper seal head reaiig rig (lcaed iside he bm  he righ pper be), sig exeral sap rig pliers. Pll dw ad remve he rebd damper ad seal head assembly rm he pper be. Slide seal head  damper sha ad remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew -rigs ad reisall. Spray isprpyl alchl  r ebd damper sha, ad clea wih a rag ( picred). I damaged, replace rebd damper pis glide rig. Psii pper be base rig  p  seal head sep ad slide rebd seal head assembly  rebd damper sha. Spray isprpyl alchl i he pper be. Wrap a clea rag ard a dwel ad clea he iside  he pper be ( picred).

2

3

5

6

7

4

9

95-4015-016-000 REV A

oPtionAl - CoMPRESSion DAMPER UPgRADE: non-REMotE to REMotE ADjUSt (ExClUDES BoxxER) upgradig rm a -reme cmpressi adjs rk  a reme cmpressi adjs (rm a crw med adjser kb  a reme PpL c r PshLc lever adjser), reqires replacig he -reme cmpressi damper wih a rem e cmpressi damper ad cable-sp clamp. the reme re r sprig is desiged i he cmpressi damper ad is reqired r se wih  he PpLc ad PshLc reme lever assembly.

DAMPER inStAllAtion inStRUCtionS 11. Iser rebd damper pis i he bm  he pper be a a agle, wih he pe-eded side  he glide rig ace ward. Cie  agle ad rae il glide rig is i  he pper be. Psii he pper be base rig seal ad seal head i he pper be. 12. Psii he pper be base rig seal ad seal head i he pper be ad press i  he pper be wih yr hmb. 13. use ieral sap rig pliers   secre seal head i pper be wih reaiig rig. 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. Pll rebd damper sha dw, i he  lly exeded psii. Measre ad pr 5w sspesi il i he pper be, hrgh he crw, sig he vlmes lised 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


120cc /ml 110cc /ml 118cc /ml

409, 426

114cc /ml

1

DAMPER inStAllAtion inStRUCtionS (Cont) 15. Iser cmpressi damper i pper be. Press dw ad wis   wrk damper i pper be. 16. tr he damper clckwise  hread i he pper be. Be carel   damage he pper damper -rig. Cie  hread p cap dw i pper be hreads ad had ighe. usig a 24 mm scke wrech, ighe  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 cmpressi adjser kb  cmpressi damper p cap wih  he kb dial se i he 3 'clck psii. usig exeral sap rig pliers, secre he cmpressi adjser kb wih a ew sap rig. or

17

oR

I rk is eqipped wih a reme cmpressi lck eare, place reme spl  cmpressi damper p cap wih he cable se screw i he 3 'clck psii. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig. 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)


DAMPER REMovAl/SERviCE inStRUCtionS 1. 2. 3.

4. 5.

Remve reme cable sp clamp sig a 2 mm hex wrech. Remve Fldgae adjser kb sig a 1.5 mm hex wrech. Remve exeral sap rig  rm cmpressi adjser spl sig exeral sap rig pliers ad remve cmpressi adjser spl ad rer sprig. uhread cmpressi damper p cap wih a 24 mm scke wrech. Remve cmpressi damper, damper be ad rebd damper assembly rm pper be/ crw by pllig p ad wis ig side  side. Clea pper be hreads wih 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.

Pll he rebd damper/seal head assembly rm he bm  he dampig be. Be sre  wrap a rag ard he damper be, as il will drai rm he assembly. Pr remaiig il rm damper be i il pa. Remve cmpressi damper rm damper be by pllig p gely. Allw ay excess il  drai i il pa. Pll sraigh ; d' wis. Spray cmpressi damper assembly ad damper be (iside ad ) wih isprpyl alchl. Wipe grease ad il rm damper assembly ad side  damper be. Wrap a clea rag ard a dwel ad clea he iside  he damper be ( picred). Slide seal head  rebd damper sha ad remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew -rigs ad isall. Spray rebd damper sha wih isprpyl alchl, ad clea wih a rag ( picred). Ispec rebd damper pis glide rig ad damper sha. Replace eiher, i damaged. Slide rebd damper seal head back  rebd damper sha. Iser a 2 .5 mm hex wrech (r rebd adjser kb) i rebd damper adjser a he bm  he sha, ad r cer-clckwise  pe he rebd damper valve. this allws il  fw i he damper valve whe re-llig damper be wih il.


6



DAMPER REMovAl/SERviCE inStRUCtionS (Cont) 13. Lbricae rebd damper ad seal head by sbmergig i a caier  sspesi il. 14. Remve cmpressi damper -rigs (lwer, ieral faig pis - IFP, ad primary). Apply a ew drps  sspesi il  ew rigs ad isall.

13

14

DAMPER inStAllAtion inStRUCtionS 15. Place gld Fldgae adjser kb back  he cmpressi damper ad ighe wih a 1.5 mm hex wrech. 16. tr he cmpressi spl adjser hex cer-clckwise il i sps. this is he ll pe psii. 17. Apply sspesi il  bh he mai pis  ad IFP - rigs  he cmpressi damper. 18. Iser he cmpressi damper back i he damper be ad slide eire damper assembly i he be. Press p cap rmly i place. 19. Hldig damper be wih he pe ed p, pr 5w sspesi il i he damper be il be is apprximaely hal-ll. tap he cmpressi damper be lighly  a fa srace  release ay air bbbles rapped iside he damper. 20. Pr addiial 5w  sspesi il i damper be il cmpleely ll. 21. Remve rebd damper ad seal head rm he il caier i which i was sbmerged. Wrap a rag ard he damper be  cach displaced il. Wih he seal head bmed , slwly iser rebd pis i  he damper be, by pshig  he seal head, il i is lly seaed. Wipe all il rm 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. Iside he damper pper be is a -rig ha sis be wee he damper be/rebd seal head assembly ad he pper be  hread base reaier. Esre he -rig is psiied fa  he hreaded pper be base reaier. I he -rig came  wi h he damper be assembly, apply a small am  grease  he -rig ad re-psii i  he b m  he rebd damper seal head. 23. Iser he damper assembly back i he pper be, rebd sha rs . Gide he ed  he rebd damper hrgh he ceer  he hreaded base re aier, slidig he damper cmpleely i he pper be. 24. Had hread he cmpressi damper p cap i he pper be. use a 24 mm scke wrech ad ighe p cap  60 i-lb.

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24

25

important: do not allow rebound damper shaft to scrape the retainer upon insertion.

25. Iser he rebd damper exeral adjser kb i he b m  he rebd damper sha ad r clckwise il damper is i he ll clsed psii. this will prec he damper rd whe isallig he lwer leg sha bl.

oPtionAl - REMotE ADjUSt to non-REMotE Swichig rm a rem e cmpressi adjs  a crw med cmpressi adjs reqires ly he remval  he reme spl ad cable sp clamp assemblies, ad isallai  he s adard cmpressi adjser kb. ulike sadard Mi Crl cmpressi dampers, he 07 SID Mi Crl cmpressi damper reme rer sprig is not iegraed i he damper assembly. the reme PpLc r P shLc lever adjser ca eiher be remved rm he hadlebar, r simply remve he cable/cable hsig ad leave he PpLc r PshLc lever  yr hadlebar, i case y chse  re-isall  he reme spl i he re.

DAMPER inStAllAtion inStRUCtionS (Cont) 26. Remve Fldgae adjser kb agai, sig a 1.5 mm hex wrech ( picred) 27. Place cable sp clamp  he p cap wih he cable sp psiied a apprximaely 90° r ward rm he seerer be. tr he cmpressi spl adjser sha (hex shaped) cer-clckwise il i s ps,  esre i is i he pe (lcked) psii. 28. Place he reme spl  he cmpressi spl adjser sha ad r clckwise il i sps, i he clsed (lck) psii. Hld he reme spl i he clsed psii ad se yr ree had  ra e he cable sp clamp cer-clckwise il i  ches he reme spl sp. 29. tighe cable sp clamp wih a 2.5 mm hex wrech. Check he psii  he reme spl by raig i cer-clckwise  he ll pe (lcked) psii. the se screw shld be i lie wih  he pe mark  he cable sp clamp.


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28

29 cable set-screw

open mark

5

DAMPER inStAllAtion inStRUCtionS (Cont) 30. Remve he reme spl w hile he cmpressi adjser is i he pe (lck) psii. Apply a small am  grease  he reme spl rer sprig (grease will hld he re r sprig i he reme spl drig isallai). Iser he rer sprig i he derside  he reme spl, wih he lg sprig leg acig . 31. Place he reme spl ad rer sprig  he cmpressi damper adjser hex by aligig he lg leg  he rer sprig   i e dee hle i  he p cap, a he same ime as aligig he cable se screw wih he pe mark  he cable sp clamp. 32. tr he reme spl clckwise il splsp res s i he clsed psii agais he cable sp clamp sp. I he sp  he reme spl des  ch he sp  he cable sp clamp, lse cable sp clamp ad rae i  cer-clckwise il  he w s ps ch ad reighe cable sp clamp. Release he spl rm he clse psii ad es he rer   he pe psii. 33. usig exeral sap rig pliers, secre he reme spl wih a ew sap rig. 34. Place he Fldgae adjser kb back  he cmpressi damper spl sha . tighe he Fldgae adjser kb se screw  he fa  srace  he black adjser rd wih a 1.5 mm hex wrech.

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31

insert spring leg into detent hole

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33

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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)


DAMPER REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the pure delite air chamber before proceeding . remove

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air valve cover cap and depress schrader valve to release any air pressure.

1.

uhread cmpressi damper p cap wih a 24 mm scke wrech. 2. Pll p ad remve he eire Pre Deli e damper assembly rm he pper be. Remve he p cap by pllig   he Pre Deli e damper be. 3. Iver he damper assembly ad gely, b rmly, pll he rebd damper seal head assembly rm he Pre be. Hld a rag ard be while pllig,  cach ay il ha may spill. Pr ay remaiig il rm he Pre be i il pa. 4. Remve he Ieral Flaig Pis (IFP), which is lcaed iside he Pre damper be, i he ceer  he be. the IFP is he seal ha separaes he il rm he air i  he Delie air chamber. t remve he IFP, iser a lg dwel rd (plasic r wd) i he Pre be il he rd ches he derside  he IFP. Psh rmly  he rd  release he IFP rm he Pre 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 Pre Delie Damper assembly cmpes. Remve IFP ier ad er -rigs. Apply a ew drps  sspesi il  ew -rig ad re-isall ( picred). Slide seal head  rebd damper sha ad remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew -rigs ad re-isall. Ispec damper sha r scraches ad replace i damaged. Place seal head back  rebd damper sha.





Iser IFP i he Pre be a a deph  6 iches. t d his, m a lg dwel rd (plasic r wd) i a bicycle sad clamp r bech vise wih 6 iches  expsed rd. Place he IFP  he ed  he dwel, pckeed side dw. Place e ed  he Pre tbe ver he IFP ad press rmly dw il he IFP is seaed iside he be. note : be careful not to damage

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10

ifp o-ring or your

hands on the sharp edges of the pure tube. use a rag to protect your hands.

10. Cie  press he IFP i  he Pre be il he be ed is fsh agais he bicycle clamp r vise. the IFP is w seaed rmly iside he Pre be a a 6 ich deph. Pll he Pre be  he dwel. 11. Hld he Pre be ver il pa, wih he pckeed side  he IF P acig dw (rded side acig p) ad ll he be cmpleely wi h 15w sspesi il. 12. Make sre he rebd damper is i he pe psii.

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note : be sure piston seal head is topped against rebound piston.

Gely ad slwly iser  he rebd damper pis head i he il lled Pre be. the il will slwly ll he damper valves (sme il will spill). Allw egh il  ll he damper valve caviies ad p   il vlme i ecessary. Wih he seal head bmed , gely press dw  he seal head il i saps i  he Pre be secrely. Yr damper is w sealed. important: do not cycle the damper shaft until the delite air top cap has been installed and pressurized.

13. Iser he Pre Delie damper assembly i he pper be hrgh he crw. 14. Add 6cc/ml  15w  sspesi il  he p chamber  he damper. this will lbricae he IFP -rig. 15. Had hread he damper p cap i he pper be. use a 24 mm scke wrech ad ighe p cap  60 i-lb. Pressrize he air chamber wih yr shck pmp  20-6 0psi. the IFP is w pressre se ad yr damper sealed. 16. Iser he rebd damper exeral adjser kb i he b m  he rebd damper sha ad r clckwise il damper is i he ll clsed psii. this will prec he damper rd whe isallig he lwer leg sha bl. 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)


DAMPER REMovAl/SERviCE inStRUCtionS 1.

tr ble high speed cmpressi kb clckwise,  se i he maximm cmpressi psii. ( picred) 2. tr Fldgae  " " psii by pshig lw speed cmpressi adjser dw ad r aig cer-clckwise 9 0°. 3. uhread cmpressi damper p cap wih a hi 24 mm wrech. Access  he p cap is der he high speed cmpressi kb.

2

3

floodgate in off position

oR

or

4.

5.

6.

7.

8. 9.

Iser a 2.5 mm hex wrech i he gld lw speed cmpressi kb ad r i cerclckwise il i sps ( picred). this allws maximm iseri deph r he 4 mm wrech. Gely grasp he lw speed cmpressi kb wih he slip ji pliers, sig a 4 mm hex wrech  remve lw speed cmpressi screw. Li  ad remve he lw speed cmpressi kb. the, sig a 1.5 mm hex wrech, lse bh reaiig bls   he high speed cmpressi kb. Remve he high speed cmpressi kb. this allws access  he p cap. uhread cmpressi damper p cap sig a 24 mm scke wrech. Remve cmpressi damper rm pper be/ crw by pllig p ad wis ig side  side. oce remved, clea pper be hreads wih a rag. Remve glide rig  rm cmpressi damper pis assembly. Apply a ew drps  sspesi il  ew glide rig ad re-isall. Remve rk rm bicycle sad ad pr remaiig il i pa. Rer rk  bicycle sad. Remve rebd damper seal head reaiig rig (lcaed iside he bm  he righ pper be), sig ieral sap rig pliers. Pll dw ad remve he rebd damper assembly rm he pper be. Psh pward  rebd sha  separae rebd pis assembly rm rebd be. Spray rebd damper sha wih isprpyl alchl, ad clea wih a rag ( picred).


4

7

5

6

8

9

DAMPER REMovAl/SERviCE inStRUCtionS (Cont) 10. Remve ier ad er -rigs rm rebd seal head. Apply a ew drps  sspesi il  ew -rigs ad re-isall.

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. Remve glide rig rm rebd sha  assembly. Apply a ew drps  sspesi il  ew glide rig ad re-isall.

DAMPER inStAllAtion inStRUCtionS 12. Isall rebd sha assembly i rebd be.

12

13

14

note : be sure not to damage rebound tube inner o- ring .

13. Isall rebd assembly i pper be ad secre wih reaiig rig sig ieral sap rig 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. Pll rebd damper sha dw i he ll y exeded psii. 15. Measre ad pr 5w sspesi il i he pper be, hrgh he crw, sig he llwig vlmes:

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. Dble check he Fldgae  esre i is i he " " psii. Isall Missi Crl damper assembly i pper be hrgh he crw. Had hread he cmpressi damper p cap i he pper be. use a hi 24 mm scke wrech ad ighe p cap  60 i -lb.

16

oR

or

Dble check he Fldgae  esre i is i he " " psii. Iser Missi Crl damper assembly i pper be hrgh he crw. Had hread he cmpressi damper p i he pper be. use a 24 mm scke wrech ad ighe p cap  60 i-lb. Isall high speed cmpressi kb sig a 1.5 mm hex wr ech  ighe screws. Isall lw speed cmpressi kb by gely graspig he kb wih slip ji pliers ad sig a 4 mm hex wrech  ighe 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!


41

42

95-4015-016-000 REV A

SPRing SERviCE


4

Coil SPRing SERviCE (ARgYlE 302, 318 - DARt 1, 2, 2 (With tURnkEY), 3 - DoMAin 302, 318 - toRA 289, 302, 318)


Coil SPRing REMovAl/SERviCE inStRUCtionS 1.

uhread ad remve sprig p cap wih a 24 mm scke wrech.

1

2

important: press down firmly when loosening top

pre -load spacer

cap.

Argyle 302 , 318 oly: Remve sprig pre-lad spacer(s). 3. Psh sprig sha pward, rm he b m  he pper be, he remve sprig ad sprig spacers rm pper be. 4. tr rk pside dw ad slide he sprig sha assembly   he pper be. Remve sprig sha assembly ad ispec  r damage. 5. Spray isprpyl alchl  sprig, sprig sha assembly ad he iside ad side  he pper be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i  he pper be  clea iside he pper be ( picred).

3

2.

4

Coil SPRing inStAllAtion inStRUCtionS 5.

6. 7. 8. 9.

Iser ad drp sprig sha assembly i  pper be hrgh he crw. Gide he hreaded ed hrgh he sha gide a he bm   he pper be ad gely pll sha  hrgh  ll exesi. Apply resh grease liberally  sprig/sprig spacer assembly. Iser ad drp sprig assembly i pper be hrgh he crw. Argyle 302 , 318 oly: Isall sprig pre-lad spacers. Clea p cap, he apply a small am   grease  p cap hreads. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe  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)


SPRing REMovAl/SERviCE inStRUCtionS 1.

uhread ad remve sprig p cap wih a 24 mm scke wrech.

1

2

important: press down firmly when loosening top

pre -load spacer

cap.

Remve sprig pre-lad spacer(s) ad pll sprig rm pper be. 3. Remve he sprig sha base plae re aiig rig sig ieral sap rig pliers. 4. Pll sprig sha ad base plae rm pper be. Ispec assembly r damage ad replace eire assembly i ecessary. 5. Spray isprpyl alchl  sprig, sprig islars (islars are BXXer ly), sprig sha ad he iside ad side  he pper be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper  be ( picred).

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.

Iser sprig sha assembly back i bm  pper be s he base plae assembly is seaed i he pper be sep. Secre sprig sha assembly wih re aiig rig, sig ieral sap rig pliers. 7. Apply resh grease liberally  sprig ad sprig islars (islars are BXXer ly). 8. Iser sprig back i pper be ad place sprig prelad spacer(s)  p  sprig iside pper be. 9. Clea p cap, he apply a small am  grease  p cap hreads. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe  60 i-lb.

6

7

8

9



45

Coil U-tURn SPRing SERviCE (DoMAin 302, 318 - toRA 289, 302, 318)

intRoDUCtion A his pi y shld already have have he lwers remved rm yr rk. I , y will eed  rer   he Lwer Leg Remval seci  his maal ad llw he isrcis r remvig yr rk lwers. Coil U-tURn SPRing REMovAl/SERviCE inStRUCtionS 1.

Remve u-tr u-tr kb screw wih a 2.5 mm hex wrech ad remve u -tr -tr adjser kb. 2. Remve dee ball bearigs ad dee sprigs rm p cap sig a mage. 3. uhread ad remve sprig p cap wih a 24 mm scke wrech. wrech. the sprig is aached  he p cap cap ad sprig sha. Pll ad li eire sprig assembly rm pper be.

1

2

3

important: press down firmly when loosening top cap.

4.

5.

Remve u-tr u-tr egaive sprig assembly rm pper be, y may eed  r rk pside dw  remve. Spray isprpyl alchl  eire sprig assembly, egaive sprig, ad he iside ad side  he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be ( picred).

4

Coil U-tURn SPRing inStAllAtion inStRUCtionS 6. 7. 8.

9.

10.

11.

Apply resh grease liberally  egaive sprig, he eire sprig assembly, ad p cap hreads. Iser ad drp egaive sprig i pper be hrgh he crw. Iser u-tr sprig assembly i pper be hrgh crw, sha sha ed rs. Alig ad sea sea he sprig sha hrgh he sha gide/base plae. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke scke wrech, ighe  60 i-lb. usig a mage, iser each dee sprig i p cap dee dee  hles, evely spaced. spaced. Place each dee ball bearig  p  each dee sprig. Place u-tr adjser kb  p  hex. tighe u-tr kb screw wih a 2.5 mm hex wrech.

6

7

8

9

10

11


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 pi y shld already have have he lwers remved rm yr rk. I , y will eed  rer   he Lwer Leg Remval seci  his maal ad llw he isrcis r remvig yr rk lwers. Coil U-tURn SPRing REMovAl/SERviCE inStRUCtionS 1.

Remve u-tr u-tr kb screw wih a 2.5 mm hex wrech ad remve u -tr -tr adjser kb. 2. Remve dee ball bearigs ad dee sprigs rm p cap sig a mage. 3. uhread ad remve sprig p cap wih a 24 mm scke wrech. wrech. the sprig is aached  he p cap cap ad sprig sha. Pll ad li eire sprig assembly rm pper be.

1

2

3

important: press down firmly when loosening top cap.

4.

Spray isprpyl alchl  eire sprig assembly ad he iside ad side  he pper be ad wipe wih a clea rag. rag. Wrap a clea rag ard a lg dwel ad iser iser i  he pper be  clea iside he pper be ( picred).

Coil U-tURn SPRing inStAllAtion inStRUCtionS 5. 6.

7.

8.

9.

Apply resh grease liberally  he e ire sprig assembly, ad p cap hreads. Iser u-tr sprig assembly i pper be hrgh crw, sha sha ed rs. Alig ad sea sea he sprig sha hrgh he sha gide/base plae. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke scke wrech, ighe  60 i-lb. usig a mage, iser each dee sprig i p cap dee dee  hles, evely spaced. spaced. Place each dee ball bearig  p  each dee sprig. Place u-tr adjser kb  p  hex. tighe u-tr kb screw wih a 2.5 mm hex wrech.

5

6

8

9

7



4

Solo AiR SPRing SERviCE (ARgYlE 409 - toRA 302, 318)

intRoDUCtion A his pi y shld already have have he lwers remved rm yr rk. I , y will eed  rer   he Lwer Leg Remval seci  his maal ad llw he isrcis r remvig yr rk lwers.

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.

uhread air sprig p cap wih a 2 4 mm scke wrech. the air sprig sprig assembly is aached  he p cap. Pll ad li eire air sprig assembly rm pper be. Pll p cap   air be assembly ad pr ay air seal lbrica i il pa. Remve air sha ad air seal head rm he b m  he air be by pllig sha sha dw ad wis ig side  side. Spray isprpyl alchl  he iside ad side  he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be ( picred). Remve air pis reaier rig sig exeral sap rig pliers. the remve air air pis wavy sprig washer ad pis pis rm air sha . Slide air sleeve seal head assembly rm air sha. Remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew rigs ad re-isall.

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 isprpyl alchl ad wipe clea wih a rag ( picred). 9. Iser air pis back  air sha head. Isall sprig wavy washer  air sha ed ad secre i place place wih air pis reaier rig, sig exeral sap rig pliers. Check reaiig rig   make sre i secres he air pis  air sha sha head. the pis shld cmpress slighly wih sprig resis ace agais agais wavy sprig washer ad reaiig rig.

48

95-4015-016-000 95-4015-016-000 REV A

Solo AiR SPRing REMovAl/SERviCE inStRUCtionS (Cont) 10. Remve bm-  bmper ad kick plae rm egaive air sleeve/seal head. 11. Remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew rigs ad re-isall.

11

10


oPtionAl - All tRAvEl ConFigURAtionS (toRA 318) All ravel spacers are lcaed js abve he air seal head. I y wa  chage he ravel  yr rk , sap he ravel spacer  seal head  decrease ravel, r remve  icrease ravel.

30 mm

50 mm

no spacer

spacer

spacer

80 mm


100

mm

130 mm

49

Solo AiR SPRing inStAllAtion inStRUCtionS 12. Iser b m- bmper ad pad back  air seal head. Slide air seal head/sleeve assembly back i air sha, bmpers rs. 13. Iser lbricaed air assembly, bh piss ad air sleeve i e ed  air be. Psh air seal head i air be il rmly seaed. 14. Iser air sha i p  pper be, hrgh crw. Gide he bm  he air sha hrgh he sha gide i he bm   he pper be. Iser air be assembly i pper be il i ress iside pper be. 15. Measre ad pr 6cc/ml  15w  sspesi il i pper be hrgh he crw. Sspesi il i he air chamber lbricaes he air seal rig drig se ad maiais he air seal. 16. Psh air sha  li  air be   pper be a cple  iches. Iser he air p cap i air be ad press igh i air be. 17. Drp air be/p cap assembly i pper be. Check bm  pper be ad make sre air sha gide is seaed i pper be sha  gide. 18. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe  60 i-lb.

12

13

14

15

16

17

18


50

95-4015-016-000 REV A

Solo AiR SPRing SERviCE (BoxxER WC - lYRik - RECon - totEM)


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.

uhread ad remve air sprig p cap wih a 24 mm scke wrech. Remve rk rm sad ad pr ay air seal lbrica i il pa. 2. use yr ger  press he air seal head i he pper be. Y will eel i break ree ad slide i he be ab 3 mm. 3. Remve he air assembly sha gide reaiig rig rm he b m  he le pper be, sig exeral sap rig pliers. Pll air sha dw  remve air sprig assembly ad sha gide rm pper be. 4. Spray isprpyl alchl  he iside ad side  he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be ( picred). 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

Remve air pis reaier rig sig exeral sap rig pliers. the remve air pis wavy sprig washer ad pis rm air sha . Slide air sleeve/seal head assembly rm air sha. Remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew rigs ad re-isall. 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 isprpyl alchl ad wipe clea wih a rag ( picred).


51

Solo AiR SPRing REMovAl/SERviCE inStRUCtionS (Cont) 9.

Iser air pis back  air sha head. Isall sprig wavy washer  air sha ed ad secre i place wih air pis re aier rig, sig exeral sap rig pliers. Check reaiig rig   make sre i secres he air pis   air sha head. the pis shld cmpress slighly wih sprig resis ace agais wavy sprig washer ad reaiig rig. 10. Remve bm-  bmper ad kick plae rm egaive air sleeve/seal head. 11. Remve ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew rigs ad re-isall.

9

10

11


oPtionAl - All tRAvEl ConFigURAtionS (RECon 327, 335, 351) All ravel spacers are lcaed js abve he air seal head. I y wa  chage he ravel  yr rk , sap he ravel spacer  seal head  decrease ravel, r remve  icrease 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. Iser b m- bmper ad kick plae back  air seal head. Slide air seal head/sleeve assembly back i air sha, bmpers rs . 13. Iser lbricaed air pis i b m  pper be ad slide he lwer air pis /sleeve assembly i pper be. 14. Sea he sha gide rig ad wavy washer i pper be sep,  he slide egaive air sleeve i pper be ad sea sha gide base i pper be sep. 15. Secre reaiig rig i pper be reaiig rig grve sig exeral sap rig pliers. Psii reaiig rig hles ard reaiig rig psiier  base plae. Veriy reaiig rig is secre i pper be. 16. Measre ad pr 6cc/ml  15w  sspesi il i air be hrgh he crw. Sspesi il i he air chamber lbricaes he air seal  -rig drig se ad maiais he air seal. 17. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe  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!


5

DUAl AiR SPRing SERviCE (PikE 409, 426, 45 4 - REBA Sl, RACE, tEAM, WC - REvEl Ation 409, 426)


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.

uhread ad remve Dal Air p cap wih a 24 mm scke wrech. Remve rk rm s ad ad pr ay air seal lbrica i il pa. Clamp rk back i bicycle sad ad w ipe sha ad base plae wih a rag. Psh egaive air sha p ad i base plae, leavig ly he ip  he  hreaded sha ed prrdig rm 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 scke l (r similar hllw l) ver he air sha ed ad press r mly agais he base plae. While pressig he air base plae p ad i he pper be, remve he reaiig rig sig exeral sap rig pliers. oce reaiig rig is remved, gel y pll air sha dw   remve air sprig assembly ad base plae rm pper be. Spray isprpyl alchl  he iside ad side  he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be ( picred). Remve base plae, base plae -r ig/bmper, ad egaive air pis rm he Dal Air sha. Remve er ad ier egaive air pis -rigs. Apply a ew drps  sspesi il  ew -rigs ad re-isall.

air piston o - ring base plate


10. Remve er psiive air pis -rig. Apply a ew drps  sspesi il  ew -rig ad re-isall. 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 lcaed js abve he bm  bmper washer. I y wa  chage he ravel  yr rk, sap he ravel spacer  he Dal Air sha  decrease ravel, r remve  icrease 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-isall he egaive air pis, base plae -rig/ bmper ad base plae  he Dal Air sha ad re-apply sspesi il  -rigs. 12. Iser Dal Air assembly i pper be, psiive air pis rs , llwed by he egaive air pis. Iser base plae assembly i pper be sep ad press i rmly. 13. usig yr hmb, press base plae i pper be. While pressig base plae, isall exeral reaiig rig sig exeral sap rig pliers. Veriy re aiig rig is secre i pper be grve. Alig reaiig rig accrdig  he rieai  he base plae reaiig rig grve. 14. Measre ad pr 6cc/ml  15w  sspesi il i air be hrgh crw. Sspesi il i he air chamber lbricaes he air seal  -rig drig se ad maiais he air seal. 15. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe  60 i-lb.

11

12

14

15

13



55

DUAl AiR SPRing SERviCE (SiD RACE, tEAM, WC)


DUAl AiR SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress positive

1

2

3


1.

uhread ad remve Dal Air sprig p cap wih a 24 mm scke wrech. 2. Remve rk rm s ad ad pr ay il rm psiive air chamber i il pa. 3. Remve hreaded pper be reaier sig he SID Dal Air pper be reaier l ad a scke wrech. important: the retainer is reverse threaded. turn the wrench

4.

clockwise to unthread.

Pll Dal Air sprig 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 isprpyl alchl  he iside ad side  he pper be ad wipe wi h a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be ( picred). 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 egaive air pis sleeve rm air sprig sha. Spray isprpyl alchl  he air sha ad wipe wih a clea rag ( picred). Remve he er ad ier egaive air pis -rigs as well as he er psiive air pis -rig. Apply a ew drps  sspesi il  ew -rigs ad re-isall. important: if using a pick to remove o-rings, do not scratch seal head . scratches may cause oil to leak.

9.

56

Slide egaive air sprig sleeve back  air sprig sha.

95-4015-016-000 REV A

oPtionAl - All tRAvEl ConFigURAtionS All ravel spacers are lcaed js abve he egaive sleeve p  bmper. t chage he ravel  yr rk, slide egaive sleeve dw ad sap he ravel spacer  seal head  decrease ravel, r remve  icrease ravel.

20 mm spacer

60

no spacer

80 mm

mm

DUAl AiR SPRing inStAllAtion inStRUCtionS 10. Re-apply resh sspesi il  ew psiive ad egaive air pis -rigs. 11. Iser psiive air pis i bm  pper be ad psh air pis/sha  assembly i pper be. 12. Slide he egaive air pis sleeve dw air sprig sha ad i he b m  he pper be. Cie  slide eire egaive air sprig 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 Dal Air sprig assembly  hreaded base reaier i he pper be by had. usig he SID Dal Air pper be reaier l ad a scke wrech, press i reaier rmly ad ighe he hreaded pper be/base reaier  30 i-lb. important: the retainer is reverse threaded. turn by hand and wrench

counter-clockwise to

thread .

14. Make sre rk is psiied prigh i wrksad. Measre ad pr 6cc/ml  15w sspesi il i psi ive air chamber, hrgh he crw. note : suspension oil on top of the positive air piston o- ring is critical to lubrication and maintenance of the air seal .

15. Iser p cap i pper be/crw ad had hread i pper be. usig a 24 mm scke wrech, ighe  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!


5

AiR U-tURn SPRing SERviCE (PikE 409, 429, 454 - REBA RACE, tEAM - REvElAtion 409, 429)


AiR U-tURn SPRing REMovAl/SERviCE inStRUCtionS important: verify all air pressure is removed from the air chamber before proceeding . depress positive

1

2


1.

2.

Adjs ravel seig  max (ll) ravel. Psh exeral re aiig clip rm abve u-tr kb wih a pick r screwdriver ad remve adjser kb. Remve dee ball bearigs ad dee sprigs rm p cap sig a mage. 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.

tr Air u-tr ravel adjs sha , which prrdes rm bh  he ceer  he p cap ad he bm  he air sha, CloCkWiSE  hread he air sprig assembly rm he A ir u-tr p cap (p cap shld be igh iside crw/pper be). Pll dw  he A ir u-tr sha ad remve he eire sprig assembly rm he bm  he pper be. Remve ef washer rm iside  p cap. t remve, psh dw wih a pick r fa-head screwdriver. Washer will exi bm  he pper be. Remve small exeral reaiig rig lcaed a he b m  he air chamber sig exeral sap rig pliers, he remve gide plae. Psh dw  seal head wih a fa-head screwdriver (psii screwdriver head agais sep, away rm sha) ad ree he re aiig rig rm he seal head. oce seal head slides i air  be, remve seal head reaiig rig, sig sap rig 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.

Pll air sha, egaive air seal head ad psiive air pis assemblies   air be. Slide ad remve almim seal head rm air sha . 9. Spray isprpyl alchl  air sha ad wipe wih a clea rag ( picred). 10. Remve seal head rm air pis sha . Remve he ier ad er seal head -rigs as well as he small er -rig lcaed  he air pis  sha grve. Apply a ew drps  sspesi il  ew -rigs ad re-isall.

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. Hldig he air be, place pper chke assembly ed  fa srace. Firmly press be dw  fa sr ace  break he seal ad psh chke assembly hrgh 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 -meallic dwel  cie  psh he assembly hrgh ad   he air be. Remve assembly cmpleely rm 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 isprpyl alchl  he iside ad side  he air  be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be ( picred). 14. Remve exeral chke reaiig rig rm ravel adjsme sha, sig exer al sap rig pliers. Remve chke pis ad chke/sha washer. 15. Remve exeral chke -rig. Apply a ew drps  sspesi il  ew -rig ad reisall.

17

important: if using a pick to remove o-ring, do not scratch choke piston. scratches may cause air leak .

16. Remve pper seal head rm adjser sha . 17. use a fa head screwdriver ad remve ier rig reaiig rig. the remve bh he ier ad er seal head -rigs. Apply a ew drps  sspesi il  ew -rigs ad re-isall. use a fa head screwdriver  re-is all ier -rig reaiig rig.


59

AiR U-tURn SPRing REMovAl/SERviCE inStRUCtionS (Cont) 18. Re-isall pper seal head  ravel adjsme sha ad apply sspesi il  adjser sha ad ier seal head -rig. 19. Isall chke pis ad secre wih a nE W 10 mm exeral re aiig rig, sig exeral sap rig pliers. 20. Apply sspesi il  bh pis -rigs.

18

19

20

AiR U-tURn SPRing inStAllAtion inStRUCtionS 21. Apply a hi lm  grease  he iside grve  he pe ed  he air sprig be. Iser he pper chke assembly i pe ed  air sprig be, schrader valve rs, ad press cmpleely i air be. 22. usig a lg -meallic dwel, psh assembly p i he air be  il seaed fsh agais he rlled ed  he air be. 23. Hld air be wih pe ed p. Measre ad pr 6cc/ml  15w sspesi il i air be/psiive air chamber,  p   he pper chke assembly. this will lbricae he chke -rig ad psiive air pis -rig whe rk is cmpressed. Se aside air be, prigh, s il des  spill. 24. Re-apply sspesi il  ier seal head rig ad slide egaive air seal head  Dal Air sha, fa ed rs. Slide p  bm  bmper. 25. Re-apply sspesi il  psiive ad egaive air pis -rigs ad iser psiive air pis i pe ed  air sprig. Psh air sha assembly i air be. 26. usig a small fahead screwdriver, press dw  seal head sha sep  sea i  place iside air be. Secre seal head i air be wih reaiig rig, sig ieral sap rig 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 psiive air chamber (40-6 0psi)  esre assembly cmpes are seaed prperly iside air be.

60

95-4015-016-000 REV A

AiR U-tURn SPRing inStAllAtion inStRUCtionS (Cont) 28. Iser air be gide plae i  he ed  air be. Secre ard small seal head grve wih a ew 13 mm exeral reaiig rig, sig exeral sap rig pliers. Veriy reaiig rig is seaed agais gide plae s i  ca mve 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 ed, fa agais ravel sha. Iser Air u-tr assembly i bm  le rk pper be, adjser ed rs. 30. Slide i pper be il pper assembly egages p cap. thread assembly i p cap by hldig he bm  he air sha ad rig Cuer-ccwse il i sps. 31. Iser each dee sprig i p cap dee hles, evely spaced. Place each dee  ball bearig  p  each dee sprig. 32. Place Air u-tr adjser kb  hex sha ed. Secre kb  air sha wi h exeral reaiig rig, sig exeral sap rig pliers. Make sre reaiig rig is isered i  grve,  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 counterclockwise 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!


61

2-StEP AiR SPRing SERviCE (lYRik - totEM)


2-StEP AiR SPRing REMovAl/SERviCE inStRUCtionS 1.

Remve all air pressre rm he sysem by depressig air valve a he b m  he le leg, ad he remve he 2-S ep schrader valve sig 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.

usig a 2 mm hex wrech remve 2-Sep adjser xig screw ad crl kb. usig a 24 mm scke wrech, hread ad remve he 2-Sep p cap. Ispec 2-Sep p cap -rig r damage. Replace i ecessar y. Remve rk rm bicycle sad ad pr ay remaiig il i il pa. Rer rk  bicycle sad. usig exeral sap rig pliers, remve reaiig rig rm he bm  he le pper be. Gely pll dw  he air sha  remve he eire 2-Sep assembly. Remve lwer seal head rm sha assembly ad se aside. Separae he 2-Sep assembly i 3 pars: sha assembly, air be, ad pis  hsig (i rder i picre). 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.

Remve pis rm he IFP pis hsig. Ispec IFP pis hsig r damage r scraches, payig clse aei he iside srace  he IFP pis hsig. I damaged r scrached, replace he IF P pis hsig. 10. Remve pis -rig. Clea pis wih isprpyl alchl. Apply a ew drps  sspesi il  ew -rig ad re-isall. 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. Ispec IFP pis hsig -rig r damage. Replace i ecessary. Re-assemble IFP ad IFP pis hsig. the IFP shld be isered i he hsig wih he -r ig side dw. Press he IFP i  he IFP pis hsig il i bms  cmpleely.

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 isprpyl alchl  he iside ad side  he air  be ad wipe wih a clea rag. Wrap a clea rag ard a lg dwel ad iser i he pper be  clea iside he pper be. Ispec he air be r damage ad scraches . Replace i damaged r scrached ( picred). 13. Rer  lwer seal head. Remve ier ad er lwer seal head -rigs. Apply a ew drps  sspesi il  ew -rigs ad reisall. 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. Remve lwer faig pis rm he air sha assembly. Remve lwer faig pis ier ad er -rigs. Spray lwer faig pis wih isprpyl alchl ad wipe wih a clea rag. Apply a ew drps  sspesi il  ew -rigs ad re-isall. 15. Remve rbber cshi ad sig a fa head screw driver, carelly remve p  sprig assembly rm he air sha. Spray wih isprpyl alchl ad wipe wih a clea rag. 16. usig exeral sap rig pliers, remve he reaiig rig ad wavy sprig washer lcaed  p  he mai pis. 17. Remve he ier ad er pis -rigs. Spray he mai pis wi h isprpyl alchl ad wipe wih a clea rag. Apply a ew drps  sspesi il  ew -rigs ad re-isall.

16

17

2-StEP AiR SPRing inStAllAtion inStRUCtionS 18. Ispec he ace seal -rig, makig sre i is seaed prperly. A prperly seaed -rig will  have ay disri i is shape ( picred). 19. Spray air sha wi h isprpyl alchl ad wipe wih a clea rag. Ispec air sha r damage r scraches. Replace i damaged r scrached ( picred).


6

2-StEP AiR SPRing inStAllAtion inStRUCtionS (Cont) 20. Reassemble mai pis ad kick plae ad isall  air sha. Slide wavy washer  p  mai pis ad secre i place wih sap rig. 21. Isall p  sprig assembly, rbber cshi, ad lwer faig pis  air sha. D  isall lwer seal head a his ime. 22. Isall sha assembly i  air be, air valve rs, i he side ppsie he w hles  he air be. Isall lwer seal head  sha assembly. 23. Measre ad pr 5cc/ml  15w  sspesi il i he p  he air be assembly. 24. Iser he IFP pis  hsig i he air be assembly, beig carel   spill he il already i air be. 25. Iser he 2-Sep assembly i he bm  he pper be. Secre wih re aiig rig.

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. Gely pll dw  air sha  exed  maximm legh. 27. Lyrik oly: Measre ad pr 35cc/ml  2.5w  sspesi il i he p  he pper be. tem oly: Measre ad pr 135cc/ml  2.5w  sspesi 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. Iser p cap i pper be/crw ad had hread i pper be. usig he 2-Sep adjser kb, r he adjser   he mimm ravel seig. Remve he adjser kb ad sig a 24 mm scke wrech, ighe p cap  60 i-lb. 29. Isall 2-S ep adjser kb ad secre xig screw wih a 2 mm hex wr ech. 30. Isall schrader valve i b m  air sha, sig schrader valve l. 31. Add 100psi  he 2-Sep sysem. Rae adjser kb  miimm ravel psii ad cmpress air sha  esre prper ci. Rae adjser kb  ll ravel psii ad veriy rer  ll exesi.

31

this concludes the spring service for your fork .

64

95-4015-016-000 REV A



65

loWER lEg inStAllAtion (All FoRkS)

intRoDUCtion A his pi y shld already have already servised yr rk bshigs, damper sysem, ad sprig sysem. oce y have re-isalled yr rk lwers, y will have sccesslly serv ised yr rk ad y will be ready  ride!

loWER lEg inStAllAtion inStRUCtionS 1.

Spray pper bes wi h isprpyl alchl ad wipe wih a clea rag ( picred). 2. Pr r ijec 15w sspesi il  ew r clea am rigs, js der ds seals iside each lwer leg. 3. Slide lwer leg assembly  he pper bes il y eel he lwer bshig ch he ed  he pper bes.

2

3

4

important: make sure both dust seals slide onto the tubes correctly and do not fold under .

4.

Iver rk  ab 4 5°, rk legs piig pward. Measre ad ijec sspesi il i lwer legs hrgh each sha bl hle, accrdig he bm vlme vales d i he oil Vlme char lcaed i he Ge ig Sared Irmai seci  his maal. Wipe all excess il rm lwer 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.

Ispec ad clea air sprig sha bl s, black yl crsh washers ad crsh wash reaiers. Replace crsh washers ad crsh washer reaiers i damaged ( picred). note : damaged or dirty crush washers can cause oil to leak.

6.

66

Iser rebd damper ad air sprig sha bls i hreaded sha eds,  hrgh lwer leg sha hles ad ighe w ih a 5 mm hex r 10 mm scke wrech  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.

Iser ex eral rebd damper kb i rebd damper sha bl. Psh i il secre. Adjs as desired. 8. Fr air sprig rks, reer  he air char  yr rk ad ifae psi ive ad egaive air chambers  apprpriae psi. Fr cil rks, mve  Sep 9. 9. Spray isprpyl alchl  eire rk ad wipe wih a clea rag ( picred). 10. thread psiive ad egaive air valve cap cvers  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


8

10

6

68

95-4015-016-000 REV A

-RiDE SPRing SERviCE


69

-RiDE SPRing SERviCE intRoDUCtion t maiai he high perr mace, saey, ad lg lie  yr i-Ride rk , peridic maieace is reqired. I y ride i exreme cdiis, maieace shld be perrmed mre reqely.

SERviCE inStRUCtionS remove

1. 2. 3.

4. 5.

-ride

fork from the bike (not pictured)

Remve he r wheel. Remve he r brake. -Rde: usig a 5 mm hex, remve he headse bl,  he remve he headse cap. -Rde w M10 sar u : usig a 8 mm hex, remve he headse bl, he remve he headse cap. Lse he sem bl(s) ad remve he sem wih he hadlebar iac. Carelly pll he rk dw   he headbe. Reai spacers ad headse pars as y g.

a b

c

d

e

f

g

h

i

j

k

l

disassemble steerer assembly

6.

Wih  he r side  he i-Ride rk acig y, lcae he p  he seerer be ad wrie he wrd 'r '  he seerer be i permae marker. 7. usig eiher a 14 mm scke  he ed  a scke exesi r a lg 6 mm hex, lse ad remve he reaiig . Iver he rk ad le he lck washer all i yr had.

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 .

-Rde w M10 sar u : usig a lg 6 mm hex hrgh he ceer  he sar , lse he reaiig . usig a pick, pll he lck washer   he hreaded iser.

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 .

-Rde: Clea he reaiig  wih isprpyl alchl ad wipe wih a clea rag. Apply ble hreadlck (Lcie 244 0)  he hreads per maacrer's isrcis ( picred). this will allw ime r he  hreadlck  dry. 9. Carelly c he zip  ie secrig he b  he er seerer, ad pll he bm  he b ver he lwer leg crw fage. 8.

7

9

i- ride with m10 star nut

0

95-4015-016-000 REV A

SERviCE inStRUCtionS (Cont) 10. Pll he er seerer pwards il i clears he ier seerer ad remve.

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. Remve he b ad he b m  bmper. remove coil spring, clean and lubricate

12. usig a clh  prec he palm  yr had, cmpress he cil sprig by pressig dw  he hreaded hreaded iser. I is  ecessary ecessary  lly cmpress he sprig, js press egh  relieve pressre  he reaiig c-clip.

14

note : you may want may want to place the fork between your feet to stabilize the fork during this process.

13. usig sap rig pliers while he sprig is cmpressed, remve he reaiig c-clip rm wihi he ier seerer. seerer. the sprig assembly assembly will decmpress ad rise   he ier seerer. 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. Separae he cmpressi washer, p  sprig, cmpressi sha, p sprig gide, ad cmpressi sprig. 15. Lcae he derside derside  he rk crw. usig a lg, 7 mm (1/4”) diameer dwel psh he b m sprig gide   he ier seerer. 16. Spray all pars wi h isprpyl alchl ad wipe wih a clea rag. Ispec all pars r wear ( picred). 17. Geersly apply grease  cmpressi ad p  sprigs. 18. Iser he sprig gides i he cmpressi sprig. Slide he cmpressi cmpressi sprig assembly assembly i he ier s eerer. 19. Slide he p-  sprig, washer, ad c-clip ver he cmpressi cmpressi sha assembly. Slide he cmpressi sha assembly i ier seerer. 20. usig a clh  prec he palm  yr had, cmpress he cmpressi sprig by pressig dw  he hreaded hreaded iser iser . usig sap sap rig pliers, re-isall 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 .


1

SERviCE inStRUCtionS inspect, clean , and grease steerer assembly

21

23 11

24 11

25

outer steerer

21. Spray isprpyl alchl iside he er s eerer. Wrap a clea rag ard a dwel ad clea he iside  he er s eerer. 22. Ispec he bshigs ad iside seerer srace r excessive wear. ( picred) 23. usig a grease brsh, apply a medim ca  grease (Maxima SG-920)   he bshigs ad ad D-sl fas. inner steerer

24. Spray isprpyl alchl  he iside ad side  he ier seerer be. Wrap a clea clea rag ard a dwel ad clea he iside  he ier seerer. Clea he side  he ier ier seerer be wih a rag. 25. Spray isprpyl alchl alchl  he bm-  bmper ad clea clea wih a rag. Ispec he b m- bmper r damage ad replace i ecessary ( picred). 26. Ispec he seerer sr ace r excessive wear ( picred). 27. Re-isall he b m  bmper by slidig i  he base  he seerer. 28. usig a grease brsh, apply a liberal caig   grease (Maxima SG-920)   he ier seerer.

28

29

boot

29. Clea he b wih sapy waer. Ispec r cs r damage, ad 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 seerer s he wrd ‘ r’ is acig y. Slide he er er seerer ver he ier seerer, wachig hrgh he p r he hreaded iser  alig ad pass hrgh he baseplae. Wipe  ay excess excess grease. grease. tip : use the pick to guide the threaded insert through the baseplate if necessary.

31. We a small pach  a clea clh wih isprpyl alchl. usig a dwel rd  wrk he clh i he s eerer  clea ay grease rm he hreaded iser ( picred). 32. usig a 6 mm hex, psii  he lck washer ad reaiig   he hreaded iser. -Rde w M10 sar u : usig a pick r 6 mm hex wrech, alig he lck washer ver he hreaded iser as y brig he seerers i psii ad psii he reaiig   p  he hreaded iser iser.. Pass a lg 6 mm hex hrgh he ceer  he sar  ad ighe he reaiig . D  ver ighe.

2

30

32

i-ride with ride with m10 star nut

95-4015-016-000 95-4015-016-000 REV A

SERviCE inStRUCtionS 33. usig a rqe wrech wih a 14 mm scke exesi ighe he reaiig   120i-lb (13.6 nm). 34. Place he p  he b ver he fage  he er seerer 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. Pll he bm   he b ver he lwer leg crw fage, he alig a zip ie i he grve a he p  he b s ha he aseer is i he middle  he fa ch  he  p b fage. tighe he zip  ie  he back  he b ad c  he excess. 36. Check he ci  he rk. Re-isall rk ad brake caliper accrdig  maacrer's isrcis ( picred).


flat notch



4

95-4015-016-000 REV A

REAR ShoCk SERviCE


5

toolS nEEDED FoR SERviCE (REAR ShoCkS) the llwig char is a lis  he mdel year 2008 ls eeded r service  yr RckShx rear shck. While his char is ieded  be cmprehesive, i is sill ly a gide. the ls reqired r each sep  service are deailed i he ex  each service seci. Keep i mid yr specic shck may  reqire every l lised. ARio - BAR MC - PEARl

Marc

vd

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 Prir  ser vicig yr rear shck, y will rs  eed  remve i rm yr bicycle rame accrdig  yr bicycle maacre's isrcis. oce yr shck is  yr bicycle, be sre  remve he shck m hardware.

AiR CAn REMovAl/SERviCE inStRUCtionS getting started

usig eiher yr gers r a pair  pliers, be sre  remve shck mig hardware. Spray isprpyl alchl  eire shck ad wipe wih a clea rag ( picred). air can removal

1.

Remve air valve cver cap. usig a small hex wrech r pick, depress schrader valve ad release all air rm shck. use a Schrader valve l  remve he valve cre. important: to avoid injury, all air pressure must be released from shock prior to removing the air can .

2.

1

2

3

4

5

Gely secre air ca shck eyele i bech vise. note : use aluminum vise " soft- jaws " to protect the shock eyelet when clamped .

3.

Grip he air ca by had ad r rmly cerclckwise. Pll he air ca p shck damper bdy slwly  remve. note : air pressure may release , so hold air can tightly while pulling up.

4.

Remve egaive sprig spacer ad egaive sprig bmper. Spray bh wih isprpyl alchl ad wipe wih a clea rag. important: do not attempt to disassemble shock damper and / or shock eyelet assembly. they are not serviceable .

5. 6.

usig a sharp pick, remve he black rbber ds seal rm he air ca. Hld air ca, arrw ed dw ad remve ble air ca glide rig wih a sharp pick. important: do not scratch the inside of the air can with pick . scratches can cause permanent air bypass .

7.

Spray isprpyl alchl iside air ca ad wipe wih a clea rag. Ispec he iside  he air ca r ay rgh sraces r scraches. R yr ger alg he iside srace  he air ca  eel r rgh sraces r scraches as well. Replace air ca i scrached r damaged ( picred).


6



AiR CAn REMovAl/SERviCE inStRUCtionS 8.

Remve large xed air pis -rig. Apply a ew drps  sspesi il  ew -rig ad re-isall.

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.

Isall ew air ca glide rig ad ew air ca ds seal. 10. Spray isprpyl alchl  air ca hreads ad eyele bdy hreads ad wipe wih a clea rag ( picred). 11. Apply 2-3 drps   ble hreadlck  eyele bdy hreads, evely spaced. Spread evely  hreads ad wipe away excess hreadlck wih a clea rag. 12. Apply a small am  5w  sspesi il  he iside  he air ca. usig yr ger, spread ad ca he eire ier air ca srace wih he il. Re-apply a ew drps  sspesi il  he glide rig ad rbber ds 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. Isall egaive sprig bmper ad egaive sprig spacer. 14. Psii air ca ver shck eyele ad slide dw  shck bdy. Press air ca dw rmly ad hread clckwise  ighe i eyele bdy as ighly as pssible by had. 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-isall  he valve cre. ( picred) 16. usig a shck pmp, ifae shck  desired air pressre ad isall valve cver cap ( picred). 17. Spray isprpyl alchl  eire shck ad wipe wih a clea rag ( picred). 18. Iser mig hardware i bh eyeles ( picred). 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)


SERviCE inStRUCtionS getting started

usig eiher yr gers r a pair  pliers, be sre  remve shck mig hardware ( picred). Place a il pa  he fr dereah he area  he shck. Place a large il absrbig rag direcly dereah he vise where  he shck will be clamped  cach all il ha will spill rm he shck drig service ( picred). tr Rebd Adjser lly cer-clckwise, ward he rabbi. Swich Gae (i applicable)  he ll pe, lcked, psii.

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air can removal

1. 2.

Remve swivel air valve cap. usig a pick, depressrize air ca by depressig valve. usig a Schrader valve l, remve i rge pr cap. usig a pick, depressrize irge by depressig valve. usig Schrader valve l, remve he irge valve cre. important: to avoid injury, all air and nitrogen pressure must be released from shock prior to servicing.

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Secre shck sideways, by air ca sha eyele, i bech vise. note : use aluminum vise " soft- jaws " to protect the shaft eyelet when clamped .

4.

Grip air ca ad r cer-clckwise  hread. Remve 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 .

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Remve he egaive sprig bmper r m iside he air ca. shaft assembly service

6.

Secre bdy eyele i vise. note : use aluminum vise " soft- jaws " to protect the body eyelet when clamped .


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SERviCE inStRUCtionS 7.

usig a 2 mm hex, hread ad remve bleed screw.

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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.

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usig a adjsable wrech, lse ad remve sha assembly rm shck bdy. note : oil will spill from the shock body and / or shaft assembly.

9.

Hld he sha eyele wih e had, ad psh seal head ward air ca cap wih yr  her had  expse bleed hle  derside  seal head. note : be careful not to pinch your fingers as you slide the seal head .

10. usig a pick, psh ad remve he whie cmpressi ball   he backside  seal head hrgh bleed hle. 11. Spray eire sha assembly wih isprpyl alchl ad wipe wih a clea rag ( picred). 12. usig a pick, remve seal head er glide r ig ad er seal. usig a pick remve pis glide rig. Apply a small am  grease  ew seal head er glide rig ad er seal ad pis glide rig ad re-isall.

seal head outer glide ring

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seal head outer seal

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ifp and shock body service

13. Remve shck bdy rm vise, ad pr remaiig il i il pa. 14. Wrap a rag ard ed  shck bdy, iser air cmpressr chck i irge ll hle, ad rce air i bdy  remve 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 isprpyl alchl  he iside ad side  shck bdy ad wipe wih a clea rag. Ispec he iside  he shck bdy r scraches. ( picred) 16. Spray IFP wih isprpyl alchl ad wipe wih a clea rag. usig a pick, carelly remve IFP -rig. Apply a small am  grease  ew -rig ad re-isall. 17. usig a gage l, iser IFP i shck bdy wih he sepped side visible. Se IFP heigh  vale idicaed i he able belw.

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important: measure ifp height from the bottom of the step on the ifp.

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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. usig a Schrader valve cre l, isall irge valve. 19. Clamp shck by sha eyele back i vise. 20. Pr ew il il i is level wih he p  he shck bdy. 21. Slide seal head dw agais pis.

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note : be sure gate is in full open (unlocked) position.

22. usig a 1.5 mm hex wr ech, depress he ppe valve a he bm  sha assembly. this will esre il ery  he sha. note : the popet should not remain open .

23. Hldig  he seal head, place i  he shck bdy. thread sha assembly   shck bdy. 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. usig a rqe wrech wih crw's , rqe sha assembly  250 i/lb. important: install crow 's foot at

90°

to torque

wrench

25. Iser ew whie cmpressi ball i bleed hle. 26. usig a 2.5 mm hex, gely hread bleed screw i bleed hle il y eel i ch he whie cmpressi ball. tighe a addiial ½ r. 27. Spray assembly wih isprpyl alchl ad wipe wih a clea rag ( picred). 28. Remve shck rm vise. usig a gaged pmp, pressrize shck bdy  250-300psi. usig a Schrader valve l  re-isall irge pr cap. 29. usig a pick, remve ier al glide rig  air ca. Apply a small am  grease  ew glide rig ad re-isall. 30. Grease he seal head er glide rig,  er seal, ad egaive sprig bmper ( picred). 31. Slide egaive sprig bmper, chamered side rs,  shck bdy. 32. Re-clamp shck by sha eyele ad isall air ca, wis clckwise while pshig. 33. Isall red ravel idicar -rig. ( picred) 34. Isall swivel air valve cap. ( picred)

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REAR ShoCk SERviCE (viviD)


SERviCE inStRUCtionS getting started (not pictured)

eXploded view

usig eiher yr gers r a pair  pliers, be sre  remve shck mig hardware.

b

a

- vivid rear shock assembly

d

c

e

f

Place a il pa  he fr dereah he area  he shck. Place a large il absrbig rag direcly dereah he vise where  he shck will be clamped  cach all il ha will spill rm he shck drig service.

h

Recrd he adjsme seigs r ps-service se-p. tr he Begiig Srke Rebd ad Edig Srke Rebd adjsmes  he ll pe psii, ward he rabbi. tr he Lw Speed Cmpressi adjsme  he  ll clsed psii, ward he rle.

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

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ifp resevoir

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3

spring removal

1. 2.

tr pre-lad cllar cer-clckwise il i  sps. Remve sprig reaier, sprig ad drp sp. Se aside pars  il Shck Bleed & Reassembly seci.

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 shck by bdy eyele i vise. note : use aluminum vise " soft jaws " to protect the shaft eyelet when clamped .

4.

usig a t-10 trx, remve he I FP cap rm  he IFP reser vir ad discharge air by depressig he valve. usig a Schrader valve l, remve he Schrader valve cre.

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5 hold pin spanner in place

important: be sure to completely discharge the ifp reservoir to avoid personal injury during disassembly .

5.

usig he RckShx 24 mm pi spaer, 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.

82

95-4015-016-000 REV A

SERviCE inStRUCtionS (Cont) 6.

Pll p  seal head ad remve eire sha assembly.

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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.

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usig yr gers, remve ier be rm shck bdy. Remve shck rm vise ad pr all il rm shck i il pa ( picred). Crm ha he ceerig rig, lcaed i he bm  he shck bdy, is sill i place ( picred). 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 shck bdy ver pick. usig he pick as a hk, gely cach he bm  he ceerig rig ad pll back  he shck bdy  disldge he ceerig rig. Y may have  hk he pick ard he ceerig rig i several places i rder  disldge. important: do not to scratch the bottom of the shock body with the pick ; this is the sealing surface.

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damage to this surface will interfere with the performance of the shock.

shock body shaft assembly service

11. Spray sha assembly wi h isprpyl alchl ad wipe wih a clea li-ree rag ( picred). 12. usig he RckShx 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. usig a pick, remve glide rig  he mai pis. Apply a small am  grease  ew glide rig ad re-isall. 14. usig a 13 mm wrech, hread pis bl. Carelly remve mai pis assembly (pis bl, mai pis, ad shim sack washers), keepig all pars geher ad se aside. 15. Firmly pll p  seal head ad remve. 16. usig a pick, remve he sha w iper seal ad mai sha -rig lcaed i he ierir  he seal head. Remve he qad rig p  pad lcaed  he backside  he side head. Apply a small am  grease  ew sha wiper seal, mai sha -rig ad qad rig p  pad ad re-isall. 17. Ispec he bdy seal -rig lcaed  he derside lip  he seal head r wear r damage. Replace i ecessar y. 18. Se aside seal head ad mai pis assembly ( picred).


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SERviCE inStRUCtionS (Cont) 19. Flip sha assembly i sha clamp s sha eyele is accessible. usig 13 mm wrech, hread he eyele ad remve. 20. Clea Lcie rm hreads  sha eyele ( picred). 21. usig a pick, carelly psh  he red Begiig Srke Rebd Adjser kb   he sha  eyele.

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note : the beginning stroke rebound adjuster knob houses the detent ball and spring . be careful not to lose these parts.

22. usig a pick, remve he Begiig Srke Rebd Adjser kb -rig. Apply a small am  grease  ew -rig ad re-isall. 23. usig a cresce wrech, hread he rebd eedle ad remve. important: be very careful not to damage the heX on the rebound needle with the crescent wrench.

24. usig a pick, remve he rebd eedle -rig. Apply a small am  grease  ew -r ig ad re-isall. Se aside rebd eedle. 25. Carelly iser dee sprig llwed by dee ball i  he se hle i he sha eyele. Slide rebd kb, wih dee eares ieracig wih  he dee ball, back i sha eyele. Se aside sha eyele. 26. Flip sha assembly i sha  clamp s rebd bleed pr is accessible. Grease ierir  seal head ad isall  sha assembly wi h seal head hreads rieed p ward y. important: make sure the shaft wiper seal does not fold over when installing seal head.

27. usig a 13 mm wrech, hread pis assembly back  sha assembly ad rqe  70 i-lbs. 28. Flip sha assembly i sha clamp s sha eyele hreads are expsed. While pshig dw, hread rebd eedle i sha by had il i sps. 29. Clea sha assembly hreads wih alchl. Place a cple  drps  red Lcie  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 wih alchl ( picred). 31. Hldig 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.

Aer apprximaely 4 ll rs, y will hear a adible clickig sd, idicaig he rebd eedle has egaged he adjser k b. Cie  hread sha eyele assembly by had il igh. usig a 13 mm wrech  130 i-lbs.

84

95-4015-016-000 REV A

SERviCE inStRUCtionS (Cont) 32. Remve sha assembly rm vise ad se aside il Shck Bleed & Reassembly seci ( picred).

33

34

35

36

37

ifp reservoir & low speed compression valve service ifp reservoir service

33. Clamp shck bdy by he bdy eyele i vise. usig a 30 mm fa wrech a he base  IFP reservir ( keep he reser vir rm spiig) ad a 24 mm pi spaer wrech  he p  he reservir, hread he IF P seal head cap ad remve. 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. Ispec IFP seal head -rig  r damage. Replace i ecessary. 35. usig a 30 mm fa w rech a he base  he IFP reservir, hread ad remve he IFP reservir. 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. usig yr ger, psh he IFP   he IFP reservir rm  he backside. 37. usig a pick, remve ble glide rig ad mai seal -rig rm he IFP. Apply a small am  grease  ew glide rig ad -rig ad reisall. 38. usig a t-10 trx, remve IFP bleed screw. usig a pick, remve IFP bleed screw -rig. Apply a small am  grease  ew -r ig ad re-isall. 39. Se aside IFP reservir, IFP, ad IFP bleed screw il Shck Bleed & Reassembly seci ( picred).

38

40

41

42

43

low speed compression valve service

40. usig a 2 mm hex, remve he lw speed cmpressi kb. tip : you do not need to completely remove the retaining screw to remove the knob.

41. Sqeeze he Lw Speed C mpressi valve assembly bewee yr gers, ad carelly psh i p ad    he bdy side IFP reservir. 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. Ispec bdy side IFP reservir -rig r damage. Apply grease  ew -rig ad replace i ecessary. 43. Separae ier kb ad dee ball ad sprig, rm Lw Speed Cmpressi valve assembly. Slide shim check sprig  valve assembly.


85

SERviCE inStRUCtionS (Cont) 44. usig yr gers, hread cmpressi eedle rm he back  he Lw Speed Cmpressi valve assembly. 45. Ispec check shim r damage ad 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. Remve he Lw Speed Cmpressi valve mai -rig, cmpressi pis -rig, ad cmpressi eedle -rig. Apply grease  ew mai, cmpressi, ad eedle -rigs ad re-isall. 47. Remve shck rm vise ad pr  ay remaiig il. Clamp shck by bdy eyele back i vise ( picred). 48. usig yr gers, hread cmpressi eedle back i Lw Speed C mpressi valve assembly. 49. Slide shim check sprig  assembly. usig a dab  grease  hld pars  geher, iser dee sprig llwed by dee ball i ier kb. 50. Isall ier kb   cmpressi eedle ad hld eire assembly geher by sqeezig i bewee yr gers. 51. Carelly iser lw speed cmpressi valve assembly i shck bdy, ier kb rs.

48

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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. Had hread IFP reservir  shck bdy il i is igh. important: make sure there is no gap between the ifp reservoir and shock body.

53. usig a 2 mm hex, re-is all lw speed cmpressi kb. ending stroke rebound service

54. Clamp shck i vise sideways by bdy eyele s he Edig S rke Rebd adjser is easily accessible. usig a 2.5 mm hex, r he Edig Srke Rebd adjser 5 clicks rm lly pe. 55. usig a pick, remve Edig Srke Rebd reaiig rig.

86

54

55

95-4015-016-000 REV A

SERviCE inStRUCtionS (Cont) 56. usig a 2.5 mm hex hread he Edig Srke Rebd adjser screw ad remve.

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. Remve Edig Srke Rebd adjser screw -rig. Apply grease  ew -rig ad reisall. 58. Replace rebd shims. 59. usig a dab  grease  hld pars ge her, sack he 6 mm shim (arrw shim)  rebd plg, llwed by 7 mm shim (wider shim). Carelly drp rebd plg, shims rs, i rebd hle. Iser High Speed Rebd cil sprig  p  rebd plg.

58

6 mm shim

tip : gently seat the rebound plug into place with a pick .

60. Grease Edig Srke Rebd adjser screw. Iser dee sprig i hle, llwed by dee balls i hles  eiher side. use a dab  grease  keep he dee balls i place. 61. Carelly iser Edig Sr ke Rebd adjser screw i Edig Srke Rebd hsig. usig a 2.5 mm hex, hread il i sps. All pars are prperly seaed whe y hear 'clickig' sds.

59

7 mm shim

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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. usig yr gers, re-isall Edig Srke Rebd reaiig rig. 63. usig a 2.5 mm hex, r he Edig Sr ke Rebd adjser lly cer-clckwise, ward he rabbi  esre he re aiig rig is lly seaed. shock bleed & re -assembly procedures

64. Clamp shck by bdy eyele s he shck bdy ad IFP reser vir are accessible. 65. Grease he -rig grve  he Ceerig Rig ad re-isall he  ace seal -rig, smhig grease ver he -rig  keep i i place. usig he ier be as a psh rd, press he Ceerig Rig, -rig side dw, i he bm  he shck bdy. 66. usig a 2.5 mm hex, esre he Edig Srke Rebd Adjser is red lly cerclckwise, ward he rabbi ( picred). 67. 5.1 onLY: tr he Lw Speed Cmpressi Kb lly cer-clckwise, away rm “+” sig ( picred).


8

SERviCE inStRUCtionS (Cont) 68. usig 3w il (r high grade 2.5w), ll he IFP reservir  he p. oil will gradally fw rm he IFP reser vir i he shck bdy hrgh he small pr lcaed a he bm  he IFP reservir. Cie  ll IFP reservir il he il level i he shck bdy reaches apprximaely 25 mm i deph. 69. Begi he reverse prcess  prig il i he shck bdy. Cie il il sar s  verfw   he IFP reservir. this prcedre eec ively disldges air bbbles rm he sysem. tp   he il i he shck bdy i rder  cie il fw rm  he shck bdy  he IFP reservir. 70. Gely slide he IFP, sep side dw,  p  he IFP reservir. Le he IFP 'fa'  p  he il i IFP reser vir. 71. Cver he bleed hle  he IFP wih yr hmb  creae a seal ad rmly psh he IFP dw i he IFP reser vir apprximaely 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. tp  he il i he shck bdy agai i rder  cie il fw rm he shck bdy   he IFP reservir.

72

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74

75

76

77

important: wait for the oil to overflow from the ifp reservoir before continuing.

73. usig he t-10 trx, isall he IFP bleed screw. tighe il he IFP spis. 74. usig he t-10 trx as a psh rd, rmly psh he IFP dw i IFP reservir il i sps, apprximaely 45.5 mm rm  p  IFP reservir. 75. Iser he shck bdy ier be i  he shck bdy wih he crss hles p ward  he peig. important: it is critical that the cross holes are facing up toward the shock body opening.

76. Gely wiggle he ier be side  side agais he shck bdy wih yr ger  disldge ay air bbbles bewee he w walls. 77. tp  il i he shck bdy e las ime. 78. Sea he seal head lly agais he pis  he sha assembly. Place he pis i il  p  he shck bdy a a 4 5 degree agle. Rae he sha  assembly 2-3 imes  cver he pis assembly i il. Cie  rae he sha assembly as y alig i ver ically, ad gely iser he assembly i he shck bdy. this prcess miimizes rapped air drig he assembly prcess.

88

cross holes

78

95-4015-016-000 REV A

SERviCE inStRUCtionS (Cont) 79. Hld he sha assembly by he seal head ad swy hread he seal head  he shck wih yr gers. trapped air ad il shld 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. Cie  hread he seal head dw il  he seal head -rig is egaged. usig he 24 mm pi spaer l, rqe 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. Remve he shck rm he vise ad pr  ay excess il ha is remaiig abve he IFP. important: failure to remove this eXcess oil will reduce the ifp volume and limit shock travel .

82. Clamp he shck back i he v ise a he Bdy Eyele ad isall he IF P reservir seal head. usig he 24 mm pi spaer l, rqe  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. Isall he Vi vid air adaper  a gaged pmp, ad charge he IFP chamber : Shck Mdel

Pressre

Vivid 5.1

200psi (13.8 bar)

Vivid 4.1

230psi (15.9 bar)

84. usig a t-10 trx®, isall he IFP ed cap   he reservir. 85. Spray he eire shck wih alchl ad wipe clea wih a li r ee rag ( picred).


89

90

95-4015-016-000 REV A

CoPYRight All ce iclded i his caalg, icldig b  limied  ex, graphics r images is cpyrighed as a cllecive wrk der he uied Saes ad her cpyrigh laws, ad is he prpery  SRAM Crprai. Cpyrigh 2007, SRAM Crprai. ALL RIGHtS RESERVED. Ay her se, icldig b  limied  he reprdci, disribi, display r rasmissi  his ce  his caalg is sricly prhibied. oher ames  prdcs ad cmpaies meied i his caalg may be he rademarks  heir respecive wers. All irmai ad specicais i his caalg are sbjec  chage wih ice. the llwig are rademarks r regisered rademarks  SRAM Crprai i he uied Saes ad her cries: SRAM, RckShx, Avid, trvaiv, 1:1, Grip Shi, trped, u-tr, Bar, BXXer, Pike, SID, Reba, BlackBx, Climb I Crl, tlli, Jicy, Sigle Digi, Speed Dial, Arch Rival, Black ops, Flak Jacke, Fll Meal Jacke, Hsseel, Hlzeller, Lalarm, Syl, Firex, IsFlw, tr, Giga Pipe, FiveD, Isis Drive (desig), Wav, X.0, X.9, X.7, 5.0, 4.0, 3.0, SX4, SX5, 1:1 Acai Rai, tRX, Aack, Rcke, SRAM Rcke, Ceera, MRX, PwerChai, PwerGlide, PwerLik, PwerLck, SalShaker, Implse techlgy, thmbs up, Zer Lss travel, C3 Cmpsie, Zer Lss travel, Cable Cradle, SraighSh, ui-Lever, Qick View, i-LIGHt, i-BRAKE, i-MotIon, i-MotIon 3, i-MotIon 9, Sparc, S7, P5, t3, DalDrive, twiDrive, Badix, Frce, Rival, Dbletap, HCt, oCt, Exac Acai, Missi Crl, 2-Sep, Maxle, Maxle 360, Sl Air, Dal Air, trKey, IsLie, IsLie Cshi, Air u-tr, Rear Maxle, PpLc, PpLc Dal, PpLc Adjs, PshLc, Ari, Pearl, MC, Argyle, Dmai, tem, Lyrik, revelai, Rec, tra, Dar, Cde, ulimae, Shry, Frce Vecr Aligme, BB5, BB7, FR5, Bxgide, Shigide, Egieerig he shi, XR, team, LE, 3D, XR 3D, team 3D, Rler, team BMX, Racig XR, Racig team, Racig Jir, Rki, nir, Blaze, 5D, X-Flw, Elia, Pwer Splie, GXP, Giga X Pipe, ISIS, overdrive, Sqare LE, Hwizer, Beyd Perrmace ad Ivaive Bicycle Cmpes.

WoRlD hEADQUARtERS SRAM Crprai 1333 n. Kigsbry, 4h Flr Chicag, Illiis 60622 uied Saes  America Phe: +1-312-664-8800 Fax: +1-312-664-8826 E-mail: sram[email protected]m ASiAn hEADQUARtERS SRAM taiwa n. 1598-8 Chg Sha Rad She Kag Hsiag, taichg Cy 429 taiwa R.o.C. Phe: +886-4-2561-3678 Fax: +886-4-2561-3686 E-mail: [email protected]m EURoPEAn hEADQUARtERS SRAM Erpe Basicweg 12-D 3821 BR Amersr the neherlads Phe: +31-33-450-6060 Fax: +31-33-457-0200 E-mail: sramer[email protected]m


91

Rockshox Service Manuals 2009

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