2005 RockShox Wartungshandbuch

2005
S USPENSION T ECHNICAL M ANUAL

(ENGLISH)
PART# 95.4309.921.000, REV. A
For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com. Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at www.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others. SRAM Corporation August 2004 PN 95.4309.884.000, Rev. A
2004-2005 JUDY TT/C/XC/SL SERVICE GUIDE
2004-2005 Judy TT/C//XC/SL Service Guide

Perform service every 100 hours of riding (less depending on riding conditions and riding style). Regular maintenance ensures your fork performs as it should. For bushing removal and installation, please reference the Bushing Service Guide. Right side equals riders right; left side equals riders left.
G E T T I N G S TA R T E D
1. 2. 3. 4. Remove fork from bicycle. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes. Lay tools out on work bench, and provide a clean work area for internals service. Place oil pan under fork on floor.
TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand/Clean Work Table/Area 24mm 6-point Socket Plastic-Faced Mallet 6mm and 2mm hex wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe and Measuring cup 5wt Suspension Oil Isopropyl Alcohol (in Spray Bottle) Judy Butter/Grease
L O W E R L E G / I N T E R N A L S R E M O VA L
1. Clamp fork steerer tube into bicycle stand clamp. 2. Using a 6mm hex wrench, loosen both shaft bolts three to four turns or half way.
3. With hex wrench in shaft bolt, tap right shaft bolt free with plastic mallet. This frees the shaft end from lower leg shaft bore press-fit, and allows lower leg to be removed from upper tubes.
SRAM Corporation 2004-2005 JUDY SERVICE GUIDE
2004-2005 Judy TT/C/XC/SL Service Guide

4. Using your fingers, remove shaft bolts from both threaded shaft ends. Judy XC/SL: Damping oil is inside the right fork leg. When shaft bolt is removed, oil will drain. Place oil pan directly under the fork. 5. Firmly pull/slide lower leg assembly down by holding each leg or the brake arch (fig 5). Spray isopropyl alcohol into each leg. Wrap a clean rag around long dowel and clean inside of each lower leg, as well as both dust seals.
6. If dust seals are worn, replace with current SID/Pilot dust seals (11.4307.250.000). Using a rag, wipe dust seals clean. Spray both upper tubes and crown with isopropyl alcohol; wipe clean. Apply fresh
grease to underside of the dust seal for lubrication (fig 6).
I N T E R N A L S : R E M O VA L
7. Judy SL U-Turn: Using a 2mm hex wrench, remove U-Turn knob screw. Lift and remove U-Turn adjuster knob. Using a magnet, remove the detent ball bearings and springs from top cap.
7a
7b
7c
8. Using a 24mm socket wrench, loosen and remove both the preload adjuster top cap (TT/C/ XC) and non-adjust top cap (all Judys). Judy SL: Loosen U-Turn spring top cap. The spring is attached to the top cap and spring shaft. Pull and lift entire spring assembly from upper tube. IMPORTANT! PRESS
DOWN FIRM WHEN LOOSENING TOP CAPS.
8a
8b
8c
8d
PN 95.4309.884.000, Rev. A

9. Remove both shaft bottom-out bumpers (fg 10a). Push the spring shaft, from the bottom, up about an inch (fig 10b). Remove the spring and spacer from upper tube (fig 10c). Wipe spring and spacer(s) with a clean rag.
9a
9b
9c
10. Remove fork from bicycle stand. Turn fork upside down, over work bench area. Compression shaft will slide down and out of upper tube. Remove spring shaft and set aside. You may need to insert a long thin dowel into right (damper) upper tube shaft guide to push rebound damper through and out of upper tube.
10a
10b
11. Wipe both shaft assemblies clean with a rag. Spray with isopropyl alcohol and wipe clean. Set parts aside. 12. Clamp steerer tube back into bicycle stand. 13. Spray isopropyl alcohol into each upper tube. Wrap a clean rag around a long dowel. Insert into each upper tube and wipe inside of upper tubes clean. 14. Spray all 'loose' parts with isopropyl alcohol and clean with a rag.
I N T E R N A L S : I N S TA L L AT I O N
REBOUND DAMPER: ALL FORKS
15. Insert the rebound shaft back into right-side upper tube, through the crown (fig 15a). Push down with long thin dowel if needed. You may need to align the end of the threaded shaft, through the center of the upper tube shaft guide, with your finger or a small hex wrench. Align and seat the spring shaft through shaft guide (fig 15b).
15a
15b
S P R I N G A S S E M B LY: J U D Y T T / C / X C
16. Repeat procedure for spring shaft assembly; left upper tube. 17. Apply grease to outside of entire coil spring (fig 17a). Insert spring into left upper tube through crown (fig 17b). The coil spring will rest on the spring shaft assembly inside upper tube.
17a
17b

S P R I N G A S S E M B LY: J U D Y S L
18. Apply grease to outside of entire coil spring and spring isolators (fig 18a). Insert spring assembly into left upper tube, through crown (fig 18b). Align and seat spring shaft through shaft guide.
18a
18b
19. Using your fingers, press down on U-Turn spring assembly top cap and hand-thread top cap into upper tube. Using a 24mm socket wrench, tighten top cap to 60 in-lb.
19
20. Insert each detent spring into top cap detent holes, evenly spaced. Place each detent ball bearing on top of each detent spring (fig 20a). Place UTurn adjuster knob on top of hex. Secure with knob screw. Tighten screw with 2mm hex wrench (fig 20b).
20a
20b
L O W E R L E G I N S TA L L AT I O N
21. Wipe upper tubes with clean rag. 22. Slide lower leg assembly over and onto the ends of each upper tube. Make sure both dust seals slide onto the tubes correctly and dust seals do not fold under.
22
PN 95.4309.884.000, Rev. A

23. Slide lower leg up onto upper tubes and align threaded shaft ends with shaft holes at bottom of lower leg. You may need to use a thin hex wrench or screwdriver to align the shaft ends. The threaded shaft end should appear in the center of shaft hole (fig 23a). Hand-thread the spring side (left) shaft bolt into threaded shaft end, through lower leg shaft hole. Using a 6mm hex wrench, tighten to 60 in-lb (fig 23b)
23a
23b
24. Insert long thin dowel through right-side of the crown, into upper tube. Hold down on dowel to firmly seat rebound/shaft assembly into bottom of upper tube (fig 24a). Hand-thread the rebound side (right) shaft bolt into threaded shaft end, through the lower leg shaft hole. This secures the damper shaft into bottom of lower leg while threading the shaft bolt (fig 24b). Using a 5mm hex wrench, tighten to 60 in-lb. Remove dowel.
24a
24b
25. Wipe lower leg and shaft bolts with clean rag. JUDY TT
AND
C,
SKIP TO STEP
27.
OIL FILL
26. Judy XC/SL only: Measure and pour RockShox 5wt suspension oil into right-side upper tube, through crown.
26
Judy XC 80mm Judy XC 100mm Judy SL U-Turn
100cc/ml 130cc/ml 150cc/ml
27. Apply a light coat of grease to non-adjust top cap threads and o-ring. Insert into upper tube/crown and hand thread (fig 27a). Using a 24mm socket wrench, tighten to 40 in-lb (fig 27b).
27a
27b
28. Spray entire fork with isopropyl alcohol and clean with a clean rag.
TUNING COIL SPRINGS

JUDY TT/C/XC Rider Weight (approximate)
<140lb (63kg) * > 140lb (63kg)
PART #
11.4308.640.000 (Soft) *11.4308.294.000 (Standard)
*Add tuning bumper to increase spring rate. (11.4306.171.000, Tuning Bumper Kit)
JUDY SL U-TURN Rider Weight (approximate)

<140 lbs (63 kg) 140-170 lbs (63 to 85 kg) >180 lbs (80 kg)
PART #
11.4308.292.001 (Soft) 11.4308.292.000 (Standard) 11.4308.292.003 (Firm)
TROUBLE-SHOOTING
DECREASE OR LOSS OF SMOOTH COMPRESSION STROKE
Fork upper tubes are dry or dirty. Disassemble, clean and regrease.
F O R K ' B O T TO M S - O U T ' E A S I LY
Spring is too light. Install tuning bumper to increase spring rate (resistance to compression).
F O R K I S D I F F I C U LT TO C O M P R E S S W I T H S TA N D A R D S P R I N G R AT E
Install soft tuning spring to decrease spring. Works best for lighter riders. Inspect your shaft bolt crush washers. Replace if worn or damaged. Inspect your top cap o-rings. Replace if torn or knicked.
OIL LOSS
PN 95.4309.884.000, Rev. A
2005 PILOT XC/SL SERVICE GUIDE
2005 Pilot XC/SL Service Guide

Perform service every 100 hours of riding (less depending on riding conditions and riding style). Regular maintenance will keep ensure your Pilot performs as it should For bushing removal and installation, please reference the Bushing Service Guide Right side equals riders right; left side equals riders left.
1. 2. 3. 4. Remove fork from bicycle. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes. Lay tools out on work bench, and provide a clean work area for internals service. Place oil pan under fork on floor.
TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand and Clean Work Area 24mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) Shock Pump 5mm Hex Wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe and Measuring cup Isopropyl Alcohol/Spray Bottle 5wt and 15wt Suspension Oil Isopropyl Alcohol (in Spray Bottle)
LOWER LEG / INTERNALS REMOVAL

1. Remove air valve cover cap; left side. Depress the schrader valve and remove all air from AirAssist chamber.
2. Gently pull external rebound adjuster knob and remove from right shaft bolt. (11.4308.846.000, 05 External Rebound Adjuster Knob, Short)
12
SRAM Corporation 2005 PILOT SERVICE GUIDE

3. Using a 5mm hex wrench, loosen both shaft bolts three to four turns (fig 3a). With hex wrench still in shaft bolt, tap each bolt free with plastic mallet (fig 3b). Using your fingers, remove both shaft bolts completely.
3a
3b
4. Firmly pull the lower leg assembly down by holding each leg or the brake arch. Spray isopropyl alcohol onto each upper tube. Wipe upper tubes with a clean rag.
4a
4b
5. Using a 24mm socket wrench remove Air Assist top cap (left side). Pilot XC: Remove non-adjust top cap as well (right side).
5a
5b
5c
6. Pilot SL: Using external snap ring pliers, remove external compression adjuster knob (plastic or aluminum remote) retaining ring.
6a
6b
6c
Remote: Using a 2mm hex wrench, remove remote cable from adjuster cap before removing retaining ring.
PN 95.4309.885.000, Rev. A
13

7. Pilot SL: Remove compression adj knob (fig 7a) and top cap seal (fig 7b) (Standard and Remote).
7a
7b
8. Using a 24mm socket, loosen compression damper top cap from upper tube (fig 8a). By hand, slowly pull and remove compression damper from upper tube (fig 8b). Lift and remove cable stop clamp (not shown). IMPORTANT! USE CARE WHEN REMOVING COMPRESSION DAMPER FROM UPPER TUBE. USE A SLOW TWISTING MOTION. THIS HELPS EASE THE O-RING PAST THE UPPER TUBE THREADS.
9a
9b
9. Inspect compression damper o-rings (located at top and bottom of damper) and replace if necessary. Apply grease to new o-rings.
10. Remove fork from bicycle stand and pour damper oil into oil pan.
10
UPGRADE: NON-REMOTE
Upgrading a non-remote compression adjust fork (crown-mounted adjuster knob) to Remote compression adjust (PopLoc adjuster), requires replacing the nonremote compression damper with a Remote compression damper. The remote return spring is designed into the compression damper, and is required for use with the PopLoc remote lever assembly.
TO
REMOTE ADJUST
Standard Compression Adjust Damper (non-remote) External Gate Adjuster Knob Spring Tube
Remote Compression Adjust Damper
Remote No Remote Return Spring Return Spring
14
REMOVAL: REBOUND DAMPER AND SEAL HEAD

11. Using a long, thin dowel or rod, push the rebound damper shaft up and through upper tube (fig 11a). Pull damper up, and out of upper tube, through the crown (fig 11b)
11a
11b
12. Using external snap ring pliers, remove external seal head retaining ring and spacer. NOTE: IT HELPS TO INVERT THE FORK (UPSIDE-DOWN) FOR BETTER ACCESS TO THE RETAINING RING AND SPACER.
12a
12b
13. Using a long dowel, push rebound damper seal head up through the upper tube.
13a
13b
13c
14. Using a sharp pick or dental pick, remove rebound damper o-ring, inner and outer seal-head o-rings (figs 14a & 14b). Remove o-ring located on outer boss of seal-head (fig 14c).
14a
14b 7
14c
15. Replace rebound damper piston o-ring (fig 15a). Apply grease to rebound damper o-ring and all new seal head o-rings (fig 15b). Replace outer seal-head boss o-ring (fig 15b, lower o-ring pictured). (11.4309.084.000 PILOT MOTION CONTROL DAMPER SERVICE KIT)
15a
15b
PN 95.4309.885.000, Rev. A
15
R E B O U N D D A M P E R I N S TA L L AT I O N ( P I L O T X C & S L )
16. Insert rebound damper seal head assembly into upper tube through crown (fig 16a). Using a long dowel, push to seat the seal head into the upper tube end, with narrow end out (fig 16b). Invert the fork in bicycle stand (upside-down). Place seal-head spacer over seal-head boss that protrudes from upper tube (fig 16c). Using snap ring pliers, secure with external retaining ring (fig 16d). TIP: TO ASSIST IN SECURING SEAL-HEAD RETAINING RING, INSERT LONG DOWEL INTO UPPER TUBE, THROUGH CROWN, AND APPLY PRESSURE TO SEALHEAD WHILE SECURING OUTER SEAL-HEAD RETAINING RING WITH SNAP RING PLIERS.
16a
16b
16c
16d
17. Insert rebound damper into upper tube, through crown, shaft end first (fig 17a). Using a long dowel, push the damper down to bottom of upper tube (fig 17b). Pull shaft end through the seal head until seated at full extension, while pushing down on dowel (fig 17c).
17b
17c
17a
18. With rebound damper shaft in the fully extended position, measure and pour 95cc (+/-5cc) of RockShox 5wt suspension oil into upper tube, through crown (fig 18a). TIP: YOU MAY ALSO POUR OIL INTO UPPER TUBE THROUGH CROWN, AND MEASURE 5" (+/0.25") (127MM) OIL-HEIGHT LEVEL, MEASURED FROM THE TOP OF CROWN, DOWN TO TOP OF OIL LEVEL (FIG 18B). IMPORTANT! OIL HEIGHT IS CRITICAL. TOO LITTLE OIL DECREASES DAMPING PERFORMANCE. TOO MUCH OIL REDUCES AVAILABLE FORK COMPRESSION/TRAVEL AND POSSIBLE DAMAGE TO FORK FROM COMPRESSION BOTTOM-OUT. 19. Pilot XC: Hand-thread the non-adjust top cap into upper tube. Using a 24mm socket wrench, tighten to 60 in-lb.
18a
18b
19
16
C O M P R E S S I O N D A M P E R I N S TA L L AT I O N ( P I L O T S L )
20. Insert compression damper into upper tube, through crown. Pressing firm, push damper into upper tube slowly. Use a slow twisting motion while firmly pressing compression damper into upper tube. Push down and hand-thread compression damper top cap into upper tube (fig 20a). Using a 24mm socket wrench, tighten to 60 in-lb. (fig 20b).
20a
20b
Motion Control Remote:
Position cable stop base onto crown before inserting compression damper into upper tube. Center cable stop base over upper tube hole, with alignment tab against back of crown.
21. Insert compression damper top cap seal (o-ring) over top cap (fig 21a). Place compression knob onto top cap, with dial at 3 o'clock position. The Remote knob should also be positioned with cable set-screw at 3 o'clock (fig 22b). Using snap ring pliers, secure compression knob with external retaining ring (fig 21c). Insert gate adjuster cover cap (fig 21d). NOTE: USE THE SAME PROCEDURE FOR REMOTE KNOB.
21a
21b
21c
21d
22. Motion Control Remote Forks: Cable Installation a) Thread remote cable through cable-stop base. b) Thread cable around compression knob, under cable set-screw, and tighten with 2mm hex wrench. Knob should be positioned in 3 o'clock position in full-open position. c) Test remote lever function for proper lockout/compression adjust. d) Adjust cable tension as needed.
22
S P R I N G A S S E M B LY R E M O V A L
23. Using your hand, push spring shaft up and remove coil spring assembly from upper tube.
23b
23a
PN 95.4309.885.000, Rev. A 17

24. Using a long dowel, push spring shaft up and through upper tube (fig 24a). Remove from upper tube, through crown, by hand. Pull firmly to remove (fig 24b).
24a
24b
25. Using sharp pick or dental pick, remove Air Assist o-ring air seal from spring shaft perch (fig 25a). Replace o-ring and apply grease (fig 25b).
25a
25b
A L L - T R AV E L S PA C E R C O N F I G U R AT I O N S 80mm Travel: Snap All-Travel spacer onto topout spring, located just under the spring plunger shaft glide ring base. 100mm Travel: Remove All-Travel spacer from spring plunger topout spring. Snap All-Travel spacer onto bottom of main coil spring.
100 mm All-Travel Spacer Configuration 80 mm All-Travel Spacer Configuration
S P R I N G A S S E M B LY I N S T A L L A T I O N
26. Insert the spring plunger assembly back into upper tube/crown, shaft end first. Press firmly to install and push assembly down into upper tube. Push plunger assembly down using a dowel to seat the shaft through the shaft guide at the bottom of the upper tube. Pull shaft end through shaft guide until it stops. You may need to guide the shaft end through shaft guide with a screwdriver, as you push down on the plunger.
26
18

27. Measure and pour 6cc of RockShox 15wt suspension oil into spring chamber (fig 27a). Insert coil spring into upper tube through crown. Insert coil spring spacer on top of spring (fig 27b).
27b
27a
28. Apply grease to Air Assist top cap o-ring, and hand-thread top cap into upper tube (fig 28a). Tighten with socket wrench; torque to 60 in-lb (fig 28b).
28a
28b
S P R I N G A S S E M B LY I N S T A L L A T I O N
29. Invert fork in bicycle stand to a 45 degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a clean rag. 30. Apply a light coating of Judy Butter, or oil-soluble grease to inside of dust seal (fig 30a). Pour a small amount of 5, 10 or 15wt RockShox suspension oil to new or clean foam rings; enough to saturate foam rings (fig 30b).
30b
30a
31. Slide lower leg assembly down upper tubes until you feel the lower bushings touch the end of the upper tubes and stop. Measure and pour (or inject...an oil syringe works best) 10cc of 5wt, 10wt or 15wt (stock) RockShox suspension oil into both lower legs, through the shaft bolt holes. Wipe all excess oil from lower leg. IMPORTANT! THREADED SHAFT BOLT HOLES.
SHAFT ENDS SHOULD NOT BLOCK
31a
31b
31c
PN 95.4309.885.000, Rev. A
19

32. Slide the lower leg assembly onto upper tubes until both shaft ends appear in the lower leg shaft holes. You may need to guide threaded shaft ends, using a hex tool, into each lower leg shaft hole. 33. Inspect and clean each shaft bolt and black nylon crush washer. Replace crush washers and crush washer retaininers if damaged (fig 33a). Damaged crush washers can cause oil to leak. Insert both shaft bolts into threaded shaft ends (hollow bolt damper side; solid bolt - spring side) and tighten with a 5mm hex wrench to 60 inlb (fig 33b). Wipe away excess oil.
33a
33b
34. Insert external rebound adjuster knob through damper shaft bolt, and press firm to seat. Turn to adjust to desired rebound setting.
34
35. Spray a light coating of isopropyl alcohol onto entire fork, and wipe with a clean rag. Inflate fork with shock pump, to desire air pressure. See chart, or decal on back of fork, for reference.
35
20
AIR
Rider Weight (lbs/kg)
<140lb (63kg) 140-160lb (63-72kg) 160-180lb (72-81kg) 180-200lb (81-90kg) >220lb (>99kg)
Air Pressure
0 psi 0-5 psi 5-10 psi 10-15 psi 15-20 psi
OIL
Right Leg Top (Volume)
95cc/ml
RIGHT LEG Right Leg Bottom Oil Weight (Volume)

5wt 10cc/ml
Oil Weight
5, 10 or 15wt (stock)
Left Leg Top (Volume)

6cc/ml
LEFT LEG Left Leg Bottom Oil Weight (volume)

15wt 10cc/ml
Oil Weight
TUNING COIL SPRINGS

Rider Weight (approximate)
<140lb (63kg) 140-160lb (63-72kg) 160-180lb (72-81kg) >180 lbs (80 kg)
PART #
11.4308.942.000 (Soft) 11.4306.208.000 (Standard) 11.4308.812.000 (Firm) 11.4308.813.000 X-Firm)
TROUBLESHOOTING
Air Loss
Inspect air piston o-ring and replace if necessary. To avoid air loss, remove air top cap every month and pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. This keeps the air seal lubricated. Maximum air pressure may have been exceeded. Do not exceed 20 psi in AirAssist spring chamber! Inspect all damper o-rings. Replace and grease. Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height. Correct height is 5 inches from the top of the upper tube (when fork is set at 115mm travel). Add or remove oil as needed. Remote: Inspect remote cable tension. Cable may stretch or become loose. Loosen cable screw, tension cable and then tighten. Test and adjust as needed. Remove both shaft bolts. Pull lowers down about an inch. Allow oil to drain. Inject or pour 10cc of fresh suspension oil into lower leg through shaft bolt holes. Lubricate upper tubes near dust seals. Press down on fork a few times. Wipe away excess lubricant. Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced approximately once a year. 21
L o s s o f / o r Va r i a n c e i n D a m p i n g
C o m p r e s s i o n St r o k e n o t S m o o t h

PN 95.4309.885.000, Rev. A
TROUBLESHOOTING (CONTINUED)
Bushing Play
Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100-200 riding hours, depending your riding style, riding conditions, and body weight. If you ride a lot, check the bushings! SEE THE 'BUSHING INSTALLATION' GUIDE AT WWW.ROCKSHOX.COM FOR PROCEDURES.
Oil Loss
Inspect the air piston o-ring for air bypass. Air pressure can force oil out of the left dust seal. Inspect your shaft bolt crush washers. Replace if worn or damaged. Inspect your top cap o-rings. Replace if torn or knicked.
22
For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com. Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at www.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others. SRAM Corporation August 2004 PN 95.4309.886.000, REV. A
2005 DUKE AIR XC/SL/RACE SERVICE GUIDE
2005 Duke Air XC/SL/Race Service Guide

1. 2. 3. 4. Remove fork from bicycle. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes. Lay tools out on work bench, and create a clean work area for internals service. Place oil pan on floor, under fork.
TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand and Clean Work Table/Area 24mm & 15mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) Shock Pump 5mm Hex Wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe and Measuring cup Isopropyl Alcohol/Spray Bottle 5wt and 15wt Suspension Oil Isopropyl Alcohol (in Spray Bottle)
1. Remove top positive air cover cap (fig 1a). Depress positive schrader valve to release air pressure (fig 1b).
1a
1b
2. Gently pull external rebound adjuster knob and remove from the right shaft bolt (fig 2a). Using a 5mm hex wrench, loosen right and left shaft bolts 3 to 4 turns (fig 2b).
2a
2b
2b
24
SRAM Corporation 2005 DUKE AIR XC/SL/RACE SERVICE GUIDE

4. Using a plastic mallet, tap both shaft bolts free. This frees the shaft ends from the lower leg shaft bore press-fit, and allows the lower leg assembly to be removed from the upper tubes (fig 4a and 4b). Using the 5mm hex wrench, or your fingers, remove the shaft bolts from both threaded shaft ends (fig 4c).
4a
4b
4c
5. Firmly pull the lower leg assembly down by holding each leg or the brake arch. Spray isopropyl alcohol into lower legs. Wrap a rag around a dowel and wipe inside of lower legs clean. NOTE: SEE
AND REPLACEMENT PROCEDURES. THE
5a
5b
BUSHING SERVICE GUIDE
FOR BUSHING INSPECTION
6. Spray isopropyl alcohol onto each upper tube and wipe clean.
HYDRA AIR SPRING SERVICE

R E M O VA L
7. Using a 24mm socket wrench, press firm on top cap, turn counterclockwise, and remove (figs 7a & 7b). IMPORTANT! ENSURE REMOVING TOP CAP.
ALL AIR PRESSURE IS REMOVED BEFORE
7a
7b
8. Remove fork from bicycle stand and pour any oil inside air chamber into an oil pan.
PN 95.4309.886.000, REV. A
25

9. Clamp fork back into bicycle stand, and wipe shaft and base plate with a rag. Push air shaft up and into base plate, leaving only tip of threaded shaft end protruding base valve (fig 9a & b). Slide a 15mm socket tool over end of the threaded shaft end and press firmly against base plate. While pressing firmly to unseat base valve, use internal snap ring pliers to remove external retaining ring. (fig 9c).
9a
9b
15mm Socket
9c
10. When retaining ring is removed, pull air shaft to remove air spring assembly and base plate assembly from upper tube (fig 10a, b, & c).
10a
10b
10c
11. Spray the inside of air upper tube with isopropyl alcohol (fig 11a). Wrap a clean rag around a dowel, and wipe the inside of the upper tube clean (fig 11b).
11a
11b
H Y D R A A I R S E RV I C E
REQUIRED KITS: 11.4309.206.000 (05 DUKE MOTION CONTROL DAMPER SERVICE KIT) 11.4306.297.000 (DUKE AIR SPRING SERVICE KIT) 12. Remove base plate, wavy spring and base ring from Hydra Air shaft (fig 12a). Remove the air piston o-ring and replace (figs 12b). Apply grease to air piston o-ring. (fig 12c).
12a
12b
12c
13. Insert air piston into bottom of upper tube and push up to insert (fig 13a). Insert the base plate ring into the upper tube and position it flat into upper tube step (fig 13b). Insert wavy spring into upper tube, and position it flat against base ring (fig 13c). Slide the base plate over the air shaft and insert it into the upper tube. Press it into the upper tube and against the wavy washer. You will feel resistance, so press firmly. NOTE: BEFORE INSTALLING HYDRA AIR SPRING ASSEMBLY, ENSURE INSIDE OF THE
UPPER TUBE IS CLEANED WITH ISOPROPYL ALCHOHOL AND A CLEAN RAG. ARE ANY FOR SCRATCHES INSIDE UPPER.
13a
13b
13c
CHECK IF THERE SCRATCHES, REPLACE CSU.
26

14. Slide base plate over air shaft, and insert into upper tube. Press into upper tube against the wavy spring. You will feel resistance, so press firmly (fig 14a). Using a 15mm socket tool, press the base plate into the upper tube, to compress the wavy spring. Secure retaining ring (sharp edge facing out) while pressing against base plate. (fig 14c)
14
15mm Socket
15. Pour 3 to 5cc/ml of 5 wt suspension oil into upper tube (air spring side), through crown (fig 14a). Oil inside air chamber lubricates o-ring during use and maintains air seal. Clean air top cap threads and hand threaded into upper tube (fig 14b). Using a 24mm socket, tighten to 60 in-lb. (fig 14c).
15a
15b
15c
MOTION CONTROL DAMPER SERVICE

R E M O VA L
16. Duke XC Air: Skip to step 19. 17. Compression knob (Duke SL and Race only): Using external snap ring pliers, remove external compression adjuster knob (plastic or aluminum remote) retaining ring (fig. 17a). Remove the compression adjuster knob (figs 17b) and top cap seal*. *Blue plastic manual knob has an o-ring top cap seal. *Blue aluminum remote knob has a white plastic top cap seal. NOTE:
FOLLOWS THE SAME PROCEDURE.
17a
17b
REMOVAL
OF THE REMOTE COMPRESSION ADJUSTER KNOB
18. Using a 24mm socket wrench, loosen compression damper top cap from upper tube (fig 18a). By hand, slowly pull compression damper from upper tube (figs 18b & 18c).
COMPRESSION DAMPER FROM UPPER TUBE.
18a
USE
18b
18c
IMPORTANT!
USE
CARE WHEN REMOVING
A SLOW TWISTING MOTION WHILE PULLING UP. TUBE THREADS.
THIS
HELPS EASE THE O-RING PAST THE UPPER
19. Inspect compression damper o-rings (located at top and bottom of damper) and replace if necessary. Apply oil to new o-rings.
19
PN 95.4309.886.000, REV. A
27

UPGRADE: Non-Remote to Remote Adjust
Upgrading a non-remote compression adjust fork (crownmounted adjuster knob) to remote compression adjust (remote lever (PopLoc) adjuster), requires replacing the non-remote compression damper with a remote compression damper. The remote return spring is designed into the compression damper, and is required for use with the PopLoc remote lever assembly.
Remote Compression Adjust Damper Standard Compression Adjust Damper (non-remote) External Gate Adjuster Knob Spring Tube
20. Duke XC Air ONLY: Using a 24mm socket wrench, loosen and remove the nonadjust rebound top cap (figs 19a and b). NOTE: DUKE XC AIR FEATURES THE MOTION CONTROL REBOUND THE MOTION CONTROL COMPRESSION DAMPER (STANDARD AND REMOTE) CAN BE INSTALLED TO UPGRADE THE FORK TO LOCKOUT AND COMPRESSION ADJUST. SEE ABOVE FOR DETAILS. SEE THE 2005 SPARE PARTS CATALOG FOR PART NUMBERS.
DAMPER ONLY.
20a
20b
21
22. Use snap ring pliers to remove rebound damper/seal head retaining ring and base ring, located inside bottom of right upper tube (figs 22a & 22b). Pull to remove the rebound damper and seal head from upper tube (fig 22c & 22d).
22a
22b
Seal Head
22c
22d
23. Slide seal head off damper shaft. Remove and replace inner and outer seal head o-rings. Coat new o-rings with suspension oil (5, 10 or 15wt).
23a
Seal Head
23b
23c
23d
23e
28

24. Spray rebound damper shaft with isopropyl alcohol. Wipe shaft with a clean rag. 25. Remove and replace rebound damper piston o-ring (fig 25a and b). Apply a coat of suspension oil to new piston o-ring.
25a
25b
26. Spray isopropyl alcohol into damper-side upper tube. Wrap a clean rag around a long dowel/rod. Insert rag into upper tube and clean inside of tube.
23a
23b
I N S TA L L AT I O N
27. Insert rebound damper seal head back onto rebound damper shaft (fig 27a). Insert rebound damper piston into bottom of upper tube (fig 27b). Slide seal head up into upper tube step (fig 27b).
27a
27b
27c
28. Press seal head firmly into upper tube (fig 28a). Secure seal head into upper tube with retaining ring, sharp edge facing out. (fig 28b) Ensure retaining ring is secure in upper tube groove. Pull rebound damper shaft down (out) into the fully extended position.
28a
28b
29. With rebound damper shaft in the fully-extended position, measure and pour 120cc (+/-5cc) RockShox 5wt suspension oil into upper tube, through crown (fig 29a). Or, pour oil into upper tube through crown, and measure 5" (+/- 0.25") (127mm) oil height level, measured from the top of the crown, down to top of oil level (fig 29b).
DAMPING PERFORMANCE.
29a
29b
IMPORTANT! OIL
HEIGHT IS CRITICAL.
FORK FROM COMPRESSION BOTTOM-OUT.
COMPRESSION/TRAVEL, AS WELL AS POSSIBLE RISK OF DAMAGE TO
TOO
TOO
LITTLE OIL DECREASES
MUCH OIL REDUCES AVAILABLE FORK
PN 95.4309.886.000, REV. A
29
30. Standard Compression Knob Duke Models: Insert compression damper into upper tube, through crown. Press firm and push damper into upper tube slowly. Use a slow twisting motion while firmly pressing compression damper into upper tube (fig 30a). Remote Duke Models: Position the cable stop clamp on top of the crown, with the cable stop guide facing forward. Insert the compression through cable stop clamp, and into upper tube (fig 30b). Using a 24mm socket wrench, tighten to 60 in-lb (fig 30c). NOTE: MAKE THE FULL-OPEN
SURE COMPRESSION DAMPER IS IN POSITION (TURN ADJUSTER SHAFT
30a
30b
30c
Remote: Cable-Stop Clamp
COUNTERCLOCKWISE).
31. Insert compression damper top cap seal (o-ring or white plastic seal) over top cap. Place compression knob onto top cap, with dial at the 3 o'clock position. Using snap ring pliers, secure the compression knob with external retaining ring (fig 28b). Remote knob should be positioned with cable set screw at approximately 3 o'clock.
AT RIGHT
31a
31b
31c
NOTE: REMOTE KNOB TOP CAP SEAL PICTURED (FIGS 28C). REMOTE COMPRESSION
KNOB USES A WHITE PLASTIC
ADJUSTER
WASHER/TOP CAP SEAL.
32. Motion Control Remote Forks: Cable Installation 1) Thread the remote cable through cable stop base. 2) Thread cable around compression knob, under cable set-screw, and tighten with 2mm hex wrench. Knob should be positioned in 3 o'clock position and full-open. 3) Test PopLoc remote lever function for proper lockout/compression adjust. 4) Adjust cable tension as needed.
33. Invert fork in bicycle stand to 45-degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a clean rag. 34. Pour, or inject, a small amount of 5, 10 or 15wt RockShox suspension oil onto new or clean foam rings, just under dust seal, inside lower leg (each side).
31
30

35. Slide lower leg assembly over and onto the ends of each upper tube. Ensure both dust seals slide onto the tubes correctly and do not fold under. Slide lower leg assembly onto upper tubes until you feel the lower bushings touch the end of the upper tubes. Stop.
35a
35b
36. Invert fork about 30 to 45 degress in bicycle stand. Measure and pour (or inject with an oil mixing syringe works best) 15cc of 5wt, 10wt, or 15wt (stock) RockShox suspension oil into both lower legs, through the shaft bolt holes. Wipe all excess oil from lower leg.
36
37. Inspect and clean damper shaft bolt (hollow/right side), spring shaft bolt (solid/left side), and black nylon crush washers. Replace crush washers and crush washer retainers if damaged. Damaged crush washers can cause oil to leak.
34
38. Slide lower leg assembly onto upper tubes until both shaft ends appear in lower leg shaft holes. You may need to guide both shaft ends, with a hex tool, into each lower leg shaft hole. Insert damper shaft bolt into damper threaded shaft end (right side) and tighten with a 5mm hex wrench to 60 in-lb (fig 38a). Insert Hydra Air spring shaft bolt and tighten with a 5mm hex wrench to 60 in/lb (fig 38b). Wipe away excess oil. 39. Insert external rebound damper knob into damper shaft bolt. Push in to secure.
38a
38b
39
40. Using a shock pump, inflate positive air pressure. Refer to either the air chart in this guide or the air pressure decal on the back of the fork lower leg for air pressure settings (fig 37a). Install the air valve cover cap (fig 37b).
40a
40b
41. Spray a light coating of isopropyl alcohol onto entire fork, and wipe with a clean rag. PN 95.4309.886.000, REV. A 31
OIL
RIGHT LEG
Right Leg Top (Volume) 95 cc/ml Left Leg Top (Volume) 3 - 5 cc/ml Oil Weight 5wt Right Leg Bottom (Volume) 10 cc/ml Oil Weight 5, 10 or 15wt (stock)
LEFT LEG
Oil Weight 5wt Left Leg Bottom (volume) 10 cc/ml Oil Weight 5, 10 or 15wt (stock)
AIR PRESSURE SETTINGS

Rider Weight < 140 (63kg) 140 - 160 (63-72 kg) 160 - 180 (72-81 kg) 180 - 200 (81-90 kg) >220 (99 kg) Air Pressure 70-115 psi 115 -130 psi 130 -145 psi 145 -160 psi 160 - 180 psi
TROUBLE-SHOOTING
AIR LOSS Inspect air piston o-ring and replace if necessary. To avoid air loss, defate positive air chamber, remove air top cap every month and pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. This keeps air seal lubricated. Maximum air pressure may have been exceeded. Do not exceed receommended air pressures! L O S S O F / O R VA R I A N C E I N D A M P I N G Inspect all damper o-rings. Replace and grease. Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height. Correct height is five inches from the top of the upper tube (when fork is set at 140mm travel). Add or remove oil as needed. REMOTE: INSPECT REMOTE CABLE TENSION. CABLE MAY STRETCH TENSION CABLE, AND TIGHTEN. TEST. ADJUST AS NEEDED. COMPRESSION STROKE NOT SMOOTH
OR BECOME LOOSE.
LOOSEN
CABLE SCREW,
Remove both shaft bolts. Pull lowers down about an inch. Allow oil to drain. Inject or pour 15cc of fresh suspension oil into lower
leg through shaft bolt holes.
Lubricate upper tubes near dust seals. Press down on fork a few times. Wipe away excess lubricant.
B U S H I N G P L AY Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100-200 riding hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings! SEE
THE
'BUSHING INSTALLATION'
GUIDE AT WWW.ROCKSHOX.COM FOR PROCEDURES.
OIL LOSS
Inspect the air piston o-rings for air bypass. Air pressure can force oil out of the left dust seal. Inspect your shaft bolt crush washers. Replace if worn or damaged. Inspect your top cap o-rings. Replace if torn or knicked.
32
2005 REBA SL/RACE/TEAM SERVICE GUIDE
2005 Reba SL/Race/Team Service Guide

1. Remove fork from bicycle. 2. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes. 3. Lay tools out on work bench, and create a clean work area for internals service. 4. Place oil pan under fork on floor.
TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand and Clean Work Table/Area 24mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) Shock Pump 2mm, 2.5mm, 3mm, 5mm Hex Wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe and Measuring cup Isopropyl Alcohol/Spray Bottle 5wt and 15wt Suspension Oil Isopropyl Alcohol (in Spray Bottle)
1. Remove both air valve cover caps from the left side of the fork. Depress positive schrader valve (upper) FIRST and remove all air from air spring chamber. Depress negative schrader valve (lower) SECOND and remove all air pressure.
1a
1b
1c
1d
2. Gently pull external rebound adjuster knob and remove from right shaft bolt (11.4308.846.000, 05 External Rebound Adjuster Knob, Short).
34
SRAM Corporation 2005 REBA SL/RACE/TEAM SERVICE GUIDE

3. Using a 5mm hex wrench, loosen both shaft bolts 3 to 4 turns. Using a 10mm open end wrench, loosen the DualAir shaft bolt. Unthread by hand so bolt is unthreaded just past the end of the threaded shaft end.
3a
3b
4. With the hex wrench in shaft bolt, tap bolt free with plastic mallet. Using your fingers, remove shaft bolt completely. DualAir side: Place 10mm socket tool onto DualAir nut; tap socket with plastic mallet until shaft breaks free from lower leg casting. Using your fingers, remove shaft bolt and threaded shaft nut from both threaded shaft ends.
4a
4b
5. Firmly pull the lower leg assembly down by holding each leg or the brake arch. Spray isopropyl alcohol into each leg. Wrap a clean rag around a long dowel and clean inside of lower legs. IMPORTANT! DO MAGNESIUM.
NOT STRIKE OR TAP THE BRAKE ARCH WITH A MALLET.
THIS
DAMAGES THE
6. Spray isopropyl alcohol into each upper tube; wipe clean. Wrap a clean rag around a long dowel and clean the inside of each lower leg. Reba Dual Air: Skip to Step 35.
6a
6b
AIR SPRING SERVICE

A I R U - T U R N S P R I N G A S S E M B LY Removal
(Part kit required: 11.4309.010.000, Reba U-Turn Air Spring O-Ring Service Kit) 7. Adjust travel setting to 115mm (full travel). Ensure all air pressure is removed from positive and negative air chambers.
PN 95.4309.887.000, REV. A
35

8. Using a sharp pick or screwdriver, push external retaining clip from above U-Turn knob (fig 8a). Remove adjuster knob. Remove each detent ball bearing and spring from top cap (fig 8c) by using a magnet. IMPORTANT! IN THE EVENT THE AIR U-TURN (24MM) TOP CAP MUST BE REMOVED FROM UPPER TUBE/CROWN, USE A 24MM SOCKET WRENCH TO REMOVE. BEFORE INSTALLATION, ADD A FEW
THREADS. 9. Turn Air U-Turn travel adjust shaft, or bottom of air shaft, CLOCKWISE to unthread air spring assembly from Air U-Turn top cap. Top cap should be tight inside crown/upper tube. Pull down on Air UTurn shaft to remove entire spring assembly from bottom of upper tube. DROPS OF BLUE THREADLOCK TO THE TOP CAP
8a
8b
8c
9a
9b
AIR U-TURN SPRING ASSEMBLY INCLUDES: Spring travel adjuster assembly Air spring tube Positive/negative air spring assembly
D I S A S S E M B LY & S E RV I C E : U - T U R N A I R P I S TO N / S H A F T A S S E M B LY
Disassembly and Service should be performed on a clean work surface.
10. Remove Teflon washer from inside of top cap by pushing down with a pick or flat-head screwdriver. The washer exits the bottom of upper tube.
A SHARP PICK TO DISLODGE.
10
USE
NOTE: GREASE
MAY CAUSE
TEFLON
WASHER TO REMAIN IN UNDERSIDE OF TOP CAP.
11. Using external snap ring pliers, remove small external retaining ring (fig 11a). This secures air tube guide plate. Remove guide plate (fig 11b).
11a
11b
12. Using a flat-head screwdriver, push down on seal head (position screwdriver head against step, away from shaft) to free the retaining ring from seal head (fig 12a). You may need to deflate positive air to help release seal head. After the seal-head slides into air tube, use snap ring pliers to remove seal-head retaining ring from air tube (fig 12b). IMPORTANT! DO NOT SCRATCH AIR SHAFT. A SCRATCH CAUSES AIR LEAK.
12a
12b
36

13. Pull air shaft, negative air seal head and positive air piston assemblies out of air tube (fig 13a). Slide and remove aluminum seal head from air shaft (fig 13b). IMPORTANT! DO NOT SCRATCH O-RING REMOVING O-RINGS. DAMAGE WILL CAUSE
PERMANENT AIR LEAK. GROOVES WHEN
13a
13b
14. Use external snap ring pliers to remove positive air piston retaining ring (fig 14a). Remove positive air piston (fig 14b).
14a
14b
15. Pinch the small o-ring on air

piston shaft groove; remove and replace (figs 15a & 15b). Coat new o-ring with suspension oil (5, 10 or 15wt) (figs 15c & 15d).
15a
15b
15c
15d
16. Pinch external air piston o-ring; remove and replace (fig 1). Use a sharp pick to remove seal head external and internal o-rings (fig 2). Coat new o-ring with suspension oil (5, 10 or 15wt) (fig 3).
16a
16b
16c
17. Place the air piston back onto shaft end and secure with NEW 10mm external retaining ring. IMPORTANT! THE 10MM
LOOSE. EXTERNAL RETAINING RING MAY BECOME
17a
17b
DAMAGED IF STRETCHED OPEN TOO FAR DURING ASSEMBLY.
ENSURE
THE RETAINING RING IS FULLY SEATED INTO SHAFT GROOVE AND NOT
PINCH
RETAINING RING TIGHT WITH PLIERS IF NECESSARY.
PN 95.4309.887.000, REV. A
37
2005 Reba SL/Race/Team Service Guide D I S A S S E M B LY & S E RV I C E : T R AV E L A D J U S T E R / C H O K E A S S E M B LY

Disassembly and Service should be performed on a clean work surface. 18. Holding air tube, place upper choke assembly end on flat surface. Firmly press tube down on flat surface to push choke assembly through tube. Press firm to break the seal. Choke assembly will feel tight inside tube.
18a
18b
19. Use a nonmetallic rod (a large magic marker, or wood/plastic dowel also works well) to continue to push the assembly through and out of air tube. Remove assembly completely from air tube (figs 19a to 19c). NOTE: POUNDING
ORING OUT THE ROD ON THE FLAT SURFACE MAY BE NECESSARY TO FORCE THE
19b
19c
(FIG 19C). A
IMPORTANT!
NOT SCRATCHED.
NONMETALIC
DOWEL/ROD
19a 20
ENSURES THAT THE INSIDE OF THE AIR TUBE IS
20. Spray isopropyl alcohol inside of air tube. Wrap clean rag around end of dowel and push through tube to clean inside tube surface.
21. Remove external choke retaining ring from travel adjustment shaft (fig 21a). Remove choke piston and choke/shaft washer (fig 21b).
21a 21b
22. Remove external choke o-ring. Replace o-ring and apply suspension oil (not grease) to new o-ring.
22a
22b
38

23. Remove the upper seal-head from adjuster shaft (fig 23a). Remove upper seal head outer and inner o-rings. Use a sharp flat-head screwdriver to remove inner o-ring retaining ring (figs 23b & 23c). Replace both o-rings and coat new o-ring with 5, 10 or 15wt suspension oil. Reinstall inner o-ring retaining ring with small, sharp flat-head screwdriver.
23a
23b
23c
23d
23e
23f
24. Re-install the upper seal head onto travel adjustment shaft (fig 24a). Apply oil to adjuster shaft, and onto inner seal head o-ring (fig 24b). Install the choke piston and secure with new 10mm external retaining ring (fig 24c).
24a
24b
24c
25. Apply a few drops of RockShox 15wt suspension oil to the exposed shaft in between upper seal head and choke piston (fig 25a). Apply oil to both piston o-rings (figs 25b and c).
25a
25b
25c
26. Insert the upper choke assembly into the open end of air spring tube, schrader valve end first (fig 26a-c). Using a long plastic/wood dowel, push assembly up into the air tube until seated flush against rolled end of air tube (fig 26d). IMPORTANT! BOTH UPPER SEAL - HEAD AND CHOKE PISTON O - RINGS
MUST BE WELL LUBRICATED WITH BEFORE INSTALLATION.
26a
26b
26c
26d
5, 10
OR
15WT
OIL
27. Hold air tube with open end up. Pour 3 - 5cc RockShox 15wt suspension oil into air tube/positive air chamber, on top of upper choke assembly. This lubricates the choke o-ring and positive air piston o-ring when the fork is compressed. Set aside, upright, so oil does not spill.
27
PN 95.4309.887.000, REV. A
39

28. Slide negative air seal-head onto DualAir spring shaft (flat end first). Slide up to bottom out bumper. Inner seal head o-ring must be lubricated with oil.
28
29. Lubricate positive and negative air piston o-rings well with with 5, 10 or 15wt oil before installation (figs 29a and b). Insert positive air piston into open end of air spring tube. Push into tube. (fig 29c) Using a small flat-head screwdriver, press down on the seal head shaft step to seat into place. (fig 29d) Secure the seal-head into air tube step with retaining ring. (figs 29e and f) IMPORTANT! CHECK
RETAINING RING; MUST BE FULLY SEATED IN UPPER TUBE GROOVE.
29a 29b
29c
29d
29e
29f
30. Pressurize the positive air chamber (40 to 60 psi) to ensure assembly components are seated properly inside tube.
30
31. Insert air tube guide plate onto end of air tube (fig 31a). Secure around small seal-head groove with NEW 13mm external retaining ring (fig 31b). Verify retaining ring is seated against guide plate so it can not move freely (fig 31c). IMPORTANT! PINCH EXTERNAL
RETAINING RINGS
31b
31c
MAY DEFORM WHEN REMOVED AND INSTALLED. CORRECT FIT. ENDS TIGHT WITH PLIERS TO ENSURE
31a
TUBE/CROWN.
THE U-TURN AIR SPRING ASSEMBLY
IS NOW ASSEMBLED AND READY TO BE INSTALLED INTO FORK UPPER
32. Place Teflon washer over threaded shaft end, (flat against travel shaft).
32a
40
32b

33. Insert the Air U-Turn spring assembly into the bottom left fork upper tube (adjuster end first, fig 33a). Slide the assembly into upper tube until it engages the top cap (fig 33b). Hold bottom of air shaft, turn counterclockwise, and thread assembly into top cap until it stops (fig 33c).
33b
33c
33a
34. Insert each detent spring into top cap detent hole. Place detent ball bearings on top of detent springs (fig 34a). Place the Air U-Turn adjuster knob onto hex shaft end. Secure with external retaining clip. Press clip into groove with small flat-head screwdriver (fig 34b). Make sure retaining clip is inserted into groove, not air shaft threads. IMPORTANT! AIR U-TURN FORK MUST BE SET TO FULL-TRAVEL SETTING BEFORE INSTALLING LOWER LEGS . TURN AIR U-TURN KNOB COUNTERCLOCKWISE TO SET TRAVEL TO 115MM (FIG 3). S K I P TO S T E P 4 7 . D U A L - A I R S P R I N G A S S E M B LY
34a
34a
34c
R E M O VA L
35. Remove all air pressure from positive (top) and negative (bottom) air chambers. Depress the schrader valves to remove air (fig 35a). Using a 24mm socket wrench, loosen and remove the DualAir top cap assembly from upper tube/crown (fig 35b).
35a
35b
36. Using snap ring pliers, remove the air spring shaft guide retaining ring from bottom of upper tube.
36
37. Insert a dowel into upper tube, through crown. Push down while pulling DualAir spring assembly down and out of upper tube. Air spring assembly fits tightly into upper tube so you must pull hard!
37a
PN 95.4309.887.000, REV. A
37b
41

38. Spray isopropyl alcohol into upper tube (fig 38a). Wrap a clean rag around a long dowel. Insert rag into upper tube and clean inside of tube (fig 38b).
38a
38b
D I S A S S E M B LY A N D S E RV I C E
Service Kit Part# Required: 11.4309.004.000, AM REBA DUALAIR O-RING SERVICE KIT 39. Spray DualAir assembly with isopropyl alcohol to clean assembly parts (fig 39a). Remove the DualAir positive air piston o-ring and replace (fig 39b).
39a
39b
40. Slide the negative air piston/seal head assembly off DualAir spring shaft (fig 40b-d).
40a
40b
40c
40d
41. Remove the negative air piston outer and inner o-rings (figs 41a and b). Replace and coat new inner o-ring with suspension oil (5, 10 or 15wt) (fig 41c).
41a
41b
41c
42. Coat positive and negative outer piston o-rings with suspension oil (5, 10 or 15wt) (figs 42a and b). Slide negative air piston/seal head assembly back onto DualAir spring shaft (fig 42c).
42a
42b
42c
42
2005 Reba SL/Race/Team Service Guide A L L - T R AV E L C O N F I G U R AT I O N S

All Travel shaft spacers are located just under the positive air piston. Remove spacer to increase travel or add spacer to decrease travel.
43. Insert positive air piston/shaft assembly (piston first) into bottom of clean upper tube (fig 43a). Push into upper tube (fig 43b). Insert negative air piston into upper tube. Push into upper tube completely (fig 43c). You may need to press negative schrader valve while pushing assembly to relieve pressure.
43a
44. Install the flat retaining washer against upper tube step (fig 44a). Insert wavy washer against retaining ring. Push shaft base into upper tube (fig 44b). IMPORTANT! EXTERNAL RETAINING RING MUST FIT UPPER TUBE GROOVE. VERIFY BEFORE CONTINUING.
SECURE INTO
43b 44a
43c 44b
45. Insert the shaft base plate/guide into upper tube step (fig 45a). Push in and secure with external retaining ring (fig 45b).
45a 45b
46. Invert the fork in bicycle stand 90 degress. Measure and pour or inject, 3 to 5cc/ml, 5wt RockShox suspension oil into air spring chamber (fig 46a). Oil lubricates positive air spring o-ring/seal. Install DualAir top cap; tighten and torque to 60 in-lb using a 24mm socket wrench (fig 46b).
46a
46b
PN 95.4309.887.000, REV. A
43
MOTION CONTROL DAMPER SERVICE (ALL REBA FORKS)

R E M O VA L
47. Compression Knob: Using snap ring pliers, remove external compression adjuster knob (plastic or aluminum remote) retaining ring (fig 47a). Remove compression adj. knob and top cap seal (o-ring) (fig 47b & 47c). NOTE: THE REMOTE
PICTURED AT RIGHT
47a
47b
47c
(FIG. 47C).
KNOB TOP CAP SEAL IS
REMOTE
COMPRESSION ADJUSTER KNOBS USE A WHITE PLASTIC WASHER/TOP CAP SEAL.
48. Using a 24mm socket wrench, loosen compression damper top cap from upper tube (fig 48a). By hand, slowly pull and remove compression damper from upper tube (fig 48b). IMPORTANT! USE CARE WHEN REMOVING COMPRESSION DAMPER FROM UPPER TUBE. USE A SLOW TWISTING MOTION WHILE PULLING UP SLOWLY. THIS EASES THE O-RING PAST THE UPPER TUBE THREADS.
48a
48b
49. Inspect compression damper o-rings (located at top and bottom of damper) and replace if worn, knicked or torn. Apply oil to new o-rings.
49
Upgrade: Non-Remote to Remote Adjust
Upgrading a non-Remote compression adjust fork (crown-mounted adjuster knob) to a Remote compression adjust (Remote lever (PopLoc) adjuster), requires replacing the non-Remote compression damper with a remote compression damper. The Remote return spring is designed into the compression damper, and is required for use with the PopLoc Remote lever assembly.
44

50
51. Use snap ring pliers to remove rebound damper/seal head retaining ring and base ring, located inside bottom of right upper tube (fig 51a). Pull to remove rebound damper and seal head from upper tube (figs 51b to d).
51a
51b
51c
51d
52. Slide the seal head off damper shaft (figs 52a and b). Remove and replace outer and inner seal head o-rings (figs 52c and d). Coat
new o-rings with suspension oil (5, 10 or 15wt) (fig 5).
52a
52b
52c
52d
52e
53. Spray rebound damper shaft with isopropyl alcohol. Wipe shaft with a clean rag. 54. If damaged, remove and replace rebound damper piston glide ring.
53a
53b
55. Spray isopropyl alcohol into the upper tube. Wrap a clean rag around a long dowel/rod. Insert rag into the upper tube and clean inside of tube.
55a
55b
PN 95.4309.887.000, REV. A
45
2005 Reba SL/Race/Team Service Guide I N S TA L L AT I O N

56. Insert rebound damper piston into bottom of upper tube. Insert it at an angle, open ended side of glide ring out. This aids insertion of piston and glide ring. Angle and rotate until glide ring is inside upper tube (fig 56a). Slide seal head up into upper tube step. Position basering/washer and seal-head into upper tube step. (figs56a and b)
56a
56b
56c
57. Press seal head firmly into upper tube (fig 57a). Secure seal head into upper tube with retaining ring (fig 57b). Ensure retaining ring is secure in the upper tube groove. Pull rebound damper shaft down/out to full fork travel/extension.
57a
57b
58. With rebound damper shaft in the fully extended position, measure and pour 110cc (+/-5cc) RockShox 5wt suspension oil into upper tube through crown (fig 58a). Or, pour oil into upper tube through crown, and measure 5" (+/- 0.25") (127mm) oil-height level, measured from the top of the crown, down to top of the oil level (fig 58b). IMPORTANT! OIL
DAMPING PERFORMANCE. HEIGHT IS CRITICAL.
58a
58b
COMPRESSION/TRAVEL, AS WELL AS RISK DAMAGE TO FORK FROM COMPRESSION BOTTOM-OUT.
TOO
TOO
59. Insert compression damper into upper tube, through crown. Press firm and push damper into upper tube slowly. Use a slow twisting motion while firmly pressing compression damper into upper tube. Using a 24mm socket wrench, tighten to 60 in-lb. NOTE:
POSITION
59a
59b
ENSURE COMPRESSION DAMPER IS IN THE (TURN ADJUSTER SHAFT COUNTERCLOCKWISE).
FULL-OPEN
60. Insert the compression damper top cap seal (o-ring) over top cap (fig 60a). Place compression knob onto top cap, with the dial at the 3 o'clock position Using snap ring pliers, secure compression knob with external retaining ring (fig 60b and d). Remote knob should be positioned with cable set screw at three o'clock (fig 60d). NOTE: REMOTE
60a
60b
60c
60d
USES A WHITE PLASTIC WASHER/TOP CAP SEAL.
KNOB TOP CAP SEAL PICTURED AT RIGHT (FIG
60C). REMOTE
COMPRESSION ADJUSTER KNOB
46

61. Motion Control Remote Forks: Cable Installation a. Thread remote cable through cable-stop base. b. Thread cable around compression knob, under cable set-screw, and tighten with a 2mm hex wrench. Knob should be in the 3 o'clock position and full-open. c. Test PopLoc remote lever function for proper lockout/compression adjust. d. Adjust cable tension as needed.
62. Invert fork in bicycle stand to 45 degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a clean rag. 63. Pour, or inject, a small amount of 5, 10 or 15wt RockShox suspension oil onto new or clean foam rings, just under dust seal, inside lower leg; each side. NOTE: FOR GUIDE.
FOAM RING AND DUST SEAL INSTALLATION, SEE THE
63
BUSHING INSTALLATION
64. Slide the lower leg assembly over and onto the ends of each upper tube. Make sure both dust seals slide onto the tubes correctly and do not fold under.
64a
64b
65. Slide lower leg assembly onto upper tubes until you feel the lower bushings touch the end of the upper tubes and stop (fig 65a). Measure and pour (or inject...an oil syringe works best) 15cc of 5, 10, or 15wt RockShox suspension oil into both Lower Legs, through both (left and right) shaft bolt holes (fig 65b). Wipe all excess oil from lower legs (fig 65c).
65a
65b
65c
66. Inspect and clean damper shaft bolt and black nylon crush washer. Replace crush washer and crush washer retainer if damaged. Damaged crush washers can cause oil to leak (fig 1). Insert damper shaft bolt into threaded shaft end and tighten with a 5mm hex wrench to 60 in-lb (fig 2). Insert external rebound damper knob into damper shaft bolt. Push in to secure (fig 3).
65a
65b
65c
PN 95.4309.887.000, REV. A
47

67. Inspect and clean DualAir shaft nut crush washer. Replace if damaged (fig 1). Thread nut onto DualAir threaded shaft (fig 2). Using a 10mm open-end wrench, tighten to 60 in-lb (fig 3). Wipe away excess oil.
67a
67b
67c
68. Spray a light coating of isopropyl alcohol onto entire fork, and wipe with a clean rag. Replace decals if needed. 69. Inflate positive air chamber first, with shock pump, to desired air pressure. See chart or decal on back of fork lower leg, for reference. Thread air valve cover cap onto threaded valve shaft. 70. Next, inflate negative air chamber, with shock pump, to desired air pressure. See chart, or decal on back of fork lower leg, for reference. Thread air valve cover cap onto threaded valve shaft.
COMPRESSION BREAK-AWAY FORCE REQUIRED, MAKING FORK MORE ACTIVE OVER SMALL BUMPS. WITH NEGATIVE AIR PRESSURE TO FIND DESIRED RIDE CHARACTERISTICS.
NOTE: ALWAYS
INFLATE POSITIVE AIR FIRST!
INCREASED
NEGATIVE AIR PRESSURE DECREASES INITIAL
EXPERIMENT
AIR
A i r Sp r i n g Tu n i n g
With independently adjustable positive (top) and negative (bottom) air chambers, the air spring system of your Reba fork can be easily tuned for your weight and riding style. Use the following instructions as a starting point. If further fine tuning is desired, follow the hints at the end of this section.
Positive air pressure determines the amount of force required to compress your fork. More positive air pressure will result in less suspension sag and higher bottom out forces. Less positive air pressure will result in more suspension sag and lower bottom out forces. Using the chart below as a guideline, inflate the positive air chamber to the desired pressure. NOTE: AIR U-TURN
PRESSURE SHOULD BE SET AT
STEP 1 - SELECTING POSITIVE AIR PRESSURE
115MM
OF TRAVEL.
Rider Weight < 120 120-140 140-160 160-180 >180 (99 kg)
Air U-Turn Air Pressures 80-115 psi 115-130 psi 130-145 psi 145-160 psi 180 psi
Dual Air Air Pressures 70-100 psi 100-115 psi 115-130 psi 130-145 psi 160 psi
Negative air pressure effects the amount of force required to initiate suspension travel. Negative air pressure works with bump input AGAINST the force of the positive air chamber. More negative air pressure results in a suspension set-up that is more active, especially to small bump input. Less negative air pressure results in a suspension set-up does not move or "bob" under rider input or small bumps. Using the chart below as a guideline, inflate the negative air chamber to the desired pressure.
S T E P 2 - S E L E C T I N G N E G AT I V E A I R P R E S S U R E
Rider Weight < 120

120-140 140-160 160-180 >180 48
Air U-Turn Air Pressures More Active Less Active 80-115 psi 50-70 psi 115-130 psi 70-80 psi 130-145 psi 80-90 psi 145-160 psi 90-100 psi 180 psi 110 psi
Dual Air Air Pressures More Active Less Active 70-100 psi 40-60 psi 100-115 psi 60-70 psi 115-130 psi 70-80 psi 130-145 psi 80-90 psi 160 psi 100 psi
TROUBLESHOOTING
Air Loss
Inspect air piston o-rings. Replace if necessary. To avoid air loss, remove DualAir top cap and check oil level inside air chamber, every 25-50 riding hours. If there is little or no oil on top of air piston o-ring, pour 3 - 5cc RockShox 15wt suspension oil into air spring chamber. For UTurn Air version, the schrader valve core can be removed to add oil tothe positive chamber. This keeps air seal lubricated. Inspect schrader valve assembly. Replace if damaged or malfunctioning. Clean if clogged.
L o s s o f / o r Va r i a n c e i n D a m p i n g
Inspect all damper o-rings. Replace and grease. Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height. Correct height is 5 inches from the top of the upper tube. Add or remove oil as needed. Remote: Inspect remote cable tension. Cable may stretch, or become loose. Loosen cable screw, tension cable, and tighten. Test. Adjust as needed.
Bushing Play
Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100200 riding hours, depending your riding style, condition, riding time, and body weight. If you ride a lot, check the bushings! See the 'Bushing Installation' guide at www.rockshox.com for procedures.
Oil Loss
PN 95.4309.887.000, REV. A
49
2005 PIKE SL/RACE/TEAM (COIL) SERVICE GUIDE
2005 Pike SL/Race/Team Service Guide

TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand/Clean Work Table/Area 24mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) Shock Pump 5mm Hex Wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe and Measuring cup Isopropyl Alcohol/Spray Bottle 5wt and 15wt Suspension Oil Isopropyl Alcohol (in Spray Bottle)
1. Gently pull external rebound adjuster knob and remove from the right shaft bolt (fig 1a). Using a 5mm hex wrench, loosen right and left shaft bolts 3 to 4 turns (fig 1b). (11.4308.846.000 05 External Rebound Adjuster Knob, Short)
1a
1b
2. With hex wrench in shaft bolt, tap each shaft bolt free with plastic mallet. This frees the shaft ends from the lower leg shaft bore press-fit, and allows the lower leg to be removed from upper tubes (fig 2a). Using your fingers, remove shaft bolts from both threaded shaft ends (fig 2b).
2a
2b
52
SRAM Corporation 2005 PIKE SERVICE GUIDE

3. Firmly pull the lower leg assembly down by holding each leg or the brake arch. Spray isopropyl alcohol into lower legs. Wrap a rag around a dowel and wipe inside of lower legs clean.
MALLET.
3a
3b
IMPORTANT! DO NOT STRIKE OR TAP THIS DAMAGES THE MAGNESIUM.

THE
THE BRAKE ARCH WITH A
NOTE: SEE
AND REPLACEMENT PROCEDURES.
4. Spray isopropyl alcohol onto and into each upper tube; wipe clean.
4a
4b
U-TURN COIL SPRING

R E M O VA L
5. Using a 2.5mm hex wrench, remove U-Turn knob screw (fig 5a). Remove U-Turn adjuster knob (fig 5b). Using a magnet, remove detent ball bearings and detent springs from top cap (fig 5c).
5a
5b
5c
6. Using a 24mm socket wrench, loosen and remove U-Turn spring top cap (fig 6a). The spring is attached to the top cap and spring shaft. Pull and lift entire spring assembly from upper tube (fig 6b, 6c).
WHEN LOOSENING TOP CAPS.
6a
6b
6c
IMPORTANT! PRESS
DOWN SQUARE AND FIRM
7. Spray entire spring assembly with isopropyl alcohol and wipe all grease and oil from top cap, spring and shaft. 8. Using snap ring pliers, remove U-Turn base plate assembly from bottom of upper tube. Check assembly for damage and clean with a rag.
8a
8b
PN 95.4309.888.000, Rev. A
53

9. Insert U-Turn base plate assembly back into bottom of upper tube and secure with retaining ring. Make sure retaining ring is secure in bottom of upper tube groove. 10. Apply grease to outside of entire coil spring and spring isolators (fig 10a).
10a
11. Insert spring assembly into left upper tube, through crown. Align and seat the spring shaft through shaft guide/base plate. Press down on U-Turn spring top cap and thread into upper tube/crown (fig 11a). Using a 24mm socket wrench, tighten to 60 in-lb. (fig 11b).
11a
11b
12. Insert each detent spring into the top cap detent holes, evenly spaced. Place each detent ball bearing on top of each detent spring (fig 12a). Place U-Turn adjuster knob on top of hex. Secure with the knob screw. Tighten the screw with 2.5mm hex wrench (fig 12b).
12a
12b
MOTION CONTROL DAMPER SERVICE (ALL PIKE FORKS)

R E M O VA L
13. Compression knob: Using snap ring pliers, remove external compression adjuster knob (plastic or aluminum remote) retaining ring (figs 13a, 13d). Remove the compression adjuster knob (figs 13b, 13e) and top cap seal (figs 13c, 13e). NOTE: THE
CROWN-MOUNTED COMPRESSION ADJUSTER KNOB USES AN
13a
13b
O-RING TOP CAP SEAL
(FIG 13E).
13c
13d
13e
54

14. Using a 24mm socket wrench, loosen compression damper top cap from upper tube (fig 14a). By hand, slowly pull compression damper from upper tube (fig 14b, 14c).
14a
14b
14c
IMPORTANT!
USE
CARE WHEN REMOVING
TUBE THREADS.
THIS
A SLOW TWISTING MOTION WHILE PULLING UP. HELPS EASE THE O-RING PAST THE UPPER
USE
15

Upgrading a non-remote compression adjust fork (crown-mounted adjuster knob) to remote compression adjust (remote lever (PopLoc) adjuster), requires replacing the non-remote compression damper with a remote compression damper. The remote return spring is designed into the compression damper, and is required for use with the Pop-Loc remote lever assembly.
Remote Compression Adjust Damper Standard Compression Adjust Damper (non-remote) External Gate Adjuster Knob Spring Tube
16
17. Use snap ring pliers to remove rebound damper / seal head retaining ring and base ring, located inside bottom of right upper tube (figs 17a, 17b). Pull to remove the rebound damper and seal head from upper tube (fig 17c, 17d).
17a
17b
17c
17d
PN 95.4309.888.000, Rev. A
55

18. Slide seal head off damper shaft. Remove and replace outer and inner seal head o-rings. Coat new o-rings with suspension oil (5, 10 or 15wt).
18a
18b
18c
18d
18e
20a
20b
21. Spray isopropyl alcohol into uppertube. Wrap a clean rag around a long dowel/rod. Insert rag into upper tube and clean inside of tube.
21a
21b
56

22. Insert rebound damper piston into bottom of upper tube. Insert at an angle, open ended side of glide ring out. This aids insertion of piston and glide ring. Angle and rotate until glide ring is inside upper tube (fig 22a). Slide seal head up into upper tube step (fig 22b). Position base ring/washer and seal head into the upper tube step (fig 22c).
22a
22b
22c
23. Press seal head firmly into upper tube (fig 23a). Secure seal head into upper tube with retaining ring (fig 23b). Make sure retaining ring is secure in upper tube groove. Pull rebound damper shaft down (out) into the fully extended position.
23a
23b
24. With rebound damper shaft in the fully-extended position, measure and pour 120cc (+/-5cc) RockShox 5wt suspension oil into upper tube, through crown (fig 24a). Or, pour oil into upper tube through crown, and measure 5" (+/- 0.25") (127mm) oilheight level, measured from the top of crown, down to top of oil level (fig 24b).
24a
24b
IMPORTANT! OIL
HEIGHT IS CRITICAL.
COMPRESSION/TRAVEL, AS WELL AS RISK DAMAGE TO FORK FROM COMPRESSION BOTTOM-OUT.
TOO
TOO
25. Insert compression damper into upper tube, through crown. Press firm and push damper into upper tube slowly. Use a slow twisting motion while firmly pressing compression damper into upper tube (fig 25a). Using a 24mm socket wrench, tighten to 60 in-lb (fig 25b). NOTE:
POSITION
25a
25b
MAKE (TURN
ADJUSTER SHAFT COUNTERCLOCKWISE).
SURE COMPRESSION DAMPER IS IN THE FULL-OPEN
26. Insert compression damper top cap seal (o-ring) over top cap (fig 26a). Place compression knob onto top cap, with dial at the 3 o'clock position. Using snap ring pliers, secure compression knob with external retaining ring (fig 26b). Remote knob should be positioned with cable set screw at 3 o'clock. NOTE: REMOTE KNOB TOP CAP SEAL PICTURED AT RIGHT (FIGS 26C). REMOTE COMPRESSION
ADJUSTER WASHER/TOP CAP SEAL. KNOB USES A WHITE PLASTIC
26a
26b
26c
PN 95.4309.888.000, Rev. A
57

27. Motion Control Remote Forks: Cable Installation 1) Thread remote cable through cable stop base. 2) Thread cable around compression knob, under cable set-screw, and tighten with 2mm hex wrench. Knob should be positioned in 3 o'clock position and full-open. 3) Test PopLoc remote lever function for proper lockout/compression adjust. 4) Adjust cable tension as needed. L O W E R L E G I N S TA L L AT I O N 28. Invert fork in bicycle stand to 45-degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a clean rag. 29. Pour, or inject, a small amount of 5, 10 or 15wt RockShox suspension oil onto new or clean foam rings, just under dust seal, inside lower leg; each side.
29a
30. Slide lower leg assembly over and onto the ends of each upper tube. Ensure both dust seals slide onto the tubes correctly and do not fold under (fig 30a). Slide lower leg assembly onto upper tubes until you feel the lower bushings touch the end of the upper tubes (fig 30b). Stop.
30a
30b
31. Invert fork about 45-degress in bicycle stand. Measure and pour (or inject...an oil syringe works best) 15cc of 5wt, 10wt, or 15wt (stock) RockShox suspension oil into both lower legs, through the shaft bolt holes. Wipe all excess oil from lower leg.
31
32
58

33. Slide lower leg assembly onto upper tubes until both shaft ends appear in lower eg shaft holes. You may need to guide damper threaded shaft end, with a hex tool, into each lower leg shaft hole (fig 33a). Insert damper shaft bolt into damper threaded shaft end (right side) and tighten with a 5mm hex wrench to 60 in-lb. Repeat for spring side. Wipe away excess oil (fig 33b).
33a
33b
34. Insert external rebound damper knob into damper shaft bolt. Push in to secure.
34
35. Spray a light coating of isopropyl alcohol onto entire fork, and wipe with a clean rag.
M A X L E : D I S A S S E M B LY / S E R V I C E / A S S E M B LY
36. Remove Maxle from Pike dropouts and clean with a rag. Remove Maxle end nut. Remove small axle wedge (cone-shaped), and wedge spring. 37. Slide axle from Maxle body. Remove wedge spring, and large wedge (cone-shaped). Clean all parts with isopropyl alcohol and a rag, including Maxle QR axle and lever assembly. 38. Reassemble in the same order as removal. NOTE: DEPENDING
LOWER LEG. ON YOUR HUB WIDTH, THE CLOSE IN THE DESIRED POSITION
LOOSEN THE AXLE NUT, SLIDE THE AXLE OUT OF THE MAXLE BODY AND ROTATE THE LEVER TO THE OPPOSITE POSITION IN THE BODY. TIGHTEN END NUT, CLOSE, AND CHECK FOR THE DESIRED CLOSED LEVER POSITION.
(UP
OR DOWN) WHEN THREADED INTO
MAXLE
LEVER MAY NOT
OIL
120cc/ml

5wt 15cc/ml
Oil Weight

X

X 15cc/ml
Oil Weight
TUNING COIL SPRINGS

Rider Weight (approximate)
<140lb (63kg) 140-160lb (63-72kg) 160-180lb (72-81kg) >180 lbs (80 kg) PN 95.4309.888.000, Rev. A
PART #
11.4309.043.000 (Soft) Yellow 11.4309.044.000 (Standard) Red 11.4309.045.000 (Firm) Blue 11.4309.046.000 (X-Firm) Black 59
TROUBLE-SHOOTING
AIR LOSS
Inspect air piston o-ring and eplace if necessary. To avoid air loss, remove air top cap every month and pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. This keeps air seal lubricated. Maximum air pressure may have been exceeded. Do not exceed 20psi in AirAssist spring chamber!
L O S S O F / O R VA R I A N C E I N D A M P I N G
Inspect all damper o-rings. Replace and grease. Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height. Correct height is five inches from the top of the upper tube (when fork is set at 115mm travel). Add or remove oil as needed.
TENSION CABLE, AND TIGHTEN.
REMOTE: INSPECT
REMOTE CABLE TENSION.
CABLE MAY STRETCH TEST. ADJUST AS NEEDED.
OR BECOME LOOSE.
LOOSEN
CABLE SCREW,
COMPRESSION STROKE NOT SMOOTH

Remove both shaft bolts. Pull lowers down about an inch. Allow oil to drain. Inject or pour 10cc of fresh suspension oil into lower leg through shaft bolt holes. Lubricate upper tubes near dust seals. Press down on fork a few times. Wipe away excess lubricant.
B U S H I N G P L AY
Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100-200 riding hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings! SEE
THE
OIL LOSS
60
2005 PIKE SL/RACE/TEAM (AIR) SERVICE GUIDE
2005 Pike SL/Race/Team Air Service Guide

TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand/Clean Work Table/Area 24, 15 and 10mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) Shock Pump 5mm Hex Wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe and Measuring cup Isopropyl Alcohol/Spray Bottle 5wt and 15wt Suspension Oil Isopropyl Alcohol (in Spray Bottle)
1. Remove positive and negative air caps (figs 1a/1b). Depress negative schrader valve and release air pressure (fig 1c). Depress positive schrader valve; release air pressure (fig 1d).
1a
1b
1c
1d
Negative Air
Positive Air
2. Gently remove external rebound adjuster knob from the right shaft bolt (fig 2a). Using a 5mm hex wrench, loosen right and left shaft bolts 3 to 4 turns (fig 2b). (11.4308.846.000 05 External Rebound Adjuster Knob, Short)
2a
2b
62
SRAM Corporation 2005 PIKE AIR SERVICE GUIDE

3. Using a 10mm socket wrench, loosen DualAir shaft nut (3a). Loosen the nut so it is unthreaded just past the threaded shaft end (3b). Using a plastic mallet, tap shaft nut to free shaft press-fit inside lower leg (3b).
3a
3b
4. Using a plastic mallet, tap rebound shaft bolt free. This frees the shaft ends from the lower leg shaft bore pressfit, and allows the lower leg to be removed from upper tubes (fig 4a). Using your fingers, remove shaft bolt from both threaded shaft ends (fig 4b). Remove threaded shaft nut (fig 4c).
4a
4b
4c
5. Firmly pull the lower leg assembly down by holding each leg or the brake arch. Spray isopropyl alcohol into lower legs. Wrap a rag around a dowel and wipe inside of lower legs clean. IMPORTANT! DO NOT STRIKE OR TAP MALLET. THIS DAMAGES THE MAGNESIUM. NOTE: SEE
AND THE THE BRAKE ARCH WITH A
BUSHING SERVICE GUIDE REPLACEMENT PROCEDURES.
NO!!
6a 6b
6. Spray isopropyl alcohol onto each upper tube; wipe clean.
DUAL AIR SPRING SERVICE

R E M O VA L
7. Using a 24mm socket wrench, press firm on top cap, turn counterclockwise, and remove (figs 7a & 7b). IMPORTANT! ENSURE REMOVING TOP CAP.
ALL AIR PRESSURE IS REMOVED BEFORE
7a
7b
PN 95.4309.889.000, Rev. A
63

8. Remove fork from the bicycle stand and pour any oil inside air chamber, into oil pan.
9. Clamp fork back into bicycle stand, and wipe shaft and base plate with a rag (fig 9a).Push negative air shaft up and into base plate, leaving only tip of threaded shaft end protruding base valve (fig 9b). You may need to press the negative schrader valve to release air pressure while pushing the shaft. Slide a 15mm socket tool over the end of the threaded shaft end, and press firmly against base plate. While pressing firmly to unseat base plate, use internal snap ring pliers to remove external retaining ring. (fig 9c).
9a
9b
9c
10. When the retaining ring is removed, pull air shaft to remove air spring assembly and base plate assembly from upper tube (fig 10).
10
The DualAir spring assembly includes the following components:
Air Spring Seal Dual Air Seal Head Base Plate
S E RV I C E
11. Remove base plate, base plate o-ring/bumper and negative air piston from DualAir shaft (fig 11a). Remove both the outer and inner negative air piston o-rings (figs 11b & 11c). Replace both orings and apply grease to the new o-rings.
11a
11b
11c
12. Remove positive air piston o-ring (fig 12a). Replace with new o-ring and apply grease to new o-ring (fig 12b).
12a
12b
64

13. Insert positive air piston, followed by negative air piston into bottom of upper tube. Push up to insert (fig 13a). Insert base plate assembly into upper tube step and press in firmly. Install external retaining ring, sharp edge facing out, and ensure retaining ring is secure in upper tube groove. Note orientation of base plate / retaining ring groove, and align retaining ring accordingly (fig 13b). NOTE: BEFORE INSTALLING THE DUAL AIR SPRING ASSEMBLY, ENSURE
INSIDE OF UPPER TUBE HAS BEEN CLEANED WITH ISOPROPYL ALCHOHOL THERE ARE ANY SCRATCHES, REPLACE CROWN STEERER UPPER TUBE. AND A CLEAN RAG.
13a
13b
CHECK
FOR SCRATCHES INSIDE UPPER TUBE.
IF
14. Pour 3 to 5cc/ml of 5 wt suspension oil into upper tube (air spring side), through crown (fig 14a). Oil inside air chamber lubricates o-ring during use and maintains air seal. Clean air top cap threads and hand threaded into upper tube (fig 14b). Using a 24mm socket, tighten to 60 in-lb (fig 14c).
14a
14b
14c
MOTION CONTROL DAMPER SERVICE (ALL PIKE FORKS)

R E M O VA L
15. Compression knob: Using snap ring pliers, remove external compression adjuster knob (plastic or aluminum remote) retaining ring (figs 15a, 15c). Remove the compression adjuster knob (figs 15b, 15d) and top cap seal (figs 15b, 15e). REMOTE KNOB
AN O-RING TOP CAP SEAL
15a
15b
15c
NOTE: THE
CROWN-MOUNTED COMPRESSION ADJUSTER KNOB USES
STANDARD KNOB
(FIG 15E).
FEATURE A WHITE PLASTIC TOP CAP SEAL
REMOTE (15B).
ADJUSTER KNOBS
15d
15e
16. Using a 24mm socket wrench, loosen compression damper top cap from upper tube (fig 16a). By hand, slowly pull compression damper from upper tube (figs 16b & 16c).
16a
16b
16c
IMPORTANT!
USE
CARE
WHEN
REMOVING
SLOW TWISTING MOTION WHILE PULLING UP. THREADS.
HELPS EASE THE O-RING PAST THE UPPER TUBE
USE A THIS
PN 95.4309.889.000, Rev. A
65

17

Upgrading a non-remote compression adjust fork (crown-mounted adjuster knob) to remote compression adjust (remote lever (PopLoc) adjuster), requires replacing the non-remote compression damper with a remote compression damper. The remote return spring is designed into the compression damper, and is required for use with the Pop-Loc remote lever assembly. NOTE: SEE
FOR PART
2005 SPARE PARTS CATALOG NUMBERS.

THE
Remote No Remote Return Return Spring Spring
18
19. Use snap ring pliers to remove rebound damper / seal head retaining ring and base ring, located inside bottom of right upper tube (figs 19a & 19b). Pull to remove the rebound damper and seal head from upper tube (fig 19c & 19d).
19a
19b
19c
19d
66

20. Slide seal head off damper shaft. Remove and replace outer and inner seal head o-rings. Coat new o-rings with suspension oil (5, 10 or 15wt).
20a
20b
20c
20d
20e
22a
22b
23. Spray isopropyl alcohol into upper tube. Wrap a clean rag around a long dowel/rod. Insert rag into upper tube and clean inside of tube.
23a
23b
24. Insert rebound damper piston into bottom of upper tube. Insert at an angle, open ended side of glide ring out. This aids insertion of piston and glide ring. Angle and rotate until glide ring is inside upper tube (fig 24a). Slide seal head onto rebound damper shaft (fig 24b). Position base ring/washer and seal head into the upper tube step (fig 24c).
24a
24b
24c
25. Press seal head firmly into upper tube (fig 25a). Secure seal head into upper tube with retaining ring (fig 25b). Ensure retaining ring is secure in upper tube groove. Pull rebound damper shaft down (out) into the fully extended position.
25a
25b
PN 95.4309.889.000, Rev. A
67

26. With rebound damper shaft in the fully-extended position, measure and pour 120cc (+/-5cc) RockShox 5wt suspension oil into upper tube, through crown (fig 26a). Or, pour oil into upper tube through crown, and measure 5" (+/- 0.25") (127mm) oilheight level, measured from the top of crown, down to top of oil level (fig 26b).
26a
26b
IMPORTANT! OIL
HEIGHT IS CRITICAL.
COMPRESSION/TRAVEL, AS WELL AS DAMAGE TO THE FORK FROM COMPRESSION BOTTOM-OUT.
TOO
TOO
27. Insert compression damper into upper tube, through crown. Press firm and push damper into upper tube slowly. Use a slow twisting motion while firmly pressing compression damper into upper tube (fig 27a). Using a 24mm socket wrench, tighten to 60 in-lb (fig 27b). NOTE:
POSITION
27a
27b
MAKE (TURN
ADJUSTER SHAFT COUNTERCLOCKWISE).
SURE COMPRESSION DAMPER IS IN THE FULL-OPEN
28. Insert compression damper top cap seal (o-ring) over top cap (fig 28a). Place compression knob onto top cap, with dial at the 3 o'clock position. Using snap ring pliers, secure compression knob with external retaining ring (fig 28b). Remote knob should be positioned with cable set screw at approximately 3 o'clock. NOTE: REMOTE KNOB TOP CAP SEAL PICTURED (FIGS 28C). REMOTE COMPRESSION ADJUSTER KNOB USES A WHITE PLASTIC WASHER/TOP
AT RIGHT
28a
28b
28c
CAP SEAL.
29. Motion Control Remote Forks: Cable Installation 1) Thread remote cable through cable stop base. 2) Thread cable around compression knob, under cable set-screw, and tighten with 2mm hex wrench. Knob should be positioned in 3 o'clock position and full-open. 3) Test PopLoc remote lever function for proper lockout/compression adjust. 4) Adjust cable tension as needed.
30. Invert fork in bicycle stand to 45-degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a clean rag. 31. Pour, or inject, a small amount of 5, 10 or 15wt RockShox suspension oil onto new or clean foam rings, just under dust seal, inside lower leg; (each side).
31
68

32. Slide lower leg assembly over and onto the ends of each upper tube. Ensure both dust seals slide onto the tubes correctly and do not fold under. Slide lower leg assembly onto upper tubes until you feel the lower bushings touch the end of the upper tubes and stop.
32
33. Invert the fork about 30 - 45 degress in bicycle stand. Measure and pour (or inject...an oil syringe works best) 15cc of 5wt, 10wt, or 15wt (stock) RockShox suspension oil into both lower legs, through the shaft bolt holes. Wipe all excess oil from lower leg.
33
34
35. Slide lower leg assembly onto upper tubes until both shaft ends appear in lower leg shaft holes. You may need to guide damper threaded shaft end, with a hex tool, into each lower leg shaft hole. Insert damper shaft bolt into damper threaded shaft end (right side) and tighten with a 5mm hex wrench to 60 in-lb (fig 35a). Thread shaft nut onto threaded shaft end; tighten with 10mm socket wrench (fig 35b). Wipe away excess oil.
35a
35b
36. Insert external rebound damper knob into damper shaft bolt. Push in to secure.
36
37. Using a shock pump, inflate positive air pressure first. Refer to either the air chart in this guide or the air pressure decal on the back of the fork lower leg for air pressure settings (fig 37a). Install the air valve cover cap (fig 37b).
37a
37b
PN 95.4309.889.000, Rev. A
69

38. Using a shock pump, inflate negative air pressure. Refer to either the air chart in this guide or the air pressure decal on the back of the fork lower leg for air pressure settings (fig 38a). Install the air valve cover cap (fig 38b).
38a
38b
39. Spray a light coating of isopropyl alcohol onto entire fork and wipe with a clean rag.
M A X L E : D I S A S S E M B LY / S E R V I C E / A S S E M B LY
40. Remove Maxle from Pike dropouts and clean with a rag. Remove Maxle end nut. Remove small axle wedge (cone-shaped), and wedge spring. 41. Slide axle from Maxle body. Remove wedge spring, and large wedge (coneshaped). Clean all parts with isopropyl alcohol and a rag, including Maxle QR axle and lever assembly. 42. Reassemble in the same order as removal. NOTE: DEPENDING
INTO LOWER LEG. THE IN THE BODY. NOT CLOSE IN THE DESIRED POSITION (UP OR DOWN) WHEN THREADED ON YOUR HUB WIDTH, THE
Maxle Axle Assembly Components
MAXLE
LEVER MAY
MAXLE
LOOSEN
THE AXLE NUT, SLIDE THE AXLE OUT OF
BODY AND ROTATE THE LEVER TO THE OPPOSITE POSITION
DESIRED CLOSED LEVER POSITION.
TIGHTEN
END NUT, CLOSE, AND CHECK FOR THE
70
OIL
120cc/ml

5wt 15cc/ml
Oil Weight

3 - 5 cc/ml

5wt 15cc/ml
Oil Weight
AIR PRESSURE SETTINGS

With independently adjustable positive (top) and negative (bottom) air chambers, the air spring system of your Pike Air fork can easily be tuned for your weight and riding style. Use the following instructions as a starting point. If further fine tuning is desired, follow the hints at the end of this section.
A i r Sp r i n g Tu n i n g
Positive air pressure determines the amount of force required to compress your fork. More positive air pressure results in less suspension sag and higher bottom out forces. Less positive air pressure results in more suspension sag and lower bottom out forces. Using the chart below as a guideline, inflate the positive air chamber to the desired pressure.
St e p 1 - S e l e c t i n g P o s i t i v e A i r P r e s s u r e
Rider Weight < 140 (63kg) 140 - 160 (63-72 kg) 160 - 180 (72-81 kg) 180 - 200 (81-90 kg) >220 (99 kg)
Dual Air Positive Air Pressure 70-100 psi 100-115 psi 115-130 psi 130-145 psi 160 psi
Negative air pressure effects the amount of force required to initiate suspension travel. Negative air pressure works with bump input against the force of the positive air chamber. More negative air pressure results in a suspension set-up that is more active, especially to small bump input. Less negative air pressure results in a suspension set-up does not move or "bob" under rider input or small bumps. Using the chart below as a guideline, inflate the negative air chamber to the desired pressure. Adjust as needed to achieve the desired compression stroke.
St e p 2 - S e l e c t i n g N e g a t i v e A i r P r e s s u r e
Rider Weight < 140 (63kg) 140 - 160 (63-72 kg) 160 - 180 (72-81 kg) 180 - 200 (81-90 kg) >220 (99 kg)
Dual Air Negative Air Pressure 70-100 psi 100-115 psi 115-130 psi 130-145 psi 160 psi
PN 95.4309.889.000, Rev. A
71
TROUBLE-SHOOTING
AIR LOSS
Inspect air piston o-ring and replace if necessary. To avoid air loss, defate positive air chamber, remove air top cap every month and pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. This keeps air seal lubricated. Maximum air pressure may have been exceeded. Do not exceed receommended air pressures!
L O S S O F / O R VA R I A N C E I N D A M P I N G
Inspect all damper o-rings. Replace and grease. Inspect damper oil volume. Remove damper top cap/compression damper assembly. Using a thin ruler, measure the oil height. Correct height is five inches from the top of the upper tube (when fork is set at 140mm travel). Add or remove oil as needed.
TENSION CABLE, AND TIGHTEN.
REMOTE: INSPECT
REMOTE CABLE TENSION.
CABLE MAY STRETCH TEST. ADJUST AS NEEDED.
OR BECOME LOOSE.
LOOSEN
CABLE SCREW,
COMPRESSION STROKE NOT SMOOTH

Remove both shaft bolts. Pull lowers down about an inch. Allow oil to drain. Inject or pour 15cc of fresh suspension oil into lower
leg through shaft bolt holes.
Lubricate upper tubes near dust seals. Press down on fork a few times. Wipe away excess lubricant.
B U S H I N G P L AY
Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100-200 riding hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings! SEE
THE
OIL LOSS
Inspect the air piston o-rings for air bypass. Air pressure can force oil out of the left dust seal. Inspect your shaft bolt crush washers. Replace if worn or damaged.
72
For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com. Contact your local distributor or visit the RockShox website at www.rockshox.com for ordering information. Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at www.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others. SRAM Corporation August 2004 PN 95.4309.890.000, Rev. A
2005
BOXXER RIDE (U-TURN) SERVICE GUIDE
2005 Boxxer Ride Service Guide

1. 2. 3. 4. Remove upper crown, and remove fork from bicycle. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes. Lay tools out on work bench, and provide a clean work area for internals service. Place oil pan under fork on floor.
TOOLS
Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand and Clean Work Table/Area 24mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) 2.5mm, 5mm Hex Wrench Long and Short Plastic or Wood Dowel, 3/4" diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe & Measuring cup Isopropyl Alcohol/Spray Bottle 5wt Suspension Oil or Oil Soluable Grease Isopropyl Alcohol (in Spray Bottle)
1. Clamp the fork steerer tube into bicycle stand. Using a 4mm hex wrench, loosen lower crown bolts. Slide each upper tube down and out of crown. (fig 1a & 1b) Remove crown/steerer assembly from bicycle stand.
1a
1b
74
SRAM Corporation 2005 BOXXER RIDE SERVICE GUIDE

2. Clamp right (damper side) upper tube into bicycle stand. Using a 5mm hex wrench, loosen right shaft bolt 2 to 3 turns. Do not remove shaft bolt completely. (fig 2a) Tap shaft bolt free using a plastic mallet. This frees the damper shaft press-fit from the inner shaft bore inside bottom of lower leg. (fig 2b) NOTE: RIGHT
SIDE EQUALS RIDERS RIGHT; LEFT SIDE EQUALS
2a
2b
RIDERS LEFT.
3. Position oil pan directly below fork. Firmly pull lower leg down from upper tube. Oil will drain into oil pan. (fig 3a) Remove lower leg completely, and allow all oil to drain into oil pan. Wipe lower leg clean with a rag. The left upper tube will still be installed in left side of the lower leg. (fig 3b) Remove right side upper tube/damper assembly from bicycle stand clamp, and place on clean rag
3a
3b
4. Clamp left (spring side) upper tube into bicycle stand clamp. (fig 4a) Using a 5mm hex wrench, loosen left shaft bolt 2 to 3 turns. Do not remove shaft bolt completely. (fig 4b)
4a
4b
5. Using a plastic mallet, tap shaft bolt. (fig 5a) This frees the damper shaft press-fit from the inner shaft bore inside the bottom of the lower leg. Remove shaft bolt completely, and allow oil to drain into oil pan. (fig 5b)
5a
5b
PN 95.4309.890.000, REV. A
75

6. Firmly push or pull the lower leg down upper tube. (fig 6a) Remove the lower leg assembly completely, and allow all oil to drain into oil pan. (fig 6b & 6c) Remove upper tube from bicycle stand and set on clean rag.
6a
6b
6c
U - T U R N S P R I N G D I S A S S E M B LY
7. With the U-Turn spring upper tube still clamped in the bicycle stand clamp, use a 2.5mm hex to remove U-Turn knob screw. (fig 7a) Remove UTurn knob. (fig 7b) Using a magnet, remove all three detent ball bearings and springs. (fig 7c)
7a
7b
7c
8. Using a 24mm socket, remove the U-Turn spring top cap. (fig 8a) Pull the top cap up and lift the entire spring assembly out of the upper tube. (fig 8b) The U-Turn spring assembly consists of the top cap, spring and shaft assemblies. (fig 8c) Spray the top cap threads and U-Turn spring and spring isolators with isopropyl alcohol and wipe clean. Apply fresh grease to the spring and spring isolators.
8a
8b
8c
9. Remove the upper tube from the bicycle stand clamp. Using snap ring pliers, remove U-Turn spring base plate retaining ring from bottom of upper tube. (fig 9a & 9b) Remove base plate assembly. Check for damage, clean with isopropyl alcohol and a rag. (fig 9c) Insert base plate assembly back into upper tube, and secure with retaining ring, sharp end of retaining ring first. (Reverse removal procedure)
9a
9b
9c
76
R E B O U N D D A M P E R D I S A S S E M B LY
10. Clamp the right (rebound damper) upper tube assembly back into the bicycle stand. Using a 24mm socket, loosen and remove the damper top cap. (fig 10a & 10b) Clean top cap threads with isopropyl alcohol and a rag. Remove upper tube from bicycle stand clamp.
10a
10b
11. Using snap ring pliers, remove the rebound damper base valve retaining ring. (fig 11a) Pull to remove the damper assembly and damper base valve from upper tube. (fig 11b)
11a
11b
12. Using a dental pick, or sharp pick, check and remove the rebound damper glide ring. (fig 12a) If worn, replace with a new rebound damper glide ring.
12
HC2 REBOUND DAMPER BASE VALVE ASSEMBLY The HC2 rebound damper base valve assembly consists of: Red base valve Wavy spring washer Plastic valve washer Base valve carrier
PN 95.4309.890.000, REV. A
77
R E B O U N D D A M P E R I N S TA L L AT I O N
13. Insert the rebound damper into bottom of the right upper tube, piston first. (fig 13a) Slide base valve assembly into bottom of upper and seat snug into upper tube step. (fig 13b) Using snap ring pliers, insert and secure retaining ring, sharp end positioned out, into upper tube retaining ring groove. (fig 13b) Pull rebound damper shaft down to fully extended position.
13a
13b
14. Apply fresh grease around inside of oil seal and dust seal. (fig 14) NOTE: REFERENCE
REPLACEMENT
BUSHING SERVICE GUIDE PROCEDURES.

THE
14
FOR OIL SEAL AND DUST SEAL
15. Clamp rebound damper upper tube into bicycle stand clamp. Pull rebound damper shaft down, to the fully extended postion. Position dust seal over end of upper tube, and slide lower leg assembly up and over rebound damper upper tube. Check for proper dust seal fit. Slide lower leg up upper tube and position damper shaft end into lower leg shaft hole. (fig 15a) Clean the hollow rebound shaft bolt with isopropyl alcohol, and check the crush washer for damage. Replace if damaged. (fig 15b) Hand-thread the hollow rebound shaft bolt into threaded shaft end, and tighten with a 5mm hex wrench to 60 in-lb. (fig 15c) NOTE: INSERT
KEEP REBOUND A LONG DAMPER PLASTIC IN OR
15a
15b
15c
WOODEN DOWEL INTO THE UPPER TUBE TO EXTENDED POSITON.
TIGHTENING THE SHAFT BOLT.
THIS
FULLY
HELPS WHEN
(FIG 20C)
78

16. When shaft bolt has been tightened, pull down to extend upper tube fully. Measure and pour 220cc of 5wt suspension oil into upper tube. (fig 16a) Clean top cap threads with isopropyl alcohol and a rag. Insert into top of upper tube, and hand-thread tight. Using a 24mm socket wrench, tighten to 60 in-lb. (fig 16b)
16a
16b
U - T U R N S P R I N G I N S TA L L AT I O N
17. Insert the U-Turn spring assembly, shaft first, into U-Turn spring upper tube (gradients printed on outside of tube). Seat the shaft end through the base plate and pull shaft through base plate. (fig 17)
17
18. Insert the U-Turn spring assembly into the upper tube, shaft end first. Slide the upper tube into the dust seal and push into lower leg. Ensure the dust seal does not fold over upper tube. The threaded shaft end should be aligned into lower leg shaft bolt hole. (fig 18a) Clean the hollow rebound shaft bolt with isopropyl alcohol, and check the crush washer for damage. Replace if damaged. Hand-thread the hollow rebound shaft bolt into threaded shaft end, and tighten with a 5mm hex wrench to 60 in-lb. (fig 18b)
18a
18b
19. Using an oil mixing syringe, measure 50 cc/ml of 10wt suspension oil, and inject slowly into upper tube, through coil spring. (figs 19a) Using your hand, press down on spring top cap and hand-thread top cap into upper tube. (fig 19b) Using a 24mm socket wrench, tighten to 60 in/lbs. (fig 19c)
19a
19b
19c
PN 95.4309.890.000, REV. A
79

20. Insert each (3) detent spring into the top cap, evenly spaced. (fig 15a) Place each (3) detent ball bearings on top of each detent spring. (fig 15a) Place UTurn adjuster knob on top of top cap, over hex adjuster shaft. (fig 15b) Using a 2.5mm hex wrench, insert hex screw into adjuster shaft, through knob hole and tighten. (fig 15c)
20a
20b
FINISHING UP
21. Clamp fork steerer tube into bicycle stand. (fig 21a) Insert each upper tube into each side of crown, and slide up into crown. (fig 21a) From the tapered crease on top of upper tube, measure 154mm down to top of crown. Hold upper tube in place, and tighten crown bolt with a 4mm hex wrench. (fig 21b)
21a
21b
154mm
22. Spray isopropyl alcohol onto entire fork, and wipe clean with a clean rag. 23. Remove fork from bicycle stand clamp. Place bottom of lower legs on rubber mat, or rag, holding top of upper tubes with your hands. Slowly cycle fork up and down to circulate damping oil through rebound damper.
80
OIL
Right Leg Top (Volume) 220 cc/ml Oil Weight 5wt Left Leg Top (Volume) 50 cc/ml Oil Weight 10wt
SPRINGS
Rider Weight (approximate) < 150 lbs (60 kg) 150 - 175 lbs (60 - 80 kg) 175 - 200 lbs (80 - 90 kg) 200 - 225 lbs (90 - 102 kg) > 225 lbs (102 kg) PART # 11.4309.239.000 (Silver/Yellow, X-SOFT) 11.4309.240.000 (Yellow, SOFT) 11.4309.241.000 (Yellow/Red, MED) 11.4309.242.000 (Red, FIRM) Standard 11.4309.870.000 (Black, X-FIRM)
TROUBLE-SHOOTING
NOISE DURING COMPRESSION STROKE
Inspect coil spring isolators. Remove top caps and springs. Check spring isolators. Replace or add additional isolators, if necessary. See MY05 Spare Parts Catalog for part#s.
L O S S , O R D A M P I N G VA R I A N C E
Check shaft bolts and dust seals for oil leaks. Remove rebound damper and inspect for damage. Replace if necessary. Replace oil and dust seals, if worn. Refill with new oil to correct oil volumes and weights.
LIMITED COMPRESSION STROKE

Replace coil spring with lighter spring rate. See chart above. If fork bottoms easily during compression stroke, replace with firmer spring rate. Check oil volumes; replace oil if necessary with correct oil volumes.
PN 95.4309.890.000, REV. A
81
2005 ARIO/ARIO LOCKOUT, MC3/MC3R SERVICE
2005 Ario/Ario Lockout, MC3/MC3R Service Guide

Perform service every 100 hours of riding (or less depending on riding conditions and riding style). Check bicycle frame rear suspension pivot and shock mounting bolts regularly to ensure there is no side to side movement. Side-to-side frame movement can damage any rear shock internally. Regular maintenance ensures your rear shock performs as it should. Model year 2005 rear shock damper internals are NOT serviceable or tunable. Do NOT attempt to disassemble air shock damper body assembly!
ARIO REBOUND ADJUST SHOCK PICTURED. SAME PROCEDURE FOR ARIO LOCKOUT, MC3 AND MC3R.
1. Remove rear shock from bicycle frame. 2. Spray entire rear shock with isopropyl alcohol and wipe all dirt and mud from shock. 3. Lay tools out on work bench and provide a clean work area for service.
TOOLS
Safety Glasses Clean Rags Workbench with Mounted Vice 1.5mm Hex Wrench Sharp Pick/Dental Pick Rear Shock Pump (300 psi) Pliers 5wt Suspension Oil Isopropyl Alcohol (in Spray Bottle) Blue Threadlock
A I R C A N R E M O VA L A N D S E R V I C E
1. Spray the entire shock with isopropyl alcohol, and wipe clean with a rag. 2. Using your fingers or pliers, remove all shock eyelet mounting hardware (fig 2a, 2b).
2a
2b
3. Remove air valve cover cap (fig 3a). Using a small hex wrench, or pick, press schrader valve pin and release all air from shock (fig 3b).
SHOCK PRIOR TO REMOVING AIR CAN.
3a
3b
IMPORTANT! ALL
AIR PRESSURE MUST BE RELEASED FROM
84
SRAM Corporation 2004-2005 ARIO/ARIO LOCKOUT MC3/MC3R SERVICE GUIDE

4. Gently secure air can shock eyelet into bench vice. TIP: ALUMINUM
VICE SOFT-JAWS PROTECT THE SHOCK EYELET WHEN CLAMPED.
5. Grip the air can by hand, and turn firmly counterclockwise (fig 5a). Firmly, pull the air can up shock damper body slowly. Air pressure may release so hold can tightly while pulling up (fig 5b). Pull up and remove air can. (fig 5c)
5a
5b
5c
6. Remove negative spring spacer (white, fig 6a) and negative spring bumper (orange, fig 6b). Clean both the spacer and bumper with isopropyl alcohol and a rag.
DAMPER AND/OR SHOCK EYELET ASSEMBLY.
6a
6b
IMPORTANT! DO MC3/MC3R
NOT ATTEMPT TO DISASSEMBLE SHOCK
SHOCK DAMPERS ARE NOT SERVICEABLE.
THE ARIO
AND
AIR CAN / AIR SEAL SERVICE

7. Using a sharp pick, remove the black rubber dust seal. (fig 7a, 7b)
7a
7b
8. Hold air can, narrow end down. Using a sharp pick, remove blue air can glide ring (fig 8a, 8b).
PICK.
8a
8b
IMPORTANT! DO NOT SCRATCHES CAUSE
SCRATCH INSIDE OF AIR CAN WITH PERMANENT AIR BYPASS.
PN 95.4309.891.000, Rev. A
85

9. Spray inside of air can with isopropyl alcohol (fig 9a). Wipe inside of air can with a clean rag (fig 9b). Look inside the air can and check for any rough surfaces or scratches. Run your finger along the inside of air can to feel for scratches as well. Replace air can if scratched or damaged (fig 9c).
9a
9b
9c
10. Pinch large air piston o-ring and remove (fig 10a, 10b). NOTE: THE FIXED AIR PISTON O-RING BE SURE TO REPLACE THIS O-RING.
IS THE MAIN AIR SEAL.
10a
10b
Kit required: Ario/MC3/MC3R Service Kit (11.4309.278.000)
11. Install NEW air piston o-ring onto fixed air piston (fig 11a). Coat new
o-ring with 5wt suspension oil (fig 11b).
11a
11b
12. Install NEW blue air can glide ring (fig 12a). Install NEW air can dust seal (fig 12b).
12a
12b
12c
13. Clean air can threads (fig 13) and eyelet body threads with isopropyl alcohol and a rag.
13
86

14. Apply two or three small drops of blue threadlock to eyelet body threads, evenly spaced. Spread evenly on threads; wipe away excess threadlock.
14
15. Apply a small amount of 5wt suspension oil to inside of air can. Using your finger, spread and coat entire inner air can surface (fig 15a). Apply a light coat of 5wt suspension oil to blue glide ring and black rubber dust seal. IMPORTANT! LUBRICATION PISTON O-RING. LUBRICATION
OF PISTON O-RING REDUCES FRICTION AND O-RING WEAR. INSIDE AIR CAN ENSURES LUBRICATION OF FIXED AIR
15
16. Install negative spring bumper (fig 16a.) Install negative spring bumper spacer. (fig 16b)
16a
16b
17. Position air can over shock eyelet and slide down on shock body (fig 17a, 17b). Press air can down firmly and thread air can into eyelet body. Thread air can clockwise and tighten air can into eyelet body as tightly as possible by hand. (fig 17c) TIP: MAKE
IS FREE OF OIL. SURE OUTSIDE OF AIR CAN
17a
17b
17c
THIS
ALLOWS MORE
LEVERAGE WHEN TIGHTENING AIR CAN ONTO SHOCK EYELET BODY.
18. Inflate to desired air pressure. Install air valve cover cap. 19. Spray shock with isopropyl alcohol and wipe clean. Replace decals if necessary. 20. Insert mounting hardware into both eyelets.
18
PN 95.4309.891.000, Rev. A
87
LOCKOUT LEVER REPLACEMENT / ARIO LOCKOUT

19. Insert 1.5mm hex wrench through hole in end of lockout lever, and into hex bolt head. Unthread hex bolt and remove. Remove lockout lever and replace. IMPORTANT! REPLACE
LOCKOUT LEVER ONLY IF DAMAGED.
19
DISASSEMBLE LOCKOUT/EYELET ASSEMBLY.
LOCKOUT
ASSEMBLY IS NOT SERVICEABLE.
DO
NOT ATTEMPT TO
88
A I R P R E S S U R E S E T- U P
SETTING SAG
Sag is the amount of shock travel that is used as the rider sits stationary on the bike. Typically, sag is 15 to 25 percent of all available wheel travel. Check with your bicycle manufacturer to determine the rear wheel travel and recommended sag for your particular bike before setting sag. For the Ario rear shocks you change the air spring rate to set sag. Adjusting air pressure determines the spring rate, or stiffness, of the shock. The more you increase the air pressure, the firmer your shock will be.
S E L E C T I N G A I R P R E S S U R E ( S P R I N G R AT E )
1. Depressurize the air chamber by removing the air cap and depressing the valve core stem. 2. Because every bike is different, a good starting point is to pressurize the air chamber to an air pressure equaling half your body weight.
EQUALNG HALF YOUR BODY WEIGHT.
NOTE: AS
BICYCLE DESIGNS DIFFER SIGNIFICANTLY, YOUR BICYCLE MAY REQUIRE DIFFERENT PRESSURES
With the shock in the open position (unlocked): 3. After adding air to your shock, based on your body weight, and without sitting on the bike, move the travel indicator o-ring up next to the air can. 4. Applying your full weight, gently sit on the bike and then dismount. Measure the distance from the indicator o-ring to the wiper seal. Write it down. This measurement is your sag. Determine what percentage of total wheel travel this sag represents. 5. If the sag is less than the bicycle manufacturers recommendation, a lower air pressure should be used. Using the shock, release air pressure, and check your sag again. If the sag is greater than your bicycle manufacturers recommendation, increase the air pressure. Check you sag again. IMPORTANT! DO NOT EXCEED 250 PSI! 6. Install the air cap and ride.
TROUBLE-SHOOTING
DECREASE OR LOSS OF SMOOTH COMPRESSION STROKE
Shock body and dust seal may be dry. Apply a small amount of lubrication to shock body. Compress the shock a few times and wipe away excess lubrication.
S H O C K ' B O T TO M S - O U T ' E A S I LY
Air pressure is too light. Add air pressure and check sag. Refer to above air pressure set-up guide.
OIL LOSS
Inspect your shocks mounting hardware and eyelet bushings. If loose, replace. Remove air can and inspect shock damper/seal head/shaft. If oil is leaking from seal head, replace shock damper. Inspect air can dust seal. If cracked, knicked, or cut, replace dust seal and glide ring. Inspect frame alignment. Remove shock. Clamp bicycle in bicycle work stand. Holding the seatpost and the rear end of the frame, move rear end side to side. If pivots are loose, tighten according to manufacturers recommended torque settings.
SHOCK DOES NOT LOCK OUT

Inspect shock for oil loss. If oil is leaking, replace shock damper assembly. Contact your distributor or dealer for the correct damper assembly.
PN 95.4309.891.000, Rev. A
89
For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com. Contact your local distributor or visit the RockShox website at www.rockshox.com for ordering information. Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at www.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others. SRAM Corporation August 2004 PN 95.4309.892.000, Rev. A
2005
2005 Bushing Service Guide
WHY DO YOU NEED
TO
REPLACE YOUR SUSPENSION FORK BUSHINGS?
Suspension fork bushings are considered a wear and tear part and require regular maintenance, depending on frequency of riding, riding terrain, rider body weight, use of disc brakes, and the type of fork you ride. The more you ride, the more frequently your bushings need to be replaced. S Y M P TO M S O F W O R N B U S H I N G S
Headset may feel loose Fork may knock when ridden
HOW
TO
CHECK
FOR
LOOSE BUSHINGS
1. Hold the front brake lever tight, and rock the bike back and forth. If the fork feels like its knocking, or the headset feels loose, proceed to steps 2 and 3. 2. Check the fork: Wrap your fingers around the dust seal and upper tube area. Rock the bike back and forth once again. Listen and feel if there is any play between the upper tube and the dust seal. If so, the bushings are loose. 3. Check the headset: Wrap your fingers around the headset upper cup, or lower cup/race areas. Holding the brake, rock the bike back and forth and feel if the headset is loose. If so, tighten the headset and check again.
PA R T S N E E D E D
Visit your local SRAM dealer for parts you will need. If the parts are not in stock, your dealer can place an order with their SRAM distributor. For a more comprehensive list of RockShox spare parts, check out the Spare Catalog at www.rockshox.com.
DUST SEAL KITS 11.4307.250.000 11.4307.298.000 11.4308.850.000 11.4307.312.000 11.4307.251.000 11.4307.280.000 11.4307.296.000 11.4308.851.000 11.4305.621.000 PILOT/SID DUST SEAL KIT PSYLO/DUKE DUST SEAL/FOAM RING KIT REBA/PIKE DUST SEAL/OIL SEAL/FOAM RING KIT BOXXER DUST/OIL SEAL REPLACEMENT KIT BUSHING KITS SID, PILOT, JUDY BUSHING KIT (10mm Upr, 20mm Lwr) DUKE BUSHING KIT (30mm Upr/30mm Lwr) PSYLO BUSHING KIT (30mm Upr/45mm Lwr) REBA/PIKE BUSHING KIT (30mm Upr/30mm Lwr) BOXXER BUSHING KIT (10mm Upr/76mm Lwr)
92
SRAM Corporation 2005 BUSHING SERVICE GUIDE
TOOLS
STANDARD SHOP TOOLS

AND
LUBRICANTS NEEDED
Plastic Mallet Oil Pan Work bench with mounted vice 24mm Socket Wrench 22mm Socket Wrench (00-02 Boxxer) 10mm Socket Wrench (SID DualAir fork, 05 Reba, 05 Pike Air, 02 Duke Race, 02 Psylo Race) 5mm hex wrench Flat-head screw driver Shock Pump (Air forks only) Clean rags Oil mixing syringe Isopropyl Alcohol/Spray Bottle RedRum or 15wt suspension fork oil Oil Soluable Grease 5wt Suspension Fork Oil
LUBRICANTS
ROCKSHOX BUSHING TOOLKITS

11.4306.351.000 11.4306.352.000 11.4306.353.000 11.4306.354.000 11.4306.357.000 11.4307.498.000 11.4309.121.000 11.4307.499.000 11.4308.585.000 11.4308.722.000 FORK BUSHING REMOVAL TOOLKIT (32MM/30MM/28MM) FORK BUSHING INSTALLATION TOOLKIT (30MM/28MM) 32MM BUSHING INSTALL TOOL (BOXXER/REBA/PIKE) PSYLO/DUKE BUSHING INSTALLATION SLEEVE KIT BOXXER BUSHING INSTALLATION SLEEVE KIT JUDY/PILOT/SID BUSHING INSTALLATION SLEEVE KIT REBA/PIKE BUSHING INSTALLATION SLEEVE KIT PSYLO/DUKE BUSHING REMOVAL PLATE KIT DUST SEAL INSTALLATION TOOL (28MM/30MM) BOXXER/REBA/PIKE DUST/OIL SEAL INSTALLATION TOOL
28mm/30mm Bushing Installation Tool Pilot/SID Sleeve & Spacers Duke/Psylo Sleeve & Spacers
Mallet Drift
32mm Bushing Installation Tool Boxxer/Reba/Pike Oil Seal/Dust Seal Tool Reba/Pike Sleeve & Spacer 00-05 Boxxer Sleeve & 05 Spacer 28mm/30 mm Dust Seal Tool
Univeral Bushing Removal Tool
28mm 30mm 32mm Bushing Removal Plates
PN 95.4309.892.000, Rev. A
93
R E M O VA L : D U S T S E A L S , O I L S E A L S
SEE
AND
BUSHINGS
PIKE
PICTURED)
THE APPROPRIATE COMPLETE SERVICE GUIDES FOR FORK DISASSEMBLY AND ASSEMBLY PROCEDURES.
D U S T S E A L / O I L S E A L R E M O V A L (A L L
FORK MODELS :
SID,B OXXER
AND
1. Using a medium to large flat-head screwdriver, pry the old dust seal from the lower leg (fig. 1). 2. Remove the oil foam ring (fig. 2). 3. 2000 and 2001 Judy, SID and Psylo forks feature an inner oil seal, located just below the dust seal. To remove this oil seal, use a flathead screwdriver to pry the seal from the lower leg. The improved current Samurai dust seal eliminates the need for the oil seal. 4. All Boxxer, Reba and Pike forks feature an inner oil seal. You will need to remove this if you plan to replace it (Boxxer pictured). a. 2000 - 2002 Boxxer: Remove snap ring and large washer. b. Using a flat-head screwdriver, pry the oil seal out of lower leg and discard. To protect the lower leg paint, place a rag in between the lower leg and the screwdriver (fig. 3 & 4).
PIKE/REBA
REMOVE WORN BUSHINGS : A LL MODELS

1. Clamp Bushing Removal Handle/Puller tool into bench vice. Clamp vice tight (fig. 1). 2. With the correct bushing removal plate installed onto handle end, slide lower leg over the removal plate, below the upper bushing. (fig. 2) 28mm Plate (Judy/Pilot/SID) 30mm Plate (Duke/Psylo) 32mm Plate (Boxxer) 3. Slide the removal plate past the upper bushing, pull lower leg away from puller, and hook the flat end of the plate secure under the bushing. The removal plate pivots when inserted. When plate is secure under bushing, begin to remove (fig. 3).
Remove screw to change plate
32mm Removal Plate
30mm Removal Plate
28mm Removal Plate
94

4. To pull the upper bushing free from the lower leg, using a plastic mallet, firmly hit the top of the lower leg on the flat dust seal surface-area, until bushing pulls free. NOTE: SAME
PROCEDURE FOR
B OX X E R .
SID
DUKE
PSYLO
PIKE/REBA
SID
DUKE
PSYLO
PIKE/REBA
4. To pull the lower bushing free from the lower leg, slide the removal plate past the lower bushing, and hook the flat end of the plate secure under the bushing. Again, firmly hit the top of the lower leg, flat dust seal surface area, until bushing pulls free. Longer lower bushings require more force. 5. Repeat other side.
SID
DUKE
PSYLO
REBA/PIKE
SID
DUKE
PSYLO
REBA/PIKE
PN 95.4309.892.000, Rev. A
95
B U S H I N G I N S TA L L AT I O N
B U S H I N G I N S TA L L AT I O N : 2 8 M M ( P I L O T & S I D )
PREPARATION: CLAMP 28MM/30MM VICE.
BUSHING INSTALLATION TOOL INTO BENCH-MOUNTED
LOWER BUSHING: 28MM JUDY/PILOT/SID

1. 2. 3. 4. 5. 6. Slide lower 28mm Judy/Pilot/SID bushing sleeve onto bushing installation post (fig. 1). Slide 20mm lower bushing onto top of lower bushing installation sleeve (fig. 2). Slide lower leg over installation post, and rest on top of lower bushing (fig. 3). Insert the mallet drift tool into the lower leg shaft hole, and hold in place with one hand (fig. 4). Using a plastic mallet, hit the drift to press the bushing into the lower leg (fig. 4). Hit the drift until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel the stop-point, as the bushing is set into the lower leg (fig. 4). 7. Repeat on other side. NOTE: SID LOWER LEG PICTURED. SAME PROCEDURE FOR PILOT AND 00-02 JUDY.
Clamp Installation Plate/Post, tapered edge aligned with end of vice
1
Lower Bushing Sleeve 20mm Lower Bushing
3
Drift tool
UPPER BUSHING: 28MM JUDY/PILOT/SID

1. Remove lower bushing installation sleeve from bushing installation post. 2. Slide 5mm Judy/Pilot/SID upper bushing installation spacer onto bushing installation post (fig. 1). 3. Slide 10mm Judy/Pilot/SID upper bushing installation spacer onto bushing installation post. Spacer will rest on top of 5mm spacer (fig. 1) 4. Slide 10mm upper bushing onto bushing installation post. Bushing will rest on top of 10mm spacer (fig. 2). 5. Slide lower leg over installation post, and rest on top of upper bushing (fig. 3). 6. Insert mallet drift tool into the lower leg shaft hole, and hold in place. 7. Using a plastic mallet, hit the mallet drift to press the bushing into the lower leg. 8. Hit the drift until the lower leg dust seal ridge is flush with the installation post plate. You will feel the stop point as the bushing is set into lower leg (fig 3). 9. Remove lower leg from tool. Inspect bushing. Bushing should be flush with the top of the dust seal counter bore step. Do not press bushing below bore step. It is best to tap the bushing in, then remove lower leg and check the fit. Continue to tap bushing until it is flush with bore step (fig 3). 10. Repeat other side. NOTE: SID
LOWER LEG PICTURED.
SAME
PROCEDURE FOR
PILOT
AND
0 0 - 0 2 J U D Y.
96
10mm Spacer 5mm Spacer
20mm Lower Bushing
Flush with spacer
B U S H I N G I N S TA L L AT I O N : 3 0 M M D U K E LOWER BUSHING: 30MM DUKE

1. Slide lower 15mm Duke lower bushing sleeve spacer (for 30mm lower bushing) onto installation post (fig. 1). 2. Slide the long Duke/Psylo lower bushing sleeve onto bushing installation post. The sleeve will rest on top of 15mm spacer (fig. 1). 3. Slide 30mm slotted bushing (thin-walled) onto top of lower bushing installation sleeve (fig. 2). 4. Slide Duke lower leg over installation post, and rest on top of lower bushing (fig. 3). 5. Insert the mallet drift tool into the lower leg shaft hole, and hold in place (fig. 4). 6. Using the plastic mallet, hit the mallet drift tool to press the bushing into lower leg (fig. 4). 7. Hit the drift until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel the stop-point, as the bushing is set into the lower leg (fig. 5). 8. Repeat on other side.
Duke / Psylo Lower Bushing Sleeve
1
30mm Duke Lower Bushing 15mm Duke Sleeve Spacer
PN 95.4309.892.000, Rev. A
97

UPPER BUSHING: 30MM DUKE FOR
IMAGES, SEE
P S Y L O U P P E R B U S H I N G I N S TA L L AT I O N ( S A M E
PROCEDURE)
1. Remove Duke lower bushing sleeve and spacer from bushing installation post. 2. Slide Duke/Psylo upper bushing installation sleeve onto bushing installation post. Bushing will rest on top of Duke/Psylo upper installation sleeve (fig. 1). 3. Slide 30mm Duke (thick-walled) upper bushing onto bushing installation post. Bushing will rest on top of Duke/Psylo upper bushing installation sleeve (fig. 2). 4. Slide Duke lower leg over installation post, and rest on top of upper bushing (fig. 3). 5. Insert the mallet drift tool into the lower leg shaft hole, and hold in place (fig. 4). 6. Using the plastic mallet, hit the mallet drift tool to press the bushing into lower leg (fig. 4). 7. Hit the drift until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel the stop-point, as the bushing is set into the lower leg (fig. 5). 8. Remove lower leg, and check bushing. Upper bushing should be flush with top of dust seal counter-bore step. 9. Repeat on other side.
B U S H I N G I N S TA L L AT I O N : 3 0 M M P S Y L O LOWER BUSHING: 45MM PSYLO

IMPORTANT: 45MM LOWER LEGS, REPLACE LOWER LEG
BUSHING NOT COMPATIBLE WITH ASSEMBLY WITH
2004
LOWER LEG ASSEMBLY IF BUSHINGS NEED TO BE REPLACED.
2001 PSYLO
LOWER LEGS.
FOR 2001 PSYLO
LOWER
Slide the Duke/Psylo lower bushing sleeve onto bushing installation post. (fig. 1) Slide 45mm slotted bushing (thin-walled) onto top of lower bushing installation sleeve (fig. 1). Slide Psylo lower leg over installation post, and rest on top of lower bushing (fig. 2). Insert the mallet drift tool into the lower leg shaft hole, and hold in place (fig. 3). Using the plastic mallet, hit the mallet drift tool to press the bushing into lower leg (fig. 3). Hit the drift until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel the stop-point, as the bushing is set into the lower leg (fig. 3). 7. Repeat on other side.
1. 2. 3. 4. 5. 6.
Duke / Psylo Lower Bushing Sleeve
1
Psylo Lower Bushing
98

U P P E R B U S H I N G : 3 0 M M P S Y L O ( C O M PAT I B L E
WILL ALL
PSYLO
LOWER LEGS)
1. Remove Duke/Psylo lower bushing sleeve from bushing installation post. 2. Slide Duke/Psylo upper bushing installation sleeve onto bushing installation post, thin side up. (fig. 1) 3. Slide 30mm Psylo upper bushing (thick-wall bushing) onto bushing installation post. Bushing will rest on top of bushing installation sleeve. (fig. 2) 4. Slide lower leg over installation post, and rest on top of upper bushing. (fig. 3) 5. Insert mallet drift tool into Psylo lower leg shaft hole, and hold in place. (fig. 4) 6. Using a plastic mallet, hit the mallet drift tool to press the bushing into the lower leg. (fig. 4) 7. Hit the drift until the lower leg dust seal ridge is flush with the installation post plate. You will feel the stop-point as the bushing is set into lower leg. (fig. 5) 8. Remove lower leg from post tool and check upper bushing. Bushing should be flush with the top of the dust seal counterbore step. 9. Repeat other side.
1
Duke/Psylo Upper Bushing Sleeve Duke/Psylo Upper Bushing
B U S H I N G I N S TA L L AT I O N : 3 2 M M B O X X E R LOWER BUSHING: 30MM & 76MM BOXXER LOWER BUSHING 76MM 2005 BOXXER LOWER BUSHING
NOTE: 05
BUSHING IS COMPATIBLE WITH THE
00-04 BOXXER
LOWER LEGS.
BOTH
PROCEDURES INCLUDED.
PREPARATION: CLAMP
BOXXER BUSHING INSTALLATION
POST TOOL INTO VICE.
1. 2000-2004 BOXXER: Slide the Boxxer lower bushing sleeve onto bushing installation post (fig. 1). 2005 BOXXER: Slide 05 Boxxer lower bushing installation spacer over post tool, and rest at bottom on plate (fig. 3). 2. 2000-2004 BOXXER: Slide 30mm bushing onto top of lower bushing installation sleeve (fig. 2). 2005 BOXXER: Slide 76mm lower bushing on top of lower bushing installation sleeve (not pictured). 3. Slide Boxxer lower leg over installation post, and rest on top of lower bushing (fig. 4). 4. Insert the mallet drift tool into the lower leg shaft hole, and hold in place (fig. 5). 5. Using the plastic mallet, hit the mallet drift tool to press the bushing into lower leg (fig. 6). 6. Hit the drift until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel the stop-point, as the bushing is set into the lower leg (fig. 6). 7. Repeat on other side.
PN 95.4309.892.000, Rev. A
99
05 Boxxer Installation Spacer (76mm Lower Bushing)
UPPER BUSHING: 10MM BOXXER ( C O M PAT I B L E

WITH
00-05 BOXXER
LOWER LEGS)
1. Remove Boxxer lower bushing sleeve, and 05 lower bushing spacer (if used on 05 Boxxer lower leg) from Boxxer bushing installation post. 2. Slide 10mm Boxxer upper bushing onto Boxxer bushing installation post (fig. 1) 3. Slide lower leg over installation post, and rest on top of upper bushing (fig. 2). 4. Insert Boxxer mallet drift tool into the lower leg shaft hole, and hold in place (fig. 3). 5. Using the plastic mallet, hit the mallet drift tool to press the upper bushing into lower leg (fig.3). 6. Hit the drift until the lower leg dust seal ridge is flush with the upper bushing/oil seal step in the lower leg. The stop-point on the post tool is about 5mm above the plate. You will feel the stop-point, as the bushing is set into the lower leg. Remove the lower leg from ths installation post, and check the bushing fit. The top of the bushing should be flush/level with oil seal step in the lower leg (fig. 4). 7. Repeat on other side.
1
10mm Upper Bushing
3
Tap upper bushing until lower leg is 5mm above post step.
100

B U S H I N G I N S TA L L AT I O N : 3 2 M M R E B A / P I K E LOWER BUSHING: 30MM REBA/PIKE (PIKE
1. 2. 3. 4. 5. 6.
PICTURED, SAME PROCEDURE FOR BOTH)
Slide the Reba/Pike lower bushing sleeve spacer onto 32mm bushing installation post. (fig. 1). Slide Reba/Pike lower bushing installation sleeve on 32mm bushing installation post (fig. 2). Slide Reba/Pike 30mm slotted lower bushing onto the top of the lower installation sleeve (fig. 3). Slide lower leg over installation post and rest on top of lower bushing (fig. 4). Reba: insert mallet drift tool into the lower leg shaft hole and hold in place. Using a plastic mallet, hit the bottom of the lower leg (Pike), or the mallet drift tool (Reba) to press the bushing into the lower leg (fig. 4). 7. Hit the lower leg, or mallet drift, until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel the stop-point, as the bushing is set into the lower leg(fig. 5).. 8. Repeat on other side.
1
Reba/Pike Lower Bushing Install Spacer Reba/Pike Lower Bushing Install Sleeve
Reba/Pike Lower Bushing
UPPER BUSHING: 30MM REBA/PIKE (PIKE
PICTURED, SAME PROCEDURE FOR BOTH)
1. Remove Reba/Pike lower bushing sleeve. Leave lower bushing spacer on installation post/base tool (fig. 1). Reba/Pike Upper 2. Slide 30mm Reba/Pike upper bushing (nonBushing slotted) onto 32mm bushing installation post. (fig. 1). 3. Slide lower leg over installation post, and rest Reba/Pike on top of the upper bushing (fig. 2). Install Sleeve 4. Reba: insert mallet drift tool into the lower leg Spacer shaft hole and hold in place. 5. Using the plastic mallet, hit the mallet drift tool (Reba), or bottom of lower leg (Pike), to press the upper bushing into lower leg (fig. 2). 6. Hit the drift until the lower leg rests flush on top of install spacer. You will feel the stop-point, as the bushing is set into the lower leg. Remove the lower leg from the installation post, and check the bushing fit. The top of the bushing should be flush/level with oil seal step in the lower leg. (fig. 2) 7. Repeat on other side.
PN 95.4309.892.000, Rev. A
101
I N S TA L L AT I O N : D U S T S E A L S , F O A M R I N G S , & O I L S E A L S
PILOT / SID / DUKE / PSYLO
SID L O W E R L E G P I C T U R E D . S A M E P R O C E D U R E F O R P I L O T , D U K E A N D P S Y L O . 1. Soak new foam rings in 5, 10 or 15wt suspension oil (fig. 1). 2. Slide 28mm/30mm Dust Seal Installation Tool over 28mm/30mm Bushing Installation Post tool (fig. 2). 3. Slide new dust seal over bushing installation post tool and fit on top of Dust Seal Installation tool (fig. 3). 4. Slide oil-saturated foam ring over bushing installation post tool and fit on top of dust seal. Seat the foam ring inside the under cavity of dust seal (fig. 4). 5. Using a clean rag and isopropyl alcohol, clean the inside of the dust seal area of the lower leg (fig. 5). 6. Slide lower leg onto bushing installation post, on top of new dust seal. Using a plastic mallet, lightly tap on the lower leg drop-out until dust seal seats inside lower leg, flush with the top of lower leg dust seal step (fig. 6). 7. Dust seal should be press-fit snug into the lower leg (fig. 7). 8. Repeat on other side.
102

REBA / PIKE / BOXXER
SAME PROCEDURE FOR REBA, PIKE, AND BOXXER. BOXXER PICTURED. 1. Apply grease or 15wt suspension oil to the inside of the Reba, Pike or Boxxer lower leg oil seal counter-bore. (fig. 1) 2. Insert the oil seal onto the stepped end of the 32mm Oil Seal Installation tool (fig 2). 3. Using the 32mm Oil Seal Installation tool, insert the oil seal down and into the oil step in the lower leg. Apply pressure on all sides of the oil seal to seat it into place (fig. 3 & 4). BOXXER NOTE: THE 2000-2002 OIL SEAL WASHER AND SNAP RING ARE NO LONGER REQUIRED WHEN REPLACING OIL AND DUST SEALS. NO NEED TO RE-INSTALL. 2004 DUST SEAL KITS DO NOT INCLUDE THE OIL SEAL WASHER AND SNAP RING. 4. Reba/Pike: Insert new oil-saturated foam ring onto lower leg and on top of newly installed oil seal. 5. Insert new dust seal into the other (wide) end of the 32mm dust seal installation tool (fig. 5). 6. Insert dust seal into lower leg, and press straight down evenly to seat into lower leg (fig. 6). 7. Dust seal should be press-fit snug and flush into lower leg (fig. 7 and 8). REBA / PIKE NOTE: CHECK FOAM RING UNDER DUST SEAL. FOAM RING SHOULD NOT PROTRUDE FROM DUST SEAL AND OIL RING. IF SO, ADJUST FOAM RING INSIDE LOWER LEG, FLUSH ALL ON SIDES. 8. Repeat on other side.
FINISHING
1. 2. 3. 4.
UP!
Spray entire completed lower leg assembly with isopropyl alcohol. Wipe lower leg assembly clean with a rag. Check decals and replace if necessary. Refer to the Lower Leg Removal and Installation Service Guide or the fork model service guide for installation procedures.
PN 95.4309.892.000, Rev. A
103
www.sram.com www.rockshox.com
WORLD HEADQUARTERS SRAM Corporation 1333 North Kingsbury, 4th floor Chicago, Illinois 60622 phone: +1-312-664-8800 fax: +1-312-664-8826 EUROPEAN HEADQUARTERS SRAM Europe Basicweg 12-D 3821 BR Amersfoort The Netherlands phone: +31-33-450-6060 fax: +31-33-457-0200 ASIAN HEADQUARTERS SRAM Taiwan No. 1598-8 Chung Shan Road Shen Kang Hsiang, Taichung County 429 Taiwan phone: +886-4-2561-3678 fax: +886-4-2561-3686

2005 RockShox Wartungshandbuch

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2005

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