2007 RockShox Technical Manual Rev B1

2007 ROCKSHOX TECHNICAL MANUAL (ENGLISH)Part# 95-4015-011-000, Rev. B

© SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL �

TABLE OF CONTENTS

Getting Started Information...................................................................................................................5ForkTechnologyDesignation..................................................................................................................................6ToolsNeededforService........................................................................................................................................8OilVolumes...............................................................................................................................................................10

Lower Leg Removal (All Forks)...............................................................................................................................13

Bushing Service (All Forks)......................................................................................................................................15

Damper Service...............................................................................................................................................................25Rebound & Turnkey(Dart2,2withTurnkey,3-Domain302-Recon335-Tora289,302)..............................................................26Motion Control(Argyle318,409-Domain318-Tora318)............................................................................................................29Motion Control(BoXXerRace,Team,WC-Pike409,426-RebaSL,Race,Team,WC-Recon351-Revelation409,426)................................................................................................................................................32Motion Control(SIDTeam,WC)........................................................................................................................................................35Pure Delite(SIDRace).................................................................................................................................................................39Mission Control(Lyrik-Totem)...........................................................................................................................................................41

Spring Service.................................................................................................................................................................45Coil(Argyle302,318-Dart1,2,2(withTurnkey),3-Domain302,318-Tora289,302,318)...............................46Coil(BoXXerRace,Team-Recon327,335,351-Totem)..........................................................................................47Coil U-Turn(Domain302,318-Tora289,302,318).................................................................................................................48Coil U-Turn(Lyrik-Pike409,426,454-Recon327,351-Revelation426)...........................................................................49Solo Air(Argyle409,Recon335,351-Tora318)...............................................................................................................50Solo Air(BoXXerWC-Lyrik-Recon327,335,351-Totem).............................................................................................53Dual Air(Pike409,426-RebaSL,Race,Team,WC-Revelation409,426)...................................................................56Air U-Turn(Pike409,429-RebaRace,Team-Revelation409,429)..................................................................................602-Step Air(Lyrik-Totem)............................................................................................................................................................64

Lower Leg Installation (All Forks)..........................................................................................................................67

Rear Shock Service (All Shocks)...........................................................................................................................71

95-4015-011-000, REv. B4 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 5

GETTING STARTED INFORMATION

Forexplodeddiagramsandpartnumberinformation,pleaserefertotheSparePartsCatalog,whichisavailableonourwebsiteatwww.rockshox.com

Fororderinginformation,pleasecontactyourlocaldistributororvisitourwebsiteatwww.rockshox.com.

Informationcontainedinthispublicationissubjecttochangeatanytimewithoutpriornotice.Forthelatesttechnicalinformation,pleasevisitourwebsiteatwww.rockshox.com.Productnamesusedinthismanualmaybetrademarksorregisteredtrademarksofothers.

SAFETY FIRST!At SRAM Corporation, we care about YOU, our customer.

Please, ALWAYS wear your safety glasses when servicing your RockShox fork. There are just too many trails to ride, vistas to

summit and sunrises to see.Protect your eyes! Wear your safety glasses!

95-4015-011-000, REv. B� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 7

FORK TECHNOLOGY DESIGNATION (CONT)

FORK MODEL

DAMPER TECHNOLOGY

SPRING TECHNOLOGY

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REVELATION409DUALAIR X X

REVELATION409AIRU-TURN X X

REVELATION426DUALAIR X X

REVELATION426COILU-TURN X X

REVELATION426AIRU-TURN X X

SIDRACE X X

SIDTEAM X X

SIDWORLDCUP X X

TOTEMCOIL X X

TOTEMSOLOAIR X X

TOTEM2-STEP X X

TORA289 X X

TORA289 X X

TORA302 X X

TORA302 X X

TORA318 X X

TORA318 X X

TORA318 X X

FORK TECHNOLOGY DESIGNATION(ALL FORKS)

Thefollowingchartisacompletelistofthe2007RockShoxforkline-up.Itdetailstheforkmodelandcorrespondingdamper and spring technology specific to each fork. It is important to determine the technology used in your fork, in order tosuccessfullyserviceit,asthismanualissectionedbytechnology,ratherthanforks.Ifyouareunsureofthetechnol-ogyusedinyourfork,consultyourlocalRockShoxdealerforassistance.

FORK MODEL

DAMPER TECHNOLOGY

SPRING TECHNOLOGY

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ARGYLE302 X X

ARGYLE318 X X

ARGYLE409 X X

BOXXERRACE X X

BOXXERTEAM X X

BOXXERWORLDCUP(WC) X X

DART1 X

DART2(WITHTURNKEY) X X

DART2 X X

DART3 X X

DOMAIN302 X X

DOMAIN302COILU-TURN X X

DOMAIN318 X X

DOMAIN318COILU-TURN X X

LYRIKCOILU-TURN X X

LYRIKSOLOAIR X X

LYRIK2-STEP X X

PIKE409COILU-TURN X X

PIKE409AIRU-TURN X X

PIKE409DUALAIR X X



PIKE426DUALAIR X X

PIKE454DUALAIR X X



REBASL X X

REBARACE X X

REBARACEAIRU-TURN X X

REBATEAM X X

REBATEAMAIRU-TURN X X

REBAWORLDCUP(WC) X X

RECON327SOLOAIR X X

RECON335 X X

RECON335SOLOAIR X X

RECON351 X X

RECON351COILU-TURN X X

RECON351SOLOAIR X X

95-4015-011-000, REv. B� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 9

TOOLSLOWER LEG

REMOVALBUSHING SERVICE

DAMPER SERVICE

SPRING SERVICE

LOWER LEG INSTALLA-

TION

REAR SHOCK

SERVICEOIL/LIQUIDS2.5,5,10OR15WTSUSPENSIONOIL X X X X X

GREASE X X X X

OILMEASURINGDEVICE X X X X X

ISOPROPYLALCOHOL X X X X X X

BLUETHREADLOCK X

COLDFROSTYBEVERAGE X X X X X X

TOOLS NEEDED FOR SERVICE (CONT)TOOLS NEEDED FOR SERVICE(ALL FORKS)

Thefollowingchartisalistofthemodelyear2007toolsneededforserviceonyourRockShoxfork.Whilethischartisintendedtobecomprehensive,itisstillonlyaguide.Thetoolsrequiredforeachstepofservicearedetailedinthetextofeach service section. Keep in mind your specific fork may not require every tool listed.

TOOLSLOWER LEG

REMOVALBUSHING SERVICE

DAMPER SERVICE

SPRING SERVICE

LOWER LEG INSTALLA-

TION

REAR SHOCK

SERVICESAFETY/STARTING EQUIPMENTSAFETYGLASSES X X X X X X

APRON X X X X X X

RUBBERGLOVES X X X X X X

CLEANRAGS(LINTFREE) X X X X X X

OILPAN X X X X X X

CLEANWORKAREA X X X X X X

BICYCLESTAND X X X X

BENCHVICE X X

WRENCHES/PLIERS1.5MMHEX X

2MMHEX X

2.5MMHEX X X X

4MMHEX X¹ X² X¹

5MMHEX X X

10MMSOCKETOROPENENDEDWRENCH X X

15MMSOCKET X

24MMSOCKET X X

24MMTHINWRENCH X²

TORQUEWRENCH X X

SLIPJOINTPLIERS X² X

SNAPRINGPLIERS-INTERNAL X X

SNAPRINGPLIERS-EXTERNAL X X

MISC TOOLSPLASTICMALLET X X X X X

MALLETDRIFTTOOL X

LONGDOWELROD(PLASTICORWOOD) X X X X X

FLATHEADSCREWDRIVER X X

SHARPPICK X X X

SHOCKPUMP X³ X X X

MAGNET X

RULER X³ X¹

SIDDUALAIRUPPERTUBERETAINERTOOL X4

BUSHINGREMOVALTOOL/PLATE X

¹BoXXerOnly²MissionControlOnly³SIDRaceOnly4SIDModelsOnly


OIL VOLUMES (CONT)

FORK MODEL

RIGHT LEG (DAMPER) LEFT LEG (SPRING)

TOP BOTTOM TOP BOTTOM

VOLUME(CC/ML) OILWT

VOLUME(CC/ML) OILWT

VOLUME(CC/ML) OILWT

VOLUME(CC/ML) OILWT

REVELATION409DUALAIR 115 5 15 15 6 15 15 15

REVELATION409AIRU-TURN 115 5 15 15 6 15 15 15

REVELATION426DUALAIR 115 5 15 15 6 15 15 15

REVELATION426COILU-TURN 115 5 15 15 - - 30 15

REVELATION426AIRU-TURN 115 5 15 15 6 15 15 15

SIDRACE 5 15 10 15 6 15 10 15

SIDTEAM - - 10 15 6 15 10 15

SIDWORLDCUP - - 10 15 6 15 10 15

TOTEMCOIL 137 5 20 15 - - 20 15

TOTEMSOLOAIR 137 5 20 15 6 15 20 15

TOTEM2-STEP 137 5 20 15 135 2.5 20 15

TORA289 145 5 15 15 - - 20 15

TORA289COILU-TURN 145 5 15 15 - - 30 15

TORA302 145 5 15 15 - - 20 15

TORA302COILU-TURN 145 5 15 15 - - 30 15

TORA318 145 5 15 15 - - 20 15

TORA318COILU-TURN 145 5 15 15 - - 20 15

TORA318SOLOAIR 130 5 15 15 6 15 15 15

OIL VOLUMES(ALL FORKS)

Thefollowingchartisacompletelistofthemodelyear2007RockShoxforkline-up.Itdetailstheoilvolumeandweightforeachforkleg.

FORK MODEL

RIGHT LEG (DAMPER) LEFT LEG (SPRING)TOP BOTTOM TOP BOTTOM

VOLUME(CC/ML) OILWT

VOLUME(CC/ML) OILWT

VOLUME(CC/ML) OILWT

VOLUME(CC/ML) OILWT

ARGYLE302 130 5 10 15 - - 30 15

ARGYLE318 130 5 10 15 - - 30 15

ARGYLE409 130 5 10 15 6 15 15 15

BOXXERRACE 150 5 15 15 30 15 - -

BOXXERTEAM 150 5 15 15 30 15 - -

BOXXERWORLDCUP(WC) 150 5 15 15 6 15 15 15

DART1 - - 20 15 - - 20 15

DART2(WITHTURNKEY) 93 5 10 15 - - 20 15

DART2 150 5 - - - - 20 15

DART3 93 5 10 15 - - 20 15

DOMAIN302 200 5 10 15 - - 15 15

DOMAIN302COILU-TURN 200 5 10 15 - - 15 15

DOMAIN318 200 5 10 10 - - 15 15

DOMAIN318COILU-TURN 200 5 10 10 - - 15 15

LYRIKCOILU-TURN 112 5 15 15 - - 15 15

LYRIKSOLOAIR 112 5 15 15 6 15 15 15

LYRIK2-STEP 112 5 15 15 40 2.5 10 15

PIKE409COILU-TURN 120 5 15 15 - - 15 15

PIKE409AIRU-TURN 120 5 15 15 6 15 15 15

PIKE409DUALAIR 120 5 15 15 6 15 15 15

PIKE426COILU-TURN 120 5 15 15 - - 15 15

PIKE426AIRU-TURN 120 5 15 15 6 15 15 15

PIKE426DUALAIR 120 5 15 15 6 15 15 15

PIKE454DUALAIR 120 5 15 15 6 15 15 15

PIKE454COILU-TURN 120 5 15 15 - - 15 15

PIKE454AIRU-TURN 120 5 15 15 6 15 15 15

REBASL 110 5 15 15 6 15 15 15

REBARACE 110 5 15 15 6 15 15 15

REBARACEAIRU-TURN 110 5 15 15 6 15 15 15

REBATEAM 110 5 15 15 6 15 15 15

REBATEAMAIRU-TURN 110 5 15 15 6 15 15 15

REBAWORLDCUP(WC) 110 5 15 15 6 15 15 15

RECON327SOLOAIR 120 5 15 15 6 15 15 15

RECON335 120 5 15 15 - - 30 15

RECON335SOLOAIR 120 5 15 15 6 15 15 15

RECON351 118 5 15 15 - - 30 15

RECON351COILU-TURN 118 5 15 15 - - 30 15

RECON351SOLOAIR 118 5 15 15 6 15 15 15

95-4015-011-000, REv. B12 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 1�

LOWER LEG REMOVAL


BUSHING SERVICE

LOWER LEG REMOVAL(ALL FORKS)

LOWER LEG REMOVAL INSTRUCTIONSnote: boXXer only - loosen upper crown bolts with a 4mm heX wrench and remove upper crown. spray isopropyl alcohol onto upper tubes and under frame bumpers. twist and pull up to remove bumpers. finally, use a 4mm heX wrench to loosen lower crown bolts and remove uppers from crown by twisting and sliding each upper down and out of crown.Removetheairchambervalvecovercapfromtheleftforklegtopcap.Ifforkhasanegativeairchamber,removethenegativeairchambervalvecovercapfromthebot-tomoftheleftforkleg.Depressschradervalveandreleaseallairfromtheairchamber.Ifforkhasanega-tiveairchamber,startwiththenegativeairchamber first, then proceed to the positive airchamber.Gentlypullexternalreboundadjusterknobandremovefromtherightshaftbolt.Usea5mmhexwrenchtoloosenbothshaftbolts3to4turns.ForDualAirequippedforks,usea10mmsocket(oropenend)wrenchtoloosenandunthreadtheDualAirshaftnutjustpastthethreadedshaftend.Useaplasticmallettogentlytapeachshaftbolt free from its press-fit to the lower leg and use your fingers to remove shaft bolts completely.Removethelowerlegassemblyfromforkbyfirmly pulling it downward, holding onto both legsorthebrakearch.Useoilpantodrainexcessoilfromlowerlegassembly.Sprayisopropylalcoholontoandintothelowerlegassembly.Wipethelowerlegsclean,thenwrapacleanragaroundadowelandcleantheinsideofeachlowerleg(notpictured).

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INTRODUCTION

Removing the lower legs of your fork is the first step in servicing your fork. It allows you access to your fork bushings, dampersystemandspringsystem.Onceyouhaveremovedyourforklowerlegs,you'llbereadytomoveontothenextsection.

95-4015-011-000, REv. B1� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 17

DUST & OIL SEAL REMOVAL (ALL FORKS)

Removethedustsealusingamediumtolarge flat-head screwdriver to carefully pry it fromthelowerleg.note: not all forks contain a foam ring. if your fork does not have a foam ring, please move onto step 3.Remove the oil foam ring with your fingers.note: not all forks contain an inner oil seal. if your fork does not have an inner oil seal, please move onto the neXt section, bushing removal.Removetheinneroilseal,locatedjustbelowthe dust seal using a flat head screwdriver. Toprotectthelowerlegpaint,placearaginbetweenthelowerlegandthescrewdrivernote: the new improved samurai dust seal eliminates the need to replace the oil seal.note: all dart forks and tora 289, 302 do not have serviceable bushings, please move onto the section dust & oil seal installation.

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BUSHING REMOVAL (ALL ARGYLE - BOxxER - DOMAIN - LYRIK - PIKE - REBA - RECON - REVELATION - SID - TOTEM & TORA 318)

Clampbushingremovalhandle/pullertoolintobenchvicetightly.Installthecorrectbushingremovalplateontohandleendandsecurewithhandleplatescrew.

28mmplate(SID)32mmplate(Argyle,BoXXer,Pike,Reba,Recon,Revelation,Tora)35mmplate(Domain,Lyrik)40mmplate(Totem)

Slidetheremovalplatepasttheupperbush-ing,pulllowerlegawayfrompullertool,andhook the flat end of the plate secure under thebushing.Theremovalplatepivotswheninserted.Whentheplateissecureunderbushing,begintoremove.Topulltheupperbushingfreefromthelower leg, use a plastic mallet to firmly and squarelyhitthetopofthelowerlegontheflat dust seal surface area until upper bush-ingpullsfree.Topullthelowerbushingfreefromthelowerleg,slidetheremovalplatepastthelowerbushing and hook the flat end of the plate secure under the bushing. Again, firmly and squarelyhitthetopofthelowerlegontheflat dust seal surface area until the lower bushingpullsfree.Longerlowerbushingsmayrequiremoreforce.ReturntoStep3andrepeatfortheotherforkleg.Sprayisopropylalcoholinsidelowerlegs.Wrapacleanragaroundadowelandcleantheinsideofthelowerlegs(notpictured).

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BUSHING SERVICE(ALL FORKS)

INTRODUCTIONSuspensionforkbushingsareconsidered"wearandtear"partsandrequireregularmaintenance,dependingonthefre-quencyofriding,ridingterrain,riderbodyweight,andtypeoffork.Themoreyouride,themorefrequentlyyourbushingsneedtobereplaced.ThefollowingchaptercoversDust&OilSealRemoval,BushingRemoval,BushingInstallation,andDust&OilSealInstallation.

HOW TO CHECK FOR LOOSE BUSHINGSCompressfork5timestocirculatelowerleglube(notpictured).Holdthefrontbrakelevertightandrockthebikebackandforth.Iftheforkfeelslikeit's"knocking",ortheheadsetfeelsloose,proceedtosteps2and3.Check the fork: wrap your fingers around thedustsealanduppertubearea.Rockthebikebackandforthagain.Listenandfeelifthereisanyplaybetweentheuppertubeandthedustseal.Ifso,thebushingsareloose.Check the headset: wrap your fingers aroundtheheadsetuppercuporlowercup/raceareas.Holdingthebrake,rockthebikebackandforthandfeeliftheheadsetisloose.Ifso,tightentheheadsetandcheckagain.

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SYMPTOMS OF WORN BUSHINGS

Symptomsofwornbushingsthatneedtobereplacedinclude,a"knocking"soundfromtheforkwhenridingand/ortheheadsetmayfeelloosewhenitisn't.

PARTS AND TOOL KITS NEEDED FOR BUSHING SERVICE

Toobtainthepartsandtoolkitsneededtoserviceyourforkbushings,visityourlocalSRAMdealer.Ifthepartsand/ortoolkitsarenotinstock,yourdealercanplaceanorderwiththeirSRAMdistributor.ForacomprehensivelistofRock-Shoxsparepartsandtoolkits,pleasevisituson-lineatwww.rockshox.comorwww.sram.comundertheSparePartsCatalog.


BUSHING INSTALLATION32MM UPPER TUBE DIAMETER (ARGYLE - PIKE - REBA - RECON - REVELATION - TORA 318)

32MM UPPER TUBE DIAMETER (BOxxER)lower bushing installation with bushing size:32mm X 30mm - slotted (argyle, pike, reba, recon, revelation, tora 318)32mm X 76mm - non-slotted (boXXer)Clamp32mmbushinginstallationtoolintobenchmountedvice.Slidelowerbushinginstallationspacerontobushinginstallationpost.note: recon, revelation, and tora 318 use two spacers, use the short spacer for this step.Slidethelowerbushingsleeveontobushinginstallationpost.Recon,Revelation,Tora318Only:Slidethetalllowerbushingspacerontothebushinginstallationpost.Slidelowerbushingontothetopofthelowerinstallationsleeve.note: boXXer lower bushing is not slotted.Slidelowerlegoverinstallationpostandrestontopoflowerbushing.Insertmalletdrifttoolintothelowerlegshaftholeandholdinplace.Usingaplasticmallet,hitthemalletdrifttooltopressthebushingintothelowerleg.Continuetohitthemalletdrifttool,untilthelowerlegdustsealridgeislevelwiththetopoftheinstallationpostspacer.Youwillfeelitstopasthebushingis"set"inthelowerleg.Removelowerlegfromtoolandinspectthefitofthelowerbushingbyslidingoneuppertubeintothelowerleg.Holdlowerleg90°horizontallyandrelease.Lowerlegshouldswing45°downandstop(notpictured).note: if lower leg swings too freely, repeat step 8. if lower leg feels tight or does not move at all, slide lower leg back onto bush-ing installation post and rock side to side to loosen fit.ReturntoStep1andrepeatforotherleg.

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bushing sleevelower spacer

(short)

lower bushing

lower spacer (tall)

BUSHING INSTALLATION - 28MM UPPER TUBE DIAMETER (SID)

lower bushing installation with bushing size:28mm X 20mm (sid)Clamp28mmbushinginstallationtoolintobenchmountedvice.Slidethelowerbushingsleeveontobushinginstallationpost.Slidelowerbushingontotopoflowerbush-inginstallationsleeve.Slidelowerlegoverinstallationpostandrestontopoflowerbushing.Insertthemalletdrifttoolintothelowerlegshaftholeandholdinplacewithonehand.Usingaplasticmallet,hitthemalletdrifttooltopressthebushingintothelowerleg.Continuetohitthemalletdrifttooluntilthelowerlegdustsealridgeislevelwiththetopoftheinstallationpostspacer.Removelowerlegfromtoolandinspectthefit of the lower bushing by sliding one upper tubeintothelowerleg.Holdlowerleg90°horizontallyandrelease.Lowerlegshouldswing45°downandstop(notpictured).note: if lower leg swings too freely, repeat step 6. if lower leg feels tight or does not move at all, slide lower leg back onto bush-ing installation post and rock side to side to loosen fit.Returntostep1andrepeatforotherleg.

upper bushing installation with bushing size:28mm X 10mm (sid)Removeupperbushinginstallationsleevefrombushinginstallationpost.Slide10mmthen5mmupperbushinginstal-lationspacersontobushinginstallationpost.Slideupperbushingontobushinginstalla-tionpost,ontopofthe5mmspacer.Slidelowerlegoverinstallationpostandrestontopofupperbushing.Insertmalletdrifttoolintothelowerlegshaftholeandholdinplace.Usingaplasticmallet,hitthemalletdrifttooltopressthebushingintothelowerleg.Continuetohitthemalletdrifttooluntilthelowerlegdustsealridgeisflushwiththe5mminstallationspacer.Removelowerlegfromtoolandinspectthefitoftheupperbushingbyslidingoneuppertubeintothelowerleg.Holdlowerleg90°horizontallyandrelease.Lowerlegshouldswing45°downandstop(notpictured).note: do not press bushing below bore step.note: if lower leg swings too freely, repeat step 14. if lower leg feels tight or does not move at all, slide lower leg back onto bush-ing installation post and rock side to side to loosen fit.ReturntoStep9andrepeatforotherleg.

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5mm spacer10mm bushing

bushing sleeve


BUSHING INSTALLATION35MM UPPER TUBE DIAMETER (DOMAIN - LYRIK)

40MM UPPER TUBE DIAMETER (TOTEM)lower bushing installation with bushing size:35mm X 30mm - slotted (domain, lyrik)40mm X 30mm - slotted (totem)Clamp32mmbushinginstallationtoolintobenchmountedvice.Slidebushinginstallationtooladapteroverbushinginstallationpost.Slidelowerbushingsleeveontotheadapter.Slidelowerbushingontotheadapter.Slidelowerlegoverinstallationpostandrestontopoflowerbushing.Insertmalletdrifttoolintothelowerlegshaftholeandholdinplace.Usingaplasticmallet,hitthemalletdrifttooltopressthebushingintothelowerleg.Continuetohitthemalletdrifttool,untilthelowerlegdustsealridgeislevelwiththetopoftheinstallationpostspacer.Youwillfeelthestoppingpointasthebushingis"set"intothelowerleg.Removelowerlegfromtoolandinspectthefitofthelowerbushingbyslidingoneuppertubeintothelowerleg.Holdlowerleg90°horizontallyandrelease.Lowerlegshouldswing45°downandstop(notpictured).note: if lower leg swings too freely, repeat step 7. if lower leg feels tight or does not move at all, slide lower leg back onto bush-ing installation post and rock side to side to loosen fit.ReturntoStep1andrepeatforotherleg.

upper bushing installation with bushing size:35mm X 30mm - non slotted (domain, lyrik)40mm X 30mm - non slotted (totem)Removelowerbushingsleevefromtheadapterandslideupperbushingontotheadapter.Slidelowerlegoverinstallationpost,andrestontopoftheupperbushing.Insertmalletdrifttoolintothelowerlegshaftholeandholdinplace.Usingaplasticmal-let,hitthemalletdrifttooltopresstheupperbushingintolowerleg.Continuetohitthemalletdrifttooluntilthelowerlegrestsflushontopoftheinstallspacer.Youwillfeelitstopasthebushingis"set"inthelowerleg.Thetopofthebush-ingshouldbeflush/levelwithoilsealstepinthelowerleg.

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lower bushing

BUSHING INSTALLATION (CONT)32MM UPPER TUBE DIAMETER (ARGYLE - PIKE - REBA - RECON - REVELATION - TORA 318)

32MM UPPER TUBE DIAMETER (BOxxER)upper bushing installation with bushing size:32mm X 30mm non-slotted (argyle, pike, reba, recon, revelation, tora 318)32mm X 10mm - non-slotted (boXXer)Removelowerbushingsleeve(andtalllowerbushingspacerforRecon,Revelation,andTora318).Leaveonlythelowerbushingspaceronbushinginstallationtool.Slideupperbushingontobushinginstalla-tionpost.Slidelowerlegoverinstallationpost,andrestontopoftheupperbushing.Insertmalletdrifttoolintothelowerlegshaftholeandholdinplace.Usingaplasticmal-let,hitthemalletdrifttooltopresstheupperbushingintolowerleg.Continuetohitthemalletdrifttooluntilthelowerlegrestsflushontopoftheinstallspacer.Youwillfeelitstopasthebushingis"set"inthelowerleg.Thetopofthebush-ingshouldbeflush/levelwithoilsealstepinthelowerleg.Removelowerlegfromtoolandinspectthefitofthelowerbushingbyslidingoneuppertubeintothelowerleg.Holdlowerleg90°horizontallyandrelease.Lowerlegshouldswing45°downandstop(notpictured).note: if lower leg swings too freely, repeat step 15. if lower leg feels tight or does not move at all, slide lower leg back onto bush-ing installation post and rock side to side to loosen fit.ReturntoStep11andrepeatforotherleg.

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DUST & SEAL INSTALLATION (SID)

foam ring and dust seal installationSoaknewfoamringsinsuspensionoil.Slidedustsealinstallationtooloverthe28mmbushinginstallationtool.Slidenewdustsealoverbushinginstallationtool and fit on top of dust seal installation tool.Slideoil-saturatedfoamringoverbushinginstallation tool and fit on top of dust seal. Seatthefoamringinsidetheundercavityofthedustseal.Wipeexcessoiloffthedustsealwithacleanrag.Slidelowerlegontobushinginstallationtool,ontopofnewdustseal.Insertmalletdrifttoolintothelowerlegshaftholeandholdinplace.Usingaplasticmallet,hitthemalletdrifttooluntildustsealseatsinsidelowerleg, flush with the top of the lower leg dust sealstep.Dust seal should be press-fit snug into the lowerleg.ReturntoStep1andrepeatforotherleg.

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5 64

DUST & OIL SEAL INSTALLATION (RECON - REVELATION - TORA 318)

foam ring installationSoaknewfoamringsinsuspensionoil.Insertnewoil-saturatedfoamringintolowerleg.

dust seal installationInsertnewdustsealintothewideendofthedustsealinstallationtool.Insertdustsealintolowerlegandpressstraightdownandevenlytoseatintolowerleg.Dust seal should be press-fit snug and flush intolowerleg.note: check foam ring under dust seal. foam ring should not protrude from dust seal. if so, adjust foam ring inside lower leg, flush on all sides.ReturntoStep1andrepeatforotherleg.

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BUSHING INSTALLATION (CONT)35MM UPPER TUBE DIAMETER (DOMAIN - LYRIK)

40MM UPPER TUBE DIAMETER (TOTEM)upper bushing installation with bushing size:35mm X 30mm - non slotted (domain, lyrik)40mm X 30mm - non slotted (totem)Removelowerlegfromtoolandinspectthefitofthelowerbushingbyslidingoneuppertubeintothelowerleg.Holdlowerleg90°horizontallyandrelease.Lowerlegshouldswing45°downandstop(notpictured).note: if lower leg swings too freely, repeat step 8. if lower leg feels tight or does not move at all, slide lower leg back onto bush-ing installation post and rock side to side to loosen fit.ReturntoStep10andrepeatforotherleg.

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DUST & OIL SEAL INSTALLATION (ARGYLE - BOxxER - DOMAIN - LYRIK - PIKE - REBA - TOTEM)

oil seal installationApplygreaseorsuspensionoiltotheinsideofthelowerlegoilsealcounter-bore.Insertthenewoilsealontothesteppedendoftheoil/dustsealinstallationtool.Usingtheoil/dustsealinstallationtool,inserttheoilsealdownandintotheoilstepinthelowerleg.Applypressureonallsidesoftheoilsealtoseatitintoplace.

foam ring installationnote: for domain, lyrik, and totem, please move onto dust seal installation, step 6.Soaknewfoamringsinsuspensionoil.Insertnewoil-saturatedfoamringintolowerlegontopofoilseal.

dust seal installationInsertnewdustsealintothewideendoftheoil/dustsealinstallationtool.Usingtheoil/dustinstallationtool,insertdustsealintolowerleg.Applypressureonallsidesofthedustsealtoseatitintoplace.Dust seal should be press-fit snug and flush intolowerleg.note: check foam ring under dust seal. foam ring should not protrude from dust seal. if so, adjust foam ring inside lower leg, flushon all sides.ReturntoStep1andrepeatforotherleg.

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COMPLETING BUSHING SERVICE (ALL FORKS)

Completethebushingserviceofyourforkbydetailingthelowerlegs.Sprayisopropylalcoholonentirelowerlegassem-blyandwipewithacleanrag.Checkthedecalsonyourforkandreplaceifnecessary.

this concludes the bushing service for your fork. you did a great job! you are now ready to move onto the neXt section, damper service. enjoy!

DAMPER SERVICE


REBOUND & TURNKEY DAMPER SERVICE(ARGYLE 302 - DART 2, 2 WITH TURNKEY, 3 - DOMAIN 302 - RECON 335 - TORA 289, 302)

INTRODUCTIONAtthispointyoushouldalreadyhavethelowersremovedfromyourfork.Ifnot,youwillneedtoreturntotheLowerLegRemovalsectionofthismanualandfollowtheinstructionsforremovingyourforklowers.

DAMPER REMOVAL/SERVICE INSTRUCTIONSnote: for dart 2, and tora 289 please skip step 1 and move onto step 2.Removeexternalsnapringfromcompres-sionadjusterknobusingexternalsnapringpliersandremovecompressionadjusterknobando-ring.orIfforkisequippedwitharemotecompres-sionlockoutfeature,removeexternalsnapringfromcompressionadjusterspoolusingexternalsnapringpliersandremovecom-pressionadjusterspoolandwhitetopcapshield.Unthreadcompressiondampertopcapwitha24mmsocketwrench.note: for argyle 302, dart 2, domain 302, and tora 289 please move onto step 5.Removecompressiondamperbypullingupandgentlyrockingsidetoside.Ifforkisequippedwitharemotelockoutfeature,besuretoremovetheremotecompressiondampercable-stopclamp;whichislocatedunderthecompressiondampertopcap.Onceremoved,cleanuppertubethreadswitharag.Replacecompressiondampertopcapo-ringbygentlypinchingo-ringtoremove.Applyafewdropsofsuspensionoiltonewo-ringandre-install.Removeforkfrombicyclestandandpourremainingoilintopan.note: for dart 2, this completes the removal procedures, please move onto step 10.Turnforkupsidedownandpushrebounddampershaftthroughshaftguide.Usealongdowelrodtohelppushdamperpistonpastuppertubethreadsandremovefromuppertube.Removerebounddampero-ringanddamp-erinnerseal-heado-ring(locatedinthebot-tomoftheuppertube).Applyfreshgreasetonewo-ringsandre-install.important: if using a pick to remove inner seal head o-ring, do not scratch o-ring gland. scratches may cause oil to leak.

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OPTIONAL - COMPRESSION DAMPER UPGRADE: NON-REMOTE TO REMOTE ADjUST

Upgradingfromanon-remotecompressionadjustforktoaremotecompressionadjust(fromacrownmountedadjusterknobtoaremotePopLocorPushLocleveradjuster),requiresreplacingthenon-remotecompressiondamperwitharemotecompressiondamperandcable-stopclamp.TheremotereturnspringisintegratedintothecompressiondamperandisrequiredforusewiththePopLocandPushLocremoteleverassembly.

DAMPER INSTALLATION INSTRUCTIONS

Clampforkbackintobicyclestandandapplya light film of grease to upper tube threads. Insertrebounddamperbackintorightsideof upper tube, shaft first and press piston intouppertubepasttubethreads.Pushrebounddamperintouppertubeusingalongdowelrod.Guiderebounddampershaftthroughdampersealheadatthebot-tomoftheuppertubeandpullshaftthroughbyhandintothefullyextendedposition.Measureandpour5wtsuspensionoilintotheuppertubeusingthefollowingvolumes:

forkoil volume (±5cc/ml)

argyle 302 130cc/ml

dart 2 150cc/ml

dart 2 (with turnkey) 93cc/ml

dart 3 93cc/ml

domain 302 200cc/ml

tora 289 145cc/ml

tora 302 145cc/ml

note: for dart 2 and tora 289 please move onto step 12.important: oil volume is critical. too much oil reduces available travel, which can lead to fork damage from compression bottom out. too little oil decreases damping perfor-mance.RemoteOnly:Positioncable-stopclampinthe10o'clockpositionaroundtheuppertubeholeonthecrownpriortoinsertingcompressiondamper.Greaseuppertubethreadsliberallytheninsertcompressiondamperintouppertube.Pressdownandtwisttoworkdamperintouppertube.Becarefulnottodamageo-ringsealsonuppertubethreads.Presstopcapdownintouppertubethreadsandhandtighten.Usinga24mmsocketwrench,tightento60in/lbs.note: for dart 2 and tora 289, this com-pletes the installation instructions. you are ready to move onto the neXt section in this manual, spring service.

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DAMPER INSTALLATION INSTRUCTIONS (CONT)

note: turn compression adjuster heX coun-terclockwise to the open position.Placecompressionadjusterknobontocom-pressiondampertopcapwiththeknobdialsetinthe3o'clockposition.Usingexternalsnapringpliers,securethecompressionadjusterknobwithanewsnapring.orIfforkisequippedwitharemotecompres-sionlockoutfeature,placeremotespoolontocompressiondampertopcapwiththecablesetscrewinthe3o'clockposition.Usingexternalsnapringpliers,securetheremotespoolwithanewsnapring.

this concludes the damper service for your fork. you did a great job! you are now ready to move onto the neXt section, spring service. enjoy!

13.

OR

13MOTION CONTROL DAMPER SERVICE

(ARGYLE 318, 409- DOMAIN 318 - TORA 318)


DAMPER REMOVAL/SERVICE INSTRUCTIONSnote: for argyle 318 and 409, it is not nec-essary to remove the motion control knob, please skip step one and move onto step 2.Removeexternalsnapringfromcompres-sionadjusterknobusingexternalsnapringpliersandremovecompressionadjusterknobando-ringseal.orIfforkisequippedwitharemotecompres-sionlockoutfeature,removeexternalsnapringfromcompressionadjusterspoolusingexternalsnapringpliersandremovecom-pressionadjusterspoolandwhitetopcapseal.Unthreadcompressiondampertopcapwitha24mmsocketwrench.Removecompressiondamperfromuppertube/crownbypullingupandgentlytwistingsidetoside.Ifforkisequipped,besuretoremovetheremotecompressiondampercable-stopclamp;whichislocatedunderthecompressiondampertopcap.Oncere-moved,cleanuppertubethreadswitharag.Withasharppick,removethecompressiondampertopcapo-ring(locatedatthetopofthedamper)andthecompressiondamperseal(locatedatthebottomofthedamper).Applyafewdropsofsuspensionoiltothenewo-ringandsealandinstall.Removeforkfrombicyclestandandpourremainingoilintopan.Turnforkupsidedown.Pushrebounddampershaftintouppertube/sealheadandremoverebounddamperfromuppertube.Removerebounddamperglideringandin-nersealheado-ring.Applyfreshgreasetonewo-ringsandre-install.important: if using a pick to remove inner seal head o-ring, do not scratch o-ring gland. scratches may cause oil to leak.

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95-4015-011-000, REv. B�0 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL �1

OPTIONAL - COMPRESSION DAMPER UPGRADE: NON-REMOTE TO REMOTE ADjUST (TORA 318 ONLY)

Upgradingfromanon-remotecompressionadjustforktoaremotecompressionadjust(fromacrownmountedadjusterknobtoaremotePopLocorPushLocleveradjuster),requiresreplacingthenon-remotecompressiondamperwitharemotecompressiondamperandcable-stopclamp.TheremotereturnspringisdesignedintothecompressiondamperandisrequiredforusewiththePopLocandPushLocremoteleverassembly.


Clampforkbackintobicyclestand.Insertrebounddamperbackintorightsideofup-per tube, shaft first. Guide rebound damper throughdampersealheadatbottomofup-pertubeandpullthrough.Threadshaftboltintorebounddampershaftendandpullrebounddampershaftdownthroughsealheadintofullyextendedposi-tion.Measureandpour5wtsuspensionoilintotheuppertube,throughthecrownusingthefollowingvolumes:

forkoil volume(±5cc/ml)

argyle 318 130cc/ml

argyle 409 130 cc/ml

domain 318 200 cc/ml

tora 318 145 cc/ml

important: oil volume is critical. too much oil reduces available travel, which can lead to fork damage from compression bottom out. too little oil decreases damping perfor-mance.RemoteOnly:Slidecompressiondamperthroughcable-stopclamppriortoinser-tion.Positionthecable-stopclampinthe10o'clockpositiononthecrown.Greaseuppertubethreadsliberally,theninsertcompressiondamperintouppertube.Pressdownandtwisttoworkdamperintouppertube.Assoonasthedampersealpassesthroughtheuppertubethreads,pullthedamperupslightly,thenpushbackdown.Thecom-pressiondampershouldslideupanddowneasily,indicatingthesealintheproperposi-tion,andnotfoldedover.Repeatprocedureuntilthecompressiondamperslidesupanddowneasily.Thenpressthecompressiondamperdownuntiltheuppero-ringcontactstheuppertubethreads.

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Turnthedamperclockwiseandthreadintotheuppertube.Becarefulnottodam-agetheupperdampero-ring.Continuetothreadtopcapdownintouppertubethreadsandhandtighten.Usinga24mmsocketwrench,tightento60in/lbs.note: for argyle 318 and 409 this completes the installation process. note: turn compression adjuster heX coun-terclockwise to the open position.Placecompressionadjusterknobontocom-pressiondampertopcapwiththeknobdialsetinthe3o'clockposition.Usingexternalsnapringpliers,securethecompressionadjusterknobwithanewsnapring.orIfforkisequippedwitharemotecompres-sionlockoutfeature,placeremotespoolontocompressiondampertopcapwiththecablesetscrewinthe3o'clockposition.Usingexternalsnapringpliers,securetheremotespoolwithanewsnapring.


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95-4015-011-000, REv. B�2 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL ��

MOTION CONTROL DAMPER SERVICE(BOxxER RACE, TEAM, WC - PIKE 409, 426 - REBA SL, RACE, TEAM, WC - RECON 351 - REVELATION 409, 426)


DAMPER REMOVAL/SERVICE INSTRUCTIONSnote: boXXer only, it is not necessary to remove the motion control adjuster knob. please skip step 1 and move onto step 2.Removeexternalsnapringfromcompres-sionadjusterknobusingexternalsnapringpliersandremovecompressionadjusterknobando-ringseal.orIfforkisequippedwitharemotecompres-sionlockoutfeature,removeexternalsnapringfromcompressionadjusterspoolusingexternalsnapringpliersandremovecom-pressionadjusterspoolandwhitetopcapseal.Unthreadcompressiondampertopcapwitha24mmsocketwrench.Removecompressiondamperfromuppertube/crownbypullingupandtwistingsidetoside.Onceremoved,cleanuppertubethreadswitharag.Withasharppick,removecompressiondampero-rings(locatedatthetopandbot-tomofthedamper).Applyafewdropsofsuspensionoiltonewo-ringsandre-install.Removeforkfrombicyclestandandpourremainingoilintopan.Removerebounddampersealheadretain-ingring(locatedinsidethebottomoftherightuppertube),usingexternalsnapringpliers.Pulldownandremovetherebounddamperandsealheadassemblyfromtheuppertube.Slidesealheadoffdampershaftandremoveinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.Sprayisopropylalcoholonrebounddampershaft,andcleanwitharag(notpictured).Ifdamaged,replacerebounddamperpistonglidering.Positionuppertubebaseringontopofsealheadstepandslidereboundsealheadassemblyontorebounddampershaft.Sprayisopropylalcoholintotheuppertube.Wrapacleanragaroundadowelandcleantheinsideoftheuppertube(notpictured).

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Insertrebounddamperpistonintothebottomoftheuppertubeatanangle,withtheopen-endedsideoftheglideringfaceoutward.Continuetoangleandrotateuntilglideringisintheuppertube.Positiontheuppertubebaseringsealandsealheadintotheuppertube.Positiontheuppertubebaseringsealandsealheadintotheuppertubeandpressintotheuppertubewithyourthumb.Useinternalsnapringplierstosecuresealheadintouppertubewithretainingring.important: make sure the retaining ring is securely fastened in the upper tube groove. you can check this by using the snap ring pli-ers to rotate the retaining ring in the shaft one complete revolution.Pullrebounddampershaftdown,intothefullyextendedposition.Measureandpour5wtsuspensionoilintotheuppertube,throughthecrown,usingthefollowingvol-umes:


boXXer race, team, wc 150cc/ml*pike 409, 426 120cc/ml

reba sl, race, team, wc 110cc/ml

recon 351 118cc/ml

revelation 409, 426 114cc/ml

*boXXer only optional procedure: you can use a suspension oil height tool to measure oil volume. measure and set syringe needle stop to 205mm. pour 5wt oil into upper tube. insert syringe needle into the upper tube, resting the stop flat on upper tube. pull out any eXcess oil with syringe plunger. remove oil height tool from upper tube.important: oil volume is critical. too much oil reduces available travel, which can lead to fork damage from compression bottom out. too little oil decreases damping perfor-mance.

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OPTIONAL - COMPRESSION DAMPER UPGRADE: NON-REMOTE TO REMOTE ADjUST (ExCLUDES BOxxER)

Upgradingfromanon-remotecompressionadjustforktoaremotecompressionadjust(fromacrownmountedadjusterknobtoaremotePopLocorPushLocleveradjuster),requiresreplacingthenon-remotecompressiondamperwitharemotecompressiondamperandcable-stopclamp.TheremotereturnspringisdesignedintothecompressiondamperandisrequiredforusewiththePopLocandPushLocremoteleverassembly.

boXXer only boXXer only



Insertcompressiondamperintouppertube.Pressdownandtwisttoworkdamperintouppertube.Turnthedamperclockwiseandthreadintotheuppertube.Becarefulnottodam-agetheupperdampero-ring.Continuetothreadtopcapdownintouppertubethreadsandhandtighten.Usinga24mmsocketwrench,tightento60in/lbs.note: for boXXer, this completes the instal-lation procedures.note: turn compression adjuster heX coun-terclockwise to the open position.Placecompressionadjusterknobontocom-pressiondampertopcapwiththeknobdialsetinthe3o'clockposition.Usingexternalsnapringpliers,securethecompressionadjusterknobwithanewsnapring.orIfforkisequippedwitharemotecompres-sionlockoutfeature,placeremotespoolontocompressiondampertopcapwiththecablesetscrewinthe3o'clockposition.Usingexternalsnapringpliers,securetheremotespoolwithanewsnapring.


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15 16MOTION CONTROL DAMPER SERVICE

(SID TEAM, WORLD CUP)


DAMPER REMOVAL/SERVICE INSTRUCTIONSRemoveremotecablestopclampusinga2.5mmhexwrench.RemoveFloodgateadjusterknobusinga1.5mmhexwrench.Removeexternalsnapringfromcompres-sionadjusterspoolusingexternalsnapringpliersandremovecompressionadjusterspoolandreturnspring.Unthreadcompressiondampertopcapwitha24mmsocketwrench.Removecompressiondamper,dampertubeandrebounddamperassemblyfromuppertube/crownbypullingupandtwistingsidetoside.Cleanuppertubethreadswitharag.note: leave the threaded base retainer inside the bottom of the upper tube.Pulltherebounddamper/sealheadassem-blyfromthebottomofthedampingtube.Besuretowraparagaroundthedampertube,asoilwilldrainfromtheassembly.Pourremainingoilfromdampertubeintooilpan.Removecompressiondamperfromdampertubebypullingupgently.Allowanyexcessoiltodrainintooilpan.Spraycompressiondamperassemblyanddampertube(insideandout)withisopropylalcohol.Wipegreaseandoilfromdamperassemblyandoutsideofdampertube.Wrapacleanragaroundadowelandcleantheinsideofthedampertube(notpictured).Slidesealheadoffrebounddampershaftandremoveinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandinstall.Sprayrebounddampershaftwithisopropylalcohol,andcleanwitharag(notpictured).Inspectrebounddamperpistonglideringanddampershaft.Replaceeither,ifdam-aged.Sliderebounddampersealheadbackontorebounddampershaft.Inserta2.5mmhexwrench(orreboundadjusterknob)intorebounddamperadjusteratthebottomoftheshaft,andturncoun-terclockwisetoopentherebounddampervalve. This allows oil to flow into the damper valve when re-filling damper tube with oil.

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95-4015-011-000, REv. B�� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL �7

DAMPER REMOVAL/SERVICE INSTRUCTIONS (CONT)Lubricaterebounddamperandsealheadbysubmerginginacontainerofsuspensionoil.Removecompressiondampero-rings(lower, internal floating piston - IFP, and primary).Applyafewdropsofsuspensionoiltonewo-ringsandinstall.

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PlacegoldFloodgateadjusterknobbackontothecompressiondamperandtightenwitha1.5mmhexwrench.TurntheFloodgateandcompressionspooladjusterhexcounterclockwiseuntilitstops.Thisisthefullopenposition.note: the floodgate adjustment affects the blow-off threshold while the compression damper is in the 'lock-out' position. the more open the floodgate, the lower the amount of force that is required to compress the fork in the lock-out position.ApplysuspensionoiltoboththemainpistonandIFPo-ringsofthecompressiondamper.Insertthecompressiondamperbackintothedampertubeandslideentiredamperassembly into the tube. Press top cap firmly intoplace.Holdingdampertubewiththeopenendup,pour5wtsuspensionoilintothedampertubeuntiltubeisapproximatelyhalf-full.Tapthecompressiondampertubelightlyon a flat surface to release any air bubbles trappedinsidethedamper.Pouradditional5wtsuspensionoilintodampertubeuntilcompletelyfull.Removerebounddamperandsealheadfromtheoilcontainerinwhichitwassub-merged.Wraparagaroundthedampertubetocatchdisplacedoil.Withthesealheadbottomedout,slowlyinsertreboundpistonintothedampertube,bypushingonthesealhead,untilitisfullyseated.Wipealloilfromdampertube.important: do not cycle the rebound damper into the damper tube. the compression damper is not secure in the damper tube until threaded into the upper and tightened with a socket wrench.

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floodgate open

floodgate closed

DAMPER INSTALLATION INSTRUCTIONS (CONT)Insidethedamperuppertubeisano-ringthatsitsbetweenthedampertube/reboundsealheadassemblyandtheuppertubethreadbaseretainer.Ensuretheo-ringispositioned flat on the threaded upper tube baseretainer.Iftheo-ringcameoutwiththedampertubeassembly,applyasmallamountofgreasetotheo-ringandre-posi-tionitonthebottomoftherebounddampersealhead.Insertthedamperassemblybackintotheupper tube, rebound shaft first. Guide the endoftherebounddamperthroughthecen-terofthethreadedbaseretainer,slidingthedampercompletelyintotheuppertube.Handthreadthecompressiondampertopcapintotheuppertube.Usea24mmsock-etwrenchandtightentopcapto60in-lb.important: do not allow rebound damper shaft to scrape the retainer upon insertion.

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OPTIONAL - REMOTE ADjUST TO NON-REMOTE

Switchingfromaremotecompressionadjusttoacrownmountedcompressionadjustrequiresonlytheremovaloftheremotespoolandcablestopclampassemblies,andinstallationofthestandardcompressionadjusterknob.UnlikestandardMotionControlcompressiondampers,the07SIDMotionControlcompressiondamperremotereturnspringisNOTintegratedintothedamperassembly.TheremotePopLocorPushLocleveradjustercaneitherberemovedfromthehandlebar,orsimplyremovethecable/cablehousingandleavethePopLocorPushLocleveronyourhandlebar,incaseyouchoosetore-installtheremotespoolinthefuture.

DAMPER INSTALLATION INSTRUCTIONS (CONT)RemoveFloodgateadjusterknobagain,us-inga1.5mmhexwrench(notpictured)Placecablestopclampontothetopcapwiththecablestoppositionedatapproximately90°forwardfromthesteerertube.Turnthecompressionspooladjustershaft(hexshaped)counterclockwiseuntilitstops,toensureitisintheopen(unlocked)position.Placetheremotespoolontothecompres-sionspooladjustershaftandturnclockwiseuntilitstops,intheclosed(lockout)position.Holdtheremotespoolintheclosedpositionanduseyourfreehandtorotatethecablestopclampcounterclockwiseuntilittouchestheremotespoolstop.Tightencablestopclampwitha2.5mmhexwrench.Checkthepositionoftheremotespoolbyrotatingitcounterclockwisetothefullopen(unlocked)position.Thesetscrewshouldbeinlinewiththeopenmarkonthecablestopclamp.

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cable set-screw

open mark


DAMPER INSTALLATION INSTRUCTIONS (CONT)Removetheremotespoolwhilethecom-pressionadjusterisintheopen(unlock)position.Applyasmallamountofgreasetotheremotespoolreturnspring(greasewillholdthereturnspringintheremotespoolduringinstallation).Insertthereturnspringintotheundersideoftheremotespool,withthelongspringlegfacingout.Placetheremotespoolandreturnspringontothecompressiondamperadjusterhexbyaligningthelonglegofthereturnspringto fit into one detent hole in the top cap, atthesametimeasaligningthecablesetscrewwiththeopenmarkonthecablestopclamp.Turntheremotespoolclockwiseuntilspool-stoprestsintheclosedpositionagainstthecablestopclampstop.Ifthestopontheremotespooldoesnottouchthestoponthecablestopclamp,loosencablestopclampandrotateitcounterclockwiseuntilthetwostopstouchandretightencablestopclamp.Releasethespoolfromtheclosepositionandtestthereturntotheopenposition.Usingexternalsnapringpliers,securetheremotespoolwithanewsnapring.PlacetheFloodgateadjusterknobbackontothecompressiondamperspoolshaft.Tight-entheFloodgateadjusterknobsetscrewtothe flat surface of the black adjuster rod with a1.5mmhexwrench.


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insert spring leg into detent hole

PURE DELITE DAMPER SERVICE(SID RACE)


DAMPER REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the pure delite air chamber before proceeding. remove air valve cover cap and depress schrader valve to release any air pressure.Unthreadcompressiondampertopcapwitha24mmsocketwrench.PullupandremovetheentirePureDelitedamperassemblyfromtheuppertube.Re-movethetopcapbypullingoutofthePureDelitedampertube.Invertthedamperassemblyandgently,butfirmly, pull the rebound damper seal head assemblyfromthePuretube.Holdaragaroundtubewhilepulling,tocatchanyoilthatmayspill.PouranyremainingoilfromthePuretubeintooilpan.RemovetheInternalFloatingPiston(IFP),whichislocatedinsidethePuredampertube,inthecenterofthetube.TheIFPisthesealthatseparatestheoilfromtheairintheDeliteairchamber.ToremovetheIFP,insertalongdowelrod(plasticorwood)intothePuretubeuntiltherodtouchestheunderside of the IFP. Push firmly on the rod toreleasetheIFPfromthePuretube.important: be careful not to scratch the inside of the pure tube with the dowel rod. scratches will cause oil/air to leak and the pure delite damper system will not function properly.ReviewthePureDeliteDamperassemblycomponents.RemoveIFPinnerandoutero-rings.Applyafewdropsofsuspensionoiltonewo-ringandre-install(notpictured).Slidesealheadoffrebounddampershaftandremoveinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.Inspectdampershaftforscratchesandreplaceifdamaged.Placesealheadbackontorebounddampershaft.

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top cap

pure tube

ifp

damper


DAMPER INSTALLATION INSTRUCTIONSInsertIFPinthePuretubeatadepthof6inches.Todothis,mountalongdowelrod(plasticorwood)intoabicyclestandclamporbenchvicewith6inchesofexposedrod.PlacetheIFPontheendofthedowel,pock-etedsidedown.PlaceoneendofthePureTube over the IFP and press firmly down untiltheIFPisseatedinsidethetube.note: be careful not to damage ifp o-ring or your hands on the sharp edges of the pure tube. use a rag to protect your hands.ContinuetopresstheIFPintothePuretubeuntil the tube end is flush against the bicycle clamp or vice. The IFP is now seated firmly insidethePuretubeata6inchdepth.PullthePuretubeoffthedowel.HoldthePuretubeoveroilpan,withthepocketedsideoftheIFPfacingdown(rounded side facing up) and fill the tube completelywith15wtsuspensionoil.Makesuretherebounddamperisintheopenposition.Gentlyandslowlyinserttherebounddamperpistonheadintotheoilfilled Pure tube. The oil will slowly fill the dampervalves(someoilmayspill).Allowenough oil to fill the damper valve cavities andtopoffoilvolumeifnecessary.Withthesealheadbottomedout,gentlypressdownonthesealheaduntilitsnapsintothePuretubesecurely.Yourdamperisnowsealed.note: be sure piston seal head is topped against rebound piston.important: do not cycle the damper shaft until the delite air top cap has been installed and pressurized.InsertthePureDelitedamperassemblyintotheuppertubethroughthecrown.Add6cc/mlof15wtsuspensionoiltothetopchamberofthedamper.ThiswilllubricatetheIFPo-ring.Handthreadthedampertopcapintotheuppertube.Usea24mmsocketwrenchandtightentopcapto60in-lb.Pressurizetheairchamberwithyourshockpumpto20-60psi.TheIFPisnowpressuresetandyourdampersealed.Inserttherebounddamperexternaladjusterknobintothebottomoftherebounddampershaftandturnclockwiseuntildamperisinthefullclosedposition.Thiswillprotectthedamperrodwheninstallingthelowerlegshaftbolt.


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MISSION CONTROL DAMPER SERVICE(LYRIK - TOTEM)


DAMPER REMOVAL/SERVICE INSTRUCTIONSTurnbluehighspeedcompressionknobclockwise,tosetinthemaximumcompres-sionposition.Unthreadcompressiondampertopcapwithathin24mmwrench.Accesstothetopcapisunderthehighspeedcompressionknob.orLoosenandremovethegoldlowspeedcompressionknobbygentlygraspingthelowspeedcompressionknobwithslipjointpliersandusinga4mmhexwrenchtoremovelowspeedcompressionscrew.Liftandremovethelowspeedcompressionknob.Then,loosenandremovebothretain-ingboltsonthehighspeedcompressionknob,usinga1.5mmhexwrench.Again,liftandremovethehighspeedcompressionknob.Thisallowsaccesstothetopcap.Unthreadcompressiondampertopcapus-inga24mmsocketwrench.Removecompressiondamperfromuppertube/crownbypullingupandtwistingsidetoside.Onceremoved,cleanuppertubethreadswitharag.Removeglideringfromcompressiondamperpistonassembly.Applyafewdropsofsuspensionoiltonewglideringandre-install.Removeforkfrombicyclestandandpourremainingoilintopan.Returnforktobicyclestand.Removerebounddampersealheadretain-ingring(locatedinsidethebottomoftherightuppertube),usinginternalsnapringpliers.Pulldownandremovetherebounddamperassemblyfromtheuppertube.Pushupwardonreboundshafttoseparatereboundpistonassemblyfromreboundtube.Sprayrebounddampershaftwithisopropylalcohol,andcleanwitharag(notpictured).

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76

OR


DAMPER REMOVAL/SERVICE INSTRUCTIONS (CONT)Removeinnerandoutero-ringsfromreboundsealhead.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove inner seal head o-ring, do not scratch o-ring gland. scratches may cause oil to leak.Removeglideringfromreboundshaftas-sembly.Applyafewdropsofsuspensionoiltonewglideringandre-install.

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DAMPER INSTALLATION INSTRUCTIONSInstallreboundshaftassemblyintoreboundtube.note: be sure not to damage rebound tube inner o-ring.Installreboundassemblyintouppertubeandsecurewithretainingringusinginternalsnapringpliers.important: make sure the retaining ring is securely fastened in the upper tube groove. you can check this by using the snap ring pli-ers to rotate the retaining ring in the shaft one complete revolution.Pullrebounddampershaftdownintothefullyextendedposition.Measureandpour5wtsuspensionoilintotheuppertube,throughthecrown,usingthefollowingvolumes:


lyrik 112cc/ml*totem 137cc/ml

important: oil volume is critical. too much oil reduces available travel, which can lead to fork damage from compression bottom out. too little oil decreases damping perfor-mance.

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DAMPER INSTALLATION INSTRUCTIONS (CONT)TurnFloodgateto"off"positionbypushinglowspeedcompressionadjusterdownandrotatingcounterclockwise90°.InstallMis-sionControldamperassemblyintouppertubethroughthecrown.Handthreadthecompressiondampertopcapintotheuppertube.Useathin24mmsocketwrenchandtightentopcapto60in-lb.orInsertMissionControldamperassemblyintouppertubethroughthecrown.Handthreadthecompressiondampertopintotheuppertube.Usea24mmsocketwrenchandtightentopcapto60in-lb.Installhighspeedcompressionknobusinga1.5mmhexwrenchtotightenscrews.Installlowspeedcompressionknobbygentlygrasp-ingtheknobwithslipjointpliersandusinga4mmhexwrenchtotightenscrew.


15.

OR


SPRING SERVICE


COIL SPRING SERVICE(ARGYLE 302, 318 - DART 1, 2, 2 (WITH TURNKEY) 3 - DOMAIN 302, 318 - TORA 289, 302, 318)


COIL SPRING REMOVAL/SERVICE INSTRUCTIONSUnthreadandremovespringtopcapwitha24mmsocketwrench.important: press down firmly when loosening top cap.Argyle302,318Only:Removespringpre-loadspacer(s).Pushspringshaftupward,fromthebottomoftheuppertube,thenremovespringandspringspacersfromuppertube.Turnforkupsidedownandslidethespringshaftassemblyoutoftheuppertube.Re-movespringshaftassemblyandinspectfordamage.Sprayisopropylalcoholonspring,springshaftassemblyandtheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).

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5 7COIL SPRING INSTALLATION INSTRUCTIONS

Insertanddropspringshaftassemblyintouppertubethroughthecrown.Guidethethreadedendthroughtheshaftguideatthebottomoftheuppertubeandgentlypullshaftthroughtofullextension.Applyfreshgreaseliberallytospring/springspacerassembly.Insertanddropspringassemblyintouppertubethroughthecrown.Argyle302,318Only:Installspringpre-loadspacers.Cleantopcap,thenapplyasmallamountofgreasetotopcapthreads.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.

this concludes the spring service for your fork. you did a great job! you are now ready to move onto the neXt section, lower leg installation. enjoy!

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COIL SPRING SERVICE(BOxxER RACE, TEAM - RECON 327, 335, 351 - TOTEM)


SPRING REMOVAL/SERVICE INSTRUCTIONSUnthreadandremovespringtopcapwitha24mmsocketwrench.important: press down firmly when loosening top cap.Removespringpre-loadspacer(s)andpullspringfromuppertube.Removethespringshaftbaseplateretainingringusinginternalsnapringpliers.Pullspringshaftandbaseplatefromuppertube.Inspectassemblyfordamageandreplaceentireassemblyifnecessary.Sprayisopropylalcoholonspring,springisolators(isolatorsareBoXXeronly),springshaftandtheinsideandoutsideoftheup-pertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).

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9

7COIL SPRING INSTALLATION INSTRUCTIONS

Insertspringshaftassemblybackintobot-tomofuppertubesothebaseplateas-semblyisseatedintotheuppertubestep.Securespringshaftassemblywithretainingring,usinginternalsnapringpliers.Applyfreshgreaseliberallytospringandspringisolators(isolatorsareBoXXeronly).Insertspringbackintouppertubeandplacespringpreloadspacer(s)ontopofspringinsideuppertube.Cleantopcap,thenapplyasmallamountofgreasetotopcapthreads.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.


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pre-load spacer

3pre-load spacer

pre-load spacer

9


COIL U-TURN SPRING SERVICE(DOMAIN 302, 318 - TORA 289, 302, 318)


COIL U-TURN SPRING REMOVAL/SERVICE INSTRUCTIONSRemoveU-Turnknobscrewwitha2.5mmhexwrenchandremoveU-Turnadjusterknob.Removedetentballbearingsanddetentspringsfromtopcapusingamagnet.Unthreadandremovespringtopcapwitha24mmsocketwrench.Thespringisat-tachedtothetopcapandspringshaft.Pullandliftentirespringassemblyfromuppertube.important: press down firmly when loosening top cap.RemoveU-Turnnegativespringassemblyfromuppertube,youmayneedtoturnforkupsidedowntoremove.Sprayisopropylalcoholonentirespringas-sembly,negativespring,andtheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).

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76 8COIL U-TURN SPRING INSTALLATION INSTRUCTIONS

Applyfreshgreaseliberallytonegativespring,theentirespringassembly,andtopcapthreads.Insertanddropnegativespringintouppertubethroughthecrown.InsertU-Turnspringassemblyintouppertube through crown, shaft end first. Align andseatthespringshaftthroughtheshaftguide/baseplate.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.Usingamagnet,inserteachdetentspringintotopcapdetentholes,evenlyspaced.Placeeachdetentballbearingontopofeachdetentspring.PlaceU-Turnadjusterknobontopofhex.TightenU-Turnknobscrewwitha2.5mmhexwrench.


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COIL U-TURN SPRING SERVICE(LYRIK - PIKE 409, 426, 454 - RECON 327, 351 - REVELATION 426)


COIL U-TURN SPRING REMOVAL/SERVICE INSTRUCTIONSRemoveU-Turnknobscrewwitha2.5mmhexwrenchandremoveU-Turnadjusterknob.Removedetentballbearingsanddetentspringsfromtopcapusingamagnet.Unthreadandremovespringtopcapwitha24mmsocketwrench.Thespringisat-tachedtothetopcapandspringshaft.Pullandliftentirespringassemblyfromuppertube.important: press down firmly when loosening top cap.Sprayisopropylalcoholonentirespringassemblyandtheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).

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5 7COIL U-TURN SPRING INSTALLATION INSTRUCTIONS

Applyfreshgreaseliberallytotheentirespringassembly,andtopcapthreads.InsertU-Turnspringassemblyintouppertube through crown, shaft end first. Align andseatthespringshaftthroughtheshaftguide/baseplate.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.Usingamagnet,inserteachdetentspringintotopcapdetentholes,evenlyspaced.Placeeachdetentballbearingontopofeachdetentspring.PlaceU-Turnadjusterknobontopofhex.TightenU-Turnknobscrewwitha2.5mmhexwrench.


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SOLO AIR SPRING SERVICE(ARGYLE 409 - RECON 335, 351- TORA 318)


SOLO AIR SPRING REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the air chamber before proceeding. depress schrader valve again to remove any remaining air pressure.Unthreadairspringtopcapwitha24mmsocketwrench.Theairspringassemblyisattachedtothetopcap.Pullandliftentireairspringassemblyfromuppertube.Pulltopcapoutofairtubeassemblyandpouranyairseallubricantintooilpan.Removeairshaftandairsealheadfromthebottomoftheairtubebypullingshaftdownandtwistingsidetoside.Sprayisopropylalcoholontheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).Removeairpistonretainerringusingexter-nalsnapringpliers.Thenremoveairpistonwavyspringwasherandpistonfromairshaft.Slideairsleevesealheadassemblyfromairshaft.Removeinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head. scratches may cause oil to leak. Sprayairshaftwithisopropylalcoholandwipecleanwitharag(notpictured).Insertairpistonbackontoairshafthead.Installspringwavywasherontoairshaftendandsecureinplacewithairpistonretainerring,usingexternalsnapringpliers.Checkretaining ring fit to make sure it secures theairpistontoairshafthead.Thepistonshouldcompressslightlywithspringre-sistanceagainstwavyspringwasherandretainingring.

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SOLO AIR SPRING REMOVAL/SERVICE INSTRUCTIONS (CONT)Removebottom-outbumperandpadfromnegativeairsleeve/sealhead.Removeinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head. scratches may cause oil to leak.

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OPTIONAL - ALL TRAVEL CONFIGURATIONS (TORA 318)Alltravelspacersarelocatedjustabovetheairsealhead.Ifyouwanttochangethetravelofyourfork,snapthetravelspacerontosealheadtodecreasetravel,orremovetoincreasetravel.

80mm 100mm 130mm

no spacer

30mm spacer50mm

spacer


12

SOLO AIR SPRING INSTALLATION INSTRUCTIONS

Insertbottom-outbumperandpadbackontoairsealhead.Slideairsealhead/sleeveas-sembly back into air shaft, bumpers first.Insertlubricatedairassembly,bothpistonsandairsleeveintooneendofairtube.Pushair seal head into air tube until firmly seated.Insertairshaftintotopofuppertube,throughcrown.Guidethebottomoftheairshaftthroughtheshaftguideinthebottomoftheuppertube.Insertairtubeassemblyintouppertubeuntilitrestsinsideuppertube.Measureandpour6cc/mlof15wtsuspen-sionoilintouppertubethroughthecrown.Suspensionoilintheairchamberlubricatestheairsealo-ringduringuseandmaintainstheairseal.Pushairshafttoliftairtubeoutofuppertubeacoupleofinches.Inserttheairtopcapintoairtubeandpresstightintoairtube.Dropairtube/topcapassemblyintouppertube.Checkbottomofuppertubeandmakesureairshaftguideisseatedintouppertubeshaftguide.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.


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SOLO AIR SPRING SERVICE(BOxxER WC - LYRIK - RECON 327, 335, 351 - TOTEM)


SOLO AIR SPRING REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the air chamber before proceeding. depress schrader valve again to remove any remaining air pressure.Unthreadandremoveairspringtopcapwitha24mmsocketwrench.Removeforkfromstandandpouranyairseallubricantintooilpan.Use your finger to press the air seal head intotheuppertube.Youwillfeelitbreakfreeandslideintothetubeabout3mm.Removetheairassemblyshaftguideretain-ingringfromthebottomoftheleftuppertube,usingexternalsnapringpliers.Pullairshaftdowntoremoveairspringassemblyandshaftguidefromuppertube.Sprayisopropylalcoholontheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).note: for lyrik, and totem it is not necessary to perform steps 5, 6, 7 or 9. simply inspect retainer ring and wavy washer (and cushion on lyrik and totem). if damaged, you will need to replace the air piston head assembly. otherwise please complete step 8, then move onto step 11.Removeairpistonretainerringusingexter-nalsnapringpliers.Thenremoveairpistonwavyspringwasherandpistonfromairshaft.Slideairsleeve/sealheadassemblyfromairshaft.Removeinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head. scratches may cause oil to leak. Sprayairshaftwithisopropylalcoholandwipecleanwitharag(notpictured).

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SOLO AIR SPRING REMOVAL/SERVICE INSTRUCTIONS (CONT)Insertairpistonbackontoairshafthead.Installspringwavywasherontoairshaftendandsecureinplacewithairpistonretainerring,usingexternalsnapringpliers.Checkretaining ring fit to make sure it secures theairpistontoairshafthead.Thepistonshouldcompressslightlywithspringre-sistanceagainstwavyspringwasherandretainingring.Removebottom-outbumperandpadfromnegativeairsleeve/sealhead.Removeinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head. scratches may cause oil to leak.

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OPTIONAL - ALL TRAVEL CONFIGURATIONS (RECON 327, 335, 351)Alltravelspacersarelocatedjustabovetheairsealhead.Ifyouwanttochangethetravelofyourfork,snapthetravelspacerontosealheadtodecreasetravel,orremovetoincreasetravel.

9 1110

80mm 100mm 130mm

no spacer

30mm spacer50mm

spacer

SOLO AIR SPRING INSTALLATION INSTRUCTIONS

Insertbottom-outbumperandpadbackontoairsealhead.Slideairsealhead/sleeveas-sembly back into air shaft, bumpers first.Insertlubricatedairpistonintobottomofup-pertubeandslidethelowerairpiston/sleeveassemblyintouppertube.Seattheshaftguideringandwavywasherintouppertubestep,thenslidenegativeairsleeveintouppertubeandseatshaftguidebaseintouppertubestep.Secureretainingringintouppertuberetain-ingringgrooveusingexternalsnapringpliers.Positionretainingringholesaroundretainingringpositioneronbaseplate.Verifyretainingringissecureinuppertube.Measureandpour6cc/mlof15wtsuspen-sionoilintoairtubethroughthecrown.Sus-pensionoilintheairchamberlubricatestheairsealo-ringduringuseandmaintainstheairseal.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.


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base plate retaining ring positioner

retaining ring holes


DUAL AIR SPRING SERVICE(PIKE 409, 426 - REBA SL, RACE, TEAM, WC - REVELATION 409, 426)


DUAL AIR SPRING REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the air chamber before proceeding. de-press positive and negative schrader valves again to remove any remaining air pressure.UnthreadandremoveDualAirtopcapwitha24mmsocketwrench.Removeforkfromstandandpouranyairseallubricantintooilpan.Clampforkbackintobicyclestandandwipeshaftandbaseplatewitharag.Pushnegativeairshaftupandintobaseplate,leavingonlythetipofthethreadedshaftendprotrudingfrombasevalve.note: you may need to depress the schrader valve as you push the shaft, to prevent a vacuum.Slidea15mmsockettool(orsimilarhollowtool) over the air shaft end and press firmly againstthebaseplate.Whilepressingtheairbaseplateupandintotheuppertube,removetheretainingringusingexternalsnapringpliers.Onceretainingringisremoved,gentlypullairshaftdowntoremoveairspringassem-blyandbaseplatefromuppertube.Sprayisopropylalcoholontheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).Removebaseplate,baseplateo-ring/bum-per,andnegativeairpistonfromtheDualAirshaft.Removeouterandinnernegativeairpistono-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head. scratches may cause oil to leak. Removeouterpositiveairpistono-ring.Applyafewdropsofsuspensionoiltonewo-ringandre-install.important: if using a pick to remove o-ring, do not scratch seal head. scratches may cause oil to leak.

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air piston

o-ring

base plate

OPTIONAL - ALL TRAVEL CONFIGURATIONSAlltravelspacersarelocatedjustabovethebottomoutbumperwasher.Ifyouwanttochangethetravelofyourfork,snapthetravelspacerontotheDualAirshafttodecreasetravel,orremovetoincreasetravel.

11DUAL AIR SPRING INSTALLATION INSTRUCTIONS

Re-installthenegativeairpiston,baseplateo-ring/bumperandbaseplateontotheDualAirshaftandre-applysuspensionoiltoo-rings.InsertDualAirassemblyintouppertube,positive air piston first, followed by the nega-tiveairpiston.Insertbaseplateassemblyinto upper tube step and press in firmly.Usingyourthumb,pressbaseplateintoup-pertube.Whilepressingbaseplate,installexternalretainingringusingexternalsnapringpliers.Verifyretainingringissecureinuppertubegroove.Alignretainingringaccordingtotheorientationofthebaseplateretainingringgroove.Measureandpour6cc/mlof15wtsuspen-sionoilintoairtubethroughcrown.Suspen-sionoilintheairchamberlubricatestheairsealo-ringduringuseandmaintainstheairseal.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.


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pike: 140mmreba: 115mmrevelation: 130mm

no spacer

pike: 10mmrevelation: 15mmreba: 15mmspacer(above washer)

pike: 130mmreba: 100mmrevelation: 115mm


DUAL AIR SPRING SERVICE(SID RACE, TEAM, WC)


DUAL AIR SPRING REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the air chamber before proceeding. de-press positive and negative schrader valves again to remove any remaining air pressure.UnthreadandremoveDualAirspringtopcapwitha24mmsocketwrench.Removeforkfromstandandpouranyoilfrompositiveairchamberintooilpan.RemovethreadeduppertuberetainerusingtheSIDDualAiruppertuberetainertoolandasocketwrench.important: the retainer is reverse threaded. turn the wrench clockwise to unthread.PullDualAirspringshaftassemblyfromuppertube.note: you may need to depress the nega-tive schrader valve as you pull the dual air shaft; pressure builds up as you pull.Sprayisopropylalcoholontheinsideandoutsideoftheuppertubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).important: look inside the upper tube using a light and check for scratches. if the inside surface of the upper tube is scratched, re-place the assembly. scratches can cause air bypass and effect the performance of your fork.Slidethenegativeairpistonsleevefromairspringshaft.Sprayisopropylalcoholontheairshaftandwipewithacleanrag(notpictured).Removetheouterandinnernegativeairpis-tono-ringsaswellastheouterpositiveairpistono-ring.Applyafewdropsofsuspen-sionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head. scratches may cause oil to leak. Slidenegativeairspringsleevebackontoairspringshaft.

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OPTIONAL - ALL TRAVEL CONFIGURATIONSAlltravelspacersarelocatedjustabovethenegativesleevetopoutbumper.Tochangethetravelofyourfork,slidenegativesleevedownandsnapthetravelspacerontosealheadtodecreasetravel,orremovetoincreasetravel.

DUAL AIR SPRING INSTALLATION INSTRUCTIONSRe-applyfreshsuspensionoiltonewposi-tiveandnegativeairpistono-rings.Insertpositiveairpistonintobottomofuppertubeandpushairpiston/shaftassemblyintouppertube.Slidethenegativeairpistonsleevedownairspringshaftandintothebottomoftheuppertube.Continuetoslideentirenegativeairspringsleeveintouppertube.note: you may need to depress the negative schrader air valve as you push the negative sleeve into the upper tube to release the air pressure build up and aid in installation.ThreadDualAirspringassemblythreadedbaseretainerintotheuppertubebyhand.UsingtheSIDDualAiruppertuberetainertoolandasocketwrench,pressintoretainerfirmly and tighten the threaded upper tube/baseretainerto30in-lb.important: the retainer is reverse threaded. turn by hand and wrench counter-clockwise to thread.Makesureforkispositioneduprightinwork-stand.Measureandpour6cc/mlof15wtsuspensionoilintopositiveairchamber,throughthecrown.note: suspension oil on top of the positive air piston o-ring is critical to lubrication and maintenance of the air seal.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.


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13 1514

80mm

no spacer

20mm spacer

60mm


AIR U-TURN SPRING SERVICE(PIKE 409, 429 - REBA RACE, TEAM - REVELATION 409, 429)


AIR U-TURN SPRING REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the air chamber before proceeding. de-press positive and negative schrader valves again to remove any remaining air pressure.Adjusttravelsettingtomax(full)travel.PushexternalretainingclipfromaboveU-Turnknobwithapickorscrewdriverandremoveadjusterknob.Removedetentballbearingsanddetentspringsfromtopcapusingamagnet.important: it is not necessary to remove the u-turn top cap to service the air u-turn spring assembly. in the event the top cap must be removed, unthread with a 24mm socket wrench. before re-installing top cap, clean old thread-lock off top cap. then add a few drops of blue thread-lock to the top cap threads and tighten with socket wrench to 60 in-lb.TurnAirU-Turntraveladjustshaft,whichprotrudesfromboththecenterofthetopcapandthebottomoftheairshaft,CLOCK-WISEtounthreadtheairspringassemblyfromtheAirU-Turntopcap(topcapshouldbetightinsidecrown/uppertube).PulldownontheAirU-Turnshaftandremovetheentirespringassemblyfromthebottomoftheuppertube.Remove teflon washer from inside of top cap.Toremove,pushdownwithapickorflat-head screwdriver. Washer will exit bot-tomoftheuppertube.Removesmallexternalretainingringlo-catedatthebottomoftheairchamberusingexternalsnapringpliers,thenremoveguideplate.Push down on seal head with a flat-head screwdriver(positionscrewdriverheadagainststep,awayfromshaft)andfreetheretainingringfromthesealhead.Oncesealheadslidesintoairtube,removesealheadretainingring,usingsnapringpliers.important: do not scratch air shaft. scratches with cause air to leak and effect the performance of your fork.

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AIR U-TURN SPRING REMOVAL/SERVICE INSTRUCTIONS (CONT)Pullairshaft,negativeairsealheadandpositiveairpistonassembliesoutofairtube.Slideandremovealuminumsealheadfromairshaft.Sprayisopropylalcoholonairshaftandwipewithacleanrag(notpictured).Removesealheadfromairpistonshaft.Re-movetheinnerandoutersealheado-ringsaswellasthesmalloutero-ringlocatedontheairpistonshaftgroove.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch seal head or o-rings. scratches will cause permanent air leak.Holdingtheairtube,placeupperchokeassembly end of flat surface. Firmly press tube down on flat surface to break the seal andpushchokeassemblythroughtube.note: the choke assembly will feel tight in-side tube while pushing choke out of air tube. you may need to tap the end of the air shaft onto a flat working surface to free the up-per air spring assembly from the air tube.Useanon-metallicdoweltocontinuetopushtheassemblythroughandoutoftheairtube.Removeassemblycompletelyfromairtube.important: using a non-metallic dowel helps to ensure the inside of the air tube does not get scratched.Sprayisopropylalcoholontheinsideandoutsideoftheairtubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube(notpictured).Removeexternalchokeretainingringfromtraveladjustmentshaft,usingexternalsnapringpliers.Removechokepistonandchoke/shaftwasher.Removeexternalchokeo-ring.Applyafewdropsofsuspensionoiltonewo-ringandre-install.important: if using a pick to remove o-ring, do not scratch choke piston. scratches may cause air leak.Removeuppersealheadfromadjustershaft.Use a flat head screwdriver and remove in-nero-ringretainingring.Thenremoveboththeinnerandoutersealheado-rings.Applyafewdropsofsuspensionoiltonewo-ringsand re-install. Use a flat head screwdriver tore-installinnero-ringretainingring.

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95-4015-011-000, REv. B�2 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL ��

AIR U-TURN SPRING REMOVAL/SERVICE INSTRUCTIONS (CONT)Re-installuppersealheadontotraveladjust-mentshaftandapplysuspensionoiltoadjustershaftandinnersealheado-ring.InstallchokepistonandsecurewithaNEW10mmexternalretainingring,usingexternalsnapringpliers.Applysuspensionoiltobothpistono-rings.

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AIR U-TURN SPRING INSTALLATION INSTRUCTIONSApply a thin film of grease to the inside grooveoftheopenendoftheairspringtube.Inserttheupperchokeassemblyintoopenendofairspringtube,schradervalvefirst, and press completely into air tube. Usingalongnon-metallicdowel,pushas-sembly up into the air tube until seated flush againsttherolledendoftheairtube.Holdairtubewithopenendup.Measureandpour6cc/mlof15wtsuspensionoilintoairtube/positiveairchamber,ontopoftheupperchokeassembly.Thiswilllubricatethechokeo-ringandpositiveairpistono-ringwhenforkiscompressed.Setasideairtube,upright,sooildoesnotspill.Re-applysuspensionoiltoinnersealheado-ringandslidenegativeairsealheadontoDual Air shaft, flat end first. Slide up to bot-tomoutbumper.Re-applysuspensionoiltopositiveandneg-ativeairpistono-ringsandinsertpositiveairpistonintoopenendofairspring.Pushairshaftassemblyintoairtube.Using a small flathead screwdriver, press downonsealheadshaftsteptoseatintoplaceinsideairtube.Securesealheadintoairtubewithretainingring,usinginternalsnapringpliers.important: retaining ring must be fully seated in upper tube groove. check retaining ring closely to ensure secure fit.Addairtothepositiveairchamber(40-60psi)toensureassemblycomponentsareseatedproperlyinsideairtube.

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AIR U-TURN SPRING INSTALLATION INSTRUCTIONS (CONT)Insertairtubeguideplateintotheendofairtube.Securearoundsmallsealheadgroovewithanew13mmexternalretainingring,usingexternalsnapringpliers.Verifyretainingringisseatedagainstguideplatesoitcannotmovefreely.important: eXternal retaining rings may de-form when removed and installed. pinch ends tight with pliers, to ensure correct fit. note: the u-turn air assembly is now as-sembled and ready to be installed into fork upper tube/crown.Place Teflon washer over threaded shaft end, flat against travel shaft. Insert Air U-Turnassemblyintobottomofleftforkuppertube, adjuster end first. Slideintouppertubeuntilupperassemblyengagestopcap.ThreadassemblyintotopcapbyholdingthebottomoftheairshaftandturningCOUNTERCLOCKWISEuntilitstops.Inserteachdetentspringintotopcapdetentholes,evenlyspaced.Placeeachdetentballbearingontopofeachdetentspring.PlaceAirU-Turnadjusterknobontohexshaftend.Secureknobontoairshaftwithexternalretainingring,usingexternalsnapringpliers.Makesureretainingringisin-sertedintogroove,notairshaftthreads.important: air u-turn fork must be set to full travel setting before installing lower legs. turn air u-turn knob counterclockwise to set to full travel.


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2-STEP AIR SPRING SERVICE(LYRIK - TOTEM)


2-STEP AIR SPRING REMOVAL/SERVICE INSTRUCTIONSimportant: verify all air pressure is removed from the air chamber before proceeding. depress schrader valve again to remove any remaining air pressure, then remove 2-step schrader valve, located at the bottom of the lower leg air shaft, using a schrader valve tool.Remove the 2-Step adjuster fixing screw, us-inga2mmhexwrenchandremove2-Stepcontrolknob.Unthreadandremovethe2-Steptopcap,usinga24mmsocketwrench.Inspect2-Steptopcapo-ringfordamage.Replaceifnecessary.Removeforkfrombicyclestandandpouranyremainingoilintooilpan.Returnforktobicyclestand.Removeretainingringfromthebottomoftheleftuppertubeusinginternalsnapringpliers.Gentlypulldownontheairshafttoremovetheentire2-Stepassembly.Separatethe2-Stepassemblyinto3parts:shaftassembly,airtube,andpistonhousing(inorderinpicture).Removepistonfromthepistonhous-ing.Inspectpistonhousingfordamageorscratches,payingcloseattentiontheinsidesurfaceofthepistonhousing.Ifdamagesorscratched,replacethepistonhousing.Removepistono-ring.Cleanpistonwithisopropylalcohol.Applyafewdropsofsus-pensionoiltonewo-ringandre-install.Inspectpistonhousingo-ringfordamage.Replaceifnecessary.Re-assemblepistonandpistonhousing.Thepistonshouldbeinsertedintothehous-ingwiththe'holeside'down.Presspistonintohousinguntilitbottomsoutcompletely.note: improper installation of the piston will change 2-step air spring performance.

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2-STEP AIR SPRING REMOVAL/SERVICE INSTRUCTIONS (CONT)Sprayisopropylalcoholontheinsideandoutsideoftheairtubeandwipewithacleanrag.Wrapacleanragaroundalongdowelandinsertintotheuppertubetocleaninsidetheuppertube.Inspecttheairtubefordam-ageandscratches.Replaceifdamagedorscratched(notpictured).Removebaseplatefromshaftassembly.Removeinnerandouterbaseplateo-rings.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.important: if using a pick to remove o-rings, do not scratch base plate or o-rings. scratches will cause permanent air leak.Remove floating piston from the air shaft assembly. Remove inner and outer floating piston o-rings. Spray floating piston with isopropylalcoholandwipewithacleanrag.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.Removethetopoutspringfromtheairshaftandspraywithisopropylalcoholandwipewithacleanrag.Removetheretainingringlocatedontopofthemainpistonusingexternalsnapringpli-ers.Thenremovethewavyspringwasher.Using a small flathead screwdriver, carefully separatethekickplateandthemainpiston.important: do not damage either the kick plate or the piston.Removetheinnerandouterpistono-rings.Spraythemainpistonwithisopropylalco-holandwipewithacleanrag.Applyafewdropsofsuspensionoiltonewo-ringsandre-install.Sprayairshaftwithisopropylalcoholandwipewithacleanrag.Inspectairshaftfordamageorscratches.Replaceifdamagedorscratched(notpictured).

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2-STEP AIR SPRING INSTALLATION INSTRUCTIONSReassemblemainpistonandkickplateandinstallontoairshaft.Slidewavywasherontopofmainpistonandsecureintoplacewithsnapring.Install top out spring (spring side first), and floating piston (black quad ring side first) ontoairshaft.Donotinstallbaseplateatthistime.

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2-STEP AIR SPRING INSTALLATION INSTRUCTIONS (CONT)

Installshaftassemblyintoairtube,airvalvefirst, in the side opposite the two holes on theairtube.Installbaseplateonshaftas-sembly.Measureandpour5cc/mlof15wtsuspen-sionoilintothetopoftheairtubeassembly.Insertthepistonhousingintotheairtubeas-sembly,beingcarefulnottospilltheoil.Insertthe2-Stepassemblyintothebottomoftheuppertube.Securewithretainingringusinginternalsnapringpliers.important: retaining ring must be fully seated in upper tube groove. check retaining ring closely to ensure secure fit.Gentlypulldownonairshafttoextendtomaximumlength.LyrikOnly:Measureandpour40cc/mlof2.5wtsuspensionoilintothetopoftheup-pertube.TotemOnly:Measureandpour135cc/mlof2.5wtsuspensionoilintothetopoftheuppertube.note: the oil will just reach the bottom of the upper tube threads.Inserttopcapintouppertube/crownandhandthreadintouppertube.Usinga24mmsocketwrench,tightento60in-lb.Install 2-Step adjuster knob and secure fix-ingscrewwitha2mmhexwrench.Installschradervalveintobottomofairshaft,usingschradervalvetool.Add50psitothe2-Stepsystem.Rotateadjusterknobtominimumtravelpositionandcompressairshafttoensureproperfunction.Rotateadjusterknobtofulltravelpositionandverifyreturntofullextension.


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LOWER LEGINSTALLATION


LOWER LEG INSTALLATION(ALL FORKS)

LOWER LEG INSTALLATION INSTRUCTIONSSprayuppertubeswithisopropylalcoholandwipewithacleanrag(notpictured).Pourorinject15wtsuspensionoilontoneworcleanfoamrings,justunderdustsealsinsideeachlowerleg.Slidelowerlegassemblyontheuppertubesuntilyoufeelthelowerbushingtouchtheendoftheuppertubes.important: make sure both dust seals slide onto the tubes correctly and do not fold under.Invertforktoabout45°,forklegspointingupward.Measureandinjectsuspensionoilintolowerlegsthrougheachshaftbolthole,accordingthebottomvolumevaluesfoundintheOilVolumechartlocatedintheGettingStartedInformationsectionofthismanual.Wipeallexcessoilfromlowerlegs.note: boXXer only - slide damper side fork leg back onto upper tube until the lower bushing touches the end of the upper tube after injecting oil.Inspectandcleanairspringshaftbolts,blacknyloncrushwashersandcrushwashretainers.Replacecrushwashersandcrushwasherretainersifdamaged(notpictured).note: damaged or dirty crush washers can cause oil to leak.Insertrebounddamperandairspringshaftboltsintothreadedshaftends,throughlowerlegshaftholesandtightenwitha5mmhexor10mmsocketwrenchto60in-lb.

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INTRODUCTIONAtthispointyoushouldalreadyhavealreadyservicedyourforkbushings,dampersystem,andspringsystem.Onceyouhavere-installedyourforklowers,youwillhavesuccessfullyservicedyourforkandyouwillbereadytoride!

boXXer onlyboXXer onlyboXXer only

note: boXXer only - insert each upper tube evenly into the lower crown. pull upper tubes up and into the crown, twisting gently as the upper tubes ease into the holes. pull left (damper side) upper tube up to the fully eXtended position (do not over eXtend!). measure 205mm from the dust/lower leg to the bottom of the lower crown hole and tighten the crown bolt with a 4mm heX to 65 in/lb. pull the right (spring side) upper tube even with the left and tighten the crown bolt to 65 in/lb. make sure the upper tubes are positioned at an even height! refer to the diagram for crown measurements. slide each upper tube/frame bumper onto each upper tube. install upper crown onto upper tubes and steerer tube. refer to the diagram for appropriate measurements. tighten upper crown with a 4mm heX wrench to 65 in-lb.Insertexternalrebounddamperknobintorebounddampershaftbolt.Pushinuntilsecure.Adjustasdesired.Forairspringforks,refertotheairchartonyour fork and inflate positive and negative airchamberstoappropriatepsi.Forcoilforks,moveontoStep9.Sprayisopropylalcoholontoentireforkandwipewithacleanrag(notpictured).Threadpositiveandnegativeairvalvecapcoversontoairtopcap.

this concludes the service for your fork. you did a great job! you are now ready to install your fork on your bike and go for a ride!

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LOWER LEG INSTALLATION INSTRUCTIONS (CONT)

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short upper crown152mm (±2mm)tall upper crown182mm (±2mm)

boXXer crown heights

frame/upper tube bumper

lower crown205mm (±2mm)


REAR SHOCKSERVICE


REAR SHOCK SERVICE(ALL SHOCKS)

INTRODUCTIONPrior to servicing your rear shock, you will first need to remove it from your bicycle frame.

AIR CAN REMOVAL/SERVICE INSTRUCTIONSSprayisopropylalcoholonentireshockandwipewithacleanrag(notpictured).Using your fingers or pliers, remove all shockeyeletmountinghardware.Removeairvalvecovercap.Usingasmallhexwrenchorpick,depressschradervalveandreleaseallairfromshockimportant: to avoid injury, all air pressure must be released from shock prior to re-moving the air can.Gentlysecureaircanshockeyeletintobenchvice.note: use aluminum vice "soft-jaws" to pro-tect the shock eyelet when clamped.Grip the air can by hand and turn firmly counterclockwise.Pulltheaircanupshockdamperbodyslowlytoremove.note: air pressure may release, so hold air can tightly while pulling up.Removenegativespringspacerandnega-tivespringbumper.Spraybothwithisopro-pylalcoholandwipewithacleanrag.important: do not attempt to disassemble shock damper and/or shock eyelet assembly. they are not serviceable.Usingasharppick,removetheblackrubberdustsealfromtheaircan.Holdaircan,narrowenddownandremoveblueaircanglideringwithasharppick.important: do not scratch the inside of the air can with pick. scratches can cause per-manent air bypass.Sprayisopropylalcoholinsideaircanandwipewithacleanrag.Inspecttheinsideoftheaircanforanyroughsurfacesorscratches. Run your finger along the inside surfaceoftheaircantofeelforroughsur-facesorscratchesaswell.Replaceaircanifscratchedordamaged(notpictured).Remove large fixed air piston o-ring. Apply afewdropsofsuspensionoiltonewo-ringandre-install.important: the fiXed air piston o-ring is the main air seal. be sure to replace this o-ring.

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AIR CAN REMOVAL/SERVICE INSTRUCTIONSInstallnewaircanglideringandnewaircandustseal.Sprayisopropylalcoholonaircanthreadsandeyeletbodythreadsandwipewithacleanrag(notpictured).Apply2-3dropsofbluethreadlocktoeyeletbodythreads,evenlyspaced.Spreadevenlyontothreadsandwipeawayexcessthreadlockwithacleanrag.Applyasmallamountof5wtsuspensionoilto the inside of the air can. Using your fin-ger,spreadandcoattheentireinneraircansurfacewiththeoil.Re-applyafewdropsofsuspensionoiltotheglideringandrubberdustseal.important: coating the inside the air can with suspension oil ensures lubrication of the fiXed air piston o-ring, which reduces friction and o-ring wear.Installnegativespringbumperandnegativespringspacer.Positionaircanovershockeyeletandslidedownonshockbody.Pressaircandownfirmly and thread clockwise to tighten into eyeletbodyastightlyaspossiblebyhand.note: ensure the outside of the air can is free from oil. this allows more leverage when tightening air can onto shock eyelet body.Using a shock pump, inflate shock to desired airpressureandinstallvalvecovercap(notpictured).Sprayisopropylalcoholonentireshockandwipewithacleanrag(notpictured).Insertmountinghardwareintobotheyelets(notpictured).

this concludes the spring service for your shock. you did a great job! you are now ready to re-install your shock onto your bike and go for a ride!

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www.sram.com www.rockshox.com

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Documents

2007 RockShox Technical Manual Rev B1