Beruflich Dokumente
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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 November 2005
PN 95.4311.776.000, Rev C
Perform service every 100 hours of riding (less depending on riding conditions and riding style).
Regular maintenance ensures your RockShox suspension 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.
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
L O W E R L E G R E M O VA L
PROCEDURES
FOR
2006 SID RACE, TEAM AND WORLD CUP LOWER LEG AND DUAL AIR REMOVAL/INSTALLATION ARE THE
REFER TO THE 03-05 SID SERVICE GUIDE FOR SID RACE DAMPING INTERNALS SERVICE
1. TEAM/WORLD CUP: Remove air valve cover cap from left side air top cap (fig 1a).
Remove negative (bottom) air valve
cap from lower air shaft (fig 1b).
1a
1b
1c
1d
2c
2d
2. Firmly pull external rebound adjuster knob from rebound damper shaft bolt (fig 2a).
Using a 5mm hex wrench loosen
rebound damper shaft bolt 3 to 4 full
turns (fig 2b).
2a
2b
3a
3b
4b
4c
4a
5. Spray isopropyl alcohol onto each upper tube and wipe with a clean rag.
S I D D U A L A I R S P R I N G A S S E M B LY
R E M O VA L
6. Verify all air pressure is removed from air chamber before proceeding. Depress schrader air valve again to remove any remaining air
pressure.
6a
6b
6c
6d
PN 95.4311.776.000, REV C
7a
7b
7c
7d
8a
8b
8c
9b
9c
Look inside the upper tube using a light and check for
scratches. If inside of upper tube is scratched, replace
CSU assembly. Scratches can cause air bypass.
D I S A S S E M B LY & S E R V I C E
PA R T
KIT REQUIRED:
SID S E R V I C E K I T (11.4310.703.000)
9. Slide the negative air piston sleeve from air spring shaft (fig
9a/9b).
9a
10a
10b
10d
10c
IMPORTANT: REPLACEMENT OF AIR PISTON O-RINGS ENSURES THAT SID MAINTAINS A SOLID AIR SEAL. LUBRICATE ALL NEW
O-RINGS THOROUGHLY WITH SUSPENSION OIL OR OIL SOLUBLE GREASE BEFORE INSTALLATION.
11. Slide negative air spring sleeve back onto air spring shaft (figs 11a/11b).
11a
11b
THE SID DUAL AIR ALL TRAVEL SPACER IS LOCATED JUST ABOVE THE NEGATIVE SLEEVE TOP OUT
BUMPER. TO INSTALL, SLIDE NEGATIVE SLEEVE DOWN AND SNAP ALL TRAVEL SPACER ONTO AIR
SPRING SHAFT TO DECREASE TRAVEL.
20mm
Spacer
No
Spacer
60mm
80mm
12a
12b
12c
13a
13b
13. Slide the negative air piston sleeve down air spring shaft and into bottom of upper
tube (fig 13a). Continue to slide entire negative air spring sleeve into upper tube.
You may need to press the negative schrader air valve as you push the negative
sleeve into upper tube to release air pressure. This aids installation.
By hand, thread the air spring assembly threaded base retainer into upper tube
(fig 13b). This part is reverse threaded, so turn counterclockwise to thread into
upper tube.
14. Using the SID Dual Air upper tube retainer tool and a socket wrench, press into retainer firm and square
and tighten the threaded upper tube/base retainer to 30 in-lb (fig 14).
14
15
Measure and pour, or inject, 3 to 5 cc/ml of 15wt suspension oil into positive air chamber, through crown
and into upper tube (fig 15). Suspension oil on top of the positive air piston o-ring is critical to lubrication
and maintenance of the air seal.
TIP: EVERY MONTH, RELEASE ALL POSITIVE AND NEGATIVE AIR PRESSURE AND REMOVE AIR TOP CAP.
POUR OUT ANY REMAINING SUSPENSION OIL FROM POSITIVE AIR CHAMBER AND REFILL WITH 3 TO 5
CC/ML OF FRESH 15WT SUSPENSION OIL. THIS REDUCES AIR SPRING SERVICE INTERVALS AND IMPROVES
THE FUNCTION OF YOUR FORK.
16. Clean the air top cap and upper tube threads with a clean
rag.
16a
16b
16c
PN 95.4311.776.000, REV C
17a
17b
17c
17d
18a
18b
18c
19a
19b
19c
19d
20a
20b
20c
21a
21b
21. Pull the Motion Control damper from the damper tube
using a slow twisting motion (figs 21a/21b). This assists
the damper out of the damper tube.
Allow any excess oil to drain into an oil pan.
Spray entire compression damper with isopropyl alcohol
and wipe all grease and oil from damper assembly.
6
23a
23b
23c
24. Using a sharp pick remove the inner and outer seal head o-rings and replace with
new o-rings (figs 24a/24b).
24a
24b
25b
25c
26b
26c
27a
27b
25. Slide rebound damper seal head back onto rebound damper
shaft (fig 25a).
25a
26. Pinch lower/primary damper piston o-ring and remove (fig 26a). Replace with new o-ring.
Pinch internal floating piston (IFP) o-ring (upper) and
remove (fig 26b). Replace with new o-ring.
26a
Pinch and remove top cap o-ring (fig 26c). Replace with
new o-ring.
Lubricate all new o-rings with 15wt suspension oil.
I N S TA L L AT I O N
27. Place the gold floodgate adjuster knob back onto the compression damper (fig 27a)
and tighten with a 1.5mm hex wrench (fig 27b).
PN 95.4311.776.000, REV C
28b
28a
28c
Floodgate Open
29a
29c
29d
29e
30a
30b
30c
31a
31b
31c
31d
29b
30. Holding the damper tube with the open end of the tube
facing up, pour 5wt suspension oil into the damper tube
until the tube is approximately half-full (fig 30a).
Tap the compression damper/damper tube assembly on a
flat surface lightly to release any air bubbles that may be
trapped inside the damper (figs 30b/30c).
31. Pour additional 5wt suspension oil into damper tube until completely full (fig 31a).
Remove the rebound damper/seal head assembly from the oil container
(remember, the rebound damper/seal head assembly should be submerged in oil).
Wrap a rag around the damper tube to catch displaced oil. Insert the rebound
piston into the damper tube slowly (fig 31b). Slide the piston into the damper
tube (fig 31c).
Insert the rebound damper seal head into the end of the damper tube and press
firmly into place (fig 31d).
Wipe away all displaced oil from the damper tube.
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.
32
If this o-ring came out with the damper tube assembly, apply a small amount of grease to the o-ring and
place it on the bottom of the rebound damper seal head (fig 32).
o-ring
33. Insert Motion Control damper assembly back into the upper tube, rebound shaft first (fig 33a). Guide the end of the rebound
damper through the center of the threaded base retainer. Be careful and do not allow the rebound damper shaft to scrape the
retainer.
Slide the damper completely into
the upper tube (fig 33b). By
hand, thread the compression
damper top cap into the upper
tube (fig 33c).
33a
33b
33c
33d
35d
35c
Using a 2.5mm hex wrench, tighten the cable stop clamp screw (fig 35e).
Rotate the remote spool counterclockwise to the full open (unlocked) position. The
set screw should be positioned in line with the open mark on the cable stop clamp
(fig 35f).
35e
cable set-screw
35f
open-mark on cable
stop clamp
PN 95.4311.776.000, REV C
35g
35h
35i
35j
Apply a small amount of grease to the remote spool torsion return spring. Grease
will hold the torsion spring in the remote spool during installation. Insert the
torsion spring into the underside of the remote spool knob, with the prong facing
out (figs 35g & 35h).
Place the remote spool and torsion spring back onto the compression damper
adjuster hex. The torsion spring prong fits into one detent hole in the top cap
(fig 35i). The cable set screw in the remote spool should be positioned in line with
the alignment mark on the cable set screw (fig 35j).
Turn the remote spool clockwise until spool-stop stops in the closed position
against the cable stop clamp stop (fig 35k) If the stop on the remote spool does
not touch the stop on the cable stop clamp, rotate the clamp counterclockwise until
the two stops touch.
Release the spool and test the return to the open position.
35k
open-mark on cable
stop clamp
35l
Secure the remote spool with a new remote spool retaining ring using external snap
ring pliers (fig 35l).
36. Place the gold floodgate adjuster knob back onto the compression damper spool shaft.
36
Tighten the floodgate adjuster knob set screw to the flat surface of the black adjuster rod with a 1.5mm hex
wrench (fig 36).
.
S I D R E M O T E S P O O L / C A B L E S T O P C L A M P O R I E N TAT I O N
Torque to:
1.4 N-m +/- 0.2 N-m
Torque to:
1.0 N-m +/- 0.2 N-m
4
2
10
P O P L O C R E M O T E L E V E R / C A B L E I N S TA L L AT I O N
INSTALL THE POPLOC LEVER ASSEMBLY ONTO YOUR HANDLEBAR IN THE DESIRED ORIENTATION BEFORE CABLE INSTALLATION. THE
POPLOC LEVER SHOULD BE IN THE OPEN POSITION.
37a
37b
37c
37d
37. Insert PopLoc shifter cable through cable stop clamp and position the cable
housing into the stop. Thread the shifter cable through the small cable guide hole
on the remote spool (fig 37a).
Insert the end of the cable into the cable guide hole under the remote spool cable
set screw (fig 37b).
Pull the shifter cable tight while rotating the remote spool into the position as
pictured. Align the remote spool stop with the alignment mark on the cable stop
clamp (figs 37c & 37d).
pull cable
Using a 1.5mm hex wrench, tighten the cable set screw and secure cable (fig 37d).
Test the function of the PopLoc remote lever and remote spool (fig 37e).
alignment mark
When in the locked out (closed position) the remote spool stop should touch the
cable stop clamp, as pictured (fig 37f).
alignment mark
37f
37e
Press the PopLoc open button and test the return to open position.
remote spool should
touch cable stop
clamp
OPTIONAL:
REMOTE ADJUST
TO
NON-REMOTE ADJUST
SWITCHING FROM REMOTE COMPRESSION ADJUST TO A CROWN-MOUNTED COMPRESSION ADJUSTER REQUIRES ONLY
THE REMOVAL OF THE REMOTE SPOOL AND CABLE STOP CLAMP ASSEMBLIES, AND INSTALLATION OF THE STANDARD
COMPRESSION ADJUSTER KNOB (11.4311.392.000 06 SID MOTION CONTROL COMP KNOB).
UNLIKE
STANDARD
MOTION CONTROL
COMPRESSION
DAMPER REMOTE RETURN SPRING IS NOT DESIGNED INTO THE DAMPER ASSEMBLY.
POPLOC LEVER ADJUSTER CAN EITHER BE REMOVED FROM THE HANDLEBAR, OR SIMPLY REMOVE THE
POPLOC LEVER ON YOUR HANDLEBAR, IF YOU CHOOSE TO INSTALL THE
SPOOL IN THE FUTURE.
THE REMOTE
L O W E R L E G I N S TA L L AT I O N
38. Thoroughly clean the dust seals and upper bushing with a clean rag and isopropyl alcohol. Replace dust
seals and foam rings if worn or damaged. Refer to the Bushing Service Guide for procedures at
www.rockshox.com.
38
Pour or inject 15wt suspension oil onto new or clean foam rings just under dust seal inside lower leg; each
side (fig 38). This provides additional lubrication during use.
PN 95.4311.776.000, REV C
11
39a
39b
39c
40. Measure and pour (or inject...an oil syringe works best) 5cc/ml of 15wt suspension oil into lower legs (left
and right sides), through both shaft bolt holes (fig 40). This provides lubrication for the bushings during
use.
40
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 39a).
Continue sliding lower leg assembly onto upper tubes until
you feel the lower bushings touch the end of the upper
tubes (fig 39b). Pull lower leg assembly back off just
slightly so lower bushing is not touching bottom of upper tube. Stop (fig 39c).
41. Inspect and clean the rebound damper shaft bolt, Dual Air shaft nut and black nylon crush washers (fig 41).
Replace crush washers and crush washer retainer if damaged. Damaged or dirty crush washers can cause oil
to leak.
41
42. Slide lower leg assembly further down upper tubes until shaft ends are seated inside lower leg shaft holes. You may need to use a
small hex wrench or screw driver to guide the shaft ends into the holes (fig 42a)
Insert rebound damper shaft bolt
into threaded shaft end (right
side), through lower leg shaft
hole. Hand thread into shaft and
tighten with a 5mm hex wrench
to 60 in-lb (fig 42b).
42a
42b
42d
42c
44a
44b
Thread both air valve cover caps back onto air top cap and negative air shaft.
12
AIR
AIR PRESSURE
RIDER WEIGHT
POSITIVE (TOP)
70-80 psi
80-100 psi
100-120 psi
120-140 psi
140-160 psi
NEGATIVE (BOTTOM)
(XC SETTING)
70-80 psi
80-100 psi
100-120 psi
120-140 psi
140-160 psi
NEGATIVE (BOTTOM)
(RACING SETTING)
40-60 psi
60-80 psi
80-100 psi
100-120 psi
120-140 psi
OIL
SID RACE DUAL AIR RIGHT LEG
PURE DELITE/MOTION
CONTROL
1/2 Full
TOP VOLUME
3cc/ml
PURE DELITE/MOTION
CONTROL
Full
(fill from bottom of tube)
TOP VOLUME
3cc/ml
OIL WEIGHT
BOTTOM VOLUME
5 wt
10cc/ml
SID RACE DUAL AIR LEFT LEG
OIL WEIGHT
BOTTOM VOLUME
15 wt
10cc/ml
SID TEAM/WORLD CUP DUAL AIR RIGHT LEG
OIL WEIGHT
15 wt
OIL WEIGHT
15 wt
OIL WEIGHT
BOTTOM VOLUME
OIL WEIGHT
5 wt
10cc/ml
15 wt
OIL WEIGHT
15 wt
TROUBLE-SHOOTING
AIR LOSS
L O S S O F, O R VA R I A N C E I N D A M P I N G
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 to 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-ring for air bypass. If there is a repeated loss of air pressure, air may be the cause of oil loss at 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.
PN 95.4311.776.000, REV C
13