2011 Tora Technical Manual

8/6/2019 2011 Tora Technical Manual

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2011 Tccl Ml


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sraM LLC warranTySRAM warrants its products to be ree rom deects in materials or workmanship or a period o two

years ater original purchase. This warranty only applies to the original owner and is not transerable.

Claims under this warranty must be made through the retailer where the bicycle or the SRAM

component was purchased. Original proo o purchase is required.

This warranty statement gives the customer specic legal rights. The customer may also have other

rights which vary rom state to state (USA), rom province to province (Canada), and rom country to

country elsewhere in the world.

To the etent that this warranty statement is inconsistent with the local law, this warranty shall be

deemed modied to be consistent with such law, under such local law, certain disclaimers and

limitations o this warranty statement may apply to the customer. For eample, some states in the

United States o America, as well as some governments outside o the United States (including

provinces in Canada) may:

a. Preclude the disclaimers and limitations o this warranty statement rom limiting the statutory rights o

the consumer (e.g. United Kingdom).

b. Otherwise restrict the ability o a manuacturer to enorce such disclaimers or limitations.

To the etent allowed by local law, ecept or the obligations specically set orth in this warranty

statement, in no event shall SRAM or its third-party suppliers be liable or direct, indirect, special,

incidental, or consequential damages.

This warranty does not apply to products that have been incorrectly installed and/or adjusted

according to the respective SRAM technical installation manual. The SRAM installation manuals can be

ound online at www.sram.com, www.rocksho.com, www.avidbike.com, www. truvativ.com, or

www.zipp.com.

This warranty does not apply when the product has been modied.

This warranty does not apply when the serial number or production code has been deliberately altered,

deaced or removed.

This warranty does not apply to damage to the product caused by a crash, impact, abuse o the product,

non-compliance with manuacturers specications o usage or any other circumstances in which the

product has been subjected to orces or loads beyond its design.

This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a

result o normal use, ailure to service according to SRAM recommendations and/or riding or installation

in conditions or applications other than recommended.

w t t t :

Dust seals/Bushings/Air sealing o-rings/Glide rings/Rubber moving parts/Foam rings/Rear shock

mounting hardware and main seals/Stripped threads and bolts (aluminum,titanium, magnesium or steel)/

Upper tubes (stanchions)/Brake sleeves/Brake pads/Chains/Sprockets/Cassettes/Shiter and brake

cables (inner and outer)/Handlebar grips/Shiter grips/Jockey wheels/Disc brake rotors/Wheel braking

suraces/Bottom out pads/Bearings/Bearing Races/Pawls/Transmission gears/Spokes/Free hubs/

Aero bar pads/Corrosion/Tools

This warranty shall not cover damages caused by the use o parts o dierent manuacturers.

This warranty shall not cover damages caused by the use o parts that are not compatible, suitable and/or authorized by SRAM or use with SRAM components.

This warranty shall not cover damages resulting rom commercial (rental) use.

roCkshox suspension serviCeWe recommend that you have your RockSho suspension serviced by a qualied bicycle mechanic.

Servicing RockSho suspension requires knowledge o suspension components as well as the special

tools and fuids used or service.

Used suspension fuid should be recycled or disposed o in accordance to local and ederal regulations.

NEVER pour suspension fuid down a sewage or drainage system or into the ground or a body o water.

This publication includes trademarks and registered trademarks o SRAM Corporation designated by the symbols and , respectively.

Copyright SRAM LLC 2010

For eploded diagram and part number inormation, please reer to the Spare Parts Catalog available on our web site at www.sram.com.

For order inormation, please contact your local SRAM distributor or dealer.

Inormation contained in this publication is subject to change at any time without prior notice. For the latest technical inormation, please visit our website at www.sram.com.

Your products appearance may dier rom the pictures/diagrams contained in this catalog.

Product names used in this document may be trademarks or registered trademarks o others.


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GEN.0000000003197 REV A3

TabLe o ConTenTs

serviCe inTervaLs ....................................................................................................................................................................................................................................5

TooLs needed or serviCe ...................................................................................................................................................................................................................6

parTs needed or serviCe ...................................................................................................................................................................................................................6

TeChnoLogy and oiL voLuMes ...........................................................................................................................................................................................................7

Torque TighTening vaLues ..................................................................................................................................................................................................................7

Lower Leg bushing inspeCTion .........................................................................................................................................................................................................8

Lower Leg reMovaL ................................................................................................................................................................................................................................9

Lower Leg seaL serviCe ......................................................................................................................................................................................................................11

CoiL spring serviCe ...............................................................................................................................................................................................................................13(argyLe r, rC - darT 1, 2, 2 (wiTh Turnkey), 3 - doMain r, rC - Tora 289, 302)

CoiL spring serviCe ...............................................................................................................................................................................................................................14(reCon siLver - reCon goLd - sekTor - Tora T k)

CoiL u-Turn spring serviCe ...............................................................................................................................................................................................................15(doMain 302, 318 - Tora 289, 302)

soLo air spring serviCe ......................................................................................................................................................................................................................16(reCon siLver - Tora 302)

rebound daMper serviCe ...................................................................................................................................................................................................................19(argyLe r - darT 2 - doMain r - reCon siLver r - Tora 289)

Turnkey daMper serviCe....................................................................................................................................................................................................................21(darT 2, 3 - reCon siLver Tk - Tora 30 2, Tk)

Lower Leg insTaLLaTion .....................................................................................................................................................................................................................24reMoTe serviCe ........................................................................................................................................................................................................................................26(pushLoC - popLoC adjusT - popLoC)


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GEN.0000000003197 REV A4

saeTy irsT!At SRAM, we care about YOU. Please, always wear your saety glasses

and protective gloves when servicing your RockSho suspension.

Protect yoursel! Wear your saety gear!


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GEN.0000000003197 REV A5

serviCe inTervaLs

The ollowing chart is a summary o the maintenance/service intervals or RockSho orks. Following this schedule is important to

ensure the consistent perormance and longevity o your ork. Some o the inormation listed may not be applicable to your ork.

Mtc itl (h)

Inspect carbon crown-steerer Every ride

Clean dirt and debris rom upper tubes Every ride

Check air pressure (air orks only) Every ride

Inspect upper tubes or scratches Every ride

Lubricate dust seals and upper tubes Every ride

Change Speed Lube oil bath 25

Check ront suspension asteners or proper torque 25

Clean and lubricate remote lockout cable and housing 25

Remove lowers, clean/ inspect bushings and change oil bath

(i applicable)50

Clean and lubricate air spring assembly 50

Change oil in damping system (including hydraulic lockout) 100

Clean and lubricate coil spring assembly (coil orks only) 100


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GEN.0000000003197 REV A6

parTs needed or serviCe

Prior to servicing your ork, it is important that you have all o the necessary replacement parts. For eploded diagram and part

number inormation, please reer to the Spare Parts Catalog available on our web site at www.sram.com. For order inormation,

please contact your local SRAM distributor or dealer.

TooLs needed or serviCe

The ollowing chart is a list o the model year 2011 tools needed or service on your Tora suspension ork. While this chart is intended

to be comprehensive, it is still only a guide. The tools required or each step o service are detailed in the tet o the service section.

Tl

Saety/Starting Equipment

Saety Glasses

Nitrile Gloves

Apron

Clean Rags (Lint Free)

Oil Measuring Device

Oil Pan

Clean Work Area

General Tools

He Key Set (Sizes 1.5 mm - 5 mm)Plastic Mallet

Socket Wrench

24 mm Socket

Torque Wrench

Snap Ring Pliers (Eternal)

Snap Ring Pliers (Internal)

Long Dowel Rod

Sharp Pick

Oil/Liquids

Suspension Oil (Rocksho 5wt)Grease (Suspension Oil Soluble)

Isopropyl Alcohol


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GEN.0000000003197 REV A7

Torque TighTening vaLues

The ollowing chart is a summary o the primary torque tightening values or Tora orks. The torque tightening values or asteners

that require a specic torque are detailed in the tet o each service section.

t T vl

Top Cap 7.3 Nm (65 in-lb)

Bottom Bolt/Shat Nut 6.8 Nm (60 in-lb)

Brake Caliper Mounting Bolts (Cantilever/Linear -Pull) 5-7 Nm (43-61 in-lb)

TeChnoLogy and oiL voLuMes

The ollowing chart is a complete list o the 2011 RockSho Tora line-up. It details the model, corresponding damper and spring

technology, along with the oil volume and RockSho oil weight required or each upper tube and lower leg.

DamperTechnology(Drive Side)

Volume(ml)

Oilwt

Volume(ml)

Oilwt SpringTechnology

(Non-Drive Side)

Volume(ml)

Oilwt

Volume(ml)

Oilwt

Upper Tube Lower Leg Upper Tube Lower Leg

Tora

TK Turnkey 145 5 5 15 Solo Air 3 15 10 15

2 89 Rebound Only

150 5 15 15

Coil

- -

20

15

Coil U-Turn 30

302 Turnkey

Coil 20

Coil U-Turn 30

Solo Air 3 15 15


8/28

8

Lower Leg bushing inspeCTion

inTroduCTion

Suspension ork bushings are considered "wear and tear" parts. The rate and amount o wear will depend on the requency o

ork service, requency o riding, riding terrain, rider body weight, and type o ork. I your bushings are worn, you will need to

replace your lower leg assembly. The ollowing chapter covers how to check or bushing wear.

CheCk or bushing wear

Mt 1: Check or bushing wear while the orkis installed on the bike

Compress the ork 5 times to circulate lower leg1.

lubrication.

Wrap your ngers around the lower leg just2.

below the the dust seal. Hold the ront brake

lever tight while rocking the bike back and orth

(you may need someone to do this or you while

you hold the lower leg). I you hear or eel any

"knocking" at the lower leg, the bushings are

worn.

Mt 2: Check or bushing wear while the orkis removed rom the bike

Compress the ork 5 times to circulate lower leg1.

lubrication.

Brace the ork on a table or the foor to hold it2.

steady. Hold the ork crown tight in one handand the brake arch in the other hand. Try to

move the brake arch back and orth. I you hear

or eel any "knocking", the bushings are worn.

I you have determined that the bushings are

worn, you will need to replace the lower leg

assembly. Reerence the 2011 RockSho Spare

Parts Catalog or inormation on the correct

lower leg and correspoding part number or your

ork.

1 2

2

or


9/28

9

Lower Leg reMovaL

Lower Leg reMovaL

Cl :1. Proceed to Step 4.a :2. Remove the positive air chamber valvecap rom the top cap located on the non-drive

side ork leg. I the ork also has a negative air

chamber, remove the valve cap located at the

bottom o the non-drive side air chamber.

The positive air chamber valve cap or 2-Step

and Dual Position Air orks is located at the

bottom o the non-drive side ork leg.

Depress the Schrader valve and release all o the3.

air pressure rom the air chamber.I the ork has a negative air chamber, start with

the negative air chamber frst, then proceed to

the positive air chamber.

CauTionv ll m m t c. l t c lt / m t t .Remove the eternal rebound adjuster knob (i4.

applicable) by pulling it rom the shat bolt at the

bottom o the right ork leg.

Use a 5 mm he wrench to loosen both shat5.

bolts 3 to 4 turns.

dl a, a u-T, 2-st, dl pta : Use a 10 mm socket (or openend) wrench to loosen and unthread the shat

nut at the bottom o the let ork leg until it is

fush with the threaded shat end.

For hollow bottom ork legs you will need to use

a deep 10 mm socket to loosen and unthread the

air shat nut.

Place an oil pan beneath the ork to catch any6.

draining oil. Use a plastic mallet to rmly strike

each shat bolt /nut ree rom its press-t to the

lower leg and use your ngers to remove the

shat bolts/nut completely.For hollow bottom ork legs tap the 5 mm hex

wrench and 10 mm deep socket while engaged in

the bolts to ree them rom the press-ft.

inTroduCTion

Removing the lower legs is the rst step in servicing your ork. Once you have removed your ork lower legs, you'll be ready to

move onto the net section.

2 3

4 5 6


10/28

10

Lower Leg reMovaL (ConTinued)

Firmly pull the lower leg downward until oil7.

begins to drain.

i t t t l t t ll l t m t , t t t t() t t l l m tll . r-tll t t lt() 2 t 3t ( -tll t t t f t t

t t ) t st 6. d t tt c t tl m tl l t cl m t .Remove the lower leg rom the ork by pulling it8.

downward, holding onto both legs or the brake

arch.

Spray isopropyl alcohol on and into the lower leg9.

assembly. Wipe the lower legs clean, then wrap

a clean rag around a dowel and clean the inside

o each lower leg.

7 8


11/28

11

Lower Leg seaL reMovaL

Select one side o the lower leg to work on rst.1.

ol l: I your ork has a black oil seal betweenthe dust wiper and the upper bushing, position

the tip o a downhill tire lever or large, fat head

screwdriver between the lower lip o the black

oil seal and the upper bushing.

n l l: I your ork does not have a blackoil seal between the dust wiper and the upper

bushing, place the tip o the tool underneath the

lower lip o the wiper seal.

i ft c, m t t. a c t t ll m t l.Stabilize the lower leg upright on a bench top or2.

on the foor. Hold the lower leg rmly and use

downward orce on the tool handle to leverage

the seal(s) out.

k t l l ml tl. d tll t l l t tt tct, cm t c t

ll t. T ll m t l lml.I your ork has an oil oam ring, remove it with3.

your ngers.

Repeat steps 1 - 3 or the other side o the lower4.

leg.

Spray isopropyl alcohol on and into the lower leg.5.

Wipe the lower legs clean, then wrap a clean,lint

ree rag around a dowel and clean the inside o

each lower leg.

Lower Leg seaL serviCe

inTroduCTion

Suspension ork seals are considered "wear and tear" parts and require regular maintenance, depending on the requency o

riding, riding terrain, and type o ork. The more you ride, the more requently your seals need to be replaced. The ollowing

chapter covers wiper and oil seal removal and installation. At this point you should already have the lower legs removed romyour ork. I not, you will need to return to the Lower Leg Removal section o this manual and ollow the instructions or removing

your ork lower legs.

1 2

3


12/28

12

Lower Leg seaL insTaLLaTion

m tlltI your ork has oam rings, soak the new oam1.

rings in 15wt RockSho suspension oil.

Insert a new oil-saturated oam ring into each2.

side o the lower leg.

ol l tlltPosition the oil seal, with the grooved side1.

visible, onto the stepped side o the seal

installation tool.

Hold one o the lower legs rmly and use the seal2.

installation tool to push the oil seal evenly and

completely into that leg. Repeat or the otherleg.

b t tlz t l l tt t m l l tll t l.

dt tlltPosition the dust wiper into the recessed side o1.

the seal installation tool, so that the grooved side

o the seal is visible.

Hold one o the lower legs rmly and use the seal2.installation tool to push the dust wiper evenly

and completely into that leg. There should be no

visible gap between the dust wiper and the lower

leg. Repeat or th other leg.

b t tlz t l l tt t m l l tll t l.

1 2

1 2

1 2


13/28

13

CoiL spring serviCe(argyLe r, rC - darT 1, 2, 2 (wiTh Turnkey), 3 - doMain r, rC - Tora 289, 302)

inTroduCTion

At this point you should already have the lower legs removed rom your ork. I not, you will need to return to the Lower Leg

Removal section o this manual and ollow the instructions or removing your ork lower legs.

CoiL spring reMovaL insTruCTions

Unthread and remove1. the spring top cap with a24 mm socket and socket wrench. Onceremoved, clean the upper tube threads with arag.

p ml l t t c.al l:2. Remove the spring pre-loadspacer(s).Push the spring shat upward, rom the bottom3.o the upper tube, then remove the coil springand spring spacers rom the upper tube.

al, dt , T l: i t cl lt t ct t cl , t lt l t cl t t ct t t t /tt t.Turn the ork upside down and slide the spring4.shat assembly out o the upper tube. Removethe spring shat assembly. Clean the springshat assembly and inspect it or damage.Spray isopropyl alcohol on the spring, spring5.shat assembly and the inside and outside o theupper tube and wipe with a clean rag. Wrap aclean rag around a long dowel and insert it intothe upper tube to clean inside the upper tube.

1 2

3 4

CoiL spring insTaLLaTion insTruCTions

Insert6. the spring shat assembly into the uppertube rom the top. Guide the threaded endthrough the shat guide at the bottom o theupper tube and gently pull the shat through toull etension.Apply resh grease liberally to the coil spring/7.spring spacer assembly.Insert the coil spring/spring spacer assembly8.into the upper tube rom the top.

al l:9. Install the spring pre-load spacersonto the coil spring.Clean the top cap, then apply a small amount10.o grease to the top cap threads (al dm l). Insert and hand thread the topcap into the upper tube. Use a 24 mm socketand socket wrench to tighten the top cap to7.3 Nm (65 in-lb).

6 7 8

9 10


14/28

14

CoiL spring serviCe(reCon siLver - reCon goLd - sekTor - Tora Tk)

inTroduCTion

At this point you should already have the lower leg removed rom your ork. I not, you will need to return to the Lower Leg


CoiL spring reMovaL insTruCTions

Use a 2.5 mm he wrench to remove the preload1.adjuster knob screw, then remove the adjusterknob. Use a magnet to remove the detent ballsand springs rom the top cap (rc sl,rc gl l).Unthread and remove the spring top cap with a2.24 mm socket wrench.p ml l t t c.Push the spring shat upward, rom the bottom o3.the upper tube, then remove the coil spring and

spring shat rom the upper tube. Once removed,clean the upper tube threads with a rag.Spray isopropyl alcohol on the spring, spring4.shat assembly and the inside and outside o theupper tube and wipe with a clean rag. Wrap aclean rag around a long dowel and insert it intothe upper tube to clean inside the upper tube.i t cl lt t ct tcl , t lt l t cl tt ct t t t/tt t.Use a pick to remove the o-ring rom the preload5.adjuster on top o the spring. Apply grease to

the new o-ring and install it.

CoiL spring insTaLLaTion insTruCTions

Apply resh grease liberally to the spring.6.Insert the spring shat and7. spring assembly backinto the upper tube.Clean the top cap, then apply a small amount o8.grease to the top cap threads. Insert and handthread the top cap into the upper tube. Use a24 mm socket wrench to tighten it to7.3 Nm (65 in-lb).Re-install the detent springs and balls into the9.top cap (rc sl, rc gl l). Re-install the preload adjuster knob and knob screw.Tighten the preload adjuster knob screw with a2.5 mm he wrench to1.4 Nm (12 in-lb).

21

3 5

6 7 8

9


15/28

15

CoiL u-Turn spring serviCe(doMain r, rC - Tora 289, 302)

inTroduCTion



CoiL u-Turn spring reMovaL insTruCTions

Remove the U-Turn adjuster knob screw with1.

a 2.5 mm he wrench and remove the U-Turn

adjuster knob.

Remove the three detent ball bearings and2.

detent springs rom the top cap using a magnet.

Unthread and remove the spring top cap with a3.

24 mm socket wrench. The spring is attached

to the top cap and spring shat. Pull and lit the

entire spring assembly rom the upper tube.

Once removed, clean the upper tube threads

with a rag.p ml l t t c.Turn the ork upside-down to remove the U-Turn4.

negative spring assembly rom the upper tube.

Spray isopropyl alcohol on the entire spring5.

assembly, negative spring, and the inside and

outside o the upper tube and wipe with a clean

rag. Wrap a clean rag around a long dowel and

insert it into the upper tube to clean inside the

upper tube.

1 2

3 4

CoiL u-Turn spring insTaLLaTion insTruCTionsApply resh grease liberally to the negative6.

spring, the entire spring assembly, and the top

cap o-ring.

Insert the negative spring into the upper tube7.

rom the top.

Insert the U-Turn spring assembly into the upper8.

tube rom the top, shat end rst. Align and seat

the spring shat through the shat guide/base

plate.

rtt t ml t l l t t t t t / lt.Insert and hand thread the top cap into the9.

upper tube. Use a 24 mm socket wrench to

tighten to 7.3 Nm (65 in-lb).

Place the adjuster detent springs into the top10.

cap detent holes, evenly spaced. Place a detent

ball bearing on top o each detent spring.

M ll t , t t c t c tl t .Place the U-Turn adjuster knob on top o he-11.

shaped adjuster. Tighten the U-Turn adjuster

knob screw with a 2.5 mm he wrench to

1.4 Nm (12 in-lb).

86

9

7

10 11


16/28

16

soLo air spring serviCe(reCon siLver - Tora 302)

inTroduCTion



soLo air spring reMovaL/serviCe insTruCTions

CauTionv ll m m t c. d t sc l t m m .l t c lt /m t t .Use a 24 mm socket wrench to unthread the1.

air spring top cap. The air spring assembly is

attached to the top cap. Pull and lit the entire

air spring assembly rom the upper tube. Onceremoved, clean the upper tube threads with a

rag.

Pull the top cap out o the air tube assembly and2.

pour any oil rom the air tube into an oil pan.

Remove the air shat/piston assembly rom the3.

bottom o the air tube by pulling the shat down

and rocking it rom side to side.

Spray isopropyl alcohol on the inside and outside4.

o the upper tube and wipe it with a clean rag.

Wrap a clean rag around a long dowel and insert

it into the upper tube to clean inside the upper

tube. Spray isopropyl alcohol on the inside andoutside o the air tube and wipe it with a clean

rag. Wrap a clean rag around a long dowel and

insert it into the air tube to clean inside the air

tube.

Use small eternal snap ring pliers to remove the5.

air piston snap ring. Remove the air piston wavy

spring washer and piston rom the air shat.

e t t t tm t t.

o-t t c mtlm t c ml l.

Use a pick to remove the air piston outer o-ring.6.Apply grease to the new o-ring and install it.Use a pick to remove the ace seal o-ring rom7.the underside o the air piston. Use isopropylalcohol and a clean rag to clean the o-ringgroove. Install the new, dry o-ring into thegroove.pc t t c l - t t c ll t m t. d t c t- t t m m t t lc.

1 2

3

6

5

7


17/28

17

soLo air spring reMovaL/serviCe insTruCTions (ConTinued)

Install the air piston and spring wavy washer8.

onto the air shat and use small eternal snap

ring pliers to secure the air piston snap ring in

the snap ring groove. Check the snap ring t to

make sure it secures the air piston and wavy

washer to the air shat head. The air piston

should compress upward slightly with spring

resistance rom wavy spring washer and snapring.

e t t t -tll tt t t. o-t t c mtl m t c ml l.Slide the air sleeve/negative piston assembly9.

rom the air shat. Spray the air shat with

isopropyl alcohol and wipe it with a clean rag.

Remove the top-out bumper and kick plate rom10.

the air sleeve/negative piston.

Use a pick to remove the inner and outer11.

negative piston o-rings. Apply grease to the

new o-rings and install them.w c t m -, tctc t t t. sctc mc t l.

9

10 11

8

opTionaL - aLL TraveL ConiguraTions

All Travel spacers are located above the top out bumper. I you want to change the travel o your ork, add a spacer to decrease

travel, or remove the spacer to increase travel.

nc20 mm

c

80 mm 100 mm 120 mm

40 mmc


18/28

18

soLo air spring insTaLLaTion insTruCTions

Insert the top-out bumper and kick plate back12.

onto the negative piston. Re-install the negative

piston/sleeve assembly onto the air shat , with

the kick plate oriented toward the air piston.

Apply grease to the air assembly outer o-rings.13.

Insert the air assembly into one end o the air

tube. Push the negative piston into the air tube

until it is rmly seated.Hold the air tube at a slight angle, then pour 3 mL14.

o 15 wt RockSho oil into the top o the air tube.

d t l tt t t ct t t.Insert the air top cap into the air tube and press15.

it tight into the air tube.

Insert the air assembly, shat rst, into the upper16.

tube rom the top. Guide the bottom o the air

shat through the shat guide in the bottom o the

upper tube. Check the bottom o the upper tube

and make sure the air shat guide is seated into

the upper tube shat guide.

Apply a small amount o grease to the top cap17.threads and o-ring. Hand thread the top cap into

the upper tube. Be careul not to damage the top

cap o-ring upon installation.

Use a 24 mm socket wrench to tighten the top18.

cap to 7.3 Nm (65 in-lb).

12 13 14

16

18

15


19/28

19

rebound daMper serviCe(argyLe r - darT 2 - doMain r - reCon siLver r - Tora 289)

inTroduCTion



daMper serviCe insTruCTionsUse a 24 mm socket wrench to unthread the1.

top cap. Once removed, clean the upper tube

threads with a rag.

Remove the ork rom the bicycle stand and2.

pour the oil into an oil pan.

Turn the ork upside down and push the3.

rebound damper shat through the shat guide/

seal head. Use a long dowel rod to push the

damper piston past the upper tube threads and

remove the damper rom the upper tube.

Remove the rebound damper piston o-ring/4.

glide ring. Apply a ew drops o RockSho

suspension oil to the new o-ring/glide ring andinstall it.

al r, dm r, rc sl r, 5.T 289 l: Use a pick to remove the damperinner seal head o-ring, located in the bottom o

the upper tube. Apply a ew drops o RockSho

suspension oil to a new o-ring and install it.

i c t m -, t ctct - l. sctc m c l tl.Clamp6. the ork back into the bicycle stand.

Apply grease to the upper tube threads. Insert

the rebound damper back into the drive sideupper tube, shat rst, and push the piston into

the upper tube.

Use a long dowel rod to push the rebound7.

damper into the upper tube. Guide the rebound

damper shat through the damper shat guide/

seal head at the bottom o the upper tube and

pull the shat through by hand into the ully

etended position.

1 2

3 4

5 6

7


20/28

20

daMper serviCe insTruCTions

Orient the ork upright in the bicycle stand.8.

Measure and slowly pour 5wt RockSho

suspension oil into the upper tube using the

volumes listed in the chart below.

ol lm ctcl. T mc l cll tl, t lttl l cm mc.

Press the top cap down into the upper tube9.

threads and hand tighten it. Use a 24 mm

socket wrench to tighten the top cap to

7.3 Nm (65 in-lb).

ol vlm

(3 mL)

Argyle R 130 mL

Dart 2 150 mL

Domain R 200 mL

Tora 289 150 mL

Recon Silver R 147 mL

8 9


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21

Turnkey daMper serviCe(darT 2, 3 - reCon siLver Tk - Tora 302, Tk)

inTroduCTion



daMper serviCe insTruCTions

C Mt (-mt) l:1. Use eternalsnap ring pliers to remove the eternal snap ring

rom the compression adjuster knob. Remove

the adjuster knob and o-ring.

or

rmt l: Use a 2 mm he wrench to loosenthe cable pinch bolt and remove the cable.

y t t m t mt cll.Unthread the compression damper top cap with2.

a 24 mm socket and socket wrench.

Remove the compression damper by pulling up3.

and gently rocking it rom side to side. I the ork

is equipped with a mt lockout eature, besure to remove the remote compression damper

cable-stop clamp; which is located under the

compression damper top cap. Once removed,

clean the upper tube threads with a rag.

Remove the compression damper top cap4.

o-ring and piston o-ring. Apply a ew drops o

RockSho suspension oil to the new o-rings andinstall them.

Remove the ork rom the bicycle stand and pour5.

the oil into an oil pan.

Turn the ork upside down and push the rebound6.

damper shat through the shat guide/seal head.

Use a long dowel rod to help push the damper

piston past the upper tube threads and remove

the damper rom the upper tube.

1

2 3

4 5

6

orC Mt

rmt


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22

opTionaL - CoMpression daMper upgrade: non-reMoTe To reMoTe adjusT

Upgrading rom a non-remote compression adjust ork to a remote compression adjust (rom a crown mounted adjuster knob to

a remote PopLoc or PushLoc lever adjuster), requires replacing the non-remote compression damper with a remote compression

damper and cable-stop clamp. The remote return spring is integrated into the compression damper and is required or use with

the PopLoc and PushLoc remote lever assembly.

daMper serviCe insTruCTions (ConTinued)

Remove the rebound damper piston o-ring/glide7.

ring. Apply a ew drops o RockSho suspension

oil to the new o-ring/glide ring and install it.

Use a pick to remove the damper inner seal head8.

o-ring (located in the bottom o the upper tube).

Apply a ew drops o RockSho suspension oil to

a new o-ring and install it.

i c t m -, t ctct - l. sctc m c l tl.Clamp9. the ork back into the bicycle stand. Applygrease to the upper tube threads. Insert therebound damper back into the drive side upper

tube, shat rst, and push the piston into theupper tube.Push the10. rebound damper into the upper tubeusing a long dowel rod. Guide the rebounddamper shat through the damper shat guide/seal head at the bottom o the upper tube andpull the shat through by hand into the ullyetended position.Orient the ork upright in the bicycle stand.11.Measure and slowly pour 5wt RockShosuspension oil into the upper tube using thevolumes listed in the chart below.ol lm ctcl. T mc l cll tl, t lttl l c mmc.

C Mt (-mt) l:12. Turn the

he-shaped compression adjuster ully counter-clockwise.

or

rmt l: Position the cable-stop clampin the 10 o'clock position around the uppertube hole on the crown prior to inserting thecompression damper.

ol vlm

(3 mL)

Dart 2 (with Turnkey), 3:

80-100 mm

120mm

93 mL

109 mL

Recon Silver TK 147 mL

Tora 302 150 mL

ToraTK 145 mL

10 11

12

9

7 8

or


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23

daMper serviCe insTruCTions (ConTinued)

Insert the compression damper into the upper13.tube through the crown. Press down on androck the damper rom side to side to work it intothe upper tube, being careul not to damage theo-ring on the upper tube threads. Hand tightenthe damper into the upper tube.Use a 24 mm socket wrench to tighten the14.compression damper to 7.3 Nm (65 in-lb).

C Mt (-mt) l:15. Placethe compression adjuster knob onto thecompression damper top cap with the knob dialset in the 2 o'clock position. Using eternal snapring pliers, secure the compression adjusterknob with a new snap ring.

or

rmt l: Move on to the Remote Servicesection or instructions on how to install theremote lever and cable assembly.

14 15

13

C Mt


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24

Lower Leg insTaLLaTion

Lower Leg insTaLLaTion insTruCTions

Spray the upper tubes with isopropyl alcohol and1.

wipe them with a clean rag.

Apply a small amount o grease to the inner2.

suraces o the dust wipers, oil seals, and oam

rings (i applicable).

ll ttm l, t t 6.n-ll ttm l:3. Slide the lowerleg assembly onto the upper tube assembly just

enough to engage the upper bushing with the

upper tubes.

M t t l l t t ttt l t t l t l.Reerence the oil chart at the beginning o this4.

manual or proper oil weight and volumes or

lower leg lubrication. Invert the ork so that the

bottom o the ork is angled upward at about

45. Measure and inject/pour suspension oil into

each lower leg through the shat bolt hole.

Slide the lower leg assembly along the upper5.

tubes until it stops and the spring and damper

shats are visible through the shat bolt holes

(dl a, a u-T, dl pt a spring shats should etend through the shatbolt hole). Wipe all ecess oil rom the outer

surace o the lower legs. Skip to step 8.

inTroduCTion

At this point you should already have already serviced your ork seals, damper system, and spring system. Once you have re-

installed your ork lower legs, you will have successully ser viced your ork and you will be ready to ride!

2

4

3

5


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25

hll ttm l:Reerence the oil chart at the beginning o6.

this manual or proper oil weight and volumes

or lower leg lubrication. Hold the lower

leg assembly horizontally and inject/pour

suspension oil into each leg rom the dust seal

side.

Position the upper tube assembly horizontally7. then slide the lower leg assembly onto the upper

tube assembly until it stops and the spring and

damper shats are visible through the shat bolt

holes (dl a, a u-T, dl pta spring shats should etend through theshat bolt hole). Wipe all ecess oil rom the

outer surace o the lower legs.

b cl t t ll l m t l l tll t t t t.

M t t l l t t t tt l t t l t l.

Inspect and clean the damper and air spring8.shat bolts/nut, nylon crush washers and crush

wash retainers. Replace crush washers and

crush washer retainers i damaged.

y mt cl t c lcftt m c /c t. dt m c c c l t l m t .Insert the shat bolts into the threaded shat9.

ends through the lower leg shat holes (or air

shat nut onto the threaded shat end), and

tighten with a 5 mm he (bolt) or 10 mm socket

wrench (nut) to 7.3 Nm (65 in-lb).

ll ttm l ll t ct t t 5 mm lt 10 mm ct t t t dl a t t. t tl t10. ,insert the eternal rebound damper knob into

the rebound damper shat bolt. Push it in until

secure. Adjust as desired.

11. , reer to the air chart onyour ork and infate the positive and negative

(i applicable) air chamber(s) to the appropriate

pressure.

Spray isopropyl alcohol on entire ork and wipe it12.

with a clean rag.

13. , thread the positive andnegative (i applicable) air valve cap(s) onto the

air valve(s).

Lower Leg insTaLLaTion insTruCTions (ConTinued)

6 7

11

9 10

13


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26

reMoTe serviCe(pushLoC - popLoC adjusT - popLoC)

inTroduCTion

Damper service or orks equipped with remote lockouts will require cable and housing removal and installation. Also, periodic

replacement o the cable and housing is recommended or optimal remote perormance.

CabLe reMovaL insTruCTions

pLc l:1. Push the remote lever until itreturns toward you.

pLc pLc at l: Press thebutton net to the remote lever to set the lever to

the ully released, or "Unlocked" position.

blcb Mt Ctl, L rLr, 2.L rLr+ l: Use a 2 mm he wrench toloosen the cable pinch bolt on the spool and pull

the cable out o the cable end slot. Use pliers to

remove the cable end.

or

Mt Ctl l: Use a 2 mm he wrenchto loosen the cable pinch bolt on the spool. Use

pliers to remove the cable end.

pLc l:3. Push the remote lever to the"Locked Out" position. Use your nger to open

the cable hatch cover (labeled CC, or Cable

Change). Push the cable through the spool on

the ork until the cable head is ar enough out o

the lever to access.

pLc pLc at l: Push the cablethrough the spool until the cable head is ar

enough out o the lever to grab onto.Pull the cable head to remove the cable4.

completely rom the remote system.

I replacing the cable housing, detach the cable5.

housing and end caps rom the lever and the

cable housing stop on the ork.

1

2

3

pLcpLc/pLc

at

pLcpLc/pLc

atpLc

blcb Mt Ctl

sl

pc lt

Cl lt

t

h t

blcb l

ork LoCkouT anaToMy


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27

CabLe insTaLLaTion insTruCTions

I replacing the cable housing, attach the new6.

housing and end caps to the remote lever and

the cable housing stop on the ork. Be sure

to use compressionless (shit) housing cut to

an adequate length to accomodate or travel

change and suspension movement.

pLc pLc at l7. : Push the

release button to veriy the remote is in the"Unlocked" position.

pLc at l: Turn the blue compressionadjustment dial counter-clockwise until it stops.

Insert the tip o a new shiter cable into the8.

port on the lever and eed the cable through the

housing and the cable housing stop on the ork.

Pull the cable until the cable head is seated9.

completely in the remote lever.

pLc l: Once the cable head is seatedin the remote lever body, close the cable hatch

cover and push the lever to return it to the

"Unlocked"position.

blcb Mt Ctl, L rLr, 10.L rLr+ l: Wrap the cable around thespool and insert it through the cable ing port.

While pulling the cable rmly, use a 2 mm he

wrench to tighten the cable pinch bolt to 0.9 Nm

(8 in-lb). Cut the ecess cable, leaving 30 mm

protruding rom the cable ing port. Cap the

end o the cable with a non-fanged, or "road

sty le" cable end. Tuck the cable end into the

cable end slot in the spool.

or

Mt Ctl l: Wrap the cable around thespool. While pulling the cable rmly, use a 2 mm

he wrench to tighten the cable pinch bolt to

0.9 Nm (8 in-lb). Cut the ecess cable and cap it

with a cable end.

7

8

pLc

pLc/pLcat

pLc/pLc

at

9

pLcpLc/pLc

at pLc

10

blcbblcbblcb

Mt Ctl Mt Ctl


28/28

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No. 1598-8 Chung Sahn RdShen Kang Hsiang, Taichung

european headquarTersSRAM Europe

Paasbosweg 14-163862ZS Nijkerk

.m.cm

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1333 N. Kingsbury St., 4th FlChicago, Il 60642

Documents

2011 Tora Technical Manual