Rock Shox Service Manual

8/4/2019 Rock Shox Service Manual

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(english)tec

hnicalm

anual


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sram corporation warrantyExtEnt of LimitEd warranty

SRAM 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 transer-

able. Claims under this warranty must be made through the retailer where the bicycle or the SRAMcomponent was purchased. Original proo o purchase is required.

LocaL LawThis warranty statement gives the customer speciic 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 extent that this warranty statement is inconsistent with the local law, this warranty shall be

deemed modiied to be consistent with such law, under such local law, certain disclaimers and limita-tions o this warranty statement may apply to the customer. For example, some states in the United

States o America, as well as some governments outside o the United States (including provinces inCanada) may:

a. Preclude the disclaimers and limitations o this warranty statement rom limiting the statutory rightso the consumer (e.g. United Kingdom).

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

Limitations of LiabiLityTo the extent allowed by local law, except or the obligations speciically 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.

Limitations of warranty

This warraty ds t appy t prducts that ha b icrrcty istad ad/r adjustd ac -

cording to the respective SRAM technical installation manual. The SRAM user manuals can be ound

online at www.sram.com, www.rockshox.com or www.avidbike.com.

This warraty ds t appy wh th prduct has b mdifid.

This warraty ds t appy wh th sria umbr r prducti cd has b dibratyaltered, deaced or removed.

This warraty ds t appy t damag t th prduct causd by a crash, impact, abus f th

product, non-compliance with manuacturers speciications o usage or any other circumstances in

which th prduct has b subjctd t frcs r ads byd its dsig.

This warraty ds t appy t rma war ad tar. War ad tar parts ar subjct t damag

as a rsut f rma us, faiur t sric accrdig t SRAM rcmmdatis ad/r ridig r

installation in conditions or applications other than recommended.

ExampLEs of wEar and tEar:

Dust sas/Bushigs/Air saig -rigs/Gid rigs/Rubbr mig parts/Fam rigs/Rar shcmutig hardwar ad mai sas/Strippd thrads ad bts (aumium, titaium, magsium r

st)/Uppr tubs (stachis)/Bra ss/Bra pads/Chais/Sprcts/Casstts/Shiftr ad

bra cabs (ir ad utr)/Hadbar grips/Shiftr grips/Jcy whs/Disc bra rtrs/Wh

braig surfacs/Bttmut pads/Barigs/Paws/Trasmissi gars/Ts

This warraty sha t cr damags causd by th us f parts f diffrt maufacturrs.

This warraty sha t cr damags causd by th us f parts that ar t cmpatib, suitab

ad/r authrizd by SRAM fr us with SRAM cmpts. This warraty sha t cr damags rsutig frm cmmrcia (rta) us.

rockshox suspEnsion sErvicEW rcmmd that yu ha yur RcSh suspsi sricd by a uaifid bicyc mchaic.

Servicing RockShox suspension requires knowledge o suspension components as well as the specialtools and luids used or service.

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

NEVER pour suspension luid 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 Corporation 2008

For exploded 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.Ifrmati ctaid i this pubicati is subjct t chag at ay tim withut prir tic. Fr th atst tchica ifrmati, pas isit ur wbsit at www.sram.cm.

Yur prducts apparac may diffr frm th picturs/diagrams ctaid i this catag.Product names used in this document may be trademarks or registered trademarks o others.


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copyright SRAM CORPORATION 2009 ROCKSHOX TECHNICAL MANUAL 3

tabLE of contEnts

front suspEnsion sErvicE - GEttinG startEd..................................................................................................................................................................5FRonT SUSPenSIon TeCHnoloGY AnD oIl volUMeS (All FoRkS) ...................................................................................................................................................... 6FRonT SUSPenSIon ToolS neeDeD FoR SeRvICe (All FoRkS) .............................................................................................................................................................. 8FRonT SUSPenSIon ToRqUe TIGHTenInG vAlUeS (All FoRkS).......................................................................................................................................................... 10

LowEr LEG .........................................................................................................................................................................................................................................11

rEmovaL ..............................................................................................................................................................................................................................................11loWeR leG ReMovAl (All FoRkS)................................................................................................................................................................................................................... 12

LowEr LEG bushinG & sEaL sErvicE .......................................................................................................................................................................................13loWeR leG BUSHInG & SeAl SeRvICe (Al l FoRkS) .................................................................................................................................................................................. 14dampEr sErvicE ..............................................................................................................................................................................................................................22

ReBoUnD & TURnkeY DAMPeR SeRvICE(ARGYle 30 2 - DART 2, 3 - DoMAIn 302 - lYRIk DFR - PIke 327 - ReCon 327, 335, Sl, xC - ToRA 289, 302, xC, Sl) ....................................................................2 3MoTIon ConTRol DAMPeR SeRvICE(ARGYle 318, 409- DoMAIn 318 - lYRIk IS - ToRA 318 - ToTeM IS) .......................................................................................................................................................... 26MoTIon ConTRol/BlACkBox MoTIon ConTRol DAMPeR SeRvICE(BoxxeR RACe, TeAM, WC - PIke 409, 426, 454 - ReBA Sl, RACe, Te AM - ReCon 351 - RevelATIon 409, 426 - SID RACe, TeAM, WC) ........................... 29MISSIon ConTRol DAMPeR SeRvICE(lYRIk - ToTeM) ....................................................................................................................................................................................................................................................... 33

sprinG sErvicE ................................................................................................................................................................................................................................36CoIl SPRInG SeRvICE(ARGYle 302 , 318 - DART 1, 2, 2 (WITH TURnkeY), 3 - DoMAIn 302, 318 - ToRA 289, 302 , 318, xC, Sl) .......................................................................................... 37CoIl SPRInG SeRvICE(BoxxeR RACe, TeAM - ReCon 335, 351, RACe, Sl - ToT eM).................................................................................................................................................................... 38CoIl U-TURn SPRInG SeRvICE(DoMAIn 302, 318 - ToRA 289, 302, 318)............................................................................................................................................................................................................ 39

CoIl U-TURn SPRInG SeRvICE(lYRIk - PIke 327, 351, 409, 426, 454 - ReCon 351, RACe - RevelATIon 426) .........................................................................................................................................4 0Solo AIR SPRInG SeRvICE(ARGYle 409 - ToRA 302, 318) .............................................................................................................................................................................................................................. 41Solo AIR SPRInG SeRvICE(BoxxeR WC - lYRIk - ReCon - ToTeM)...........................................................................................................................................................................................................4 4DUAl AIR SPRInG SeRvICE(PIke 409, 426, 454 - ReBA Sl, RACe, TeAM - Rev elATIon 409, 426 - SID RACe, TeAM, WC).......................................................................................................... 47AIR U-TURn SPRInG SeRvICE(PIke 409, 429, 454 - ReBA RACe, TeAM - RevelATIon 409, 429) ............................................................................................................................................................. 502-STeP AIR SPRInG SeRvICE(lYRIk - ToTeM) ....................................................................................................................................................................................................................................................... 54

LowEr LEG instaLLation ............................................................................................................................................................................................................57loWeR leG InSTAllATIon (All FoRkS) ........................................................................................................................................................................................................ 58

-ridE sprinG .....................................................................................................................................................................................................................................60

sErvicE ................................................................................................................................................................................................................................................60i-RIDe SPRInG SeRvICe......................................................................................................................................................................................................................................... 61

rEar shock sErvicE - GEttinG startEd ..............................................................................................................................................................................65ToolS neeDeD FoR SeRvICe (All ReAR SHoCkS) ......................................................................................................................................................................................6 6ReAR SHoCk SeRvICe (ARIo - BAR) .................................................................................................................................................................................................................. 67MoUnTInG HARDWARe ReMovAl & BUSHInG SeRvICe (MonARCH - vIvID) ................................................................................................................................... 69ReAR SHoCk SeRvICe (MonARCH) ................................................................................................................................................................................................................... 70ReAR SHoCk SeRvICe (vIvID)............................................................................................................................................................................................................................. 74


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front suspEnsionsErvicE - GEttinG startEd

GEttinG startEd - hELpfuL hintsThe RockShox Technical Manual separates ront suspension into ive main service categories:

1. lower leg removal2. lower leg bushing and seal service

3. dampr sric

4. spring service

5. wr g istaati

Th sric f frt suspsi damprs ad sprigs is furthr sub-catgrizd basd th tch-

ogy o the damper and spring, rather than by the name o the ork. Thereore, it is imperative or you

determine the technology used in your ront suspension. I you are unsure o the technology used inyour ront suspension, contact your local RockShox dealer or assistance.


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GEN.0000000000322 REV A

damper

technology

(rightleg)

volume

(ml)

oilwt

volume

(ml)

oilwt

spring

technology

(leftleg)

volume

(ml)

oilwt

volume

(ml)

oilwt

upperleg lowerleg upperleg lowerleg

argyle

30 2 reboundonly

130 5 10 15

coil- - 30

15318motioncontrol

coil

40 9 soloair 6 15 15

boxxer race, team

motioncontrol 150 5 15 15

coil 30

15

- -

worldcup (wc) soloair 6 15 15

dart

1 none - - - -

coil - - - -2 (w/turnkey) turnkey 93

5

10 15

2 reboundonly 150 - -

3, 29r turnkey 93 10 15

domain

30 2 reboundonly

200 5 10 5

coil

- - 15 15coilu-turn

318 motioncontrolcoil

coilu-turn

lyrik

dfr reboundonly 145

5 15 15

coil - -

15

15

soloair 6 15

coilu-turn

motioncontrolis

112

u-turn - -

soloair soloair 6 15

2-step 2-step 35 2.5 10

coilu-turn

missioncontrol

u-turn - -15

issoloair soloair 6 15

is2-step 2-step 35 2.5 10

pike

32 7 reboundonly

120 5 15 15

coilu-turn- -

15 15

351

motioncontrol

40 9

coilu-turn

airu-turn6 15

dualair

426coilu-turn

- -

airu-turn6 15

dualair

45 4

coilu-turn - -

airu-turn6 15

dualair

reba

sl, race motioncontrol 123

5 10 15

airu-turn

5 15 10 15dualair

teamblackboxmotion

control133

airu-turn

dualair

front suspEnsion tEchnoLoGy and oiL voLumEs(aLL forks)

Th fwig chart is a cmpt ist f th 2009 RcSh frt suspsi i-up. It dtais th frt suspsi md,

corresponding damper and spring technology, along with the oil volume and oil weight required or each ork leg.


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damper

technology

(rightleg)

volume

(ml)

oilwt

volume

(ml)

oilwt

spring

technology

(leftleg)

volume

(ml)

oilwt

volume

(ml)

oilwt

upperleg lowerleg upperleg lowerleg

recon

32 7, xc reboundonly

120

5 15 15

soloair 6 15 15

15

33 5, 33 5sl turnkeycoil - - 30

soloair 6 15 15

351,351race motioncontrol 118

coil- - 30

coilu-turn

soloair 6 15 15

revelation 409, 426 Qr

motioncontrol

115

5 15 15

airu-turn

6 15 15 15dualair

409, 426 20mm 120airu-turn

dualair

sid

race motioncontrol

93 5 5 15 dualair 5 15 5 15team

worldcup (wc)

blackbox

motioncontrol

totem

coil

missioncontrol137 5 20 15

coil - -

20 15soloair soloair 6 15

2-step 2-step 135 2.5

iscoil motioncontrolis coil - -

tora

28 9 reboundonly

1455 15 15

coil

- -

20

15

coilu-turn 30

30 2 turnkeycoil 20

coilu-turn 30

318 motioncontrol

coil20

coilu-turn

130 soloair 6 15 15

front suspEnsion tEchnoLoGy and oiL voLumEs (cont)


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GEN.0000000000322 REV A

front suspEnsion tooLs nEEdEd for sErvicE(aLL forks)

Th fwig chart is a ist f th md yar 2009 ts dd fr sric yur RcSh frt suspsi. Whi 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 text

o each service section. Keep in mind your specic ork may not require every tool listed.

tooLsLowEr LEGrEmovaL

bushinG &sEaL sErvicE

dampErsErvicE

sprinGsErvicE

LowEr LEGinstaLLation

safEty/startinG EQuipmEnt

SAFeTY GlASSeS x x x x x

APRON x x x x x

RUBBeR GloveS x x x x x

CleAn RAGS (lInT FRee) x x x x x

oIl PAn x x x x x

CleAn WoRk AReA x x x x x

BICYCle STAnD x x x x

BenCH vISe x

wrEnchEs/pLiErs

1.5 mm Hex x

2 mm Hex x

2.5 mm Hex x x x

5 mm Hex x x

6 mm Hex x4

8 mm Hex x4

10 mm SoCkeT oR oPen enDeD WRenCH x x

14 mm SOCKET x4

15 mm SoCkeT x

24 mm SOCKET x x

SoCkeT exTenSIon x3 x4 x3

24 mm THIn WRenCH oR

MISSIon ConTRol WRenCHx

ToRqUe WRenCH x x

SlIP JoInT PlIeRS x

SnAP RInG PlIeRS - InTeRnAl x x

SnAP RInG PlIeRS - exTeRnAl x x

misc tooLs

PlASTIC MAlleT x x x x x

MAlleT DRIFT Tool x

lonG DoWel RoD (PlASTIC oR WooD)* x x x x x

FlATHeAD SCReWDRIveR x x

SHARP PICk x x

SHoCk PUMP x x

SCHRADeR vAlve CoRe Tool x5

MAGneT x

RUleR x

BUSHInG ReMovAl Tool/PlATe x

Bxxr oy

Mission Control Only

SID Only

4i-Ride Only52-Step Air Only

* usig a -mtaic dw rd hps t sur th i sid f air tubs r wr gs d t gt scratchd


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tooLsLowEr LEGrEmovaL

bushinG &sEaL sErvicE

dampErsErvicE

sprinGsErvicE

LowEr LEGinstaLLation

oiL/LiQuids

2.5, 5, 10 oR 15WT SUSPenSIon oIl x x x x

GReASe x x x x

i-RIDe GReASe (Maima SG-920) x

CleAn RAGS (lInT FRee) x x x x x

oIl MeASURInG DevICe x x x x

ISoPRoPYl AlCoHol x x x x x

FRoSTY ColD BeveRAGe x x x x x

front suspEnsion tooLs nEEdEd for sErvicE (cont)

Bxxr oy

Mission Control Only

SID Only4i-Ride Only52-Step Air Only


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GEN.0000000000322 REV A0

front suspEnsion torQuE tiGhtEninG vaLuEs(aLL forks)

The ollowing chart is a summary o the primary torque tightening values common to all RockShox orks. The torque tightening

values or asteners that require a specic torque are detailed in the text o each service section. Keep in mind your specic

ork may not have all o the options listed in the chart below.

front suspEnsion fastEnErtorQuE vaLuE

-l (n)

ToP CAPS (exCePT AIR U-TURn) 65 (7.3)

ToP CAPS (AIR U-TURn onlY) 130 (14.7)

BoTToM BolT (DAMPeR SIDe) 60 (6.8)

BoTToM BolT (AIR SIDe) 45 (5.1)

PoPloC/PUSHloC ReMoTe HAnDleBAR ClAMP BolT 20 (2.3)

PoPloC/PUSHloC ReMoTe CABle FIxInG BolT 8 (0.9)

U-TURn knoB FIxInG BolT 12 (1.4)

DIReCT MoUnT STeM BolTS 75 (8.5)


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LowEr LEGrEmovaL

LowEr LEG rEmovaL - hELpfuL hintsRemoving the lower legs o your RockShox ront suspension provides service access to the bushings

and wiper seals located in the lower legs. It also provides service access to the damper and spring

components o your suspension.


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GEN.0000000000322 REV A2

LowEr LEG rEmovaL(aLL forks)

LowEr LEG rEmovaL instructions

note: boxxeronly - loosenuppercrownboltswith

a4mmhexwrenchandremoveuppercrown. spray

isopropylalcoholonuppertubesandunderframe

bumpers. twistandpulluptoremovebumpers.

finally, usea4mmhexwrenchtoloosenlowercrown

boltsandremoveuppersfromcrownbytwistingand

slidingeachupperdownandoutofcrown.

Remove the air chamber valve cover cap rom1.the let ork leg top cap. I ork has a negative air

chamber, remove the negative air chamber valve

cover cap rom the bottom o the let ork leg.

Depress schrader valve and release all air2.

rom the air chamber. I ork has a negative air

chamber, star t with the negative air chamber

rst, then proceed to the positive air chamber.

Pu tra rbud adjustr b ad rm3.

rom the right shat bolt.

Us a 5 mm h wrch t s bth shaft4.

bts 3 t 4 turs. Fr Dua Air uippd frs,

use a 10 mm socket (or open end) wrench to

s ad uthrad th Dua Air shaft ut just

past the threaded shat end.

note: forhollowbottomforklegsyouwillneedto

useadeep10mmsockettoloosenandunthreadthe

dualairshaftnut.

Use a plastic mallet to gently tap each shat5.

bolt ree rom its press-t to the lower leg and

us yur grs t rm shaft bts/ut

completely.

note: forhollowbottomforklegstapthe5mmhex

wrenchand10mmdeepsocketwhileengagedinthe

boltstofreethemfromthepress-fit.

Remove the lower leg assembly rom ork by6.rmly pulling it downward, holding onto both

legs or the brake arch.

important: donothitthebrakearchwithanytool

whenremovingthelowerlegassemblyyoucould

damagethefork.

Use oil pan to drain excess oil rom lower leg7.

assembly.

Spray isopropyl alcohol on and into the lower8.

g assmby. Wip th wr gs ca, th

wrap a clean rag around a dowel and clean the

inside o each lower leg (not pictured).

4

7

65

321

boxxeronly boxxeronly boxxeronly

introduction

Removing the lower legs o your ront suspension is the irst step in servicing your ork. It allows you access to the ork bush-

ings, wiper seals, damper and spring systems. Once you have removed your ork lower legs, you'll be ready to move onto thenext section.


13/82


LowEr LEG bushinG& sEaL sErvicE

bushing&sealservice - helpfulhintsThe bushings and seals o your RockShox ront suspension contribute to the consistent and plush

eel o your ork. Perorming routine service on the bushing and seals will help maintain your ork'sperormance as well as reduce overall maintenance costs.


14/82

GEN.0000000000322 REV A4

LowEr LEG bushinG & sEaL sErvicE(aLL forks)

introduction

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

o riding, riding terrain, rider body weight, and type o ork . The more you ride, the more requently your bushings need to be

replaced. The ollowing chapter covers how to check or bushing wear, wiper and oil seal removal, bushing removal, bushinginstallation, and wiper and oil seal installation.

At this pit yu shud arady ha th wrs rmd frm yur fr. If t, yu wi d t rtur t th lwr lg R-

moval section o this manual and ollow the instruct ions or removing your ork lowers.

chEck for bushinG wEar

Bfr yu rpac yur bushigs, yu shud chc

or bushing wear. Symptoms o worn bushings that

need to be replaced include, a "knocking" sound

frm th fr wh ridig, ad/r th hadst may

eel loose when it isn't.

me 1: o-be e

Cmprss fr 5 tims t circuat wr g1.

lube (not pictured).

Hd th frt bra r tight ad rc th2.

bike back and orth. I the ork eels like it's

"knocking", or the headset eels loose, proceed

t stps 3 ad 4.

Check the ork: wrap your ngers around the3.

dust seal and upper tube area. Rock the bike

bac ad frth agai. list ad f if thr is

any play between the upper tube and the dustseal. I so, the bushings are loose.

Check the headset: wrap your ngers around4.

th hadst uppr cup r wr cup/rac aras.

Hdig th bra, rc th bi bac ad frth

and eel i the headset is loose. I so, tighten the

headset and check again.

me 2: o-be e

Cmprss fr 5 tims t circuat wr g1.

lube (not pictured).

Hd th fr crw t ight i had ad th2.

brake arch in the other hand. Try and move the

brake arch back and orth. I you can eel any

play, or i the ork eels like it's "knocking", the

bushings are loose.

note: youmaywishtobracetheforkonatableoron

thefloortosteadyit.

3 42

2


15/82


wipEr & oiL sEaL rEmovaL (aLL forks)

Remove the wiper seal using a medium to large1.

fat-head screwdriver to careully pry i t rom the

lower leg.

Remove the oil oam ring with your ngers.2.

note: notallforkscontainafoamring. ifyourfork

doesnothaveafoamring, pleasemoveontostep3.

Rm th ir i sa, catd just bw3.

the dust seal using a fat head screwdriver.To protect the lower leg paint , place a rag in

between the lower leg and the screwdriver.

note: notallforkscontainaninneroilseal.

2 31

bushinG rEmovaL(aLL arGyLE - boxxEr - domain - Lyrik - pikE - rEba - rEcon - rEvELation - sid - totEm & tora 318)

important: alldartmodelsaswellastora289, 302have

non-serviceablebushings, pleasemoveontodust&oil

sealinstallation.

Camp bushig rma had/pur t it1.

bench vise tightly.

Install the correct bushing removal plate onto2.

handle end and secure with handle plate screw.

32 mm pat (Argy, Bxxr, Pi, Rba,

Recon, Revelation, SID, Tora)

35 mm pat (Dmai, lyri)

40 mm plate ( Totem)

Slide the removal plate into the lower leg past3.

the upper bushing. The removal plate pivots

when inserted. Pull lower leg away rom puller

tool and hook the fat end o the plate secure

udr th bushig. Wh th pat is scurunder bushing, begin to remove.

Use a plastic mallet to rmly and squarely hit the4.

top o the lower leg on the fat dust seal surace

area until upper bushing pulls ree.

important: donothitthebrakearchtoremovethe

bushing. thiscandamageyourfork.

To pull the lower bushing ree rom the lower5.

leg, slide the removal plate past the lower

bushing and hook the fat end o the plate secure

under the bushing. Again, rmly and squarely

hit the top o the lower leg on the fat dust seal

surace area until the lower bushing pulls ree.lgr wr bushigs may ruir mr frc.

Rtur t Stp 3 ad rpat fr th thr fr6.

leg.

Spray isprpy ach isid wr gs. Wrap7.

a clean rag around a dowel and clean the inside

o the lower legs (not pictured).

3

4

1

5

2

32 , 35 , or40mm

plate


16/82

GEN.0000000000322 REV A6

bushinG instaLLation32 mm uppEr tubE diamEtEr (arGyLE - boxxEr - pikE - rEba - rEcon - rEvELation - sid - tora 318)

lowerbushinginstallationwithbushingsize:

32mmx25mm - slotted(sid)

32mmx30mm - slotted(argyle, pike, reba, recon,

revelation, tora318)

32mmx76mm - non-slotted(boxxer)

Camp 32 mm bushig istaati t it1.

bench mounted vise.Slide lower bushing installation spacer onto2.

bushing installation post.

note: recon, revelation, andtora318usetheshort

spacerinthisstep.

Slide the lower bushing sleeve onto bushing3.

installation post.

Rc, Rati, Tra 318 oy: Sid th4.

tall lower bushing spacer onto the bushing

installation post.

Slide lower bushing onto the top o the lower5.

installation sleeve.

note: boxxerlowerbushingisnotslotted.Slide lower leg over installation post and rest on6.

top o lower bushing.

Insert mallet drit tool into the lower leg shat7.

hole and hold in place. Using a plastic mallet, hit

the mallet drit tool to press the bushing into the

lower leg.

Continue to hit the mallet drit tool, until the8.

lower leg dust seal ridge is level with the top o

the installation post spacer. You will eel it stop

as the bushing is "set" in the lower leg.

Remove lower leg rom tool and inspect the it o9.

the lower bushing by sliding one upper tube into

th wr g. Hd wr g 90 hriztay

ad ras. lwr g shud swig 45 dw

and stop (not pictured).

note: iflowerlegswingstoofreely, repeatstep8. if

lowerlegfeelstightordoesnotmoveatall , slide

lowerlegbackontobushinginstallationpostand

rocksidetosidetoloosenfit.

Return to Step 1 and repeat or other leg.10.

2 31

5 64

87

bushingsleevelowerspacer

(short)

lowerbushing

lowerspacer

(tall)


17/82


bushinG instaLLation (cont)32 mm uppEr tubE diamEtEr (arGyLE - boxxEr - pikE - rEba - rEcon - rEvELation - sid - tora 318)

upperbushinginstallationwithbushingsize:

32mmx25mmnon-slotted(sid)

32mmx30mmnon-slotted(argyle, pike, reba, recon,

revelation, tora318)

32mmx10mm - non-slotted(boxxer)

Remove lower bushing sleeve (and tall lower11.

bushing spacer or Recon, Revelation, and Tora318). la y th wr bushig spacr

bushing installation tool.

Slide upper bushing onto bushing installation12.

post.

Slide lower leg over installation post, and rest13.

on top o the upper bushing.



the mallet drit tool to press the upper bushing

into lower leg.

Continue to hit the mallet drit tool until the15.

lower leg rests lush on top o the install spacer.You will eel it stop as the bushing is "set " in

the lower leg. The top o the bushing should be

fush/ with i sa stp i th wr g.






note: iflowerlegswingstoofreely, repeatstep15.

iflowerlegfeelstightordoesnotmoveatall , slide




12 1311

1514

upperbushinglowerspacer

(short)


18/82

GEN.0000000000322 REV A8

bushinG instaLLation35 mm uppEr tubE diamEtEr (domain - Lyrik)

40 mm uppEr tubE diamEtEr (totEm)

lowerbushinginstallationwithbushingsize:

35 mmx30mm - slotted(domain, lyrik)

40mmx30mm - slotted(totem)

Camp 32 mm bushig istaati t it1.

bench mounted vise.

Slide bushing installation tool adapter over2.

bushing installation post.Slide lower bushing sleeve onto the adapter.3.

Slide lower bushing onto the adapter.4.

Slide lower leg over installation post and rest on5.

top o lower bushing.



the mallet drit tool to press the bushing into the

lower leg.

Continue to hit the mallet drit tool, until the7.

lower leg dust seal ridge is level with the top o

the installation post spacer. You will eel the

stopping point as the bushing is "set" into thelower leg.












35mmx30mm - nonslotted(domain, lyrik)

40mmx30mm - nonslotted(totem)

Remove lower bushing sleeve rom the adapter10.

and slide upper bushing onto the adapter.

Slide lower leg over installation post, and rest11.

on top o the upper bushing.



the mallet drit tool to press the upper bushing

into lower leg.

Continue to hit the mallet drit tool until the13.

lower leg rests lush on top o the install spacer.You will eel it stop as the bushing is "set" in

the lower leg. The top o the bushing should be

fush/ with i sa stp i th wr g.

2 31

5 64

7

sleeve

lower

bushing

1110

upper

bushing

12 13


19/82


bushinG instaLLation (cont)35 mm uppEr tubE diamEtEr (domain - Lyrik)

40 mm uppEr tubE diamEtEr (totEm)


35mmx30mm - nonslotted(domain, lyrik)

40mmx30mm - nonslotted(totem)




ad ras. lwr g shud swig 45 dwand stop (not pictured).







20/82

GEN.0000000000322 REV A0

foam rinG & wipEr sEaL instaLLation (rEba - rEcon - rEvELation - tora 318)

foamringinstallation

Sa w fam rigs i 15wt suspsi i.1.

Insert new oil-saturated oam ring into lower2.

leg.

dustsealinstallation

Insert new wiper seal into the wide end o the3.

dust seal installation tool.Insert wiper seal into lower leg and press4.

straight down and evenly to seat into lower leg.

Wipr sa shud b prss-t sug ad ush5.

into lower leg.

note: checkfoamringunderwiperseal. foamring

shouldnotprotrudefromwiperseal. ifso, adjust

foamringinsidelowerleg, flushonallsides.


2

3

1

54


21/82


foam rinG, wipEr & oiL sEaL instaLLation (arGyLE - boxxEr - domain - Lyrik - pikE - rEba - sid - totEm)

oilsealinstallation

Apply grease or suspension oil to the inside o1.

the lower leg oil seal counter-bore.

Insert the new oil seal onto the stepped end o2.

th i/dust sa istaati t.

Usig th i/dust sa istaati t, isrt3.

the oil seal down and into the oil step in the

lower leg. Apply pressure on all sides o the oilseal to seat it into place.

foamringinstallation

note: fordomain, lyrik, andtotem, pleasemoveonto

wipersealinstallation, step6.

Sa w fam rigs i 15wt suspsi i.4.

Insert new oil-saturated oam ring into lower leg5.

on top o oil seal.

wipersealinstallation

Insert new wiper seal into the pocketed end o6.

th i/wipr sa istaati t.Usig th i/wipr istaati t, isrt wipr7.

seal into lower leg. Apply pressure on all sides

o the wiper seal to seat it into place.

Wipr sa shud b prss-t sug ad ush8.

into lower leg.

note: checkfoamringunderwiperseal. foamring

shouldnotprotrudefromwiperseal. ifso, adjust

foamringinsidelowerleg, flushonallsides.


2 31

5 64

87

compLEtinG bushinG sErvicE (aLL forks)

Complete the bushing service o your ork by detailing the lower legs. Spray isopropyl alcohol on entire lower leg assembly and

wipe with a clean rag. Check the decals on your ork and replace i necessary.

thisconcludesthelowerlegbushing&sealserviceforyourfork. youdidagreatjob! youarenowreadytomoveontothenextsection:

damperservice. enjoy!


22/82

GEN.0000000000322 REV A2

dampEr sErvicE

dampEr sErvicE - hELpfuL hintsServicing the damper o your ront suspension helps ensure consistent rebound and compression

perormance.


23/82


rEbound & turnkEy dampEr sErvicE(arGyLE 302 - dart 2, 3 - domain 302 - Lyrik dfr - pikE 327 - rEcon 327, 335, sL, xc - tora 289, 302, xc, sL)

introduction

At this pit yu shud arady ha th wrs rmd frm yur fr. If t, yu wi d t rtur t th lwr lg

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

dampEr rEmovaL/sErvicE instructions

note: fordart2, lyrikdfr, tora289, andtoraxc

pleaseskipstep1andmovetostep2.

Remove external snap ring rom compression1.

adjustr b usig tra sap rig pirs

ad rm cmprssi adjustr b ad

o-ring.

or

I ork is equipped with a remote compression

lockout eature, remove external snap ring romcmprssi adjustr sp usig tra sap

rig pirs ad rm cmprssi adjustr

spool and white top cap shield.

Unthread compression damper top cap with a2.

24 mm socket wrench.

note: forargyle302, dart2, domain302, andtora289

pleasemovetostep5.

Remove compression damper by pulling up3.

and gently rocking side to side. I ork is

equipped with a remote lockout eature, be

sure to remove the remote compression damper

cable-stop clamp; which is located under the

compression damper top cap. Once removed,

clean upper tube threads with a rag.

Replace compression damper top cap o-ring by4.

gently pinching o-ring to remove. Apply a ew

drops o suspension oil to new o-ring and re-

install in top cap.

Remove ork rom bicycle stand and pour5.

remaining oil into pan.

note: fordart2, thiscompletestheremoval

procedures, pleasemovetostep10.

Turn ork upside down and push rebound6.

damper shat through shat guide. Use a long

dowel rod to help push damper piston pastupper tube threads and remove rom upper tube.

Remove rebound damper o-ring and damper7.

inner seal-head o-ring (located in the bottom

o the upper tube). Apply resh grease to new

o-rings and re-install.

important: ifusingapicktoremoveinnersealhead

o-ring, donotscratcho-ringgland. scratchesmay

causeoiltoleak.

2

5

3

1

4

or

6

7


24/82

GEN.0000000000322 REV A4

optionaL - comprEssion dampEr upGradE: non-rEmotE to rEmotE adjust

Upgradig frm a -rmt cmprssi adjust fr t a rmt cmprssi adjust (frm a crw mutd adjustr

b t a rmt Pplc r Pushlc r adjustr), ruirs rpacig th -rmt cmprssi dampr with a rmt

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

ruird fr us with th Pplc ad Pushlc rmt r assmby.

dampEr instaLLation instructions

Clamp ork back into bicycle stand and apply a8.

light lm o grease to upper tube threads. Insert

rebound damper back into right side o upper

tube, shat rst and press piston into upper tube

past tube threads.

Push rebound damper into upper tube using a9.

g dw rd. Guid rbud dampr shaft

through damper seal head at the bot tom o the

upper tube and pull shat through by hand into

the ully extended position.

Masur ad pur 5wt suspsi i it th10.

upper tube using the volumes listed in the chart

at right.note: fordart2andtora289pleasemovetostep12.

important: oilvolumeiscritical. toomuchoil

reducesavailabletravel, toolittleoildecreases

dampingperformance.

Remote Only: Position cable-stop clamp in the11.

10 o'clock position around the upper tube hole

on the crown prior to inser ting compression

dampr. Gras uppr tub thrads ibray

then insert compression damper into upper

tube. Press down and twist to work damper into

uppr tub. B carfu t t damag -rig

seals on upper tube threads.Press top cap down into upper tube threads and12.

hand tighten. Using a 24 mm socket wrench,

tight t 65 i/b.

note: fordart2andtora289, thiscompletesthe

installationinstructions. youarereadytomoveon

tothenextsectioninthemanual: springservice.

11

8 9 10

12

fork oilvolume(3ml)

argyle302 130ml

dart2 150ml

dart2(withturnkey), 3 93ml

domain302 200ml

lyrikdfr 145ml

pike327 120ml

recon32 7,33 5, xc, sl 120ml

tora28 9, 30 2, xc, sl 120ml


25/82


dampEr instaLLation instructions (cont)

note: turncompressionadjusterhexcounter-

clockwisetotheopenposition.

Pac cmprssi adjustr b t13.

compression damper top cap with the knob dial

st i th 3 'cc psit i. Usig tra sap

rig pirs, scur th cmprssi adjustr

knob with a new snap ring.

or


lockout eature, place remote spool onto

compression damper top cap with the cable set

scrw i th 3 'cc psiti. Usig tra

snap ring pliers, secure the remote spool with a

new snap ring.

thisconcludesthedamperserviceforyourfork. you

didagreatjob! youarenowreadytomoveontothe

nextsection: springservice. enjoy!

or

13


26/82

GEN.0000000000322 REV A6

motion controL dampEr sErvicE(arGyLE 318, 409- domain 318 - Lyrik is - tora 318 - totEm is)

introduction




note: forargyle318and409, itisnotnecessaryto

removethemotioncontrolknob, pleaseskipstep1

andmovetostep2.

Remove external snap ring rom compression1.



o-ring seal.

or


lockout eature, remove external snap ring rom

cmprssi adjustr sp usig tra sap

rig pirs ad rm cmprssi adjustr

spool and white top cap seal.

or

I ork is equipped with Motion Control IS, use

a 2 mm hex to remove screw rom compression

th adjustr b. Rm cmprssi

adjustr b (t picturd).



Rm cmprssi dampr frm uppr tub/3.crown by pulling up and gently twisting side to

side. I ork is equipped, be sure to remove the

remote compression damper cable-stop clamp;

which is located under the compression damper

top cap. Once removed, clean upper tube

threads with a rag.

With a sharp pic, rm th cmprssi4.

damper top cap o-ring (located at the top o

the damper) and the compression damper seal

(located at the bottom o the damper). Apply a

ew drops o suspension oil to the new o-ring

and seal and install.important: ifusingapicktoremoveinnersealhead


causeoiltoleak.



Turn ork upside down. Push rebound damper6.

shaft it uppr tub/sa had ad rm

rebound damper rom upper tube.

Remove rebound damper glide ring and inner7.

seal head o-ring. Apply resh grease to new

o-rings and re-install.

2

5

3

1

6

4

7

or


27/82


optionaL - comprEssion dampEr upGradE: non-rEmotE to rEmotE adjust (tora 318 onLy)



compression damper and cable-stop clamp. The remote return spring is designed into the compression damper and is required

fr us with th Pplc ad Pushlc rmt r assmby.


Clamp ork back into bicycle stand. Insert8.

rebound damper back into right side o upper

tub, shaft rst. Guid rbud dampr thrugh

damper seal head at bottom o upper tube and

pull through.

Thread shat bolt into rebound damper shat end9.

and pull rebound damper shat down through

seal head into ully extended position.

Masur ad pur 5wt suspsi i it10.

the upper tube, through the crown using the

ollowing volumes:

fork

oilvolume

(3ml)

argyle318, 409 130ml

domain318 200ml

tora318 145ml



dampingperformance.

Remote Only: Slide compression damper11.

through cable-stop clamp prior to insertion.

Position the cable-stop clamp in the 10 o'clockposition on the crown.

Gras uppr tub thrads ibray, th isrt

compression damper into upper tube. Press

down and twist to work damper into upper tube.

As soon as the damper seal passes through the12.

upper tube threads, pull the damper up slightly,

then push back down. The compression damper

should slide up and down easily, indicating

the seal in the proper position, and not olded

over. Repeat procedure until the compression

damper slides up and down easily. Then press

the compression damper down until the upper

o-ring contacts the upper tube threads.

8 9

1110

12


28/82

GEN.0000000000322 REV A8

13


Turn the damper clockwise and thread into the13.

uppr tub. B carfu t t damag th uppr

damper o-ring. Continue to thread top cap down

into upper tube threads and hand tighten. Using

a 24 mm sct wrch, tight t 65 i/b.

note: forargyle318and409thiscompletesthe

installationprocess.

note: turncompressionadjusterhexcounter-clockwisetotheopenposition.






or


lockout eature, place remote spool onto

compression damper top cap with the cable set


snap ring pliers, secure the remote spool with anew snap ring.




or

14


29/82


motion controL/bLackbox motion controL dampEr sErvicE(boxxEr racE, tEam, wc - pikE 409, 426, 454 - rEba sL, racE, tEam - rEcon 351 - rEvELation 409, 426 - sid racE, tEam, wc)

introduction




note: boxxeronly, itisnotnecessarytoremovethe

motioncontroladjusterknob. pleaseskipstep1and

movetostep2.

c e e e:1.Remove external snap ring rom compression



o-ring seal.

orRm dgat b usig a 1.5 mm h ad

rm cmprssi adjustr b ad -rig

seal.

ree e e e:Remove external snap ring rom compression

adjustr sp usig tra sap rig pirs

ad rm cmprssi adjustr sp ad

white top cap seal.

or

Rm dgat b usig a 1.5 mm h ad

rm cmprssi adjustr sp ad whit

top cap seal.Unthread compression damper top cap with a2.


Rm cmprssi dampr frm uppr tub/3.

crown by pulling up and twist ing side to side.

Once removed, clean upper tube threads with a

rag.

With a sharp pic, rm cmprssi dampr4.

o-rings (located at the top and bottom o the

damper). Apply a ew drops o suspension oil to

new o-rings and re-install.



2

5

3

1

4

or


30/82

GEN.0000000000322 REV A0

dampEr rEmovaL/sErvicE instructions (cont)

Remove rebound damper seal head retaining6.

ring (located inside the bottom o the right upper

tube), using external snap ring pliers. Pull down

and remove the rebound damper and seal head

assembly rom the upper tube.

Slide seal head o damper shat and remove7.

inner and outer seal head o-rings. Apply a ew

drops o suspension oil to new o-rings and re-install.

Spray isopropyl alcohol on rebound damper8.

shat , and clean with a rag (not pictured).

I damaged, replace rebound damper piston9.

glide ring. Position upper tube base ring on top

o seal head step and slide rebound seal head

assembly onto rebound damper shat.

Spray isopropyl alcohol into the upper tube.10.

Wrap a ca rag arud a dw ad ca th

inside o the upper tube (not pictured).

6 7

9


31/82



Insert rebound damper piston into the bottom o11.

the upper tube at an angle, with the open-ended

side o the glide ring ace outward. Continue to

angle and rotate until glide ring is in the upper

tube. Position the upper tube base ring seal and

seal head into the upper tube.

Position the upper tube base ring seal and seal12.

head into the upper tube and press into the

upper tube with your thumb.

Use internal snap ring pliers to secure seal head13.

into upper tube with retaining ring.

important: makesuretheretainingringissecurely

fastenedintheuppertubegroove. youcancheckthisbyusingthesnapringplierstorotatetheretaining

ringintheshaftonecompleterevolution.

Pull rebound damper shat down, into the ully14.

tdd psiti. Masur ad pur 5wt

suspension oil into the upper tube, through the

crown, using the volumes listed in the chart at

right.

*boxxeronlyoptionalprocedure: youcanusea

suspensionoilheighttooltomeasureoilvolume.

measureandsetsyringeneedlestopto205mm. pour

5wtoilintouppertube. insertsyringeneedleintotheuppertube, restingthestopflatonuppertube. pull

outanyexcessoilwithsyringeplunger. removeoil

heighttoolfromuppertube.



dampingperformance.

11 12

14

13

optionaL - comprEssion dampEr upGradE: non-rEmotE to rEmotE adjust (ExcLudEs boxxEr)



compression damper and cable-stop clamp. The remote return spring is designed into the compression damper and is required

fr us with th Pplc ad Pushlc rmt r assmby.

boxxeronly boxxeronly

fork oilvolume(3ml)

boxxerrace, team, wc 150ml*

pike351, 40 9, 426, 454 120ml

rebasl, race, team, wc 110ml

recon351 118ml

revelation40 9, 426 114ml


32/82

GEN.0000000000322 REV A2


Insert compression damper into upper tube.15.

Press down and twist to work damper into upper

tube.

Turn the damper clockwise to thread into the16.

uppr tub. B carfu t t damag th uppr

damper o-ring. Continue to thread top cap down

into upper tube threads and hand tighten. Using

a 24 mm sct wrch, tight t 65 i/b.note: forboxxer, thiscompletestheinstallation

procedures.

note: turncompressionadjusterhexcounter-

clockwisetotheopenposition.






or


lockout eature, place remote spool ontocompression damper top cap with the cable set


snap ring pliers, secure the remote spool with a

new snap ring.




or

17

1615


33/82


mission controL dampEr sErvicE(Lyrik - totEm)

introduction




Turn blue high speed compression knob1.

clockwise, to set in the maximum compression

position. (not pictured)

Turn Floodgate to "o " posit ion by pushing low2.

spd cmprssi adjustr dw ad rtatig

cutr-ccwis 90.


thin 24 mm wrench. Access to the top cap is

under the high speed compression knob.or

Isrt a 2.5 mm h wrch it th gd w

speed compression knob and turn it counter-

clockwise until it stops (not pictured). This

allows maximum insertion depth or the 4

mm wrch. Gty grasp th w spd

cmprssi b with th sip jit pirs,

using a 4 mm hex wrench to remove low speed

cmprssi scrw. lif t ad rm th w

spd cmprssi b. Th, usig a 1.5 mm

hex wrench, loosen both retaining bolts on the

high speed compression knob. Remove the highspeed compression knob. This allows access to

the top cap. Unthread compression damper top

cap using a 24 mm socket wrench.

Rm cmprssi dampr frm uppr tub/4.

crown by pulling up and twist ing side to side.

Once removed, clean upper tube threads with a

rag.

Remove glide ring rom compression damper5.

piston assembly. Apply a ew drops o

suspension oil to new glide ring and re-install.


remaining oil into pan. Return ork to bicycle

stand.

Remove rebound damper seal head retaining7.

ring (located inside the bottom o the right upper

tube), using internal snap ring pliers. Pull down

and remove the rebound damper assembly rom

the upper tube.

Push upward on rebound shat to separate8.

rebound piston assembly rom rebound tube.

Spray rebound damper shat with isopropyl9.

alcohol, and clean with a rag (not pictured).

3

64

2

5

87

or

floodgateinoffposition


34/82

GEN.0000000000322 REV A4

dampEr rEmovaL/sErvicE instructions (cont)

Remove inner and outer o-rings rom rebound10.

seal head. Apply a ew drops o suspension oil

to new o-rings and re-install.

important: ifusingapicktoremoveinnersealhead


causeoiltoleak.

Remove glide ring rom rebound shat assembly.11.

Apply a ew drops o suspension oil to new glidering and re-install.

1413

11

12


Install rebound shat assembly into rebound12.

tube.

note: besurenottodamagereboundtubeinner

o-ring.

Install rebound assembly into upper tube and13.

secure with retaining ring using internal snap

ring pliers.important: makesuretheretainingringissecurely

fastenedintheuppertubegroove. youcancheckthis

byusingthesnapringplierstorotatetheretaining

ringintheshaftonecompleterevolution.

Pull rebound damper shat down into the ully14.

extended position.

Masur ad pur 5wt suspsi i it15.

the upper tube, through the crown, using the

ollowing volumes:

fork oilvolume(3ml)

lyrik 112ml

totem 137ml



dampingperformance.

15

10


35/82


36/82

GEN.0000000000322 REV A6

sprinG sErvicE

sprinG sErvicE - hELpfuL hintsServicing your ork spring helps reduce riction and ensure consistent, reliable perormance rom

your ront suspension.


37/82


coiL sprinG sErvicE(arGyLE 302, 318 - dart 1, 2, 2 (with turnkEy), 3 - domain 302, 318 - tora 289, 302, 318, xc, sL)

introduction



coiL sprinG rEmovaL/sErvicE instructions

Unthread and remove spring top cap with a1.


important: pressdownfirmlywhenlooseningtop

cap.

Argy 302 , 318 oy: Rm sprig pr-ad2.

spacer(s).

Push spring shat upward, rom the bottom o3.

the upper tube, then remove spring and spring

spacers rom upper tube.

Turn ork upside down and slide the spring sha t4.assembly out o the upper tube. Remove spring

shat assembly and inspect or damage.

Spray isopropyl alcohol on spring, spring shat5.

assembly and the inside and outside o the

uppr tub ad wip with a ca rag. Wrap a

clean rag around a long dowel and insert into

the upper tube to clean inside the upper tube

(not pictured).

2

6

4

1

5 7

coiL sprinG instaLLation instructions

Insert and drop spring shat assembly into upper5.

tub thrugh th crw. Guid th thradd

end through the shat guide at the bottom o the

upper tube and gently pull shat through to ull

extension.

Appy frsh gras ibray t sprig/sprig6.

spacer assembly.

Insert and drop spring assembly into upper tube7.

through the crown.

Argy 302, 318 oy: Ista sprig pr-ad8.

spacers.

Clean top cap, then apply a small amount o9.

grease to top cap threads. Insert top cap into

uppr tub/crw ad had thrad it uppr

tube. Using a 24 mm socket wrench, tighten to

65 i-b.

thisconcludesthespringserviceforyourfork. you


nextsection: lowerleginstallation. enjoy!

8

3

pre-loadspacer

pre-loadspacer

9


38/82

GEN.0000000000322 REV A8

coiL sprinG sErvicE(boxxEr racE, tEam - rEcon 335, 351, racE, sL - totEm)

introduction



sprinG rEmovaL/sErvicE instructions

Unthread and remove spring top cap with a1.



cap.

Remove spring pre-load spacer(s) and pull2.

spring rom upper tube.

Remove the spring shat base plate retaining3.

ring using internal snap ring pliers.

Pull spring shat and base plate rom upper tube.4.

Inspect assembly or damage and replace entireassembly i necessary.

Spray isopropyl alcohol on spring, spring5.

isatrs (isatrs ar Bxxr y), sprig

shat and the inside and outside o the upper

tub ad wip with a ca rag. Wrap a ca

rag around a long dowel and insert into the

upper tube to clean inside the upper tube (not

pictured).

note: youcansecurethespringisolatorstothe

spring(boxxeronly)byusingaheatgunorhairdryer

toshrinkthemaroundthespring. gentlyheatthe

isolatorsuntiltheyemitvapors. becarefulnottoget

theheatguntoocloseoryoumayburnaholeinthe

isolator.

2 31

4

6

9

7

coiL sprinG instaLLation instructions

Insert spring shat assembly back into bottom o6.

upper tube so the base plate assembly is seated

into the upper tube step. Secure spring shat

assembly with retaining ring, using internal snap

ring pliers.

Apply resh grease liberally to spring and spring7.

isatrs (isatrs ar Bxxr y).

Insert spring back into upper tube and place8.

spring preload spacer(s) on top o spring insideupper tube.

Clean top cap, then apply a small amount o9.

grease to top cap threads. Insert top cap into

uppr tub/crw ad had thrad it uppr

tube. Using a 24 mm socket wrench, tighten to

65 i-b.




8

pre-loadspacer


39/82


coiL u-turn sprinG sErvicE(domain 302, 318 - tora 289, 302, 318)

introduction



coiL u-turn sprinG rEmovaL/sErvicE instructions

Rm U-Tur b scrw with a 2.5 mm h1.

wrch ad rm U-Tur adjustr b.

Remove detent ball bearings and detent springs2.

rom top cap using a magnet.

Unthread and remove spring top cap with a 243.

mm socket wrench. The spring is attached to

the top cap and spring shat. Pull and lit entire

spring assembly rom upper tube.


cap.

Remove U-Turn negative spring assembly rom4.upper tube, you may need to turn ork upside

down to remove.

Spray isopropyl alcohol on entire spring5.

assembly, negative spring, and the inside and

outside o the upper tube and wipe with a clean

rag. Wrap a ca rag arud a g dw ad

insert into the upper tube to clean inside the

upper tube (not pictured).

76 8

coiL u-turn sprinG instaLLation instructions

Apply resh grease liberally to negative spring,6.

the entire spring assembly, and top cap threads.

Insert and drop negative spring into upper tube7.

through the crown.

Insert U-Turn spring assembly into upper tube8.

through crown, shat end rst. Align and seat

th sprig shaft thrugh th shaft guid/bas

plate.

Isrt tp cap it uppr tub/crw ad had9.

thread into upper tube. Using a 24 mm socket

wrch, tight t 65 i-b.Using a magnet, guide each detent spring into10.

top cap detent holes, evenly spaced. Place each

detent ball bearing on top o each detent spring.

important: makesureyouuseallthreespringsand

bearings, otherwisetheknobcanturnandchange

travelonitsown.

Pac U-Tur adjustr b tp f h.11.

Tight U-Tur b scrw with a 2.5 mm h

wrench to 12 in-lb.


didagreatjob! youarenowreadytomoveontothenextsection: lowerleginstallation. enjoy!

10 119

4

2 31


40/82

GEN.0000000000322 REV A0

coiL u-turn sprinG sErvicE(Lyrik - pikE 327, 351, 409, 426, 454 - rEcon 351, racE - rEvELation 426)

introduction



coiL u-turn sprinG rEmovaL/sErvicE instructions

Rm U-Tur b scrw with a 2.5 mm h1.

wrch ad rm U-Tur adjustr b.

Remove detent ball bearings and detent springs2.

rom top cap using a magnet.

Unthread and remove spring top cap with a 243.

mm socket wrench. The spring is attached to

the top cap and spring shat. Pull and lit entire

spring assembly rom upper tube.


cap.

Spray isopropyl alcohol on entire spring4.assembly and the inside and outside o the

uppr tub ad wip with a ca rag. Wrap a

clean rag around a long dowel and insert into

the upper tube to clean inside the upper tube

(not pictured).

2

6

31

5 7

coiL u-turn sprinG instaLLation instructions

Apply resh grease liberally to the entire spring5.

assembly, and top cap threads.

Insert U-Turn spring assembly into upper tube6.

through crown, shat end rst. Align and seat

th sprig shaft thrugh th shaft guid/bas

plate.



wrch, tight t 65 i-b.

Using a magnet, guide each detent spring into8.

top cap detent holes, evenly spaced. Place eachdetent ball bearing on top o each detent spring.

important: makesureyouuseallthreespringsand

bearings, otherwisetheknobcanturnandchange

travelonitsown.

Pac U-Tur adjustr b tp f h.9.

Tight U-Tur b scrw with a 2.5 mm h

wrench to 12 in-lb.




98


41/82


soLo air sprinG sErvicE(arGyLE 409 - tora 302, 318)

introduction



soLo air sprinG rEmovaL/sErvicE instructions

important: verifyallairpressureisremovedfrom

theairchamberbeforeproceeding . depressschrader

valveagaintoremoveanyremainingairpressure.

Unthread air spring top cap with a 24 mm socket1.

wrench. The air spring assembly is attached

to the top cap. Pull and lit entire air spring

assembly rom upper tube.

Pull top cap out o air tube assembly and pour2.

any air seal lubricant into oil pan.Remove air shat and air seal head rom the3.

bottom o the air tube by pulling shat down and

twist ing side to side.

Spray isopropyl alcohol on the inside and4.





Remove air piston retainer ring using external5.

snap ring pliers. Then remove air piston wavy

spring washer and piston rom air shat .

Slide air sleeve seal head assembly rom air6. shat.

Remove inner and outer seal head o-rings.7.

Apply a ew drops o suspension oil to new o-

rings and re-install.

important: ifusingapicktoremoveo-rings, donot

scratchsealhead. scratchesmaycauseoiltoleak.

Spray air shat with isopropyl alcohol and wipe8.

clean with a rag (not pictured).

Insert air piston back onto air shat head. Install9.

spring wavy washer onto air shat end and

secure in place with air piston retainer ring,

using external snap ring pliers. Check retaining

ring t to make sure it secures the air piston

to air shat head. The piston should compress

slightly with spring resistance against wavy

spring washer and retaining ring.

21

53

9

6

7


42/82


43/82


12

soLo air sprinG instaLLation instructions

Insert bot tom-out bumper and kick plate back12.

t air sa had. Sid air sa had/s

assembly back into air shat, bumpers rst.

Insert lubricated air assembly, both pistons and13.

air sleeve into one end o air tube. Push air seal

head into air tube until rmly seated.

Insert air shat into top o upper tube, through14.

crw. Guid th bttm f th air shaftthrough the shat guide in the bottom o the

upper tube. Insert air tube assembly into upper

tube until it rests inside upper tube.

Masur ad pur 6 ml f 15wt suspsi i15.

into upper tube through the crown. Suspension

oil in the air chamber lubricates the air seal

o-ring during use and maintains the air seal.

Push air shat to lit air tube out o upper tube a16.

couple o inches. Insert the air top cap into air

tube and press tight into air tube.

Drp air tub/tp cap assmby it uppr tub.17.

Check bottom o upper tube and make sureair shat guide is seated into upper tube shat

guide.







16 17

13 14

15

18


44/82

GEN.0000000000322 REV A4

soLo air sprinG sErvicE(boxxEr wc - Lyrik - rEcon - totEm)

introduction



soLo air sprinG rEmovaL/sErvicE instructions


theairchamberbeforeproceeding . depressschrader

valveagaintoremoveanyremainingairpressure.

Unthread and remove air spring top cap with a1.

24 mm socket wrench. Remove ork rom stand

and pour any air seal lubricant into oil pan.

Use your nger to press the air seal head into2.

the upper tube. You will eel it break ree and

sid it th tub abut 3 mm.Remove the air assembly shat guide retaining3.

ring rom the bottom o the let upper tube, using

external snap ring pliers. Pull air shat down to

remove air spring assembly and shat guide rom

upper tube.






note: forlyrik, andtotemitisnotnecessaryto

performsteps5, 6, 7or9. simplyinspectretainerringandwavywasher(andcushiononlyrikandtotem). if

damaged, youwillneedtoreplacetheairpistonhead

assembly. otherwisepleasecompletestep8, then

movetostep11.

Remove air piston retainer ring using external5.

snap ring pliers. Then remove air piston wavy

spring washer and piston rom air shat.

Sid air s/sa had assmby frm air6.

shat.






Spray air shat with isopropyl alcohol and wipe8.

clean with a rag (not pictured).

31 2

5 6

7


45/82


soLo air sprinG rEmovaL/sErvicE instructions (cont)

Insert air piston back onto air shat head. Install9.

spring wavy washer on air shat end and secure

in place with air piston retainer ring, using

external snap ring pliers. Check retaining ring

t to make sure it secures the air piston to air

shat head. The piston should compress slightly

with spring resistance against wavy spring

washer and retaining ring.Remove bottom-out bumper and kick plate rom10.

gati air s/sa had.






optionaL - aLL travEL confiGurations (rEcon 327, 335, 351)

A tra spacrs ar catd just ab th air sa had. If yu wat t chag th tra f yur fr , sap th tra spacr

onto seal head to decrease travel, or remove to increase travel.

9 1110

80mm 100mm 130mm

nospacer30mm

spacer50mm

spacer


46/82

GEN.0000000000322 REV A6

soLo air sprinG instaLLation instructions

Insert bot tom-out bumper and kick plate back12.

t air sa had. Sid air sa had/s

assembly back into air shat, bumpers rst.

Insert lubricated air piston into bottom o upper13.

tub ad sid th wr air pist/s

assembly into upper tube.

Seat the shat guide ring and wavy washer into14.

upper tube step, then slide negative air sleeveinto upper tube and seat shat guide base into

upper tube step.

Secure retaining ring into upper tube retaining15.

ring groove using external snap ring pliers.

Position retaining ring holes around retaining

ring positioner on base plate. Veriy retaining

ring is secure in upper tube.

Masur ad pur 6 ml f 15wt suspsi i16.

into air tube through the crown. Suspension oil

in the air chamber lubricates the air seal o-r ing

during use and maintains the air seal.

Isrt tp cap it uppr tub/crw ad had17. thread into upper tube. Using a 24 mm socket





15

14

16

17

12 13

baseplateretainingring

positioner

retainingringholes


47/82


duaL air sprinG sErvicE(pikE 409, 426, 454 - rEba sL, racE, tEam - rEvELation 409, 426 - sid racE, tEam, wc)

introduction



duaL air sprinG rEmovaL/sErvicE instructions


theairchamberbeforeproceeding . depresspositive

andnegativeschradervalvesagaintoremoveany

remainingairpressure.

Unthread and remove Dual Air top cap with a 241.

mm socket wrench.

Remove ork rom stand and pour any air seal2.

lubricant into oil pan.

Clamp ork back into bicycle stand and wipe3.shat and base plate with a rag.

Push negative air shat up and into base plate,4.

leaving only the tip o the threaded shat end

protruding rom base valve.

note: youmayneedtodepresstheschradervalveas

youpushtheshaft, topreventavacuum.

Sid a 15 mm sct t (r simiar hw t)5.

over the air shat end and press rmly against

th bas pat. Whi prssig th air bas

plate up and into the upper tube, remove the

retaining ring using external snap ring pliers.

Once retaining ring is removed, gently pull air6. shat down to remove air spring assembly and

base plate rom upper tube.






Rm bas pat, bas pat -rig/bumpr,8.

and negative air piston rom the Dual Air shat.

re l: Remove wavy washer, base plate,base plate bumper, fat washer, and negative air

piston rom the Dual Air shat.

21

5

3

6

8

4

airpistonairpiston

o-ringbaseplatebumper

baseplate

baseplate

washers


48/82

GEN.0000000000322 REV A8

duaL air sprinG rEmovaL/sErvicE instructions (cont)

Remove outer and inner negative air piston9.

o-rings. Apply a ew drops o suspension oil to

new o-rings and re-install.

re l: Remove outer and inner negative airpiston o-rings. Apply a ew drops o suspension

oil to new o-rings and re-install. Remove inner

oam ring. Apply a ew drops o suspension oil

to new oam rings and re-install.important: ifusingapicktoremoveo-ringsandfoam

ring, donotscratchsealhead. scratchesmaycause

oiltoleak.

Remove outer positive air piston o-ring. Apply10.

a ew drops o suspension oil to new o-ring and

re-install.

re l: Remove outer positive air pistono-ring and oam ring. Apply a ew drops o

suspension oil to new o-ring and oam ring and

re-install.

important: ifusingapicktoremoveo-ringandfoam

ring, donotscratchsealhead. scratchesmaycause

oiltoleak.

10

9

optionaL - aLL travEL confiGurations

A tra spacrs ar catd just ab th bttm ut bumpr washr. If yu wat t chag th tra f yur fr, sap th

travel spacer onto the Dual Air shat to decrease travel, or remove to increase travel.

pike: 140mm

revelation: 140mm

nospacer pike: 10mm

revelation: 20mm

(abovewasher)

reba: 20mm

(abovebaseplatebumper)

pike: 130mm

revelation: 120mm

reba: 100mm (1spacer)

reba: 80mm (2spacers)

rebaonly

rebaonly

rebaonly

rebaonly

rebaonly


49/82


11

duaL air sprinG instaLLation instructions

Re-install the negative air piston, base plate11.

-rig/bumpr ad bas pat t th Dua Air

shat and re-apply suspension oil to o-rings.

re l: Re-install the negative air piston,fat washer, base plate bumper, base plate, and

wavy washer onto the Dual Air shat and re-

apply suspension oil to o-rings and oam rings.

Insert Dual Air assembly into upper tube,12.positive air piston rst , ollowed by the negative

air piston. Insert base plate assembly into

upper tube step and press in rmly.

Using your thumb, press base plate into upper13.

tub. Whi prssig bas pat, ista tra

retaining ring using external snap ring pliers.

Veriy retaining ring is secure in upper tube

groove. Align retaining ring according to the

orientation o the base plate retaining ring

groove.

Masur ad pur 6 ml f 15w t suspsi i14.

into air tube through crown. Suspension oil inthe air chamber lubricates the air seal o-ring

during use and maintains the air seal.







12

1413 15

rebaonly


50/82

GEN.0000000000322 REV A0

air u-turn sprinG sErvicE(pikE 409, 429, 454 - rEba racE, tEam - rEvELation 409, 429)

introduction



air u-turn sprinG rEmovaL/sErvicE instructions


theairchamberbeforeproceeding . depresspositive

andnegativeschradervalvesagaintoremoveany

remainingairpressure.

Adjust tra stt ig t ma (fu) tra. Push1.

external retaining clip rom above U-Turn knob

with a pic r scrwdrir ad rm adjustr

knob.

Remove detent ball bearings and detent springs2.rom top cap using a magnet.

important: itisnotnecessarytoremovetheu-turn

topcaptoservicetheairu-turnspringassembly. in

theeventthetopcapmustberemoved, unthreadwith

a24mmsocketwrench. beforere-installingtopcap,

cleanoldthread-lockofftopcap. thenaddafew

dropsofbluethread-locktothetopcapthreadsand

tightenwithsocketwrenchto130in-lb.

Tur Air U-Tur tra adjust shaf t, which3.

protrudes rom both the center o the top cap

and the bottom o the air shat, cLockwisE to

unthread the air spring assembly rom the AirU-Turn top cap (top cap should be tight inside

crw/uppr tub).

Pull down on the Air U-Turn shat and remove4.

the entire spring assembly rom the bottom o

the upper tube.

Remove Tefon washer rom inside o top cap.5.

To remove, push down with a pick or fat-head

scrwdrir. Washr wi it bttm f th

upper tube.

Remove small external retaining ring located6.

at the bot tom o the air chamber using external

snap ring pliers, then remove guide plate.

Push down on seal head with a fat-head7.

screwdriver (position screwdriver head against

step, away rom shat) and ree the retaining

ring rom the seal head. Once seal head slides

into air tube, remove seal head retaining ring,

using snap ring pliers.

important: donotscratchairshaft. scratcheswith

causeairtoleakandeffecttheperformanceofyour

fork.

21

5

3

6 7

4


51/82


air u-turn sprinG rEmovaL/sErvicE instructions (cont)

Pull air shat, negative air seal head and positive8.

air piston assemblies out o air tube. Slide and

remove aluminum seal head rom air shat.

Spray isopropyl alcohol on air shat and wipe9.

with a clean rag (not pictured).

Remove seal head rom air piston shat. Remove10.

the inner and outer seal head o-rings as well as

the small outer o-ring located on the air pistonshat groove. Apply a ew drops o suspension

oil to new o-rings and re-install.


scratchsealheadoro-rings. scratcheswillcause

permanentairleak.

Hdig th air tub, pac uppr ch11.

assembly end o fat surace. Firmly press tube

down on fat surace to break the seal and push

choke assembly through tube.

note: thechokeassemblywillfeeltightinsidetube

whilepushingchokeoutofairtube. youmayneedto

taptheendoftheairshaftonaflatworkingsurface

tofreetheupperairspringassemblyfromtheair

tube.

Use a dowel to continue to push the assembly12.

through and out o the air tube. Remove

assembly completely rom air tube.


outside o the air tube and wipe with a clean




Remove external choke retaining ring rom14.

tra adjustmt shaft, usig tra sap rig

pirs. Rm ch pist ad ch/shaftwasher.

Remove external choke o-ring. Apply a ew15.

drops o suspension oil to new o-ring and re-

install.

important: ifusingapicktoremoveo-ring, donot

scratchchokepiston. scratchesmaycauseairleak.

Rm uppr sa had frm adjustr shaft .16.

Use a fat head screwdriver and remove inner17.

o-ring retaining ring. Then remove both the

inner and outer seal head o-rings. Apply a ew

drops o suspension oil to new o-rings and re-

install. Use a fat head screwdriver to re-installinner o-ring retaining ring.

8 10

11 12

14 16

pushdown

withdowel

15

17


52/82

GEN.0000000000322 REV A2

air u-turn sprinG rEmovaL/sErvicE instructions (cont)

Re-install upper seal head onto travel18.

adjustmt shaft ad appy suspsi i t

adjustr shaft ad ir sa had -rig.

Ista ch pist ad scur with a neW 1019.

mm external retaining ring, using external snap

ring pliers.

Apply suspension oil to both piston o-rings.20.

air u-turn sprinG instaLLation instructions

Apply a thin lm o grease to the inside groove21.

o the open end o the air spring tube. Insert

the upper choke assembly into open end o

air spring tube, schrader valve rst , and press

completely into air tube.

Using a long non-metallic dowel, push assembly22.

up into the air tube unt il seated fush against therolled end o the air tube.

Hd air tub with p d up. Masur ad23.

pur 6 ml f 15wt suspsi i it air tub/

positive air chamber, on top o the upper choke

assembly. This will lubricate the choke o-ring

and positive air piston o-ring when ork is

compressed. Set aside air tube, upright, so oil

does not spill.

Re-apply suspension oil to inner seal head o-24.

ring and slide negative air seal head onto Dual

Air shat, fat end rst . Slide up to bottom out

bumper.Re-apply suspension oil to positive and negative25.

air piston o-rings and insert positive air piston

into open end o air spring. Push air shat

assembly into air tube.

Using a small fathead screwdriver, press down26.

on seal head shat step to seat into place inside

air tube. Secure seal head into air tube with

retaining ring, using internal snap ring pliers.

important: retainingringmustbefullyseatedin

uppertubegroove. checkretainingringcloselyto

ensuresecurefit.

Add air to the positive air chamber (40-60psi)27.

to ensure assembly components are seatedproperly inside air tube.

21 22 23

24 25

26 27

18 19 20


53/82


air u-turn sprinG instaLLation instructions (cont)

Insert air tube guide plate into the end o air28.

tube. Secure around small seal head groove

with a w 13 m

Documents

Rock Shox Service Manual