Rock Shox reverb a2 Service Manual Download Page 10

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Exploded View - Assembly

E x p l o d e d V i e w - A s s e m b l y

Retaining Ring

Saddle Clamp Assembly

Saddle Clamp Bolt (x2)

Post Head

Upper Post

Brass Key (x3)

IFP Tube

Internal Floating Piston (IFP)

Foam Ring

Bottomout O-ring

Internal Seal Head

Inner Shaft Assembly

Poppet Valve

Air Valve Base Plate

Lower Post

Top Cap Assembly

Remote Lever

Hose Barb

Remote Lever

Actuator

Poppet Valve Cover

Poppet Cover Retaining Ring

Bleed Screw

Inner Shaft Piston

Air Valve Cap

Inner Shaft Assembly

Internal Floating Piston Assembly

Poppet Valve Assembly

Bleed Screw

Summary of Contents for reverb a2

Page 1: ...Reverb A2 B1 GEN 0000000005342 Rev A 2017 SRAM LLC s e r v i c e m a n u a l...

Page 2: ...lso entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by l...

Page 3: ...SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing RockShox products Protect yourself Wear your safety gear...

Page 4: ...HING REPLACEMENT 19 200 A2 400 B1 Hour Service INNER SHAFT AND SEAL HEAD REMOVAL 22 POPPET VALVE REMOVAL 24 UPPER POST DISASSEMBLY 26 TOP CAP INSTALLATION 28 INNER SHAFT ASSEMBLY 29 INTERNAL FLOATING...

Page 5: ...rmation about RockShox remotes user manuals are available at www sram com service Clean the exterior of the product with mild soap and water to avoid contamination of internal sealing part surfaces S...

Page 6: ...e r b Production versions of Reverb can be identified visually Your Reverb can be identified by the color of the Speed adjuster and graphic on the upper post A2 Remote Black Speed Adjuster A2 Upper Po...

Page 7: ...n Perform full hydraulic remote system bleed Ensures proper remote actuation function Reverb B1 Service Hours Interval Maintenance Benefit Every ride Clean dirt and debris from seatpost Extends wiper...

Page 8: ...N m 35 45 in lb Post hose barb 7 mm open end wrench 3 4 4 5 N m 30 40 in lb Post bleed screw T10 TORX wrench 1 1 2 2 N m 10 20 in lb Remote bleed screw T10 TORX wrench 1 1 2 2 N m 10 20 in lb Seatpost...

Page 9: ...m Flat soft jaw vise inserts aluminum Hex bit socket 4 mm Hex wrenches 1 5 4 mm Internal retaining ring pliers small Metric tape measure or ruler Needle nose pliers Open end wrenches 7 23 26 34 mm Pic...

Page 10: ...Floating Piston IFP Foam Ring Bottomout O ring Internal Seal Head Inner Shaft Assembly Poppet Valve Air Valve Base Plate Lower Post Top Cap Assembly Remote Lever Hose Barb Remote Lever Actuator Poppe...

Page 11: ...Internal Floating Piston IFP B1 Foam Ring Bottomout O ring Internal Seal Head B1 Inner Shaft Poppet Valve Seatpost Hose Barb Hose Barb Sleeve Air Valve Base Plate B1 Lower Post Top Cap Assembly Remote...

Page 12: ...e removed from the bicycle Do not clamp the Reverb seatpost in a bicycle work stand before removal Record your saddle position setting Remove the saddle and saddle clamps from the seatpost Disconnect...

Page 13: ...Hydraulic fluid may drip from the hose barb Cover the end of the hose barb with a shop towel if necessary WARNING Do not allow Reverb hydraulic fluid to come into contact with any brake components Con...

Page 14: ...vise Insert flat soft jaw inserts into the vise Clamp the post head into the vise NOTICE Clamp only the flat surfaces of the post head Do not clamp over the bleed port or on the hose barb port Remove...

Page 15: ...ing from the lower post B1 Lift the scalloped end of the retaining ring and remove the retaining ring from the post Slide the lower post down to expose the air valve base plate Remove the seatpost fro...

Page 16: ...and remove the air valve base plate from the inner shaft Remove the seatpost and vise blocks from the vise A2 Remove the air valve base plate o ring Clean the air valve base plate and o ring Apply gr...

Page 17: ...wer post with isopropyl alcohol and a shop towel then set it aside 50 Hour Service Set the foam ring and o ring aside on a clean shop towel A2 200 Hour Service Discard the foam ring and o ring B1 200...

Page 18: ...ize marked on the brass keys for future reference The brass keys should be replaced with new brass keys of the same size if worn during each service interval Clean the upper post and keys with isoprop...

Page 19: ...y B1 To continue with the 400 Hour Service proceed to Inner Shaft and Seal Head Removal B1 A2 To continue with the 200 Hour Service proceed to Inner Shaft and Seal Head Removal A2 Remove the seal head...

Page 20: ...p assembly and onto the seals Install the new top cap assembly wiper seal end first over the seal head and onto the upper post assembly Slide the top cap assembly down until it is positioned below the...

Page 21: ...and Seal Head Bushing Replacement Install a new o ring and bushing onto the seal head Pinch the bushing to secure it around the seal head To continue the 200 B1 Hour Service proceed to Brass Keys Inst...

Page 22: ...en the seal head is completely unthreaded Do not remove the shop towel from over the seal head until the seal head is completely unthreaded Carefully remove the seal head and inner shaft assembly from...

Page 23: ...23 Inner Shaft and Seal Head Removal Remove the upper post from the vise and pour the hydraulic fluid into an oil pan or container 4...

Page 24: ...ise inserts Remove the poppet cover retaining ring Thread the RockShox Bleed syringe fitting into the poppet cover Pull the poppet cover out of the post head with the syringe fitting Unthread the popp...

Page 25: ...25 Poppet Valve Removal Remove the poppet valve from the housing and inner shaft Set the poppet valve aside 3 Needle Nose Pliers...

Page 26: ...a 1 5 mm hex wrench into one of the cross holes in the IFP tube Carefully pull the IFP tube up Use your other hand to guide the IFP tube straight out of the upper post using care not to scratch the in...

Page 27: ...IFP from the upper post Insert seven to nine plastic cable ties cable tie size may vary one at a time into the upper post and through the center of the IFP Pull the cable ties out of the upper post a...

Page 28: ...p assembly and onto the seals Install the new top cap assembly wiper seal end first onto the upper post assembly Slide the top cap assembly down until it is positioned below the upper post key slots N...

Page 29: ...move the seal or o ring Spray isopropyl alcohol on each part and clean with a clean lint free shop towel Apply only SRAM Butter grease to all Reverb parts seals and o rings Remove the inner shaft pist...

Page 30: ...l firmly into the poppet valve port in the post head Close the bleed hose clamp Spray the upper post and Park Tool AV 5 vise inserts with isopropyl alcohol and wipe them clean with a clean shop towel...

Page 31: ...inside the bottom of the upper post When the IFP tube snaps securely into place a click will be heard Ensure the IFP tube is secured and centered The IFP tube should be below the top of the upper pos...

Page 32: ...ol in place With the other hand slowly press the IFP into the upper post with your thumb and finger press only the edges of the IFP When the IFP is inside the upper post level with the top of the tube...

Page 33: ...the post head to prevent it from dislodging With your other hand push the IFP into the upper post with the IFP height tool slowly and carefully to the correct height Stop when the measurement mark on...

Page 34: ...sert the inner shaft piston into the IFP tube and stop when you feel hydraulic resistance Do not push the inner shaft piston into the IFP tube any further Remove the seatpost from the vise Hold the pi...

Page 35: ...TICE Do not push the inner shaft into the upper post Fluid will be forced out of the IFP tube through Reverb bleed tool hose If fluid drains out of the hose the IFP removal and installation processes...

Page 36: ...f any gap or movement is felt fluid volume is insufficient and the IFP removal and installation processes must be repeated If no gap is felt remove the seatpost from the vise Clamp the seatpost back i...

Page 37: ...ss fluid from the upper post with the syringe Discard the excess fluid into an oil pan Repeat this step one additional time to remove any remaining excess fluid NOTICE Only use the syringe included wi...

Page 38: ...ing just below it Grease under the large poppet piston o ring will limit function when the remote actuator is pressed Use a clean shop towel to wipe away any excess grease from under the large poppet...

Page 39: ...thread the syringe fitting from the poppet cover Install the poppet valve cover retaining ring into the post head groove NOTICE Confirm the retaining ring is properly seated by using the retaining rin...

Page 40: ...line with the rear facing brass key slot Apply a liberal amount of SRAM Butter grease to the seal head bushing NOTICE Clamp only the flat surfaces of the post head Do not clamp over the bleed port or...

Page 41: ...and have the same number of etched lines as the original brass keys for proper function Refer to the RockShox Spare Parts Catalog at www sram com service for a list of brass key kits available Apply a...

Page 42: ...st by hand B1 all lengths and A2 380 mm 50 Hour Service Install the original bottomout o ring and foam ring in that order onto the inner shaft 200 and 400 Hour Service Install a new bottomout o ring a...

Page 43: ...shaft hand tight Remove the seatpost from the vise Spray the inner shaft and RockShox vise blocks with isopropyl alcohol and wipe them with a clean shop towel The clamping surfaces must be free of oi...

Page 44: ...ntil it snaps completely into the groove Remove the seatpost from the vise CAUTION Verify the retaining ring is securely in place with a pick before continuing Failure to properly secure the retaining...

Page 45: ...essurize Seatpost 5 0 2 0 0 4 0 0 H o u r S e r v i c e P r e s s u r i z e S e a t p o s t Pressurize the seatpost to 250 psi 17 2 bar Reinstall the air cap and tighten until hand tight 1 250 psi 17...

Page 46: ...hread the remote lever hose barb into the hydraulic hose Hold the end of the hose at the hose barb and rotate the remote lever clockwise while pushing the remote lever barb into the hose Stop when the...

Page 47: ...o B i c y c l e Secure the bicycle in an upright position Apply a light amount of friction paste to the outside of the seatpost Install the seatpost and tighten the seatpost collar WARNING Failure to...

Page 48: ...fluid to come into contact with brake levers and calipers brake pads disc brake rotors or braking surfaces Secure the hose to the frame Install the remote in the desired position and tighten the clam...

Page 49: ...ublication includes trademarks and registered trademarks of the following companies TORX is a registered trademark of Acument Intellectual Properties LLC Park Tool is a registered trademark of Park To...

Page 50: ...Chung Shan Road Shen Kang Hsiang Taichung City Taiwan R O C WORLD HEADQUARTERS SRAM LLC 1000 W Fulton Market 4th Floor Chicago Illinois 60607 USA EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 14 16 386...

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Rock Shox reverb a2, Service Manual

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