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RockShox 35 2020, Service Manual, Page: 4 / 47

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RockShox 35 2020 Service Manual Download Page 4

TABLE OF CONTENTS

ROCKSHOX® SERVICE ........................................................................................................................................................................................5

PART PREPARATION  ......................................................................................................................................................................................................................................5
SERVICE PROCEDURES .................................................................................................................................................................................................................................5
PARTS, TOOLS, AND SUPPLIES ..................................................................................................................................................................................................................6
RECOMMENDED SERVICE INTERVALS ....................................................................................................................................................................................................7
RECORD YOUR SETTINGS ............................................................................................................................................................................................................................7
TORQUE VALUES .............................................................................................................................................................................................................................................7
OIL VOLUME AND LUBRICANT ...................................................................................................................................................................................................................8

EXPLODED VIEW - 35™ GOLD RL - DEBONAIR™ .............................................................................................................................................9

LOWER LEG REMOVAL AND SERVICE ...........................................................................................................................................................10

50/200 HOUR SERVICE

LOWER LEG REMOVAL .................................................................................................................................................................................................................................10

50 HOUR SERVICE

LOWER LEG SERVICE.................................................................................................................................................................................................................................... 12

200 HOUR SERVICE

LOWER LEG SEAL SERVICE ........................................................................................................................................................................................................................ 14

AIR SPRING SERVICE ........................................................................................................................................................................................ 17

200 HOUR SERVICE

AIR SPRING REMOVAL ................................................................................................................................................................................................................................. 17
AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS™ (OPTIONAL) ............................................................................................................................. 23
DEBONAIR - TRAVEL AND BOTTOMLESS TOKEN TUNING ........................................................................................................................................................... 23
AIR SPRING AND ALL-TRAVEL SPACER CONFIGURATIONS .......................................................................................................................................................... 23
BOTTOMLESS TOKENS INSTALLATION (OPTIONAL) ....................................................................................................................................................................... 24
AIR SPRING INSTALLATION ....................................................................................................................................................................................................................... 25

DAMPER SERVICE ............................................................................................................................................................................................ 30

200 HOUR SERVICE

DAMPER REMOVAL ......................................................................................................................................................................................................................................30
DAMPER SERVICE ......................................................................................................................................................................................................................................... 34
REBOUND DAMPER INSTALLATION ........................................................................................................................................................................................................37
COMPRESSION DAMPER INSTALLATION ............................................................................................................................................................................................. 39

LOWER LEG ASSEMBLY ................................................................................................................................................................................... 42

50/200 HOUR SERVICE

LOWER LEG INSTALLATION ...................................................................................................................................................................................................................... 42

Summary of Contents for 35 2020

Page 1: ...SERVICE MANUAL GEN 0000000005886 Rev A 2019 SRAM LLC 2020 35...

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: ...ICE 12 200 HOUR SERVICE LOWER LEG SEAL SERVICE 14 AIR SPRING SERVICE 17 200 HOUR SERVICE AIR SPRING REMOVAL 17 AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS OPTIONAL 23 DEBONAIR TRAVEL AND BOTTOMLESS...

Page 5: ...additional information 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...

Page 6: ...hox x Abbey Bike Tools 35 mm Flangeless Dust Seal Installation Tool RockShox shock pump Bicycle Tools Bicycle work stand Downhill tire lever Shock pump Common Tools Hex bit sockets 2 2 5 5 mm Hex wren...

Page 7: ...iction Extends bushing lifespan Every 200 hours Perform damper and spring service Extends suspension lifespan Restores small bump sensitivity Restores damping performance R e c o r d Y o u r S e t t i...

Page 8: ...ght wt Oil Height mm Volume mL Oil Weight wt Volume mL Oil Weight wt and or Grease Volume mL Oil Weight wt Volume mL 2020 35 Gold RL Motion Control 5 85 90 170 15 10 DebonAir 5 2 15 10 RL R Oil Height...

Page 9: ...ound adjuster knob Steerer tube Air cap Air valve Air spring top cap Bottomless Token s optional 32 mm black Upper tube Sag o ring Air spring piston Top out bumper All Travel spacer s optional Retaini...

Page 10: ...ON EYE HAZARD Verify all pressure is removed from the fork before proceeding Failure to do so can result in injury and or damage to the fork Wear safety glasses Turn the rebound adjuster knob counter...

Page 11: ...s not slide off of the upper tube or if oil does not drain from either side the press fit of the shaft s into the lower leg may still be engaged Reinstall the bottom bolts 2 to 3 turns and repeat the...

Page 12: ...12 Lower Leg Service 5 0 H o u r S e r v i c e L o w e r L e g S e r v i c e Remove the foam rings Clean the foam rings Replace the foam rings if worn damaged or excessively contaminated 1 Pick 2...

Page 13: ...ngs under the wiper seals Confirm the foam rings are installed evenly and sqaure in the space under the wiper seals and do not protrude out of the groove Saturate the foam rings with suspension oil 50...

Page 14: ...Place the tip of a downhill tire lever under the wiper seal Press down on the downhill tire lever handle to remove the seal Repeat on the other side Discard the wiper seals NOTICE Keep the lower leg...

Page 15: ...e narrow end of a new wiper seal into the recessed end of the 35 mm Dust Seal Installation tool NOTICE If the RockShox x Abbey Bike Tools installation tool is used confirm the 35 mm installation puck...

Page 16: ...bbey Bike Tools installation tool is used use a mallet to seat the seal Repeat on the other side NOTICE Only press the wiper seal into the lower leg until it is flush with the top surface of the lower...

Page 17: ...injury and or damage to the fork Remove the air spring top cap Clean the upper tube threads Remove the top cap o ring and discard it Apply grease to a new o ring and install it Push the air shaft into...

Page 18: ...taining ring Use your finger to guide the retaining ring over the air spring shaft Thread the shaft bolt into the end of the air spring shaft and pull the shaft out Wrap a shop towel around the bottom...

Page 19: ...19 Air Spring Removal Push the air shaft in then pull the air shaft out firmly to dislodge the seal head Remove the air spring assembly from the upper tube Remove the bolt 7...

Page 20: ...a scratch is visible the air spring assembly may need to be replaced Remove the o ring seal from the air piston and discard it Clean the air piston Apply grease to a new o ring seal and install it NO...

Page 21: ...ng gland of the seal head Apply grease to the new inner o ring and insert it into the inner gland Apply grease to the ball end of a second clean 8 mm hex wrench and use it to push the inner o ring int...

Page 22: ...pper tube Inspect the inside and outside of the upper tube for damage NOTICE Scratches on the inside surface of the upper tube can cause air to leak If an internal scratch is visible the crown steerer...

Page 23: ...o fine tune the spring curve and bottom out feel Use the table below to help determine the number of Bottomless Tokens that can be used with each fork travel option If fork travel is changed from stoc...

Page 24: ...ork and create greater ramp at the end of the fork travel Add Tokens to tune your fork s bottomless feel See Air Spring Travel Change and Bottomless Tokens for the maximum number of Tokens for your fo...

Page 25: ...r i n g I n s t a l l a t i o n Apply a liberal amount of grease to the inside of the upper tube from the end of the tube to approximately 60 mm into the tube Install the top out bumper onto the shaf...

Page 26: ...ped or added if travel is reduced seal head and seal head bumper All Travel Refer to page 23 for spacer configurations Install the retaining washer a new wave spring and the base plate in that order o...

Page 27: ...into the upper tube Firmly push the air piston into the upper tube Position the A flat retaining washer into the upper tube followed by the B wavy washer Press the base plate into the upper tube unti...

Page 28: ...upper tube while installing the retaining ring into the groove Confirm the retaining ring is properly seated in the retaining ring groove by using the retaining ring pliers to rotate the retaining ri...

Page 29: ...29 Air Spring Installation Install the air spring top cap into the upper tube and tighten it 11 24 mm 28 2 N m 250 in lb...

Page 30: ...l RL Turn the compression adjuster knob counter clockwise to the full open position Remove the retaining screw and remove the compression damper adjuster knob RL R Loosen the set screw and remove the...

Page 31: ...r motion NOTICE Do not force the damper out of the upper tube if there is resistance This can cause separation of the piston from the damper tube Remove the fork from the work stand and pour the suspe...

Page 32: ...er the rebound shaft NOTICE Do not scratch the rebound damper shaft Scratches will allow oil to leak into the lower leg resulting in reduced damper performance and potential damage to the fork Pull th...

Page 33: ...pper tube Inspect the inside and outside of the upper tube for scratches NOTICE Scratches on the inside surface of the upper tube can cause oil to leak If an internal scratch is visible the crown stee...

Page 34: ...and discard them Apply grease to new o rings and install them Remove the bottom bolt Remove the rebound damper seal head Clean the rebound damper shaft and inspect the shaft for scratches NOTICE Scrat...

Page 35: ...35 Damper Service Remove the inner and outer seal head o rings and discard them Apply grease to the new o rings and install them 3...

Page 36: ...36 Damper Service Remove the glide ring and discard it Install a new glide ring Install the seal head onto the rebound damper shaft 4 5...

Page 37: ...rper edged side and a rounder edged side Installing retaining rings with the sharper edged side facing the tool will allow for easier installation and removal Install the retaining ring into the upper...

Page 38: ...38 Rebound Damper Installation Pull the rebound damper shaft out to the fully extended position and remove the bottom bolt 4...

Page 39: ...ces available travel and can damage the fork Too little suspension oil decreases damping performance RL Use the compression adjuster knob to open the valve A Rotate the knob counter clockwise until it...

Page 40: ...per tube and tighten it RL Apply grease to the top cap detents and detent spring RL Install the adjuster knob with the tab in the 7 8 o clock unlocked position Install and tighten the retaining screw...

Page 41: ...d permanent damage to the set screw threads do not over tighten the set screw Install the remote spool A onto the hex adjuster with the cable set screw B 20 40 degrees from the edge of the cable stop...

Page 42: ...r seals Install the lower leg assembly onto the upper tubes and slide it just enough to engage the upper bushings with the upper tubes NOTICE Make sure both wiper seals slide onto the tubes without fo...

Page 43: ...ot exceed the recommended oil volume per leg as this can damage the fork Slide the lower leg assembly toward the crown until it stops The spring and damper shafts should be visible through the bottom...

Page 44: ...tall a new crush washer retainer and crush washer onto each bolt NOTICE Do not damage the bolt threads Do not reuse crush washers or crush washer retainers Dirty or damaged crush washers can cause oil...

Page 45: ...to your pre service recorded settings or use the air chart on the fork s lower leg and pressurize the air spring You may see a drop in the indicated air pressure on the pump gauge while filling the a...

Page 46: ...and registered trademarks of the following companies Abbey Bike Tools is a trademark owned by Abbey Bike Tools LLC Boost is a trademark owned by Trek Bicycle Corporation Liquid O Ring is a registered...

Page 47: ...598 8 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 U S A EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 1...

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