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RockShox Duke SL Air, Service Manual, Page: 9 / 11

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RockShox Duke SL Air Service Manual Download Page 9

2003 D

Duke S

SL A

Air &

& U

U-T

Turn S

Service G

Guide 

R

EV

. A

9

44. Gently insert the rebound damper piston head into the oil-filled Pure tube. The oil

will slowly fill the damper valves. Allow enough oil to fill the cavities and top-off the

oil volume until completely full. Gently press down on the white seal head until it snaps

into the Pure tube securely. Your damper is now sealed. (44a and b).

N

OTE

: P

ISTON SEAL HEAD MUST BE TOPPED AGAINST REBOUND PISTON

.

R

EBOUND DAMPING SETTING MUST BE OPEN

(

FULL COUNTERCLOCKWISE

).

N

OTE

: D

O NOT CYCLE THE DAMPER SHAFT UNTIL THE

D

ELITE AIR TOP CAP HAS

BEEN INSTALLED AND PRESSURIZED

!

45. Slide your Pure Delite oil-filled damper unit into the bottom of the upper (right side

from rider's perspective).

46. Add 3cc/ml of 15wt RockShox fork oil to the top chamber of the Pure Delite

damper (fig. 46). This will lubricate the IFP o-ring. Install the Delite air top cap with
a 24mm socket tool to 50 in-lb and pressurize the chamber 20 to 60 psi with your
shock pump. The IFP is now pressure-set and your damper is sealed.

I

MPORTANT

: 60 

PSI IS THE

MAXIMUM 

AIR PRESSURE

!

47.

IMPORTANT! 

Insert a 2.5mm hex wrench into the rebound damper shaft end

through the lower leg bolt hole and engage the hex wrench into the inner adjuster rod
hex fitting (fig. 47). Turn clockwise until damper is in the full closed position. This
step will protect the internal damper rod when installing the shaft bolt.

44a

44b

46

47

Summary of Contents for Duke SL Air

Page 1: ...the Pure DeLite Damper Setting the IFP Depth Inside the Pure Tube 8 Installing the Lower Legs 10 Warranty 11 Duke SL Air and U Turn For exploded diagram and part number information refer to the 2003 Spare Parts Catalog P N 950 007563 00 Contact your local distributor or visit the RockShox website at www rockshox com for ordering information Information contained in this publication is subject to c...

Page 2: ...n work area 24mm Socket Tool and Wrench 5mm and 2 5mm Hex Wrench Dental Pick or sharp pick Snap ring pliers 300psi Shock Pump part 120 004873 00 Plastic Mallet Bike Work Stand Lint Free Rag Oil Pan Red Rum RockShox 5wt or 15wt SL oil Isopropyl Alcohol Spray Bottle Torque Wrench Safety Glasses NOTE RIGHT SIDE EQUALS RIDER S RIGHT LEFT SIDE EQUALS RIDER S LEFT THIS SERVICE MAY ALSO BE PERFORMED WHIL...

Page 3: ... upper tube assembly should be replaced fig 7 NOTE SET THE LOWER LEG ASSEMBLY RIGHT SIDE UP IN AN OIL PAN TO ALLOW THE EXCESS OIL BATH TO DRAIN 8 Using a 24mm socket wrench loosen and remove the air top cap left side To remove the U Turn spring assembly go to step 18 Inspect the top cap o ring for wear Replace if worn or cut Clean the underside of the top cap with isopropyl alcohol fig 8 9 You may...

Page 4: ...tends the life of the seal 15 Carefully insert the Hydra Air spring assembly into the bottom of the upper tube Be sure to push the air piston straight into the upper tube Use care not to damage the o ring on the upper tube machining Fig 11 16 Insert the flat copper colored base ring and wavy washer into the upper tube base plate step Next insert the white base plate over the shaft and into the upp...

Page 5: ... MAGNET MAY ALSO BE USED TO REMOVE THE BALL BEARINGS AND SPRINGS 22 Using a 24mm socket wrench loosen the U Turn spring top cap turning counterclockwise Unthread completely and pull up on top cap spring to remove spring assembly from the upper tube fig 22 23 Removal of U Turn base plate assembly Position fork to horizontal position in bike stand Using snap ring pliers remove the base plate snap ri...

Page 6: ...juster knob onto the hex shaft in the center of the U Turn spring assembly top cap Using a 2 5mm hex wrench torque the adjuster knob screw to12 in lb fig 18 Do not over torque the knob may become damaged 29 Test the U Turn adjuster knob for proper installation The knob should click as it is turned for proper indexing 30 Press the schrader valve on the Pure DeLite air top cap and release any air pr...

Page 7: ...rom the air in the Delite air chamber 37 Using a long plastic rod insert the rod into the Pure tube until the rod touches the underside of the IFP Make sure the rod engages only the pocketed side of the IFP This ensures that you do not damage the inside of the Pure tube with the rod Press firmly on the rod only when it is engaged safely into the IFP fig 36a Push firmly down to release the IFP from...

Page 8: ...he Pure tube up and off of the rod dowel The IFP is now seated firmly inside the tube at a 6 inch depth 42 Before installing the Pure rebound damper assembly remove the white seal head assembly from the rebound damper shaft The seal head includes an outer o ring oil seal and an inner shaft o ring oil seal Inspect and replace if damaged or worn using the Pure Damper o ring service kit part 110 0062...

Page 9: ...RIZED 45 Slide your Pure Delite oil filled damper unit into the bottom of the upper right side from rider s perspective 46 Add 3cc ml of 15wt RockShox fork oil to the top chamber of the Pure Delite damper fig 46 This will lubricate the IFP o ring Install the Delite air top cap with a 24mm socket tool to 50 in lb and pressurize the chamber 20 to 60 psi with your shock pump The IFP is now pressure s...

Page 10: ...ugh the bolt holes You may need to use a small hex wrench to align the shaft ends with the lower leg shaft boltholes Wipe the bottom of lower leg ends with a clean rag to remove any excess oil or debris 53 Clean each black nylon crush washer inspect for wear and replace if necessary 110 005552 00 Crush Washer Kit fig 53 Insert and tighten the clean hollow rebound damper and solid air U Turn shaft ...

Page 11: ...not include or cover common wear and tear parts which are subject to damage as a result of normal use failure to service product according to RockShox recommendations wet conditions racing use of disc brakes rider weight riding or installation in conditions or applications other than recommended Wear and Tear parts are identified as External dust seals bushings foam rings rubber moving parts such ...

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