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RockShox Duke SL Air, Service Manual

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RockShox Duke SL Air Service Manual Download Page 10

2003 D

Duke S

SL A

Air &

& U

U-T

Turn S

Service G

Guide 

48. Clean and inspect the dust seals and foam rings. Replace if necessary (Part# 110-

007250-00). For bushing removal and installation, refer to the Bushing Service Guide
available at www.rockshox.com

49. Saturate the foam rings with 5wt or 15wt fork oil. This will provide lubrication to the

resi wiper and upper tubes when the fork is in use.

50. Gently, slide the lower leg assembly back onto the upper tubes. Be sure the dust seals

do not fold over!  Slide the lower leg assembly up just until you feel the lower
bushing touch the bottom of each upper tube. The shaft rods should not be visible
through the shaft bolt holes of the lower leg.

51. Invert the fork in the bicycle stand (90 degrees) with the dropouts facing up. Using

an oil syringe, add 10cc of 5wt RockShox fork oil to the bottom of the fork, through
each of the bolt holes (fig. 51).

52. Slide the lower leg assembly up the fork upper tubes until both the rebound and

air/U-Turn shafts seat through 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 bolts. Hand-thread the bolts and tighten with a
5mm hex wrench to 60 in/lb. See Fig 4.

54. Insert the rebound damper external adjuster knob. Adjust to full-close position, and

back off one turn for standard rebound setting. Adjust as necessary to preferred
rebound rate. Cycle the fork to test rebound function.

55. AIR FORKS ONLY: Inflate the positive air chamber to the desired pressure. Install

and tighten the air top cap.

P

O S I T I V E

A

I R

P

R E S S U R E

G

U I D E L I N E S

Rider Weight (lb)

Air Pressure

<140 (63 kg)

80-115 psi

140-160 (63-72 kg)

115-130 psi

160-180 (72-81 kg)

130-145 psi

180-200 (81-90 kg)

145-160 psi

>220 (99 kg)

180 psi

N

OTE

: M

AXIMUM AIR PRESSURE IS

180 

PSI

.

56. Spray a light coat of isopropyl alcohol on the entire fork, and wipe down with a

clean rag.

10

2003 D

UKE

S

ERVICE

G

UIDE

51

I

NSTALLING THE

L

OWER

L

EGS

53

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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