2003 D
Duke S
SL A
Air &
& U
U-T
Turn S
Service G
Guide
11. Pull the shaft and remove the Hydra Air spring assembly from the upper tube (fig. 11)
12. The Hydra Air spring assembly includes the positive air piston, air seal o-ring and
negative coil spring (fig. 12a). Inspect the air seal o-ring for wear and tear. Remove
and replace if needed.
N
OTE
: R
EPLACE THE AIR SEAL O
-
RING USING KIT
#110-006297-00 (02-03
D
UKE
A
IR
O-
RING
S
ERVICE
K
IT
)
13. Inspect the inner diameter or surface of the upper tube for wear. Clean with
isopropyl alcohol and a lint-free rag. You may need to wrap the clean rag around a
long dowel. Allow cleaned tube to dry.
14.
VERY IMPORTANT!
After the air seal o-ring has been replaced, apply a light
coating of RockShox 15 wt. oil or RedRum to the o-ring air seal (aids installation).
Proper lubrication of the air seal decreases heat friction, wear and tear, and extends
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 upper tube.
Press firmly against white base plate with a flat hex wrench or flat head screwdriver to
preload the wavy washer spring, and insert the snap ring (sharp end out) with snap
ring pliers. Using a flat head screwdriver, press each side of the snap ring until it
clicks into place (fig. 10).
17. Rotate fork in bike stand to the vertical, upright position. Add 3 cc of 15wt oil or
RockShox RedRum into the positive air chamber (fig. 17). This lubricates the positive
air seal o-ring and protects it from heat friction and wear. Install the air top cap with
a 24mm socket to 50 in-lb.
4
2003 D
UKE
S
ERVICE
G
UIDE
11
12a
12b
I
N S TA L L AT I O N O F T H E
H
Y D R A
A
I R
S
P R I N G
A
S S E M B LY
17
