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SRAM Rock Shox Lyrik 2019, Service Manual, Page: 45 / 75

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SRAM Rock Shox Lyrik 2019 Service Manual Download Page 45

45

Damper Installation

2 0 0   H o u r   S e r v i c e

D a m p e r   I n s t a l l a t i o n

Install the Charger 2 Damper™ assembly into the damper side upper 
tube. Thread the top cap into the upper tube.

Tighten the top cap.

1 

Top Cap / Cassette Tool

RC2 / RCT3 / RC

24 mm

RCT R / RC R

2 

Top Cap / Cassette Tool

28 N·m (250 in-lb)

RC2 / RCT3 / RC 

24 mm

28 N·m (250 in-lb)

RCT R / RC R

Summary of Contents for Rock Shox Lyrik 2019

Page 1: ...GEN 0000000005684 Rev B 2018 SRAM LLC 2019 s e r v i c e m a n u a l Lyrik Yari...

Page 2: ...o 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 loc...

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: ...SERVICE 19 AIR SPRING SERVICE 22 200 HOUR SERVICE AIR SPRING REMOVAL 22 AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS OPTIONAL 25 DEBONAIR TRAVEL AND BOTTOMLESS TOKEN TUNING LYRIK 25 DEBONAIR TRAVEL...

Page 5: ...LOWER LEG ASSEMBLY 69 50 200 HOUR SERVICE LOWER LEG INSTALLATION 69...

Page 6: ...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 7: ...Installation Tool RockShox Shock Pump RockShox Top Cap Cassette tool 3 8 24 mm or RockShox x Abbey Bike Tools Top Cap Cassette Tool Bicycle Tools Bicycle work stand Cassette tool Downhill tire lever P...

Page 8: ...nimizes lower leg contamination Every 50 hours Perform lower leg service Restores small bump sensitivity Reduces friction Extends bushing lifespan Every 200 hours Perform damper and spring service Ext...

Page 9: ...ound damper Charger 2 Damper Lyrik 23 mm crowfoot 5 1 N m 45 in lb Set screw rebound adjuster knob 2 5 mm hex bit socket 0 85 N m 7 5 in lb Set screw remote cable stop collar 2 mm hex bit socket 0 25...

Page 10: ...er seal head Maxle Stealth Crush washer Bottom bolt Rebound adjuster knob Steerer tube Air cap Air valve Air spring top cap Upper tube Air spring piston Top out bumper Lower leg Air spring seal head R...

Page 11: ...djuster knob Steerer tube Air cap Air valve Air spring top cap Upper tube Air spring piston Top out bumper Lower leg Air spring seal head Retaining ring Air spring shaft Crush washer Bottom bolt Cartr...

Page 12: ...head Maxle Stealth Crush washer Bottom bolt Rebound adjuster knob Steerer tube Air cap Air valve Air spring top cap Upper tube Air spring piston Top out bumper Lower leg Air spring seal head Retaining...

Page 13: ...seal head Maxle Ultimate Crush washer Bottom bolt Rebound adjuster knob Air cap Air valve Air spring top cap Bottomless Token s optional 35 mm grey Upper tube Air spring piston Top out bumper Lower le...

Page 14: ...damper seal head Retaining ring Maxle Ultimate Crush washer Bottom bolt Rebound adjuster knob Air cap Air valve Air spring top cap Upper tube Air spring piston Top out bumper Lower leg Air spring seal...

Page 15: ...moved 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 clockwise until it stops This is the fu...

Page 16: ...nward to remove the lower leg If the lower leg does 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 Reins...

Page 17: ...17 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 Soak the foam rings in RockShox suspension oil 1 2 3 0w 30...

Page 18: ...eg Clean the wiper seals Install the foam rings under the wiper seals Confirm the foam rings are installed evenly in the space under the wiper seals and do not protrude over the bushings 50 Hour Servi...

Page 19: ...top 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 l...

Page 20: ...he 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 21: ...the top of the lower leg Optional If the Abbey 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...

Page 22: ...NOTICE Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspension Scratches can cause leaks When replacing seals and o rings use your fingers or a pick to remov...

Page 23: ...rom the upper tube A build up of negative air pressure may prevent the air spring from being pulled out of the upper tube If the air spring is difficult to remove use a clean plastic dowel to push the...

Page 24: ...NOTICE Do not scratch the air piston Scratches will cause air to leak Clean the inside and outside of the upper tube Inspect the inside and outside of the upper tube for damage NOTICE Scratches on the...

Page 25: ...m fork travel option If fork travel is changed from stock it may be necessary to add or remove Bottomless Tokens Refer to the RockShox Spare Parts Catalog at www sram com service for available air spr...

Page 26: ...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 fork DebonAir Thread a Bottomles...

Page 27: ...ottomless Tokens Refer to Air Spring Travel Change and Bottomless Tokens for details Refer to the RockShox Spare Parts Catalog available at www sram com service for the required spare part kits For pa...

Page 28: ...nto the air shaft Apply red Loctite 2760 to the first two to three full threads on the end of the air shaft Clamp an 8 mm hex wrench into a vise Insert the air piston onto the wrench to secure it Inst...

Page 29: ...ring Guide the retaining ring with your finger to prevent the shaft from from getting scratched while installing the retaining ring Use the pliers to push the seal head into the upper tube while insta...

Page 30: ...Lyrik damper service go to Charger 2 Damper Service Lyrik 200 Hour Service To continue with Yari Charger Damper RC damper service go to Charger Damper RC Service Yari 200 Hour Service To continue with...

Page 31: ...er service procedures 2 0 0 H o u r S e r v i c e D a m p e r R e m o v a l The compression damper must be in the full open position in order to perform bleed procedure RC2 RCT3 RCT R RC Turn the comp...

Page 32: ...retaining screw RC2 RCT3 RC Remove the low speed compression adjuster knob RC2 Remove the high speed compression adjuster knob RCT3 Remove the compression mode adjuster knob 2 2 mm RC2 RCT3 RCT R 2 m...

Page 33: ...oval RCT R RC R Loosen the remote cable stop collar set screw and remove the collar RCT R Remove the low speed knob remote spool assembly RC R Remove the remote spool 4 2 mm RCT R RCT R 2 mm RC R RC R...

Page 34: ...34 Damper Removal Unthread the damper top cap and remove the Charger 2 Damper assembly Clean the upper tube threads 6 Top Cap Cassette Tool RC2 RCT3 RC 24 mm RCT R RC R...

Page 35: ...o a new o ring and install it Clamp the cartridge tube wrench flats in a vise with flat soft jaw inserts with the rebound damper oriented upwards Wrap a rag around the cartridge tube to absorb oil Unt...

Page 36: ...piston Install a new glide ring Apply grease to the new rebound damper seal head seals Install the new seal head onto the rebound damper shaft threaded end first and slide it towards the piston until...

Page 37: ...oupler wrench flats back into the vise Spray RockShox Suspension Cleaner or isopropyl alcohol into the cartridge tube Squeeze the bladder 5 6 times to circulate the cleaner into the damper Remove the...

Page 38: ...38 Damper Service Dry the cartridge tube and compression damper assembly with compressed air 12 Air Compressor and Air Gun Nozzle...

Page 39: ...the cartridge tube until it is full Squeeze the bladder until trapped bubbles stop purging Pour additional oil into the cartridge tube until full The rebound damper must be in the full open fastest r...

Page 40: ...embly Insert the rebound damper piston slowly into the cartridge tube and thread the sealhead into the tube Tighten the seal head Thread the rebound bottom bolt into the shaft 3 4 turns 3 23 mm 5 1 N...

Page 41: ...ntly damage the seals and will cause the fork to malfunction Thread the syringe bleed fitting into the seal head bleed port Depress the plunger to pressurize the damper assembly Push the rebound dampe...

Page 42: ...expand and retract until it stops in a resting position Unthread the syringe bleed fitting from the bleed port CAUTION EYE HAZARD Oil may eject from the bleed port if the bladder is not in a resting p...

Page 43: ...43 Damper Bleed Cycle the rebound shaft a few times Remove the bottom bolt and clean the Charger 2 Damper assembly 7...

Page 44: ...sh down on the damper assembly to test the bleed RCT3 RCT R The rebound damper shaft should not move more than 2 mm If the shaft moves more than 2 mm while locked out repeat the bleed process RC2 RC R...

Page 45: ...t i o n Install the Charger 2 Damper assembly into the damper side upper tube Thread the top cap into the upper tube Tighten the top cap 1 Top Cap Cassette Tool RC2 RCT3 RC 24 mm RCT R RC R 2 Top Cap...

Page 46: ...with the tab in the forward unlocked position RC2 Install the high speed compression adjuster knob RC2 RCT 3 Install the low speed compression adjuster knob onto the hex adjuster rod Install and tight...

Page 47: ...and tighten the retaining screw RCT R Install the cable stop collar with the housing guide in the 6 o clock forward position angled 20 degrees from center Push the low speed adjuster knob spring reta...

Page 48: ...b onto the hex adjuster Install and tighten the knob retaining screw RC R Install the cable stop collar with the housing guide in the 6 o clock forward position angled 20 degrees from center Install t...

Page 49: ...Consult the applicable remote user manual at www sram com rockshox components remotes for cable and remote installation instructions 200 Hour Service Continue the 200 Hour Service with Lower Leg Insta...

Page 50: ...r v i c e D a m p e r R e m o v a l Turn the compression adjuster knob counter clockwise to the full open position until it stops Remove the retaining screw and remove the knob RC Unthread the damper...

Page 51: ...ber strap from a strap wrench around the cartridge tube below the shop towel Apply opposing pressure with the strap wrench and unthread the top cap from the tube IMPORTANT The cartridge tube and rubbe...

Page 52: ...Damper Service Carefully remove the compression damper Remove the cartridge tube and rebound damper assembly from the vise and pour the oil into an oil pan Clean the exterior of the cartridge tube 3...

Page 53: ...se Remove the seal head from the rebound damper shaft Discard the seal head Spray RockShox Suspension Cleaner or isopropyl alcohol into the cartridge tube and clean the inside of the tube with a clean...

Page 54: ...em Apply grease to new o rings and install them Remove the glide ring from the rebound damper piston and discard it Install a new glide ring Apply grease to the inner seal and bushing in the new rebou...

Page 55: ...to the end of the rebound damper shaft Insert the rebound damper shaft into the recessed end of the seal head Slide the seal head toward the piston Insert the rebound adjuster knob into the rebound d...

Page 56: ...ight Pull the damper shaft to full extension Secure a shop towel around the cartridge tube to absorb oil Pour 57 mL RockShox 3wt suspension oil into the tube Thread a bottom bolt into the rebound damp...

Page 57: ...idge tube and slowly push it into the tube The rebound damper will slowly extend as the compression damper is installed this is normal Firmly push down and thread the top cap into the tube Tighten the...

Page 58: ...d face away from the purge hole when compressing the rebound damper Slowly push the rebound damper shaft into the tube until the cable tie contacts the seal head then stop Do not push the damper in an...

Page 59: ...nd keep your eyes and face away from the purge hole when compressing the rebound damper Push down on the damper assembly slowly to test the firmest compression setting Firm and consistent resistance s...

Page 60: ...ll the damper assembly into the damper side upper tube Thread the top cap into the upper tube and tighten it Install the adjuster knob with the tab in the 7 8 o clock unlocked position Install and tig...

Page 61: ...r top cap Remove the compression damper by pulling up firmly and slowly while gently rotating the damper in a circular motion NOTICE Do not force the damper out of the upper tube if there is resistanc...

Page 62: ...d seal head Clean the inside and outside of the upper 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...

Page 63: ...shaft into the 9 16 opening of a Park Tool AV 4 or AV 5 aluminum axle and spindle vise insert NOTICE Clamp the damper at the bottom of the shaft near the threaded shaft bolt insert to avoid scratchin...

Page 64: ...64 Damper Service Remove the glide ring and discard it Install a new glide ring 4...

Page 65: ...acing the rebound damper piston Add a small drop of Loctite Threadlocker Blue 242 to the rebound damper piston threads Thread the damper piston onto the shaft and tighten it Insert the rebound damper...

Page 66: ...the tips of the internal retaining ring pliers into the eyelets of the retaining ring and install the retaining ring into the groove NOTICE Do not scratch the rebound damper shaft Scratches will allo...

Page 67: ...il reduces available travel and can damage the fork Too little suspension oil decreases damping performance Use the compression adjuster knob to open the valve A A closed compression valve will restri...

Page 68: ...on Damper Installation Tighten the top cap Install the adjuster knob with the tab in the 7 8 o clock unlocked position Install and tighten the retaining screw 4 24 mm 28 N m 250 in lb RC 5 2 5 mm 1 2...

Page 69: ...TICE Make sure both wiper seals slide onto the tubes without folding the outer lip of either seal The inside bottom of the lower leg should not contact the spring or damper shafts A gap between the sh...

Page 70: ...bly toward the crown until it stops The spring and damper shafts should be visible through the bottom bolt holes Verify each shaft is centered and seated in the lower leg shaft bolt hole and no gap is...

Page 71: ...old the crush washer with needle nose pliers and unthread it from the bolt by turning the bolt counter clockwise Discard the crush washers Clean the bolts and install new crush washers NOTICE Dirty or...

Page 72: ...the set screw Do not over tighten the set screw Over tightening will seize the adjuster knob and it will not turn Yari Install the rebound adjuster knob and press it firmly onto the bolt Refer to your...

Page 73: ...the pump gauge while filling the air spring this is normal Continue to fill the air spring to the recommended air pressure Cycling the fork will equalize the positive and negative air chambers After...

Page 74: ...Boost is a trademark owned by Trek Bicycle Corporation Loctite and Blue 242 are registered trademarks of Henkel Corporation 2760 is a trademark of Henkel Corporation Park Tool is a registered tradema...

Page 75: ...an No 1598 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 USA EUROPEAN HEADQUARTERS SRAM Europe Paasbos...

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