SRAM RockShox DebonAir Upgrade Manual Download Page 4

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TABLE OF CONTENTS

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

PART PREPARATION ......................................................................................................................................................................................................................................5

SERVICE PROCEDURES .................................................................................................................................................................................................................................5

PARTS, TOOLS, AND SUPPLIES ..................................................................................................................................................................................................................6

MODEL CODE IDENTIFICATION .......................................................................................................................................................................7

LYRIK / PIKE / REVELATION / YARI / ZEB UPGRADE KIT COMPATIBILITY ................................................................................................7

SEAL HEAD ONLY UPGRADE .....................................................................................................................................................................................................................7

DEBONAIR UPGRADE, TRAVEL CHANGE, AND BOTTOMLESS TOKENS ....................................................................................................................................7

LYRIK / PIKE / REVELATION / YARI / ZEB DEBONAIR UPGRADE KIT INSTALLATION .............................................................................9

LOWER LEG REMOVAL ...................................................................................................................................................................................................................................9

AIR SPRING REMOVAL .................................................................................................................................................................................................................................. 11

BOTTOMLESS TOKENS INSTALLATION (OPTIONAL) ......................................................................................................................................................................... 11

DEBONAIR SEAL HEAD ONLY UPGRADE ............................................................................................................................................................................................. 14

DEBONAIR SPRING INSTALLATION .........................................................................................................................................................................................................16

LOWER LEG ASSEMBLY ...............................................................................................................................................................................................................................19

BOXXER DEBONAIR SPRING UPGRADE KIT COMPATIBILITY ................................................................................................................ 22

DEBONAIR UPGRADE, TRAVEL CHANGE, AND BOTTOMLESS TOKENS .................................................................................................................................22

BOXXER DEBONAIR UPGRADE AND TRAVEL CHANGE KIT INSTALLATION ....................................................................................... 23

FORK REMOVAL ............................................................................................................................................................................................................................................ 23

DEBONAIR SPRING REMOVAL .................................................................................................................................................................................................................29

BOTTOMLESS TOKENS (OPTIONAL) ....................................................................................................................................................................................................... 31

DEBONAIR - TRAVEL AND BOTTOMLESS TOKEN TUNING ............................................................................................................................................................ 31

LOWER LEG INSTALLATION ...................................................................................................................................................................................................................... 35

FORK INSTALLATION ....................................................................................................................................................................................................................................37

Summary of Contents for RockShox DebonAir

Page 1: ...DebonAir Upgrade and Travel Change Kit UPGRADE MANUAL GEN 0000000005734 Rev E 2022 SRAM LLC...

Page 2: ...NOT APPLY TO YOU LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed adjusted and or maintained according to the respective SRAM user manual The SRAM...

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: ...LESS TOKENS INSTALLATION OPTIONAL 11 DEBONAIR SEAL HEAD ONLY UPGRADE 14 DEBONAIR SPRING INSTALLATION 16 LOWER LEG ASSEMBLY 19 BOXXER DEBONAIR SPRING UPGRADE KIT COMPATIBILITY 22 DEBONAIR UPGRADE TRAVE...

Page 5: ...with RockShox Suspension Cleaner or isopropyl alcohol and Clean the part with RockShox Suspension Cleaner or isopropyl alcohol and a clean lint free shop towel For hard to reach places e g upper tube...

Page 6: ...hox Top Cap Cassette tool 3 8 24 mm or RockShox x Abbey Bike Tools Top Cap Cassette Tool Bicycle Tools Bench vise Bicycle work stand Cassette tool Shock pump Common Tools Hex bit sockets 2 5 5 8 mm He...

Page 7: ...rk with a 2019 DebonAir air spring previously installed Lyrik Pike Revelation Yari 2019 2020 00 4020 573 000 AM UPGR DB C1 35MM SEAL HEAD D e b o n A i r U p g r a d e T r a v e l C h a n g e a n d B...

Page 8: ...B1 29 160 00 4020 572 002 5 150 00 4020 572 003 5 140 00 4020 572 004 6 130 00 4020 572 005 6 120 00 4020 572 006 7 REVELATION 2018 A1 27 5 29 160 00 4020 552 000 4 PLUSH Light 10 PLUSH Light 10 150...

Page 9: ...mall hex wrench to depress the Schrader valve and release all air pressure from the air chamber CAUTION EYE HAZARD Verify all pressure is removed from the fork before proceeding Failure to do so can r...

Page 10: ...m hex wrench to remove the bottom bolts from the lower leg Firmly pull the lower leg downward until oil begins to drain Continue pulling downward to remove the lower leg from the fork If the lower leg...

Page 11: ...r ramp at the end of the fork travel Add tokens to tune your fork s bottomless feel See Travel Change and Bottomless Tokens for the maximum number of Tokens for your fork Thread a Bottomless Token int...

Page 12: ...ining ring 2018 DebonAir and Solo Air Press firmly on the pliers to push the SA seal head into the upper tube enough to compress and remove the retaining ring Slide the retaining ring onto your finger...

Page 13: ...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 air spring piston d...

Page 14: ...t Discard the seal head Clean and inspect the shaft for damage Clean and inspect the shaft for damage Clean the top out bumper Clean the top out bumper NOTICE Scratches on the air spring shaft can cau...

Page 15: ...onto the wrench to secure it Install the new red air shaft nut onto the air shaft wrench to secure it Install the new red air shaft nut onto the air shaft and tighten it and tighten it NOTICE To ensur...

Page 16: ...ase to the inside surface of the upper tube approximately apply the grease to the inside surface of the upper tube approximately 150 mm into the tube 150 mm into the tube Apply grease to the air pisto...

Page 17: ...getting scratched while installing the retaining ring Use the pliers to push the seal head into the upper tube while installing Use the pliers to push the seal head into the upper tube while installi...

Page 18: ...g top cap into the upper tube and tighten it Press Install the air spring top cap into the upper tube and tighten it Press down firmly when tightening the top cap down firmly when tightening the top c...

Page 19: ...ugh to engage the upper bushings with the upper tubes enough to engage the upper bushings with the upper tubes NOTICE Make sure both wiper seals slide onto the tubes without folding the outer lip of e...

Page 20: ...amage the fork Slide the lower leg assembly along the upper tubes until it stops and the spring and damper shafts are visible through the lower leg bolt holes Use a shop towel to clean all excess oil...

Page 21: ...normal Continue to fill the air spring to while filling the air spring this is normal Continue to fill the air spring to the recommended air pressure the recommended air pressure Cycling the fork will...

Page 22: ...propriate RockShox suspension fork service manual available at www sram com service for service specifications and procedures Fork Model Year Generation Wheel Size in Desired Max Travel mm Upgrade Kit...

Page 23: ...onvenient than working around a complete bicycle Secure the bicycle in a bicycle work stand Secure the bicycle in a bicycle work stand To assist you with post service assembly record the distance from...

Page 24: ...mper side of the lower leg unthread the Maxle DH counter clockwise and remove it from lower leg counter clockwise and remove it from lower leg Remove the wheel Remove the wheel Remove the brake hose g...

Page 25: ...so they clear the upper crown Leave Slide the upper tubes down so they clear the upper crown Leave enough clearance between the upper tube and upper crown to remove enough clearance between the upper...

Page 26: ...ube they are loose on the upper tube Remove the frame bumpers from the upper tubes Remove the frame bumpers from the upper tubes Loosen the lower crown pinch bolt Slide the upper tubes through the Loo...

Page 27: ...compress while applying opposing Slowly allow the lower leg to compress while applying opposing pressure until you feel a sudden decrease in compressing resistance pressure until you feel a sudden dec...

Page 28: ...s inside the upper tube pressurize the air spring reinstall the lower leg compress the fork a few times to the air spring reinstall the lower leg compress the fork a few times to pressurize the negati...

Page 29: ...e the seal or o ring Spray isopropyl alcohol on each part and clean with a clean lint free shop towel Apply SRAM Butter grease to the new seals and o rings Remove the air spring top cap Remove the air...

Page 30: ...stic dowel to push If the air spring is difficult to remove use a clean plastic dowel to push the air spring piston down while pulling the air shaft out the air spring piston down while pulling the ai...

Page 31: ...e b o n A i r T r a v e l a n d B o t t o m l e s s T o k e n T u n i n g 27 5 Boost and 29 Boost Fork Travel Bottomless Tokens Factory Installed Bottomless Tokens Maximum 200 0 6 190 1 6 180 2 6 B o...

Page 32: ...pproximately 150 mm from one end Use the dowel to apply the grease to the inside surface of the upper tube approximately apply the grease to the inside surface of the upper tube approximately 150 mm i...

Page 33: ...sert the air spring assembly into the upper tube Firmly push the air piston into the upper tube piston into the upper tube Insert the seal head into the upper tube and firmly press it into the Insert...

Page 34: ...retaining ring into the groove Release the retaining ring pliers when the ring is fully seated in the groove when the ring is fully seated in the groove Confirm the retaining ring is properly seated i...

Page 35: ...g side lower leg onto the upper tube and slide it just enough to engage the upper bushing enough to engage the upper bushing NOTICE Make sure the wiper seal slides onto the tube without folding the ou...

Page 36: ...bottom bolt hole Verify the shaft is centered and seated in the lower leg shaft bolt hole Verify the shaft is centered and seated in the lower leg shaft bolt hole and no gap is visible between the lo...

Page 37: ...ugh clearance between the upper tube and upper crown to install the frame clearance between the upper tube and upper crown to install the frame bumpers bumpers Some bicycle frames include integrated f...

Page 38: ...s extend past the top of the upper crown by an equal upper tubes extend past the top of the upper crown by an equal amount and at least 2 mm amount and at least 2 mm Measure the distance from the top...

Page 39: ...epeat this tightening procedure for the bolts on the other side of the lower crown lower crown Tighten each upper crown pinch bolt to the specified torque Tighten each upper crown pinch bolt to the sp...

Page 40: ...damper side of Install the threaded end of the Maxle DH through the damper side of the lower leg and through the hub until it engages the threads in the the lower leg and through the hub until it enga...

Page 41: ...le filling the air spring this is normal Continue to fill the air spring to the recommended air pressure the recommended air pressure Cycling the fork will equalize the positive and negative air chamb...

Page 42: ...i 3 Impress Jaws Jet Kage Karoo Komfy LINK Lyrik MatchMaker Maxle Maxle 360 Maxle DH Maxle Lite Maxle Lite DH Maxle Stealth Maxle Ultimate Micro Gear System Mini Block Mini Cluster Monarch Monarch Pl...

Page 43: ...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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