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SRAM RockShox Deluxe RLR, Service Manual, Page: 4 / 58

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SRAM RockShox Deluxe RLR Service Manual Download Page 4

TABLE OF CONTENTS

GETTING STARTED ..............................................................................................................................................................................................6

RECOMMENDED SERVICE INTERVALS ....................................................................................................................................................................................................6

RECORD YOUR SETTINGS ............................................................................................................................................................................................................................6

TORQUE VALUES .............................................................................................................................................................................................................................................6

EXPLODED VIEW .................................................................................................................................................................................................8

EXPLODED VIEW - RTR .......................................................................................................................................................................................9

EXPLODED VIEW - BEARING MOUNT .............................................................................................................................................................9

ROCKSHOX® SUSPENSION SERVICE ............................................................................................................................................................10

REMOTE CABLE AND HOUSING REMOVAL - RTR ONLY............................................................................................................................10

PARTS, TOOLS, AND SUPPLIES ................................................................................................................................................................................................................10

REMOTE CABLE AND HOUSING REMOVAL .........................................................................................................................................................................................10

SHOCK EYELET SERVICE ..................................................................................................................................................................................11

MOUNTING HARDWARE AND BUSHING SERVICE ............................................................................................................................................................................. 11

PARTS, TOOLS, AND SUPPLIES ................................................................................................................................................................................................................. 11

MOUNTING HARDWARE REMOVAL ......................................................................................................................................................................................................... 11

EYELET BUSHING REPLACEMENT .......................................................................................................................................................................................................... 13

BEARING MOUNT SERVICE ........................................................................................................................................................................................................................ 14

PARTS, TOOLS, AND SUPPLIES ................................................................................................................................................................................................................ 14

BEARING REMOVAL ...................................................................................................................................................................................................................................... 14

BEARING INSTALLATION ............................................................................................................................................................................................................................16

DAMPER BEARING REPLACEMENT ......................................................................................................................................................................................................... 18

SUPER DELUXE™ SERVICE ...............................................................................................................................................................................19

PARTS, TOOLS AND SUPPLIES ................................................................................................................................................................................................................. 19

50/200 HOUR SERVICE

AIR CAN REMOVAL.......................................................................................................................................................................................................................................20

BOTTOMLESS TUNING ............................................................................................................................................................................................................................... 23

AIR CAN SERVICE ......................................................................................................................................................................................................................................... 24

200 HOUR SERVICE

IFP RESERVOIR SERVICE ............................................................................................................................................................................................................................ 28

REMOTE SPRING REPLACEMENT - RTR ONLY .................................................................................................................................................................................... 33

DAMPER BODY SERVICE ............................................................................................................................................................................................................................ 36

PISTON SERVICE ............................................................................................................................................................................................................................................37

SHOCK ASSEMBLY AND BLEED ..............................................................................................................................................................................................................40

50/200 HOUR SERVICE

AIR CAN INSTALLATION .............................................................................................................................................................................................................................50

SHOCK EYELET ASSEMBLY ............................................................................................................................................................................ 52

EYELET BUSHING INSTALLATION .......................................................................................................................................................................................................... 52

MOUNTING HARDWARE INSTALLATION .............................................................................................................................................................................................. 53

REMOTE CABLE AND HOUSING INSTALLATION - RTR ONLY .................................................................................................................. 55

PARTS, TOOLS, AND SUPPLIES ...............................................................................................................................................................................................................55

Summary of Contents for RockShox Deluxe RLR

Page 1: ...GEN 0000000005317 Rev E 2018 SRAM LLC 2018 Super Deluxe s e r v i c e m a n u a l...

Page 2: ...lso 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 l...

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: ...BUSHING REPLACEMENT 13 BEARING MOUNT SERVICE 14 PARTS TOOLS AND SUPPLIES 14 BEARING REMOVAL 14 BEARING INSTALLATION 16 DAMPER BEARING REPLACEMENT 18 SUPER DELUXE SERVICE 19 PARTS TOOLS AND SUPPLIES 1...

Page 5: ...Clean the exterior of the product with mild soap and water to avoid contamination of internal sealing part surfaces S e r v i c e P r o c e d u r e s The following procedures should be performed thro...

Page 6: ...amper and spring service Extends suspension lifespan Restores damping performance R e c o r d Y o u r S e t t i n g s Use the charts below to record your shock settings to return your shock to its pre...

Page 7: ...in Service Kits RockShox Tools RockShox Air Valve Adapter Tool Rear Shock red adapter RockShox 1 2 x 1 2 rear shock bushing removal installation tool RockShox IFP Height Tool Super Deluxe RockShox Re...

Page 8: ...Counter Measure IFP Internal Floating Piston Damper body Bottom out washer and o ring Seal head air piston Reservoir mount IFP reservoir IFP bleed screw Retaining ring IFP reservoir cap IFP reservoir...

Page 9: ...el limit screw Cap screw Cam housing Spring Spring tang Cam Cable hanger Cable spool Remote screw Cable spool cap Cable set screw Dust cover Bearing Shaft eyelet Spacer Bearing Dust cover Damper body...

Page 10: ...rom the pictures contained in this publication R e m o t e C a b l e a n d H o u s i n g R e m o v a l R T R O n l y Prior to servicing the rear shock remove the remote cable and housing from the shoc...

Page 11: ...and Oils RockShox Dynamic Seal Grease Common Tools Adjustable wrench Bench vise with aluminum soft jaws Open end wrenches 13 mm x2 M o u n t i n g H a r d w a r e R e m o v a l N OTI C E To prevent d...

Page 12: ...spacer and the bushing pin if it slides out easily If the bushing pin did not remove easily unthread the push pin from the threaded rod to remove the end spacer then reinstall the push pin onto the t...

Page 13: ...tcher onto the rod until it rests on the eyelet Hold the catcher secure with a 13 mm open end or adjustable wrench Use a second 13 mm wrench to thread the push pin along the rod until the push pin pus...

Page 14: ...body only Safety and Protection Supplies Clean lint free shop towels Nitrile gloves Safety glasses Common Tools Bearing press tool 22 mm OD x 10 mm ID Bench wise with aluminum soft jaws Hammer Small d...

Page 15: ...er and place the punch against the back of the other bearing and tap out the bearing NOTICE Do not damage the air valve when tapping out the bearing Spray isopropyl alcohol in the bearing bores and cl...

Page 16: ...press tool contacts both the inner and outer races of the bearing Insert a new spacer into the eyelet then install a new bearing into the other bearing bore Clamp the eyelet and bearing into a vise w...

Page 17: ...Bearing Installation Remove the shock from the vise The bearings should sit approximately 1 mm below the outer edge of the bearing bore Reinstall dust covers before installing the shock on the bicycle...

Page 18: ...dust covers may fall off This is normal NOTICE If you are completing the 50 or 200 hour service set the bearing assembly aside until service is complete The air can cannot be removed with the bearing...

Page 19: ...ter Tool Rear Shock RockShox IFP Height Tool Super Deluxe RockShox Rear Shock Vise Block Bicycle Tools Schrader valve core tool High Pressure Shock Pump 600 psi Common Tools Bench vise with aluminum s...

Page 20: ...vise jaws For bearing mount shocks wrap a rag around the eyelet then clamp the eyelet flat into the vise Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspens...

Page 21: ...forcefully eject from the shock Wear safety glasses Slowly release the air from the air can to make sure the air is removed from both chambers Quickly releasing the air can trap air in the negative c...

Page 22: ...ir can Wrap the strap around the section of the air can furthest from the shaft eyelet Turn the wrench counter clockwise to unthread the air can NOTICE Do not place the strap wrench on the air can dec...

Page 23: ...ng tokens from the eyelet Move the bottom out washer and o ring away from the shaft eyelet then snap the Gnar Dog Token onto the damper shaft with the flat side facing out of the eyelet Slide the toke...

Page 24: ...seal or o ring Only use RockShox Dynamic Seal Grease when servicing RockShox Super Deluxe rear shocks Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspensio...

Page 25: ...pyl alcohol inside the air can and clean it with a rag Remove a glove and use your finger to inspect the inside and outside of the air can for scratches dents or other surface deformations Replace the...

Page 26: ...er of the ring into the can so that it rests on top of the quad seal Orient the new wiper seal step side up Install it into the wiper seal groove at the top of the air can Apply a thin layer of grease...

Page 27: ...cohol on the seal head air piston and clean it with a rag Install the thicker glide ring below the seal head air piston seal and the thinner glide ring above To continue with the 50 Hour Service go to...

Page 28: ...e when servicing RockShox shocks To prevent damage to the shock use aluminum soft jaws and position the eyelet in the vise so that the adjustment knobs are clear of the vise jaws For bearing mount sho...

Page 29: ...x service center for further service CAUTION EYE HAZARD Verify all pressure is removed from the shock before proceeding Failure to do so can cause the damper body to separate from the shaft eyelet at...

Page 30: ...ide of the IFP reservoir Remove the IFP reservoir cap from the IFP reservoir Remove the IFP reservoir cap o ring Install a new o ring Loosen the IFP reservoir from the eyelet Remove the shock from the...

Page 31: ...31 IFP Reservoir Service Push the IFP out of the IFP reservoir Remove the IFP bleed screw Remove the IFP o ring Install a new o ring 9 10 T10 TORX 11...

Page 32: ...he piston nut while rocking it from side to side to remove the compression assembly from the IFP reservoir mount RTR Remove the lock spring and lock shim and set them aside RC3 and RTR Soak up excess...

Page 33: ...Clean the cam assembly Clamp grooved soft jaws into a vise Gently clamp the cam into the groove in the soft jaws Preload the spring clockwise until it stops then remove the travel limit screw Careful...

Page 34: ...Apply a thick layer of grease to the cam Apply a thick layer of grease to the inside and outside of the new remote spring then install the spring onto the cam with the spring tang in the spring tang...

Page 35: ...alled correctly CAUTION If not unloaded slowly the spring can reset rapidly causing the hex wrench to eject from the cam assembly Spray isopropyl alcohol on the remote subassembly and clean it with a...

Page 36: ...hes Do not scratch any sealing surfaces when servicing your suspension Scratches can cause leaks Clamp the damper body eyelet into a vice Wrap a rag around the damper body Loosen and remove the seal h...

Page 37: ...t knobs are clear of the vise jaws For bearing mount shocks wrap a rag around the eyelet then clamp the eyelet flat into the vise Inspect each part for scratches Do not scratch any sealing surfaces wh...

Page 38: ...ther and set them aside If the main piston assembly is disassembled it will need to be replaced Remove the seal head air piston from the damper shaft Remove the bottom out o ring from the damper shaft...

Page 39: ...e seal head air piston position the shaft in the vise so that the piston and IFP reservoir are clear of the vise jaws Install the main piston assembly that was removed in step 5 onto the damper shaft...

Page 40: ...ly grease to the new seal or o ring Only use RockShox Dynamic Seal Grease when servicing RockShox shocks To prevent damage to the shock use aluminum soft jaws and position the eyelet in the vise so th...

Page 41: ...ck to verify the lock shim is correctly installed Insert the pick into the refill holes on the compression assembly to make sure the lock shim is able to flex If the lock shim is not able to flex remo...

Page 42: ...e the system is purged of bubbles cover the damper shaft with your finger to temporarily seal the system With your finger still on the damper shaft opening pour RockShox 7wt suspension oil into the IF...

Page 43: ...should be submerged in oil Pour out any excess oil Remove the shock from the vise and slide the seal head air piston until it stops at the end of the damper shaft Clamp the damper body eyelet into the...

Page 44: ...body Pressure will continue to build against the IFP as the shaft assembly is tightened Keep your thumb on the IFP to ensure the best bleed Remove your thumb once the shaft assembly has been tightene...

Page 45: ...through the travel CAUTION EYE HAZARD Do not look directly into the reservoir as you push on the damper body Oil may be ejected from the IFP reservoir if you push the damper down to fast Wear safety g...

Page 46: ...nding on your shock stroke 45 65 mm shock stroke 33 mm 75 mm shock stroke 39 mm Use the IFP bleed tool to slowly push the IFP into the reservoir to the appropriate depth for your shock stroke CAUTION...

Page 47: ...eyelet into the vise so the shock is vertical To check the bleed quality install the IFP Height Tool into the IFP reservoir and apply force to the IFP Height Tool approximately 25 lbs The IFP should f...

Page 48: ...nto the IFP reservoir cap Install the RockShox air valve adaptor tool onto the shock pump and thread the adaptor tool into the reservoir air valve Inflate the reservoir to 250 psi Remove the adaptor t...

Page 49: ...isopropyl alcohol on the shock and clean it with a rag RTR Install the cable hanger onto the remote subassembly then tighten the cable hanger screw to 0 45 N m 4 in lb RTR Install the cable spool onto...

Page 50: ...icing your suspension Scratches can cause leaks Install the Counter Measure onto the damper body Apply RockShox Dynamic Seal Grease to the seal head air piston seals NOTICE If a brush is used to apply...

Page 51: ...it with a rag Remove the shock from the vise Turn it over and clamp the damper body eyelet in the vise Stabilize the air can with a strap wrench to prevent it from rotating Tighten the air can to 4 5...

Page 52: ...dle to begin pressing the eyelet bushing into the shaft eyelet Check the alignment of the bushing as it enters the eyelet If the bushing starts to enter the eyelet at an angle remove the bushing from...

Page 53: ...mount Next press an end spacer large diameter side first onto each end of the bushing pin If this works you have completed mounting hardware and bushing service If you are unable to install your mount...

Page 54: ...ions Use a shock pump to pressurize the shock to the desired air pressure After adding air to the shock the pressure will need to be equalized between the shock chambers Record the air pressure value...

Page 55: ...ses Nitrile gloves Common Tools 2 and 3 mm hex wrenches 2 and 3 mm hex bit sockets 5 mm open end wrench Torque wrench Cable and Housing Cutters After the housing has been routed and installed on the b...

Page 56: ...ap and tuck the cable into the pocket Install the cable spool cap and tighten to 0 8 N m 7 in lb The cable spool will rotate with the spool cap when tightening Continue to rotate the spool cap clockwi...

Page 57: ...includes trademarks and registered trademarks of the following companies TORX is a registered trademark of Acument Intellectual Properties LLC Maxima Maxum4 Extra 15w 50 is a registered trademark of M...

Page 58: ...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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