SRAM RockShox RS-1 Service Manual Download | Manualshive

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27

Charger 2 Damper Removal

Clamp the wrench flats of the cartridge tube into a vise. With the cartridge

tube facing upward, spray isopropyl alcohol into it. Squeeze the bladder 2-3

times to ingest alcohol into the bladder.

Remove the assembly from the vise. With the cartridge tube downward,

squeeze the bladder until all of the isopropyl alcohol is drained into an oil
pan. Use an air compressor nozzle to dry the assembly.

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Summary of Contents for RockShox RS-1

Page 1: ...GEN 0000000005735 Rev A 2018 SRAM LLC 2015 2019 RS 1 s e r v i c e m a n u a l ...

Page 2: ...so 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 local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party suppliers be liable for direct indirect special incidental or consequenti...

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: ...AVEL CHANGE ADJUSTMENT OPTIONAL 17 SOLO AIR BOTTOMLESS TOKEN OPTIONAL INSTALLATION 17 AIR SPRING INSTALLATION 18 CARBON FIBER UPPER SERVICE 20 CHARGER 2 DAMPER SERVICE 23 200 HOUR SERVICE CHARGER 2 DAMPER REMOVAL 23 BLEED PROCEDURE 28 CARBON FIBER UPPER SERVICE 33 CHARGER 2 DAMPER INSTALLATION 35 CHARGER 2 DAMPER INSTALLATION CROWN ADJUST 37 CHARGER 2 DAMPER INSTALLATION REMOTE 39 ACCELERATOR DAMP...

Page 5: ...d Top out bumper cone Air piston Stanchion Dropout Air shaft Bottom cap Air valve cap Low speed compression knob and lockout adjuster knob Lockout extension shaft Brake hose guide Bladder Damper anchor Cartridge tube Bleed port Damper seal head Rebound piston Rebound Shaft Stanchion Bottom cap Bottom bolt Rebound adjuster Air Shaft Assembly Compression Damper Assembly Rebound Damper Assembly Carbo...

Page 6: ...port washer Floating seal head Top out bumper cone Air piston Stanchion Dropout Air shaft Bottom cap Air valve cap RL remote Lockout extension shaft Brake hose guide Bladder Cartridge tube Bleed port Damper seal head Rebound piston Rebound Shaft Stanchion Bottom cap Bottom bolt Rebound adjuster Air Shaft Assembly Compression Damper Assembly Rebound Damper Assembly Carbon fiber upper Bottomless Tok...

Page 7: ...ut bumper Wave spring Support washer Floating seal head Top out bumper cone Air piston Stanchion Dropout Air shaft Bottom cap Air valve cap Grommet XLoc hose Connectamajig Knurled collar Damper anchor Compression Damper Cartridge tube Dig Valve Damper seal head Rebound Shaft Stanchion Dropout Bottom bolt Rebound adjuster Air Shaft Assembly Compression Damper Assembly Rebound Damper Assembly Carbon...

Page 8: ...f applicable For 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 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 throughout service unless otherwise specified Clean the part with isopropyl alcohol and a c...

Page 9: ...amper Liquid O Ring PM600 military grease or SRAM Butter grease Bicycle Tools Bicycle stand Downhill tire lever Shock pump Common Tools 1 3 2 2 5 5 8 mm hex wrench 5 mm long hex bit socket 2 2 5 and 5 mm hex bit socket 9 12 15 and 22 mm crowfoot 6 9 12 15 and 22 mm open end wrenches 24 and 30 mm sockets T10 TORX Adjustable wrench Air compressor and nozzle Bench vise and aluminum soft jaws Flat bla...

Page 10: ...estores 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 settings to return your fork to its pre service settings Record your service date to track service intervals Service Hours Interval Date of Service Air Pressure Rebound setting count the number of clicks while turning the rebound adjuster fully counter clockwise Charger 2 Damper Only Low speed Compr...

Page 11: ...rease to the new seal or o ring Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspension Scratches can cause leaks Remove the air spring access cover NOTICE Do not pierce the air spring access cover Remove the air valve cap from the bottom cap Depress the Schrader valve and release all air pressure WARNING EYE HAZARD Verify all pressure is removed from the...

Page 12: ...ing assembly from the carbon fiber upper If the stanchion does not slide out of the carbon fiber upper then the press fit of the shaft may still be engaged Reinsert the 5 mm long hex bit socket and repeat the previous step Insert the anchor tool into the bottom of the carbon fiber upper so that it engages the anchor Rotate the anchor tool clockwise and unthread the anchor Remove the anchor tool th...

Page 13: ... install a new o ring Remove the anchor o ring Apply grease and install a new o ring Remove the jounce bottom out bumper from the air shaft Depress the Schrader valve in the air shaft and release the air pressure from the negative air chamber 8 9 10 Small hex 11 ...

Page 14: ...ing ring NOTICE Scratches on the air shaft will allow air to bypass the air shaft guide into the lower legs resulting in reduced spring performance Thread the anchor bolt into the air shaft 3 4 turns Firmly pull on the bolt to remove the air shaft assembly from the stanchion Remove the anchor bolt from the air shaft Insert the Maxle Ultimate through the dropout Leverage the Maxle Ultimate against ...

Page 15: ... the inside and outside of the stanchion Remove the seal head assembly from the air shaft Clean the air shaft assembly Remove the outer and inner o rings on the floating seal head Apply grease and install the new o rings 16 17 18 ...

Page 16: ...ng Removal Remove the air piston outer o ring Apply grease and install a new o ring Remove the top out bumper cone from the air piston Clean the air piston Install the top out bumper cone onto the air piston 19 20 ...

Page 17: ... part kit details S o l o A i r B o t t o m l e s s T o k e n O p t i o n a l I n s t a l l a t i o n Bottomless Tokens can be added to or removed from the air top cap to fine tune the bottomout feel and spring curve Bottomless Tokens reduce the air volume in your fork to create greater ramp at the end of the fork travel Add tokens to maintain your fork s bottomless feel Thread a Bottomless Token ...

Page 18: ...e air shaft Install the floating seal head floating seal head top out bumper aluminum support washer wavy washer and air shaft guide in that order onto the air shaft Push the air shaft and seal head assembly into the unthreaded end of the stanchion Orient the washers so that the aluminum support washer goes into the upper tube first followed by the wavy washer Use your fingers to firmly press the ...

Page 19: ... should be positioned between the retaining ring eyelets Thread the anchor bolt into the air shaft 3 4 turns then pull the air shaft out of the stanchion Remove the anchor bolt Confirm the retaining ring is properly seated in the retaining ring groove by using the retaining ring pliers to rotate the retaining ring and air shaft guide back and forth a few times Install the Maxle Ultimate through th...

Page 20: ...l tire lever handle to remove the wiper seal Clean the inside and outside of the carbon fiber upper Remove the wire spring from a new wiper seal Insert the narrow end of the wiper seal into the recessed end of the flangeless seal installation tool Use a soft face mallet to gently tap the seal installation tool and push the wiper seal into the leg until the seal contacts the bottom of the leg bore ...

Page 21: ...ol from the carbon fiber upper For easier installation apply a thin layer of grease to the inside lip of the anchor tool Position the carbon fiber upper at an angle with the upper leg hole facing upward Angle a syringe fitting in the upper leg hole so the oil will only contact the inside of the leg Inject suspension oil into the carbon fiber upper leg NOTICE Do not exceed the recommended oil volum...

Page 22: ...le Use a magnet to help remove the bolt and repeat the step Tighten the anchor bolt Install the access cover Refer to your pre service recorded settings to pressurize your air spring or use the air chart on the fork s upper leg and pressurize the air spring You may see a drop in the indicated air pressure on the pump gauge while filling the air spring this is normal Continue to fill the air spring...

Page 23: ...hes 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 remove the seal or o ring Spray isopropyl alcohol on each part and clean with a rag Apply grease to the new seal or o ring Crown Adjust Turn the lockout adjuster knob to the open unlocked position Crown Adjust Remove the low speed compressi...

Page 24: ...zontally in the bicycle stand Remove the rebound adjuster knob Place an oil pan beneath the fork to catch the draining oil Loosen the damper side bottom bolt 3 to 4 turns Strike the bottom bolt to dislodge the shaft from the stanchion Remove the bottom bolt 2 5 mm RL remote RL remote 2b Flat blade screwdriver 3 4 5 mm 5 Mallet 5 mm ...

Page 25: ...ious step Insert the anchor tool into the bottom of the carbon fiber upper so that it engages the damper anchor on the Charger 2 Damper Rotate the anchor tool clockwise and unthread the Charger 2 Damper assembly Remove the anchor tool and the Charger 2 Damper assembly from the carbon fiber upper Clamp the wrench flats of the Charger 2 Damper assembly in a vise with the rebound shaft oriented upwar...

Page 26: ...assembly Wrap a rag around the cartridge tube to absorb oil Remove and discard the seal head on the rebound damper shaft Remove the cartridge tube from the vise and pour the oil into an oil pan Squeeze the bladder to drain the oil from the bladder assembly into an oil pan 15 mm 10 11 12 13 ...

Page 27: ...cing upward spray isopropyl alcohol into it Squeeze the bladder 2 3 times to ingest alcohol into the bladder Remove the assembly from the vise With the cartridge tube downward squeeze the bladder until all of the isopropyl alcohol is drained into an oil pan Use an air compressor nozzle to dry the assembly 14 15 ...

Page 28: ... tube into a vise Wrap a rag around the cartridge tube to absorb oil Pour 3wt RockShox suspension oil into the cartridge tube Squeeze the bladder until trapped air bubbles stop purging Pour additional oil into the cartridge tube to top it off Replace the glide ring on the Dig Valve on the rebound damper 1 2 3wt 3 4 ...

Page 29: ...knob into the rebound damper shaft until it contacts the rebound adjuster screw Rotate the knob counter clockwise until it stops to open the rebound Remove the rebound adjuster knob from the shaft Wrap a rag around the cartridge tube to absorb oil Install the rebound assembly into the cartridge tube Tighten the rebound seal head 5 6 T10 7 2 5 mm hex or rebound adjuster knob 8 15 mm 9 10 N m 80 90 ...

Page 30: ...it Do not use syringes that have been in contact with DOT brake fluid DOT brake fluid will permanently damage the damper Thread the syringe into the seal head bleed port Depress the plunger to pressurize the damper assembly Push the rebound damper shaft down Keep pressure on the plunger as the syringe fills with oil Pull up slowly on the rebound damper shaft Keep pressure on the syringe as oil fil...

Page 31: ... filling Use a rag to cover the bleed tip and Charger bleed port then unthread and remove the syringe CAUTION EYE HAZARD Fluid may eject from the bladder assembly if the bladder is not in its resting position Wear safety glasses Install the bleed screw Cycle the rebound damper shaft a few times Remove the bottom bolt from rebound damper shaft Clean the Charger 2 Damper assembly 13 14 T10 1 1 2 3 N...

Page 32: ...32 Bleed Procedure Remove the damper anchor o ring Apply grease and install a new o ring RLC RL remote 16 ...

Page 33: ...ll tire lever handle to remove the dust wiper seal Clean the inside and outside of the carbon fiber upper Remove the wire spring from a new wiper seal Insert the narrow end of the wiper seal into the recessed end of the flangeless seal installation tool Use a soft face mallet to gently tap the seal installation tool and push the wiper seal into the leg until the seal contacts the bottom of the leg...

Page 34: ...n angle with the upper leg hole facing upward Angle a syringe fitting in the upper leg hole so the oil will only contact the inside of the leg Inject suspension oil into the carbon fiber upper NOTICE Do not exceed the recommended oil volume as this can damage the fork 4 SRAM butter 15wt RockShox standard syringe 10mL 5 ...

Page 35: ...r upper NOTICE Make sure the wiper seal slides onto the tool without folding the outer lip of the seal Tighten the anchor counter clockwise Remove the anchor tool from the carbon fiber upper For easier installation apply a thin layer of grease to the inside lip of the anchor tool Clean the inside and outside of the stanchion Slide the stanchion into the carbon fiber upper until it stops and the sh...

Page 36: ...urning the bolt counter clockwise with a 5 mm hex wrench NOTICE Dirty or damaged crush washers can cause oil to leak from the fork Install the bottom bolt and tighten Clean the entire fork 200 Hour Service Continue the 200 Hour Service with Charger 2 Damper Crown Installation 200 Hour Service Continue the 200 Hour Service with Charger 2 Damper Remote Installation 5 5 mm pick 5 mm pliers 6 5 mm 6 8...

Page 37: ... springs and detent balls from the underside of the low speed compression knob Clean the knob Install a new glide ring into the groove Install a spring into the hole on the underside of the low speed compression knob Install a detent ball on top of the spring Apply grease to the underside of the low speed compression knob to hold the spring and ball in place 1 2 RLC RLC RLC RLC 3 RLC RLC ...

Page 38: ... Install the lockout adjuster knob on the knob base so the knob rotates from open to closed Install the low speed compression knob so the set screw in the knob is aligned with the flat part of the lockout extension shaft Tighten the set screw This concludes the service of your RockShox RS 1 RLC suspension fork 4 RLC RLC 5 RLC RLC 1 3 mm 0 3 N m 2 5 in lb ...

Page 39: ...ase Install and seat the lower spool on the cable stop Position the upper spool so the tab is 190 CCW from the cable stop Install and tighten the retention screw This concludes the service of your RockShox RS 1 RL remote suspension fork For Remote user manuals please visit www sram com service 1 1 2 2 5 mm RL remote RL remote 2 5 mm 0 9 N m 8 in lb ...

Page 40: ...cing seals and o rings use your fingers or a pick to remove the seal or o ring Spray isopropyl alcohol on each part and clean with a rag Apply grease to the new seal or o ring Inspect each part for scratches Do not scratch any sealing surfaces when servicing your suspension Scratches can cause leaks Push the XLoc button in to the compressed unlocked position Position the fork horizontally in the b...

Page 41: ...ttom of the carbon fiber upper so that it engages the damper anchor on the Accelerator Damper Rotate the anchor tool clockwise and unthread the Accelerator Damper assembly Remove the anchor tool from the carbon fiber upper The XLoc hose will spin as you loosen the anchor from the carbon fiber upper This is normal Guide the XLoc hose through the grommet while pulling down on the anchor tool to reve...

Page 42: ...majig NOTICE Failure to lock the XLoc remote before disconnecting it will result in oil leaking from the XLoc This will require a complete bleed of the system Loosen the grommet from the assembly hole Remove the hose and grommet Insert the Maxle Ultimate through the dropout Leverage the Maxle Ultimate against a bench top then use a wrench to unthread the bottom cap counter clockwise to loosen and ...

Page 43: ...43 Accelerator Damper Removal Remove the bottom cap o ring Apply grease and install a new o ring 11 ...

Page 44: ...er anchor from the cartridge tube and remove the compression damper NOTICE The components of this fork are made from lightweight materials and can be damaged by improper tool usage Make sure the wrench does not slip off the wrench flats This can cause damage by rounding the edges Clean the compression damper Remove both of the compression damper o rings Apply grease and install new o rings 1 2 12 ...

Page 45: ...ained from the system Clamp the cartridge tube into a bicycle stand with the rebound shaft oriented upward Unthread the damper seal head from the cartridge tube and remove the rebound assembly NOTICE The components of this fork are made from lightweight materials and can be damaged by improper tool usage Do not allow the wrench to slip off the wrench flats This can cause damage by rounding the edg...

Page 46: ...46 Accelerator Damper Service Clean the inside and outside of the cartridge tube Clean the rebound assembly Remove the damper seal head from the rebound shaft 9 10 11 ...

Page 47: ...ll the stepped face of the rod wiper seal into the threaded end of the seal head Remove the glide ring from the Dig Valve Install a new glide ring Install the damper seal head onto the rebound shaft with the threads oriented toward the piston NOTICE Do not allow the outer lip of the rod wiper seal to fold over when installing the damper seal head onto the rebound shaft 12 13 14 ...

Page 48: ...embly into the cartridge tube While holding the cartridge tube in place thread the damper seal head into the cartridge tube and tighten the rebound assembly Remove the cartridge tube assembly from the bicycle stand turn it over and clamp the cartridge tube assembly into the bicycle stand so the rebound shaft is oriented downward Pull down on the rebound shaft 15 16 17 22 mm 12 4 N m 110 in lb Wren...

Page 49: ...slowly to avoid introducing air into the fluid Slowly cycle the rebound shaft a few times to bleed the system CAUTION EYE HAZARD Pull the rebound shaft down slowly Failure to do so can result in fluid ejecting from the cartridge tube Wear safety glasses Thread the knurled collar onto the Connectamajig until it is finger tight Push the XLoc button in to the compressed unlocked position 19 2 5 mm 20...

Page 50: ...d firmly grasp the cartridge tube to prevent fluid from ejecting from the bleed hole Slowly push the rebound shaft into the cartridge tube until there is about 30 mm of shaft exposed and then fully extend again Cycle the rebound shaft a few times always leaving 30 mm of shaft exposed to purge the system of excess fluid and air bubbles NOTICE Do not push the rebound shaft all the way into the cartr...

Page 51: ...o release it to the extended locked position Unthread the Connectamajig from the knurled collar NOTICE Failure to lock the XLoc remote before disconnecting it will result in fluid leaking from the XLoc This will require a complete bleed of the system 27 ...

Page 52: ...ll tire lever handle to remove the dust wiper seal Clean the inside and outside of the carbon fiber upper Remove the wire spring from a new wiper seal Insert the narrow end of the wiper seal into the recessed end of the flangeless seal installation tool Use a soft face mallet to gently tap the seal installation tool and push the wiper seal into the leg until the seal contacts the bottom of the leg...

Page 53: ...ngle with the upper leg hole facing upward Angle a syringe fitting in the upper leg hole so the oil will only contact the inside of the leg Inject 10 mL suspension oil into the carbon fiber upper NOTICE Do not exceed the recommended oil volume as this can damage the fork 4 SRAM Butter 15wt RockShox standard syringe 10mL 5 ...

Page 54: ...g N NOTICE Make sure the wiper seal slides onto the tool without folding the outer lip of the seal Feed the hose through the carbon fiber upper until it comes through the inside of the tool Remove the anchor tool Thread the Connectamajig into the knurled collar and tighten Push the XLoc button in to the compressed unlocked position Anchor tool 1 2 6 9 mm ...

Page 55: ...to the tool without folding the outer lip of the seal Tighten the anchor counter clockwise The XLoc hose will spin as you tighten the anchor This is normal Remove the anchor tool Clean the inside and outside of the stanchion Install the Maxle Ultimate through the dropout Thread the bottom cap into the bottom of the stanchion Leverage the Maxle Ultimate against a bench top then tighten clockwise An...

Page 56: ...o release it to the extended locked position Slide the stanchion into the carbon fiber upper until it stops and the shaft is visible through the bottom bolt hole Install the bottom bolt and tighten Install the rebound adjuster knob 7 8 5 mm 6 8 N m 60 in lb 9 ...

Page 57: ...llation Press the grommet into the assembly hole Clean the entire fork This concludes the service of your RockShox RS 1 Accelerator Damper suspension fork For Remote bleed and user manuals please visit www sram com service 10 11 ...

Page 58: ...ion includes registered trademarks and trade names of the following companies Liquid O Ring is a registered trade name of Oil Center Research Inc TORX is a registered trademark of Acument Intellectual Properties LLC ...

Page 59: ...wan 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 Paasbosweg 14 16 3862ZS Nijkerk The Netherlands ...

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