SRAM RockShox SEKTOR Service Manual Download Page 6 | Manualshive

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6

Parts, Tools, and Supplies

P a r t s , T o o l s , a n d S u p p l i e s

Parts

• RockShox® Sektor™ 200 Hour Service Kit

Safety and Protection Supplies

•  Apron
•  Clean, lint-free shop towels
•  Nitrile gloves
•  Oil pan
•  Safety glasses

Lubricants and Fluids

•  Liquid-O-Ring® PM600 grease
•  RockShox 5wt suspension oil
•  RockShox 15wt suspension oil
•  RockShox Suspension Cleaner or isopropyl alcohol
•  SRAM® Butter grease

RockShox Tools

• RockShox Bleed Syringe
•

RockShox x Abbey Bike Tools™ Flangeless Dust Seal Installation Tool

or RockShox 32 mm Flangeless Dust Seal Installation Tool

• RockShox shock pump

Bicycle Tools

•  Bicycle work stand
•  Downhill tire lever
•  Shock pump

Common Tools

•  Hex bit sockets: 2, 2.5, 5 mm
•  Hex wrenches: 2, 2.5, 5, 8, 10 mm
•  Internal retaining ring pliers
•  Long plastic or wooden dowel (≤ 25 mm diameter)
•  Needle nose pliers
•  Pick
•  Rubber or plastic mallet
•  Socket:

RockShox x Abbey Bike Tools 24 mm Top Cap Socket

or 24 mm

• Socket wrench
• Torque wrench

SAFETY INSTRUCTIONS

Always wear safety glasses and nitrile gloves when working with suspension oil.
Place an oil pan on the floor underneath the area where you will be working on the suspension fork.

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Summary of Contents for RockShox SEKTOR

Page 1: ...SERVICE MANUAL GEN 0000000005948 Rev A 2019 SRAM LLC 2019 2020 SEKTOR ...

Page 2: ...also 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 consequen...

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: ...1 50 HOUR SERVICE LOWER LEG SERVICE 13 200 HOUR SERVICE LOWER LEG SEAL SERVICE 15 AIR SPRING SERVICE 18 200 HOUR SERVICE AIR SPRING REMOVAL 18 AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS OPTIONAL 24 DEBONAIR TRAVEL AND BOTTOMLESS TOKEN TUNING 24 AIR SPRING AND ALL TRAVEL SPACER CONFIGURATIONS 24 BOTTOMLESS TOKENS INSTALLATION OPTIONAL 25 AIR SPRING INSTALLATION 26 DAMPER SERVICE 30 200 HOUR SER...

Page 5: ...ional 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 RockShox Suspension Cleaner or isopropyl alcoho...

Page 6: ...ngeless Dust Seal Installation Tool or RockShox 32 mm Flangeless Dust Seal Installation Tool RockShox shock pump Bicycle Tools Bicycle work stand Downhill tire lever Shock pump Common Tools Hex bit sockets 2 2 5 5 mm Hex wrenches 2 2 5 5 8 10 mm Internal retaining ring pliers Long plastic or wooden dowel 25 mm diameter Needle nose pliers Pick Rubber or plastic mallet Socket RockShox x Abbey Bike T...

Page 7: ...rform damper and spring service Extends suspension lifespan Restores small bump sensitivity Restores damping performance R e c o r d Y o u r S e t t i n g s Use the table below to record your suspension settings to return your suspension to its pre service settings Record your service dates to track service intervals Service Hours Interval Date of Service Air Pressure Rebound setting Count the num...

Page 8: ...ght wt Oil Height mm Volume mL Oil Weight wt Volume mL Oil Weight wt and or Grease Volume mL Oil Weight wt Volume mL 2019 2020 Sektor RL Motion Control 5 80 85 130 15 6 DebonAir 5 2 15 6 RL R Oil Height Measure from the top of the crown above the upper tube down to the oil Remote Adjust Apply grease PM600 or SRAM Butter to the air piston in addition to suspension oil ...

Page 9: ...ebound adjuster knob Steerer tube Air cap Air valve Air spring top cap Bottomless Token s optional 32 mm black Upper tube Air spring piston Top out bumper All Travel spacer optional Retaining ring Retaining washer Seal head base plate assembly Air spring shaft Air Spring Assembly Compression Damper Assembly Rebound Damper Assembly Brake hose guide Lower leg Sag o ring Wave spring Arch 2 0 1 9 S e ...

Page 10: ...juster knob Steerer tube Air cap Air valve Air spring top cap Upper tube Air spring piston Top out bumper All Travel spacer optional Retaining ring Retaining washer Floating seal head Air spring shaft Air Spring Assembly Compression Damper Assembly Rebound Damper Assembly Brake hose guide Lower leg Sag o ring Wave spring Arch Base plate Bottomless Token s optional 32 mm black Bottom out bumper 2 0...

Page 11: ...ION EYE HAZARD Verify all pressure is removed 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 full open fast rebound setting Remove the rebound adjuster knob Place an oil pan beneath the fork to catch the draining oil Loosen both bottom bolts 3 to 4 turns ...

Page 12: ...g 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 Reinstall the bottom bolts 2 to 3 turns and repeat the previous step NOTICE Do not strike the fork arch with any tool when removing the lower leg as this could damage the lower leg 50 Hour Service Continue the 50 Hour Service with Lo...

Page 13: ...13 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 Replace the foam rings if worn damaged or excessively contaminated 1 Pick 2 ...

Page 14: ...the wiper seals Install the dry foam rings under the wiper seals Confirm the foam rings are installed evenly and sqaure in the space under the wiper seals and do not protrude out of the groove 50 Hour Service Continue the 50 Hour Service with Lower Leg Installation 3 Dowel 4 ...

Page 15: ...e 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 leg stable Do not allow the lower leg to twist in opposite directions compress toward each other or be pulled apart This will damage the lower leg Clean the inside and outside of the lower leg 1 2 Downhill tire le...

Page 16: ...w end of a new wiper seal into the recessed end of the 32 mm Flangeless Dust Seal Installation tool NOTICE If the RockShox x Abbey Bike Tools installation tool is used confirm the 32 mm installation puck is tightened hand tight on the installation tool handle to avoid damage to the installation puck during use 4 15wt 5 6 Abbey Bike Tools Dust Seal Installation Tool RockShox Flangeless Dust Seal In...

Page 17: ... the seal is flush with the top of the lower leg Repeat on the other side NOTICE Only press the wiper seal into the lower leg until it is flush with the top surface of the lower leg Pressing the wiper seal below the top surface of the lower leg will compress the foam ring Install the outer wire springs 7 Abbey Bike Tools Dust Seal Installation Tool 8 ...

Page 18: ...ve any remaining air pressure Failure to do so can result in injury and or damage to the fork 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 remove the seal or o ring Spray RockShox Suspension Cleaner or isopropyl alcohol on each part and clean with a ...

Page 19: ...ft Scratches on the air shaft will allow air to bypass the seal head into the lower leg resulting in reduced spring performance Remove the retaining ring Use your finger to guide the retaining ring over the air spring shaft Thread the shaft bolt into the end of the air spring shaft and pull the shaft out to full extension Flat blade screwdriver 3 4 Retaining ring pliers 5 A ...

Page 20: ...er Clean and inspect the shaft for damage 130 mm 150 mm Remove the base plate wave spring retaining washer seal head bumper All Travel spacer if installed not pictured floating seal head and top out bumper Clean and inspect the shaft for damage NOTICE Scratches on the air spring shaft can cause air to leak If a scratch is visible the air spring assembly may need to be replaced 6 7 80 mm 120 mm 80 ...

Page 21: ...ew o ring seal and install it NOTICE Do not scratch the air piston Scratches will cause air to leak Remove the inner and outer o ring seals from the seal head and discard them Clean the seal head NOTICE Do not scratch the seal head Scratches will cause air to leak 8 9 80 mm 120 mm 80 mm 120 mm 130 mm 150 mm 130 mm 150 mm ...

Page 22: ... mm hex wrench Insert the ball end of the wrench into the base plate and stop just below the inner o ring gland of the seal head Apply grease to the ball end of a clean 8 mm hex wrench and use it to push the inner o ring into the gland using the 10 mm hex wrench to guide the o ring into the gland 10 80 mm 120 mm 10 mm 80 mm 120 mm 80 mm 120 mm 8 mm 80 mm 120 mm 80 mm 120 mm 80 mm 120 mm 80 mm 120 ...

Page 23: ...upper tube Inspect the inside and outside of the upper tube for damage NOTICE Scratches on the inside surface of the upper tube can cause air to leak If an internal scratch is visible the crown steerer upper tube assembly may need to be replaced 11 Dowel Dowel ...

Page 24: ...ption Bottomless Tokens can be added to or removed from the DebonAir top cap to fine tune the spring curve and bottom out feel Use the table below to help determine the number of Bottomless Tokens that can be used with each 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...

Page 25: ...fork and create greater ramp at 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 Thread a Bottomless Token into another Bottomless Token or into the the bottom of the top cap and tighten 8 mm 4 N m 35 in lb 24 mm 8 mm 4 N m 35 in lb 24 mm ...

Page 26: ... Bottomless Tokens Refer to Air Spring Tra vel 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 part ordering information please contact your local SRAM distributor or dealer Apply a liberal amount of grease to the inside of the upper tube from the end of the tube to approximately 60 mm into th...

Page 27: ...aining washer a new wave spring and the base plate in that order onto the air shaft Slide all the parts to the air piston until they stop Insert the air spring assembly into the upper tube Firmly push the air piston into the upper tube Position the flat retaining washer A into the upper tube followed by the wavy washer B Use your fingers to firmly press the seal head into the upper tube until it s...

Page 28: ... pliers to push the seal head into the upper tube while installing the retaining ring into the groove Confirm the retaining ring is properly seated in the retaining ring groove by using the retaining ring pliers to rotate the retaining ring and seal head back and forth a few times then firmly pull the air shaft out NOTICE Do not scratch the air spring shaft Scratches on the air shaft will allow ai...

Page 29: ...29 Air Spring Installation Install the air spring top cap into the upper tube and tighten it 10 24 mm 12 4 N m 110 in lb ...

Page 30: ...m o v a l Remove the retaining screw and remove the knob RL or upper remote spool RL R 2019 RL R Loosen the set screw and remove the cable stop clamp Remove the lower remote spool 1 2 5 mm 2019 2020 RL 2019 2020 RL 2 5 mm 2019 RL R 2019 RL R 2a 2 mm 2019 RL R 2019 RL R 2019 RL R 2019 RL R ...

Page 31: ...pool Unthread the compression damper 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 resistance This can cause separation of the piston from the damper tube 2b 2 mm 2020 RL R 2 5 mm 2020 RL R 2c 24 mm ...

Page 32: ...to the rebound damper shaft and push the shaft into the upper tube Remove the retaining ring Use your finger to guide the retaining ring over the rebound shaft NOTICE Do not scratch the rebound damper shaft Scratches will allow oil to leak into the lower leg resulting in reduced damper performance and potential damage to the fork 3 4 5 Retaining ring pliers ...

Page 33: ...d 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 If an internal scratch is visible the crown steerer upper tube assembly may need to be replaced 6 7 8 Dowel ...

Page 34: ...per o rings and discard them Apply grease to new o rings and install them Remove the bottom bolt Remove the seal head Clean the damper shaft and inspect the shaft for scratches NOTICE Scratches on the shaft can cause oil to leak If a scratch is visible the rebound damper may need to be replaced 1 2 ...

Page 35: ...35 Damper Service Remove the inner and outer seal head o rings and discard them Apply grease to the new o rings and install them Remove the glide ring and discard it Install a new glide ring 3 4 ...

Page 36: ...36 Damper Service Install the seal head onto the rebound damper shaft 5 ...

Page 37: ...arper edged side and a rounder edged side Installing retaining rings with the sharper edged side facing the tool will allow for easier installation and removal Install the retaining ring into the upper tube groove NOTICE Do not scratch the rebound damper shaft Scratches will allow oil to leak into the lower leg resulting in reduced damping performance CAUTION Confirm the retaining ring is properly...

Page 38: ...38 Rebound Damper Installation Pull the rebound damper shaft out to the fully extended position and remove the bottom bolt 4 ...

Page 39: ...oil reduces available travel and can damage the fork Too little suspension oil decreases damping performance RL Use the compression adjuster knob to open the valve A Rotate the knob counter clockwise until it stops A closed compression valve will restrict oil flow during installation Insert the compression damper into the upper tube Press down slowly and rotate in a circular motion until the dampe...

Page 40: ... tube and tighten it RL Apply grease to the top cap detents and detent spring RL Install the adjuster knob with the tab in the 7 8 o clock unlocked position Install and tighten the retaining screw 4 24 mm 12 4 N m 110 in lb 5 Grease 6a RL 2 5 mm 2 5 mm 1 4 N m 12 in lb ...

Page 41: ...e set screw Install the lower remote spool A onto the hex adjuster Install the upper spool with the alignment indicator dot B positioned within the range bracket C Install the spool retaining screw thread it in and stop when it contacts the upper spool Do not tighten the screw 6b 2019 RL R 20 30 2 mm 0 25 0 6 N m 2 2 5 3 in lb 2019 RL R 2019 RL R A B C 2 mm 2019 RL R ...

Page 42: ...permanent damage to the set screw threads do not over tighten the set screw Install the remote spool A onto the hex adjuster with the cable set screw B 20 40 degrees from the edge of the cable stop groove towards the front of the crown Install and tighten the retaining screw Consult the applicable remote user manual at www sram com rockshox component remotes for cable and remote installation instr...

Page 43: ... s e m b l y 5 0 2 0 0 H o u r S e r v i c e L o w e r L e g I n s t a l l a t i o n Clean the upper tubes Saturate the foam rings with suspension oil Apply grease to the inner surfaces of the dust wiper seals 1 2 15wt RockShox Bleed Syringe 3 ...

Page 44: ...er seal The inside bottom of the lower leg should not contact the spring or damper shafts A gap between the shaft ends and the lower leg bolt holes should be visible Position the fork at an angle with the bolt holes oriented upward Inject 6 mL of RockShox 15wt suspension oil into each lower leg through the bottom bolt holes NOTICE Do not exceed the recommended oil volume per leg as this can damage...

Page 45: ...ice Remove the old crush washer retainer and crush washer from each bottom bolt Compress and hold the crush washer retainer with needle nose pliers and unthread it and the crush washer from the bolt by turning the bolt counter clockwise Install a new crush washer retainer and crush washer onto each bolt NOTICE Do not damage the bolt threads Do not reuse crush washers or crush washer retainers Dirt...

Page 46: ... to the end of the rebound adjuster hex and around the outside of the damper bottom bolt Install the rebound adjuster knob onto the rebound damper bottom bolt Press the knob firmly onto the bolt until it clicks into place Refer to your pre service recorded rebound setting to adjust the rebound damping 8 5 mm Spring side 5 mm 6 8 N m 60 in lb 5 mm Damper side 5 mm 6 8 N m 60 in lb 9 ...

Page 47: ... pump gauge while filling the air spring this is normal Continue to fill the air spring to the recommended air pressure Compressing the fork will equalize the positive and negative air chambers After the fork is cycled 3 4 times check the pressure and add air as needed Install the air valve cap Clean the entire fork This concludes the service of your RockShox Sektor suspension fork 10 Shock pump 1...

Page 48: ...is publication includes trademarks and registered trademarks of the following companies Boost is a trademark owned by Trek Bicycle Corporation Abbey Bike Tools is a trademark owned by Abbey Bike Tools LLC ...

Page 49: ...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 U S A EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 14 16 3862ZS Nijkerk The Netherlands ...

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