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60

Lower Leg Installation

 200 Hour Service 

 Remove the old crush washers from each  

bottom bolt.
Hold 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 damaged crush washers can cause oil to leak from the fork.

6 

5 mm

Yari

Lyrik

Lyrik

Lyrik

Lyrik

Содержание ROCK SHOX Lyrik

Страница 1: ...GEN 0000000005295 Rev E 2022 SRAM LLC 2018 s e r v i c e m a n u a l Lyrik Yari...

Страница 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...

Страница 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...

Страница 4: ...LOWER LEG SERVICE 16 200 HOUR SERVICE LOWER LEG SEAL SERVICE 18 AIR SPRING SERVICE 21 200 HOUR SERVICE AIR SPRING REMOVAL 21 AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS OPTIONAL 26 DEBONAIR TRAVEL...

Страница 5: ...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 i...

Страница 6: ...ct version associated with the production model year Product details can be used to identify spare parts service kit and lubricant compatibility Model Code example FS LYRK RCT3 C1 FS Product Type Fron...

Страница 7: ...stallation tool 35 mm RockShox Shock Pump RockShox Top Cap Cassette tool 3 8 24 mm Bicycle Tools Bicycle work stand Cassette tool Downhill tire lever Park Tool AV 4 or AV 5 aluminum axle and spindle v...

Страница 8: ...re Rebound setting Count the number of clicks while turning the rebound adjuster fully counter clockwise Low Speed Compression setting Count the number of clicks while turning the low speed compressio...

Страница 9: ...Light 10 RCT R RC Dual Position Air RC R 2018 Yari RC Motion Control RockShox 5wt 100 106 180 DebonAir Remote Adjust Oil Height Measure from the top of the crown above the upper tube down to the oil S...

Страница 10: ...t Rebound adjuster knob Steerer tube Air cap Air valve Air spring top cap Bottomless Token Upper tube Air spring piston Top out bumper Lower leg Retaining washer Wave spring Air spring seal head Retai...

Страница 11: ...damper shaft Rebound damper seal head Maxle Stealth Crush washer Bottom bolt Rebound adjuster knob Steerer tube Air cap Air valve Air spring top cap Bottomless Token Upper tube Air spring piston Top o...

Страница 12: ...mper piston Rebound damper shaft Rebound damper seal head Retaining ring Maxle Ultimate Crush washer Bottom bolt Rebound adjuster knob Air cap Air valve Air spring top cap Bottomless Tokens Upper tube...

Страница 13: ...ft Rebound damper seal head Maxle Stealth Crush washer Bottom bolt Rebound adjuster knob Steerer tube Air cap Air valve Air spring top cap Bottomless Token Upper tube Air spring piston Top out bumper...

Страница 14: ...emoved 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 f...

Страница 15: ...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...

Страница 16: ...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 suspension oil 1 2 Isopropyl Alcohol 3 Maxima PLUSH Dynamic Suspensio...

Страница 17: ...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...

Страница 18: ...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...

Страница 19: ...l Stabilize the lower leg on a bench top Hold the lower leg steady and press the wiper seal into the lower leg until the top of the seal is flush with the top of the lower leg Repeat on the other side...

Страница 20: ...20 Lower Leg Seal Service Install the outer wire springs 8...

Страница 21: ...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 l...

Страница 22: ...the upper tube threads Remove the top cap o ring and discard it Apply grease to a new o ring and install it 2 RockShox Top Cap Cassette Tool DebonAir Lyrik 24 mm DebonAir Yari 24 mm Dual Position Air...

Страница 23: ...ith your thumb Push the seal head tab A into the upper tube and under the retaining ring Trapped negative air pressure creates increased resistance when pushing the shaft in Wear a thicker glove to pr...

Страница 24: ...move the bolt Remove the seal head wave spring retaining washer and top out bumper from the air spring shaft Discard the seal head and wave spring Clean and inspect the shaft for damage Clean the top...

Страница 25: ...he quad ring seal from the air piston and discard it Clean the air piston Apply grease to a new quad ring seal and install it Clean the inside and outside of the upper tube Inspect the inside and outs...

Страница 26: ...details For part ordering information please contact your local SRAM distributor or dealer D 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 L y r i k 29 Boost 27 5 Boost Fo...

Страница 27: ...fork s bottomless feel See Air Spring Travel Change and Bottomless Tokens for the maximum number of Tokens for your fork DebonAir Thread a Bottomless Token into another Bottomless Token or into the t...

Страница 28: ...dd or remove Bottomless 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 pa...

Страница 29: ...stall the retaining washer backup ring a new wave spring and the new seal head assembly in that order onto the air shaft Apply grease to the air piston and seal head outer o rings seals 4 DebonAir Deb...

Страница 30: ...e 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 stop...

Страница 31: ...eal head into the upper tube while installing the retaining ring into the groove Hold the retaining ring in place and seat the retaining ring eyelets on either side of the seal head tab A The seal hea...

Страница 32: ...out until it stops Remove the bolt Dual Position Air Apply a liberal amount of grease to the top cap upper air spring shaft DebonAir Inject or pour Maxima PLUSH Dynamic Suspension Lube Heavy into the...

Страница 33: ...he first detent space Thread the knob retaining nut onto the threaded air valve body and tighten the knob retaining nut 200 Hour Service To continue with Lyrik damper service go to Charger 2 Damper Se...

Страница 34: ...full open position in order to perform bleed procedure RCT3 Turn the compression adjuster knobs counter clockwise to the full open position until they stop RCT R Turn the low speed compression adjuste...

Страница 35: ...he collar RCT R Remove the low speed knob remote spool assembly RC R Remove the remote spool Unthread the damper top cap and remove the Charger 2 damper assembly Clean the upper tube threads 3 2 mm RC...

Страница 36: ...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...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...39 Damper Service Dry the cartridge tube and compression damper assembly with compressed air 12 Air Compressor and Air Gun Nozzle...

Страница 40: ...dge 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 rebound sett...

Страница 41: ...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...

Страница 42: ...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 damper shaft int...

Страница 43: ...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...

Страница 44: ...44 Damper Bleed Cycle the rebound shaft a few times Remove the bottom bolt and clean the Charger 2 damper assembly 7...

Страница 45: ...sing the damper Push 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 blee...

Страница 46: ...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 RCT3 RC 24 mm RCT R RC R 2 Top Cap...

Страница 47: ...d position Install the low speed compression adjuster knob onto the hex adjuster rod Install and tighten the retaining screw RC Install the compression adjuster knob onto the top cap with the tab in t...

Страница 48: ...spring retainer A in and push the knob out of the remote spool Remove the top cap seal Clean each part Install the remote spool onto the hex adjuster with the spool cable set screw oriented within the...

Страница 49: ...screw oriented within the 87 range zone Tighten the spool retaining screw RCT R RC R Tighten the cable stop collar set screw Consult the OneLoc user manual at www sram com rockshox products oneloc for...

Страница 50: ...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...

Страница 51: ...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...

Страница 52: ...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...

Страница 53: ...53 Damper Service Remove the glide ring and discard it Install a new glide ring 4...

Страница 54: ...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...

Страница 55: ...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...

Страница 56: ...duces 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 restrict oi...

Страница 57: ...p cap Install the adjuster knob with the tab in the 7 8 o clock unlocked position Install and tighten the retaining screw 200 Hour Service Continue the 200 Hour Service with Lower Leg Installation 4 2...

Страница 58: ...r seals Install the lower leg assembly onto the upper tubes and slide it just enough to engage the upper bushings with the upper tubes NOTICE Make sure both wiper seals slide onto the tubes without fo...

Страница 59: ...NOTICE Do not exceed the recommended oil volume per leg as this can damage the fork Slide the lower leg assembly toward the crown until it stops The spring and damper shafts should be visible through...

Страница 60: ...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...

Страница 61: ...ghten 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 t...

Страница 62: ...e 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 the fork is cy...

Страница 63: ...Stealth Maxle Ultimate Micro Gear System Mini Block Mini Cluster Monarch Monarch Plus Motion Control Motion Control DNA MRX MX Noir NX OCT OmniCal OneLoc Paceline Paragon PC 1031 PC 1110 PC 1170 PG 11...

Страница 64: ...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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