Recon Silver - Cycle Service Nordic
Contents
1. 302 REBOUND DAMPER SERVICE 17 TURNKEY DAMPER SERVICE 19 DART 2 3 RECON SILVER TK 302 LOWER LEGINSTALLATION A 22 REMOTE SERVICE 24 PUSHLOC POPLOC ADJUST POPLOC 3 GEN 0000000003196 REV A SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your RockShox suspension Protect yourself Wear your safety gear 4 GEN 0000000003196 REV A SERVICE INTERVALS The following chart is a summary of the maintenance service intervals for RockShox forks Following this schedule is important to ensure the consistent performance and longevity of your fork Some of the information listed may not be applicable to your fork Every ride Every ride Every ride Every ride Every ride Change Speed Lube oil bath 25 Check front suspension fasteners for proper torque 25 Clean and lubricate remote lockout cable and housing 25 Remove lowers clean inspect bushings and change oil bath if applicable Clean and lubricate air spring assembly Change oil in damping system including hydraulic lockout Clean and lubricate coil spring assembly coil forks only 5 0000000003196 TOOL2. 3 Non hollow bottom fork legs Slide the lower leg assembly onto the upper tube assembly just enough to engage the upper bushing with the upper tubes Make sure both dust seals slide onto the tubes without folding the outer lip of either seal 4 Reference the oil chart at the beginning of this manual for proper oil weight and volumes for lower leg lubrication Invert the fork so that the bottom of the fork is angled upward at about 45 Measure and inject pour suspension oil into each lower leg through the shaft bolt hole 5 Slide the lower leg assembly along the upper tubes until it stops and the spring and damper shafts are visible through the shaft bolt holes Dual Air Air U Turn and Dual Position Air spring shafts should extend through the shaft bolt hole Wipe all excess oil from the outer surface of the lower legs Skip to step 8 23 10 11 13 LOWER LEG INSTALLATION INSTRUCTIONS CONTINUED Hollow bottom fork legs Reference the oil chart at the beginning of this manual for proper oil weight and volumes for lower leg lubrication Hold the lower leg assembly horizontally and inject pour suspension oil into each leg from the dust seal side Position the upper tube assembly horizontally then slide the lower leg assembly onto the upper tube assembly until it stops and the spring and damper shafts are visible through the shaft bolt holes Dual Air Air U Turn and Dual Position Air spring shafts should ex
3. SRAM or its third party suppliers be liable for direct indirect special incidental or consequential damages This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM technical installation manual The SRAM installation manuals can be found online at www sram com www rockshox com www avidbike com www truvativ com or Www zipp com This warranty does not apply when the product has been modified This warranty does not apply when the serial number or production code has been deliberately altered defaced or removed This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturer s specifications of usage or any other circumstances which the product has been subjected to forces or loads beyond its design This warranty does not apply to normal wear and tear Wear and tear parts are subject to damage as a result of normal use failure to service according to SRAM recommendations and or riding or installation in conditions or applications other than recommended Wear and tear parts are identified as Dust seals Bushings Air sealing o rings Glide rings Rubber moving parts Foam rings Rear shock mounting hardware and main seals Stripped threads and bolts aluminum titanium magnesium or steel Upper tubes stanchions Brake sleeves Brake pads Chains Sprockets Cassettes Shifter and brake ca
4. air pressure from the air chamber Ifthe fork has a negative air chamber start with the negative air chamber first then proceed to the positive air chamber A CAUTION Verify all pressure is removed from the fork before proceeding Failure to do so can result in injury and or damage to the fork 4 Remove the external rebound adjuster knob if applicable pulling it from the shaft bolt at the bottom of the right fork leg 5 Use a5dmmhex wrench to loosen both shaft bolts 3 to 4 turns Dual Air Air U Turn 2 Step and Dual Position Air equipped forks Use a 10 mm socket or open end wrench to loosen and unthread the shaft nut at the bottom of the left fork leg until it is flush with the threaded shaft end For hollow bottom fork legs you will need to use a deep 10 mm socket to loosen and unthread the air shaft nut 6 Place an oil pan beneath the fork to catch any draining oil Use a plastic mallet to firmly strike each shaft bolt nut free from its press fit to the lower leg and use your fingers to remove the shaft bolts nut completely For hollow bottom fork legs tap the 5 mm hex wrench and 10 mm deep socket while engaged in the bolts to free them from the press fit LOWER LEG REMOVAL CONTINUED Firmly pull the lower leg downward until oil begins to drain If the upper tubes do not slide out of the lower leg or if oil doesn t drain from either side the press fit of the shaft s to the lower
5. if applicable air valve cap s onto the air valve s 24 REMOTE SERVICE PUSHLOC POPLOC ADJUST POPLOC INTRODUCTION Damper service for forks equipped with remote lockouts will require cable and housing removal and installation Also periodic replacement of the cable and housing is recommended for optimal remote performance CABLE REMOVAL INSTRUCTIONS FORK LOCKOUT ANATOMY Housing stop Cable end slot Pinch bolt 1 only Push the remote lever until it returns toward you PopLoc and PopLoc Adjust only Press the button next to the remote lever to set the lever to the fully released or Unlocked position 2 BlackBox Motion Control Lyrik RLR and Lyrik RLR only Use a 2 hex wrench to loosen the cable pinch bolt on the spool and pull the cable out of the cable end slot Use pliers to remove the cable end OR Motion Control only Use a 2 mm hex wrench to loosen the cable pinch bolt on the spool Use pliers to remove the cable end 3 PushLoc only Push the remote lever to the Locked position Use your finger to open the cable hatch cover labeled CC for Cable Change Push the cable through the spool on the fork until the cable head 15 far enough out of the lever to access PopLoc and PopLoc Adjust only Push the cable through the spool until the cable head Is far enough out of the lever to grab onto 4 Pull the cable head to remove the cable complete
6. may cause air to leak OPTIONAL ALL TRAVEL CONFIGURATIONS All Travel spacers are located above the top out bumper If you want to change the travel of your fork add a spacer to decrease travel or remove the spacer to increase travel spacer spacer spacer 16 SOLO AIR SPRING INSTALLATION INSTRUCTIONS Insert the top out bumper and kick plate back onto the negative piston Re install the negative piston sleeve assembly onto the air shaft with the kick plate oriented toward the air piston Apply grease to the air assembly outer o rings Insert the air assembly into one end of the air tube Push the negative piston into the air tube until it is firmly seated Hold the air tube slight angle then pour 3 mL of 15 wt RockShox oil into the top of the air tube Do not pour oil straight down into the center of the tube Insert the air top cap into the air tube and press it tight into the air tube Insertthe air assembly shaft first into the upper tube from the top Guide the bottom of the air shaft through the shaft guide in the bottom of the upper tube Check the bottom of the upper tube and make sure the air shaft guide Is seated into the upper tube shaft guide Apply a small amount of grease to the top cap threads and o ring Hand thread the top cap into the upper tube Be careful not to damage the top Cap o ring upon installation Use a 24 sock
7. spring spring shaft assembly and the inside and outside of the upper tube and wipe with clean Wrap clean rag around a long dowel and insert it into the upper tube to clean inside the upper tube If the coil spring isolator is not centered on the coil spring wind the isolator along the coils to the center of the spring and use a heat gun to shrink tighten it 5 Usea pick to remove the o ring from the preload adjuster on top of the spring Apply grease to the new o ring and install it COIL SPRING INSTALLATION INSTRUCTIONS 6 Apply fresh grease liberally to the spring 6 7 Insertthe spring shaft and spring assembly back into the upper tube 8 Clean the top cap then apply a small amount of grease to the top cap threads Insert and hand thread the top cap into the upper tube Use a 24 mm socket wrench to tighten it to 7 3 N m 65 in Ib 9 Re install the detent springs and balls into the top cap Recon Silver Recon Gold only Re install the preload adjuster knob and knob screw Tighten the preload adjuster knob screw with a 2 5 mm hex wrench to 1 4 N m 12 13 14 SOLO AIR SPRING SERVICE RECON SILVER TORA 302 INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs SOLO AIR
8. stabilize the lower leg in order to prevent it from slipping while installing the seal Dust wiper installation Position the dust wiper into the recessed side of the seal installation tool so that the grooved side of the seal 15 visible Hold one of the lower legs firmly and use the seal installation tool to push the dust wiper evenly and completely into that leg There should be no visible gap between the dust wiper and the lower leg Repeat for th other leg Be sure to stabilize the lower leg in order to prevent it from slipping while installing the seal COIL SPRING SERVICE RECON SILVER RECON GOLD SEKTOR TORA TK INTRODUCTION At this point you should already have the lower leg removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs COIL SPRING REMOVAL INSTRUCTIONS Use a 2 5 mm hex wrench to remove the preload adjuster knob screw then remove the adjuster knob Use a magnet to remove the detent balls and springs from the top cap Recon Silver Recon Gold only 2 Unthread and remove the spring top cap with a 24 mm socket wrench Press down firmly when loosening the top cap 3 Push the spring shaft upward from the bottom of the upper tube then remove the coil spring and spring shaft from the upper tube Once removed clean the upper tube threads with a rag 4 Spray isopropyl alcohol on the
9. RECON SILVER 2011 Technical Manual TRU ari SRAM LLC WARRANTY SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase This warranty only applies to the original owner and is not transferable Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased Original proof of purchase 15 required This warranty statement gives the customer specific legal rights The customer may also have other rights which vary from state to state USA from province to province Canada and from country to country elsewhere in the world To the extent that this warranty statement is inconsistent with the local law this warranty shall be deemed modified to be consistent with such law under such local law certain disclaimers and limitations of this warranty statement may apply to the customer For example some states in the United States of America as well as some governments outside of the United States including provinces in Canada may Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall
10. S NEEDED FOR SERVICE The following chart is a list of the model year 2011 tools needed for service on your Recon Silver suspension fork While this chart is intended to be comprehensive it 15 still only a guide The tools required for each step of service are detailed in the text of the service section Tools Safety Starting Equipment Safety Glasses Nitrile Gloves Apron Clean Rags Lint Free Oil Measuring Device Clean Work Area General Tools Hex Key Set Sizes 1 5 mm 5 mm Plastic Mallet Socket Wrench 24 Socket Torque Wrench Snap Ring Pliers External Snap Ring Pliers Internal Long Dowel Rod Sharp Pick Oil Liquids Suspension Oil RockShox 5wt Grease Suspension Oil Soluble Isopropyl Alcohol PARTS NEEDED FOR SERVICE Prior to servicing your fork it is important that you have all of the necessary replacement parts For exploded diagram and part number information please refer to the Spare Parts Catalog available on our web site at www sram com For order information please contact your local SRAM distributor or dealer 6 GEN 0000000003196 REV A TECHNOLOGY AND VOLUMES The following chart is a complete list of the 2011 RockShox Recon Silver line up It details the model corresponding damper and spring technology along with the oil volume and RockShox oil weight required for each upper tube and lower leg D Volume Oil Volume Oil Spri Volume Oil Volume Oi
11. SPRING REMOVAL SERVICE INSTRUCTIONS A CAUTION Verify all pressure is removed from the fork before proceeding Depress the Schrader valve again to remove any remaining air pressure Failure to do so can result in injury and or damage to the fork 1 Use 24 socket wrench unthread the air spring top cap The air spring assembly is attached to the top cap Pull and lift the entire air spring assembly from the upper tube Once removed clean the upper tube threads with a rag 2 Pullthe top cap out of the air tube assembly and pour any oil from the air tube into an oil pan 3 Remove the air shaft piston assembly from the bottom of the air tube by pulling the shaft down and rocking it from side to side 4 Spray isopropyl alcohol on the inside and outside of the upper tube and wipe it with a clean rag Wrap clean around a long dowel and insert it into the upper tube to clean inside the upper tube Spray isopropyl alcohol on the inside and outside of the air tube and wipe it with a clean rag Wrap clean rag around a long dowel and insert it into the air tube to clean inside the air tube 5 Use small external snap ring pliers to remove the air piston snap ring Remove the air piston wavy spring washer and piston from the air shaft Expand the snap ring just enough to disengage from the air shaft Over extending the snap ring can permanently damage it and cause air spring assembly failure 6 Use a pick to r
12. UED 7 Remove the rebound damper piston o ring glide ring Apply a few drops of RockShox suspension oil to the new o ring glide ring and install it 8 Use a pick to remove the damper inner seal head o ring located in the bottom of the upper tube Apply a few drops of RockShox suspension oil to new o ring and install it If using a pick to remove o rings do not scratch the o ring glands Scratches may cause oil to leak 9 Clamp the fork back into the bicycle stand Apply grease to the upper tube threads Insert the rebound damper back into the drive side upper tube shaft first and push the piston into the upper tube 10 Push the rebound damper into the upper tube using long dowel rod Guide the rebound damper shaft through the damper shaft guide seal head at the bottom of the upper tube and pull the shaft through by hand into the fully extended position 11 Orient the fork upright in the bicycle stand Measure and slowly pour 5wt RockShox Suspension oil into the upper tube using the volumes listed in the chart below Oil volume is critical Too much oil reduces available travel too little oil decreases damping performance 011 Volume 3 mL Dart 2 with Turnkey 3 80 100 mm 120mm Recon Silver TK Tora 302 Tora IK 12 Crown Mount non remote only Turn the hex shaped compression adjuster fully counter clockwise OR Remote only Position the cable stop clamp in the 10 o clock position
13. around the upper tube hole on the crown prior to inserting the compression damper 20 21 13 14 15 DAMPER SERVICE INSTRUCTIONS CONTINUED Insert the compression damper into the upper tube through the crown Press down on and rock the damper from side to side to work it into the upper tube being careful not to damage the o ring on the upper tube threads Hand tighten the damper into the upper tube Use a 24 mm socket wrench to tighten the compression damper to 7 3 N m 65 in Ib Crown Mount non remote only Place the compression adjuster knob onto the compression damper top cap with the knob dial set in the 2 clock position Using external snap ring pliers secure the compression adjuster knob with a new snap ring OR Remote only Move on to the Remote Service section for instructions on how to install the remote lever and cable assembly LOWER LEG INSTALLATION INTRODUCTION At this point you should already have already serviced your fork seals damper system and spring system Once you have re installed your fork lower legs you will have successfully serviced your fork and you will be ready to ride LOWER LEG INSTALLATION INSTRUCTIONS 1 Spray the upper tubes with isopropyl alcohol and wipe them with a clean rag 2 Apply a small amount of grease to the inner surfaces of the dust wipers oil seals and foam rings if applicable For hollow bottom fork legs skip to step 6
14. ble end into the cable end slot in the spool OR Motion Control only Wrap the cable around the spool While pulling the cable firmly use 2 hex wrench to tighten the cable pinch bolt to 0 9 N m 8 in lb Cut the excess cable cap it with a cable end PopLoc PopLoc just Motion Control PopLoc PopLoc Adjust Motion PushLoc PushLoc BlackBox WORLD HEADQUARTERS SRAM LLC 1333 Kingsbury St 4th FI Chicago 11 60642 Phone 1 312 664 8800 Fax 1 312 664 8826 www sram com EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 14 16 386225 Nijkerk The Netherlands Phone 31 33 450 6060 Fax 31 33 457 0200 ASIAN HEADQUARTERS SRAM Taiwan No 1598 8 Chung Sahn Rd Shen Kang Hsiang Taichung County 429 Taiwan R 0 C Phone 886 4 2564 3678 FAX 886 4 2561 3686
15. bles inner and outer Handlebar grips Shifter grips Jockey wheels Disc brake rotors Wheel braking surfaces Bottom out pads Bearings Bearing Races Pawls Transmission gears Spokes Free hubs Aero bar pads Corrosion Tools This warranty shall not cover damages caused by the use of parts of different manufacturers This warranty shall not cover damages caused by the use of parts that are not compatible suitable and or authorized by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use ROCKSHOX SUSPENSION SERVICE We recommend that you have your RockShox suspension serviced by a qualified bicycle mechanic Servicing RockShox suspension requires knowledge of suspension components as well as the special tools and fluids used for service Used suspension fluid should be recycled or disposed of in accordance to local and federal regulations NEVER pour suspension fluid down a sewage or drainage system or into the ground or a body of water This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols and respectively Copyright SRAM LLC 2010 For exploded diagram and part number information please refer to the Spare Parts Catalog available on our web site at www sram com For order information please contact your local SRAM distributor or dealer Information contained in this publication is subject to change at any time w
16. emove the air piston outer o ring Apply grease to the new o ring and install it 7 Use pick to remove the face seal o ring from the underside of the air piston Use isopropyl alcohol and a clean rag to clean the o ring groove Install the new dry o ring into the groove Pierce into the face seal o ring with the pick and pull to remove it Do not scoop or dig the o ring out as this may damage the piston sealing surface SOLO AIR SPRING REMOVAL SERVICE INSTRUCTIONS CONTINUED 8 Install the air piston and spring wavy washer onto the air shaft and use small external snap ring pliers to secure the air piston snap ring in the snap ring groove Check the snap ring fit to make sure secures the air piston and wavy washer to the air shaft head The air piston should compress upward slightly with spring resistance from wavy spring washer and snap ring Expand the snap ring just enough to re install it onto the air shaft Over extending the snap ring can permanently damage it and cause air spring assembly failure 9 Slide the air sleeve negative piston assembly from the air shaft Spray the air shaft with isopropyl alcohol and wipe it with a clean rag 10 Remove the top out bumper and kick plate from the air sleeve negative piston 11 Use a pick to remove the inner and outer negative piston o rings Apply grease to the new o rings and install them When using a pick to remove o rings do not scratch the negative piston Scratches
17. et wrench to tighten the top cap to 7 3 N m 65 in lb REBOUND DAMPER SERVICE ARGYLE R DART 2 DOMAIN RECON SILVER 289 INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs DAMPER SERVICE INSTRUCTIONS Use 24 socket wrench to unthread the top cap Once removed clean the upper tube 1 threads with a rag 2 Remove the fork from the bicycle stand and pour the oil into an oil pan 3 Turn the fork upside down and push the rebound damper shaft through the shaft guide seal head Use a long dowel rod to push the damper piston past the upper tube threads and remove the damper from the upper tube 4 Remove the rebound damper piston o ring glide ring Apply a few drops of RockShox suspension oil to the new o ring glide ring and install it 5 Argyle R Domain R Recon Silver R and Tora 289 only Use a pick to remove the damper inner seal head o ring located in the bottom of the upper tube Apply a few drops of RockShox Suspension oil to a new o ring and install it If using a pick to remove o rings do not scratch the o ring glands Scratches may cause oil to leak 6 Clamp the fork back into the bicycle stand Apply grease to the upper tube threads Insert the rebound damper back into the drive side upper tube
18. ithout prior notice For the latest technical information please visit our website at www sram com Your product s appearance may differ from the pictures diagrams contained in this catalog Product names used in this document may be trademarks or registered trademarks of others TABLE CONTENTS cect pace cst mca 5 TOOLS NEEDED FOR SERVICE 6 PARTS NEEDED FOR SERV UGE viii oes 6 TECHNOLOGY AND OILVOLUMES 7 TIGHTENING VALUES 7 LOWER LEG BUSHING INSPECTION 8 LOWER LEG REMOVAL 9 LOWER LEG SEAL SERVIGE 11 OTE SPRING a 13 RECON SILVER RECON GOLD SEKTOR TORA SPRING SERVICE 14 RECON SILVER
19. l amper m wt wt pring m wt wt a L Technology Drive Side Upper Tube Side Upper Tube 3 0 soca 3 Recon Silver TORQUE TIGHTENING VALUES The following chart is a summary of the primary torque tightening values for Recon Silver forks The torque tightening values for fasteners that require a specific torque are detailed in the text of each service section Torque Value Top Cap 7 3 N m 65 in Ib Brake Caliper Mounting Bolts Cantilever Linear Pull 5 7 N m 43 61 in Ib Bottom Bolt Shaft Nut 6 8 N m 60 in Ib Brake Caliper Mounting Bolts Post Mount 10 2 N m 90 in Ib 7 GEN 0000000003196 REV A LOWER LEG BUSHING INSPECTION INTRODUCTION Suspension fork bushings are considered wear and tear parts The rate and amount of wear will depend the frequency of fork service frequency of riding riding terrain rider body weight and type of fork If your bushings are worn you will need to replace your lower leg assembly The following chapter covers how to check for bushing wear CHECK FOR BUSHING WEAR Method 1 Check for bushing wear while the fork is installed on the bike 1 Compress the fork 5 times circulate lower leg lubrication 2 Wrap your fingers around the lower leg just below the the dust seal Hold the front brake lever tight while rocking the bike back and fo
20. le pinch bolt and remove the cable You do not need to remove the remote cable spool 2 Unthread the compression damper top cap with 24 socket and socket wrench 3 Remove the compression damper by pulling up and gently rocking it from side to side If the fork Is equipped with a remote lockout feature be sure to remove the remote compression damper cable stop clamp which is located under the compression damper top cap Once removed clean the upper tube threads with a rag 4 Remove the compression damper top cap O ring and piston o ring Apply few drops of RockShox suspension oil to the new o rings and Install them 5 Remove the fork from the bicycle stand and pour the oil into an oil pan 6 Turn the fork upside down and push the rebound damper shaft through the shaft guide seal head Use a long dowel rod to help push the damper piston past the upper tube threads and remove the damper from the upper tube OPTIONAL COMPRESSION DAMPER UPGRADE NON REMOTE TO REMOTE ADJUST Upgrading from a non remote compression adjust fork to a remote compression adjust from a crown mounted adjuster knob to a remote PopLoc or PushLoc lever adjuster requires replacing the non remote compression damper with a remote compression damper and cable stop clamp The remote return spring is integrated into the compression damper and is required for use with the PopLoc and PushLoc remote lever assembly DAMPER SERVICE INSTRUCTIONS CONTIN
21. leg may still be engaged Re install the shaft bolt s 2 to 3 turns or re install the shaft nut flush with the threaded shaft end and repeat Step 6 Do not hit the brake arch with any tool when removing the lower leg as this could damage the fork Remove the lower leg from the fork by pulling it downward holding onto both legs or the brake arch Spray isopropyl alcohol on and into the lower leg assembly Wipe the lower legs clean then wrap a clean rag around a dowel and clean the inside of each lower leg LOWER LEG SEAL SERVICE INTRODUCTION Suspension fork seals are considered wear and tear parts and require regular maintenance depending on the frequency of riding riding terrain and type of fork The more you ride the more frequently your seals need to be replaced The following chapter covers wiper and oil seal removal and installation At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs LOWER LEG SEAL REMOVAL Select side of the lower leg to work on first Oil seal If your fork has a black oil seal between the dust wiper and the upper bushing position the of a downhill tire lever or large head screwdriver between the lower lip of the black oil seal and the upper bushing No oil seal If your fork d
22. ly from the remote system 5 If replacing the cable housing detach the cable housing and end caps from the lever and the cable housing stop on the fork 25 10 CABLE INSTALLATION INSTRUCTIONS If replacing the cable housing attach the new housing and end caps to the remote lever and the cable housing stop on the fork Be sure to use compressionless shift housing cut to an adequate length to accomodate for travel change and suspension movement PopLoc and PopLoc Adjust only Push the release button to verify the remote is in the Unlocked position PopLoc Adjust only Turn the blue compression adjustment dial counter clockwise until it stops Insert the tip of a new shifter cable into the port on the lever and feed the cable through the housing and the cable housing stop on the fork Pull the cable until the cable head 15 seated completely in the remote lever PushLoc only Once the cable head is seated in the remote lever body close the cable hatch cover and push the lever to return it to the Unlocked position BlackBox Motion Control Lyrik RLR and Lyrik RLR only Wrap the cable around the spool and insert it through the cable fixing port While pulling the cable firmly use a 2 mm hex wrench to tighten the cable pinch bolt to 0 9 N m 8 in lb Cut the excess cable leaving 30 mm protruding from the cable fixing port Cap the end of the cable with non flanged or road style cable end Tuck the ca
23. oes not have a black oil seal between the dust wiper and the upper bushing place the tip of the tool underneath the lower lip of the wiper seal If you use a flat head screwdriver make sure it has round shaft A screwdriver with a square shaft will damage the fork leg 2 Stabilize the lower leg upright on a bench top or on the floor Hold the lower leg firmly and use downward force on the tool handle to leverage the seal s out Keep the lower leg assembly stable Do not allow the lower legs to twist in opposite directions compress toward each other or be pulled apart This will damage the lower leg assembly 3 If your fork has an oil foam ring remove it with your fingers 4 Repeat steps 1 3 forthe other side of the lower leg 5 Spray isopropyl alcohol on and into the lower leg Wipe the lower legs clean then wrap a clean lint free rag around a dowel and clean the inside of each lower leg 11 12 LOWER LEG SEAL INSTALLATION Foam ring installation If your fork has foam rings soak the new foam rings in 15wt RockShox suspension oil Insert a new oil saturated foam ring into each side of the lower leg Oil seal installation Position the oil seal with the grooved side visible onto the stepped side of the seal installation tool Hold one of the lower legs firmly and use the seal installation tool to push the oil seal evenly and completely into that leg Repeat for the other leg Be sure to
24. rth you may need someone to do this for you while you hold the lower leg If you hear or feel any knocking at the lower leg the bushings are worn OR Method 2 Check for bushing wear while the fork 15 removed from the bike 1 Compress the fork 5 times to circulate lower leg lubrication 2 Brace fork on a table or the floor to hold it steady Hold the fork crown tight in one hand and the brake arch the other hand Try to move the brake arch back and forth If you hear or feel any knocking the bushings are worn If you have determined that the bushings are worn you will need to replace the lower leg assembly Reference the 2011 RockShox Spare Parts Catalog for information on the correct lower leg and correspoding part number for your fork LOWER LEG REMOVAL INTRODUCTION Removing the lower legs 15 the first step in servicing your fork Once you have removed your fork lower legs you ll be ready to move onto the next section LOWER LEG REMOVAL Coil forks Proceed to Step 4 Air forks Remove the positive air chamber valve cap from the top cap located on the non drive side fork leg If the fork also has a negative air chamber remove the valve cap located at the bottom of the non drive side air chamber The positive air chamber valve cap for 2 Step Dual Position Air forks is located at the bottom of the non drive side fork leg 3 Depress the Schrader valve and release all of the
25. shaft first and push the piston into the upper tube 7 Use along dowel rod to push the rebound damper into the upper tube Guide the rebound damper shaft through the damper shaft guide seal head at the bottom of the upper tube and pull the shaft through by hand into the fully extended position 17 DAMPER SERVICE INSTRUCTIONS 8 Orient the fork upright in the bicycle stand Measure and slowly pour 5wt RockShox suspension oil into the upper tube using the volumes listed in the chart below Oil volume is critical Too much oil reduces available travel too little oil decreases damping performance 011 Volume 3 mL Argyle R Dart 2 Domain R Tora 289 Recon Silver R Press the top cap down into the upper tube threads and hand tighten it Use a 24 mm socket wrench to tighten the top cap to 7 3 N m 65 in Ib TURNKEY DAMPER SERVICE DART 2 3 RECON SILVER TK TORA 302 TK INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs DAMPER SERVICE INSTRUCTIONS Crown Mount only Use external snap ring pliers to remove the external snap ring from the compression adjuster knob Remove the adjuster knob and o ring Remote only Use a 2 hex wrench to loosen the cab
26. tend through the shaft bolt hole Wipe all excess oil from the outer surface of the lower legs careful not to spill any oil from the lower leg as you install it onto the upper tubes Make sure both dust seals slide onto the upper tubes without folding the outer lip of either seal Inspect and clean the damper and air spring shaft bolts nut nylon crush washers and crush wash retainers Replace crush washers and crush washer retainers if damaged You must clean dirty crush washers and replace flattened or deformed crush washers and or crush washer retainers Dirty or damaged crush washers can cause oil to leak from the fork Insert the shaft bolts into the threaded shaft ends through the lower leg shaft holes or air shaft nut onto the threaded shaft end and tighten with a 5 mm hex bolt or 10 mm socket wrench nut to 7 3 N m 65 in Ib For hollow bottom fork legs you will need to use a socket extension for the 5 mm bolt and a deep 10 mm socket to thread the Dual Air shaft nut For forks with an external rebound adjuster insert the external rebound damper knob into the rebound damper shaft bolt Push it in until secure Adjust as desired For air sprung forks refer to the air chart on your fork and inflate the positive and negative if applicable air chamber s to the appropriate pressure Spray isopropyl alcohol on entire fork and wipe it with a clean rag For air sprung forks thread the positive and negative
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