2016 Lyrik
Contents
1. Coupler Cartridge Tube Air Valve Cap Knob Retaining Nut DPA Adjuster Knob DPA Top Cap Dual Position Air DPA Bottomless Token s DPA Piston Top Out Bumper Backup Ring Wave Spring DPA Seal Head Retaining Ring Damper Seal Head Air Shaft Rebound Damper Shaft Bottom Bolt Y Bottom Bolt Rebound Adjuster Knob Set Screw Exploded View RCT3 Dual Position Air 5 Exploded View RC Solo Air Air Shaft Assembly Compression Damper Assembly Rebound Damper Assembly 2 Knob Retaining Nut Low Speed Adjuster Knob ___ Compression Top Cap Assembly RC Retaining Rings lt D LL Bleed Plug Compression Adjuster 1 4 Compression Top Cap Assembly anos Bladder Coupler Low Speed Compression Needle Cartridge Tube Bladder Sleeve SSS Bladder Compression Piston Assembly Coupler Damper Seal Head By Air Valve Cap SA Top Cap Bottomless Token s Solo Air SA SA Piston Top Out Bumper Backup Ring Wave Spring SA Seal Head Retaining Ring Air Shaft Rebound Damper Shaft Bottom soit Y y Bottom Bolt Rebound Adjuster Knob Set Screw Exploded View RC Solo Air 6 RockShox Suspension Service We recommend that you2. GEN 0000000005042 Rev A 2015 SRAM LLC SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein 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 is required Except as described herein SRAM makes no other warranties guaranties or representations of any type express or implied and all warranties including any implied warranties of reasonable care merchantibility or fitness for a particular purpose are hereby disclaimed LOCAL LAW 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 a Preclude the disclaimers and limitations of thi
3. 15 20 in lb Air Spring Installation 25 Damper Service Charger Damper Removal NOTICE Use aluminum soft jaws to protect the Charger Damper assembly when using a vise 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 isopropyl alcohol on each part and clean with a rag Apply SRAM Butter grease to the new seal or o ring RCT3 Use a 2 mm hex wrench to remove the low speed adjuster knob screw Remove the low speed adjuster knob Use a6 mm socket wrench to remove the knob retaining nut Remove the compression mode adjuster knob RC Use a 4 mm hex wrench to remove the knob retaining nut Remove the low speed adjuster knob Damper Service 26 2 Use a 30 mm socket wrench to loosen the damper top cap Remove the Charger Damper assembly from the upper tube Clean the upper tube threads with a rag Use your fingers or a pick to remove the compression top cap o ring Use your fingers to install a new o ring Clamp the cartridge tube into a bicycle stand with the 4 rebound damper shaft oriented upward Place a 21 mm open end wrench on the wrench flats of the cartridge tube Place a 23 mm open end wrench on the damper seal head Holding the cartridge tube in place turn the damper seal head counter clockwi
4. a 24 mm socket wrench to remove the top cap from the upper tube Spray isopropyl alcohol on the upper tube threads and clean the threads with a rag 3 Use your fingers or a pick to remove the top cap o ring Use your fingers to install a new o ring Do not apply grease to the top cap threads Air Spring Removal 16 4 Dual Position Air Push the air shaft into the upper tube to prevent it from getting scratched while removing the retaining ring NOTICE Scratches on the air shaft will allow air to bypass the seal head into the lower leg resulting in reduced spring performance Use a flat blade screwdriver to push the seal head tab under the retaining ring Place the tips of large internal retaining ring pliers into the eyelets of the retaining ring Press firmly on the pliers to push the seal head into the upper tube enough to compress and remove the retaining ring Solo Air Use a flat blade screwdriver to push the SA seal head tab under the retaining ring Place your finger over the end of the air spring shaft to prevent it from getting scratched while removing the retaining ring NOTICE Scratches on the air shaft will allow air to bypass the seal head into the lower leg resulting in reduced spring performance Place the tips of large internal retaining ring pliers into the eyelets of the retaining ring Press firmly on the pliers to push the SA seal head into the upper tube enough to compress and remove th
5. in Lyrik comes with additional shims installed on the piston to allow the rider to modify the rebound tune If your rebound setting is one or two clicks from open we recommend changing to a soft tune on the rebound If your rebound setting is one or two clicks from closed we recommend changing to a firm tune on the rebound All Charger Dampers in Lyrik ship with the Medium Damper Tune installed Optional Rebound Re tune Clamp the bottom of the rebound damper shaft into a RockShox Rear Shock Vise Block NOTICE To prevent damage to the rebound damper shaft do not clamp the middle of the shaft in the vise 2 Use a 10 mm socket to remove the piston nut Use your hand to stabilize the rebound damper shaft 3 Use a small wrench or pick to slide the shims off of the rebound damper piston Set the shims on a rag in the order they came off of the piston Small wrench Optional Charger Damper Re tune 34 4 Use the chart below to layout the shim stack for your desired tune on your rebound damper piston Use a metric caliper to verify the shim outer diameter and shim thickness or print the page at 100 scale to arrange the shim stack using the outlines on the page All Charger Dampers in Lyrik ship with the Medium Damper Tune installed 100 mm Print this page at 100 scale and use the chart to layout your desired rebound tune Medium Rebound Tune Stock Tune 1 1 Shim Size 1 1 Shim 1 1 Shim Size 1 1 Shi
6. A SA FA EA 4 4 4 4 4 s 4 4 ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No 1598 8 Chung Shan Road 1000 W Fulton Market 4th Floor Paasbosweg 14 16 Shen Kang Hsiang Taichung City Chicago Illinois 60607 3862ZS Nijkerk Taiwan R O C USA The Netherlands
7. RockShox Spare Parts Catalog available on our website at sram com service for spare part details For ordering information please contact your local SRAM distributor or dealer DPA Solo Air Travel and Bottomless Token Tuning 29 Wheel 27 5 Wheel Factory Installed Maximum Bottomless Tokens Bottomless Tokens Factory Installed Maximum Lyrik Yari travel Bottomless Tokens Bottomless Tokens Lyrik Yari travel 180mm O 4 170mm 1 4 160mm 2 5 160mm 2 5 150mm 2 5 150mm 2 5 140mm amp 6 140mm 5 6 130mm 3 6 130mm 3 6 120mm 4 7 120mm 4 7 Dual Position Air Travel and Bottomless Token Tuning 29 Wheel 27 5 Wheel Factory Installed Maximum Factory Installed Maximum Lyrik Yari travel Lyrik Yari travel Bottomless Tokens Bottomless Tokens Bottomless Tokens Bottomless Tokens 180mm O 4 gt 170mm 5 160mm 1 5 160mm 1 5 150mm 1 6 150mm 1 6 Spring Service 14 Air Spring Removal 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 isopropyl alcohol on each part and clean with a rag Apply SRAM Butter grease to the new seals and o rings Dual Position Air Use a 10 mm socket wrench to remove the DPA travel adjuster knob retaining nut Remove the DPA travel adjuster knob Air Spring Removal 15 2 Use
8. S TOKEN TUNIN Cn raid 14 DUAL POSITION AIR TRAVEL AND BOTTOMLESS TOKEN TUNING trs ee ee 14 AIR OFRING REMOVA eases RSS Concrete o et De e 15 AR SERINSGANS TALLA TON e 0 23 DAMPER A non asc nes nn en dr ds aa et sens amendes Tan ne ROEE ea aa is mc cr encens cents aeai bas i n sise 26 CHARGER DAMPERSMREMOVALE ai a Sat tenia Nia dee tn ne tas eS 26 OPTIONAL CHARGER DAMPER RE TUNE cs a ads 34 OPTIONAL REBOUND RE T NE ne nn cn n se aaa e aiana anoda a Aaaa a aaa Rae malt et tea ain mn ins fans 34 CHARGER DAMPER ASSEMBLY AND BLEED cuca a ne nt a a nets pidio 37 LOWER LEG ASSEMBLY sonia nds ste net ee mns ec enn ns neo os esse ca Sens sas uns memes mens rss Masson essences ee A des ce se sense 49 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 Exploded View RCT3 Dual Position Air y Air Shaft Assembly 4 Knob Retaining Screw Compression Damper Assembly Ar Low Speed Adjuster Knob Rebound Damper Assembly Knob Retaining Nut RCTS 2 Compression Mode Adjuster Knob es Retaining Rings ED Low Speed Compression Adjuster Compression Top Cap Assembly Bladder Compression Cam Assembly Low Speed Compression Needle Compression Top Cap Assembly Bladder Sleeve Bladder Compression Piston Assembly
9. Volume 2 Volume Technology Volume Volume mL nome mL mL mL pamper Height Solo Air Charger Bleed 10 mL Ow 30 Grease 10 mL Ow 30 Dual RCT3 Position Air Fluid height meaurements are taken from the top of the crown surface above the upper tube to the fluid Record Your Settings 8 Lower Leg Removal Remove the air valve cap from the top cap located on the spring side fork leg 2 Use a small hex wrench to depress the Schrader valve and release all air pressure from the air chamber Use a Schrader valve core tool to remove the valve core from the valve body Cycle the lower leg a few times to release the remaining trapped air Install a new Schrader valve core 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 3 Use a 2 5 mm hex wrench to loosen the set screw and remove the rebound adjuster knob located at the bottom of the damper side fork leg Lower Leg Removal 9 Use a 5 mm hex wrench to loosen both bottom bolts 3 to 4 turns Place an oil pan beneath the fork to catch any draining fluid Use a rubber mallet to firmly strike each bottom bolt to dislodge the air and damper shafts from the lower leg Use a 5 mm hex wrench to remove the bottom bolts from the lower leg Firmly pull the lower leg downward until fluid begins to drain Continue pulling downward to remove the lower leg fr
10. aining ring then use the pliers to push the seal head into the upper tube while installing the retaining ring into the groove Use your finger or thumb to hold the retaining ring in place while seating the retaining ring eyelets on either side of the seal head tab NOTICE Do not scratch the air spring shaft Scratches on the air shaft will allow air to bypass the seal head into the lower leg resulting in reduced spring performance 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 down on the air shaft Retaining rings have a sharper 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 Air Spring Installation 24 Install the air soring top cap into the top of the upper tube Use a torque wrench with a 24 mm socket to tighten the top cap to 28 N m 250 in lb Dual Position Air Place the DPA adjuster knob and the knob retaining nut onto the top cap with the long tab near the front of the crown Turn the DPA adjuster knob counter clockwise until it engages the first detent space Thread the knob retaining nut onto the threaded air valve body Use a torque wrench with a 10 mm socket to tighten the knob retaining nut to 1 7 2 2 Nem 15 20 in lb 26 Nem 250 in lb 1 7 2 2 Nem
11. ches 2 2 5 3 4 and 5 mm hex bit sockets 21 23 and 25 mm open end wrenches 15 mm cone wrench 23 and 25 mm crowfoot wrenches 5 8 bit socket Torque wrench Pick Needle nose pliers Bench vise with aluminum soft jaws Rubber mallet Large internal retaining ring pliers Small internal retaining ring pliers Long plastic or wooden dowel Flat blade screwdriver Graduated cylinder mL SAFETY INSTRUCTIONS Always wear safety glasses and nitrile gloves when working with suspension fluid Place an oil pan on the floor underneath the area where you will be working on the fork NOTICE Use aluminum soft jaws to protect the Charger Damper assembly when using a vice RockShox Suspension Service 7 Record Your Settings Use the charts below to record your fork settings to return your fork to its pre service settings Record your service date to track service intervals Service date helps you keep track of service intervals Rebound setting count the number of clicks while turning the rebound adjuster fully counter clockwise Compression setting count the number of clicks while turning the compression adjuster fully counter clockwise Service Interval Information Fastener Torque Values Pato Too torque Bottom bolts 5 mm hex bit socket 7 3 Nem 65 in lb 24 and 30 mm sockets 28 Nem 250 in lb Fluid Volume ae Side Spring Side UpperTube Tube Lower Lowerleg Upper Tube Spring Technology
12. d adjuster knob in place during installation to prevent damage to the bottom bolt Lower Leg Assembly 50 Refer to the air chart on the fork lower leg and pressurize the air spring to the appropriate pressure for your rider weight 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 to the recommended air pressure NOTICE Pressure in the positive and negative air chambers must be equalized after inflation to get an accurate pressure reading Cycle the fork three to five times and re check the pressure Add air pressure as needed Thread the air valve cap onto the top cap of the spring side fork leg until it stops 7 Spray isopropyl alcohol on the entire fork and clean it with a rag This concludes the service for RockShox Lyrik front suspension forks Lower Leg Assembly 5 This publication includes trademarks and registered trademarks of the following companies TORX is a registered trademark of Acument Intellectual Properties LLC SRANTTI WWwWWw sfam com We will revolutionize the relationship that our users have with SRAM products cultivating a bond between the rider and bicycle Our technical communication will be delivered in innovative and exciting ways with deliberation and accuracy that inspires loyalty and trust across the globe SRAM TechCom Vision Statement YVVVVVVVYVY RRRKRRRARAKA AEA SA SA S
13. d insert it into each lower leg to clean the inside of the lower leg 6 Install the new foam rings in the lower leg Remove the wire spring from the new dust wiper seal and set it aside Insert the narrow end of a new dust wiper seal into the recessed end of the RockShox 35 mm dust seal installation tool lt 2 Lower Leg Seal Service 12 Hold the lower leg steady and use the RockShox 35 mm dust seal installation tool to press the dust wiper seal evenly into the lower leg until the seal surface is flush with the top of the lower leg surface Reinstall the wire spring onto the dust wiper seal Repeat steps 7 8 and 9 for the other side of the lower leg NOTICE Only press the dust wiper seal into the lower leg until it is flush with the top surface of the lower leg Pressing the dust wiper seal past the top surface of the lower leg can damage the foam rings Lower Leg Seal Service 13 Spring Service Travel Change Adjustment Optional To increase or decrease the travel in your RockShox Lyrik fork the air spring shaft assembly must be replaced with the correct length Use the chart below to help determine the necessary air shaft and recommended number of bottomless tokens for your fork travel and wheel size Red DPA and grey SA bottomless tokens work on all 2016 Lyrik forks The air shaft will have the wheel size and travel information located near the bottom of the shaft Refer to the
14. de rings e Brake pads e Disc brake rotors e Aero bar pads e Rubber moving parts e Chains e Wheel braking surfaces e Corrosion e Foam rings e Sprockets e Bottomout pads e Tools e Rear shock mounting hardware e Cassettes e Bearings e Motors and main seals e Shifter and brake cables inner e Bearing races e Batteries e Upper tubes stanchions and outer e Pawls Notwithstanding anything else set forth herein the battery pack and charger warranty does not include damage from power surges use of improper charger improper maintenance or such other misuse 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 authorised by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use TABLE OF CONTENTS EXPLODED VIEW RCT3 DUAL POSITION AIR iii cw en ndsanancvdedissencsctuctadanadeudn vndtelanseetnsticesdeesteeeeeteteeds 5 EXPLODED VIEW RC SOLO AIR aida 6 ROCKSHOX SUSPENSION SERVICE aa as 7 RARTS TOOLS FIND SUPPLIESS e o ne 7 RECORD FOURSETTINES isidro ds oie ah 8 LOWER EEG REMOVAL ini incio ind caahbeaweatdesateudacuiuaawdeassausteceadaeesuseaddanabededeuasuuneaeuanawdacdeaumaaudeedeuseeareds 9 OWER CES SEAL SER MO A oor de nee rer Ame 11 SPRING SERVICE ns A A A A A A A A 14 TRAVEL CHANGE ADIISTMENTE OPTIONAL e eta 14 SOLO AIR TRAVEL ANDBO E TOMEES
15. e retaining ring Slide the retaining ring onto your finger and release the air spring shaft Air Spring Removal 17 Use your fingers to install the bottom bolt into the air shaft Firmly pull on the air shaft and bottom bolt to remove the air shaft assembly from the upper tube Unthread and remove the bottom bolt from the air shaft Clean and inspect the assembly for damage Spray isopropyl alcohol on the inside and outside of the upper tube and clean it with a rag Wrap a rag around a long dowel and insert it into the upper tube to clean inside the upper tube Remove the seal head wave spring and backup ring from the air shaft Air Spring Removal 18 Use a pick to pierce and remove the inner seal head o ring and scraper seal Use your fingers or a pick to remove the outer o ring Air Spring Removal 19 Dual Position Air Use your fingers to install a new scraper seal inner o ring and outer o ring Air Spring Removal 20 Solo Air Use your fingers to install a new inner seal head o ring into the smaller inner gland Push the o ring into the shaft hole Push one side of the o ring into the small inner gland and hold in place with your finger From the other side of the seal head push the o ring fully into the gland with the rounded end of a 5mm hex wrench Verify the o ring is fully seated in the gland NOTICE Apply grease to the tip of the hex wrench before pushing in the o rin
16. e wrench with a 6 mm socket to tighten the knob retaining nut to 3 5 4 0 Nem 30 35 in lb Make sure the knob retaining nut is not cross threaded as it can move the adjuster knob beneath it 34 RC Install the knob retaining nut While holding down the A A ms compression mode adjuster use a torque wrench with a 4 4 mm hex bit socket to tighten the nut to 4 0 5 5 Nem 40 50 in Ib RCT3 Install the low speed adjuster knob and knob retaining screw Use a torque wrench with a 2 mm hex bit socket to tighten the screw to 1 0 1 5 Nem 8 13 in Ib y Y 2 e lt Es CHARGER 1 0 1 5 Nem 8 13 in lb Charger Damper Assembly and Bleed 48 Lower Leg Assembly Spray isopropyl alcohol on the upper tubes and clean them with a rag 2 Apply a liberal amount of SRAM Butter grease to the inner surfaces of the dust wiper seals Slide the lower leg assembly onto the upper tube assembly just enough to engage the upper bushing with the upper tubes The lower leg bottom should not contact the spring or damper shaft Make sure both dust wiper seals slide onto the tubes without folding the outer lip of either seal Position the fork at a slight angle with the bottom bolt holes oriented upward Angle a syringe fitting into each lower leg bolt hole so the fluid will only contact the inside of the lower leg and not fill the shaft Using a RockShox bleed syringe inject 10 mL of RockShox Ow 30 suspension fluid into
17. eal head clockwise to tighten to 9 10 Nem 80 90 in lb Install the crowfoot onto the torque wrench at a 90 angle to the handle to ensure an accurate torque reading 9 10 Nem 80 90 in lb E Insert a 2 5 mm hex wrench into the rebound damper shaft until it contacts the rebound adjuster screw Turn the hex wrench counter clockwise until it stoos The rebound adjuster is now in the open position Charger Damper Assembly and Bleed 39 Remove the cartridge tube assembly from the bicycle stand turn it over and clamp the cartridge tube assembly in the bicycle stand so the rebound damper shaft is oriented downward Pull down on the rebound damper shaft Pour RockShox 3wt suspension fluid into the cartridge tube until it is approximately half full 7 Use the palm of your hand or a rag to cover the cartridge tube and cycle the rebound damper shaft a few times to help pre bleed air from the damper Pull down on the rebound damper shaft Pour additional RockShox 3wt suspension fluid into the cartridge tube until the fluid is level with the top of the tube Use your finger to wipe any air bubbles from the surface of the fluid Pull the rebound damper shaft down slowly Failure to do so can result in fluid ejecting from the cartridge tube Wear safety glasses Charger Damper Assembly and Bleed 40 Wrap a rag around the cartridge tube Insert the compression piston assembly into the cartridge tube S
18. entered between the ends of the sleeve 2 Apply a liberal amount of SRAM Butter onto both ends of the bladder Thread the compression top cap and coupler into either side of the bladder assembly Charger Damper Assembly and Bleed 37 3 Clamp the coupler wrench flats into a vise with the compression top cap facing upward Use a torque wrench with a 30 mm socket to tighten the compression top cap to 4 5 5 6 Nem 40 50 in lb NOTICE Ensure the bladder does not twist during installation If the bladder starts to twist unthread the compression top cap and coupler and repeat steps 1 3 4 5 5 6 Nem 40 50 in lb Spray isopropyl alcohol on the inside and outside of the cartridge tube and clean it with a rag Wrap a rag around a long dowel and insert it into the cartridge tube to clean inside the upper tube gt ii AN EN AA Install the new seal head assembly onto the rebound damper shaft with the threads oriented toward the piston 5 Charger Damper Assembly and Bleed 38 Lightly clamp the cartridge tube into a bicycle stand with the threads at the bottom and wrench flats at the top Thread the rebound assembly into the cartridge tube by hand 7 Place a torque wrench with a 23 mm crowfoot open end wrench on the wrench flats on the damper seal head Place a 21 mm open wrench on the wrench flats of the cartridge tube While holding the cartridge tube in place turn the s
19. equential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM user manual The SRAM user manuals can be found online at sram com rockshox com avidbike com truvativ com or Zipp com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not apply when the product has been modified including but not limited to any attempt to open or repair any electronic and electronic related components including the motor controller battery packs wiring harnesses switches and chargers 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 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 e Dust seals e Stripped threads bolts aluminium Handlebar grips e Transmission gears e Bushings titanium magnesium or steel e Shifter grips e Spokes e Air sealing o rings e Brake sleeves e Jockey wheels e Free hubs e Gli
20. g to avoid damage to the o ring Install a new scraper seal and a new seal head o ring Use your fingers to remove the bumper cone from the air shaft Install a new bumper cone with the wide side facing the piston Air Spring Removal 21 11 Dual Position Air Use your fingers or a pick to remove the outer air piston o ring Use a pick to pierce and remove the inner o ring Use your fingers to install new o rings Solo Air Use your fingers or a pick to remove the air piston quad ring Use your fingers to install a new quad ring Air Spring Removal 22 Air Spring Installation Apply a liberal amount of SRAM Butter grease to the new air piston Install anew backup ring and wave spring in that order onto the air shaft Install the seal head onto the air shaft 3 Apply a liberal amount of SRAM Butter grease to the seal head Air Spring Installation 23 4 5 Firmly push the air shaft assembly into the bottom of the upper tube while gently rocking the air shaft side to side Make sure the shaft remains fully extended Use your fingers to firmly press the seal head into the upper tube until it snaps into place Use your fingers to position the retaining ring into the bottom of the upper tube retaining ring groove The seal head tab should be positioned between the retaining ring eyelets Place the tips of large internal retaining ring pliers into the eyelets of the ret
21. g to be seated in its grove RC The bleed plug must be installed properly for the retaining ring to be seated in its grove Charger Damper Assembly and Bleed 45 Remove the rebound bolt from the rebound damper shaft Spray isopropyl alcohol on the Charger Damper assembly and clean it with a rag te Insert and thread the Charger Damper into the top of the damper side upper tube Use a torque wrench with a 30 mm socket to tighten the compression top cap to 28 Nem 250 in lb Charger Damper Assembly and Bleed 46 RCTS Use a 15 mm socket wrench to turn the compression cam assembly counter clockwise until it stops RC Use a 15 mm socket wrench to turn the low speed compression adjuster clockwise until it stops 32 RCTS Place the low speed adjuster knob onto the compression top cap with the long tab near the front of the crown Turn the compression mode adjuster clockwise until it engages the first detent space RC Place the compression mode adjuster knob onto the compression top cap with the long tab near the back of the crown Turn the compression mode adjuster counter clockwise until it engages the first detent space Charger Damper Assembly and Bleed 47 33 RCT3 Thread the knob retaining nut into the compression NOS lo cam assembly While holding down the compression mode adjuster knob tighten the knob retaining nut Turn the knob clockwise through both clicks until it stops and use a torqu
22. 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 Instructions apply to 15x100 and Boost 110 forks Specific part information part number information and exploded diagrams can be found in the RockShox Spare Parts Catalog available on our website at sram com service For order information please contact your local SRAM distributor or dealer Information contained in this publication is subject to change at any time without prior notice For the latest technical information please visit our website at sram com service Your product s appearance may differ from the pictures contained in this publication Parts Tools and Supplies Parts e RockShox Lyrik Service Kit Safety and Protection Supplies e Safety glasses e Nitrile gloves e Apron e Oil pan e Clean lint free rags Bicycle Tools e Downhill tire lever e Bicycle work stand RockShox Tools e RockShox Rear Shock Vise Block e RockShox 35 mm dust seal installation tool e RockShox Bleed Syringe with Charger bleed tip e RockShox shock pump 300 psi max Lubricants and Fluids e SRAM Butter grease e RockShox 3wt suspension fluid e RockShox Ow 30 suspension fluid e Loctite Threadlocker Blue 242 e Isopropyl alcohol Common Tools 6 10 15 24 and 30 mm socket wrenches 2 2 5 3 4 and 5 mm hex wren
23. ining ring pliers to remove the retaining ring from the low speed compression adjuster Charger Damper Removal 29 RC Use small retaining ring pliers to remove the retaining ring from the bleed plug 14 RCT3 Use needle nose pliers to remove the low speed compression adjuster from the compression top cap Use a pick to remove the o ring on the low speed compression adjuster Use your fingers to install a new o ring RC Use needle nose pliers to remove the bleed plug from the compression adjuster Use a pick to remove the o ring on the bleed plug Use your fingers to install a new o ring RCT3 Use small retaining ring pliers to remove the retaining ring from the compression cam assembly RC Use small retaining ring pliers to remove the retaining ring from the compression adjuster Charger Damper Removal 30 16 RCT3 Use a 2 5 mm hex wrench to remove the low speed compression needle RC Use a 4 mm hex wrench to remove the low speed compression needle RCT3 2 5 mm 17 RCT3 Use needle nose pliers to grasp the wrench flats on the compression cam assembly Pull the compression cam assembly out of the bladder assembly Use your fingers or a pick to remove the o ring on the compression cam assembly Use a pick to pierce and remove the inner o ring Use your fingers to install the new o rings RC Use needle nose pliers to grasp the wrench flats on the compression adjuster Pull the compression ad
24. juster out of the bladder assembly Use your fingers or a pick to remove the o ring on the compression adjuster Use your fingers to install a new o ring Charger Damper Removal 31 Use a 30 mm socket wrench to loosen and remove either the coupler or the compression top cap assembly from the bladder assembly whichever loosens first Remove the assembly from the vise Clamp a 5 8 bit socket into a vise If the compression top cap came off in the previous step set the bladder assembly on the bit socket with the coupler oriented upward Use a 25 mm open end wrench to remove the coupler If the coupler came off in the previous step set the bladder assembly on the bit socket with the compression top cap ori ented upward Use a 30 mm socket wrench to remove the coupler Use your fingers or a pick to remove the o ring on the compression top cap assembly Use your fingers to install a new o ring Charger Damper Removal 32 2 Use your fingers or a pick to remove the o ring inside the coupler Use your fingers to install a new o ring Do not apply grease to this o ring Use your fingers to remove the bladder from the bladder sleeve Inspect the bladder for tears or cracks If there are any tears or cracks replace the bladder Spray isopropyl alcohol on the bladder and bladder sleeve and clean them with a rag Charger Damper Removal 33 Optional Charger Damper Re tune The Charger Damper
25. m Outer Dimension Thickness Outer Dimension Thickness mm mm mm mm Soft Rebound Tune P Shim diameter 0 3 o PR 0 1 o PE 0 1 0 2 01 03 O1 Piston Face Bottom of stack 16 Hoop 0 2 Piston Face Bottom of stack If using the soft tune 16 x 6 x 0 1 14 x 6 x 0 1 and 16 x 14 x 0 2 are not used Save them so they can be reinstalled if you change your tune to Medium or Firm r Shim thickness Firm Rebound Tune 1 1 Shim Size 1 1 Shim Outer Dimension Thickness mm mm O gt 0 2 gt Piston Face Bottom of stack Optional Rebound Re tune 35 5 Install the shims on a small wrench or pick in the order of your Off center hoop shim desired tune Slide the shim stack onto the piston face Use your fingers to squeeze the stack and center the shims NOTICE Ensure the hoop shim is centered on the shim stack Centered shim stack Thread the main piston nut onto the rebound damper piston Use a torque wrench with a 10 mm socket to tighten the nut to 3 7 Nem 33 in lb NOTICE Ensure the check shim is centered and not pinched under the piston Remove the assembly from the vise Pinched check shim Centered check shim Optional Rebound Re tune 36 Charger Damper Assembly and Bleed fa Use your fingers to install the bladder onto the bladder sleeve Ensure that it is c
26. nd then unthread it 1 4 of a turn Charger Damper Assembly and Bleed 42 19 RCT3 Insert the compression cam assembly into the bladder assembly and turn it clockwise to lock it into place RC Insert the compression adjuster into the bladder assembly and turn it clockwise to lock it into place 20 RCT3 Use retaining ring pliers to install the outer retaining ring to secure the compression cam assembly Use a rag to soak up excess fluid RC Use retaining ring pliers to install the outer retaining ring to secure the compression adjuster Use a rag to soak up excess fluid 21 Use your fingers to install the bottom bolt into the rebound damper shaft then pull down on the bottom bolt to extend the shaft Fill the bleed syringe half full with 3wt suspension fluid and thread the syringe into the compression top cap assembly Use a 15 mm cone wrench to turn the compression cam assembly counter clockwise to the open position Charger Damper Assembly and Bleed 43 Create a vacuum in the damper assembly by pulling up on the syringe handle and simultaneously pushing up on the rebound damper shaft This will force bubbles out of the damper assembly Pressurize the damper assembly by pushing down on the syringe handle and simultaneously pulling down on the rebound damper shaft Continue to hold down on the syringe handle and simultaneously cycle the rebound damper shaft a few times to purge bubbles The bladder will ex
27. om the fork If the lower leg does not slide off of the upper tubes or if fluid does not drain from either side the press fit of the shaft s to the lower leg may still be engaged Reinstall the bottom bolts 2 to 3 turns and repeat the previous step NOTICE Do not hit the fork arch with any tool when removing the lower leg as this could damage the fork 2 Lower Leg Removal 10 Lower Leg Seal Service Place the tip of a downhill tire lever underneath the lower lip of the dust wiper seal NOTICE If using a flat blade screwdriver make sure it has a round shaft A screwdriver with a square shaft will damage the fork leg Wrap a rag around the screwdriver to protect the lower leg 2 Stabilize the lower leg on a bench top or on the floor Press down on the tire lever handle to remove the dust wiper seal Repeat on the other side Discard the dust seals after they are removed NOTICE Keep the lower leg assembly 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 HUB 3 Use your fingers to remove and discard the foam rings inside the lower leg Soak the new foam rings in RockShox Ow 30 suspension fluid e aye Lower Leg Seal Service 11 5 Spray isopropyl alcohol on the inside and outside of the lower leg Clean the outside of the lower leg with a rag Wrap a rag around a long dowel an
28. pand and contract This is normal Repeat pulling a vacuum and pressurizing the damper assembly until only very small bubbles emerge from the damper assembly Make sure the rebound damper shaft is fully extended Push the syringe handle down and release it Allow the bladder to come to its natural resting position by waiting a few moments until the syringe stops filling Use a rag to cover the bleed tip and charger bleed port then unthread and remove the syringe Fluid may eject from the bladder assembly if the bladder is not in its resting position Wear safety glasses Charger Damper Assembly and Bleed 44 RCT3 Use a 2 5 mm hex wrench to thread the low speed compression needle into the bladder assembly clockwise until it stops and then unthread it 1 4 of a turn 26 RCTS Insert the low speed compression adjuster into the compression cam assembly Push down and turn the low speed compression adjuster clockwise until it clicks into place RC Use needle nose pliers to insert the bleed plug into the compression adjuster until it clicks into place 27 Use retaining ring pliers to install the inner retaining ring into the retaining ring groove Check that 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 RCT3 The low speed compression adjuster must be installed properly for the retaining rin
29. pray isopropyl alcohol on the cartridge tube threads and clean the threads with a rag 13 Spray isopropyl alcohol on the threads inside the coupler and clean the threads with a rag 14 Apply a small amount of Loctite Threadlocker Blue 242 to the coupler threads NOTICE Do not allow the Loctite to come in contact with the o rings or bladder Thread the coupler onto the cartridge tube by hand 15 Place a torque wrench with a 25 mm crowfoot open end wrench on the wrench flats of the coupler Place a 21 mm open end wrench on the wrench flats on the cartridge tube While holding the cartridge tube in place tighten the coupler to 9 10 Nem 80 90 in lb Install the crowfoot onto the torque wrench at a 90 angle to the handle to ensure an accurate torque reading 9 10 Nem 80 90 in lb 21 mm Charger Damper Assembly and Bleed 41 Pour RockShox 3wt suspension fluid into the top cap until it is approximately half full 17 Use the palm of your hand or a rag to cover the top cap and cycle the rebound damper shaft a few times to help pre bleed air from the damper Pull down on the rebound damper shaft Pour additional RockShox 3wt suspension fluid into the top cap until the fluid is level with the top Use your finger to wipe any air bubbles from the surface of the fluid 18 RC Use a 4 mm hex wrench to thread the low speed compression needle into the compression piston assembly clockwise until it stops a
30. s 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 For Australian customers This SRAM limited warranty is provided in Australia by SRAM LLC 1000 W Fulton Market 4th Floor Chicago IL 60607 USA To make a warranty claim please contact the retailer from whom you purchased this SRAM product Alternatively you may make a claim by contacting SRAM Australia 6 Marco Court Rowville 3178 Australia For valid claims SRAM will at its option either repair or replace your SRAM product Any expenses incurred in making the warranty claim are your responsibility The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are 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 cons
31. se to loosen and remove the rebound assembly Charger Damper Removal 27 NOTICE Remove the cartridge tube from the bicycle stand and pour the suspension fluid into an oil pan Remove the seal head assembly from the rebound damper shaft Discard the damper seal head The damper seal head will be replaced in the Assembly and Bleed section Use your fingers to remove the glide ring from the rebound damper piston Use your fingers to install a new glide ring Clamp the wrench flats of the coupler into a vise with the cartridge tube oriented upward NOTICE thi Wi Do not clamp the cartridge tube in the vise S we Place a 21 mm open end wrench on the wrench flats of the TAE pus N cartridge tube Hold the coupler in place with the vise and A uzouvno turn the wrench counter clockwise to loosen and remove the 4 y t cartridge tube from the coupler Charger Damper Removal 28 Remove the coupler bladder and compression top cap assembly from the vise and pour the fluid into an oil pan While holding it over an oil pan use your fingers or needle nose pliers to remove the compression piston assembly Fluid will spill from the coupler 7 Use your fingers or a pick to remove the o ring on the compression piston assembly Use your fingers to install a new o ring 12 Clamp the wrench flats of the coupler into a vise with the top cap oriented upward Z RCT3 Use small reta
32. the damper side leg and 10 mL of RockShox Ow 30 suspension fluid into the spring side leg shaft holes NOTICE Do not exceed the recommended fluid volume per leg as this can damage the fork Lower Leg Fluid Volume Spring Side 10 mL Damper Side 10 mL Lower Leg Assembly 49 Slide the lower leg assembly along the upper tubes until it stops and the spring and damper shafts are visible through the lower leg bolt holes Use a rag to clean all excess fluid from the outer surface of the lower leg from each bottom bolt 6 Using a pick and needle nose pliers remove old crush washers Holding the crush washer with needle nose pliers unthread the crush washer from the bolt by turning the bolt counter clockwise with a 5 mm hex wrench NOTICE Dirty or damaged crush washers can cause leaks Install a new crush washer on each bottom bolt Spring Side Thread the black bottom bolt into the spring side lower leg 73 N m 65 in Ib Thread the silver bottom bolt into the damper side lower leg Use a torque wrench with a 5 mm hex bit socket to tighten the bolts to 7 3 N m 65 in lb 7 3 N m 65 in lb E Install the rebound adjuster knob onto the rebound damper 11 N m 10 in Ib bottom bolt Use a torque wrench with a 2 5 mm hex bit socket to tighten the set screw to 1 1 Nem 10 in lb Hold the reboun
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