2006 SID SERVICE GUIDE

Transcription

1 2006 SID SERVICE GUIDE For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at Names used in this manual may be trademarks or registered trademarks of others. SRAM Corporation November 2005 PN , Rev C

2 Perform service every 100 hours of riding (less depending on riding conditions and riding style). Regular maintenance ensures your RockShox suspension fork performs as it should. For bushing removal and installation, please reference the Bushing Service Guide. Right side equals rider s right; left side equals rider s left. GETTING STARTED 1. Remove fork from bicycle. 2. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes. 3. Lay tools out on work bench and create a clean work area for internals service. 4. Place oil pan under fork on floor. TOOLS Safety Glasses Clean Rags Oil Pan or Bucket Bicycle Stand / Clean Work Table/Area 24mm 6-point Socket Plastic-Faced Mallet Snap Ring Pliers (internal and external) Shock Pump 1.5mm, 2mm, 2.5mm, 5mm Hex Wrench SID Dual Air Upr Tube Retainer Removal Tool Long and Short Plastic or Wood Dowel, 3/4" Diameter (non-metallic) Torque Wrench Sharp Pick/Dental Pick Oil Mixing Syringe & Measuring cup Isopropyl Alcohol/Spray Bottle 5wt and 15wt Suspension Oil LOWER LEG REMOVAL PROCEDURES FOR 2006 SID RACE, TEAM AND WORLD CUP LOWER LEG AND DUAL AIR REMOVAL/INSTALLATION ARE THE SAME FOR EACH MODEL. REFER TO THE SID SERVICE GUIDE FOR SID RACE DAMPING INTERNALS SERVICE PROCEDURES 1. TEAM/WORLD CUP: Remove air valve cover cap from left side air top cap (fig 1a). Remove negative (bottom) air valve cap from lower air shaft (fig 1b). 1a 1b 1c 1d Depress schrader valves and remove all air from air spring chambers (fig 1c/1d). 2. Firmly pull external rebound adjuster knob from rebound damper shaft bolt (fig 2a). Using a 5mm hex wrench loosen rebound damper shaft bolt 3 to 4 full turns (fig 2b). 2a 2b 2c 2d Using an open-end 10mm wrench, loosen Dual Air shaft nut. Unthread shaft nut by hand until nut extends just past threaded shaft end (figs 2c/2d). 2 SRAM Corporation 2006 SID SERVICE GUIDE

3 3. With hex wrench in the rebound damper shaft bolt, tap the bolt free with plastic mallet. Tap the Dual Air shaft nut and free the shaft from the lower leg internally. You will feel the shaft release from the lower leg shaft bore (figs 3a/3b). 3a 3b Remove both the shaft bolt and shaft nut completely. 4. Firmly pull the lower leg assembly down by holding each leg or the brake arch (figs 4a/4b). 4a 4b 4c Remove lower leg assembly and allow all excess oil to drain into an oil pan (fig 4c). Place lower leg in oil pan to drain. 5. Spray isopropyl alcohol onto each upper tube and wipe with a clean rag. REMOVAL 6. Verify all air pressure is removed from air chamber before proceeding. Depress schrader air valve again to remove any remaining air pressure. 6a 6b 6c 6d Using a 24mm socket wrench, loosen air top cap assembly from upper tube/crown (fig 6a). Remove air top cap (fig 6b/6c). S ID D UAL A IR S PRING A SSEMBLY Remove fork from bicycle work stand and pour any oil from positive air chamber into oil pan (fig 6d). 7. Using the SID Dual Air upper tube retainer tool and an socket wrench, remove the threaded upper tube retainer. The retainer is reverse-threaded, so turn wrench CLOCKWISE to unthread (fig 7a). Righty, Loosey...Lefty, Tighty. Pull Dual Air spring shaft assembly from upper tube (figs 7b/7c/7d). You may need to release additional negative air as you pull; pressure will build up while pulling. 7a 7b 7c 7d PN , REV C 3

4 8. Spray the inside of the air spring upper tube with isopropyl alcohol (fig 8a). Wrap a clean rag around a thin dowel, insert into upper tube and wipe the inside surface clean (8b/8c). 8a 8b 8c Look inside the upper tube using a light and check for scratches. If inside of upper tube is scratched, replace CSU assembly. Scratches can cause air bypass. DISASSEMBLY & SERVICE PART KIT REQUIRED: SID SERVICE K IT ( ) 9. Slide the negative air piston sleeve from air spring shaft (fig 9a/9b). 9a 9b 9c Spray air shaft with isopropyl alcohol and wipe clean. Pinch the positive air piston o-ring and remove. Replace with a new o-ring and lubricate with 15wt suspension oil or oil soluble grease (fig 9c). 10. Pinch the positive and negative air piston o-rings and remove. Replace with new o-rings (figs 10a/10b). Using a sharp pick (a dental pick works best) remove the inner negative air piston o-ring and replace with a new o-ring. (fig 10c). Lubricate with 15wt suspension oil or oil soluble grease (fig 10d). 10a 10b 10c 10d IMPORTANT: REPLACEMENT OF AIR PISTON O-RINGS ENSURES THAT SID MAINTAINS A SOLID AIR SEAL. LUBRICATE ALL NEW O-RINGS THOROUGHLY WITH SUSPENSION OIL OR OIL SOLUBLE GREASE BEFORE INSTALLATION. 11. Slide negative air spring sleeve back onto air spring shaft (figs 11a/11b). ALL TRAVEL SPACER OPTION (DECREASE OR INCREASE TRAVEL) Install one 20mm All Travel spacer to decrease travel from 80mm to 60mm. Remove the 20mm All Travel spacer to increase travel from 60mm to 80mm. 11a 11b 80mm travel configuration pictured here. ALL TRAVEL CONFIGURATIONS THE SID DUAL AIR ALL TRAVEL SPACER IS LOCATED JUST ABOVE THE NEGATIVE SLEEVE TOP OUT BUMPER. TO INSTALL, SLIDE NEGATIVE SLEEVE DOWN AND SNAP ALL TRAVEL SPACER ONTO AIR SPRING SHAFT TO DECREASE TRAVEL. 20mm Spacer No Spacer 60mm 80mm 4 SRAM Corporation 2006 SID SERVICE GUIDE

5 12. Apply fresh 15wt suspension oil to new positive and negative air piston o-rings (figs 12a/12b). INSTALLATION 12a 12b 12c Insert positive air piston into bottom of upper tube. Push air piston/shaft assembly into upper tube (fig 12c). 13. Slide the negative air piston sleeve down air spring shaft and into bottom of upper tube (fig 13a). Continue to slide entire negative air spring sleeve into upper tube. You may need to press the negative schrader air valve as you push the negative sleeve into upper tube to release air pressure. This aids installation. 13a 13b By hand, thread the air spring assembly threaded base retainer into upper tube (fig 13b). This part is reverse threaded, so turn counterclockwise to thread into upper tube. 14. Using the SID Dual Air upper tube retainer tool and a socket wrench, press into retainer firm and square and tighten the threaded upper tube/base retainer to 30 in-lb (fig 14). 14 Remember, turn counterclockwise to tighten! 15. Position fork upright in bicycle work stand. Measure and pour, or inject, 3 to 5 cc/ml of 15wt suspension oil into positive air chamber, through crown and into upper tube (fig 15). Suspension oil on top of the positive air piston o-ring is critical to lubrication and maintenance of the air seal. 15 TIP: EVERY MONTH, RELEASE ALL POSITIVE AND NEGATIVE AIR PRESSURE AND REMOVE AIR TOP CAP. POUR OUT ANY REMAINING SUSPENSION OIL FROM POSITIVE AIR CHAMBER AND REFILL WITH 3 TO 5 CC/ML OF FRESH 15WT SUSPENSION OIL. THIS REDUCES AIR SPRING SERVICE INTERVALS AND IMPROVES THE FUNCTION OF YOUR FORK. 16. Clean the air top cap and upper tube threads with a clean rag. 16a 16b 16c By hand, install the air top cap (fig 16a/16b). Using a 24mm socket wrench, tighten to 60 in-lb (fig 16c). Using a shock pump, inflate positive air chamber to about 70 psi. This extends the Dual Air shaft and ease installation of the lower leg assembly. PN , REV C 5

6 SID MOTION CONTROL DAMPING ASSEMBLY (SID TEAM/WORLD C UP) THE 2006 SID MOTION CONTROL COMPRESSION DAMPER IS COMPATIBLE WITH THE PURE DAMPING SYSTEM. TO UPGRADE FROM PURE TO MOTION CONTROL, FOLLOW STEPS 19-21, AND KIT (SID DUAL AIR MOTION CONTROL UPGRADE KIT) REQUIRED. REMOVAL 17. Using a 2.5mm hex wrench loosen and remove remote cable stop clamp set screw (fig 17a and 17b). 17a 17b 17c 17d Using a 1.5mm hex wrench loosen and remove floodgate adjuster knob set screw (fig 17c and 17d). 18. Using external snap ring pliers, remove the compression spool retaining ring (fig 18a). Remove the remote compression adjust spool from top cap/compression damper (fig 18b). 18a 18b 18c Remove remote adjuster spool return spring from under spool (fig 18c). 19. Using a 24mm socket wrench loosen and unthread Motion Control compression top cap (fig 19a). By hand, pull up and remove Motion Control compression damper/damper tube/rebound damper assembly from upper tube. The entire assembly will slide out of upper tube (figs 19b/19c/19d). 19a 19b 19c 19d Leave the threaded base retainer inside bottom of upper tube. 20. Gently pull the rebound damper/seal head assembly from bottom of damping tube (figs 20a/20b). Oil will drain so wrap a rag or paper towel around damper tube as you remove damper. 20a 20b 20c Pour all oil from damper tube into an oil pan (fig 20c). 21. Pull the Motion Control damper from the damper tube using a slow twisting motion (figs 21a/21b). This assists the damper out of the damper tube. 21a 21b Allow any excess oil to drain into an oil pan. Spray entire compression damper with isopropyl alcohol and wipe all grease and oil from damper assembly. 6 SRAM Corporation 2006 SID SERVICE GUIDE

7 22. Spray isopropyl alcohol into the damper tube and clean inside surface with a dry clean rag. Use a dowel with the clean rag wrapped around the end. Insert into damper tube and clean. REBOUND DAMPER SERVICE 23. Slide the rebound damper seal head from rebound damper shaft (fig 23a/23b). 23a 23b 23c Spray isopropyl alcohol onto rebound damper shaft and wipe with clean rag. Replace the rebound damper glide ring if worn or damaged (fig 23c). 24. Using a sharp pick remove the inner and outer seal head o-rings and replace with new o-rings (figs 24a/24b). 24a 24b Lubricate both new o-rings with 15wt suspension oil. 25. Slide rebound damper seal head back onto rebound damper shaft (fig 25a). 25a 25b 25c Using a 2.5mm hex wrench, or the rebound adjuster knob, insert hex into rebound damper adjuster at bottom of shaft, and turn counterclockwise to open rebound damper valve (fig 25b). This allows oil to flow into the damper valve when re-filling damper tube with suspension oil. Insert rebound damper and seal head into a container of 5wt suspension oil (fig 25c). COMPRESSION DAMPER SERVICE 26. Pinch lower/primary damper piston o-ring and remove (fig 26a). Replace with new o-ring. Pinch internal floating piston (IFP) o-ring (upper) and remove (fig 26b). Replace with new o-ring. 26a 26b 26c Pinch and remove top cap o-ring (fig 26c). Replace with new o-ring. Lubricate all new o-rings with 15wt suspension oil. INSTALLATION 27. Place the gold floodgate adjuster knob back onto the compression damper (fig 27a) and tighten with a 1.5mm hex wrench (fig 27b). 27a 27b PN , REV C 7

8 28. Turn the floodgate adjuster knob counterclockwise until it stops (fig 28a). This is the full open position. 28a 28b 28c The floodgate adjustment affects the blow-off threshold during compression lock-out. The more open the floodgate is, the lower the amount of force is required to compress the fork in the lock-out position. Note the floodgate position orientations (figs 28b/28c). Floodgate Closed Floodgate Open 29. Apply fresh 15wt suspension oil onto both the main piston o-ring and the IFP o-ring (figs 29a/29b). Insert the compression damper back into the damper tube (fig 29c). Slide entire damper assembly into the tube (fig 29d). 29a 29c 29d 29e Press the top cap firmly into place (fig 29e). 29b 30. Holding the damper tube with the open end of the tube facing up, pour 5wt suspension oil into the damper tube until the tube is approximately half-full (fig 30a). 30a 30b 30c Tap the compression damper/damper tube assembly on a flat surface lightly to release any air bubbles that may be trapped inside the damper (figs 30b/30c). 31. Pour additional 5wt suspension oil into damper tube until completely full (fig 31a). Remove the rebound damper/seal head assembly from the oil container (remember, the rebound damper/seal head assembly should be submerged in oil). 31a 31b Wrap a rag around the damper tube to catch displaced oil. Insert the rebound piston into the damper tube slowly (fig 31b). Slide the piston into the damper tube (fig 31c). Insert the rebound damper seal head into the end of the damper tube and press firmly into place (fig 31d). 31c 31d Wipe away all displaced oil from the damper tube. IMPORTANT! DO NOT CYCLE THE REBOUND DAMPER INTO THE DAMPER TUBE. THE COMPRESSION DAMPER IS NOT SECURE IN THE DAMPER TUBE UNTIL THREADED INTO THE UPPER AND TIGHTENED WITH A SOCKET WRENCH. 8 SRAM Corporation 2006 SID SERVICE GUIDE

9 32. Inside the damper side upper tube (right) is an o-ring that sits in between the Motion Control damper tube/rebound seal head and the upper tube thread base retainer, ensure the o-ring is positioned flat on the threaded upper tube base retainer. 32 If this o-ring came out with the damper tube assembly, apply a small amount of grease to the o-ring and place it on the bottom of the rebound damper seal head (fig 32). o-ring 33. Insert Motion Control damper assembly back into the upper tube, rebound shaft first (fig 33a). Guide the end of the rebound damper through the center of the threaded base retainer. Be careful and do not allow the rebound damper shaft to scrape the retainer. 33a 33b 33c 33d Slide the damper completely into the upper tube (fig 33b). By hand, thread the compression damper top cap into the upper tube (fig 33c). Using a 24mm socket wrench, tighten to 60 in-lb. (fig 33d) 34. Using a 1.5mm hex wrench, loosen floodgate adjuster knob set screw. Remove the floodgate adjuster knob. 35. Using a 2.5mm hex wrench, loosen the cable stop clamp screw. Place the cable stop clamp on to the Motion Control top cap with the cable top positioned approximately 90 degrees forward toward the steerer tube, as pictured (fig 35a). 35a 35b Turn the compression spool adjuster shaft counterclockwise until it stops. This is the open position (fig 35b). Place the remote spool onto the compression spool adjuster shaft (hex) and turn clockwise until it stops (fig 35c). This is the closed (lockout) position. The spool stop should be in the position pictured (fig 35c). With one hand, hold the remote spool closed and rotate the cable stop clamp counterclockwise with your free hand until the cable stop touches the remote spool stop (fig 35d). The cable stop clamp should be loose enough to turn freely on the top cap hex detents. 35c 35d Using a 2.5mm hex wrench, tighten the cable stop clamp screw (fig 35e). Rotate the remote spool counterclockwise to the full open (unlocked) position. The set screw should be positioned in line with the open mark on the cable stop clamp (fig 35f). 35e cable set-screw 35f open-mark on cable stop clamp PN , REV C 9

10 Remove the remote spool while in the compression adjuster rod is in the open position (fig 35g). Apply a small amount of grease to the remote spool torsion return spring. Grease will hold the torsion spring in the remote spool during installation. Insert the torsion spring into the underside of the remote spool knob, with the prong facing out (figs 35g & 35h). 35g 35h Place the remote spool and torsion spring back onto the compression damper adjuster hex. The torsion spring prong fits into one detent hole in the top cap (fig 35i). The cable set screw in the remote spool should be positioned in line with the alignment mark on the cable set screw (fig 35j). 35i 35j Turn the remote spool clockwise until spool-stop stops in the closed position against the cable stop clamp stop (fig 35k) If the stop on the remote spool does not touch the stop on the cable stop clamp, rotate the clamp counterclockwise until the two stops touch. Release the spool and test the return to the open position. Secure the remote spool with a new remote spool retaining ring using external snap ring pliers (fig 35l). insert torsion spring prong into top cap detent hole 35k open-mark on cable stop clamp 35l 36. Place the gold floodgate adjuster knob back onto the compression damper spool shaft. Tighten the floodgate adjuster knob set screw to the flat surface of the black adjuster rod with a 1.5mm hex wrench (fig 36). 36. SID REMOTE SPOOL/CABLE STOP CLAMP ORIENTATION Torque to: 1.4 N-m +/- 0.2 N-m 5 Torque to: 1.0 N-m +/- 0.2 N-m 4 2 Ensure snap ring is fully seated and engaged in spool shaft groove. Always use a new snap ring. Position torsion spring with longer end pointing down into top cap detent hole. Turn spool shaft counterclockwise (open position) BEFORE installing remote spool and torsion spring SRAM Corporation 2006 SID SERVICE GUIDE

11 POPLOC REMOTE LEVER/CABLE INSTALLATION INSTALL THE POPLOC LEVER ASSEMBLY ONTO YOUR HANDLEBAR IN THE DESIRED ORIENTATION BEFORE CABLE INSTALLATION. THE POPLOC LEVER SHOULD BE IN THE OPEN POSITION. 37. Insert PopLoc shifter cable through cable stop clamp and position the cable housing into the stop. Thread the shifter cable through the small cable guide hole on the remote spool (fig 37a). 37a 37b Insert the end of the cable into the cable guide hole under the remote spool cable set screw (fig 37b). Pull the shifter cable tight while rotating the remote spool into the position as pictured. Align the remote spool stop with the alignment mark on the cable stop clamp (figs 37c & 37d). 37c pull cable 37d Using a 1.5mm hex wrench, tighten the cable set screw and secure cable (fig 37d). Test the function of the PopLoc remote lever and remote spool (fig 37e). When in the locked out (closed position) the remote spool stop should touch the cable stop clamp, as pictured (fig 37f). alignment mark 37e alignment mark 37f Press the PopLoc open button and test the return to open position. remote spool should touch cable stop clamp OPTIONAL: REMOTE A DJUST TO N ON-REMOTE A DJUST SWITCHING FROM REMOTE COMPRESSION ADJUST TO A CROWN-MOUNTED COMPRESSION ADJUSTER REQUIRES ONLY THE REMOVAL OF THE REMOTE SPOOL AND CABLE STOP CLAMP ASSEMBLIES, AND INSTALLATION OF THE STANDARD COMPRESSION ADJUSTER KNOB ( SID MOTION CONTROL COMP KNOB). UNLIKE STANDARD MOTION CONTROL COMPRESSION DAMPERS, THE 06 SID MOTION CONTROL COMPRESSION DAMPER REMOTE RETURN SPRING IS NOT DESIGNED INTO THE DAMPER ASSEMBLY. THE REMOTE POPLOC LEVER ADJUSTER CAN EITHER BE REMOVED FROM THE HANDLEBAR, OR SIMPLY REMOVE THE CABLE/CABLE HOUSING AND LEAVE THE POPLOC LEVER ON YOUR HANDLEBAR, IF YOU CHOOSE TO INSTALL THE REMOTE SPOOL IN THE FUTURE. LOWER LEG INSTALLATION 38. Thoroughly clean the dust seals and upper bushing with a clean rag and isopropyl alcohol. Replace dust seals and foam rings if worn or damaged. Refer to the Bushing Service Guide for procedures at 38 Pour or inject 15wt suspension oil onto new or clean foam rings just under dust seal inside lower leg; each side (fig 38). This provides additional lubrication during use. PN , REV C 11

12 39. Invert fork in bicycle stand to a 45-degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a clean rag. 39a 39b 39c Slide lower leg assembly over and onto the ends of each upper tube. Ensure both dust seals slide onto the tubes correctly and do not fold under (fig 39a). Continue sliding lower leg assembly onto upper tubes until you feel the lower bushings touch the end of the upper tubes (fig 39b). Pull lower leg assembly back off just slightly so lower bushing is not touching bottom of upper tube. Stop (fig 39c). 40. Measure and pour (or inject...an oil syringe works best) 5cc/ml of 15wt suspension oil into lower legs (left and right sides), through both shaft bolt holes (fig 40). This provides lubrication for the bushings during use. 40 Wipe all excess oil from lower legs. 41. Inspect and clean the rebound damper shaft bolt, Dual Air shaft nut and black nylon crush washers (fig 41). Replace crush washers and crush washer retainer if damaged. Damaged or dirty crush washers can cause oil to leak Slide lower leg assembly further down upper tubes until shaft ends are seated inside lower leg shaft holes. You may need to use a small hex wrench or screw driver to guide the shaft ends into the holes (fig 42a) Insert rebound damper shaft bolt into threaded shaft end (right side), through lower leg shaft hole. Hand thread into shaft and tighten with a 5mm hex wrench to 60 in-lb (fig 42b). 42a Thread the Dual Air shaft nut onto the threaded air spring shaft. Tighten with an open end 10mm wrench to 60in-lb (fig 42c). 42b 42c 42d push to snap into place Insert external rebound damper knob into rebound damper shaft bolt. Push into bolt to secure (fig 42d). Adjust as desired. 43. Spray entire fork with isopropyl alcohol and wipe down with a clean rag. 44. Inflate the positive (first) (fig 44a) and negative (second) (fig 44b) air chambers with a shock pump to desired air pressures. See the air chart in this guide, or the decal on the back of the fork lower leg for reference. 44a 44b Thread both air valve cover caps back onto air top cap and negative air shaft. 12 SRAM Corporation 2006 SID SERVICE GUIDE

13 AIR RIDER WEIGHT POSITIVE (TOP) AIR PRESSURE NEGATIVE (BOTTOM) (XC SETTING) NEGATIVE (BOTTOM) (RACING SETTING) <120 lb (54 kg) psi psi psi lb (54-64 kg) psi psi psi lb (64-73 kg) psi psi psi lb (73-82 kg) psi psi psi >180 lb (82 kg) psi psi psi OIL PURE DELITE/MOTION CONTROL SID RACE DUAL AIR RIGHT LEG OIL WEIGHT BOTTOM VOLUME OIL WEIGHT 1/2 Full 5 wt 10cc/ml 15 wt SID RACE DUAL AIR LEFT LEG TOP VOLUME OIL WEIGHT BOTTOM VOLUME OIL WEIGHT 3cc/ml 15 wt 10cc/ml 15 wt SID TEAM/WORLD CUP DUAL AIR RIGHT LEG PURE DELITE/MOTION CONTROL Full (fill from bottom of tube) OIL WEIGHT BOTTOM VOLUME OIL WEIGHT 5 wt 10cc/ml 15 wt SID TEAM/WORLD CUP DUAL AIR LEFT LEG TOP VOLUME OIL WEIGHT BOTTOM VOLUME OIL WEIGHT 3cc/ml 15 wt 10cc/ml 15 wt TROUBLE-SHOOTING AIR LOSS Inspect air piston o-rings. Replace if necessary. To avoid air loss, remove Dual Air top cap and check oil level inside air chamber, every 25 to 50 riding hours. If there is little or no oil on top of air piston o-ring, pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. Oil will keep air seal lubricated. Inspect schrader valve assembly. Replace if damaged or malfunctioning. Clean if clogged. LOSS OF, OR VARIANCE IN DAMPING Inspect all damper o-rings. Replace and lubricate. Inspect damper oil volume. Remove damper top cap/compression damper assembly. Add or remove oil as needed. Remote: Inspect remote cable tension. Cable may stretch, or become loose. Loosen cable screw, tension cable and tighten. Test. Adjust as needed. BUSHING PLAY Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100 to 200 riding hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings! See the 'Bushing Installation' guide at for procedures. OIL LOSS Inspect the air piston o-ring for air bypass. If there is a repeated loss of air pressure, air may be the cause of oil loss at the left dust seal. Inspect your shaft bolt crush washers. Replace if worn or damaged. Inspect your top cap o-rings. Replace if torn or knicked. PN , REV C 13