01 Psylo Race Owner`s Manual.qxd
Contents
1. Sth ZALE allt 2001 OWNER S MANUAL Aluminum Steerer Tube Climb it Control Positive Air Knob Valve Upper Tube XXX Seal System One Piece Lower Tube Assembly Pure Damping System Rebound Negative Adjuster Imm Air Valve Note Your fork s appearance may vary from the illustrations photos in this manual Denotes updated information since the printed version that came with your fork Congratulations You have the best in suspension components on your bicycle This manual contains important information about the safe operation and maintenance of your fork To insure that your RockShox fork performs properly we recommend that you have your fork installed by a qualified bicycle mechanic We also urge you to follow our recommendations to help make your bicycling experience more enjoyable and trouble free IMPORTANT Consumer Safety Information Before riding the bicycle be sure the brakes are properly installed and adjusted If the brakes do not work properly the rider could suffer serious and or fatal injuries If the fork ever loses oil or if it makes sounds of excessive topping out stop riding the bicycle immediately and have the fork inspected by a dealer or call RockShox Continuing to ride with the shock in these conditions could result in loss of control of the bicycle with possible serious and or fatal injuries Always use genuine RockShox parts Use of aftermarket replacement parts voids the warrant2. FAX 822 512 3230 SHIN SEUNG BLDG 4TH FLR 115 4 NONHYUN DONG KANGNAM KU SEOUL Latvia Veloserviss Phone 371 750 1292 Fax 371 750 1298 1 1 HAPSALAS ST RIGA LV 1005 Luxembourg Vertex Cycle Systems BV Phone 31 23 57 18184 FAX 31 23 57 18606 FLEMINGSTRAAT 100A 2041 VL ZANDVOORT HOLLAND Mexico Tekno Bike Phone 52 8 336 5602 FAX 52 8 338 5663 HUMBERTO LOBO 780 COL DEL VALLE GARZA GARCIA MEXICO CP 66220 Mexico New Zealand W H Whorrall amp Co Ltd Phone 64 9 63 6 06 41 FAX 64 9 63 6 06 31 43 FELIX ST PENROSE AUCKLAND NEW ZEALAND Norway Hallman Sports Phone 46 18 56 16 00 FAX 46 18 50 03 22 HALLNASGATAN 8 S 75228 UPPSALA SWEDEN Panama Distribuidora Rali S A Phone 507 220 3844 FAX 507 220 5303 VIA ESPANS EDIFICA CARCEP P 0 BOX 87 0852 PANAMA 7 Peru Rojo Sports Phone 511 447 0838 FAX 511 447 0838 AV REPUBLICA DE PANAMA 6513 LIMA 33 Poland Giant Polska S P ZOO Phone 48 22 645 14 34 FAX 48 22 645 14 36 AL NIEPODLEGLOSCI 221 4 02 087 WARSZAWA Portugal Bicimax Phone 351 44 553276 FAX 351 44 553187 APARTADO 34 2431 MARINHA GRANDE Russia Sportex Phone 7095 288 4524 FAX 7095 288 6888 KUDRINSKAYA PL 1 P O BOX 33 MOSCOW 123242 St Maarten Tri Sport International Phone 5995 43462 FAX 5995 43928 8 AIRPORT BOULEVARD SIMPSON BAY NAMIBIA Singapore Treknology Bikes 3 Phone 65 466 2673 FAX 65 466 7610
3. Sports Phone 5982 782498 FAX 5982 622532 AVDA BRASIL 2567 11800 MONTEVIDEO Venezuela Bike Sports Phone 582 751 9709 FAX 582 753 5071 CENTRO COMERCIAL IBARRA PLANTA BAJA LOCAL 3 A CALLE GARCILAZO COLINAS DE BELLO 0 CARACAS
4. This warranty is the sole and exclusive remedy RockShox shall not be held liable for any indirect special or consequential damages The warranty does not apply to products which have not been properly installed and adjusted according to RockShox installation instructions The warranty does not cover any product that has been subject to misuse or whose serial number has been altered defaced or removed This warranty does not cover paint damage or modifications to the product Proof of purchase is required Warranty Repair If for any reason it should be necessary to have warranty work done return the product to the place of purchase In the USA Dealers should call for a Return Authorization number RA prior to returning product Products returned for inspection must be sent freight prepaid and with proof of purchase to RockShox Inc 1610 Garden of the Gods Colorado Springs CO 80907 For more technical information visit our website at www rockshox com For toll free technical support in the USA call 1 800 677 7177 Customers in countries other than the USA should contact their local dealer or distributor INTERNATIONAL DISTRIBUTOR LIST Argentina Broni S A Phone 54 11 4292 3000 FAX 54 11 4292 4453 J J PASO 1260 1832 LOMAS DE ZAMORA BUENOS AIRES Australia Steve Cramer Products Phone 61 3 9587 1466 FAX 61 3 9587 2018 39 INDUSTRIAL DRIVE BRAESIDE VICTORIA 3192 Austria Barisitz Austria Phone 43 512 39 2
5. and desired ride characteristic Note ALWAYS INFLATE THE POSITIVE AIR CHAMBER FIRST 20 mm All Travel Spacer E 25 mm All 25 mm All Travel Spacer Top out Dual Air Tube Washer aL Fig 8 100 mm Fig 9 125 mm Fig 10 PURE DAMPING SYSTEM Your fork uses a Pure Damping System With the red Climb It control lever turned completely clockwise only a minimal amount of fork movement should be felt While standing astride the bicycle press down on the handlebars quickly A maximum of 6 mm fork movement should be obtainable Remember your fork has a blow off feature for big hits Some riders may be able to activate the blow off and achieve more than 6 mm of travel When checking the lockout light to medium pressure on the handlebars best simulates real world riding conditions To maintain Lockout control and damping quality the Pure Damping system should be rebuilt once a year Only a qualified bicycle mechanic with proper tools should perform a rebuild of the Pure Damping System For more detailed service information contact your local RockShox dealer or visit www rockshox com WARRANTY RockShox Inc warrants its products for a period of one year from original date of purchase to be free from defects in materials or workmanship Any RockShox product that is returned to the factory and is found by RockShox to be defective in materials or workmanship will be repaired or replaced at the option of RockShox Inc
6. 0 180lb 73 82 kg 120 140 psi 100 120 psi gt 180lb 82 kg 140 160 psi 120 140 psi External Rebound Adjustment To change the rebound damping on your Psylo locate the adjuster knob on the lower right leg A clockwise adjustment will increase the rebound damping a counterclockwise adjustment will decrease the rebound damping Small changes in knob position will make large changes on the trail Start in the middle and increase or decrease as necessary Climb It Control To change the compression damping adjustment on your Psylo locate the red adjuster knob on top of the right leg A clockwise adjustment will increase the compression damping Turning the adjuster completely clockwise will provide On The Fly Lockout to minimize movement while sprinting or climbing Incorporated into the Lockout system is a big hit blow off feature allowing for fork movement in the event of an unsuspected change in terrain MAINTENANCE To maintain the high performance safety and long life of your fork periodic maintenance is required If you ride in extreme conditions maintenance should be performed more frequently Before Every Ride Check the other components on your bicycle in accordance with the manuals supplied by the manufacturer to make sure they are in working order After Every Ride Clean and dry the exterior of your fork Avoid directing water pressure at the upper tube XXX seal junction Every 25 Hours of Riding e Using a small blad
7. 2 87 FAX 43 512 39 45 19 BERNHARD HOEFELSTRASSE 14 A 6020 INNSBRUCK Belgium Vertex Cycle Systems BV Phone 31 23 57 18184 FAX 31 23 57 18606 FLEMINGSTRAAT 100A 2041 VL ZANDVOORT HOLLAND Canada Bell Sports Canada Phone 403 273 1427 Calgary FAX 403 248 1221 BAY 147 2760 45TH AVE SE CALGARY ALBERTA T2B 3M1 Chile Bicicletas Belda Limitada Phone 56 32 881799 FAX 56 32 978799 14 NORTE 1001 VINA DEL MAR Colombia Disandina Ltda Phone 574 288 8322 FAX 574 288 6211 CIUDADELA INDUSTRIAL SIERRA MORENA BODEGA No 207 CRA 43 A No 61 SIR 152 SABANETA Costa Rica Inversiones Y Sistemes Garvi Phone 506 296 3383 FAX 506 289 7013 P O BOX 4805 1000 SAN JOSE Czech Republic Vanek Praha Phone 42 0 312 698 1889 FAX 42 0 312 698 025 CERRENY UJEZD 185 UNHOST 27351 Denmark Duell A S Phone 45 86 36 7800 FAX 45 86 36 7377 MOLLERUPVEJ 3 TAASTRUP 8410 RONDE Ecuador Bici Sport Phone 5932 248737 FAX 5932 253691 AV DE DICIEMBRE 6327 ENTRE LOUVRE Y TOMAS DE BERLANGA LOCAL 3 QUITO Estonia Hawaii Express Phone 372 6 398 508 FAX 372 6 398 566 REGATI 1 5K 102 TALLINN 11911 Estonia Or Estonian Unidream Phone 372 636 7470 Fax 372 636 7470 Paavli 2A Tallinn EE0004 Estonia Finland Mr Cool OY Phone 358 9 3250817 FAX 358 9 3250609 LINNAVUORENTIE 28 HELSINKI 00950 France Royal Velo France Phone 33 325 433 730 Fax 33 325 43 95 95 4 RUE DE
8. 24 HOLLAND GROVE ROAD SINGAPORE 1545 Slovak Republic Paul Lange Oslany Phone 42 1 862 5492 344 FAX 42 1 862 5492 350 MIEROVA 854 37 OSLANY 97247 SLOVAKIA Slovenia Proloco Trade Phone 386 64 380 200 FAX 386 64 380 2022 ENOTA KRANJ BRITOF 96A 4000 KRANJ South Africa Coolheat SA PTY Ltd Phone 27 11 807 5282 FAX 27 11 807 2998 3 RUARGH STREET PARK CENTRAL P O BOX 740 JOHANNESBURG 2001 Spain K Motor Dealer S L Phone 34 9 1 637 70 97 FAX 34 9 1 637 72 64 PARQUE INDUSTRIAL EUROPOLIS EDIFICO BRUSELA BLOQUE 4 NAVE 1 LAS ROZAS MADRID N A 28230 Sweden Hallman Sports Phone 46 18 56 16 00 FAX 46 18 50 03 22 HALLNASGATAN 8 S 75228 UPPSALA Switzerland Cilo Bike Service SA Phone 41 21 641 63 30 FAX 41 21 641 63 82 CH DE L ORIO 30 A CASE POSTALE 64 ROMANEL S LAUSANNE CH 1032 Taiwan Biketech Co Ltd Phone 886 22 694 5806 FAX 886 22 694 6133 NO 12 FU TEH ROAD 266 LANE 37 ALLEY HSICHIH TAIPEI HSIEN TAIWAN R O C Thailand Probike Co Ltd Phone 662 254 1077 FAX 662 254 1078 237 2 SARASIN ROAD LUMPINNE PATUMWAN BANGKOK 10330 Turkey EBSAT Phone 90 212 514 0525 FAX 90 212 519 4846 EBSAT EMEK BISIKLET EBUSSUUD CAD NO 67 34410 SIRKECI ISTANBUL 34410 United Kingdom Madison Phone 44 181 385 3385 Fax 44 208 345 3443 BUCKINGHAME HOUSE EAST THE BROADWAY STANMORE MIDDLESEX HA7 4EA UNITED KINGDOM Uruguay International
9. 25 and 20 mm All Travel spacers 100 mm travel requires the installation of the 25 mm All Travel spacer To obtain 125 mm of travel do not use any All Travel spacers PART VI INSTALL DUAL AIR ASSEMBLY FIGS 10 11 15 Using RockShox Redrum thoroughly lubricate the air piston o ring 16 Slide the air piston assembly into the Dual Air tube 17 Slide the Dual Air assembly into the upper tube left leg rider s perspective until it stops 18 Re install the Dual Air assembly retaining ring PART VII INSTALL LOWER TUBE ASSEMBLY 19 Pour 5 cc Redrum on top of the air piston left side rider s perspective 20 Install top cap and torque to 60 in lbs 21 Carefully engage lower tubes onto the upper tubes 22 Slide lower tube assembly onto the upper tubes until just before the lower bushing engages with the upper tube PART VIII REFILL FLurps Fic 12 23 Pour 10cc of RockShox 5 wt into each leg 24 Slide the lower legs onto the upper tubes until they engage with the damper and Dual Air shafts 25 Install the damper shaft bolt right leg and Dual Air shaft nut left side Torque to 60 in lbs 26 Re install rebound adjuster 27 Install foam ring and XXX seal pressing the XXX seal flush with the lower leg assembly A small cable tie inserted between the upper tube and the seal will help eliminate air build up behind the seal on installation Remove cable tie following seal installation 28 Repressurize the fork according to your weight
10. S AZALEES P A SUD CHAMPANGE ST THIBAULT 10800 Germany Sport Import GmbH Phone 49 44 05 9280 0 FAX 49 44 05 9280 49 INDUSTRIESTRASSE 41 B EDEWECHT 26188 Greece Gatsoulis Stefanos Imports Phone 30 12512 779 FAX 30 12533 960 8 THESSALONIKIS STREET NEW FILADELFIA ATHENS T T 14342 Guatemala BYS Importaciones S A Phone 502 366 7709 FAX 502 363 3918 18 CALLE 7 48 ZONA 10 GUATEMALA Holland Vertex Cycle Systems BV Phone 31 23 57 18184 FAX 31 23 57 18606 FLEMINGSTRAAT 100A 2041 VL ZANDVOORT HOLLAND Hong Kong Flying Ball Bicycle Company Phone 852 23813661 FAX 852 23974406 201 TUNG CHOI ST G F MONGKOK KOWLOON Hungary Prokero Ltd Co Phone 361 331 3184 FAX 361 331 3184 KALMAN IMRE UTCA 23 BUDAPEST 1054 Iceland Orninn Hjol Ltd Phone 354 588 9892 FAX 354 588 9896 SKEIFAN 11 P O BOX 8036 REYKJAVIK Ireland Madison Phone 44 181 385 3385 Fax 44 208 345 3443 BUCKINGHAME HOUSE EAST THE BROADWAY STANMORE MIDDLESEX HA7 4EA UNITED KINGDOM Israel S I Noam Phone 972 3659 7928 Fax 972 3659 7928 4 HA ATZMAUT AVE BAT YAM ISRAEL 59441 Italy Motorquality Phone 39 02 24 9511 FAX 39 02 24 951 228 20099 SESTO S GIOVANNI MI I VIA VENEZIA ANG VIA CARDUCCI MILANO Japan Yoshigai Corporation Phone 81 729 88 5461 FAX 81 729 88 5463 5 19 1 CHOME SHIMOROKUMANGI CHO HIGASHI OSAKA JAPAN 579 Korea KS Sports Phone 822 548 5408
11. ble stops Do not use a front brake cable leverage device mounted to the brace ROCKSHOX FORKS ARE DESIGNED FOR COMPETITIVE OFF ROAD RIDING AND DO NOT COME WITH THE PROPER REFLECTORS FOR ON ROAD USE YOUR DEALER SHOULD INSTALL PROPER REFLECTORS TO MEET THE CONSUMER PRODUCT SAFETY COMMISSION S CPSC REQUIREMENTS FOR BICYCLE STANDARDS IF THE FORK IS GOING TO BE USED ON PUBLIC ROADS AT ANY TIME INSTALLATION It is extremely important that your RockShox fork is installed correctly by a qualified bicycle mechanic Improperly installed forks are extremely dangerous and can result in severe and or fatal injuries 1 Remove the existing fork from the bicycle and the crown race from the fork Measure the length of the fork steerer tube against the length of the RockShox steerer tube The RockShox steerer tube may need cutting to the proper length Make sure there is sufficient length to clamp the stem refer to the stem manufacturer s instructions AWARNING DO NOT ADD THREADS TO ROCKSHOX THREADLESS STEERERS THE STEERER TUBE CROWN ASSEMBLY IS A ONE TIME PRESS FIT REPLACEMENT OF THE ASSEMBLY MUST BE DONE TO CHANGE THE LENGTH DIAMETER OR HEADSET TYPE THREADED OR THREADLESS DO NOT REMOVE OR REPLACE THE STEERER TUBE THIS COULD RESULT IN THE LOSS OF CONTROL OF THE BICYCLE WITH POSSIBLE SERIOUS AND OR FATAL INJURIES 2 Install the headset crown race 26 4mm for 1 steerers 29 9mm for 1 1 8 steerers firmly against the top of the fork cr
12. e screwdriver carefully push the XXX seal up from the lower tubes Saturate the foam wiper with RockShox RedRum Refit wiper in lower tube Note TO PREVENT SCRATCHING THE UPPER TUBES COVER THE SCREWDRIVER TIP WITH A SOFT CLOTH CAREFULLY LIFT THE FOAM LUBRICATION RING ENSURE THAT THE FOAM RING IS CLEAN AND FREE OF DEBRIS e Check top cap assemblies brake post bolts and shaft bolts for proper torque Torque Tightening Values Top Cap 60 in lb Brake Posts 80 in lb Air Shaft Nut 50 in lb Damper Shaft Bolt 50 in lb Every 50 Hours of Riding NOTE SERVICE ON YOUR PSYLO CAN BE PERFORMED WITH IT STILL INSTALLED ON YOUR BICYCLE YOU WILL NEED TO DISCONNECT THE FRONT BRAKE CABLE AND REMOVE THE WHEEL Tools Required e 5mm Hex Wrench e Torque Wrench e Plastic Face Mallet e 24mm 6 point Socket e Safety Glasses e RockShox RedRum e Small Flat Blade Screwdriver RockShox 5 wt oil e 10mm Socket e Internal Snap Ring Pliers PART I REMOVE AIR PRESSURE FIGS 1 2 1 Remove negative air valve cover Depress schrader valve to remove negative air pressure 2 Remove positive air valve cover Depress schrader valve to remove positive air pressure 3 Using a 24mm socket remove left top cap PART II Remove Lower TUBE ASSEMBLY FIGS 3 5 4 Using a small blade screwdriver carefully push the XXX seal up from the lower tubes 5 To prevent scratching the upper tubes cover the screwdriver tip with a soft cloth Carefully lift the foam
13. lubrication ring Insure that the foam ring is clean and free of debris Leave each on the upper tube 6 Gently pull downward to remove rebound adjuster 7 Loosen damper shaft bolt 5 turns and tap firmly with a plastic faced mallet to separate the shaft from the lower tubes 8 Loosen air shaft nut and unthread to the end of the negative air shaft Tap firmly with a plastic faced mallet to separate the shaft from the lower tube 9 Keep a bucket nearby to catch oil Inspect the condition of removed oil 10 Remove damper shaft bolt and Dual Air shaft nut 11 Carefully slide lower tube assembly off of upper tubes PART III CLEAN LOWER TUBE ASSEMBLY 12 Use a biodegradable solvent Simple Green Pedro s or equivalent and a 12 long 1 4 diameter soft bristle bottle brush to clean the lower tube internals Dry thoroughly PART IV Remove DUAL AIR ASSEMBLY FIG 6 AWARNING ENSURE ALL AIR IS REMOVED FROM THE FORK REMOVING THE DUAL AIR ASSEMBLY WHILE THE FORK STILL CONTAINS AIR MAY CAUSE SERIOUS BODILY INJURY 13 Using internal snap ring pliers remove the Dual Air assembly retaining ring 14 Slide the Dual Air assembly from the upper tube PART V ALL TRAVEL SYSTEM FIGs 7 9 RockShox Psylo forks can be configured for 80 100 or 125 mm of travel To change the travel either install or remove the All Travel Spacer s between the air piston and the top out washer on the negative air shaft 80 mm travel requires the use of the
14. ompression of the fork caused by the rider s weight Proper sag allows the front wheel to follow the contour of the terrain as you ride Sag is adjusted by increasing or decreasing the positive air pressure of your fork Increasing the pressure in your positive chambers will decrease sag Decreasing the pressure in your positive air chambers will increase sag Travel Sag 80 mm 13 20 mm 100 mm 18 25 mm 125 mm 20 31 mm To measure sag install a zip tie on the upper tube of the fork flush against the XXX seal Sit on the bike with normal riding apparel Step off the bike and measure the distance between the XXX seal and the zip tie This is your sag Air Pressure Guidelines Use the table below to assist with positive air pressure Always tune positive air pressure first based on the desired sag Rider Weight Positive Air Pressure gt 120lb 55 kg 70 80 psi 120 140lb 55 65 kg 80 100 psi 140 160lb 65 73 kg 100 120 psi 160 180lb 73 82 kg 120 140 psi gt 180lb 82 kg 140 160 psi Adjusting your forks negative air chamber pressure will change its ride characteristic More negative air pressure will make the fork more active over small bumps Less negative air pressure will reduce bobbing Always tune positive air pressure first then adjust negative air pressure Negative Air Pressure Rider Weight XC Racing gt 120lb 55 kg 70 80 psi 40 60 psi 120 140lb 55 65 kg 80 100 psi 60 80 psi 140 160lb 65 73 kg 100 120 psi 80 100 psi 16
15. own Install the fork assembly on the bike Adjust the headset until you feel no play or drag 3 Install the brakes according to the manufacturer s instructions and adjust brake pads properly Use the fork only with V type or hydraulic cantilever brakes mounted to the existing brake posts or disc style brakes mounted through the provided mounting holes Do not use any cantilever brake other than those intended by the brake manufacturer to work with a hangerless brace 4 Adjust the front wheel quick release to clear the dropout s counter bore The quick release nut must be tightened after the wheel is properly seated into the dropout s counter bore Make sure four or more threads are engaged in the quick release nut when it is closed Orient the quick release lever in front of and parallel to the lower tube in the locked position 5 Keep in mind tire clearance as you choose tires Maximum size is 2 6 wide or 347 mm radius installed Be sure to check this radius whenever you change tires To do this remove the air and compress the fork completely to make sure at least 5mm of clearance exists between the top of the tire and the bottom of the crown Exceeding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed PERFORMANCE TUNING RockShox Psylo forks can be tuned for your particular weight riding style and terrain Setting Sag Psylo forks are designed to sag when you are sitting on your bike Sag is the c
16. y and could cause structural failure to the shock Structural failure could result in loss of control of the bicycle with possible serious and or fatal injuries Use extreme caution not to tilt the bicycle to either side when mounting the bicycle to a carrier by the fork drop outs front wheel removed The fork legs may suffer structural damage if the bicycle is tilted while the drop outs are in the carrier Make sure the fork is securely fastened down with a quick release Make sure the rear wheel is fastened down when using ANY bike carrier that secures the fork s drop outs Not securing the rear can allow the bike s mass to side load the drop outs causing them to break or crack If the bicycle tilts or falls out of its carrier do not ride the bicycle until the fork is properly examined for possible damage Return the fork to your dealer for inspection or call RockShox if there is any question of possible damage See the International Distributor List A fork leg or drop out failure could result in loss of control of the bicycle with possible serious and or fatal injuries Only mount cantilever type brakes to the existing brake posts Forks with hangerless style braces are only designed for V style or hydraulic cantilever brakes Do not use any cantilever brake other than those intended by the brake manufacturer to work with a hangerless brace Do not route the front brake cable and or cable housing through the stem or any other mounts or ca
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