Duke - Enduro Fork Seals
Contents
1. and the zip tie This is your sag The sag should be between 15 and 25 19 to 31 mm percent of maximum travel If you re unable to achieve optimum sag you may need to change the fork s spring CHANGING THE SPRING RATE Spring rate is the amount of force needed to compress a spring one inch Changing your fork s coil spring for a spring of a higher or lower rate will alter the overall feel of your fork Higher spring rates make the fork feel more stiff while lower spring rates make the fork more supple Contact your local RockShox dealer to order replacement springs NOTE WN DECREASING TRAVEL SEE U TURN TRAVEL AD UST YOU INCREASE THE SPRING RATE External Rebound Adjustment Race SL and XC models Rebound damping controls the speed at which a fork returns to its full extension following compression Located at the bottom of the right fork leg is the rebound adjuster knob Turning the adjuster in the direction indicated by the rabbit on the rebound speed decal decreases rebound damping causing the fork to return to full extension faster Turning the adjuster in the direction indicated by the turtle increases rebound damping slowing the return of the fork to full extension Excessive rebound damping will cause the fork to pack up over successive bumps reducing travel and causing the fork to bottom out Set your fork to rebound as fast as possible without topping out or kicking back This allows your fork to follow the contou2. smaller bumps while more air pressure will make the fork feel stiffer We recommend adjusting the positive pressure before you adjust the air pressure in the Pure Delite chamber right side rider s perspective NOTE AR PRESSURE INTHE Pure DELITE SYSTEMSHOULD NOT BE USED TO TUNE THE SPRING RATE OR BOTTOM OUT FORCE REQUIRED FOR THE FORK U TURN TRAVEL ADJUST SL XC AND C U TURN MODELS Duke U turn forks can be adjusted from 63 to 108 mm of travel To determine the travel on your fork use the travel gradients on the upper tube Changing Travel Turning the U turn adjuster knob counterclockwise increases travel From minimum travel there are approximately six turns to achieve maximum travel 108 mm Each turn increases or decreases the travel by 7 5 mm fig 1 IMPORTANT STOP TURNING THE U TURN ADJ USTER KNOB AFTER YOU HAVE REACHED 108 MM OF TRAVEL MAXIMUM TRAVEL TURNING THE KNOB PAST THIS POINT MAY CAUSE DAMAGE TO THE U TURN FEATURE ROCK SHOx INC APRIL 2002 7 ENGLISH RockSHox Inc 2003 DUKE OWNER S MANUAL Spring Rate Increase Increase of Spring Rate 108 100 5 93 85 5 78 70 5 U Turn Travel Adjustment mm Fig 5 MAINTENANCE To maintain the high performance safety and long life of your fork periodic maintenance is required If you ride i
3. OWNER S MANUAL ROCK SHOX CLIMB IT C CONTROL RockSHox Inc 2003 DUKE OWNER S MANUAL ENGLISH Congratulations You have the best in suspension components on your bicyde This manual contains important information about the safe operation and maintenance of your fork To ensure that your RockShox fork performs propery we recommend that you have your fork installed by a qualified bicyde mechanic We also urge you to follow our recontrendations to help make your riding experience nore enjoyable and trouble free U tum Travel Adjust Sees TUES U turm Einsteller fr Federweg id Ajuste del recorrido con giro completo Potencia tubo de direcd n Bouton de rZigage du d ibatterrent U tum Tube pivot Regolazione del precarico Utum Camnotto di sterzo della forcella Us Y KON Bei ATI y vo F L 7 Installing benegingsruime Utun Stuurbuis Regula 20 de curso U tum Tubo de direc 3 Upper Tube Oberes Rohr Tubo superior Tube sup rieur Montagesoda frBrerse Pasador de freno Tige de frein Supporto freno FTU RAL Rerrhouder Espig o de tra o Rebound Adjuster Einstellung fr Zugstufe Ajustador extemo de rebote Bouton de r diage du rebond Regolazione del ritomo YNOY E Bas Afstelling terugvering Regulador de recupera 20 Remote Control Lockout Option Fernbedienung der Blockierfunktion Option Blocaje remoto Opci n Blocage distant Option Bloccaggio Remoto Option J 3y FA AyZ279r Avast Uitschakel
4. ag is the compression 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 Checking Sag for Models with Positive Air Race SL XC and C Sag is adjusted by increasing or decreasing the positive air pressure of your fork less air equals more sag POSITIVE AIR PRESSURE GUIDELINES Rider Weight Ib Air Pressure lt 140 63 kg 80 115 psi 140 160 63 72 kg 115 130 psi 160 180 72 81 kg 130 145 psi 180 200 81 90 kg 145 160 psi gt 220 99 kg 180 psi ROCK SHOx INC APRIL 2002 5 ENGLISH RockSHox Inc 2003 DUKE OWNER S MANUAL To measure sag use the travel indicator included with your fork or install a zip tie on the upper tube of the fork flush against the wiper seal Sit on the bike with normal riding apparel Step off the bike and measure the distance between the wiper seal and the travel indicator or zip tie This is your sag ADDING POSITIVE AIR PRESSURE Remove the air cap to expose the air valve Using a RockShox Air Pump with schrader valve add the recommended air pressure see Air Pressure Guidelines NOTE IMbamum AIR PRESSURE IS 130 PSI Checking Sag for Duke SL U Tum XC U Tum and C U Tum To measure sag set the fork to maximum travel 108 mm Install a zip tie on the upper tube of the fork flush against the wiper seal Sit on the bike with normal riding apparel Step off the bike and measure the distance between the wiper seal
5. ar shock mounting hardware and springs and fork drop outs Pioneer Support Program In the event parts are unavailable at the time of your repair at the option of RockShox or its authorized agent a replacement fork may be provided at a determined discount price Warranty Expenses Incurred The RockShox warranty policy excludes expenses incurred as a result of transportation of product from a RockShox dealer to RockShox USA or its authorized distributor labor performed by a RockShox dealer for removal of RockShox product or warranty repair work performed by a RockShox dealer Warranty work performed by a RockShox dealer is voluntary Warranty Repair If for any reason it should be necessary to have warranty work done return the product to a RockShox dealer In the USA dealers are required to call for a Return Authorization number RA prior to returning product Outside the USA dealers are required to call an authorized RockShox Distributor For more technical information visit our website at www rockshox com For toll free technical support in the USA call 1 800 677 7177 Dealers outside the USA must contact their local dealer or distributor For a complete list of Authorized Distributors outside the USA visit www rockshox com ROCK SHOx INC APRIL 2002 9
6. duct 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 4 950 006718 00 Rev A01 RockSHox Inc 2003 DUKE OWNER S MANUAL ENGLISH 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 damp the stem refer to the stem manufacturer s instructions 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 29 9mm for 1 1 8 steerers firmly against the top of the fork crown Install the f
7. ing op afstand optie Bloqueio remoto opcional NOTE YOUR FORK S APPEARANCE MAY VARY FROM THE ILLUSTRATIONS PHOTOS IN THIS MANUAL FOR THE LATEST INFORMATION ABOUT YOUR FORK VISIT OUR WEBSITE AT WAMROCKSHOX COM ROCKSHOX INC APRIL 2002 3 ENGLISH RockSHox Inc 2003 DUKE OWNER S MANUAL The fork on your bicycle is designed for use by a single rider on mountain trails and similar off road conditions 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 Your fork may fail in certain circumstances including but not limited to any condition that causes a loss of oil collision or other activity bending or breaking the fork s components or parts and extended periods of non use Fork failure may not be visible Do not ride the bicycle if you notice bent or broken fork parts loss of oil sounds of excessive topping out or other indications of a possible fork failure such as loss of shock absorbing properties Instead take your bike to a qualified dealer for inspection and repair In the event of a fork failure damage to the bicycle or personal injury may result Always use genuine RockShox parts Use of aftermarket replacement parts voids the warranty 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 injurie
8. ive to the lockout position In the center of the Remote Lockout lever is the go button Depress the go button to return your fork to the active position MOUNTING The Remote Lockout is mounted on the left hand side of the handlebar With separate brake lever and shifter setups mount the Remote Lockout between the brake lever and shifter fig 1 With integrated designs mount the Remote Lockout outboard or inboard fig 2 of the brake lever shifter setup SETUP Clamp the Remote Lockout leverin the appropriate mounting orientation see fig 1 and 2 Torque to 8 in lh Degpress the go button and rotate the lever to the open position Feed the housing into the remote damp and route the cable fig 3 Orient the Remote Cap 60 degrees dockwise from the timing mark fig 4 This is the default open position For astiffer feeling fork rotate the remote cap greater than 60 degrees from the timing mark Set the barrel adjuster in the middle of the range Tighten the remote damp screw and torque to 8 in Ib fig 4 7 Ensue proper function PWN eR Q pi Note THE CABLE IS TEFLON COATED PURE DELITE SYSTEM SL Pure DeLite offers a wide range of rebound damping adjustment Adjusting the air pressure in this chamber helps fine tune the small bump ride threshold or break away of the fork This chamber should be inflated to a minimum of 10 psi and a maximum of 60 psi Less air pressure will make the fork feel softer and helps absorb
9. n extreme conditions maintenance should be performed more frequently x WE RECOMMEND THIS SERVICE BE PERFORMED BY A QUAUFIED BICYCLE MECHANIC TO OBTAIN SERVICE INFORMATION OR INSTRUCTIONS VISIT OUR WEBSITE AT VWWWWYROCKSHOX COM OR CONTACT YOUR LOCAL ROCKSHOX DEALER OR DISTRIBUTOR Torque Tightening Values Top Caps AO in Ib Brake Posts 80 in Ib Shaft Bolts 60 in Ib Check Air Pressure See Air Pressure Guidelines Remote Lockout clamp bolt 8 in lb Pure top cap clamp screw 8 in lb Duke Model Maintenance Clean dirt and debris from upper tubes Check upper tubes for scratches Check top caps brake posts and shaft bolts for proper torque Lubricate foam ring Remove lower casting clean bushings and change oil bath SL and Race Change oil in pure system Clean and lubricate Remote Lockout assembly 8 950 006718 00 Rev A01 Rock SHox Inc 2003 DUKE OWNER S MANUAL ENGLISH WARRANTY RockShox Inc warrants its products for a period of two years from original date of purchase to be free from defects in materials or workmanship RockShox USA or an authorized RockShox Agent must inspect all RockShox products If a product is found by RockShox or its authorized agent to be defective in materials or workmanship replacement or repair is at the option of RockShox This warranty is the sole and exclusive remedy RockShox shall not be held liable for any indirect special or consequential damages Exclusions of Warranty This
10. ork 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 propery 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 hangedess braoe 4 Adjust the front wheel quick releese to clear the dropouts counter bore The quick release nut must be tightened after the wheel is property seated into the dropouts counter bore Make sure four or more threads are engaged in the quick release nut when it is dosed Orient the quick release lever in front of and parallel to the lower tube in the locked position 5 Keepin mind tire dearance as you choose tires Maximum size is 2 4 wide or 348 mm radius installed Be sure to check this radius whenever you change tires To do this remove the top caps and spring stack assemblies and compress the fork completely to make sure at least 5 mim of Clearance exists between the top of the tire and the bottom of the crown Exxoseding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed PERFORMANCE TUNING RockShox Duke forks can be tuned for your particular weight riding style and terrain Setting Sag Duke forks are designed to sag when you are sitting on your bike S
11. rs of the trail maximizing stability traction and control DUKE XC XC U TURN The knob offers 90 degrees of adjustment DUKE RACE ANDSL The knob offers three complete turns of adjustment PURE SYSTEM RACE MODEL Your fork uses the Pure Damping System This system provides maximum ride control with on the fly adjustable compression damping including lockout Climb It Control Performance Race To change the compression damping adjustment on your fork locate the adjuster knob on the top of the right leg A clockwise adjustment increases the compression damping Turning the adjuster completely clockwise provides on the fly lockout to minimize movement while sprinting or climbing Integrated into the lockout system is a big hit blow off feature allowing fork movement in the event of an unexpected change in terrain To maintain lockout control and damping quality the Pure Damping system should be rebuilt once a year We recommend that a qualified bicycle mechanic with proper tools should rebuild the Pure Damping System For more detailed service information contact your local RockShox dealer or visit www rockshox com Remote Lockout Option The Remote Lockout lever allows incremental compression adjustment and lockout of your fork without removal of your hands from the handlebars The lever offers approximately 130 degrees 6 950 006718 00 Rev A01 Rock SHox Inc 2003 DUKE OWNER S MANUAL ENGLISH of adjustment from fully act
12. s 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 cable stops Do not use a front brake cable leverage device mounted to the brace 7 Observe all owner s manual instructions for care and service of this pro
13. 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 apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturer s specifications or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not cover paint damage or modifications to the product Original proof of purchase is required Warranty repair replacement is only valid upon presentation of proof of purchase directly submitted to RockShox at the time of warranty evaluation Warranty repair or replacement is at the discretion of RockShox or its authorized agent upon physical product evaluation and proof of purchase This warranty does not include or cover common wear and tear parts which are subject to damage as a result of normal use failure to service product according to RockShox recommendations wet conditions racing use of disc brakes rider weight riding or installation in conditions or applications other than recommended Wear and Tear parts are identified as External dust seals bushings foam rings rubber moving parts such as air sealing o rings and glide rings stripped threaded shafts or bolts upper tubes stanchions re
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