03 SID Service Guide
Contents
1. Assembly IFF O ring Compression Piston O ring Pure Tube Rebound Piston Glide Ring Seal Head O ring Rebound Damper Assembly 2003 SID SERVICE GUIDE ROCK 2003 SID Service Guide NMJ 48 Insert an oil mixing syringe into the top of the top cap adjuster rod hole Slowly pour RockShox 5wt fork oil into the syringe Pull up and down slowly on the rebound damper shaft to cycle the oil into and through the pure tube damper assemblies Add oil until pure tube is completely full of oil fig 48 and oil mixing syringe is about half full NOTE ENSURE YOUR FORK IS VERTICAL WHILE BLEEDING THIS HELPS DURING THE BLEED PROCEDURE THAT FOLLOWS 49 Now bleed all of the air from the Pure tube damper With the oil syringe still in the top cap pull the rebound damper shaft slowly up and down until you no longer see ait bubbles rise from the pure tube damper This takes approximately 30 cycles of the shaft to release all of the air from the damper fig 49 NoTE SLIGHTLY ROTATING THE REBOUND SHAFT IN A TWISTING MOTION WHILE CYCLING THE REBOUND SHAFT ASSISTS IN ALLOWING TRAPPED AIR BUBBLES TO ESCAPE IT IS CRITICAL THAT ALL AIR BUBBLES ARE BLED FROM OIL BEFORE FINAL ASSEMBLY 50 Place your palm onto the top of the oil syringe to create a vacuum Pull the syringe up and release all of the excess oil into your oil pan fig 50 51 The Pure damper is now full of oil Insert the aluminum compression rod into the compression damper top cap and2. release The weight of the rod allows it to sink into the compression damper fig 51 Oil will displace and the system now contains pure oil only Hand tighten the aluminum compression rod to the fully closed position DO NOT USE A WRENCH 52 Using a 24mm socket tighten the compression damper top cap to 50in lb 53 Clean the compression damper assembly top by spraying isopropyl alcohol into the Rev A 11 ROCK lt 2003 SID Service Guide top cap detent holes and wipe clean with a rag HINT IT HELPS TO INVERT THE FORK 54 Test the lockout function With the compression damper adjuster rod in the fully closed position hand tight push up on the rebound damper shaft If the shaft does PURE CLIMB IT CONTROL KNOB INSTALLATION not move the lockout function is working If the rebound shaft compresses into the upper tube there is an air gap and the damper must be bled again Begin from step 48 55 From the back of the crown perspective insert the detent spring into the six o clock positioned detent hole Position the ball bearing on the top of the detent spring fig 55 56 Install the Pure knob over the compression damper rod with the lockout dial in the six or seven o clock position which ever is closest to the back of the crown fig 56 Tighten the knob to the assembly with the 2 5mm hex bolt 57 Test the lockout function and the compression damper setting of the Pure knob by turning counterclockwise Cycle
3. For exploded diagram and part number information refer to the 2003 Spare Parts Catalog P N 950 007563 00 Contact your local distributor or visit the RockShox website at www rockshox com for ordering information Information contained in this publication is subject to change at anytime without prior notice For the latest technical information visit our website at www rockshox com Names used in this manual may be trademarks or registered trademarks of others Table of Contents LIERNI Te S Nag Be SRR ee 2 Remove the Lower Legs b a NM ee me Bes 2 Removing the Dual Air Assembly BA Se A eee 3 All Travel Configurations and Installation of the Dual Air Assemblies 0 0 cee es 4 Removing the Compression Neutral Shaft and Rebound Assemblies 0 0c eee eee eee eae 4 Servicing the Pure Delite Rebound Damper SID Race Only Ga oe eee 5 Assembly of the Pure Delite Damper SID Race Only 50u ee ee De a eee ee eee 6 Servicing the Pure Damper with Climb it Control SID Team and World Cup a 2 2 2 255 eee ee 8 Assembling the Pure Damper p S OM GP ee 10 Installing the Lower Legs gq d EE ye E ees 12 Pure Climb It Control Knob a o T T ee 12 Aeaee Seen ees eee gt came pattie of 68 EE aerate any aan te ain tan E nage a 14 International Distributors l o r MB BBR Dw ec eee 15 Service Guide 2003 SID Service Guide e Clean work area e Bicycle st
4. ONFIGURATIONS AND INSTALLATION OF THE DUAL AIR ASSEMBLIES 14 With the 20mm All Travel spacer snapped in place on the positive air shaft Fig 14a the fork is set up for 63 mm of compression travel By removing the 20 mm All Travel spacer from the positive air shaft Fig 14b the fork is set up for 80 mm of compression travel 15 Carefully insert the Dual Air spring assembly into the bottom of the upper tube Be sure to push the piston straight into the upper tube The tube is threaded ensure you don t cut or knick the o rings see fig 11 16 Using your SID Threaded Base Plate Removal Tool thread the base plate into the upper tube turning counterclockwise Tighten firmly and remember reverse threads fig 10 4 2003 SID SERVICE GUIDE ROCK 2003 SID Service Guide Wl 17 Add 3 cc ml of 15wt oil or RockShox RedRum to the positive air chamber fig 17 This lubricates the positive air seal o ring and protects against heat friction and wear Install the air top cap with a 24mm socket to 50 in lbs 18 Remove the black cone bottom out bumper from the rebound damper shaft 19 Press the schrader valve on the Delite air top cap and release any air pressure 20 Using a 24mm socket tool loosen and remove the Pure Delite air top cap from the crown Pull up and remove the entire Pure Delite damper assembly see fig 20 from the upper tube Remove the Delite air top cap by pulling out of the Pure damper tube 21 Invert the dam
5. SE PLATE RETAINER AND THE UPPER TUBE REMOVE AND REPLACE WITH 18 0 ID x 2 5 O RING PART NUMBER 630 000904 00 AVAILABLE IN THE FOLLOWING KITS 110 006245 00 Pure REBUILD KIT AND 110 006173 00 DuaL AIR SERvicE Kit 110 006176 00 1 eS Pull the Dual Air shaft until the entire assembly is removed from the upper tube You may need to release additional negative air by pressing the negative air valve fig 11 Rev A ROCK Wt 2003 SID Service Guide REMOVING THE COMPRESSION NEUTRAL SHAFT AND REBOUND ASSEMBLIES 12 The SID Dual Air spring assembly consists of two assemblies a The positive air spring shaft and piston b The negative air shaft and piston Inspect the air seal o rings on each assembly for wear or cuts fig 12a 12b and 12c Replace o rings with the SID Dual Air O ring Service Kit 110 006176 00 IMPORTANT AFTER THE AIR SEAL O RINGS ARE REPLACED APPLY A LIGHT COATING OF 15wT OR ROCKSHOX REDRUM TO ALL THREE O RING AIR SEALS PROPER LUBRICATION OF THE AIR SEALS DECREASES HEAT FRICTION AND WEAR Fic 14 13 Inspect the inner part of the upper tube and clean with isopropyl alcohol and a clean rag You may need to wrap the clean rag around a long dowel or screwdriver Allow tube to dry Positive Air Spring Shaft 1 2 a Positive Air Seal Inner Negative O ring Air Seal Negative Air Shaft a Outer Negative O ring Air Seal Outer Negative Inner Negative P O ring Air Seal O ring Seal s ALL TRAVEL C
6. and e 24mm 15mm and 10mm Socket Wrench e 5mm and 2 5mm Hex Wrench e Dental Pick e SID Threaded Base Plate Removal Tool part 140 001905 00 e 300psi Shock Pump part 120 004873 00 e Plastic Mallet e Lint Free Rag Oil Pan e Judy Butter or Red Rum e RockShox 5 and 15wt oils e Isopropyl Alcohol Spray Bottle e Torque Wrench e Safety Glasses Note RIGHT SIDE EQUALS RIDER S RIGHT LEFT SIDE EQUALS RIDER S LEFT THIS SERVICE MAY ALSO BE PERFORMED WHILE THE FORK IS INSTALLED ON THE BICYCLE NOTE THOROUGHLY READ THIS GUIDE BEFORE PERFORMING SERVICE ON YOUR PRODUCT NOTE WHAT KIND OF KITS PARTS YOU MAY NEED TO REPLACE 1 Remove the air caps from both top caps and negative air valves on the bottom left leg 2 Starting with the negative air valve bottom left lower leg release the air pressure from all air chambers Fork should be completely deflated before disassembly fig 2 Note A SMALL AMOUNT OF OIL MAY COME OUT WHEN RELEASING THE AIR 3 Using a 10mm socket tool loosen the negative air shaft nut left side from the airshaft Loosen the nut enough so the nut extends past the threaded shaft end fig 3 4 Remove the rebound adjuster knob by pulling it from the rebound shaft bolt Using a 5mm hex wrench loosen the rebound damper shaft bolt right side about 3 turns ot half way fig 3 5 Place the 10mm socket on the negative air shaft nut left side and tap the socket using a plastic mallet until the shaft
7. 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 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 weig
8. complete list of Authorized Distributors outside the USA visit www rockshox com 14 2003 SID SERVICE GUIDE
9. e Dual Air shaft fig 34 SERVICING THE PURE DAMPER WITH CLIMB IT CONTROL SID TEAM AND WorLpb Cup 35 Remove the large bottom out bumper from the Pure rebound damper shaft 36 Using a 2 5mm hex wrench remove the Pure Climb It Control knob bolt fig 36 8 2003 SID SERVICE GUIDE ROCK 2003 SID Service Guide Wl 37 Lift the Pure knob up gently below the knob is a 5 32 ball bearing and detent spring Remove the ball and spring with a magnet fig 37 38 Using your fingers loosen and remove the aluminum compression adjuster rod fig 38 39 Use a 24mm socket tool to loosen the top cap When the top cap is loosened pull the Pure damper assembly from the upper tube fig 39 The assembly pulls out of the upper tube by lifting straight up 40 Turn damper tube assembly upside down with compression damper top cap aimed inside of your oil pan Push on the rebound damper shaft to cycle the oil from the PURE Tube assembly Cycle until most of the oil is drained fig 40 Rev A 9 ROCK wt 2003 SID Service Guide 41 Pull the top cap compression damper assembly slowly out of the Pure tube You need to pull fairly hard and twist the assembly to work it free from the Pure tube fig 41 Note IT HELPS TO HOLD A RAG AROUND THE EXPOSED COMPRESSION DAMPER ASSEMBLY AS YOU PULL UP AND TWIST THE RAG WILL ALSO COLLECT EXCESS OIL 42 Invert the tube and remove the rebound damper assembly Drain any remaining oil
10. e end of the rod should be a maximum of 8mm Floating Piston 26 Place the IFP on the end of the rod dowel with the pocketed side down This allows the IFP to be set to a depth of 6 inches inside of the Pure tube Place one end of the Pure tube onto the IFP piston o ring and press firmly down until the IFP is seated inside the tube fig 26 Be careful the Pure tube ends are sharp Use a rag to protect your hands 6 2003 SID SERVICE GUIDE ROCK 2003 SID Service Guide NMJ 27 Press down until the Pure tube end is flat against the vice or bicycle stand clamp fig 27a Pull the Pure tube up and off of the rod dowel The IFP is now seated firmly inside the tube at a 6 inch depth fig 27b 28 Before installing the Pure rebound damper assembly remove the white seal head assembly from the rebound damper shaft The seal head includes an outer o ring oil seal and an inner shaft o ring oil seal Inspect and replace if damaged or worn using the Pure Damper o ring service kit part 110 006245 00 Reinstall the seal head by sliding it over the rebound damper shaft NOTE LUBRICATE THE INNER REBOUND SHAFT O RING WITH A SMALL AMOUNT OF OIL BEFORE INSTALLATION 29 Holding the Pure tube over an oil pan with the pocketed side of the IFP facing down rounded side facing up fill the tube until completely full with 15wt RockShox fork oil fig 29 TIP FOR QUICKER REABOUND OR IN COLDER WEATHER YOU MAY SUBSTITUTE 45wT OIL FOR 10
11. fig 21 NoTE ONLY ON THE PURE SYSTEM IF THERE IS A WAVY WASHER LOCATED BETWEEN THE THREADED BASE PLATE RETAINER AND THE UPPER TUBE REMOVE AND REPLACE WITH 18 0 ID x 2 5 O RING PART NUMBER 630 000904 00 AVAILABLE IN THE FOLLOWING KITS 110 006245 00 Pure REBUILD KIT AND 110 006173 00 DuaL AIR Service Kit 110 006176 00 43 Inspect and replace all o rings and glide rings on the Pure damper assemblies fig 43 Inspect and clean the inside of the PURE tube using isopropyl alcohol and a clean rag 44 Using the SID threaded base plate removal tool remove the base plate from the bottom of the right upper tube Inspect the base plate o ring and replace if damaged Part 110 006245 00 or 110 006176 00 Reinstall the base plate 45 Install the rebound damper assembly into one end of the Pure tube fig 31 46 Insert the Pure tube and rebound damper into the upper tube through the crown rebound damper shaft facing down Using the rebound damper external adjuster knob open the rebound damper valve by turning counterclockwise fig 34 47 Apply a light coating of 5 wt fork oil to the internal floating piston o ring and fixed compression piston o ring Insert the compression assembly IFP into the top of the Pure tube through the crown Press firmly and twist side to side to work it into the Pure tube Using a 24mm socket tighten the compression assembly top cap 2 3 down fig 47 Aluminum Compression Rod Compression
12. ht 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 rear 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
13. olt holes fig 63 64 Slide the lower leg up on the upper tubes until both the rebound and Dual Air shafts slide through the bolt holes Wipe the lower leg and shafts with a clean rag to remove any excess oil or debris fig 64 65 Clean each black nylon crush washer and replace if necessary Insert and tighten the Rebound damper shaft bolt Hand thread the DualAir shaft nut and tighten with a 10mm socket Insert the rebound damper external adjuster knob 66 Inflate the positive air chamber to the desired pressure Inflate the negative air chamber to the desired pressure fig 66 Rider Weight Positive Air Pressure Left TopCap gt 120Ib 55 kg 70 80 psi 120 1401b 55 65 kg 80 100 psi 140 1601b 65 73 kg 100 120 psi 160 1801b 73 82 kg 120 140 psi gt 1801b 82 kg 140 160 psi Rider Weight XC Plush Ride Racing Firm Ride gt 120Ib 55 kg 70 80 psi40 60 psi 120 1401b 55 65 kg 80 100 psi 60 80 psi 140 1601b 65 73 kg 100 120 psi 80 100 psi 160 180lb 73 82 kg 120 140 psi 100 120 psi gt 1801b 82 kg 140 160 psi 120 140 psi 67 Spray a light coat of Isopropyl alcohol to the entire fork and wipe down with a clean rag Rev A 13 ROCK wt 2003 SID Service Guide 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 Ifa product is found
14. or 5 wt 30 Gently insert the rebound damper piston head into the oil filled Pure tube The oil will slowly fill the damper valves Allow enough oil to fill the cavities and top off the oil volume until completely full Gently press down on the white seal head until it snaps into the Pure tube securely Your damper is now sealed See FIG 31 NoTeE PISTON SEAL HEAD MUST BE TOPPED AGAINST REBOUND PISTON REBOUND DAMPING SETTING MUST BE OPEN Note Do NOT CYCLE THE DAMPER SHAFT UNTIL THE DELITE AIR TOP CAP HAS BEEN INSTALLED AND PRESSURIZED 31 Slide the Pure Delite damper unit into the top of the crown right side and upper tube just as you removed it Rev A 7 ROCK lt 2003 SID Service Guide 32 Add 3cc ml of 15wt RockShox fork oil to the top chamber of the Pure Delite damper This will lubricate the IFP o ring Install the Delite air top cap with a 24mm socket tool to 50 in lbs and pressurize the chamber 20 to 60 psi with your shock pump The IFP is now pressure set and your damper is sealed See FIG 33 IMPORTANT 60 PSI IS THE MAXIMUM AIR PRESSURE 33 Insert the rebound damper external adjuster knob into the bottom of the rebound damper shaft and turn clockwise until damper is in the full closed position This step will protect the internal damper rod when installing the shaft bolt fig 33 34 Slide the bottom out bumpers back onto to each shaft The large bumper is on the rebound shaft and the small bumper is on th
15. per and gently but firmly pull the rebound damper seal head from the Pure tube fig 21a You may want to hold a rag around the end of the Pure tube to catch any oil that spills Turn the Pure tube over and drain the oil into the oil pan see fig 21b 22 To remove the internal floating piston IFP hold the Pure tube over a clean rag with one end up The IFP is located inside the Pure damper tube in the center of the tube The IFP is the seal that separates the oil from the air in the Delite air chamber 23 Using a long plastic rod insert the rod into the Pure tube until the rod touches the underside of the IFP Make sure the rod engages only the pocketed side of the IFP This ensures that you do not damage the inside of the Pure tube with the rod Press firmly on the rod only when it is engaged safely into the IFP See fig 23a Push firmly down to release the IFP from the Pure tube See FIG 23b Pull the rod out gently without scratching the inside of the Pure tube Rev A ROCK lt 2003 SID Service Guide 24 See fig 24 for Pure Delite Damper assembly parts components Delite Air Top Cap Pure Tube 24 Pure Delite IFP Pure Rebound Damper ASSEMBLY OF THE Pure DELITE DAMPER SID Race ONLY 25 To assemble the Pure Delite damper the IFP must first be set to a 6 inch depth inside the Pure tube Mount a thin rod or dowel into the bicycle stand clamp or bench vice with 6 inches of exposed rod fig 25 The width of th
16. s are free from the lower leg You will feel the shaft release from the lower leg press fit fig 5 6 With an oil pan below the fork remove the negative air shaft nut and shaft bolt 2 2003 SID SERVICE GUIDE ROCK 2003 SID Service Guide NMJ 7 Turn fork right side up and firmly pull lower legs down Oil will drain into the oil pan fig 7 Using a clean rag and isopropyl alcohol wipe the upper tubes clean of oil and contamination Inspect the upper tubes for wear If anodization is worn from upper tubes the crown steerer upper tube assembly should be replaced NOTE SET THE LOWER LEG ASSEMBLY RIGHT SIDE UP TO ALLOW THE EXCESS OIL BATH TO DRAIN 8 Using a 24mm socket loosen and remove the air top cap left side Inspect the top cap o ring for wear Replace if worn or cut Clean the underside of the top cap with isopropyl alcohol fig 8 9 Turn fork on its side in the bicycle stand Remove the black bottom out bumper from the Dual Air negative shaft 10 Slide the SID threaded base plate removal tool attached to 15 mm socket tool or adjustable wrench over the Dual Air shaft until you get firm leverage on the inner hex fitting of the threaded base plate Press firmly into the hex fitting Turn the wrench clockwise the threaded base plate is reverse threaded to loosen the base plate Remove the base plate when unthreaded fig 10 NoTE ONLY ON THE PURE SYSTEM IF THERE IS A WAVY WASHER LOCATED BETWEEN THE THREADED BA
17. the rebound damper shaft in each position from full open to full close to test the lockout and compression damping settings fig 57a and 57b 58 Lock the damper out using the Pure knob and insert the bottom out bumper over the rebound damper shaft Insert the rebound external adjuster knob into the rebound damper shaft and turn clockwise until the damper is fully closed Remove the rebound knob INSTALLING THE LOWER LEGS Note For REMOTE CONTROL ADJUSTER KNOB INSTALLATION SEE THE REMOTE LOCKOUT LEVER INSTALLATION GUIDE 59 Clean and inspect the dust seals and foam rings Replace if necessary Part 110 007250 00 For bushing removal and installation refer to the Bushing Service Guide available at www tockshox com 60 Saturate the foam rings with 5wt or 15wt fork oil fig 60 This will provide fork lubrication to the foam rings and upper tubes when the fork is in use 61 Gently slide the lower leg assembly back onto the upper tubes Be sure the dust seals do not fold over Pull the lower leg assembly up just until you feel the lower bushing touch the bottom of each upper tube The shaft rods should not be visible through i i i lf 12 2003 SID SERVICE GUIDE ROCK 2003 SID Service Guide NMJ the shaft bolt holes of the lower leg fig 7 62 Invert the fork in the bicycle stand to about a 45 degree angle 63 Using an oil syringe add 10cc of 5wt RockShox fork oil to the bottom of the fork through each of the b
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