96 Mag Service
Contents
1. WARNING DO NOT FORCE DAMPING ADJUSTER KNOB TO TURN WHEN INSTALLING AIR CAP THE SOCKET OR BOX WRENCH MUST NOT GRAB ADJUSTER KNOB WHEN INSTALLING AIR CAP OR THE ADJUSTER ROD WILL BE DAMAGED 1993 MAG 10 When installing air cap lubricate O ring with grease and slide air cap into upper tube past wire clip groove Fig 10C Install wire clip and compress upper tube to seat air cap 8 Pressurize fork legs to 80 10Opsi for 1 hour then lower to desired setting 9 Grease dust wiper and install with small spring facing top of fork 10 Install fork boots NOTE FORK BOOTS SHOULD BE INSTALLED FOR OWNERS WHO RIDE IN MUDDY CONDITIONS OR WHO WANT TO EXTEND INTERVALS BETWEEN Fal 4 F i Ri MAINTENANCE page 10 FORK INSTALLATION INTO CROWN 1 Clean upper tube of all oil and set damping adjuster to the first index position softest setting 2 Insert upper tube 3mm above the top of crown Fig 11A 3 Turn upper tube to align 1 position on adjuster with slot on crown Fig 11B NOTE ALL TITANIUM FASTENERS ON THE MAG 21 SLTi MUST HAVE ANTI SEIZE OR LUBE ON THE THREADS DURING INSTALLATION 4 Tighten crown bolts to 60 IN LBS 6 8 Nm in an alternating fashion NOTE INSTALL STEEL CROWN BOLTS WITH AMPLE MEDIUM STRENGTH THREADLOCK WARNING DO NOT OVERTIGHTEN CROWN BOLTS 5 Rotate lower legs forward so fork brace mounting holes face front of bicycle Install brake posts and bolts through fork brace WARNING TO A2. MACs MES TUM SERVICE MANUAL L 9 9 6 For Mag 21 1993 1994 1995 and 1996 model years Mag 21SLTi 1994 model year Mag 10 1993 and 1994 model years RockShox Inc 1 800 677 7177 INTRODUCTION This service manual describes how to service the following RockShox suspension forks Mag 21 1993 1994 1995 and 1996 model years Mag 21SLTi 1994 model year Mag 10 1993 and 1994 model years The ROCK SHOX Mag suspension fork is a sophisticated system Care and patience should be used when servicing internal components The damping units are oil filled and pressurized so a thorough understanding of the disassembly procedure proper tools and a clean working area must be used to achieve correct performance and ensure that parts are not damaged Use only genuine RockShox replacement parts REQUIRED TOOLS COMMON HAND TOOLS e Quadra bushing removal tool PN 70106 e Small tip external snap ring pliers e ROCK SHOX standard pump air gauge e Small tip internal snap ring pliers PN 20109 Not Shown e 19 amp 22mm socket and ratchet or box end wrench e RockShox needle PN 56991 e Torque wrench no hole on side to tear air valve e Metric ruler 150mm or longer MISCELLANEOUS e Precision calipers 6 inch optional e High quality bearing grease e 32 amp 36mm headset wrenches Judy Butter or Non Lithium e 1 phillips screw driver e Medium strength thread lock e g Loc Tite 242 e 1 liter beaker or container for used fork oil e RO
3. Psi 40 45 Psi Oil height 35 40 mm 40 45 mm Oil viscosity SAE 5 wt RockShox SAE 5 wt RockShox Valve spring preload O 5mm O 5mm Rebound bleed hole s 1X 1 0 mm 1X 1 0 mm Compression Bleed hole 2 0 mm 2 0 mm Travel Long Travel 60 mm Long Travel GO mm page 14 WARRANTY ROCKSHOX INC WARRANTS ITS FORKS FOR A PERIOD OF ONE YEAR FROM ORIGINAL DATE OF PURCHASE TO BE FREE FROM DEFECTS IN MATERIALS OR WORKMANSHIP ANY ROCKSHOX FORK 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 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 FORKS WHICH HAVE NOT BEEN PROPERLY INSTALLED AND ADJUSTED ACCORDING TO ROCKSHOX INSTALLATION INSTRUCTIONS THE WARRANTY DOES NOT COVER ANY FORK 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 FORKS PROOF OF PURCHASE IS REQUIRED Warranty Repair IF FOR ANY REASON IT SHOULD BE NECESSARY TO HAVE WARRANTY WORK DONE RETURN THE FORK TO THE PLACE OF PURCHASE IN THE USA DEALERS SHOULD CALL FOR A RETURN AUTHORIZATION RA PRIOR TO RETURNING PRODUCT PRODUCTS RETURNED FOR INSPECTION MUST BE SENT FREIGHT PREPAID TO RockSHOX INC 401 CHARCOT Ave San Jose CA 95131 408 435 746
4. THE TOP OUT SPRING CAN FAIL IF TOO MUCH FORCE IS USED TO REMOVE MAIN SEAL PROCEED CAREFULLY AND SLOWLY APPLY HEAT TO LOWER TUBE BEFORE ATTEMPTING TO USE 32MM AND 36MM WRENCHES If the top out retaining ring fails the upper tube will separate from the lower tube and the seal bushings top out spring and top out retaining ring will remain in the lower tube Grab the bushings and the main seal with one end of the Quadra bushing removal tool PN 70106 slide the seal puller over the bushing removal tool shaft and attach the end of the bushing removal tool to a bench vice Use the seal puller to pull the bushings and main seal straight out from the lower tube An alternate method is to use a small thin flat olade screwdriver to pry the main seal from the lower tube being careful not to damage the lower tube The bushings spacer top out spring and top out retaining ring should now slide out of the lower tube Turn upside down and tap the lower tube on a bench page 4 UPPER TUBE PARTS EXPLAINED 1 Slide the seal bushing washer main seal O ring bushings bushing spacer and top out sleeve off the upper tube Fig 5C NOTE ONLY REMOVE THE VALVE BODY FROM THE UPPER TUBE IF IT NEEDS SERVICE OR REPLACEMENT OTHERWISE IT MAY BE LEFT IN THE UPPER TUBE WHILE OVERHAULING THE FORK Skip to Upper Tube Parts Assembly FOR DISASSEMBLED FORKS WHERE THE TOP OUT SPRING RETAINING RING FAILED INSPECT SNAP RING GROOVE ON VALVE BODY AND REPLA
5. 9 FAX 408 435 7468 CUSTOMERS IN COUNTRIES OTHER THAN THE USA SHOULD CONTACT THEIR DEALER OR LOCAL DISTRIBUTOR page 15
6. A car for example uses a steel coil or leaf spring and an oil damper However steel springs are much heavier than an air spring For this reason a lightweight air spring and oil damped suspension system is more appropriate for bicycles Suspension works by allowing the wheel to quickly move up and down with the irregularities of the ground without moving the mass of the rider or vehicle with it This means the wheel can stay on the ground improving control and ground feel for the rider The suspension should move as much as possible to follow the ground without bottoming out hitting the end of its travel Depending on the bump size and how fast it is hit the Suspension varies in firmness to prevent bottoming but the spring and damper do it in different ways The spring changes according to how much it is compressed while the damping changes according to the speed of the force put into it how fast it compresses This combination means the suspension can sense whether the wheel hits a big or small bump or how fast or slow and adjust its firmness accordingly The damping also has a second function of controlling the rebound extension action of the suspension A spring alone will rebound at different soeeds depending on how much it has been compressed and this would make the suspension movement very unpredictable The rebound damping allows the Suspension to rebound at a predictable speed The air spring stiffness or spring rate ca
7. CE AS NEEDED USE ONLY GENUINE ROCKSHOX REPLACEMENT PARTS 2 Place inverted upper tube in clamping blocks PN 70101 and bench vice 3 Insert pins on valve body tool PN 70105 into holes on valve body 4 Turn valve body tool PN 70105 counterclockwise with a 19mm wrench Apply downward force while applying torque to valve body tool to prevent tool from pulling out and damaging valve parts Fig 5A NOTE IF SERVICE OF THE TOP OUT SPRING IS NOT REQUIRED THE FOLLOWING STEP ME BE SKIPPED 5 Remove top out snap ring from valve body using external snap ring pliers The top out spring and top out washer should now slide off valve body Fig 5B e 1993 MAG series forks Mag 10 and Mag 21 have identical upper and lower bushings The bushings may be identified by the 1 126 28 60mm outside diameter e 1994 and later MAG series forks have different size upper and lower bushings The upper bushing outside diameter is larger than the lower bushing Because the difference between the outside diameter of the upper and lower bushings is very small it is recommended that the upper bushing be marked to avoid contusion The lower bushing may be identified by the 1 126 28 60mm outside diameter The upper bushing may be identified by the 1 157 29 39mm outside diameter For MAG series forks the 1994 and later lower fork bushings are identical to the 1993 upper and lower fork bushings Top out Top out Top out Valve Body Snap Ring Spr
8. CK SHOX fork oil Swt or 8 wt e Safety glasses e Straight blade screwdriver e Bench vice SPECIAL ROCK SHOX TOOLS 1 Upper tube clamping blocks PN 70101 2 Seal lower bushing installer PN 70103 3 Seal puller PN 70113 4 Valve body tool PN 70105 5 Drop out vice blocks PN 70107 Steerer Tube Damping Adjuster Knob Fork Crown Bolts 2 each side Fork Crown Upper Fork Tube w dust boot Fork Brace Fork Brace Bolt Brake Post Lower Tube page 1 REMOVAL OF FORK TUBES FROM FORK CROWN Note It is not necessary to remove the crown steerer assembly from the bike to service the damper units 1 Disconnect front brake cable from brake lever t etar 2 Loosen fork crown bolts alternately to avoid putting too much clamping A l force on one bolt and potentially stripping the bolt head 4mm hex key Figure 2A 3 Pull both lower fork tubes out of the crown with a slight rocking motion Fig 2A FORK BRACE REMOVAL 1 Remove brakes as per manufacturer s recommendations 2 Remove both brake posts using an 8mm open end wrench Fig 2B 3 Remove both brace screws using a 4mm hex key 4 Clean the exterior of both fork legs use Soap and water if necessary iB W DEPRESSURIZE FORK 1993 MAG 10 1993 MAG 21 1 MAG 10 1993 Pry out upper tube dust cap from the side Fig 2C MAG 21 1993 Remove air filler screw from the top of the air cap using a 1 phillips screw driver fig 2D MAG 10 1994 a
9. MAG 10 MAG 21 MAG 10 Air pressure 35 40 Psi 35 40 Psi Air pressure 42 48 Psi 42 48 Psi Oil height 45 50 mm 50 55 mm Oil height 35 40 mm 40 45 mm Oil viscosity SAE 5 wt RockShox SAE 5 wt RockShox Oil viscosity SAE 8 wt RockShox SAE 8 wt RockShox Valve spring preload O0 5mm O 5mm Valve spring preload 5 mm 1 0 mm 5 mm 1 0 mm Rebound bleed hole s none none Rebound bleed hole s none none Compression Bleed hole 1 5 mm Standard 1 0mm Compression Bleed hole Standard 1 0mm Standard 1 0mm Travel Standard 46mm Standard 46mm Travel Standard 46mm Standard 46mm DOWNHILL SETTINGS For MAG 10 MAG 21 forks with Long Travel Kit PN 59030 or Performance Tuning Kit PN 59025 LIGHT RIDER less than 140lbs HEAVY RIDER 180lbs MAG 21 MAG 10 MAG 21 MAG 10 Air pressure 38 42 Psi 38 42 Psi Air pressure 42 50 Psi 42 50 Psi Oil height 40 45 mm 45 50 mm Oil height 30 35 mm 30 35 mm Oil viscosity SAE 5 wt RockShox SAE 5 wt RockShox Oil viscosity SAE 8 wt RockShox SAE 8 wt RockShox Valve spring preload O 5mm O 5mm Valve spring preload O 5mm O 5mm Rebound bleed hole s 2X 1 0 mm 2 X 1 0 mm Rebound bleed hole s none none Compression Bleed hole 2 0 mm 2 0 mm Compression Bleed hole 1 5 mm 1 5 mm Travel Long Travel 60 mm Long Travel GO mm Travel Long Travel 60 mm Long Travel GO mm AVERAGE RIDER 140 180lbs MAG 21 MAG 10 Air pressure 40 45
10. Racing Oil is recommended for most riders Heavier riders gt 180 pounds may prefer the performance of RockShox 8 weight Racing oil because larger compression and rebound forces will be generated and require higher damping 1 Mount lower leg vertical in vice with vice blocks tools PN 70107 Fig 10A 2 Compress upper tube completely into lower tube 3 Turn adjusting rod to full counterclockwise position using an aircap or an old adjuster head Fig 10B 4 Add fork oil for oil selection see Performance Tuning to top of tube 5 Slowly pump upper tube up and down fully until no air pockets are felt in the damping approximately 10 times It will be necessary to pull up against the top out spring to reach full extension of assembly NOTE PULL UPPER TUBE UP SLOWLY AND CAREFULLY OR A VACUUM MAY FORM CAUSING THE BOTTOM PLATE TO BECOME LOOSE IF OIL IS VISIBLE IN THE DROPOUT HOLE THE LEG MUST BE COMPLETELY DISASSEMBLED AND THE BOTTOM PLATE REINSTALLED 6 Add or remove oil to obtain the correct oil level To determine the oil level measure the distance between top of upper tube and top of oil when upper tube is completely compressed For oil level selection see Performance Tuning Fig 10A 7 Install air cap MAG 21 All When installing air cap engage adjuster rod with bottom of adjuster head Turn air cap clockwise with a 19mm 1993 MAG 21 or 22mm 1994 and later MAG 21 models with a socket or box wrench Fig 10B
11. TUBE PARTS EXPLAINED THE VALVE BODY IS TIGHTENED AT THE FACTORY ONTO THE STEEL UPPER TUBE WITH 35 FT LBS OF TORQUE AND BLUE LOC TITE THEREFORE IT IS ON VERY TIGHT TO AVOID DAMAGE TO BOTH THE VALVE TOOL AND THE VALVE BODY IT MAY BE NECESSARY TO APPLY A PENETRATING OIL OR USE MILD HEAT TO LOOSEN THE THREADLOCK APPLY DOWNWARD FORCE SO VALVE BODY TOOL DOES NOT WALK OUT OF VALVE BODY Exchange the cross country travel top out sleeve PN 53124 with a long travel top out sleeve PN 53123 in both legs Read Performance Tuning and Performance Settings and perform the recommended modifications Continue with instructions in Valve Parts Explained to finish installation page 12 PERFORMANCE TUNING The standard RS settings are designed for use by riders weighing between 140 and 180 lbs 65 80 Kgs and riding on a variety of cross country type conditions When the MAG series forks will be used by riders outside of this weight range or for other applications such as downhill racing the following settings should yield greater suspension performance But first it s best to know how the ROCK SHOX MAG series fork works The Basics RockShox MAG series forks are based on an air spring oil damped suspension system An air oil suspension system is really two components working together at the same time an air spring and an oil damper shock absorber Most modern suspension systems utilize some form of spring and damper mechanism
12. VOID DAMAGE TO MAGNESIUM THREADS WHEN INSTALLING FORK BRACE PLEASE OBSERVE STEPS 6 amp 7 CAREFULLY 6 Use ample medium strength threadlock on brake posts and fork brace bolts The correct torque for all years and models of MAG series forks is only 60 IN LBS 6 8 Nm for brake posts and brake bolts 7 When installing brakes be certain that brake fastening bolt is not torqued beyond 60 IN LBS 6 8 Nm or damage to magnesium threads may occur If threads are stripped out of magnesium tubes they can be repaired with a M6 X 1 X 9 Helicoil thread repair kit 8 Install brakes as per manufacturer s specifications 9 For a brake requiring a brake cable mount route brake cable housing directly from brake levers to top of cable mount on ROCK SHOX fork brace Do not route cable through stem or any other mounts or cable stops A properly installed brake cable should be able to move freely up and down with the full travel of fork legs Full travel for MAG 21 is 50mm MAG 21 LT full travel is 63mm It may be necessary to install a new brake cable and housing Note The distance from top of brake cable hanger to bottom of cable mount on ROCK SHOX fork brace must be a minimum of 12mm with the brakes applied 10 Check Tire Clearance Maximum tire size is 2 2 wide or 335mm radius Be sure to check this radius whenever you change tires Exceeding this maximum will cause tire to jam against crown when forks are fully compressed A minimum tire clearanc
13. e The 1993 MAG valve body had two intake port valves with a wie 2 ee compression bleed hole drilled 0 028 0O 71mm 1994 and later valve bodies PN 42226 had four intake port valves with a compression bleed hole drilled to 0 040 1 02mm The intake port valves and the compression bleed hole are tuning variables e Another change made for the 1994 and later MAG series forks were that the valve plate PN 42327 was machined with a relief step of 0 005 1 Check coating on inside of bushings and replace if scratched or worn brassy colored Replace bushings as needed fig 7A WARNING BUSHINGS FROM 1993 REBUILD KIT WILL NOT WORK CORRECTLY AS UPPER BUSHINGS FOR 1994 amp LATER FORKS 2 Check upper tube for signs of nicks or scratches that could damage seal or inhibit proper seal function Replace upper tube as needed 3 Check all O rings for evidence of tears deformations or scratches Check rebound plate for deformations or scratches Replace as needed fig 7B 4 Check main seal for deformations or scratches Replace as needed fig 7C NOTE IT IS VERY RARE THAT A SEAL FAILS THE PRIMARY ae CAUSE OF SEAL LEAKAGE IS DUE TO DIRT WORKING INTO THE LIPS OF THE SEAL OR A SCRATCHED OR DAMAGED UPPER TUBE AND DISRUPTING THE SEAL S FUNCTION IN MOST CASES THEY MAY BE CLEANED AND REINSTALLED PROPER MAINTENANCE AND CLEANING OF THE UPPER TUBE AND DUST WIPERS WILL PREVENT LEAKAGE 5 Check top out spring for correct
14. e of 1 4 6 4mm is necessary NOTE TO OBTAIN THE REQUIRED CLEARANCE UPPER TUBES MAY BE ADJUSTED IN CROWN HOWEVER DO NOT RAISE UPPER TUBES IN CROWN MORE THAN 3MM FIG 11C page 11 SL UPGRADE KITS Installation of the EA 70 upper tubes and SL aircaps 1 Complete the following sections located in this manual REMOVAL OF FORK TUBES DEPRESSURIZE FORK FORK AIR CAP REMOVAL DRAIN OIL FORK BOOT AND DUST WIPER REMOVAL MAIN SEAL REMOVAL 2 Complete steps 1 through 5 in UPPER TUBE PARTS EXPLAINED THE VALVE BODY IS TIGHTENED AT THE FACTORY ONTO THE STEEL UPPER TUBE WITH 35 FT LBS OF TORQUE AND BLUE LOC TITE THEREFORE IT IS ON VERY TIGHT TO AVOID DAMAGE TO BOTH THE VALVE TOOL AND THE VALVE BODY IT MAY BE NECESSARY TO APPLY A PENETRATING OIL OR USE MILD HEAT TO LOOSEN THE THREADLOCK APPLY DOWNWARD FORCE SO VALVE BODY TOOL DOES NOT WALK OUT OF VALVE BODY Clean old threadlock from threads of valve body do not use Loc Tite on EA 70 upper tubes Install valve body into new EA 70 Taperwall upper tubes Turn to Upper Tube Parts Assembly step 1 to finish installation LONG TRAVEL CONVERSION Required parts Mag 10 Mag 21 Long Travel Kit PN 59030 or Mag 10 Mag 21 Performance Tuning Kit PN 59025 1 Complete the following sections located in this manual REMOVAL OF FORK TUBES DEPRESSURIZE FORK FORK AIR CAP REMOVAL DRAIN OIL FORK BOOT AND DUST WIPER REMOVAL MAIN SEAL REMOVAL 2 Complete steps 1 through 5 in UPPER
15. free length Measure spring from end to end Minimum length is 0 827 21 0mm Replace as needed fig 7D 6 Inspect fork brace at cable mount area for signs of damage from crashes or misuse fig 7E NOTE IF POSSIBLE ADJUST THE HANDLEBARS TO HIT THE TOP FRAME TUBE BEFORE THE FORK CAN SWING AROUND AND THE CABLE MOUNT HITS THE DOWN TUBE 7 Inspect lower tubes for signs of damage at the drop out area fig 7F Replace as needed Figure F page 7 VALVE ASSEMBLY Valve Body Rebound Plate Valve Spring plastic Valve Spring Washer aluminum y a Adjuster Rod Valve Plate Valve Spring Snap Ring Figure 8A 1 Slide the following parts onto adjuster rod in the following order rebound plate valve plate valve spring and valve spring washers fig 8A 2 Install valve spring snap ring on the damper rod using external snap ring pliers Place sharp side of snap ring away from valve v spring washer fig 8B WARNING BE CAREFUL NOT TO OVEREXTEND VALVE SPRING SNAP RING WITH THE PLIERS 3 Screw adjuster rod assembly completely into valve body 4 Install E ring on bottom of adjuster rod 5 Slide top out washer onto valve body followed by top out spring and install valve spring snap ring see fig 9C sharp side away from top out spring Fig 8A to retain the assembly Valve Body Rebound Plate Valve Spring Washer plastic preload TEC lt I Valve Bolt Valve Body Valve Plate Valve Spring Figu
16. g seal installer tool PN 70103 Fig 9B 6 Grease main seal inside and out Place main seal over upper tube NOTE INSTALL MAIN SEAL WITH SMALL SPRING SIDE FACING TOWARD INSIDE OF FORK PRESS SEAL INTO LOWER TUBE USING SEAL INSTALLER TOOL FIG 9B THE END OF TOOL WITH LARGER BORE SHOULD FACE THE SEAL 7 Install main seal snap ring sharp side up see fig 9C into lower leg using internal snap ring pliers WARNING THE SNAP RING MUST FULLY ENGAGE GROOVE IN LOWER TUBE IMPROPER A INSTALLATION MAY ALLOW THE TUBES TO SEPARATE DURING USE Top out Top out Top out Valve Body Snap Ring Spring Washer Upper Bushing Main Seal Dust Wiper Bushing Spacer Seal O ring Main Seal Bushing Washer Snap Ring Figure 9C page 9 FLUID LEVEL SETTING Introduction The air spring of the ROCK SHOX MAG series forks works by compressing a volume of air As the air compresses the pressure rises causing more force to be exerted against tubes This force creates a progressive spring curve that resists bottoming Changing the space of air inside the fork dramatically alters the spring curve Since oil is non compressible the level of oil inside the fork can be set to create the optimal spring curve The oil level is measured rather than volume to create the proper air Space and spring curve Changing fork oil viscosity will change the damping of the fork A lower viscosity fork oil allows the fork to compress and rebound faster RockShox 5 weight
17. ing Washer Upper Bushing Main Seal Dust Wiper Bushing Spacer Seal O ring Main Seal Bushing Washer Snap Ring Figure 5C page 5 MAG 21 VALVE PARTS EXPLAINED Screw adjuster rod all the way clockwise into valve body Remove E clip from bottom end of adjuster rod using a small straight blade screwdriver fig 6A Unscrew adjuster rod from valve body Remove valve spring snap ring using snap ring pliers Remove valve parts from adjuster rod fig 6B Inspect parts and replace as needed Figure 6B Valve Body Rebound Plate Valve Spring Washer plastic Valve Spring aluminum emoi Adjuster Rod Valve Plate Valve Spring Snap Ring Figure 6C 93 MAG 10 VALVE PARTS EXPLAINED Hold valve body with tool PN 70105 and remove valve bolt with flat blade screwdriver Remove E clip from valve bolt using a straight blade screwdriver Fig 6D The rebound washer valve plate valve spring and spring Figure 6D washer will now slide off Inspect parts and replace as needed Valve Body Rebound Plate Valve Spring Washer plastic preload papaia E clip Valve Plate Valve Bolt Valve Spring Figure 6E page 6 MAG COMPONENT INSPECTION e All 1993 MAG series forks were assembled with stiff valve springs PN 44103 However for 1994 and later MAG series forks the valve springs were softened PN 44306 to improve fork responsiveness The valve springs are a tuning variable gt e i
18. n be altered in many ways to suit the rider s weight terrain or riding style It can be made stiff in the beginning of the travel to stay more extended on steep downhills where more weight is on the front end or stiff at the end so it won t bottom out over jumps or if the rider is very heavy The damping can likewise be tuned The damping can be adjusted so that the fork moves when travelling over small bumps like washboards yet can be firm to absorb a large bump hit at high speed The fork can also be tuned to be rigid while pedaling by creating a minimum force threshold that must be overcome before the suspension can move normally While all this may sound simple the possible combinations are endless and many potentially bad performance side effects can arise from any change made to the spring or damping So to make tuning easier RockShox has come up with the following selection of special settings that can be safely made to suit a particular rider s needs page 14 page 13 STANDARD ROCK SHOX SETTINGS MAG 21 MAG 10 Air pressure 38 42 Psi 38 42 Psi Oil height 40 45 mm 45 50 mm Oil viscosity SAE 5 wt RockShox SAE 5 wt RockShox Valve spring preload O0 5mm 0 5 mm Rebound bleed hole s none none Compression Bleed hole 040 1 0mm Std 040 1 0mm Std Travel Standard 46mm Standard 46mm PERFORMANCE SETTINGS CROSS COUNTRY SETTINGS LIGHT RIDER less than 140lbs HEAVY RIDER 180lbs MAG 21
19. nd MAG 21 1994 and later Pry off rubber dustcap from top of air cap Fig 2E Insert a RockShox needle PN 56991 through the mar p exposed hole to depressurize the damper Fig 2F Tie WARNING POINT NEEDLE AWAY FROM YOURSELF AND OTHERS Figure 2E Figure 2F page 2 FORK AIR CAP REMOVAL 1993 MAG 10 1993 MAG 10 MAG 10 1993 4 i 1 Push the exposed aluminum air cap down into 10mm upper tube and remove the wire clip Fig 3A NOTE DO NOT SCRATCH THE INTERIOR WALLS OF THE TUBE WHEN REMOVING THE WIRE CLIP 2 Pull the air cap out of the tube with a 6mm bolt threaded into the center hole Fig 3B MAG 10 1994 1 Remove air cap by unscrewing it with an 8mm hex key 2 Inspect the adjuster head O ring for signs of wear or damage Replace if necessary Fig 3C MAG 21 ALL 1 Turn air cap counterclockwise with a 19mm 93 MAG 21 or 22mm 94 and later MAG 21 with a socket or box wrench Fig 3D NOTE DO NOT FORCE THE DAMPING ADJUSTER KNOB TO TURN WHEN REMOVING THE AIR CAP THE SOCKET OR BOX WRENCH MUST NOT GRAB THE ADJUSTER KNOB WHEN REMOVING THE AIRCAP OR THE ADJUSTER ROD WILL BE DAMAGED DRAIN OIL 1 Drain all oil by pumping unit upside down into a used oil receptacle Fig 3G PLEASE RECYCLE 2 For oil change only please see the section Fluid Level Setting ROCK i page 3 FORK BOOT AND DUST WIPER REMOVAL Figure 4A ae Figure 4C Remove fork boots by gently pulli
20. ng up on them Inspect boots for wear or damage Replace as needed Remove dust wiper by carefully prying up with a flat blunt screw driver Fig 4A 93 MAG 10 93 MAG 21 94 MAG 21 and 94 MAG 21 SLTi forks only Inspect dust wiper for wear or damage Replace as needed NOTE THE FOLLOWING MAG FORKS WILL HAVE FORK BOOTS INSTALLED AND NO DUST WIPERS 94 MAG 10 95 MAG 21 AND 96 MAG 21 MAIN SEAL REMOVAL Introduction The upper and lower tubes are held together by the main seal snap ring After removing the main seal snap ring the main seal must be pulled out to separate the two tubes Remove main seal snap ring using internal snap ring pliers fig 4B Extend upper and lower tubes to fully topped out position Place seal puller over tubes tool 70113 with the larger end over lower tube A OF N P Clamp upper tube in a vice with the vice blocks against the small end of the seal puller tool 70101 5 Unscrew seal puller by hand For hard to remove main seals refer to the instructions below fig 4C 6 Upper and lower tubes can now be pulled apart by hand fig 4D SPECIAL INSTRUCTIONS FOR HARD TO REMOVE MAIN SEALS If unable to remove seals by hand apply heat to lower tube at location of seal with a hot air gun or blow dryer WARNING DO NOT USE OPEN FLAME Carefully continue to unscrew puller If necessary use 32mm and 36mm headset wrenches on puller flats NOTE THE SNAP RING ON
21. re 8C 1 Slide the following parts onto valve bolt in the following order valve spring washer valve spring valve plate and rebound washer fig 8C 2 Install E clip with sharp side of E ring away from rebound plate 3 Thread valve bolt assembly into valve body using a straight olade screwdriver Use medium strength threadlock and torque to 36 IN LBS 3 3 Nm WARNING OVERTIGHTENING WILL BREAK THE VALVE BOLT page 8 UPPER TUBE PARTS ASSEMBLY 1 Hold upper leg in vice with upper tube blocks PN 70101 2 Tighten valve body into upper tube the valve goes into end of tube with threads all the way to edge apply three drops of medium strength threadlock to valve body threads Torque valve assembly to 35 FI LBS 48 Nm using valve body tool and 19mm 3 4 socket with torque wrench fig 9A Apply downward force while torquing to prevent tool from pulling out and damaging valve ports 3 Slide top out sleeve onto upper tube with shoulder away from top out e FigureSA OA m n spring fig 9C 4 Slide lower bushing onto upper tube followed by the bushing spacer upper bushing main seal O ring and main seal washer WARNING FOR 1994 AND LATER MAG FORKS THE UPPER BUSHING HAS A A LARGER OUTSIDE DIAMETER THAN LOWER BUSHING PLACING BUSHINGS IN THE WRONG POSITIONS WILL DAMAGE UPPER TUBES FOR IDENTIFICATION OF UPPER AND LOWER BUSHINGS SEE UPPER TUBE PARTS EXPLAINED SECTION 5 Gently press above assembly into lower tube usin
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