Rock Shox Quadra - suspensionforkparts
Contents
1. QUADRA SERVICE MANUAL ROCK SHOX 1996 Quadra 5 and Quadra 21R 1995 Quadra 5 Quadra 21 and Quadra 21R 1994 Quadra 10 and Quadra 21 1993 Quadra SUSPENSION FORKS RockShox Inc 1 800 677 7177 INTRODUCTION ROCK SHOX QUADRA To service Quadra forks you must determine which year and model of Quadra you are servicing Please refer to the chart below for assistance in identifying the fork you are working on QUADRA IDENTIFICATION GUIDE MODEL YEAR CROWN PRELOAD FORK BRACE ADJUSTER 93 Quadra BLK PRESSED ON HEX KEY BLACK ALUM 94 Q10 PRESSED ON HEX KEY BLACK ALUM 94 Q21 CLAMP ON HAND ADJUST BLACK ALUM 95 05 PRESSED ON HEX KEY STAMPED STEEL BLK ALUM 95 Q21 PRESSED ON HAND ADJUST GRAY ALUM 95 Q2IR CLAMP ON HAND ADJUST YELLOW MAG 96 05 PRESSED ON HAND ADJUST BLACK ALUM 96 Q2IR PRESS ON OE CLAMP ON DI HAND ADJUST YELLOW ALUM REQUIRED TOOLS COMMON HAND TOOLS e Small flat blade screwdriver e Small tip internal snap ring pliers e 3 8 drive torque wrench e Small tip external snap ring pliers e 22mm socket 3 8 drive or open end wrench e 4mm hex key ROCK SHOX TOOLS e 5 mm hex key e Quadra 5 10 21 bushing removal tool p n 70106 e 8 mm hex key e Quadra 5 10 21 bushing installer tool p n 70108 e 8 mm open end wrench e Upper tube clamping blocks p n 70101 e Soft face mallet e Seal puller p n 70113 e Precision calipers 6 e Quadra friction ring installer p n 70113 e Safety glass2. SAN Jose CA 95131 408 435 7469 FAX 408 435 7468 CUSTOMERS IN COUNTRIES OTHER THAN THE USA SHOULD CONTACT THEIR DEALER OR LOCAL DISTRIBUTOR page 8
3. release from assembly spray WD 40 or another thin lubricant into assembly then warm lower tube with a heatgun hairdryer NOTE 93 Quadra Main retaining ring holds fork together WARNING DO NOT USE OPEN FLAME ON MAGNESIUM LOWER LEGS Q5 Q10 Q21 and Q21R Be sure legs are compressed and use a long 5mm hex on a long extension to unscrew and remove plunger assembly from lower tube Fig 3D The lower tube can now slide free from upper tube Compress leg and then pull down sharply on lower tube NOTE 94 Q21 Disassembly requires removing plunger assembly from lower tube This model also has a retaining ring under the fork boot that retains a friction plate The retaining ring does not hold the fork together 9 793 QUADRA Proceed to Upper Tube Disassembly section Q5 Q10 Q21 and Q21R Proceed to Inspection section page 3 93 QUADRA UPPER TUBE DISASSEMBLY 1 Remove snap ring from end of plunger Fig 4A 2 Remove top out retaining clip Fig 4B 3 Remove following parts from upper tube top out spring top out washer top out sleeve bushing bushing spacer bushing compression ring and main retaining ring Fig 4C 4 Proceed to Inspection section Fig 4A Main Retaining Ring Friction Ring Friction Ring O ring Bushing Bushing Spacer I i Compression Bumper Bushing Top out Sleeve gt Plunger Guide Top out Washer ees
4. Remove sleeve from installer tool Slide greased upper bushing onto installer tool Slide installer tool into lower tube making certain to engage tool with lower bushing Using a soft mallet gently tap installer tool into lower tube until tool bottoms on lower tube Repeat procedure for other lower tube Grease inside of bushings after installation Note Bushings must be pressed in straight Use care to prevent bushings from seating at an angle Do not use lithium based grease on bushings it can damage the gray coating FORK REASSEMBLY 1 Make certain all parts are clean and properly lubed bushings and elastomers greased 2 94 Q21 Insert friction ring into upper tube small shoulder down away from fork crown Reinstall retaining ring sharp outside edge facing up towards crown Fig 6C 93 QUADRA Slide the following parts on upper tube in the following order retaining ring Sharp outside Fig 6C Fig 6E edge facing up towards fork crown compression ring side with small shoulder down away from fork crown bushing greased inside amp out bushing spacer bushing greased inside amp out top out sleeve Shoulder up towards bushing top out washer smaller diameter down towards top out spring top out spring and then install top out spring clip sharp inside edge facing down towards dropout Fig 6D 3 Q5 Q10 Q21 and Q21R Slide lower tube greas
5. TUBE BEFORE FINALIZING THIS SETTING 2 Tire radius maximum is 335mm 13 2 26 X 2 1 tire 3 Tire clearance can be checked by removing top caps see Compression Bumper Maintenance and bottoming out forks Minimum clearance from bottom of fork crown to tire with forks firmly bottomed out is 10mm 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
6. ai lt Plunger Top out Spring _ Top out Retaining gt Ring C Bottom O ring OD Bottom Plate E Plunger gt S Retaining Ring L page 4 INSPECTION Check upper tube for signs of nicks or scratches that could damage bushings Replace as needed 93 QUADRA and 94 Q21 Check wall thickness of compression ring 1 per leg Minimum thickness is 4 5 mm 177 Fig 5A Q10 and 94 Q21 Inspect plunger head If there are signs of wear or scratches then replace wear ring p n 56408 Check top out springs for uniform free length Spring length should be 25 4mm 1mm 1 00 0 04 Fig 5B Inspect fork brace at cable mount area and fastener holes for signs of damage from crashes or misuse Fig 5C Replace as needed Inspect lower tubes for signs of damage paying particular attention to drop out area Fig 5D Replace lower tube if damage is found 93 QUADRA Q5 Q10 and Q21 Check compression bumper for cracking or permanent set Permanent set minimum length 147 mm 5 80 Fig 5E Q21R Check MCU springs for cracking or permanent set Permanent set minimum length 147 mm 5 80 Fig 5E 8 Inspect coating gray in color on inside of bushings 2 per leg for scratches and wear Replace as needed See Bushing Removal and Installation 9 Proceed to Fork Reassembly once inspection and parts repla
7. cement are Fig 5D complete Q5 Q10 Q21 AND Q21R BUSHING REMOVAL BE a Fig 5A Fig 5B INTRODUCTION To maintain a close tolerance between upper and lower tubes the bushings are pressed into the lower tube As a result there is a break in period for new forks and for re built forks 1 Insert bushing removal tool into lower tube until it is past upper bushing and engages lower edge of upper bushing Fig 5A 2 Slide seal puller tool over bushing removal tool with larger end over lower tube keeping bushing removal tool engaged with bushing Fig 5B 3 Clamp bushing removal tool into a vice 4 Unscrew seal puller using 32mm and 36mm headset wrenches until upper bushing is pulled out of lower tube Fig 5B 5 Repeat steps 1 4 to remove lower bushing from lower tube then repeat for other leg page 5 Q5 Q10 Q21 AND Q21R BUSHING INSTALLATION Note Upper bushing has a larger outer diameter than lower bushing 1 Apply Judy Butter or other non lithium high quality bearing grease to outside of upper and lower bushings and bushing seat locations in lower tube 2 Slide greased lower bushing onto end of bushing installer tool with sleeve installed Fig GA 3 Using a soft mallet gently tap tool into lower tube until 4 5 6 7 8 9 tool bottoms on upper bushing seat Fig 6B Remove installer tool from lower tube
8. ed bushings installed onto lightly greased upper tube 93 QUADRA Slide bottom O ring and bottom plate onto plunger rod and install retaining ring sharp inside edge facing down Fig 6E CONT page 7 page 6 FORK REASSEMBLY CONTINUED 4 Q5 Q10 Q21 and Q21R Insert plunger assembly into upper tube with medium strength threadlock blue Loc Tite or equivalent applied to threads clean threads with alcohol if necessary Fig 7A 93 QUADRA Clamp the 93 QUADRA bushing installer onto upper tube between main snap ring and friction ring Slide lower tube over assembly and push up to fully install bushings and friction ring Tap lightly at drop out with a soft mallet if necessary Fig 7B Remove bushing installer tool 5 Q5 Q10 Q21 and Q21R Using a 5mm hex on a long extension screw plunger assembly into lower tube NOTE USE MEDIUM STRENGTH BLUE LOC TITE OR EQUIVALENT THREADLOCK AND 14FT LBS 20 Nm TORQUE 6 93 QUADRA Install retaining ring in lower tube with sharp outside edge facing up towards crown Fig 7C WARNING BE SURE MAIN RETAINING RING IS FULLY SEATED INTO GROOVE 7 ALL Locate dust boot lip over lower tube 8 93 QUADRA Q5 Q10 and Q21 Install heavily greased elastomer into upper tube Q21R Apply a dab of grease to the hole on each MCU spring during installation on skewer the spacer is installed nearest top cap This will ensure a coating of grease on
9. es e 3 8 socket drive extension 6 long minimum e 5mm long hex 3 8 drive socket e 3 8 drive ratchet NOTE DO NOT USE LITHIUM BASED GREASE FORK COMPONENT OVERVIEW MISCELLANEOUS e High quality bearing grease JUDY Butter etc Fork Fork Brace Damper Adjuster Brace Bolt Screw Lower Brake Upper Tube Fork Steerer Tube Pivot Bolt covered by Crown Tube mud boots page 1 MAINTENANCE INTERVALS 1 ROCK SHOX Quadra forks require routine maintenance After each ride wipe down the outside of the fork 2 Approximately once a month and or every 40 hours of riding inspect the fork for damage crown brace upper tubes lower tubes 3 A general service cleaning greasing elastomers and bushings should be made at approximately 200 hours of riding or more frequently if you ride in dusty or muddy conditions COMPRESSION BUMPER MAINTENANCE Fig 2C Fig 2D 93 Quadra skip to 2 1 95 Q5 and Q10 Pry off dust cap from top cap using a small straight slot screwdriver Fig 2A 794 Q21 95 Q21 DI 96 Q5 and Q21R Remove top cap by unscrewing it using a 22mm socket or wrench Fig 2B 93 Quadra 95 Q5 and Q10 Remove top cap using an 8 mm hex key Fig 2C NOTE It may be necessary to turn 4 mm adjuster screw clockwise a few turns to permit insertion of 8 mm hex key 93 Quadra Q5 Q10 and Q21 Clean and inspect each compr
10. ession bumper column for evidence of cracking or permanent set Fig 2D Minimum length permanent set 5 8 147 mm If there is evidence of damage replace as necessary Q21R Pull MCU springs and spacers from skewers or Judy Jax Clean off old grease with a rag and degreaser such as Pedros If evidence of damage replace as necessary 93 Quadra Q5 Q10 and Q21 Replace compression bumper into upper tube It should first be greased all over with a high quality non lithium grease Judy Butter etc Q21R Apply a dab of grease to the hole on each MCU spring during installation on skewer This will ensure a coating of grease on the skewer It is necessary to grease the outside of the MCU springs Be sure to use a washer between each MCU spring the solid spacers do not require a washer if on skewer or use Judy Jax and Judy Spacer 5 ALL MODELS Reinstall top cap turning clockwise Maximum torque is 60 IN LBS 6 8 Nm 6 93 Quadra 795 Q5 and Q10 Adjust preload screw using a 4 mm hex key to desired number of turns from full counter clockwise softest setting Adjust both legs equally 796 Q5 Q21 and Q21R Adjust preload by turning top cap adjuster the desired number of turns from full counter clockwise softest setting Adjust both legs equally page 2 GENERAL SERVICE Si Fig 3C Fig 3D on 0O a Remove fork brace from lower tubes INTRODUCTION The high quality bus
11. hings are designed to last many months of hard riding The protective boots a clean fork and timely greasing are the keys to long bushing life However like all moving parts bushings will eventually wear and need replacement Increased fore and aft movement of upper tubes in lower tubes similar to a loose headset slow action even after applying fresh grease visible scratches and worn coating on bushing surface all signal the bushings need replacing WARNING THE PROTECTIVE BOOTS ARE PART OF THE SYSTEM REMOVING BOOTS VOIDS WARRANTY 1 Cycle fork several times Note amount of play detected fore and aft and smoothness of stroke Excessive fore and aft movement and sticky action could mean the bushings need replacement 2 Clean exterior of fork legs Use soap and water if necessary 3 Disconnect front brake cable and remove front wheel Remove brakes according to manufacturer s instructions 4 Remove brake pivot bolts using an 8 mm wrench Fig 3A Remove fork brace screws using a 4 mm hex key Remove compression bumper Refer to Compression Bumper Maintenance 93 QUADRA Slide up fork boots to expose lower tube retaining ring Hold fork boot up and release retaining ring from lower tube use internal snap ring pliers Fig 3B Once retaining ring has been released pull lower tube off upper tube crown steerer assembly Compress leg and then pull down sharply on lower tube Fig 3C If lower tube does not easily
12. the skewer for best performance If Judy Jax are used spacer can be between any two MCU springs Grease outside of MCU stacks before installing in upper tube Applies to both skewer and Judy Jax MCU stacks 9 ALL Screw top cap assembly into upper tube until snug Do not overtighten cap Maximum torque is 60 IN LBS 6 8Nm Clamp On Crown Models Make certain upper tube surface and crown are free of residue clean with alcohol if necessary Tighten four 4mm crown bolts alternately to GO IN LBS 6 8 Nm Upper tubes should not extend above the crown more than 3mm Fig 8A NOTE CHECK CLEARANCE TO FRAME DOWN TUBE BEFORE FINALIZING THIS SETTING 10 ALL Adjust preload to the desired setting from full counter clockwise softest setting equally on both legs 11 ALL Rotate lower legs forward so fork brace bosses face the front of bicycle Install brake posts and bolts through fork brace and into lower tube Fig 7D NOTE APPLY MEDIUM STRENGTH THREADLOCK BLUE LOC TITE OR EQUIVALENT ON THREADS OF EACH BRAKE POST AND BRACE BOLT THREADS MUST BE CLEAN AND FREE OF GREASE OIL 12 ALL Torque brake posts and fork brace bolts to 60 IN LBS 6 8 Nm 13 ALL Install brakes according to manufacturer s specifications page 7 TIRE CLEARANCE CHECK Fig 8A 1 Clamp On Crown Models The upper tube should not extend above crown more than 3 mm Fig 8A NOTE CHECK CLEARANCE TO FRAME DOWN
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