Service Manual - Lyrik Rev B
Contents
1. TABLE OF CONTENTS LYRIK R RECON GOLD R SEKTOR MOTION CONTROL IS DAMPER SERVICE LYRIK RC TOTEM RC MISSION CONTROL MISSION CONTROL DR DAMPER SERVICE cca eect 3 LYRIK RC2L RC2DH TOTEM RC2L RC2DH LOWER SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing SRAM products Protect yourself Wear your safety gear SERVICE INTERVALS The following chart is a summary of the maintenance service intervals for RockShox forks Following this schedule is important to ensure the consistent performance and longevity of your fork Some of the information listed may not be applicable to your fork Every ride Every ride Every ride Every ride Every ride Change Speed Lube oil bath 25 Check front suspension fasteners for proper torque 25 Clean and lubricate remote lockout cable and housing 25 Remove lowers clean inspect bushings and change oil bath if applicable Clean and lubricate air spring assembly Change oil in damping system including hydraulic lockout Clean and lubricate coil spring assembly coil forks only TOOLS NEEDED FOR SERVICE The following chart is a list of the model year 2011 tools needed for service on your Lyrik suspension fork While this chart is intended to be comprehensive it is still only a guide The tools required for each step of ser2. ADJUSTER ANATOMY Retention screw ae A Low Speed 4 mm hex BRAA Compression Floodgate adjuster DFA l 2 5 mm hex ar S A High Speed 72 Compression 1 Turn the blue High Speed Compression knob clockwise to set it in the maximum compression position 2 Mission Control only Turn the Floodgate to the off position by pushing the Low Speed Compression adjuster down and rotating it counter clockwise 90 3 Use a 24mm flat wrench to unthread the compression damper top cap Access to the top cap is under the High Speed Compression knob Skip to Step 5 OR 1 Use a 2 5 mm hex wrench to turn the internal Floodgate adjuster screw counter clockwise until it stops this will maximize the depth of Insertion of a 4mm hex wrench into the low compression knob Mission Control only 2 Use acrescent wrench prevent the Low Speed Compression knob from rotating while using a 4 mm hex wrench to remove the Low Speed Compression knob retention screw Lift and remove the Low Speed Compression knob 3 Usea 1 5 mm hex wrench to loosen both retaining bolts on the High Speed Compression knob Remove the High Speed Compression knob This allows access to the top cap 4 Use a24mm socket wrench to unthread the compression damper top cap DAMPER REMOVAL SERVICE INSTRUCTIONS CONTINUED 5 Remove the compression damper from the upper tube crown by pulling up and rocking it from side to side 6 Remove the glide ring from the c
3. or the floor to hold it steady Hold the fork crown tight in one hand and the brake arch in the other hand Try to move the brake arch back and forth If you hear or feel any knocking the bushings are worn If you have determined that the bushings are worn you will need to replace the lower leg assembly Reference the 2011 RockShox Spare Parts Catalog for information on the correct lower leg and correspoding part number for your fork LOWER LEG REMOVAL INTRODUCTION Removing the lower legs is the first step in servicing your fork Once you have removed your fork lower legs you ll be ready to move onto the next section LOWER LEG REMOVAL Coil forks Proceed to Step 4 Air forks Remove the positive air chamber valve cap from the top cap located on the non drive side fork leg If the fork also has a negative air chamber remove the valve cap located at the bottom of the non drive side air chamber The positive air chamber valve cap for 2 Step and Dual Position Air forks is located at the bottom of the non drive side fork leg 3 Depress the Schrader valve and release all of the air pressure from the air chamber Ifthe fork has a negative air chamber start with the negative air chamber first then proceed to the positive air chamber A CAUTION Verify all pressure is removed from the fork before proceeding Failure to do so can result in injury and or damage to the fork 4 Remove the external rebound adjuster kn
4. use downward force on the tool handle to leverage the seal s out Keep the lower leg assembly stable Do not allow the lower legs to twist in opposite directions compress toward each other or be pulled apart This will damage the lower leg assembly 3 If your fork has an oil foam ring remove it with your fingers 4 Repeat steps 1 3 for the other side of the lower leg 5 Spray isopropyl alcohol on and into the lower leg Wipe the lower legs clean then wrap a clean lint free rag around a dowel and clean the inside of each lower leg 12 19 LOWER LEG SEAL INSTALLATION Foam ring installation If your fork has foam rings soak the new foam rings in 15wt RockShox suspension oil Insert a new oil saturated foam ring into each side of the lower leg Oil seal installation Position the oil seal with the grooved side visible onto the stepped side of the seal installation tool Hold one of the lower legs firmly and use the seal installation tool to push the oil seal evenly and completely into that leg Repeat for the other leg Be sure to stabilize the lower leg in order to prevent it from slipping while installing the seal Dust wiper installation Position the dust wiper into the recessed side of the seal installation tool so that the grooved side of the seal is visible Hold one of the lower legs firmly and use the seal installation tool to push the dust wiper evenly and completely into that l
5. with isopropyl alcohol and wipe clean with a rag Remove the top out bumper from the negative piston Use a pick to remove the inner and outer negative piston o rings Apply grease to the new 11 o rings and install them When using a pick to remove o rings do not scratch the negative piston Scratches may cause air to leak Insert the top out bumper and kick plate back onto the negative piston Re install the negative piston sleeve assembly onto the air shaft with the kick plate oriented toward the air piston Re install the negative piston top out bumper aluminum support washer wavy washer and base plate onto the air shaft with the small diameter side of the base plate oriented toward the negative piston Negative Aluminum Base piston support washer plate Air Top out Negative piston top Wavy Air shaft piston bumper out bumper washer OPTIONAL ALL TRAVEL CONFIGURATION LYRIK The All Travel spacer is located between the base plate and negative piston If you want to change the travel of your fork install the travel spacer to decrease travel or remove the spacer to increase travel No spacer SOLO AIR SPRING INSTALLATION INSTRUCTIONS 14 Apply grease to the air assembly outer o rings Insert the air assembly into the bottom of the upper tube by gently rocking the air shaft side to side while firmly pushing it into the upper tube 15 Install the snap ring onto large internal snap ring pliers Use the plier
6. Mission RC2L RC2DH 193 Control DH TORQUE TIGHTENING VALUES The following chart is a summary of the primary torque tightening values for Lyrik forks The torque tightening values for fasteners that require a specific torque are detailed in the text of each service section Top Cap 7 9 N m 65 in Ib Bottom Bolt Shaft Nut 6 8 N m 60 in Ib Brake Caliper Mounting Bolts Post Mount 10 2 N m 90 in Ib LOWER LEG BUSHING INSPECTION INTRODUCTION Suspension fork bushings are considered wear and tear parts The rate and amount of wear will depend on the frequency of fork service frequency of riding riding terrain rider body weight and type of fork If your bushings are worn you will need to replace your lower leg assembly The following chapter covers how to check for bushing wear CHECK FOR BUSHING WEAR Method 1 Check for bushing wear while the fork is installed on the bike 7 1 Compress the fork 5 times to circulate lower leg lubrication 2 Wrap your fingers around the lower leg just below the the dust seal Hold the front brake lever tight while rocking the bike back and forth you may need someone to do this for you while you hold the lower leg If you hear or feel any knocking at the lower leg the bushings are worn Method 2 Check for bushing wear while the fork is removed from the bike 1 Compress the fork 5 times to circulate lower leg lubrication 2 Brace the fork on a table
7. and remove the air spring top cap Once removed clean the upper tube threads with a rag Remove the fork from the stand and pour any air seal lubricant into an oil pan 2 Clamp the fork back into the bicycle stand Place the tips of large internal snap ring pliers in two of the ports in the base plate Use the snap ring pliers to firmly press the bottom of the base plate into the upper tube and rotate until the base plate tab is behind the snap ring out of the way of the snap ring eyelets 3 Use large internal snap ring pliers to remove the snap ring Guide the snap ring off of the spring shaft by hand Do not scratch the air spring shaft surface while removing the snap ring Scratches on the air spring shaft will allow air to bypass the seal head into the lower legs resulting in reduced spring performance 4 Firmly pull on the air shaft to remove the air spring assembly from the upper tube Clean and Inspect the assembly for damage 5 Spray isopropyl alcohol on the inside and outside of the upper tube Wipe the outside of the upper tube with a clean rag Wrap a clean rag around a long dowel and insert it into the upper tube to clean inside the upper tube 6 Use small external snap ring pliers to remove the air piston snap ring Remove the air piston wavy spring washer cushion and air piston from the air shaft Expand the snap ring just enough to disengage it from the air shaft Over expanding the snap ring can permanently da
8. ase plate assembly with the snap ring using large internal snap ring pliers Make sure the snap ring is securely fastened in the snap ring groove You can check this by using the snap ring pliers to rotate the snap ring back and forth a couple of times then firmly pulling down on the spring shaft Snap rings have a sharper edged side and a rounder edged side Installing snap rings with the sharper edged side facing the tool will allow for easier installation and removal 7 Apply fresh grease liberally to the spring 8 Insertthe spring back into the upper tube and place the spring preload spacer s on top of the Spring inside the upper tube 9 Clean the top cap then apply a small amount of grease to the top cap o ring Insert and hand thread the top cap into the upper tube Use a 24 mm socket wrench to tighten to 7 3 N m 65 in Ib COIL U TURN SPRING SERVICE LYRIK SEKTOR INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs COIL U TURN SPRING REMOVAL INSTRUCTIONS 1 Use a 2 5 mm hex to remove the U Turn adjuster knob screw Remove the U Turn adjuster knob 2 Use amagnetto remove the three detent ball bearings and detent springs from the top cap 3 Use a24mm socket wrench to unthread and remove the spring top cap The
9. ay 2011 Present Service Manual GEN 0000000003202 REV B SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase This warranty only applies to the original owner and is not transferable Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased Original proof of purchase Is required Except as described herein SRAM makes no other warranties guaranties or representations of any type express or implied and all warranties including any implied warranties of reasonable care merchantibility or fitness for a particular purpose are hereb disclaimed LOCAL LAW This warranty statement gives the customer specific legal rights The customer may also have other rights which vary from state to state USA from province to province Canada and from country to country elsewhere in the world To the extent that this warranty statement is inconsistent with the local law this warranty shall be deemed modified to be consistent with such law under such local law certain disclaimers and limitations of this warranty statement may apply to the customer For example some states in the United States of America as well as some governments outside of the United States including provinces in Canada may a Preclude the disclaime
10. e shaft bolts into the threaded shaft ends through the lower leg shaft holes or air shaft nut onto the threaded shaft end and tighten with a 5 mm hex bolt or 10 mm socket wrench nut to 7 3 N m 65 in Ib For hollow bottom fork legs you will need to use a socket extension for the 5 mm bolt and a deep 10 mm socket to thread the Dual Air shaft nut For forks with an external rebound adjuster insert the external rebound damper knob into the rebound damper shaft bolt Push it in until secure Adjust as desired For air sprung forks refer to the air chart on your fork and inflate the positive and negative if applicable air chamber s to the appropriate pressure Spray isopropyl alcohol on entire fork and wipe it with a clean rag For air sprung forks thread the positive and negative if applicable air valve cap s onto the air valve s WORLD HEADQUARTERS SRAM LLC 1333 N Kingsbury St 4th Chicago 60642 Phone 1 312 664 8800 Fax 1 312 664 8826 www sram com EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 14 16 380240 Nijkerk The Netherlands Phone 31 33 450 6060 Fax 31 33 457 0200 ASIAN HEADQUARTERS SRAM Taiwan No 1598 8 Chung Shan Rd Shen Kang Hsiang Taichung County 429 Taiwan R 0 C Phone 886 4 2564 3678 FAX 886 4 2561 3686
11. e side upper tube 8 Pull down and remove the rebound damper and seal head assembly from the upper tube 9 Slide the seal head off the damper shaft and use a pick to remove the inner and outer seal head o rings Apply grease to the new o rings and install them 10 Spray isopropyl alcohol on the rebound damper shaft and wipe it with a clean rag 11 Remove and replace the rebound damper piston glide ring 12 Slide the rebound seal head assembly onto the rebound damper shaft with the flat side oriented toward the piston 13 Spray isopropyl alcohol into the upper tube Wrap a clean lint free rag around a long dowel and insert into the upper tube to clean inside the upper tube DAMPER INSTALLATION INSTRUCTIONS 14 Insertthe rebound damper piston into the bottom of the upper tube at an angle with the side of the glide ring opposite the split entering the upper tube first Continue to angle and rotate until the glide ring is in the upper tube 15 Push the seal head firmly into the bottom of the upper tube until the retaining ring groove is visible 16 Push the rebound damper shaft into the seal head leaving just enough to grab onto Use large internal snap ring pliers to secure the snap ring into the snap ring groove Make sure the snap ring is securely fastened the snap ring groove You can check this by using the snap ring pliers to rotate the snap ring back and forth a couple of times then firmly pulling down o
12. eg There should be no visible gap between the dust wiper and the lower leg Repeat for th other leg Be sure to stabilize the lower leg in order to prevent it from slipping while installing the seal COIL SPRING SERVICE LYRIK TOTEM INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs COIL SPRING REMOVAL INSTRUCTIONS Unthread and remove the spring top cap with a 24mm socket wrench Once removed clean the upper tube threads with a rag Press down firmly when loosening the top cap 2 Remove the spring pre load spacer s and pull the spring from the upper tube 3 Remove the spring shaft base plate snap ring using Internal snap ring pliers 4 Pullthe spring shaft and base plate assembly from the upper tube Clean and inspect the assembly for damage Replace the entire assembly if necessary 5 Spray isopropyl alcohol on the spring spring shaft and the inside and outside of the upper tube and wipe with a clean rag Wrap a clean rag around a long dowel and insert it into the upper tube to clean Inside the upper tube COIL SPRING INSTALLATION INSTRUCTIONS 6 Insert the spring shaft base plate assembly into 1 the bottom of upper tube so the base plate is seated against the upper tube step Secure the spring shaft b
13. ft exposed to hold onto with your fingers Use large internal snap ring pliers to remove the rebound damper seal head retaining ring located inside the bottom of the drive side upper tube Pull down and remove the rebound damper and seal head assembly from the upper tube 4 Lyrik Recon Gold Sektor Solo Air only Slide Lyrik Recon Gold Sektor Coil the seal head off the damper shaft and use a pick Sektor Solo Air U Turn to remove the inner and outer seal head o rings Apply a few drops of RockShox suspension oil to new o rings and install them If using a pick to remove o rings do not scratch the o ring glands Scratches may cause oil to leak Sektor Coil and U Turn only Slide the seal head negative spring and travel spacer s if applicable off the damper shaft and use a pick to remove the inner and outer seal head o rings Tees Sa Apply a few drops of RockShox suspension oil to yon ae new o rings and install them Sektaggplo Air If using a pick to remove o rings do not scratch the o ring glands Scratches may cause oil to leak 5 Spray isopropyl alcohol on the rebound damper shaft and wipe it with a clean rag 6 Replace the rebound damper piston glide ring Position the upper tube base ring on top of the seal head step Lyrik Recon Gold only and slide the rebound seal head assembly onto the rebound damper shaft 7 Spray isopropyl alcohol into the upper tube Wrap a clean rag around a dowel and clean the inside of t
14. he upper tube DAMPER SERVICE INSTRUCTIONS CONTINUED 8 Insertthe rebound damper piston into the bottom of the upper tube at an angle with the side of the glide ring opposite the split entering the upper tube first Continue to angle and rotate until the glide ring is in the upper tube 9 Position the upper tube base ring and rebound seal head into the upper tube Push the seal head firmly into the bottom of the upper tube until the retaining ring groove is visible 10 Push the rebound damper shaft into the seal head leaving just enough to grab onto Use large internal snap ring pliers to secure the snap ring into the snap ring groove Make sure the snap ring is securely fastened in the snap ring groove You can check this by using the snap ring pliers to rotate the snap ring back and forth a couple of times then firmly pulling down on the damper shaft Snap rings have a sharper edged side and a rounder edged side Installing snap rings with the sharper edged side facing towards the tool will allow for easier installation and removal 11 Orient the fork upright in the bicycle stand Pull the rebound damper shaft down to the fully extended position Measure and slowly pour 5wt RockShox suspension oil into the upper tube using the volumes listed in the chart below Oil volume is critical Too much oil reduces available travel too little oil decreases damping performance Oil V
15. mage it and cause air spring assembly failure 10 11 12 19 SOLO AIR SPRING REMOVAL SERVICE INSTRUCTIONS CONTINUED Use a pick to remove the air piston outer o ring and foam ring Install the new o ring and a new foam ring onto the air piston Apply grease the new o ring then saturate the new foam ring with RockShox suspension oil Use a pick to remove the face seal o ring from the underside of the air piston Use isopropyl alcohol and a clean rag to clean the o ring groove Install the new o ring into the groove then apply grease to the o ring Pierce into the face seal o ring with the pick and pull to remove it Do not scoop or dig the o ring out as this may damage the piston sealing surface Install the air piston cushion and spring wavy washer onto the air shaft and use small external snap ring pliers to secure the air piston snap ring in the snap ring groove Check the snap ring fit to make sure it secures the air piston and wavy washer to the air shaft head The air piston should compress upward slightly with spring resistance from wavy spring washer and snap ring Expand the snap ring just enough to re install it onto the air shaft Over expanding the snap ring can permanently damage it and cause air spring assembly failure Slide the base plate wavy washer aluminum Support washer negative piston top out bumper negative piston top out bumper and kick plate from the air shaft Spray the air shaft
16. n the damper shaft Snap rings have a sharper edged side and a rounder edged side Installing snap rings with the sharper edged side facing towards the tool will allow for easier installation and removal 17 Orient the fork upright in the bicycle stand Pull the rebound damper shaft down to the fully extended position Measure and slowly pour 5wt RockShox suspension oil into the upper tube using the following volumes Oil Volume Fork 3 mL Lyrik RC 187 mL Totem RC 193 mL Oil volume is critical Too much oil reduces available travel too little oil decreases damping performance 18 Turn the hex shaped compression adjuster fully counter clockwise to the open position Insert the compression damper into the upper tube Press down and rock the damper from side to side to work it into the upper tube 19 Use a24mm socket wrench to thread the compression damper into the upper tube and tighten it to 7 3 N m 65 in Ib 20 Install the compression adjuster knob and retaining bolt Tighten the retaining bolt to 0 6 1 0 N m 5 9 in Ib MISSION CONTROL MISSION CONTROL DH DAMPER SERVICE LYRIK RC2L RC2DH TOTEM RC2L RC2DH INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs DAMPER REMOVAL SERVICE INSTRUCTIONS COMPRESSION
17. nap ring is securely fastened in the snap ring groove You can check this by using the snap ring pliers to rotate the snap ring back and forth a couple of times then firmly pulling down on the damper shaft Snap rings have a sharper edged side and a rounder edged side Installing snap rings with the sharper edged side facing the tool will allow for easier installation and removal Orient the fork upright in the bicycle stand Pull the rebound damper shaft down into the fully extended position Measure and pour 5wt RockShox suspension oil into the upper tube using the following volumes Oil Volume Fork 3 mL Lyrik 193 mL Totem 203 mL Oil volume is critical Too much oil reduces available travel too little oil decreases damping performance DAMPER INSTALLATION INSTRUCTIONS CONTINUED 17 Double check the Floodgate to ensure It Is in the off position Mission Control only Install the compression damper assembly into the upper Floodgate on tube Hand thread the compression damper top cam Tt cap into the upper tube 18 Use a 24mm flat wrench to tighten the top cap to 7 3 N m 65 in Ib OR 17 Insert the compression damper assembly into the upper tube Hand thread the compression damper top cap into the upper tube 18 Use a 24mm socket wrench to tighten the top cap to 7 3 N m 65 in lb 19 Install the High Speed Compression knob onto the top cap Use a 1 5 mm hex wrench to tighten the retaining bolt
18. ng shaft Snap rings have a sharper edged side and a rounder edged side Installing snap rings with the sharper edged side facing the tool will allow for easier installation and removal 10 Insert the U Turn spring assembly into the upper tube shaft end first Align and seat the spring shaft through the shaft guide base plate 11 Use a socket wrench to press down on the top cap and thread it into the upper tube Tighten the top cap to 7 3 N m 65 in Ib 12 Place the adjuster detent springs into the top cap detent holes evenly spaced Place a detent ball bearing on top of each detent spring Make sure you use all three springs and bearings otherwise the knob can turn and change travel on its own 13 Place the U Turn adjuster knob on top of hex shaped travel adjuster Use a 2 5 mm hex to tighten the U Turn adjuster knob to 1 3 N m 12 in lb SOLO AIR SPRING SERVICE LYRIK TOTEM INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs SOLO AIR SPRING REMOVAL SERVICE INSTRUCTIONS 4 CAUTION Verify all pressure is removed from the fork before proceeding Depress the Schrader valve again to remove any remaining air pressure Failure to do so can result in injury and or damage to the fork 1 Use a24mm socket wrench to unthread
19. ob if applicable by pulling it from the shaft bolt at the bottom of the right fork leg 5 Use a5 mm hex wrench to loosen both shaft bolts 3 to 4 turns Dual Air Air U Turn 2 Step and Dual Position Air equipped forks Use a 10 mm socket or open end wrench to loosen and unthread the shaft nut at the bottom of the left fork leg until it is flush with the threaded shaft end For hollow bottom fork legs you will need to use a deep 10 mm socket to loosen and unthread the air shaft nut 6 Place an oil pan beneath the fork to catch any draining oil Use a plastic mallet to firmly strike each shaft bolt nut free from Its press fit to the lower leg and use your fingers to remove the shaft bolts nut completely For hollow bottom fork legs tap the 5 mm hex wrench and 10 mm deep socket while engaged in the bolts to free them from the press fit N oa LOWER LEG REMOVAL CONTINUED 7 Firmly pull the lower leg downward until oil begins to drain If the upper tubes do not slide out of the lower leg or if oil doesn t drain from either side the press fit of the shaft s to the lower leg may still be engaged Re install the shaft bolt s 2 to 3 turns or re install the shaft nut flush with the threaded shaft end and repeat Step 6 Do not hit the brake arch with any tool when removing the lower leg as this could damage the fork 8 Remove the lower leg from the fork by pulling It downward holding onto both legs or the brake a
20. olume 3 mL Lyrik R Recon Gold R Sektor R 12 Press the top cap down into the upper tube threads and hand tighten it Use a 24 mm socket wrench to tighten the top cap to 7 3 N m 65 in Ib MOTION CONTROL IS DAMPER SERVICE LYRIK RC TOTEM RC INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs DAMPER REMOVAL SERVICE INSTRUCTIONS 1 Use a 2mm hex to remove the screw from the compression adjuster knob Remove the compression adjuster knob 2 Use a24mm socket wrench to unthread the compression damper top cap 3 Remove the compression damper from the upper tube crown by pulling up and rocking it from side to side Once the damper is removed clean the upper tube threads with a clean rag 4 Remove the compression damper top cap o ring and piston o ring Apply grease to the new O rings and install them If using a pick to remove o rings do not scratch the o ring gland Scratches may cause oil to leak 5 Remove the fork from the bicycle stand and pour any remaining oil into an oil pan 6 Push the rebound shaft into the seal head leaving just enough shaft exposed to hold onto with your fingers 7 Use large internal snap ring pliers to remove the rebound damper seal head retaining ring located inside the bottom of the driv
21. ompression damper piston assembly Apply a few drops of RockShox suspension oil to the new glide ring and install it 7 Remove the fork from the bicycle stand and pour any remaining oil into an oil pan Return the fork to the bicycle stand 8 Push the rebound shaft into the seal head leaving just enough shaft exposed to hold onto with your fingers Use large internal snap ring pliers to remove the rebound damper seal head snap ring 9 Firmly pull on the rebound shaft and remove the rebound damper and seal head from the upper tube 10 Spray the rebound damper shaft with isopropyl alcohol and wipe it with a clean rag 11 Remove the inner and outer o rings from the rebound seal head Apply a few drops of RockShox suspension oil to the new o rings and install them If using a pick to remove the inner seal head o ring do not scratch the o ring gland Scratches may cause oil to leak 12 Remove the glide ring from rebound shaft assembly Apply a few drops of RockShox suspension oil to the new glide ring and install it 19 14 15 16 DAMPER INSTALLATION INSTRUCTIONS Install the rebound assembly into the upper tube Push the seal head firmly into the bottom of the upper tube until the retaining ring groove is visible Push the rebound shaft into the seal head leaving just enough shaft exposed to hold onto with your fingers Use large internal snap ring pliers to install the snap ring Make sure the s
22. ons NEVER pour suspension fluid down a sewage or drainage system or into the ground or a body of water This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols and respectively Copyright SRAM LLC 2014 For exploded diagram and part number information please refer to the Spare Parts Catalog available on our web site at www sram com For order information please contact your local SRAM distributor or dealer Information contained in this publication is subject to change at any time without prior notice For the latest technical information please visit our website at www sram com Your product s appearance may differ from the pictures diagrams contained in this catalog Product names used in this document may be trademarks or registered trademarks of others TOOLS NEEDED FOR SERVICE PARTS NEEDED FOR SERVICE TECHNOLOGY AND OIL VOLUMES TORQUE TIGHTENING VALUEBG LOWER LEG BUSHING INSPECTION LOWER LEG REMOVAL LOWER LEG SEAL SERVICE COIL SPRING 5 LYRIK TOTEM COIL U TURN SPRING SERVICE LYRIK SEKTOR SOLO AIR SPRING 5 LYRIK TOTEM REBOUND DAMPER SERVICE
23. pads e Glide rings e Brake sleeves e Disc brake rotors e Corrosion e Rubber moving parts e Brake pads e Wheel braking surfaces e Tools e Foam rings e Chains e Bottomout pads e Motors e Rear shock mounting hardware 5 e Bearings e Batteries and main seals e Cassettes e Bearing races e Upper tubes stanchions e Shifter and brake cables inner 5 and outer Transmission gears Notwithstanding anything else set forth herein this warranty is limited to one year for all electronic and electronic related components including motors controllers battery packs wiring harnesses switches and chargers The battery pack and charger warranty does not include damage from power surges use of improper charger improper maintenance or such other misuse This warranty shall not cover damages caused by the use of parts of different manufacturers This warranty shall not cover damages caused by the use of parts that are not compatible suitable and or authorised by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use ROCKSHOX SUSPENSION SERVICE We recommend that you have your RockShox suspension serviced by a qualified bicycle mechanic Servicing RockShox suspension requires knowledge of suspension components as well as the special tools and fluids used for service Used suspension fluid should be recycled or disposed of in accordance to local and federal regulati
24. rch 9 Spray isopropyl alcohol on and into the lower leg assembly Wipe the lower legs clean then wrap a clean rag around a dowel and clean the inside of each lower leg LOWER LEG SEAL SERVICE INTRODUCTION Suspension fork seals are considered wear and tear parts and require regular maintenance depending on the frequency of riding riding terrain and type of fork The more you ride the more frequently your seals need to be replaced The following chapter covers wiper and oil seal removal and installation At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs LOWER LEG SEAL REMOVAL Select one side of the lower leg to work on first Oil seal If your fork has a black oil seal between the dust wiper and the upper bushing position the tip of a downhill tire lever or large flat head screwdriver between the lower lip of the black oil seal and the upper bushing No oil seal If your fork does not have a black oil seal between the dust wiper and the upper bushing place the tip of the tool underneath the lower lip of the wiper seal If you use a flat head screwdriver make sure it has around shaft A screwdriver with a square shaft will damage the fork leg 2 Stabilize the lower leg upright on a bench top or on the floor Hold the lower leg firmly and
25. rough the shaft bolt holes Dual Air Air U Turn and Dual Position Air spring shafts should extend through the shaft bolt hole Wipe all excess oil from the outer surface of the lower legs Skip to step 8 10 11 12 13 LOWER LEG INSTALLATION INSTRUCTIONS CONTINUED Hollow bottom fork legs Reference the oil chart at the beginning of this manual for proper oil weight and volumes for lower leg lubrication Hold the lower leg assembly horizontally and inject pour Suspension oil into each leg from the dust seal side Position the upper tube assembly horizontally then slide the lower leg assembly onto the upper tube assembly until it stops and the spring and damper shafts are visible through the shaft bolt holes Dual Air Air U Turn and Dual Position Air spring shafts should extend through the shaft bolt hole Wipe all excess oil from the outer surface of the lower legs Be careful not to spill any oil from the lower leg as you install it onto the upper tubes Make sure both dust seals slide onto the upper tubes without folding the outer lip of either seal Inspect and clean the damper and air spring shaft bolts nut nylon crush washers and crush wash retainers Replace crush washers and crush washer retainers if damaged You must clean dirty crush washers and replace flattened or deformed crush washers and or crush washer retainers Dirty or damaged crush washers can cause oil to leak from the fork Insert th
26. rs and limitations of this warranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations For Australian customers This SRAM limited warranty is provided in Australia by SRAM LLC 1333 North Kingsbury 4th floor Chicago Illinois 60642 USA To make a warranty claim please contact the retailer from whom you purchased this SRAM product Alternatively you may make 8 claim by contacting SRAM Australia 6 Marco Court Rowville 3178 Australia For valid claims SRAM will at its option either repair or replace your SRAM product Any expenses incurred in making the warranty claim are your responsibility The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party suppliers be liable for direct indirec
27. s 20 Install the Low Speed Compression knob onto the top cap then use a crescent wrench to prevent the Low Speed Compression knob from rotating while using a 4 mm hex wrench to tighten the Low Speed Compression knob retention screw LOWER LEG INSTALLATION INTRODUCTION At this point you should already have already serviced your fork seals damper system and spring system Once you have re installed your fork lower legs you will have successfully serviced your fork and you will be ready to ride LOWER LEG INSTALLATION INSTRUCTIONS Spray the upper tubes with isopropyl alcohol and wipe them with a clean rag 2 Apply a small amount of grease to the inner surfaces of the dust wipers oil seals and foam rings if applicable For hollow bottom fork legs skip to step 6 3 Non hollow bottom fork legs Slide the lower leg assembly onto the upper tube assembly just enough to engage the upper bushing with the upper tubes Make sure both dust seals slide onto the tubes without folding the outer lip of either seal 4 Reference the oil chart at the beginning of this manual for proper oil weight and volumes for lower leg lubrication Invert the fork so that the bottom of the fork is angled upward at about 45 Measure and inject pour suspension oil into each lower leg through the shaft bolt hole 5 Slide the lower leg assembly along the upper tubes until it stops and the spring and damper shafts are visible th
28. s to push the base plate into the upper tube while installing the snap ring into its groove The base plate tab should be situated between the snap ring eyelets Make sure the snap ring is securely fastened in the snap ring groove You can check this by using the snap ring pliers to rotate the snap ring back and forth a couple of times then firmly pulling down on the air shaft Snap rings have a sharper edged side and a rounder edged side Installing snap rings with the sharper edged side facing the tool will allow for easier installation and removal 16 Use isopropyl alcohol and a clean rag to clean the top cap then apply a small amount of grease Snap ring eyelets to the top cap threads and o ring Insert the top cap into the upper tube crown and hand thread it into the upper tube Be careful not to damage the top cap o ring upon installation REBOUND DAMPER SERVICE LYRIK R RECON GOLD R SEKTOR R INTRODUCTION At this point you should already have the lower legs removed from your fork If not you will need to return to the Lower Leg Removal section of this manual and follow the instructions for removing your fork lower legs DAMPER SERVICE INSTRUCTIONS Use a 24 mm socket wrench to unthread the top cap Once removed clean the upper tube ie threads with a rag 2 Remove the fork from the bicycle stand and pour the oil into an oil pan 3 Push the rebound shaft into the seal head leaving just enough sha
29. spring Is attached to the top cap and spring shaft Pull and lift the entire spring assembly from the upper tube Press down firmly when loosening the top cap 4 Lyrik only Use large internal snap ring pliers to remove the snap ring from the bottom of the spring side upper tube 5 Lyrik only Use your finger to remove the base plate top out spring assembly from the bottom of the spring side upper tube 6 Spray isopropyl alcohol on the entire spring assembly the base plate top out spring assembly and the inside and outside of the upper tube and wipe with a clean rag Wrap 8 clean rag around a long dowel and insert It into the upper tube to clean inside the upper tube and the upper tube threads COIL U TURN SPRING INSTALLATION INSTRUCTIONS 7 Apply a liberal amount of grease to the entire spring assembly top cap o ring and base plate top out spring assembly 8 Lyrik only Assemble the base plate top out spring assembly so that the wavy washer rests against the base plate and the flat washer rests against the wavy washer Install the assembly into the upper tube 9 Lyrik only Use large internal snap ring pliers to install the snap ring into the groove located at the bottom of the spring side upper tube Make sure the snap ring is securely fastened the snap ring groove You can check this by using the snap ring pliers to rotate the snap ring back and forth a couple of times then firmly pulling down on the spri
30. t special incidental or consequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM user manual The SRAM user manuals can be found online at sram com rockshox com avidbike com truvativ com or Zipp com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not apply when the product has been modified including but not limited to any attempt to open or repair any electronic and electronic related components including the motor controller battery packs wiring harnesses switches and chargers This warranty does not apply when the serial number or production code has been deliberately altered defaced or removed This warranty does not apply to normal wear and tear Wear and tear parts are subject to damage as a result of normal use failure to service according to SRAM recommendations and or riding or installation in conditions or applications other than recommended Wear and tear parts are identified as e Dust seals e Stripped threads bolts e Handlebar grips e Spokes e Bushings aluminium titanium e Shifter grips e Free hubs e Air sealing o rings magnesium or steel e Jockey wheels e Aero bar
31. vice are detailed in the text of the service section Tools Safety Starting Equipment Safety Glasses Nitrile Gloves Apron Clean Rags Lint Free Oil Measuring Device Clean Work Area General Tools Hex Key Set Sizes 1 5 mm 5 mm Plastic Mallet Socket Wrench 24 mm Socket Torque Wrench Schrader Valve Tool Snap Ring Pliers External Snap Ring Pliers Internal Long Dowel Rod Sharp Pick Magnet Oil Liquids Suspension Oil RockShox 5wt Grease Suspension Oil Soluble Isopropyl Alcohol PARTS NEEDED FOR SERVICE Prior to servicing your fork it is important that you have all of the necessary replacement parts For exploded diagram and part number information please refer to the Spare Parts Catalog available on our web site at www sram com For order information please contact your local SRAM distributor or dealer TECHNOLOGY AND OIL VOLUMES The following chart is a complete list of the 2011 RockShox Lyrik line up It details the model corresponding damper and spring technology along with the oil volume and RockShox oil weight required for each upper tube and lower leg Volume Oil Volume Oil Spring Volume Oil Volume Oil x ml wt ml wt tg cay ml wt ml wt Drive Upper upper f f SoloAir f 6 15 Stepe f 35 2541 10 Yun f f SoloAir f 6 15 25 1 35 125 10 6 1
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