Related Manuals for SRAM Rock Shox Yari 2019
Summary of Contents for SRAM Rock Shox Yari 2019
- Page 1 2019 Lyrik Yari ™ ™ & s e r v i c e m a n u a l GEN.0000000005684 Rev B © 2018 SRAM, LLC...
- Page 2 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, indirect, special, incidental, or consequential damages.
- Page 3 SAFETY FIRST! We care about YOU. Please, always wear your safety glasses and protective gloves when servicing RockShox® products. Protect yourself! Wear your safety gear!
-
Page 4: Table Of Contents
TABLE OF CONTENTS ROCKSHOX® SERVICE ......................................6 PART PREPARATION ..............................................6 SERVICE PROCEDURES ..............................................6 PARTS, TOOLS, AND SUPPLIES ..........................................7 RECOMMENDED SERVICE INTERVALS ........................................8 RECORD YOUR SETTINGS ............................................8 TORQUE VALUES ................................................9 OIL VOLUME AND LUBRICANT ...........................................9 EXPLODED VIEW - 2019 LYRIK™ RC2 - DEBONAIR™ ............................10 EXPLODED VIEW - 2019 LYRIK RCT3 - DEBONAIR ............................11 LYRIK RCT R .................................................. - Page 5 LOWER LEG ASSEMBLY ....................................69 50/200 HOUR SERVICE LOWER LEG INSTALLATION ............................................. 69...
-
Page 6: Rockshox® Service
Information contained in this publication is subject to change at any time without prior notice. Your product's appearance may differ from the pictures contained in this publication. For recycling and environmental compliance information, please visit www.sram.com/company/environment. P a r t P r e p a r a t i o n Remove the component from the bicycle before service. -
Page 7: Parts, Tools, And Supplies
• RockShox 5wt Suspension Oil (Motion Control) • Needle nose pliers • RockShox Suspension Cleaner or Isopropyl alcohol • Open end wrenches: 12, 15, 23 mm • SRAM® Butter grease • Pick RockShox Tools • Rubber or plastic mallet • RockShox Bleed Syringe •... -
Page 8: Recommended Service Intervals
Regular service is required to keep your RockShox® product working at peak performance. Follow this maintenance schedule and install the service parts included in each service kit that corresponds with the Service Hours Interval recommendation below. For spare part kit contents and details, refer to the RockShox Spare Parts Catalog at www.sram.com/service. Service Hours Interval... -
Page 9: Torque Values
*Oil Height - Measure from the top of the crown (above the upper tube) down to the oil. Non-Boost 2018 Lyrik models feature Solo Air™ and Charger Damper. Consult the 2016-2017 Lyrik Service Manual at www.sram.com/service for Solo Air and Charger Damper technical specifications and service procedures. -
Page 10: Exploded View - 2019 Lyrik™ Rc2 - Debonair
E x p l o d e d V i e w - 2 0 1 9 L y r i k ™ R C 2 - D e b o n A i r ™ Air Spring Assembly Steerer tube Compression Damper Air cap Assembly... -
Page 11: Exploded View - 2019 Lyrik Rct3 - Debonair
E x p l o d e d V i e w - 2 0 1 9 L y r i k ™ R C T 3 - D e b o n A i r ™ Air Spring Assembly Steerer tube Compression Damper Air cap... -
Page 12: Exploded View - 2019 Lyrik Rc - Debonair
E x p l o d e d V i e w - 2 0 1 9 L y r i k ™ R C - D e b o n A i r ™ Air Spring Assembly Steerer tube Air cap Compression Damper Assembly... -
Page 13: Exploded View - 2019 Yari™ Charger Damper™ Rc - Debonair
E x p l o d e d V i e w - 2 0 1 9 Y a r i ™ C h a r g e r D a m p e r ™ R C - D e b o n A i r ™ Air Spring Assembly Steerer tube Compression Damper... -
Page 14: Exploded View - 2019 Yari Rc - Debonair
E x p l o d e d V i e w - 2 0 1 9 Y a r i ™ R C - D e b o n A i r ™ Air Spring Assembly Steerer tube Compression Damper Air cap Assembly Knob retaining screw... -
Page 15: Lower Leg Removal And Service
L o w e r L e g R e m o v a l a n d S e r v i c e 5 0 / 2 0 0 H o u r S e r v i c e L o w e r L e g R e m o v a l Remove the air valve cap. -
Page 16: 50 Hour Service
Place an oil pan beneath the fork to catch the draining oil. Damper Side Loosen both bottom bolts 3 to 4 turns. Spring Side Strike each bottom bolt to dislodge the shafts from the lower leg on Spring Side each side. The bolt head should contact the bottom of the lower leg. Remove each bottom bolt. -
Page 17: Lower Leg Service
5 0 H o u r S e r v i c e L o w e r L e g S e r v i c e Remove the foam rings. Clean the foam rings. Soak the foam rings in RockShox® suspension oil. 0w-30 Lower Leg Service... - Page 18 Clean the inside and outside of the lower leg. Clean the wiper seals. Install the foam rings under the wiper seals. Confirm the foam rings are installed evenly in the space under the wiper seals and do not protrude over the bushings. 50 Hour Service Continue the 50 Hour Service with Lower Leg Installation.
-
Page 19: 200 Hour Service
2 0 0 H o u r S e r v i c e L o w e r L e g S e a l S e r v i c e Remove and discard the foam rings. Remove the outer wire springs from the dust wiper seals. Stabilize the lower leg on a bench top. - Page 20 Soak the new foam rings in RockShox® suspension oil. Install the new foam rings into the lower leg. 0w-30 Remove the outer wire spring from each new dust wiper seal and set them aside. Insert the narrow end of a new wiper seal into the recessed end of the 35 mm Dust Seal Installation tool.
- Page 21 Stabilize the lower leg on a bench top. Hold the lower leg steady and press the wiper seal into the lower leg until the top of the seal is flush with the top of the lower leg. Optional: If the Abbey Bike Tools™ installation tool is used, use a mallet to seat the seal.
-
Page 22: Air Spring Service
When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. Spray isopropyl alcohol on each part and clean with a clean lint-free rag. Apply SRAM® Butter grease to the new seals and o-rings SRAM Butter Remove the air spring top cap. - Page 23 Push the air shaft into the upper tube with your thumb. While holding the shaft in, remove the retaining ring. Slide the retaining ring onto your thumb and carefully release the air spring shaft. Trapped negative air pressure creates increased resistance when pushing the shaft in.
- Page 24 Remove the quad ring seal from the air piston and discard it. Clean the air piston. Apply grease to a new quad ring seal and install it. NOTI CE Do not scratch the air piston. Scratches will cause air to leak. Clean the inside and outside of the upper tube.
-
Page 25: Air Spring Travel Change And Bottomless Tokens™ (Optional)
Bottomless Token kits. For part ordering information, please contact your local SRAM® distributor or dealer. D e b o n A i r - T r a v e l a n d B o t t o m l e s s T o k e n T u n i n g - L y r i k 27.5"... -
Page 26: Bottomless Tokens Installation (Optional)
B o t t o m l e s s T o k e n s ™ I n s t a l l a t i o n ( o p t i o n a l ) Bottomless Tokens reduce air volume in your fork and create greater ramp at the end of the fork travel. Add tokens to tune your fork's bottomless feel. Air Spring Travel Change and Bottomless Tokens for the maximum number of Tokens for your fork. -
Page 27: Air Spring Installation
For part ordering information, please contact your local SRAM® distributor or dealer. Apply a liberal amount of grease evenly around the end of a clean plastic dowel, approximately 150 mm from one end. Use the dowel to apply the grease to the inside surface of the upper tube, approximately 150 mm into the tube. - Page 28 Apply grease to the new seal head inner seal. Install the new seal head assembly onto the air shaft. Apply red Loctite® 2760™ to the first two to three full threads on the end of the air shaft. Clamp an 8 mm hex wrench into a vise. Insert the air piston onto the wrench to secure it.
- Page 29 Apply grease to the air piston and seal head outer o-rings/seals. Insert the air spring assembly into the upper tube. Firmly push the air piston into the upper tube. Insert the seal head into the upper tube and firmly press it into the upper tube until it stops.
- Page 30 Install the air spring top cap into the upper tube and tighten it. Top Cap / Cassette Tool 28 N•m (250 in-lb) DebonAir 200 Hour Service To continue with Lyrik™ damper service, go to Charger 2™ Damper Service - Lyrik. 200 Hour Service To continue with Yari™...
-
Page 31: Charger 2 Damper™ Service - Lyrik
C h a r g e r 2 D a m p e r ™ S e r v i c e - L y r i k ™ Consult the 2016-2017 Lyrik Service Manual at www.sram.com/service for Charger Damper™ service procedures. - Page 32 Remove the knob retaining screw. 2 mm RC / RC R 2 mm RC2 / RCT3 / RCT R RC2 / RCT3 / RC: Remove the low speed compression adjuster knob. RCT3 RC2: Remove the high speed compression adjuster knob. RCT3 RCT3: Remove the compression mode adjuster knob.
- Page 33 RCT R / RC R: Loosen the remote cable stop collar set screw and RCT R remove the collar. 2 mm RCT R RC R 2 mm RC R RCT R: Remove the low speed knob/remote spool assembly. RC R RC R: Remove the remote spool.
- Page 34 Unthread the damper top cap and remove the Charger 2 Damper™ 24 mm RCT R / RC R assembly. Clean the upper tube threads. Top Cap / Cassette Tool RC2 / RCT3 / RC Damper Removal...
-
Page 35: Damper Service
2 0 0 H o u r S e r v i c e D a m p e r S e r v i c e Remove the o-ring from the top cap. Clean the top cap threads and o-ring groove. - Page 36 Remove the glide ring from the rebound damper piston. Install a new glide ring. Apply grease to the new rebound damper seal head seals. Install the new seal head onto the rebound damper shaft, threaded end first, and slide it towards the piston until it stops. Remove the bleed screw from the seal head.
- Page 37 Remove the cartridge tube from the vise and pour the oil into an oil pan. Squeeze the bladder to drain the oil from the compression damper assembly into an oil pan. Clamp the cartridge tube, on the bladder coupler wrench flats, back into the vise.
- Page 38 Dry the cartridge tube and compression damper assembly with compressed air. Air Compressor and Air Gun Nozzle Damper Service...
-
Page 39: Damper Assembly
2 0 0 H o u r S e r v i c e D a m p e r A s s e m b l y Clamp the cartridge tube wrench flats lightly into the vise and soft jaw inserts. - Page 40 Insert the rebound damper piston slowly into the cartridge tube and thread the sealhead into the tube. Tighten the seal head. 23 mm 5.1 N·m (45 in-lb) Thread the rebound bottom bolt into the shaft 3-4 turns. Damper Assembly...
-
Page 41: Damper Bleed
D a m p e r B l e e d Draw 3wt RockShox® suspension oil into a RockShox Bleed syringe until it is half full. Hold the syringe upright, cover the tip with a rag, and gently depress the plunger to purge any air bubbles from the syringe. NOTI CE Only use a RockShox bleed syringe. - Page 42 Fully extend the rebound damper shaft. Push the syringe plunger down, then release the plunger. Allow the bladder to expand and retract until it stops in a resting position. Unthread the syringe bleed fitting from the bleed port. ⚠ CAU TION - E YE HAZARD Oil may eject from the bleed port if the bladder is not in a resting position.
- Page 43 Cycle the rebound shaft a few times. Remove the bottom bolt and clean the Charger 2 Damper™ assembly. Damper Bleed...
-
Page 44: Test Lockout Or Compression
T e s t L o c k o u t o r C o m p r e s s i o n RC2 / RCT3 / RCT R: Rotate the compression cam clockwise, until it 13 mm RCT R / RC R stops, to the locked out or firm position. -
Page 45: Damper Installation
2 0 0 H o u r S e r v i c e D a m p e r I n s t a l l a t i o n Install the Charger 2 Damper™ assembly into the damper side upper tube. - Page 46 RCT3: Install the compression mode adjuster knob onto the top cap with the tab in the forward, unlocked position. RCT3 RC2: Install the high speed compression adjuster knob. RC2 / RCT 3: Install the low speed compression adjuster knob onto the 2 mm 1.2 N·m (10 in-lb) hex adjuster rod...
- Page 47 RC: Install the compression adjuster knob onto the top cap with the tab in the forward, unlocked, position. Install and tighten the retaining screw. 2 mm 1.2 N·m (10 in-lb) RCT R: Install the cable stop collar with the housing guide in the 6 o'clock forward position, angled ≈20°...
- Page 48 Install the remote spool onto the hex adjuster with the spool cable set screw oriented within the 87° range zone. Install the knob seal. Install the low speed adjuster knob onto the hex adjuster. Install and 2 mm 1.2 N·m (10 in-lb) tighten the knob retaining screw.
- Page 49 RCT R / RC R: Tighten the cable stop collar set screw. 2 mm 0.25 - 0.6 N·m (2.2 - 5.3 in-lb) Consult the applicable remote user manual at www.sram.com/ rockshox/components/remotes for cable and remote installation instructions. 2 mm 0.25 - 0.6 N·m (2.2 - 5.3 in-lb)
-
Page 50: Charger Damper Rc Service - Yari
C h a r g e r D a m p e r ™ R C S e r v i c e - Y a r i ™ 2 0 0 H o u r S e r v i c e D a m p e r R e m o v a l Turn the compression adjuster knob counter-clockwise, to the full open position, until it stops. -
Page 51: Damper Service
2 0 0 H o u r S e r v i c e D a m p e r S e r v i c e Clamp the rebound seal head into a vise with flat aluminum soft jaw inserts. - Page 52 Carefully remove the compression damper. Remove the cartridge tube and rebound damper assembly from the vise and pour the oil into an oil pan. Clean the exterior of the cartridge tube. Damper Service...
- Page 53 Clamp the rebound seal head back into the vise. Wrap the rubber strap from a strap wrench around the cartridge tube above the rebound damper seal head. Unthread and remove the tube from the seal head. Strap Wrench Remove the seal head and rebound damper from the vise. Remove the seal head from the rebound damper shaft.
- Page 54 Remove the o-rings from the compression damper and discard them. Apply grease to new o-rings and install them. Remove the glide ring from the rebound damper piston and discard it. Install a new glide ring. Apply grease to the inner seal and bushing in the new rebound damper seal head.
-
Page 55: Damper Assembly
2 0 0 H o u r S e r v i c e D a m p e r A s s e m b l y Apply grease to the end of the rebound damper shaft. Insert the rebound damper shaft into the recessed end of the seal head. - Page 56 Clamp the seal head into the vise. Pinch the glide ring while installing the cartridge tube over the piston and glide ring. Thread the tube into the seal head hand tight. Pull the damper shaft to full extension. Secure a shop towel around the cartridge tube to absorb oil. Pour 57 mL RockShox®...
- Page 57 Push the rebound damper into the cartridge tube until there is 104 mm (length) of shaft extended. Do not push the damper into the tube any further. 104 mm Insert the compression damper into the cartridge tube and slowly push it into the tube. The rebound damper will slowly extend as the compression damper is installed;...
- Page 58 Pull the rebound damper to full extension. 34 mm Secure a plastic cable tie around the shaft 34 mm from the end of the shaft. Cover the purge hole with the secured towel. ⚠ CAUTI ON Oil may exit the cartridge tube purge hole. Wear saftey glasses and keep your eyes and face away from the purge hole when compressing the rebound damper.
-
Page 59: Test Compression
T e s t C o m p r e s s i o n Use the adjuster knob to rotate the compression cam clockwise, until it stops, to the firm position. The cable tie must be 34 mm from the end of the shaft. Do not compress the rebound damper further than this point. -
Page 60: Damper Installation
2 0 0 H o u r S e r v i c e D a m p e r I n s t a l l a t i o n Install the damper assembly into the damper side upper tube. Thread the top cap into the upper tube and tighten it Top Cap / Cassette Tool 28 N·m (250 in-lb) -
Page 61: Motion Control™ Damper Service - Yari
M o t i o n C o n t r o l ™ D a m p e r S e r v i c e - Y a r i ™ 2 0 0 H o u r S e r v i c e D a m p e r R e m o v a l Turn the compression adjuster knob counter-clockwise, to the full open position, until it stops. - Page 62 Thread the bottom bolt into the damper shaft 2-3 turns. Remove the rebound damper and seal head. Clean the inside and outside of the upper tube. Inspect the inside and outside of the upper tube for scratches. NOTI CE Scratches on the inside surface of the upper tube can cause oil to leak. If an internal scratch is visible, the crown steerer upper tube assembly may need to be replaced.
-
Page 63: Damper Service
2 0 0 H o u r S e r v i c e D a m p e r S e r v i c e Remove the compression damper top cap o-ring and piston u-cup seal. Apply grease to the new o-ring and seal, and install them. The Yari™... - Page 64 Remove the glide ring and discard it. Install a new glide ring. Damper Service...
-
Page 65: Rebound Damper Installation
2 0 0 H o u r S e r v i c e R e b o u n d D a m p e r I n s t a l l a t i o n Install the seal head onto the rebound damper shaft with the flat end Loctite Threadlocker Blue 242 facing the rebound damper piston. - Page 66 Push the rebound damper shaft into the upper tube to prevent it from getting scratched while installing the retaining ring. Retaining rings have a sharper-edged side and rounder-edged side. Installing retaining rings with the sharper-edged side facing the tool will allow for easier installation and removal. Place the tips of the internal retaining ring pliers into the eyelets of the retaining ring and install the retaining ring into the groove.
-
Page 67: Compression Damper Installation
2 0 0 H o u r S e r v i c e C o m p r e s s i o n D a m p e r I n s t a l l a t i o n Pour RockShox®... - Page 68 Tighten the top cap. 24 mm 28 N·m (250 in-lb) Install the adjuster knob with the tab in the 7-8 o'clock, unlocked position. Install and tighten the retaining screw. 2.5 mm 1.2 N·m (10 in-lb) Compression Damper Installation...
- Page 69 L o w e r L e g A s s e m b l y 5 0 / 2 0 0 H o u r S e r v i c e L o w e r L e g I n s t a l l a t i o n Clean the upper tubes.
- Page 70 Slide the lower leg assembly toward the crown until it stops. The spring and damper shafts should be visible through the bottom bolt holes. Verify each shaft is centered and seated in the lower leg shaft/bolt hole and no gap is visible between the lower leg and the shaft end. Lower Leg Installation...
- Page 71 200 Hour Service Remove the old crush washers from each 5 mm bottom bolt. Hold the crush washer with needle nose pliers and unthread it from the bolt by turning the bolt counter-clockwise. Discard the crush washers. Clean the bolts and install new crush washers. NOTI CE Dirty or damaged crush washers can cause oil to leak from the fork.
- Page 72 Install the black bottom bolt into the spring side shaft. 5 mm 7.3 N·m (65 in-lb) Install the silver or red bottom bolt into the damper side shaft. 5 mm Spring Side 5 mm 7.3 N·m (65 in-lb) 5 mm Damper Side Lyrik™: Install the rebound damper knob and tighten the set screw.
- Page 73 Refer to your pre-service recorded settings, or use the air chart on the fork's lower leg, and pressurize the air spring. You may see a drop in the indicated air pressure on the pump gauge while filling the air spring; this is normal. Continue to fill the air spring to the recommended air pressure.
- Page 74 This publication includes trademarks and registered trademarks of the following companies: Boost™ is a trademark owned by Trek Bicycle Corporation. Loctite® and Blue 242® are registered trademarks of Henkel Corporation. 2760™ is a trademark of Henkel Corporation. Park Tool® is a registered trademark of Park Tool Co. TORX®...
- Page 75 ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No. 1598-8 Chung Shan Road 1000 W. Fulton Market, 4th Floor Paasbosweg 14-16 Shen Kang Hsiang, Taichung City Chicago, Illinois 60607 3862ZS Nijkerk Taiwan R.O.C. The Netherlands...