Related Manuals for SRAM RockShox Super Deluxe
Summary of Contents for SRAM RockShox Super Deluxe
- Page 1 2018 Super Deluxe™ s e r v i c e m a n u a l GEN.0000000005317 Rev E © 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!
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Page 4: Table Of Contents
TABLE OF CONTENTS GETTING STARTED ......................................6 RECOMMENDED SERVICE INTERVALS ........................................6 RECORD YOUR SETTINGS ............................................6 TORQUE VALUES ................................................6 EXPLODED VIEW .........................................8 EXPLODED VIEW - RTR .......................................9 EXPLODED VIEW - BEARING MOUNT ................................9 ROCKSHOX® SUSPENSION SERVICE ................................10 REMOTE CABLE AND HOUSING REMOVAL - RTR ONLY..........................10 PARTS, TOOLS, AND SUPPLIES ..........................................10 REMOTE CABLE AND HOUSING REMOVAL ...................................... - Page 5 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.
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Page 6: Getting Started
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 Maintenance... - Page 7 C o m p r e h e n s i v e P a r t s , T o o l s , a n d S u p p l i e s L i s t Parts Bicycle Tools •...
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Page 8: Exploded View
E x p l o d e d V i e w Shaft eyelet Bushing Compression valve Rebound adjuster knob Compression lever (RCT, RC3, RTR) Air can Reservoir mount Bottom out washer and o-ring Lock Spring (RTR) Lock Shim (RTR) Seal head / air piston Compression assembly Main piston... -
Page 9: Exploded View - Rtr
E x p l o d e d V i e w - R T R Cap screw Travel limit screw Spring tang Cam housing Threaded ferrule Cable hanger screw Spring Spring tang Ferrule lock screw Cable hanger Cable set screw Cable spool Remote screw Cable spool cap... -
Page 10: Rockshox® Suspension Service
RockShox Spare Parts catalog and technical information. For order information, please contact your local SRAM® distributor or dealer. For recycling and environmental compliance information, please visit www.sram.com. 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. -
Page 11: Shock Eyelet Service
S h o c k E y e l e t S e r v i c e M o u n t i n g H a r d w a r e a n d B u s h i n g S e r v i c e Prior to servicing the rear shock, remove it from the bicycle frame according to the bicycle manufacturer's instructions. - Page 12 Insert the threaded rod through the shaft eyelet until the push pin rests against the bushing pin. Thread the large, open end of the catcher along the rod until it rests on the end spacer. Hold the catcher secure with a 13 mm open end or adjustable wrench. Use a second 13 mm or adjustable wrench to thread the push pin along the rod until it stops against the end spacer.
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Page 13: Eyelet Bushing Replacement
E y e l e t B u s h i n g R e p l a c e m e n t To replace damaged or worn out bushings, use the RockShox® rear shock bushing removal/installation tool. Insert the threaded rod through the shaft eyelet until the base of the push pin rests against the bushing. -
Page 14: Bearing Mount Service
B e a r i n g M o u n t S e r v i c e Replace the bearings if they are not spinning freely, or if they are making a creaking noise. P a r t s , T o o l s , a n d S u p p l i e s Parts Common Tools •... - Page 15 Turn the shock over and place the punch against the back of the other bearing, and tap out the bearing. NOTI CE Do not damage the air valve when tapping out the bearing. Punch Hammer Spray isopropyl alcohol in the bearing bores and clean them with a rag.
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Page 16: Bearing Installation
B e a r i n g I n s t a l l a t i o n Install a new bearing into one bearing bore, then clamp the eyelet and 22 mm (OD) x 10 mm (ID) bearing press tool bearing into a vise with soft jaws. - Page 17 Remove the shock from the vise. The bearings should sit approximately 1 mm below the outer edge of the bearing bore. Reinstall dust covers before installing the shock on the bicycle. Bearing Installation...
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Page 18: Damper Bearing Replacement
D a m p e r B e a r i n g R e p l a c e m e n t Loosen the cap screws and remove the bearing assembly from the shock. The dust covers may fall off. This is normal. 3 mm N OTIC E If you are completing the 50 or 200 hour service, set the bearing assembly aside until service is complete. -
Page 19: Super Deluxe™ Service
S u p e r D e l u x e ™ S e r v i c e Prior to servicing your rear shock, remove it from the bicycle frame according to the bicycle manufacturer's instructions. Once the shock is removed from the bicycle, remove the mounting hardware before performing any service (see the Mounting Hardware And Bushing Service section). -
Page 20: 50/200 Hour Service
5 0 / 2 0 0 H o u r S e r v i c e A i r C a n R e m o v a l NOTI CE When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. - Page 21 Record your air pressure setting to assist with post-service set up. Remove the air valve cap by hand. Use a small hex wrench to lightly depress the Schrader valve and slowly release all air pressure from the air can. ⚠ CAUTI ON - EYE HAZARD Do not disassemble a pressurized shock, this can cause suspension oil or debris to forcefully eject from the shock.
- Page 22 Insert a rag through the damper body eyelet to prevent the air can from forcefully ejecting from the shock. ⚠ CAUTIO N- E YE HAZARD The air can may still have air pressure in the negative chamber, which may cause the air can to forcefully eject from the shock upon disassembly.
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Page 23: Bottomless Tuning
B o t t o m l e s s T u n i n g Bottomless Tokens™ and Gnar Dog™ Tokens reduce air volume in your Gnar Dog Tokens rear shock and create greater progression at the end of the shock's travel. -
Page 24: Air Can Service
Spray isopropyl alcohol on each part and clean with a rag. Apply grease to the new seal or o-ring. Only use RockShox® Dynamic Seal Grease when servicing RockShox Super Deluxe™ rear shocks. Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. - Page 25 Remove the backup ring from the second groove inside the air can. Pierce and remove the quad seal from the bottom of the second groove in the air can. Spray isopropyl alcohol inside the air can and clean it with a rag. Remove a glove and use your finger to inspect the inside and outside of the air can for scratches, dents, or other surface deformations.
- Page 26 Install the backup ring by inserting one end into the air can, then push the remainder of the ring into the can, so that it rests on top of the quad seal. Orient the new wiper seal step side up. Install it into the wiper seal groove at the top of the air can.
- Page 27 Remove the seal head/air piston seal and glide rings. Spray isopropyl alcohol on the seal head/air piston and clean it with a rag. Install the thicker glide ring below the seal head/air piston seal, and the thinner glide ring above. To continue with the 50 Hour Service go to...
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Page 28: Ifp Reservoir Service
2 0 0 H o u r S e r v i c e I F P R e s e r v o i r S e r v i c e NOTI CE When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. - Page 29 Clamp the shaft eyelet into the vise. Use a Schrader valve tool to remove the IFP reservoir valve cap. Use a small hex wrench or pick to depress the Schrader valve and release all air pressure from the IFP reservoir. Once the pressure has been released, depress the Schrader valve a second time.
- Page 30 Remove the retaining ring from the IFP reservoir. ⚠ CAUTI ON - EYE HAZARD The retaining ring can eject rapidly as it is removed. Wear safety glasses. Do not scratch the inside of the IFP reservoir. Remove the IFP reservoir cap from the IFP reservoir. Remove the IFP reservoir cap o-ring.
- Page 31 Push the IFP out of the IFP reservoir. Remove the IFP bleed screw. T10 TORX® Remove the IFP o-ring. Install a new o-ring. IFP Reservoir Service...
- Page 32 RC3 and RTR: Pull on the piston nut while rocking it from side-to-side to remove the compression assembly from the IFP reservoir mount. RTR: Remove the lock spring and lock shim and set them aside. RTR Only RC3 and RTR: Soak up excess oil in the IFP reservoir mount. IFP Reservoir Service...
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Page 33: Remote Spring Replacement - Rtr Only
2 0 0 H o u r S e r v i c e R e m o t e S p r i n g R e p l a c e m e n t - R T R O n l y Loosen the cap screw from the reservoir and remove the remote subassembly from the reservoir. - Page 34 Remove the spring from the cam and clean the cam with a rag. NOTICE Do not spray isopropyl alcohol on the cam when o-rings are installed. Isopropyl alcohol can cause the o-rings to become brittle and break. Apply a thick layer of grease to the cam. RockShox®...
- Page 35 Preload the spring clockwise until the threaded hole in the cam aligns T10 TORX® 1.5 mm 1.1 N•m (10 in-lb) 5 mm with the hole in the cam housing, then install the travel limit screw and tighten until the screw is flush. Carefully unload the spring. Place tension on the spring by preloading and unloading it to ensure it has been installed correctly.
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Page 36: Damper Body Service
2 0 0 H o u r S e r v i c e D a m p e r B o d y S e r v i c e NOTI CE When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. -
Page 37: Piston Service
2 0 0 H o u r S e r v i c e P i s t o n S e r v i c e NOTI CE When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. - Page 38 Slide the main piston assembly off the shaft and onto a small hex wrench or pick. NOTI CE Keep all the parts together and set them aside. If the main piston assembly is disassembled, it will need to be replaced. Remove the seal head/air piston from the damper shaft.
- Page 39 Squeeze the shims and center the shim stack on top of the main piston. If desired, install a new piston tune. Refer to the RockShox spare parts catalog on www.sram.com. Be sure to keep the main piston assembly parts in the same order. NOTI CE If the shims are not centered and in the correct order, the shock will not perform properly.
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Page 40: Shock Assembly And Bleed
Thread the nut onto the damper shaft. Tighten the main piston nut to 12 mm 6.8 N•m (60 in-lb) 6.8 N•m (60 in-lb). Remove the assembly from the vise. 2 0 0 H o u r S e r v i c e S h o c k A s s e m b l y a n d B l e e d NOTI CE When replacing seals and o-rings, use your fingers or a pick to remove... - Page 41 RC3 and RTR: Install the compression assembly into the reservoir mount. Push the compression assembly into the reservoir until it stops. Check that the compression lever is still in the unlocked (min) position so the compression needle does not block oil flow through the valve. RTR: Use a pick to verify the lock shim is correctly installed.
- Page 42 Pour RockShox® 7wt suspension oil into the IFP reservoir until it is level with the top of the reservoir. Use the palm of your hand to tap down on the top of the reservoir repeatedly to move oil through the damper shaft. This will assist in purging air bubbles from the system.
- Page 43 Tap the shock on the bench a few times to purge any excess bubbles, then install the IFP bleed screw into the IFP. The bleed screw should be submerged in oil. Pour out any excess oil. T10 TORX® Remove the shock from the vise, and slide the seal head/air piston until it stops at the end of the damper shaft.
- Page 44 Place your thumb on the IFP to prevent it from moving, then slowly install the seal head/air piston onto the damper body. Do not hold on to the shaft eyelet or damper shaft while inserting the seal head into the damper body. It will move the piston/shaft assembly, causing too much oil to displace out of the damper body.
- Page 45 Use a metric caliper or ruler to push the IFP into the reservoir to a depth of 20 mm. ⚠ CAUTIO N- E YE HAZARD Do not look directly into the reservoir as you push the IFP down. Oil may be ejected from the IFP bleed port if you push the IFP down too fast.
- Page 46 Install the IFP bleed screw into the IFP. The bleed screw should be submerged in oil. T10 TORX® Remove the damper body bleed screw from the damper body eyelet, and rotate the damper body away from you. Insert a small hex wrench through the slot next to the 33 or 39 mm mark on the IFP Height Tool, depending on your shock stroke.
- Page 47 Install a new damper body bleed screw into the damper body eyelet. T10 TORX 1.1 N•m (10 in-lb) Tighten the bleed screw to 1.1 N·m (10 in-lb). Spray isopropyl alcohol on the damper body and clean it with a rag. T10 TORX®...
- Page 48 Push the new retaining ring into the groove until it is seated. ⚠ CAUTIO N- E YE HAZARD The retention ring can eject rapidly as it is installed. Wear safety glasses. Pull up on the IFP reservoir cap to seat it against the retaining ring. Reinstall the Schrader valve into the IFP reservoir cap.
- Page 49 Install a new IFP reservoir fill cap o-ring, and install the fill cap into the IFP reservoir cap. Spray isopropyl alcohol on the shock and clean it with a rag. RTR: Install the cable hanger onto the remote subassembly, then 2 mm 0.45 N•m (4 in-lb) tighten the cable hanger screw to 0.45 N·m (4 in-lb).
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Page 50: 50/200 Hour Service
5 0 / 2 0 0 H o u r S e r v i c e A i r C a n I n s t a l l a t i o n NOTI CE When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. - Page 51 Press the air can onto the damper then thread it onto the shaft eyelet until it is hand tight. Spray isopropyl alcohol on the outside of the air can and clean it with a rag. Remove the shock from the vise. Turn it over and clamp the damper body eyelet in the vise.
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Page 52: Shock Eyelet Assembly
S h o c k E y e l e t A s s e m b l y E y e l e t B u s h i n g I n s t a l l a t i o n Apply a light layer of grease to the outside of the new bushing. -
Page 53: Mounting Hardware Installation
M o u n t i n g H a r d w a r e I n s t a l l a t i o n N O T I C E To prevent damage to the shock use aluminum soft jaws and position the eyelet in the vise so that the adjustment knobs are clear of the vise jaws. Some mounting hardware is easily installed using only your fingers. - Page 54 Clamp the catcher in a vise or hold it secure with a 13 mm wrench. Use a second 13 mm wrench to thread the push pin along the rod until it pushes the bushing pin into the shock eyelet bushing. Continue to thread the push pin until the bushing pin protrudes from both sides of the eyelet an equal amount.
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Page 55: Remote Cable And Housing Installation - Rtr Only
To install new cable and housing into the OneLoc™ remote, consult the OneLoc Remote User Manual on www.sram.com/service. P a r t s , T o o l s , a n d S u p p l i e s... - Page 56 Trim the cable, install an end cap, and tuck the cable into the pocket. Cable and Housing Cutters Install the cable spool cap and tighten to 0.8 N·m (7 in-lb). 3 mm 0.8 N·m (7 in-lb) The cable spool will rotate with the spool cap when tightening. Continue to rotate the spool cap clockwise until it stops, then tighten.
- Page 57 This publication includes trademarks and registered trademarks of the following companies: TORX® is a registered trademark of Acument Intellectual Properties, LLC Maxima® Maxum4 Extra 15w 50 is a registered trademark of Maxima Racing Oils...
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