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Table of Contents
Related Manuals for SRAM ROCKSHOX RUDY XPLR
Summary of Contents for SRAM ROCKSHOX RUDY XPLR
- Page 1 RUDY XPLR SERVICE MANUAL GEN.0000000006502 Rev A © 2021 SRAM, LLC...
- Page 2 LAW. FOR A FULL UNDERSTANDING OF YOUR RIGHTS, CONSULT THE LAWS OF YOUR COUNTRY, PROVINCE, OR STATE. EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein, SRAM warrants its bicycle components to be free from defects in materials or workmanship for a period of two (2) years after original purchase of the product.
- 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 ROCKSHOX SERVICE ......................................5 PART PREPARATION ..............................................5 SERVICE PROCEDURES ..............................................5 PARTS, TOOLS, AND SUPPLIES ..........................................6 RECOMMENDED SERVICE INTERVALS ........................................7 RECORD YOUR SETTINGS ............................................7 TORQUE VALUES ................................................7 OIL VOLUME AND LUBRICANT ...........................................8 EXPLODED VIEW - RUDY ....................................9 LOWER LEG REMOVAL AND SERVICE ................................10 50/200 HOUR SERVICE LOWER LEG REMOVAL .............................................. -
Page 5: 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/en/company/about/environmental-policy-and-recycling. P a r t P r e p a r a t i o n Remove the component from the bicycle before service. -
Page 6: Parts, Tools, And Supplies
P a r t s , T o o l s , a n d S u p p l i e s Parts Bicycle Tools • 2021 Rudy Ultimate Service Kit - 200 hour • Bicycle stand • 2021 Rudy Base Service Kit - 200 hour •... -
Page 7: 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 8: Oil Volume And Lubricant
O i l V o l u m e a n d L u b r i c a n t Damper Spring Upper Tube Lower Leg Upper Tube Lower Leg Fork Model Travel Damper Spring Volume Volume Volume Volume Grease Weight (mL) -
Page 9: Exploded View - Rudy
E x p l o d e d V i e w - R U D Y Air Spring Assembly Compression Damper Air valve cap Assembly Rebound Damper Top cap Lockout adjuster knob Assembly (Ultimate) Top cap cover (Base) Volume Reducer Top cap Compression damper Lower leg... -
Page 10: 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 Ultimate: Ultimate: Make sure the compression is unlocked. - Page 11 Use an 11 mm hex wrench to remove the Maxle insert from the damper Use an 11 mm hex wrench to remove the Maxle insert from the damper side of the lower leg by rotating the insert side of the lower leg by rotating the insert clockwise clockwise.
- Page 12 Place an oil pan beneath the fork to catch the draining oil. Place an oil pan beneath the fork to catch the draining oil. Oil Pan Use a 5 mm extension (minimum 110 mm length) to Use a 5 mm extension (minimum 110 mm length) to loosen the rebound loosen the rebound bottom nut and bottom bolt 3 to 4 turns.
- Page 13 Firmly pull the lower leg downward until fluid begins to drain. Continue Firmly pull the lower leg downward until fluid begins to drain. Continue pulling downward to remove the lower leg. pulling downward to remove the lower leg. If the lower leg does not slide off of the upper tube or if oil does not If the lower leg does not slide off of the upper tube or if oil does not drain from either side, the press fit of the shaft(s) into the lower leg may drain from either side, the press fit of the shaft(s) into the lower leg may...
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Page 14: Lower Leg Service
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 wire spring. Remove the wire spring. Remove the foam rings. Remove the foam rings. Pick Clean the foam rings. - Page 15 Soak the foam rings in suspension oil. Soak the foam rings in suspension oil. 0w-30 Install the foam rings under the wiper seals. Install the foam rings under the wiper seals. Confirm the foam rings are installed evenly in the space under the Confirm the foam rings are installed evenly in the space under the wiper seals and do not protrude over the bushings.
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Page 16: 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 the outer wire springs from the wiper seals. Remove the outer wire springs from the wiper seals. - Page 17 Remove the outer wire spring from each new wiper seal and set them Remove the outer wire spring from each new wiper seal and set them aside. aside. Insert the narrow end of a new wiper seal into the recessed end of the Insert the narrow end of a new wiper seal into the recessed end of the 30 mm RockShox Dust Seal Installation tool.
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Page 18: Air Spring Service
To increase or decrease the travel in your Rudy fork, the air spring must be replaced with the correct length air spring shaft assembly. Refer to the RockShox Spare Parts Catalog available on our website at www.sram.com/service for spare part kit details. - Page 19 Firmly pull on the air shaft to remove the air spring assembly from the Firmly pull on the air shaft to remove the air spring assembly from the upper tube. Clean and inspect the assembly for damage. upper tube. Clean and inspect the assembly for damage. Clean the inside and outside of the upper tube.
- Page 20 Remove the inner o-rings on the air shaft stud. Remove the inner o-rings on the air shaft stud. Clean the air shaft stud. Clean the air shaft stud. Apply grease and install a new o-ring. Apply grease and install a new o-ring. Pick Remove the o-ring from the split keeper.
- Page 21 Remove the air piston outer o-ring. Remove the air piston outer o-ring. Clean the air piston. Clean the air piston. Apply grease and install a new o-ring. Apply grease and install a new o-ring. Apply a liberal amount of grease evenly around the end of a clean Apply a liberal amount of grease evenly around the end of a clean plastic dowel, approximately 60 mm from one end.
- Page 22 Apply a liberal amount of grease around the air shaft. Apply a liberal amount of grease around the air shaft. Install the seal head, retaining ring bottom out bumper, and bottom out Install the seal head, retaining ring bottom out bumper, and bottom out platform onto the air shaft.
- Page 23 Insert the seal head into the upper tube and firmly press it into the Insert the seal head into the upper tube and firmly press it into the upper tube until it stops. upper tube until it stops. Place the tips of the retaining ring pliers into the eyelets of the Place the tips of the retaining ring pliers into the eyelets of the retaining ring.
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Page 24: Charger Race Day Damper Service
C h a r g e r R a c e D a y D a m p e r S e r v i c e 2 0 0 H o u r S e r v i c e C h a r g e r R a c e D a y D a m p e r R e m o v a l Ultimate: Ultimate:... -
Page 25: Bleed Procedure
2 0 0 H o u r S e r v i c e B l e e d P r o c e d u r e Insert the rebound adjuster knob or a 2.5 mm hex into the rebound Insert the rebound adjuster knob or a 2.5 mm hex into the rebound shaft until it contacts the rebound adjuster screw. - Page 26 Hold the damper vertically. Thread the syringe into the top cap bleed Hold the damper vertically. Thread the syringe into the top cap bleed port. Inject the oil into the damper assembly. port. Inject the oil into the damper assembly. Release the plunger and air will purge into the syringe.
- Page 27 Hold the damper vertically. Thread the syringe into the top cap bleed Hold the damper vertically. Thread the syringe into the top cap bleed port. port. Inject the oil into the damper assembly. Inject the oil into the damper assembly. Push the assembly down to compress the rebound shaft.
- Page 28 Install the bleed screw. Install the bleed screw. Rapidly push the rebound shaft in and out 15-20 times. Rapidly push the rebound shaft in and out 15-20 times. Compress the damper in a vertical position for five minutes. This will Compress the damper in a vertical position for five minutes.
- Page 29 Push the assembly down to compress the rebound shaft. The syringe Push the assembly down to compress the rebound shaft. The syringe will fill up. will fill up. Depress the syringe to inject oil into the damper assembly and allow Depress the syringe to inject oil into the damper assembly and allow the rebound shaft to fully extend.
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Page 30: Charger Race Day Damper Installation
2 0 0 H o u r S e r v i c e C h a r g e r R a c e D a y D a m p e r I n s t a l l a t i o n Install the Charger Race Day Damper into the damper side upper tube. -
Page 31: Lower Leg Assembly
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 32 Orient the fork so that it is parallel to the ground. Orient the fork so that it is parallel to the ground. Slide the lower leg onto the upper tube enough to engage the upper Slide the lower leg onto the upper tube enough to engage the upper bushing with the upper tube.
- Page 33 Install the silver bottom bolt into the Install the silver bottom bolt into the spring side spring side shaft of the lower leg. shaft of the lower leg. 5 mm (minimum 5 mm (minimum Spring Side 6.8 N·m (60 in-lb) 110 mm length) 110 mm length) Install the rebound bottom nut into the...
- Page 34 N OT ICE The Maxle inserts are reverse threaded. To avoid damaging the fork when removing or installing Maxle inserts, carefully read the instructions and follow directional arrows. Use an 8 mm hex socket to install the Maxle insert into the spring side Use an 8 mm hex socket to install the Maxle insert into the spring side of the lower leg by rotating the insert of the lower leg by rotating the insert counter-clockwise...
- Page 35 Clean the entire fork. Clean the entire fork. This concludes the service of your RockShox Rudy XPLR suspension fork. Lower Leg Installation...
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- Page 37 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. U.S.A. Niederlande...