SRAM RockShox RS-1 Service Manual
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SRAM RockShox RS-1 Service Manual

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2015-2019
RS-1™
s e r v i c e
m a n u a l
GEN.0000000005735 Rev A
© 2018 SRAM, LLC

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Summary of Contents for SRAM RockShox RS-1

  • Page 1 2015-2019 RS-1™ s e r v i c e m a n u a l GEN.0000000005735 Rev A © 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 RS-1™ RLC EXPLODED VIEW ..............................................5 RS-1 RL REMOTE EXPLODED VIEW ............................................ 6 RS-1 ACCELERATOR DAMPER™ EXPLODED VIEW......................................7 ROCKSHOX® SERVICE .......................................8 PART PREPARATION ................................................8 SERVICE PROCEDURES ................................................8 PARTS, TOOLS, AND SUPPLIES ............................................9 RECOMMENDED SERVICE INTERVALS ...........................................10 RECORD YOUR SETTINGS ..............................................10 TORQUE VALUES ..................................................10 FLUID VOLUME ..................................................10...

  • Page 5: Rlc Exploded View

    R S - 1 ™ R L C E x p l o d e d V i e w Air Shaft Assembly Compression Damper Low- speed compression knob Assembly and lockout adjuster knob Rebound Damper Knob base Assembly Lockout extension shaft Air spring access cover Brake hose guide Carbon fiber upper...

  • Page 6: Rl Remote Exploded View

    R S - 1 ™ R L R e m o t e E x p l o d e d V i e w Air Shaft Assembly Compression Damper Assembly RL remote Rebound Damper Knob base Assembly Lockout extension shaft Air spring access cover Brake hose guide Carbon fiber upper...

  • Page 7: Accelerator Damper™ Exploded View

    R S - 1 ™ A c c e l e r a t o r D a m p e r ™ E x p l o d e d V i e w Air Shaft Assembly Compression Damper Grommet Assembly Rebound Damper...

  • Page 8: Rockshox® Service

    Visit www.sram.com/service for the latest RockShox Spare Parts catalog and technical information. 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.

  • Page 9: Parts, Tools, And Supplies

    • Socket wrench • RockShox 5wt suspension oil (Accelerator Damper™) • Torque wrench • RockShox 3wt suspension oil (Charger 2 Damper™) • Liquid-O-Ring® PM600 military grease or SRAM® Butter grease Bicycle Tools • Bicycle stand • Downhill tire lever • Shock pump SAFETY I N STR UCTIONS Always wear safety glasses and nitrile gloves when working with suspension oil and bicycle grease.

  • Page 10: 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 11: Air Spring Service

    Only use SRAM® Butter grease or Liquid O-Ring® PM600 military grease when servicing RS-1™ forks. No other grease is approved for use. When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring.
  • Page 12 Remove the socket wrench and leave the hex bit socket engaged in the bolt. Strike the end of the hex bit socket to dislodge the air shaft from the carbon fiber upper. Remove the hex bit socket from the carbon fiber upper. Mallet &...
  • Page 13 Remove the anchor bolt. Apply grease and install a new o-ring. Remove the anchor o-ring. Apply grease and install a new o-ring. Remove the jounce bottom out bumper from the air shaft. Depress the Schrader valve in the air shaft and release the air pressure from the negative air chamber.
  • Page 14 Push the air shaft into the spring assembly to prevent it from getting Retaining ring pliers scratched when removing the retaining ring. Use a flat blade screwdriver to push the air shaft guide tab under the retaining ring. Place the tips of large internal retaining ring pliers into the eyelets of the retaining ring.
  • Page 15 Clean the inside and outside of the stanchion. Remove the seal head assembly from the air shaft. Clean the air shaft assembly. Remove the outer and inner o-rings on the floating seal head. Apply grease and install the new o-rings. Air Spring Removal...
  • Page 16 Remove the air piston outer o-ring. Apply grease and install a new o-ring. Remove the top out bumper cone from the air piston. Clean the air piston. Install the top out bumper cone onto the air piston. Air Spring Removal...

  • Page 17: Travel Change Adjustment - Optional

    To increase or decrease the travel in your RS-1™ 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 18: Air Spring Installation

    2 0 0 H o u r S e r v i c e A i r S p r i n g I n s t a l l a t i o n Apply a liberal amount of grease to the inside of the stanchion, from the unthreaded end of the tube to approximately 60 mm into the tube.
  • Page 19 Retaining rings have a sharper-edged side and a rounder-edged side. Install retaining rings with the sharper-edged side facing the tool to allow for easier installation and removal. Push the air shaft into the stanchion to prevent scratching the air shaft when installing the retaining ring.

  • Page 20: Carbon Fiber Upper Service

    2 0 0 H o u r S e r v i c e C a r b o n F i b e r U p p e r S e r v i c e Stabilize the carbon fiber upper on a bench top or on the floor. Place the tip of a downhill tire lever under the wiper seal.
  • Page 21 Apply grease to the inner surface of the wiper seal. SRAM® Butter Clamp the carbon fiber upper into a bicycle stand and position it at an angle 12 N·m (110 in-lb) 30 mm with the upper leg hole facing downward. Use the anchor tool to install the anchor into the carbon fiber upper.
  • Page 22 Position the fork horizontally in the bicycle stand. Thread the anchor bolt into the air shaft. For easier installation, apply a thin layer of grease to the hex wrench where it contacts the anchor bolt. NOTICE Do not allow the bolt to fall off the hex wrench into the carbon fiber upper. If the bolt falls off the hex wrench, remove the carbon fiber upper from the bicycle stand and shake it to move the bolt close to the hole.

  • Page 23: Charger 2 Damper™ Service

    C h a r g e r 2 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 2 D a m p e r R e m o v a l NOTI CE Use aluminum soft jaws to protect the Charger 2 Damper assembly when using a vise.
  • Page 24 Remote: Remove the upper spool, retention screw, and bottom spool from RL remote the knob base. 2.5 mm RL remote Position the fork horizontally in the bicycle stand. Remove the rebound adjuster knob. Flat blade screwdriver Place an oil pan beneath the fork to catch the draining oil. Loosen the damper side bottom bolt 3 to 4 turns.
  • Page 25 Remove the stanchion from the carbon fiber upper. If the stanchion does not slide out of the carbon fiber upper, the press fit of the shaft may still be engaged. Reinstall the bottom bolt 2 to 3 turns and repeat the previous step. Insert the anchor tool into the bottom of the carbon fiber upper so that it engages the damper anchor on the Charger 2 Damper™.
  • Page 26 Use the seal head wrench flats and remove the rebound damper assembly. Wrap a rag around the cartridge tube to absorb oil. 15 mm Remove and discard the seal head on the rebound damper shaft. Remove the cartridge tube from the vise and pour the oil into an oil pan.
  • Page 27 Clamp the wrench flats of the cartridge tube into a vise. With the cartridge tube facing upward, spray isopropyl alcohol into it. Squeeze the bladder 2-3 times to ingest alcohol into the bladder. Remove the assembly from the vise. With the cartridge tube downward, squeeze the bladder until all of the isopropyl alcohol is drained into an oil pan.

  • Page 28: 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 Clamp the wrench flats of the cartridge tube into a vise. Wrap a rag around the cartridge tube to absorb oil. Pour 3wt RockShox®...
  • Page 29 Apply SRAM® Butter to a new inner seal head o-ring. Install the seal head on the rebound damper shaft. Remove the bleed screw from the rebound damper seal head. Insert the rebound adjuster knob into the rebound damper shaft until it contacts the rebound adjuster screw.
  • Page 30 Reposition the Charger 2 Damper™ in the vise at an angle with the bleed port angled as upward as possible. Install the bottom bolt into the rebound damper shaft 3-4 turns. Fill a bleed syringe half full with suspension oil. Slowly depress the plunger to remove any air bubbles from the syringe.
  • Page 31 Fully extend the rebound damper shaft. Push the syringe handle down, then release the plunger. Allow the bladder to come to a natural resting position by waiting a few moments until the syringe stops filling. Use a rag to cover the bleed tip and Charger bleed port, then unthread and remove the syringe.
  • Page 32 Remove the damper anchor o-ring. Apply grease and install a new o-ring. RL remote Bleed Procedure...

  • Page 33: Carbon Fiber Upper Service

    2 0 0 H o u r S e r v i c e C a r b o n F i b e r U p p e r S e r v i c e Stabilize the carbon fiber upper on a bench top or on the floor. Place the tip of a downhill tire lever under the wiper seal.
  • Page 34 Apply grease to the inner surface of the wiper seal. SRAM® butter Position the carbon fiber upper at an angle with the upper leg hole facing upward. Angle a syringe fitting in the upper leg hole so the oil will only contact the inside of the leg.

  • Page 35: Charger 2 Damper Installation

    2 0 0 H o u r S e r v i c e C h a r g e r 2 D a m p e r ™ I n s t a l l a t i o n Install the Charger 2 Damper into carbon fiber upper until the lockout extension shaft protrudes from the hole in the knob base.
  • Page 36 Use a pick and needle nose pliers to remove the old crush washer from the 5 mm & pliers bottom bolt. Hold the crush washer with needle nose pliers and unthread the crush washer from the bolt by turning the bolt counter-clockwise with a 5 mm hex wrench.

  • Page 37: Charger 2 Damper Installation - Crown Adjust

    2 0 0 H o u r S e r v i c e C h a r g e r 2 D a m p e r ™ I n s t a l l a t i o n - C r o w n A d j u s t Clean the knob base.
  • Page 38 Remove the glide ring from the bottom of the lockout adjuster knob. Apply grease and install a new glide ring. Install the lockout adjuster knob on the knob base so the knob rotates from open to closed. Install the low speed compression knob so the set screw in the knob is aligned with the flat part of the lockout extension shaft.

  • Page 39: Charger 2 Damper Installation - Remote

    190° CCW from the cable stop. Install and tighten the retention screw. 2.5 mm RL remote 2.5 mm 0.9 N·m (8 in-lb) This concludes the service of your RockShox® RS-1™ RL remote suspension fork. For Remote user manuals, please visit www.sram.com/service. Charger 2 Damper™ Installation - Remote...

  • Page 40: Accelerator Damper Service

    Only use SRAM® Butter grease or Liquid O-Ring® PM600 military grease when servicing RS-1™ forks. No other grease is approved for use. When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring.
  • Page 41 Remove the stanchion from the carbon fiber upper. If the stanchion does not slide out of the carbon fiber upper, the press fit of the shaft may still be engaged. Reinstall the bottom bolt 2 to 3 turns and repeat the previous step. Insert the anchor tool into the bottom of the carbon fiber upper so that it engages the damper anchor on the Accelerator Damper.™...
  • Page 42 Push the XLoc™ button to release it to the extended (locked) position. Rotate the XLoc gate adjuster counter-clockwise, in the direction of the arrow, until it stops. Unthread and remove the knurled collar from the Connectamajig™. NOTICE Failure to lock the XLoc remote before disconnecting it will result in oil leaking from the XLoc.
  • Page 43 Remove the bottom cap o-ring. Apply grease and install a new o-ring. Accelerator Damper Removal...

  • Page 44: Accelerator Damper Service

    2 0 0 H o u r S e r v i c e A c c e l e r a t o r D a m p e r ™ S e r v i c e Clamp the Accelerator Damper assembly into a bicycle stand with the rebound shaft oriented downward.
  • Page 45 Remove the damper anchor o-ring. Apply grease and install a new o-ring. Remove the cartridge tube from the bicycle stand and pour the oil into an oil pan. Cycle the rebound shaft to make sure the oil has drained from the system.
  • Page 46 Clean the inside and outside of the cartridge tube. Clean the rebound assembly. Remove the damper seal head from the rebound shaft. Accelerator Damper™ Service...
  • Page 47 Remove the damper seal head o-ring. Use a pick to pierce and remove the rod wiper seal. Apply grease and install a new o-ring and rod wiper seal. Install the stepped face of the rod wiper seal into the threaded end of the seal head.
  • Page 48 Clamp the cartridge tube into a bicycle stand with the bypass hole oriented downward. Pinch the glide ring closed against the piston, then thread the seal head and rebound assembly into the cartridge tube. While holding the cartridge tube in place, thread the damper seal head into the cartridge tube and tighten the rebound assembly.
  • Page 49 Rotate the rebound adjuster counter-clockwise to the open position. The rebound adjuster screw will click as it is adjusted. 2.5 mm Pour suspension fluid into the cartridge tube. Pour the fluid slowly to avoid introducing air into the fluid. 75mL Slowly cycle the rebound shaft a few times to bleed the system.
  • Page 50 Slowly push the rebound shaft into the cartridge tube until there is about 50 mm of shaft exposed. Slowly insert the compression damper into the cartridge tube while gently rocking the compression damper side to side. Thread the compression damper into the cartridge tube. The rebound shaft will extend downward as you insert the compression damper.
  • Page 51 Push the XLoc™ button to release it to the extended (locked) position. Unthread the Connectamajig™ from the knurled collar. NOTICE Failure to lock the XLoc remote before disconnecting it will result in fluid leaking from the XLoc. This will require a complete bleed of the system. Accelerator Damper™...

  • Page 52: Carbon Fiber Upper Service

    2 0 0 H o u r S e r v i c e C a r b o n F i b e r U p p e r S e r v i c e Stabilize the carbon fiber upper on a bench top or on the floor. Place the tip of a downhill tire lever under the wiper seal.
  • Page 53 Apply grease to the inner surface of the wiper seal. SRAM® Butter Position the carbon fiber upper at an angle with the upper leg hole facing upward. Angle a syringe fitting in the upper leg hole so the oil will only contact the inside of the leg.

  • Page 54: Accelerator Damper Installation

    2 0 0 H o u r S e r v i c e A c c e l e r a t o r D a m p e r ™ I n s t a l l a t i o n Insert the anchor tool into the leg.
  • Page 55 Install the anchor tool onto the Accelerator Damper™. Insert the anchor tool and Accelerator Damper into the carbon fiber upper while simultaneously pulling the XLoc™ hose through the leg. NOTICE Make sure the wiper seal slides onto the tool without folding the outer lip of the seal.
  • Page 56 Push the XLoc™ button to release it to the extended (locked) position. Slide the stanchion into the carbon fiber upper until it stops and the shaft is visible through the bottom bolt hole. Install the bottom bolt and tighten. 5 mm 6.8 N·m (60 in-lb) Install the rebound adjuster knob.
  • Page 57 Press the grommet into the assembly hole. Clean the entire fork. This concludes the service of your RockShox® RS-1™ Accelerator Damper™ suspension fork. For Remote bleed and user manuals, please visit www.sram.com/service. Accelerator Damper™ Installation...
  • Page 58 This publication includes registered trademarks and trade names of the following companies: Liquid-O-Ring® is a registered trade name of Oil Center Research, Inc. TORX® is a registered trademark of Acument Intellectual Properties, LLC.
  • Page 59 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...

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