RockShox Duke SL Air Service Manual
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RockShox Duke SL Air Service Manual

RockShox Duke SL Air Service Manual

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For exploded diagram and part number information, refer to the 2003 Spare Parts Catalog, P/N 950-007563-00.
Contact your local distributor or visit the RockShox website at www.rockshox.com for ordering information.
Information contained in this publication is subject to change at anytime without prior notice.
For the latest technical information, visit our website at www.rockshox.com.
Names used in this manual may be trademarks or registered trademarks of others.
Table o o f C C ontents
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Remove the Lower Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Removing the Hydra Air Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation of the Hydra Air Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Removal and Installation of the U-Turn Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Servicing the Pure DeLite Rebound Damper (Duke SL Air and U-Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Installation of the U-Turn Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Removal of the Internal Floating Piston (IFP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installing the Lower Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
D u k e S L A i r a n d U - Tu r n
Service Guide

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Summary of Contents for RockShox Duke SL Air

  • Page 1: Table Of Contents

    Servicing the Pure DeLite Rebound Damper (Duke SL Air and U-Turn ......

  • Page 2: Remove The Lower Legs

    • Plastic Mallet • Bike Work Stand • Lint Free Rag • Oil Pan • Red Rum • RockShox 5wt or 15wt SL oil • Isopropyl Alcohol (Spray Bottle) • Torque Wrench • Safety Glasses IGHT SIDE EQUALS RIDER S RIGHT...

  • Page 3: Removing The Hydra Air Spring Assembly

    2003 D D uke S S L A A ir & & U U -T T urn S S ervice G G uide 6. Using a plastic mallet, firmly tap the rebound damper shaft bolt and air/U-Turn spring shaft bolt until both shafts are free from lower leg. You will feel the shafts release from the lower leg press-fit.

  • Page 4: Installation Of The Hydra Air Spring Assembly

    14. VERY IMPORTANT! After the air seal o-ring has been replaced, apply a light coating of RockShox 15 wt. oil or RedRum to the o-ring air seal (aids installation). Proper lubrication of the air seal decreases heat friction, wear and tear, and extends the life of the seal.

  • Page 5: Removal And Installation Of The U-Turn Spring Assembly

    2003 D D uke S S L A A ir & & U U -T T urn S S ervice G G uide EMOVAL AND NSTALLATION OF THE PRING SSEMBLY 18. Using a 2.5mm hex wrench, loosen and remove the U-Turn adjuster knob screw (fig. 18). 19.

  • Page 6: Servicing The Pure Delite Rebound Damper

    2003 D D uke S S L A A ir & & U U -T T urn S S ervice G G uide U - T N S TA L L AT I O N O F T H E U R N P R I N G S S E M B LY...

  • Page 7: Removal Of The Internal Floating Piston (Ifp)

    2003 D D uke S S L A A ir & & U U -T T urn S S ervice G G uide 33. Slide the Pure DeLite damper tube assembly from the bottom of the upper tube (fig. 33). ( I F P ) E M O V A L O F T H E N T E R N A L...

  • Page 8: Assembling The Pure Delite Damper: Setting The Ifp Depth Inside The Pure Tube

    OF OIL BEFORE INSTALLATION 43. Holding the Pure tube over an oil pan, with the pocketed side of the IFP facing down (rounded side facing up), fill the tube until completely full with 15wt RockShox fork oil. OR QUICKER REBOUND DAMPING...
  • Page 9 45. Slide your Pure Delite oil-filled damper unit into the bottom of the upper (right side from rider's perspective). 46. Add 3cc/ml of 15wt RockShox fork oil to the top chamber of the Pure Delite damper (fig. 46). This will lubricate the IFP o-ring. Install the Delite air top cap with a 24mm socket tool to 50 in-lb and pressurize the chamber 20 to 60 psi with your shock pump.

  • Page 10: Installing The Lower Legs

    51. Invert the fork in the bicycle stand (90 degrees) with the dropouts facing up. Using an oil syringe, add 10cc of 5wt RockShox fork oil to the bottom of the fork, through each of the bolt holes (fig. 51).

  • Page 11: Warranty

    P i o n e e r S u p p o r t P r o g r a m In the event parts are unavailable at the time of your repair, at the option of RockShox or its authorized agent, a replacement fork may be provided at a determined discount price.

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