Related Manuals for RockShox ZEB
Summary of Contents for RockShox ZEB
- Page 1 ZEB, Lyrik, Pike Ultimate Flight Attendant SERVICE MANUAL GEN.0000000006531 Rev A © 2021 SRAM, LLC...
- Page 2 SRAM LLC WARRANTY THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AGAINST SRAM, LLC. YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE, COUNTRY, OR PROVINCE. THIS WARRANTY DOES NOT AFFECT YOUR STATUTORY RIGHTS. TO THE EXTENT THIS WARRANTY IS INCONSISTENT WITH THE LOCAL LAW, THIS WARRANTY SHALL BE DEEMED MODIFIED TO BE CONSISTENT WITH SUCH LAW.
- 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
EXPLODED VIEW - 2022 LYRIK ULTIMATE FLIGHT ATTENDANT ......................10 EXPLODED VIEW - 2022 PIKE ULTIMATE FLIGHT ATTENDANT ........................11 EXPLODED VIEW - FLIGHT ATTENDANT CONTROL MODULE - ZEB, LYRIK, PIKE ................12 EXPLODED VIEW - LOWER LEG FEATURES - ZEB, LYRIK, PIKE ........................ 13 EXPLODED VIEW - BUTTERCUP - ZEB, LYRIK, PIKE ...........................14... -
Page 5: Rockshox Service
P a r t P r e p a r a t i o n Remove the component from the bicycle before service. Disconnect and remove the remote cable or hydraulic hose from the fork or rear shock, if applicable. For additional information about RockShox remotes, user manuals are available at www.sram.com. -
Page 6: Parts, Tools, And Supplies
• Hex bit sockets: 2, 2.5, 5 mm • Hex wrenches: 2, 2.5, 5, 8 mm Lubricants and Fluids • Internal retaining ring pliers (large) - air spring retaining ring (ZEB) • Maxima PLUSH 3wt Suspension Oil • Long plastic or wooden dowel •... -
Page 7: Recommended Service Intervals
R e c o m m e n d e d S e r v i c e I n t e r v a l s 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. -
Page 8: Oil Volume And Lubricant
Suspension Suspension Lube Lube Maxima PLUSH Dynamic Suspension Pike Lube* *Air Spring Oil / Grease - ZEB, Lyrik, and Pike Ultimate Flight Attendant forks are compatible with Maxima PLUSH Dynamic Suspension Lube and SRAM Butter Grease. Oil Volume and Lubricant... -
Page 9: Exploded View - 2022 Zeb Ultimate Flight Attendant
Retaining ring Rebound damper seal head Bleed port Air spring shaft ButterCup (air shaft) ButterCup (damper shaft) Crush washer Maxle Stealth Air spring bottom bolt Crush washer Rebound bottom bolt Rebound adjuster knob Exploded View - 2022 ZEB Ultimate Flight Attendant... -
Page 10: Exploded View - 2022 Lyrik Ultimate Flight Attendant
E x p l o d e d V i e w - 2 0 2 2 L y r i k U l t i m a t e F l i g h t A t t e n d a n t Air Spring Assembly Steerer tube Compression Damper... -
Page 11: Exploded View - 2022 Pike Ultimate Flight Attendant
E x p l o d e d V i e w - 2 0 2 2 P i k e U l t i m a t e F l i g h t A t t e n d a n t Air Spring Assembly Steerer tube Compression Damper... -
Page 12: Exploded View - Flight Attendant Control Module - Zeb, Lyrik, Pike
(+) Adjust button Flight Attendant Control Module Set screw AXS LED indicator Output driver (compression damper adjuster) AXS button SRAM battery Compression damper Battery latch Battery block SRAM battery Exploded View - Flight Attendant Control Module - ZEB, Lyrik, Pike... -
Page 13: Exploded View - Lower Leg Features - Zeb, Lyrik, Pike
E x p l o d e d V i e w - L o w e r L e g F e a t u r e s - Z E B , L y r i k , P i k e Fender mount (x3) Pressure Relief Valve (x2) Bolt (x2) Dropout Adapter (x2) Exploded View - Lower Leg Features - ZEB, Lyrik, Pike... -
Page 14: Exploded View - Buttercup - Zeb, Lyrik, Pike
Upper ButterCup housing Upper ButterCup housing Bushing Bushing Upper bumper O-ring ButterCup shaft end plate ButterCup shaft end plate Lower ButterCup housing Lower ButterCup housing Bumper Lower bumper O-ring Lower housing alignment bolt Exploded View - ButterCup - ZEB, Lyrik, Pike... -
Page 15: Lower Leg Removal And Service
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 ZEB is pictured in this section. Procedures are the same for Lyrik and Pike unless otherwise described. Remove the air valve cap. -
Page 16: 50 Hour Service
Place an oil pan beneath the fork to catch the draining oil. Place an oil pan beneath the fork to catch the draining oil. Loosen both bottom bolts 3 to 4 turns. Loosen both bottom bolts 3 to 4 turns. Spring side 5 mm Damper side... -
Page 17: Lower Leg Service
Replace the foam rings if worn, damaged, or excessively contaminated. Replace the foam rings if worn, damaged, or excessively contaminated. RockShox Suspension Cleaner Soak the foam rings in Maxima PLUSH Dynamic Suspension Lube Soak the foam rings in Maxima PLUSH Dynamic Suspension Lube. - Page 18 Clean the inside and outside of the lower leg. Clean the inside and outside of the lower leg. Clean the wiper seals. Clean the wiper seals. RockShox Suspension Cleaner Dowel Install the foam rings under the wiper seals. Install the foam rings under the wiper seals.
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Page 19: 200 Hour Service
This will damage the lower leg. Downhill tire lever Clean the inside and outside of the lower leg. Clean the inside and outside of the lower leg. RockShox Suspension Cleaner Dowel Lower Leg Seal Service... - Page 20 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 RockShox Dust Seal Installation Tool. RockShox Dust Seal Installation Tool.
- Page 21 Install the outer wire springs. Install the outer wire springs. Lower Leg Seal Service...
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Page 22: Air Spring Service - Debonair
A i r S p r i n g S e r v i c e - D e b o n A i r + A ZEB air spring assembly is pictured in this section. Procedures are the same for ZEB, Lyrik, and Pike unless otherwise described. - Page 23 Remove the retaining ring. Remove the retaining ring. Use your finger to guide the retaining ring and protect the air spring Use your finger to guide the retaining ring and protect the air spring shaft during removal. shaft during removal. NOTI CE Do not scratch the air spring shaft.
- Page 24 NOTI CE Scratches on the inside surface of the upper tube can cause air to leak. If an internal scratch is visible, the crown steerer upper tube assembly may need to be replaced. RockShox Suspension Cleaner Dowel Dowel RockShox Suspension Cleaner...
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Page 25: Buttercup Removal - Air Spring Shaft
Clamp the lower ButterCup housing into a vise with Reverb Vise Blocks Clamp the lower ButterCup housing into a vise with Reverb Vise Blocks or RockShox Rear Shock Vise Blocks on the wrench flats, with the air or RockShox Rear Shock Vise Blocks on the wrench flats, with the air spring oriented upward. - Page 26 Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise Blocks or RockShox Rear Shock Vise Blocks with the air piston oriented Blocks or RockShox Rear Shock Vise Blocks with the air piston oriented downward.
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Page 27: Debonair+ - Air Spring Travel Change And Bottomless Tokens (Optional)
D e b o n A i r + - A i r S p r i n g T r a v e l C h a n g e a n d B o t t o m l e s s T o k e n s ( o p t i o n a l ) To increase or decrease the travel of your RockShox fork, the air spring must be replaced with the appropriate length air spring shaft assembly. For example, to change a fork with a maximum of 140 mm of travel to a maximum of 160 mm of travel, a 160 mm air spring assembly must be installed. -
Page 28: Debonair+ - Air Spring Travel Change And Bottomless Tokens (Optional)
A i r S p r i n g S e r v i c e A ZEB air spring assembly is pictured in this section. Procedures are A ZEB air spring assembly is pictured in this section. Procedures are the same for ZEB, Lyrik, and Pike air spring assemblies. - Page 29 Remove the glide ring (upper), quad ring, and backup ring (lower) from Remove the glide ring (upper), quad ring, and backup ring (lower) from the air piston and discard them. the air piston and discard them. NOTI CE Do not scratch the air piston. Scratches will cause air to leak. Pick Clean the air piston.
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Page 30: Air Spring Assembly
A i r S p r i n g A s s e m b l y Install a new backup ring (thin, lower) onto the air piston. Install a new backup ring (thin, lower) onto the air piston. Apply grease to the new quad ring seal and install it onto the air piston Apply grease to the new quad ring seal and install it onto the air piston above the backup ring. - Page 31 Apply grease to the inner and outer seals on the Apply grease to the inner and outer seals on the new new seal head. seal head. SRAM Butter Grease SRAM Butter Grease SRAM Butter Grease Install the new seal head assembly onto the air shaft, flat side first. Install the new seal head assembly onto the air shaft, flat side first.
- Page 32 Remove the grease from the inner shaft threads. Remove the grease from the inner shaft threads. Air Spring Assembly...
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Page 33: Buttercup Installation - Air Spring Shaft
Position the upper ButterCup housing above the vise blocks. Position the upper ButterCup housing above the vise blocks. Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise Blocks or RockShox Rear Shock Vise Blocks. - Page 34 Remove the air shaft from the vise and vise blocks. Remove the air shaft from the vise and vise blocks. Clamp the lower ButterCup housing into a vise with RockShox Vise Clamp the lower ButterCup housing into a vise with RockShox Vise Blocks on the wrench flats, air spring piston oriented upward.
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Page 35: 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 SRAM Butter grease evenly around the end Apply a liberal amount of SRAM Butter grease evenly around the end of a clean plastic dowel, approximately 150 mm from one end. - Page 36 Insert the air seal head into the upper tube and firmly press it into the Insert the air seal head into the upper tube and firmly press it into the upper tube until it stops. upper tube until it stops. Apply grease to a new seal head spacer o-ring and install it onto the Apply grease to a new seal head spacer o-ring and install it onto the seal head spacer.
- Page 37 ZEB: ZEB: Eyelet re Eyelet retaining rings have a sharper edged side and a rounder taining rings have a sharper edged side and a rounder edged side. Installing retaining rings with the sharper edged side edged side. Installing retaining rings with the sharper edged side facing the tool will allow for easier installation and removal.
- Page 38 Maxima PLUSH Dynamic Suspension Lube RockShox Bleed Syringe 3 mL Install the air spring top cap into the upper tube and tighten it. Press Install the air spring top cap into the upper tube and tighten it. Press down firmly when tightening the top cap.
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Page 39: Damper Service
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 F l i g h t A t t e n d a n t C o n t r o l M o d u l e R e m o v a l The compression damper must be in the OPEN position before The compression damper must be in the OPEN position before removing the Control Module. - Page 40 Carefully remove the Flight Attendant Control Module from the Carefully remove the Flight Attendant Control Module from the compression damper top cap. Use both thumbs to evenly push the compression damper top cap. Use both thumbs to evenly push the Control Module straight up and out of the top cap.
- Page 41 Carefully remove the inner damper top cap / Control Module o-ring Carefully remove the inner damper top cap / Control Module o-ring seal. seal. NOTI CE Do not scratch the o-ring gland. Scratches can cause debris to enter the top cap under the Flight Attendant Control Module. Pick Clean the inside of the top cap and o-ring gland with a damp clean Clean the inside of the top cap and o-ring gland with a damp clean...
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Page 42: Damper Removal
Clean the upper tube threads. Clean the upper tube threads. Top cap / Cassette tool Clean the inside and outside of the upper tube. Clean the inside and outside of the upper tube. RockShox Suspension Cleaner Dowel Dowel Damper Removal... -
Page 43: Buttercup Removal - Damper Shaft
Clamp the lower ButterCup housing into a vise with Reverb Vise Blocks Clamp the lower ButterCup housing into a vise with Reverb Vise Blocks or RockShox Rear Shock Vise Blocks on the wrench flats, with the or RockShox Rear Shock Vise Blocks on the wrench flats, with the damper oriented downward. - Page 44 Clamp the damper shaft into the 10 mm slot of the RockShox Reverb Clamp the damper shaft into the 10 mm slot of the RockShox Reverb Vise Blocks or RockShox Rear Shock Vise Blocks with the damper Vise Blocks or RockShox Rear Shock Vise Blocks with the damper oriented downward.
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Page 45: 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 cartridge tube wrench flats in a vise with flat soft jaw inserts, Clamp the cartridge tube wrench flats in a vise with flat soft jaw inserts, rebound damper oriented upward. - Page 46 Apply grease to the new rebound damper seal head seals. Apply grease to the new rebound damper seal head seals. SRAM Butter Grease Install the new seal head onto the rebound damper shaft, threaded end Install the new seal head onto the rebound damper shaft, threaded end first, and slide it towards the piston until it stops.
- Page 47 Clamp the cartridge tube, on the bladder coupler wrench flats, back Clamp the cartridge tube, on the bladder coupler wrench flats, back into the vise. into the vise. Spray RockShox Suspension Cleaner or isopropyl alcohol into the Spray RockShox Suspension Cleaner or isopropyl alcohol into the cartridge tube. cartridge tube.
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Page 48: 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 Clamp the cartridge tube wrench flats lightly into the vise and soft jaw inserts. - Page 49 Insert the rebound damper piston slowly into the cartridge tube and Insert the rebound damper piston slowly into the cartridge tube and thread the sealhead into the tube. thread the sealhead into the tube. Tigthen the seal head. Tigthen the seal head. 23 mm 5.1 N∙m (45 in-lb) Thread the rebound bottom bolt into the shaft 3-4 turns.
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Page 50: Damper Bleed
2 0 0 H o u r S e r v i c e D a m p e r B l e e d Draw Maxima PLUSH 3wt suspension oil into a RockShox Bleed Draw Maxima PLUSH 3wt suspension oil into a RockShox Bleed Syringe until it is half full. - Page 51 Fully extend the rebound damper shaft. Push the syringe plunger Fully extend the rebound damper shaft. Push the syringe plunger down, then release the plunger. Allow the bladder to expand and down, then release the plunger. Allow the bladder to expand and retract until it stops in a resting position.
- Page 52 Cycle the rebound shaft a few times. Cycle the rebound shaft a few times. Remove the bottom bolt and clean the damper assembly. Remove the bottom bolt and clean the damper assembly. Damper Bleed...
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Page 53: Test Lockout Compression
2 0 0 H o u r S e r v i c e T e s t L o c k o u t C o m p r e s s i o n Use a Schrader valve core tool to rotate the keyed adjuster clockwise Use a Schrader valve core tool to rotate the keyed adjuster clockwise until it lightly contacts the stop point, to the locked out or firmest until it lightly contacts the stop point, to the locked out or firmest... -
Page 54: Buttercup Installation - Damper Shaft
Clamp the damper shaft into the 10 mm slot of the Reverb Vise Blocks Clamp the damper shaft into the 10 mm slot of the Reverb Vise Blocks or RockShox Rear Shock Vise Blocks. or RockShox Rear Shock Vise Blocks. - Page 55 Install the lower ButterCup housing bumper into the lower ButterCup Install the lower ButterCup housing bumper into the lower ButterCup housing, wide side down, in alignment with the bolt. housing, wide side down, in alignment with the bolt. Apply Threadlocker Loctite 242 (blue), or equivalent, to three full outer Apply Threadlocker Loctite 242 (blue), or equivalent, to three full outer threads on the lower ButterCup housing.
- Page 56 Remove the damper shaft from the vise and vise blocks. Remove the damper shaft from the vise and vise blocks. Clamp the lower ButterCup housing into a vise with RockShox Vise Clamp the lower ButterCup housing into a vise with RockShox Vise Blocks on the wrench flats, damper oriented upward.
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Page 57: 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 Remove the o-ring from the top cap. Remove the o-ring from the top cap. Clean the top cap threads and o-ring groove. - Page 58 Install the damper assembly into the damper side upper tube. Use Install the damper assembly into the damper side upper tube. Use your fingers to guide the damper and damper shaft into the upper tube your fingers to guide the damper and damper shaft into the upper tube without scratching the shaft.
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Page 59: Control Module Installation
2 0 0 H o u r S e r v i c e C o n t r o l M o d u l e I n s t a l l a t i o n The keyed ends of the Control Module output driver and the The keyed ends of the Control Module output driver and the compression damper adjuster must be aligned in the same orientation compression damper adjuster must be aligned in the same orientation... - Page 60 Position the back of the Control Module parallel with the crown, and Position the back of the Control Module parallel with the crown, and install the Control Module into the compression damper. install the Control Module into the compression damper. With the keyed ends of the Control Module output driver and With the keyed ends of the Control Module output driver and compression damper adjuster aligned, press the Control Module firmly...
- Page 61 Tighten each set screw evenly finger tight to center the Control Module Tighten each set screw evenly finger tight to center the Control Module position on the top cap. position on the top cap. Tighten each set screw to the specified torque. Tighten each set screw to the specified torque.
- Page 62 Check compression damper for proper function. Check compression damper for proper function. Press and hold the Menu button until the OPEN LED pulses red. Press and hold the Menu button until the OPEN LED pulses red. Press and release the ( Press and release the ( + + ) adjuster button until the LOCK LED pulses ) adjuster button until the LOCK LED pulses red.
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Page 63: 50/200 Hour Service
L o w e r L e g I n s t a l l a t i o n Clean the upper tubes. Clean the upper tubes. RockShox Suspension Cleaner Apply grease to the inner surfaces of the dust wiper seals. Apply grease to the inner surfaces of the dust wiper seals. - Page 64 Position the fork at an angle with the bolt holes oriented upward. Position the fork at an angle with the bolt holes oriented upward. Inject Maxima PLUSH Dynamic Suspension Lube into each lower leg Inject Maxima PLUSH Dynamic Suspension Lube into each lower leg through the bottom bolt holes.
- Page 65 200 Hour Service 200 Hour Service Remove the old crush washers from each bottom Remove the old crush washers from each bottom bolt. bolt. Hold the crush washer with needle nose pliers and unthread it from the Hold the crush washer with needle nose pliers and unthread it from the bolt by turning the bolt counter-clockwise.
- Page 66 Install the air valve cap. Install the air valve cap. Clean the entire fork. Clean the entire fork. RockShox Suspension Cleaner This concludes the service of your RockShox suspension fork. This concludes the service of your RockShox suspension fork. Lower Leg Installation...
- Page 67 WiFLi™, X1™, X3™, X4™, X5™, X7™, X9™, X-Actuation™, XC™, X-Dome™, XD™, XDR™, XG-1150™, XG-1175™, XG-1180™, XG-1190™, X-Glide™, X-GlideR™, X-Horizon™, XLoc Sprint™, XPLR™, XPRESSO™, XPRO™, X-Range™, XX™, Yari™, ZEB™, Zero Loss™, ZM2™, ZR1™ Specifications and colors subject to change without prior notice.
- Page 68 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. The Netherlands...
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