SRAM ROCK SHOX Lyrik Service Manual
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SRAM ROCK SHOX Lyrik Service Manual

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2018
Lyrik
Yari
&
s e r v i c e
m a n u a l
GEN.0000000005295 Rev E
© 2022 SRAM, LLC

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Summary of Contents for SRAM ROCK SHOX Lyrik

  • Page 1 2018 Lyrik Yari & s e r v i c e m a n u a l GEN.0000000005295 Rev E © 2022 SRAM, LLC...
  • Page 2 BRAND NAMES. 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. SRAM warrants all Zipp MOTO Wheels and Rims to be free from defects in materials or workmanship for the lifetime 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!

  • Page 4: Table Of Contents

    TABLE OF CONTENTS ROCKSHOX SERVICE ......................................5 PART PREPARATION ..............................................5 SERVICE PROCEDURES ..............................................5 MODEL CODE IDENTIFICATION ..........................................6 PARTS, TOOLS, AND SUPPLIES ..........................................7 RECOMMENDED SERVICE INTERVALS ........................................8 RECORD YOUR SETTINGS ............................................8 TORQUE VALUES ................................................8 OIL VOLUME AND LUBRICANT ...........................................9 EXPLODED VIEW - (A1, B1) LYRIK RCT3 - DEBONAIR (DA).........................10 LYRIK RCT R ..................................................10 EXPLODED VIEW - (B1, C1) LYRIK RC - DUAL POSITION AIR (DPA) ......................11 LYRIK RC R ..................................................

  • 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: Model Code Identification

    C1 = Version - (C - third generation, 1 - first iteration) To identify the model code, locate the serial number on the product and enter it into the Search by Model Name or Serial Number field at www.sram.com/service. Model Code Identification...

  • Page 7: Parts, Tools, And Supplies

    • Maxima PLUSH 3wt or RockShox 3wt Suspension Oil (Lyrik) • Needle nose pliers • RockShox 5wt Suspension Oil (Yari) • Open end wrenches: 15, 23 mm • SRAM Butter grease • Pick RockShox Tools • Rubber or plastic mallet •...

  • Page 8: 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 9: Oil Volume And Lubricant

    **Suspension oil/fluid - Maxima PLUSH Dynamic Suspension Lube and RockShox 0w-30 suspension oils/fluids are forward and backward compatible with RockShox Dynamic Seal Grease and SRAM Butter Grease. Use ONLY RockShox, SRAM, and Maxima suspension oils/fluids and grease, unless otherwise specified. Use of any other lubricants can damage seals and decrease performance.

  • Page 10: Exploded View - (A1, B1) Lyrik Rct3 - Debonair (Da)

    E x p l o d e d V i e w - ( A 1 , B 1 ) L y r i k R C T 3 - D e b o n A i r ( D A ) Air Spring Assembly Steerer tube Compression Damper...

  • Page 11: Exploded View - (B1, C1) Lyrik Rc - Dual Position Air (Dpa)

    E x p l o d e d V i e w - ( B 1 , C 1 ) L y r i k R C - D u a l P o s i t i o n A i r ( D P A ) Air Spring Assembly Air cap Travel adjuster knob...

  • Page 12: Exploded View - (A1, B1) Yari Rc - Debonair (Da)

    E x p l o d e d V i e w - ( A 1 , B 1 ) Y a r i R C - D e b o n A i r ( D A ) Air Spring Assembly Steerer tube Air cap Compression Damper...

  • Page 13: Exploded View - (A1, B1) Yari Rc - Dual Position Air (Dpa)

    E x p l o d e d V i e w - ( A 1 , B 1 ) Y a r i R C - D u a l P o s i t i o n A i r ( D P A ) Air Spring Assembly Air cap Steerer tube...

  • Page 14: 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 Remove the air valve cap.

  • Page 15: 50 Hour Service

    Place an oil pan beneath the fork to catch the draining oil. Damper Side Loosen both bottom bolts 3 to 4 turns. Spring Side Strike each bottom bolt to dislodge the shafts from the lower leg on Spring Side each side. The bolt head should contact the bottom of the lower leg. Remove each bottom bolt.

  • Page 16: Lower Leg Service

    5 0 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 foam rings. Clean the foam rings. Isopropyl Alcohol Soak the foam rings in suspension oil. Maxima PLUSH Dynamic Suspension Lube Light Lower Leg Service...
  • Page 17 Clean the inside and outside of the lower leg. Clean the wiper seals. Install the foam rings under the wiper seals. Confirm the foam rings are installed evenly in the space under the wiper seals and do not protrude over the bushings. 50 Hour Service Continue the 50 Hour Service with Lower Leg Installation.

  • Page 18: 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 and discard the foam rings. Remove the outer wire springs from the dust wiper seals. Stabilize the lower leg on a bench top.
  • Page 19 Soak the new foam rings in suspension oil. Install the new foam rings into the lower leg. Maxima PLUSH Dynamic Suspension Lube Light Remove the outer wire spring from each new dust wiper seal and set them aside. Insert the narrow end of a new wiper seal into the recessed end of the Dust Seal Installation tool.
  • Page 20 Install the outer wire springs. Lower Leg Seal Service...

  • Page 21: Air Spring Service

    When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. Spray isopropyl alcohol on each part and clean with a clean lint-free rag. Apply SRAM Butter grease to the new seals and o-rings. SRAM Butter Dual Position Air: Remove the travel adjuster knob retaining nut.
  • Page 22 Remove the air spring top cap. DebonAir Lyrik Clean the upper tube threads. RockShox Top Cap / Cassette Tool DebonAir Yari 24 mm Dual Position Air 24 mm Remove the top cap o-ring and discard it. Apply grease to a new o-ring DebonAir and install it.
  • Page 23 Dual Position Air: Push the air shaft into the upper tube to prevent it from getting scratched while removing the retaining ring. Push the seal head tab (A) into the upper tube and under the retaining ring. Remove the retaining ring. NOTI CE Do not scratch the air spring shaft.
  • Page 24 Thread the shaft bolt into the end of the air spring shaft for added grip. Dual Position Air With the shaft pushed half way into the upper tube, quickly and firmly pull the shaft out to remove the seal head and air spring assemblies from the upper tube.
  • Page 25 Dual Position Air: Remove the inner and outer air piston o-rings and Dual Position Air discard them. Clean the air piston. Apply grease to new o-rings and install them. NOTI CE Do not scratch the air piston. Scratches will cause air to leak. Dual Position Air DebonAir: Remove the quad ring seal from the air piston and discard it.

  • Page 26: Air Spring Travel Change And Bottomless Tokens (Optional)

    For part ordering information, please contact your local SRAM distributor or dealer. D e b o n A i r - T r a v e l a n d B o t t o m l e s s T o k e n T u n i n g - L y r i k 29"...

  • Page 27: Bottomless Tokens Installation (Optional)

    B o t t o m l e s s T o k e n s I n s t a l l a t i o n ( o p t i o n a l ) Bottomless Tokens reduce air volume in your fork and create greater ramp at the end of the fork travel. Add tokens to tune your fork's bottomless feel. Air Spring Travel Change and Bottomless Tokens for the maximum number of Tokens for your fork.

  • Page 28: Air Spring Installation

    For part ordering information, please contact your local SRAM distributor or dealer. Apply a liberal amount of grease to the inside of the upper tube, from the end of the tube to approximately 60 mm into the tube.
  • Page 29 Install the top out bumper onto the shaft. DebonAir Install the retaining washer/backup ring, a new wave spring, and the new seal head assembly, in that order, onto the air shaft. DebonAir Dual Position Air Dual Position Air Apply grease to the air piston and seal head outer o-rings/seals. DebonAir Dual Position Air Air Spring Installation...
  • Page 30 Insert the air spring assembly into the upper tube. Firmly push the air DebonAir piston into the upper tube. Position the flat retaining washer (A) into the upper tube, followed by the wavy washer (B). Use your fingers to firmly press the seal head into the upper tube until it stops.
  • Page 31 Retaining rings have a sharper-edged side and a rounder edged side. DebonAir Installing retaining rings with the sharper-edged side facing the tool will allow for easier installation and removal. DebonAir: Guide the retaining ring with your finger to prevent scratching the air shaft. Dual Position Air: Push the air shaft into the upper tube to prevent it from getting scratched while installing the retaining ring.
  • Page 32 Dual Position Air: Thread a bottom bolt onto the shaft 2 to 3 turns and pull the shaft out until it stops. Remove the bolt. Dual Position Air Dual Position Air: Apply a liberal amount of grease to the top cap upper air spring shaft.
  • Page 33 Install the air spring top cap into the upper tube and tighten it. 24 mm 28 N•m (250 in-lb) Dual Position Air 24 mm or Top Cap Tool 28 N•m (250 in-lb) DebonAir Dual Position Air: Place the adjuster knob onto the top cap with the Dual Position Air long tab near the back of the crown.

  • Page 34: Charger 2 Damper Service - Lyrik

    C h a r g e r 2 D a m p e r S e r v i c e - L y r i k Consult the 2016-2017 Lyrik Service Manual at www.sram.com/service for Charger Damper service procedures.
  • Page 35 RCT R / RC R: Loosen the remote cable stop collar set screw and RCT R remove the collar. 2 mm RCT R RC R 2 mm RC R RCT R: Remove the low speed knob/remote spool assembly. RC R RC R: Remove the remote spool.

  • Page 36: 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 Remove the o-ring from the top cap. Clean the top cap threads and o-ring groove.
  • Page 37 Remove the glide ring from the rebound damper piston. Install a new glide ring. Apply grease to the new rebound damper seal head seals. Install the new seal head onto the rebound damper shaft, threaded end first, and slide it towards the piston until it stops. Remove the bleed screw from the seal head.
  • Page 38 Remove the cartridge tube from the vise and pour the oil into an oil pan. Squeeze the bladder to drain the oil from the compression damper assembly into an oil pan. Clamp the cartridge tube, on the bladder coupler wrench flats, back into the vise.
  • Page 39 Dry the cartridge tube and compression damper assembly with compressed air. Air Compressor and Air Gun Nozzle Damper Service...

  • Page 40: 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 inserts.
  • Page 41 Insert the rebound damper piston slowly into the cartridge tube and thread the sealhead into the tube. Tighten the seal head. 23 mm 5.1 N·m (45 in-lb) Thread the rebound bottom bolt into the shaft 3-4 turns. Damper Assembly...

  • Page 42: Damper Bleed

    D a m p e r B l e e d Draw 3wt suspension oil into a RockShox Bleed syringe until it is half full. Hold the syringe upright, cover the tip with a rag, and gently depress the plunger to purge any air bubbles from the syringe. NOTI CE Only use a RockShox bleed syringe.
  • Page 43 Fully extend the rebound damper shaft. Push the syringe plunger down, then release the plunger. Allow the bladder to expand and retract until it stops in a resting position. Unthread the syringe bleed fitting from the bleed port. ⚠ CAUTI ON - EYE HAZARD Oil may eject from the bleed port if the bladder is not in a resting position.
  • Page 44 Cycle the rebound shaft a few times. Remove the bottom bolt and clean the Charger 2 damper assembly. Damper Bleed...

  • Page 45: Test Lockout

    T e s t L o c k o u t RCT3 / RCT R: Rotate the compression cam clockwise until it stops, to the locked out position. RCT R / RC R: Use the 13 mm wrench to hold the cam locked out while compressing the damper.

  • Page 46: 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 Install the Charger 2 damper assembly into the damper side upper tube.
  • Page 47 RCT3: Install the compression mode adjuster knob onto the top cap with the tab in the forward, unlocked position. RCT3 Install the low speed compression adjuster knob onto the hex 2 mm 1.2 N·m (10 in-lb) adjuster rod. Install and tighten the retaining screw. RC: Install the compression adjuster knob onto the top cap with the tab in the forward, unlocked, position.
  • Page 48 RCT R: Install the cable stop collar with the housing guide in the 6 o'clock forward position, angled ≈20° degrees from center. 87° 20° RCT R Push the low speed adjuster knob spring retainer (A) in and push the knob out of the remote spool. Remove the top cap seal.
  • Page 49 RCT R / RC R: Tighten the cable stop collar set screw. 2 mm 0.25 - 0.6 N·m (2.2 - 5.3 in-lb) Consult the OneLoc user manual at www.sram.com/rockshox/products/ oneloc for cable and remote installation instructions. 2 mm 0.25 - 0.6 N·m (2.2 - 5.3 in-lb)

  • Page 50: Motion Control Damper Service - Yari

    M o t i o n C o n t r o l D a m p e r S e r v i c e - Y a r i 2 0 0 H o u r S e r v i c e D a m p e r R e m o v a l Turn the compression adjuster knob counter-clockwise, to the full open position, until it stops.
  • Page 51 Thread the bottom bolt into the damper shaft 2-3 turns. Remove the rebound damper and seal head. Clean the inside and outside of the upper tube. Inspect the inside and outside of the upper tube for scratches. NOTI CE Scratches on the inside surface of the upper tube can cause oil to leak. If an internal scratch is visible, the crown steerer upper tube assembly may need to be replaced.

  • Page 52: 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 Remove the compression damper top cap o-ring and piston u-cup seal. Apply grease to the new o-ring and seal, and install them. The Yari rebound damper seal head cannot be removed from the end 15 mm of the damper shaft.
  • Page 53 Remove the glide ring and discard it. Install a new glide ring. Damper Service...

  • Page 54: Rebound Damper Installation

    2 0 0 H o u r S e r v i c e R e b o u n d D a m p e r I n s t a l l a t i o n Install the seal head onto the rebound damper shaft with the flat end Loctite Threadlocker Blue 242 facing the rebound damper piston.
  • Page 55 Push the rebound damper shaft into the upper tube to prevent it from getting scratched while installing the retaining ring. Retaining rings have a sharper-edged side and rounder-edged side. Installing retaining rings with the sharper-edged side facing the tool will allow for easier installation and removal. Place the tips of the internal retaining ring pliers into the eyelets of the retaining ring and install the retaining ring into the groove.

  • Page 56: Compression Damper Installation

    2 0 0 H o u r S e r v i c e C o m p r e s s i o n D a m p e r I n s t a l l a t i o n Pour RockShox 5wt suspension oil into the upper tube.
  • Page 57 Tighten the top cap. 24 mm 28 N·m (250 in-lb) Install the adjuster knob with the tab in the 7-8 o'clock, unlocked position. Install and tighten the retaining screw. 2 mm 1.2 N·m (10 in-lb) 200 Hour Service Continue the 200 Hour Service with Lower Leg Installation.

  • Page 58: 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 59 Position the fork at an angle with the bolt holes oriented upward. Inject Maxima PLUSH Dynamic Suspension Lube Light into each lower leg through the bottom bolt holes. NOTI CE Do not exceed the recommended oil volume per leg as this can damage the fork.
  • Page 60 200 Hour Service Remove the old crush washers from each 5 mm bottom bolt. Hold the crush washer with needle nose pliers and unthread it from the bolt by turning the bolt counter-clockwise. Discard the crush washers. Clean the bolts and install new crush washers. NOTI CE Dirty or damaged crush washers can cause oil to leak from the fork.
  • Page 61 Install the black bottom bolt into the spring side shaft. 5 mm 7.3 N·m (65 in-lb) Install the silver or red bottom bolt into the damper side shaft. 5 mm Spring Side 5 mm 7.3 N·m (65 in-lb) 5 mm Damper Side Lyrik: Install the rebound damper knob and tighten the set screw.
  • Page 62 Refer to your pre-service recorded settings, or use the air chart on the fork's lower leg, and pressurize the air spring. You may see a drop in the indicated air pressure on the pump gauge while filling the air spring; this is normal. Continue to fill the air spring to the recommended air pressure.
  • Page 63 Hussefelt®, Iclic®, i-Motion®, Judy®, Know Your Powers®, NSW®, Omnium®, Osmos®, Pike®, PowerCal®, PowerLock®, PowerTap®, Qollector®, Quarq®, RacerMate®, Reba®, Rock Shox®, Ruktion®, Service Course®, ShockWiz®, SID®, Single Digit®, Speed Dial®, Speed Weaponry®, Spinscan®, SRAM®, SRAM APEX®, SRAM EAGLE®, SRAM FORCE®, SRAM RED®, SRAM RIVAL®, Stylo®, TIME®, Truvativ®, TyreWiz®, UDH®, Varicrank®, Velotron®, X0®, X01®, X-SYNC®, XX1®, Zipp®...
  • Page 64 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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