SRAM RockShox DebonAir Upgrade Manual
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SRAM RockShox DebonAir Upgrade Manual

SRAM RockShox DebonAir Upgrade Manual

Upgrade and travel change kit
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DebonAir Upgrade and
Travel Change Kit
UPGRADE MANUAL
GEN.0000000005734 Rev E © 2022 SRAM, LLC

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Summary of Contents for SRAM RockShox DebonAir

  • Page 1 DebonAir Upgrade and Travel Change Kit UPGRADE MANUAL GEN.0000000005734 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 PARTS, TOOLS, AND SUPPLIES ..........................................6 MODEL CODE IDENTIFICATION ..................................7 LYRIK / PIKE / REVELATION / YARI / ZEB UPGRADE KIT COMPATIBILITY ....................7 SEAL HEAD ONLY UPGRADE ............................................. 7 DEBONAIR UPGRADE, TRAVEL CHANGE, AND BOTTOMLESS TOKENS ............................

  • 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

    Place an oil pan on the floor underneath the area where you will be working on the suspension fork. ‡Air Spring Oil / Grease - Pike, Revelation, Lyrik, Yari, ZEB, and BoXXer forks are compatible with RockShox Dynamic Seal Grease and SRAM Butter.

  • Page 7: Model Code Identification

    Bottomless Tokens that can be used with each maximum fork travel option. 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 8 Lower Leg Oil Wheel Model Desired Max Max Bottomless Damper Side Spring Side Fork Generation Size Upgrade Kit Year Travel (mm) Tokens (in) Volume Volume (mL) (mL) 00.4019.931.008 ‡ 00.4019.931.009 ‡ 00.4019.931.010 ‡ 00.4019.931.011 ‡ 00.4019.931.012 ‡ 00.4019.931.007 ‡ 00.4019.931.008 ‡ 2014- A1-A2 27.5...

  • Page 9: Lyrik / Pike / Revelation / Yari / Zeb Debonair Upgrade Kit Installation

    L y r i k / P i k e / R e v e l a t i o n / Y a r i / Z E B D e b o n A i r U p g r a d e K i t I n s t a l l a t i o n L o w e r L e g R e m o v a l Remove the air valve cap from the top cap located on the non-drive side fork leg.
  • Page 10 Place an oil pan beneath the fork to catch any draining oil. Spring Side Use a rubber or plastic mallet to firmly strike each bottom bolt, or a hex or a hex wrench inserted into the bottom bolt for hollow bottom lower legs, wrench inserted into the bottom bolt for hollow bottom lower legs, to dislodge the air and damper shafts from the lower leg.

  • Page 11: Air Spring Removal

    A i r S p r i n g R e m o v a l Use a 24 mm socket wrench or RockShox Top Cap/Cassette tool to DebonAir remove the top cap. Spray isopropyl alcohol on the upper tube threads and clean the threads with a shop towel.
  • Page 12 Solo Air: Use a flat blade screwdriver to push the SA seal head tab under the retaining ring. NOTI CE Scratches on the air shaft will allow air to bypass the seal head into the lower leg, resulting in reduced spring performance. 2018 DebonAir and Solo Air Place the tips of large internal retaining ring pliers into the eyelets of 2018 DebonAir and Solo Air...
  • Page 13 2018 DebonAir and Solo Air: Use your fingers to install the bottom bolt DebonAir into the air shaft. Firmly pull on the bottom bolt to remove the air shaft assembly from the upper tube. Unthread and remove the bottom bolt from the air shaft.

  • Page 14: Debonair Seal Head Only Upgrade

    D e b o n A i r S e a l H e a d O n l y U p g r a d e The following kit can be used to upgrade the seal head on a fork with a 2019+ DebonAir air spring previously installed. Lyrik / Pike / Revelation / Yari (2019-2020) 00.4020.573.000 AM UPGR DB C1- 35MM SEAL HEAD...
  • Page 15 Apply red Loctite 2760 or 270 to the first two to three full threads on Apply red Loctite 2760 or 270 to the first two to three full threads on the end of the air shaft. the end of the air shaft. Loctite 2760 or 270 Clamp an 8 mm hex wrench into a vise.

  • Page 16: Debonair Spring Installation

    D e b o n 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 evenly around the end of a clean Apply a liberal amount of grease evenly around the end of a clean plastic dowel, approximately 150 mm from one end.
  • Page 17 Insert the air spring assembly into the upper tube. Firmly push the air Insert the air spring assembly into the upper tube. Firmly push the air piston into the upper tube. piston into the upper tube. 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.
  • Page 18 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 24 mm or Top cap/ 28 N•m (250 in-lb) down firmly when tightening the top cap. down firmly when tightening the top cap.

  • Page 19: Lower Leg Assembly

    L o w e r L e g A s s e m b l y Spray isopropyl alcohol on the upper tubes and clean them with a shop towel. Apply grease to the inner surfaces of the dust wiper seals. Install the lower leg assembly onto the upper tubes and slide it just Install the lower leg assembly onto the upper tubes and slide it just enough to engage the upper bushings with the upper tubes.
  • Page 20 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 suspension oil into each lower leg through the bottom bolt holes. Inject suspension oil into each lower leg through the bottom bolt holes. Consult the Consult the DebonAir Upgrade, Travel Change, and Bottomless Token...
  • Page 21 Refer to your pre-service recorded settings, or use the air chart on the Refer to your pre-service recorded settings, or use the air chart on the fork's lower leg, and pressurize the air spring. fork's lower leg, and pressurize the air spring. You may see a drop in the indicated air pressure on the pump gauge You may see a drop in the indicated air pressure on the pump gauge while filling the air spring;...

  • Page 22: Boxxer Debonair Spring Upgrade Kit Compatibility

    For part ordering information, please contact your local SRAM distributor or dealer. 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 23: Boxxer Debonair Upgrade And Travel Change Kit Installation

    B o X X e r D e b o n A i r U p g r a d e a n d T r a v e l C h a n g e K i t I n s t a l l a t i o n F o r k R e m o v a l We recommend the following steps to remove your BoXXer from the bicycle.
  • Page 24 On the damper side of the lower leg, unthread the Maxle DH On the damper side of the lower leg, unthread the Maxle DH counter-clockwise and remove it from lower leg. counter-clockwise and remove it from lower leg. 6 mm Remove the wheel.
  • Page 25 Insert a brake pad spreader into the brake caliper. Insert a brake pad spreader into the brake caliper. Brake Pad Spreader Remove the brake caliper. Temporarily secure the brake caliper and Remove the brake caliper. Temporarily secure the brake caliper and brake hose to the bicycle, away from the fork.
  • Page 26 Use your thumb to pry the thickest section of each frame bumper away Use your thumb to pry the thickest section of each frame bumper away from the upper tubes. Spray isopropyl alcohol or water between each from the upper tubes. Spray isopropyl alcohol or water between each bumper and upper tube.

  • Page 27: Lower Leg Removal

    L o w e r L e g R e m o v a l Clamp the spring side upper tube into the bicycle work stand. Clamp the spring side upper tube into the bicycle work stand. Spring Side Remove the air valve cap. Remove the air valve cap.
  • Page 28 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 the spring side bottom bolt 3 to 4 turns. Loosen the spring side bottom bolt 3 to 4 turns. 5 mm Spring Side Strike the spring side bottom bolt to dislodge the shaft from the lower...

  • Page 29: Debonair Spring Removal

    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 shop towel. Apply SRAM Butter grease to the new seals and o-rings SRAM Butter Remove the air spring top cap.
  • Page 30 Wrap a shop towel around the end of the air shaft for extra grip. Push Wrap a shop towel around the end of the air shaft for extra grip. Push the shaft half way into the upper tube, then quickly and firmly pull the the shaft half way into the upper tube, then quickly and firmly pull the shaft out to dislodge the seal head.

  • Page 31: Bottomless Tokens (Optional)

    Bottomless Token kits. 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 27.5"...

  • Page 32: Debonair Spring Installation

    D e b o n 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 evenly around the end of a clean Apply a liberal amount of grease evenly around the end of a clean plastic dowel, approximately 150 mm from one end.
  • Page 33 Apply suspension oil to the spring shaft, above the seal head. Apply suspension oil to the spring shaft, above the seal head. Maxima PLUSH Dynamic Suspension Lube Heavy 1 mL Insert the air spring assembly into the upper tube. Firmly push the air Insert the air spring assembly into the upper tube.
  • Page 34 Retaining rings have a sharper-edged side and a rounder edged side. Retaining rings have a sharper-edged side and a rounder edged side. Installing retaining rings with the sharper-edged side facing the tool Installing retaining rings with the sharper-edged side facing the tool will allow for easier installation and removal.

  • Page 35: Lower Leg Installation

    L o w e r L e g I n s t a l l a t i o n Clean the upper tube. Clamp the spring side upper tube into the work stand angled slightly Clamp the spring side upper tube into the work stand angled slightly upward.
  • Page 36 Inject 10 mL of suspension oil into the lower leg through the bottom Inject 10 mL of suspension oil into the lower leg through the bottom bolt hole. bolt hole. NOTI CE Do not exceed the recommended oil volume per leg as this can damage the fork.

  • Page 37: Fork Installation

    F o r k I n s t a l l a t i o n Secure the bicycle in a bicycle work stand. Secure the bicycle in a bicycle work stand. Reinstall the sag o-ring onto the spring side upper tube. Reinstall the sag o-ring onto the spring side upper tube.
  • Page 38 Spray isopropyl alcohol or water on the inner surface of each frame Spray isopropyl alcohol or water on the inner surface of each frame bumper and the upper tubes. Reinstall the frame bumpers onto the bumper and the upper tubes. Reinstall the frame bumpers onto the upper tubes.
  • Page 39 On one side of the fork, tighten the top bolt on the lower crown to the On one side of the fork, tighten the top bolt on the lower crown to the 4 mm 5 N·m (40 in-lb) specified torque, then tighten the lower bolt on the lower crown to the specified torque, then tighten the lower bolt on the lower crown to the specified torque.
  • Page 40 Position the front wheel in the lower leg dropouts so the hub is seated Position the front wheel in the lower leg dropouts so the hub is seated in the dropouts and hold it in place. in the dropouts and hold it in place. NOTI CE Verify no parts interfere with the lower leg.
  • Page 41 Refer to your pre-service recorded settings, or use the air chart on the Refer to your pre-service recorded settings, or use the air chart on the fork's lower leg, and pressurize the air spring. fork's lower leg, and pressurize the air spring. You may see a drop in the indicated air pressure on the pump gauge You may see a drop in the indicated air pressure on the pump gauge while filling the air spring;...
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  • Page 43 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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