RockShox RUDY XPLR Manual
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RockShox RUDY XPLR Manual

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2022+
RUDY XPLR
SERVICE MANUAL
GEN.0000000006502 Rev G © 2024 SRAM, LLC

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Summary of Contents for RockShox RUDY XPLR

  • Page 1 2022+ RUDY XPLR SERVICE MANUAL GEN.0000000006502 Rev G © 2024 SRAM, LLC...
  • Page 2 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! ⚠ WAR NING - P R E SSURI ZED D EVI CE Suspension products may contain pressurized air, nitrogen, springs, and oil.

  • Page 3: Rockshox Service

    Retaining rings must be fully seated in the retaining ring groove. Confirm the retaining ring is fully seated in the retaining ring groove after installation. Do not use vinegar of any type to clean any part of a RockShox suspension product. Vinegar can cause permanent damage to parts which can, over time, result in product structural failure.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS ROCKSHOX SERVICE ......................................3 SUSPENSION SAFETY PRECAUTIONS AND WARNINGS ..........................3 PART PREPARATION AND SERVICE PROCEDURES .............................5 PART PREPARATION ..............................................5 SERVICE PROCEDURES ..............................................5 MODEL CODE IDENTIFICATION ..........................................6 WARRANTY AND TRADEMARK ...........................................6 PARTS, TOOLS, AND SUPPLIES ..........................................7 RECOMMENDED SERVICE INTERVALS ........................................8 RECORD YOUR SETTINGS ............................................8...

  • Page 5: Part Preparation And Service Procedures

    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: Model Code Identification

    M o d e l C o d e I d e n t i f i c a t i o n Product model code and specification details can be identified with the serial number on the product. Model codes can be used to identify the product type, series name, model name, and product version associated with the production model year.

  • Page 7: Parts, Tools, And Supplies

    • Long plastic or wooden dowel • RockShox Reverb vise blocks - 10 mm • Pick, non-metallic • RockShox Top Cap/Cassette tool (3/8" / 24 mm) • Plastic or rubber mallet • RockShox Dust Seal Installation Tool 30 mm • Sockets: 14 mm •...

  • Page 8: 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 9: Oil Volume And Lubricant

    Lube Lube Lube Air Piston Heavy Heavy Heavy Rebound FS-RUDY-BSE-A1 only IMPORTANT: 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. Oil Volume and Lubricant...

  • Page 10: Exploded View - Rudy Ultimate / Charger Race Day 2

    E x p l o d e d V i e w - R U D Y U L T I M A T E / C h a r g e r R a c e D a y 2 Air Spring Assembly Adjuster knob and Compression Damper...

  • Page 11: Exploded View - Rudy

    E x p l o d e d V i e w - R U D Y Air Spring Assembly Compression Damper Air valve cap Assembly Rebound Damper Top cap Lockout adjuster knob Assembly (Ultimate) Top cap cover (Base) Volume Reducer Top cap Compression damper Lower leg...

  • Page 12: 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 All fork models: Clamp the fork in a bicycle work stand vertically with All fork models: Clamp the fork in a bicycle work stand vertically with...
  • Page 13 ⚠ WAR NING - PRES SURI ZE D DE VI CE Always wear certified safety glasses (ANSI Z87.1, EN166 EU). Verify all air pressure is removed from the suspension component. Failure to do so can result in SERIOUS INJURY OR DEATH. Refer to the Suspension Safety Precautions and Warnings section for detailed Pressurized Device warnings and instructions.
  • Page 14 N OT ICE The Maxle inserts are reverse threaded. To avoid damaging the fork when removing or installing Maxle inserts, carefully read the instructions and follow directional arrows. Use an 8 mm hex wrench to remove the Maxle insert from the spring Use an 8 mm hex wrench to remove the Maxle insert from the spring side of the lower leg by rotating the insert side of the lower leg by rotating the insert clockwise...
  • Page 15 Remove the rebound mechanism from the damper side of the lower Remove the rebound mechanism from the damper side of the lower leg. leg. 2.5 mm Rebound adjuster adapter Remove the black rebound adjuster adapter from the rebound bottom Remove the black rebound adjuster adapter from the rebound bottom nut.
  • Page 16 Insert a 5 mm extension or hex wrench Insert a 5 mm extension or hex wrench (minimum 110 mm length) into the bolt head of the into the bolt head of the spring side spring side lower leg. Strike the wrench to lower leg.

  • Page 17: Lower Leg Service

    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 wire spring. Remove the wire spring. Remove the foam rings. Remove the foam rings. Pick Clean the foam rings.
  • Page 18 Soak the foam rings in suspension oil. Soak the foam rings in suspension oil. Maxima PLUSH Dynamic Suspension Lube Heavy Install the foam rings under the wiper seals. Install the foam rings under the wiper seals. Confirm the foam rings are installed evenly in the space under the Confirm the foam rings are installed evenly in the space under the wiper seals and do not protrude over the bushings.

  • Page 19: 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 the outer wire springs from the wiper seals. Remove the outer wire springs from the wiper seals.
  • 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 30 mm RockShox Dust Seal Installation tool. 30 mm RockShox Dust Seal Installation tool.

  • Page 21: Air Spring Service

    Scratches can cause leaks. When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. Spray RockShox Suspension Cleaner or isopropyl alcohol onto each part and clean with a clean lint-free shop towel.
  • Page 22 The positive and negative air spring chambers The positive and negative air spring chambers must be FULLY must be FULLY depressurized depressurized before removing the air spring top cap assembly. before removing the air spring top cap assembly. Slowly compress and extend (push up/pull down) the air spring shaft Slowly compress and extend (push up/pull down) the air spring shaft to allow any remaining negative air pressure to bypass the air transfer to allow any remaining negative air pressure to bypass the air transfer...
  • Page 23 Firmly pull on the air shaft to remove the air spring assembly from the Firmly pull on the air shaft to remove the air spring assembly from the upper tube. Clean and inspect the assembly for damage. upper tube. Clean and inspect the assembly for damage. Clean the inside and outside of the upper tube.
  • Page 24 Remove the inner o-rings on the air shaft stud. Remove the inner o-rings on the air shaft stud. Clean the air shaft stud. Clean the air shaft stud. Apply grease and install a new o-ring. Apply grease and install a new o-ring. Pick Remove the o-ring from the split keeper.
  • Page 25 Remove the air piston outer o-ring. Remove the air piston outer o-ring. Clean the air piston. Clean the air piston. Apply grease and install a new o-ring. Apply grease and install a new o-ring. 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 60 mm from one end.
  • Page 26 Slide the bottom out platform over the split keeper and check that the split-keeper o-ring is not visible. Clamp the air shaft into the 10 mm slot in the Reverb Vise Blocks. Clamp the air shaft into the 10 mm slot in the Reverb Vise Blocks. Install the air shaft stud Install the air shaft stud onto the air shaft and tighten.
  • Page 27 Install the Schrader valve core into the top cap and tighten it finger Install the Schrader valve core into the top cap and tighten it finger tight. tight. RockShox Schrader Valve Tool RockShox Schrader Valve Tool 200 Hour Service Continue the 200 Hour Service for a Charger Race Day Damper.

  • Page 28: Charger Race Day 2 Damper Service

    Scratches can cause leaks. When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. Spray RockShox Suspension Cleaner or isopropyl alcohol onto each part and clean with a clean lint-free shop towel.
  • Page 29 Unthread the damper top cap and remove the damper assembly. Press Unthread the damper top cap and remove the damper assembly. Press down firmly when loosening the top cap. down firmly when loosening the top cap. NOTI CE The fork top caps are tightened to a high torque value. Ensure the fork is held securely in the bicycle stand.

  • Page 30: 200 Hour Service

    NOTI CE Only use the syringe included with the RockShox Standard Bleed kit. Do not use syringes that have been in contact with DOT brake fluid. DOT brake fluid will permanently damage the damper.
  • Page 31 NOTI CE Only use the syringe included with the RockShox Standard Bleed kit. Do not use syringes that have been in contact with DOT brake fluid. DOT brake fluid will permanently damage the damper.
  • Page 32 Inject the oil into the damper assembly. Inject the oil into the damper assembly. Push the assembly down to compress the rebound shaft. The syringe Push the assembly down to compress the rebound shaft. The syringe will fill up. will fill up. Depress the syringe to inject oil into the damper assembly and allow Depress the syringe to inject oil into the damper assembly and allow the rebound shaft to fully extend.
  • Page 33 Rapidly push the rebound shaft in and out 15-20 times. Rapidly push the rebound shaft in and out 15-20 times. Compress the damper in a vertical position for five minutes. This will Compress the damper in a vertical position for five minutes. This will allow the remaining bubbles to float to the top.
  • Page 34 Push the syringe handle down, then release the plunger. Allow the Push the syringe handle down, then release the plunger. Allow the bladder to come to a natural resting position by waiting a few moments bladder to come to a natural resting position by waiting a few moments until the syringe stops filling.

  • Page 35: Charger Race Day 2 Damper Installation

    2 0 0 H o u r S e r v i c e C h a r g e r R a c e D a y 2 D a m p e r I n s t a l l a t i o n Install the Charger Race Day 2 Damper into the damper side upper Install the Charger Race Day 2 Damper into the damper side upper tube.
  • Page 36 Install the adjuster knob on the top cap so the flange is pointed away Install the adjuster knob on the top cap so the flange is pointed away from the steerer tube. Rotate the adjuster knob clockwise until it stops from the steerer tube.

  • Page 37: Charger Race Day Damper Service

    Scratches can cause leaks. When replacing seals and o-rings, use your fingers or a pick to remove the seal or o-ring. Spray RockShox Suspension Cleaner or isopropyl alcohol onto each part and clean with a clean lint-free shop towel.
  • Page 38 Replace the o-ring on the top cap. Replace the o-ring on the top cap. Charger Race Day Damper Removal...

  • Page 39: 200 Hour Service

    NOTI CE Only use the syringe included with the RockShox Standard Bleed kit. Do not use syringes that have been in contact with DOT brake fluid. DOT brake fluid will permanently damage the damper.
  • Page 40 NOTI CE Only use the syringe included with the RockShox Standard Bleed kit. Do not use syringes that have been in contact with DOT brake fluid. DOT brake fluid will permanently damage the damper.
  • Page 41 Hold the damper vertically. Thread the syringe into the top cap bleed Hold the damper vertically. Thread the syringe into the top cap bleed port. port. Inject the oil into the damper assembly. Inject the oil into the damper assembly. Push the assembly down to compress the rebound shaft.
  • Page 42 Install the bleed screw. Install the bleed screw. Rapidly push the rebound shaft in and out 15-20 times. Rapidly push the rebound shaft in and out 15-20 times. Compress the damper in a vertical position for five minutes. This will Compress the damper in a vertical position for five minutes.
  • Page 43 Push the assembly down to compress the rebound shaft. The syringe Push the assembly down to compress the rebound shaft. The syringe will fill up. will fill up. Depress the syringe to inject oil into the damper assembly and allow Depress the syringe to inject oil into the damper assembly and allow the rebound shaft to fully extend.

  • Page 44: 200 Hour Service

    2 0 0 H o u r S e r v i c e C h a r g e r R a c e D a y D a m p e r I n s t a l l a t i o n Install the Charger Race Day Damper into the damper side upper tube.

  • Page 45: 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 46 Orient the fork so that it is parallel to the ground. Orient the fork so that it is parallel to the ground. Slide the lower leg onto the upper tube enough to engage the upper Slide the lower leg onto the upper tube enough to engage the upper bushing with the upper tube.
  • Page 47 ⚠ WA RNI NG - CRASH HAZARD Parts must be tightened to the specified torque. Failure to do so can result in SERIOUS INJURY OR DEATH.Install the silver bottom bolt into the spring side shaft of the lower leg. Install the silver bottom bolt into the spring side shaft of the lower leg. Install the silver bottom bolt into the spring side shaft of the lower leg.
  • Page 48 N OT ICE The Maxle inserts are reverse threaded. To avoid damaging the fork when removing or installing Maxle inserts, carefully read the instructions and follow directional arrows. Use an 8 mm hex socket to install the Maxle insert into the spring side Use an 8 mm hex socket to install the Maxle insert into the spring side of the lower leg by rotating the insert of the lower leg by rotating the insert counter-clockwise...
  • Page 49 Clean the entire fork. Clean the entire fork. This concludes the service of your RockShox Rudy XPLR suspension fork. Lower Leg Installation...
  • Page 50 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 U.S.A. Niederlande...

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