SERVICE MANUAL. For Deluxe, Super Deluxe, and Super Ti Deluxe Rear Shocks. RockShox, Inc

Transcription

1 ~~-- - SERVICE MANUAL For Deluxe, Super Deluxe, and Super Ti Deluxe Rear Shocks RockShox, Inc

2 ' INTRODUCTION ROCK SHOX DEWXE-The Deluxe rear shock is designed as a high performance coii-qver, oil-damped system offering simple spring preload adjustment and changes to suit most any riding style or terrain. Bottom-out Bumper Spring Body Threads ROCK SHOX SUPER DELUXE/SUPER Ti DEWXE-The Super Deluxe/Super Ti Deluxe rear shocks are designed as a high performance coii-qver, oil-damped, concentric floating piston system offering simple spring preload and damping adjustment. External adjustability to low speed compression and rebound damping permit tuning for most any riding style or terrain. Body Eye --- Reservoir --- Body Threads --- Threaded Spring Collar -~----- Seal Head Shaft Spring Bottom-out Bumper Spring Retaining Collar Damping Adjuster Shaft Eye page1

3 REQUIRED TOOLS COMMON HAND TOOLS: 2mm hex key 5mm hex key 22mm open end wrench 10mm open end wrench Snap ring pliers Soft faced mallet Bench mounted vice 10-inch adjustable wrench 6-inch vernier calipers Safety glasses Small flat-blade screwdriver SPECIAL ROCK SHOX TOOLS: Shaft vice blocks Shaft bullet Valve core insertion tool Bushing installer tool Glide ring expander tool Glide ring sizer tool Seal installer tool High-pressure small needle pump Body tube clamp MISCELLANEOUS: Judy Butter or other high quality grease Rock Shox 5 wt shock oil Rock Shox 15 wt shock oil Loc-tite # 271 red thread adhesive REGULAR MAINTENANCE The ROCKSHOX Deluxe, Super Deluxe/Super Ti Deluxe rear shocks are designed to give you high performance under normal riding conditions. To ensure this, we recommend keeping the shaft area, seal head, and bottom-out bumper as clean as possible. Clean after every ride. NEVER USE A HIGH POWERED WASHER FOR CLEANING THE SHOCK. Keep the shaft eye and body eye bushings clean and greased. Regrease bushings once a month and/or every 40 hours of riding. Over time, the oil inside the shock will degrade. As this happens, the shock will start to lose damping. When damping loss is significant, shock service is recommended. Shock oil should be changed every 12 months or sooner. 1. Remove the shock from the bicycle. 2. Thoroughly clean the shock body threads. 3. Turn the red threaded spring collar towards the body eye (fig. 2A). 4. Now remove the spring. page 2

4 DEPRESSURIZATION/SEAL COVER REMOVAL CAUTION A POINT THE SHOCK AND NEEDLE AWAY FROM ANY BODY PARTS. THE SHOCK IS UNDER PRESSURE, AND SOME FLUID MAY BE EXPELLED WITH THE NITROGEN CHARGE. A 1. Remove the shock body eye bushing using the large diameter end of the bushing installer tool (fig. 3A). Insert the small diameter needle into the small hole at the end of the shock body. Once the nitrogen charge has been bled out, remove the needle (fig. 38). 2. Place the shock in the vice, clamping along the faces of the body eye. 3. Pry up the seal cover using a mallet and sharp screwdriver or drift. Tap lightly (fig. 3C). SHAFT EYE REMOVAL/RETAINING RING REMOVAL 1. Clamp the shock shaft between the shaft vice blocks. 2. Remove the shaft eye using a 10-inch adjustable wrench (fig. 30). 3. After threading off the shaft eye, remove the spring retainer and the bottom out bumper. 4. Remove the shock from the shaft vice blocks and remove the seal cover, seal cover washer, and the retaining ring (fig.3e). SHAFT REMOVAL FROM SHOCK BODY 1. Clamp the shock body on the body eye flats. 2. Thread the shaft eye back on the shock shaft and insert a screw driver into the shaft eye. 3. By rocking side to side while pulling up, the piston/shaft assembly can be removed (fig. 3F). page 3

5 FLOATING PISTON/AIR VALVE REMOVAL 1. Drain any remaining oil from the shock body. Grasp the open end of the shock body covering it with a rag, and insert the blunt end of a small drill bit, 0.090" or smaller (02.28mm), into the air valve hole. 2. Press the air valve out, and continue inserting the drill until the floating piston falls from the shock body (fig. 4A). Note: Some specific Deluxe TM shock models will not contain the floating piston. AIR VALVE INSERT ION 1. Insert a new, lightly greased air valve (PN 56303) into the air valve insertion tool. Slide the tool into a clean shock body (Fig. 48). 2. Once the tool bottoms out in the shock body, press the small diameter protruding rod from the air valve insertion tool to transfer the air valve to the shock body. 3. Remove the air valve tool from the shock body, and verify that the air valve is fully installed into the shock body. AIR VALVE PIERCING/FLOATING PISTON SETTING Note: If your shock model doesn't have a floating piston, skip to Oil Height. 1. Insert the small diameter needle into the air valve. Note: Place the needle as close to the center of the air valve as possible. 2. Place a new, greased 0-ring (PN 51118) on the floating piston (PN 43138). 3. Insert the floating piston (dished side up) into the shock body, and set to the correct depth (Fig. 4C). DEPTH SETTINGS: SHOCK TRAVEL 1.25" (3l.75mm) 1.50" (38.1 mm) DEPTH 2.1 OG-2.120" ( mm) 2.29G " ( mm) OIL HEIGHT 1. With the floating piston set to the correct depth, pour in the correct amount of 15 wt oi l into the shock body. 2. Measure the oil height from the top of the oi l to the end of the shock body. (Fig. 40) Oi l height measurements are as follows: OIL HEIGHT SETIINGS: SHOCK TRAVEL 1.25" (3l.75mm) 1.50" (38.1 mm) HEIGHT.95G-. 970" ( mm).95G-.970" ( mm) page 4