RockShox所有前叉拆解图示及说明(英文版)

2007 ROCKSHOX TECHNICAL MANUAL (ENGLISH) Part# 95-4015-011-000, Rev. B © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL � TABLE OF CONTENTS Getting Started Information................................................................................................................... 5 Fork Technology Designation.................................................................................................................................. 6 Tools Needed for Service........................................................................................................................................ 8 Oil Volumes............................................................................................................................................................... 10 Lower Leg Removal (All Forks)............................................................................................................................... 13 Bushing Service (All Forks)...................................................................................................................................... 15 Damper Service............................................................................................................................................................... 25 Rebound & Turnkey (Dart 2, 2 with Turnkey, 3 - Domain 302 - Recon 335 - Tora 289, 302).............................................................. 26 Motion Control (Argyle 318, 409 - Domain 318 - Tora 318)............................................................................................................ 29 Motion Control (BoXXer Race, Team, WC - Pike 409, 426 - Reba SL, Race, Team, WC - Recon 351 - Revelation 409, 426)................................................................................................................................................ 32 Motion Control (SID Team, WC)........................................................................................................................................................ 35 Pure Delite (SID Race)................................................................................................................................................................. 39 Mission Control (Lyrik - Totem)........................................................................................................................................................... 41 Spring Service................................................................................................................................................................. 45 Coil (Argyle 302, 318 - Dart 1, 2, 2 (with Turnkey), 3 - Domain 302, 318 - Tora 289, 302, 318)............................... 46 Coil (BoXXer Race, Team - Recon 327, 335, 351 - Totem).......................................................................................... 47 Coil U-Turn (Domain 302, 318 - Tora 289, 302, 318)................................................................................................................. 48 Coil U-Turn (Lyrik - Pike 409, 426, 454 - Recon 327, 351 - Revelation 426)........................................................................... 49 Solo Air (Argyle 409, Recon 335, 351 - Tora 318)............................................................................................................... 50 Solo Air (BoXXer WC - Lyrik - Recon 327, 335, 351 - Totem).............................................................................................53 Dual Air (Pike 409, 426 - Reba SL, Race, Team, WC - Revelation 409, 426)...................................................................56 Air U-Turn (Pike 409, 429 - Reba Race, Team - Revelation 409, 429).................................................................................. 60 2-Step Air (Lyrik - Totem)............................................................................................................................................................64 Lower Leg Installation (All Forks)..........................................................................................................................67 Rear Shock Service (All Shocks)........................................................................................................................... 71 95-4015-011-000, REv. B4 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 5 GETTING STARTED INFORMATION For exploded diagrams and part number information, please refer to the Spare Parts Catalog, which is available on our website at www.rockshox.com For ordering information, please contact your local distributor or visit our website at www.rockshox.com. Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, please visit our website at www.rockshox.com. Product names used in this manual may be trademarks or registered trademarks of others. SAFETY FIRST! At SRAM Corporation, we care about YOU, our customer. Please, ALWAYS wear your safety glasses when servicing your RockShox fork. There are just too many trails to ride, vistas to summit and sunrises to see. Protect your eyes! Wear your safety glasses! 95-4015-011-000, REv. B� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 7 FORK TECHNOLOGY DESIGNATION (CONT) FORK MODEL DAMPER TECHNOLOGY SPRING TECHNOLOGY R E B O U N D O N LY TU R N K E Y M O TI O N C O N TR O L P U R E D E LI TE M IS S IO N C O N TR O L C O IL C O IL U - TU R N S O LO A IR D U A L A IR A IR U - TU R N 2- S TE P REVELATION 409 DUAL AIR X X REVELATION 409 AIR U-TURN X X REVELATION 426 DUAL AIR X X REVELATION 426 COIL U-TURN X X REVELATION 426 AIR U-TURN X X SID RACE X X SID TEAM X X SID WORLD CUP X X TOTEM COIL X X TOTEM SOLO AIR X X TOTEM 2-STEP X X TORA 289 X X TORA 289 X X TORA 302 X X TORA 302 X X TORA 318 X X TORA 318 X X TORA 318 X X FORK TECHNOLOGY DESIGNATION (ALL FORKS) The following chart is a complete list of the 2007 RockShox fork line-up. It details the fork model and corresponding damper and spring technology specific to each fork. It is important to determine the technology used in your fork, in order to successfully service it, as this manual is sectioned by technology, rather than forks. If you are unsure of the technol- ogy used in your fork, consult your local RockShox dealer for assistance. FORK MODEL DAMPER TECHNOLOGY SPRING TECHNOLOGY R E B O U N D O N LY TU R N K E Y M O TI O N C O N TR O L P U R E D E LI TE M IS S IO N C O N TR O L C O IL C O IL U - TU R N S O LO A IR D U A L A IR A IR U - TU R N 2- S TE P ARGYLE 302 X X ARGYLE 318 X X ARGYLE 409 X X BOXXER RACE X X BOXXER TEAM X X BOXXER WORLD CUP (WC) X X DART 1 X DART 2 (WITH TURNKEY) X X DART 2 X X DART 3 X X DOMAIN 302 X X DOMAIN 302 COIL U-TURN X X DOMAIN 318 X X DOMAIN 318 COIL U-TURN X X LYRIK COIL U-TURN X X LYRIK SOLO AIR X X LYRIK 2-STEP X X PIKE 409 COIL U-TURN X X PIKE 409 AIR U-TURN X X PIKE 409 DUAL AIR X X PIKE 426 COIL U-TURN X X PIKE 426 AIR U-TURN X X PIKE 426 DUAL AIR X X PIKE 454 DUAL AIR X X PIKE 454 COIL U-TURN X X PIKE 454 AIR U-TURN X X REBA SL X X REBA RACE X X REBA RACE AIR U-TURN X X REBA TEAM X X REBA TEAM AIR U-TURN X X REBA WORLD CUP (WC) X X RECON 327 SOLO AIR X X RECON 335 X X RECON 335 SOLO AIR X X RECON 351 X X RECON 351 COIL U-TURN X X RECON 351 SOLO AIR X X 95-4015-011-000, REv. B� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 9 TOOLS LOWER LEG REMOVAL BUSHING SERVICE DAMPER SERVICE SPRING SERVICE LOWER LEG INSTALLA- TION REAR SHOCK SERVICE OIL/LIQUIDS 2.5, 5, 10 OR 15WT SUSPENSION OIL X X X X X GREASE X X X X OIL MEASURING DEVICE X X X X X ISOPROPYL ALCOHOL X X X X X X BLUE THREADLOCK X COLD FROSTY BEVERAGE X X X X X X TOOLS NEEDED FOR SERVICE (CONT)TOOLS NEEDED FOR SERVICE (ALL FORKS) The following chart is a list of the model year 2007 tools needed for service on your RockShox fork. While this chart is intended to be comprehensive, it is still only a guide. The tools required for each step of service are detailed in the text of each service section. Keep in mind your specific fork may not require every tool listed. TOOLS LOWER LEG REMOVAL BUSHING SERVICE DAMPER SERVICE SPRING SERVICE LOWER LEG INSTALLA- TION REAR SHOCK SERVICE SAFETY/STARTING EQUIPMENT SAFETY GLASSES X X X X X X APRON X X X X X X RUBBER GLOVES X X X X X X CLEAN RAGS (LINT FREE) X X X X X X OIL PAN X X X X X X CLEAN WORK AREA X X X X X X BICYCLE STAND X X X X BENCH VICE X X WRENCHES/PLIERS 1.5MM HEX X 2MM HEX X 2.5MM HEX X X X 4MM HEX X¹ X² X¹ 5MM HEX X X 10MM SOCKET OR OPEN ENDED WRENCH X X 15MM SOCKET X 24MM SOCKET X X 24MM THIN WRENCH X² TORQUE WRENCH X X SLIP JOINT PLIERS X² X SNAP RING PLIERS - INTERNAL X X SNAP RING PLIERS - EXTERNAL X X MISC TOOLS PLASTIC MALLET X X X X X MALLET DRIFT TOOL X LONG DOWEL ROD (PLASTIC OR WOOD) X X X X X FLATHEAD SCREWDRIVER X X SHARP PICK X X X SHOCK PUMP X³ X X X MAGNET X RULER X³ X¹ SID DUAL AIR UPPER TUBE RETAINER TOOL X 4 BUSHING REMOVAL TOOL/PLATE X ¹BoXXer Only ²Mission Control Only ³SID Race Only 4SID Models Only 95-4015-011-000, REv. B10 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 11 OIL VOLUMES (CONT) FORK MODEL RIGHT LEG (DAMPER) LEFT LEG (SPRING) TOP BOTTOM TOP BOTTOM VOLUME (CC/ML) OIL WT VOLUME (CC/ML) OIL WT VOLUME (CC/ML) OIL WT VOLUME (CC/ML) OIL WT REVELATION 409 DUAL AIR 115 5 15 15 6 15 15 15 REVELATION 409 AIR U-TURN 115 5 15 15 6 15 15 15 REVELATION 426 DUAL AIR 115 5 15 15 6 15 15 15 REVELATION 426 COIL U-TURN 115 5 15 15 - - 30 15 REVELATION 426 AIR U-TURN 115 5 15 15 6 15 15 15 SID RACE 5 15 10 15 6 15 10 15 SID TEAM - - 10 15 6 15 10 15 SID WORLD CUP - - 10 15 6 15 10 15 TOTEM COIL 137 5 20 15 - - 20 15 TOTEM SOLO AIR 137 5 20 15 6 15 20 15 TOTEM 2-STEP 137 5 20 15 135 2.5 20 15 TORA 289 145 5 15 15 - - 20 15 TORA 289 COIL U-TURN 145 5 15 15 - - 30 15 TORA 302 145 5 15 15 - - 20 15 TORA 302 COIL U-TURN 145 5 15 15 - - 30 15 TORA 318 145 5 15 15 - - 20 15 TORA 318 COIL U-TURN 145 5 15 15 - - 20 15 TORA 318 SOLO AIR 130 5 15 15 6 15 15 15 OIL VOLUMES (ALL FORKS) The following chart is a complete list of the model year 2007 RockShox fork line-up. It details the oil volume and weight for each fork leg. FORK MODEL RIGHT LEG (DAMPER) LEFT LEG (SPRING) TOP BOTTOM TOP BOTTOM VOLUME (CC/ML) OIL WT VOLUME (CC/ML) OIL WT VOLUME (CC/ML) OIL WT VOLUME (CC/ML) OIL WT ARGYLE 302 130 5 10 15 - - 30 15 ARGYLE 318 130 5 10 15 - - 30 15 ARGYLE 409 130 5 10 15 6 15 15 15 BOXXER RACE 150 5 15 15 30 15 - - BOXXER TEAM 150 5 15 15 30 15 - - BOXXER WORLD CUP (WC) 150 5 15 15 6 15 15 15 DART 1 - - 20 15 - - 20 15 DART 2 (WITH TURNKEY) 93 5 10 15 - - 20 15 DART 2 150 5 - - - - 20 15 DART 3 93 5 10 15 - - 20 15 DOMAIN 302 200 5 10 15 - - 15 15 DOMAIN 302 COIL U-TURN 200 5 10 15 - - 15 15 DOMAIN 318 200 5 10 10 - - 15 15 DOMAIN 318 COIL U-TURN 200 5 10 10 - - 15 15 LYRIK COIL U-TURN 112 5 15 15 - - 15 15 LYRIK SOLO AIR 112 5 15 15 6 15 15 15 LYRIK 2-STEP 112 5 15 15 40 2.5 10 15 PIKE 409 COIL U-TURN 120 5 15 15 - - 15 15 PIKE 409 AIR U-TURN 120 5 15 15 6 15 15 15 PIKE 409 DUAL AIR 120 5 15 15 6 15 15 15 PIKE 426 COIL U-TURN 120 5 15 15 - - 15 15 PIKE 426 AIR U-TURN 120 5 15 15 6 15 15 15 PIKE 426 DUAL AIR 120 5 15 15 6 15 15 15 PIKE 454 DUAL AIR 120 5 15 15 6 15 15 15 PIKE 454 COIL U-TURN 120 5 15 15 - - 15 15 PIKE 454 AIR U-TURN 120 5 15 15 6 15 15 15 REBA SL 110 5 15 15 6 15 15 15 REBA RACE 110 5 15 15 6 15 15 15 REBA RACE AIR U-TURN 110 5 15 15 6 15 15 15 REBA TEAM 110 5 15 15 6 15 15 15 REBA TEAM AIR U-TURN 110 5 15 15 6 15 15 15 REBA WORLD CUP (WC) 110 5 15 15 6 15 15 15 RECON 327 SOLO AIR 120 5 15 15 6 15 15 15 RECON 335 120 5 15 15 - - 30 15 RECON 335 SOLO AIR 120 5 15 15 6 15 15 15 RECON 351 118 5 15 15 - - 30 15 RECON 351 COIL U-TURN 118 5 15 15 - - 30 15 RECON 351 SOLO AIR 118 5 15 15 6 15 15 15 95-4015-011-000, REv. B12 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 1� LOWER LEG REMOVAL 95-4015-011-000, REv. B14 © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 15 BUSHING SERVICE LOWER LEG REMOVAL (ALL FORKS) LOWER LEG REMOVAL INSTRUCTIONS note: boXXer only - loosen upper crown bolts with a 4mm heX wrench and remove upper crown. spray isopropyl alcohol onto upper tubes and under frame bumpers. twist and pull up to remove bumpers. finally, use a 4mm heX wrench to loosen lower crown bolts and remove uppers from crown by twisting and sliding each upper down and out of crown. Remove the air chamber valve cover cap from the left fork leg top cap. If fork has a negative air chamber, remove the negative air chamber valve cover cap from the bot- tom of the left fork leg. Depress schrader valve and release all air from the air chamber. If fork has a nega- tive air chamber, start with the negative air chamber first, then proceed to the positive air chamber. Gently pull external rebound adjuster knob and remove from the right shaft bolt. Use a 5mm hex wrench to loosen both shaft bolts 3 to 4 turns. For Dual Air equipped forks, use a 10mm socket (or open end) wrench to loosen and unthread the Dual Air shaft nut just past the threaded shaft end. Use a plastic mallet to gently tap each shaft bolt free from its press-fit to the lower leg and use your fingers to remove shaft bolts completely. Remove the lower leg assembly from fork by firmly pulling it downward, holding onto both legs or the brake arch. Use oil pan to drain excess oil from lower leg assembly. Spray isopropyl alcohol onto and into the lower leg assembly. Wipe the lower legs clean, then wrap a clean rag around a dowel and clean the inside of each lower leg (not pictured). 1. 2. 3. 4. 5. 6. 7. 8. 1 2 3 5 6 7 4 boXXer only boXXer only boXXer only INTRODUCTION Removing the lower legs of your fork is the first step in servicing your fork. It allows you access to your fork bushings, damper system and spring system. Once you have removed your fork lower legs, you'll be ready to move onto the next section. 95-4015-011-000, REv. B1� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 17 DUST & OIL SEAL REMOVAL (ALL FORKS) Remove the dust seal using a medium to large flat-head screwdriver to carefully pry it from the lower leg. note: not all forks contain a foam ring. if your fork does not have a foam ring, please move onto step 3. Remove the oil foam ring with your fingers. note: not all forks contain an inner oil seal. if your fork does not have an inner oil seal, please move onto the neXt section, bushing removal. Remove the inner oil seal, located just below the dust seal using a flat head screwdriver. To protect the lower leg paint, place a rag in between the lower leg and the screwdriver note: the new improved samurai dust seal eliminates the need to replace the oil seal. note: all dart forks and tora 289, 302 do not have serviceable bushings, please move onto the section dust & oil seal installation. 1. 2. 3. 2 31 BUSHING REMOVAL (ALL ARGYLE - BOxxER - DOMAIN - LYRIK - PIKE - REBA - RECON - REVELATION - SID - TOTEM & TORA 318) Clamp bushing removal handle/puller tool into bench vice tightly. Install the correct bushing removal plate onto handle end and secure with handle plate screw. 28mm plate (SID) 32mm plate (Argyle, BoXXer, Pike, Reba, Recon, Revelation, Tora) 35mm plate (Domain, Lyrik) 40mm plate (Totem) Slide the removal plate past the upper bush- ing, pull lower leg away from puller tool, and hook the flat end of the plate secure under the bushing. The removal plate pivots when inserted. When the plate is secure under bushing, begin to remove. To pull the upper bushing free from the lower leg, use a plastic mallet to firmly and squarely hit the top of the lower leg on the flat dust seal surface area until upper bush- ing pulls free. To pull the lower bushing free from the lower leg, slide the removal plate past the lower bushing and hook the flat end of the plate secure under the bushing. Again, firmly and squarely hit the top of the lower leg on the flat dust seal surface area until the lower bushing pulls free. Longer lower bushings may require more force. Return to Step 3 and repeat for the other fork leg. Spray isopropyl alcohol inside lower legs. Wrap a clean rag around a dowel and clean the inside of the lower legs (not pictured). 1. 2. • • • • 3. 4. 5. 6. 7. 3 4 1 5 2 28, 32, 35, or 40mm plate BUSHING SERVICE (ALL FORKS) INTRODUCTION Suspension fork bushings are considered "wear and tear" parts and require regular maintenance, depending on the fre- quency of riding, riding terrain, rider body weight, and type of fork. The more you ride, the more frequently your bushings need to be replaced. The following chapter covers Dust & Oil Seal Removal, Bushing Removal, Bushing Installation, and Dust & Oil Seal Installation. HOW TO CHECK FOR LOOSE BUSHINGS Compress fork 5 times to circulate lower leg lube (not pictured). Hold the front brake lever tight and rock the bike back and forth. If the fork feels like it's "knocking", or the headset feels loose, proceed to steps 2 and 3. Check the fork: wrap your fingers around the dust seal and upper tube area. Rock the bike back and forth again. Listen and feel if there is any play between the upper tube and the dust seal. If so, the bushings are loose. Check the headset: wrap your fingers around the headset upper cup or lower cup/race areas. Holding the brake, rock the bike back and forth and feel if the headset is loose. If so, tighten the headset and check again. 1. 2. 3. 4. 3 42 SYMPTOMS OF WORN BUSHINGS Symptoms of worn bushings that need to be replaced include, a "knocking" sound from the fork when riding and/or the headset may feel loose when it isn't. PARTS AND TOOL KITS NEEDED FOR BUSHING SERVICE To obtain the parts and tool kits needed to service your fork bushings, visit your local SRAM dealer. If the parts and/or tool kits are not in stock, your dealer can place an order with their SRAM distributor. For a comprehensive list of Rock- Shox spare parts and tool kits, please visit us on-line at www.rockshox.com or www.sram.com under the Spare Parts Catalog. 95-4015-011-000, REv. B1� © SRAM CORPORATION • 2007 ROCKSHOX TECHNICAL MANUAL 19 BUSHING INSTALLATION 32MM UPPER TUBE DIAMETER (ARGYLE - PIKE - REBA - RECON - REVELATION - TORA 318) 32MM UPPER TUBE DIAMETER (BOxxER) lower bushing installation with bushing size: 32mm X 30mm - slotted (argyle, pike, reba, recon, revelation, tora 318) 32mm X 76mm - non-slotted (boXXer) Clamp 32mm bushing installation tool into bench mounted vice. Slide lower bushing installation spacer onto bushing installation post. note: recon, revelation, and tora 318 use two spacers, use the short spacer for this step. Slide the lower bushing sleeve onto bushing installation post. Recon, Revelation, Tora 318 Only: Slide the tall lower bushing spacer onto the bushing installation post. Slide lower bushing onto the top of the lower installation sleeve. note: boXXer lower bushing is not slotted. Slide lower leg over installation post and rest on top of lower bushing. Insert mallet drift tool into the lower leg shaft hole and hold in place. Using a plastic mallet, hit the mallet drift tool to press the bushing into the lower leg. Continue to hit the mallet drift tool, until the lower leg dust seal ridge is level with the top of the installation post spacer. You will feel it stop as the bushing is "set" in the lower leg. Remove lower leg from tool and inspect the fit of the lower bushing by sliding one upper tube into the lower leg. Hold lower le