SRAM RockShox Deluxe RT3, RockShox Deluxe RT: RockShox Deluxe RL: RockShox Deluxe R, RockShox Deluxe RLR Service Manual

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2018-2019 Deluxe™

GEN.0000000005708 Rev B

service manual

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SRAM® LLC WARRANTY

EXTENT OF LIMITED WARRANTY

Except as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase. This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased. Original proof of purchase is required. Except as described herein, SRAM

makes no other warranties, guaranties, or representations of any type (express or implied), and all warranties (including any implied warranties of reasonable care, merchantibility, or fitness for a particular purpose) are hereby disclaimed.

LOCAL LAW

This warranty statement gives the customer specic legal rights. The customer may also have other rights which vary from state to state (USA), from province to province (Canada), and from country to country elsewhere in the world.

To the extent that this warranty statement is inconsistent with the local law, this warranty shall be deemed modied to be consistent with such law,

under such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the

United States of America, as well as some governments outside of the United States (including provinces in Canada) may:

a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer

(e.g. United Kingdom).

b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.

For Australian customers:

This SRAM limited warranty is provided in Australia by SRAM LLC, 1000 W. Fulton Market, 4th Floor, Chicago, IL, 60607, USA. To make a warranty

claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6 Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses

incurred in making the warranty claim are your responsibility. The benets given by this warranty are additional to other rights and remedies that

you may have under laws relating to our products. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

LIMITATIONS OF LIABILITY

To the extent allowed by local law, except for the obligations specically set forth in this warranty statement, in no event shall SRAM or its third party

suppliers be liable for direct, indirect, special, incidental, or consequential damages.

LIMITATIONS OF WARRANTY

This warranty does not apply to products that have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The SRAM user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com.

This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers

specications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design.

This warranty does not apply when the product has been modied, including, but not limited to any attempt to open or repair any electronic and

electronic related components, including the motor, controller, battery packs, wiring harnesses, switches, and chargers.

This warranty does not apply when the serial number or production code has been deliberately altered, defaced or removed.

This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal use, failure to service according to SRAM recommendations and/or riding or installation in conditions or applications other than recommended.

Wear and tear parts are identied as:

• Dust seals

• Bushings

• Air sealing o-rings

• Glide rings

• Rubber moving parts

• Foam rings

• Rear shock mounting hardware and main seals

• Upper tubes (stanchions)

• Stripped threads/bolts

(aluminium, titanium, magnesium or steel)

• Brake sleeves

• Brake pads

• Chains

• Sprockets

• Cassettes

• Shifter and brake cables (inner

and outer)

• Handlebar grips

• Shifter grips

• Jockey wheels

• Disc brake rotors

• Wheel braking surfaces

• Bottomout pads

• Bearings

• Bearing races

• Pawls

• Transmission gears

• Spokes

• Free hubs

• Aero bar pads

• Corrosion

• Tools

• Motors

• Batteries

Notwithstanding anything else set forth herein, the battery pack and charger warranty does not include damage from power surges, use of improper charger, improper maintenance, or such other misuse.

This warranty shall not cover damages caused by the use of parts of different manufacturers.

This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM components.

This warranty shall not cover damages resulting from commercial (rental) use.

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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!

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TABLE OF CONTENTS

EXPLODED VIEW  DELUXE™ RT3,RT,RL,R ......................................................................................................................................................5

EXPLODED VIEW  DELUXE™ RLR .....................................................................................................................................................................6

EXPLODED VIEW  DELUXE BEARING MOUNT .............................................................................................................................................6

GETTING STARTED ..............................................................................................................................................................................................7

RECOMMENDED SERVICE INTERVALS .................................................................................................................................................................................................... 7

RECORD YOUR SETTINGS ............................................................................................................................................................................................................................7

TORQUE VALUES .............................................................................................................................................................................................................................................7

ROCKSHOX® SUSPENSION SERVICE ..............................................................................................................................................................8

REMOTE CABLE AND HOUSING REMOVAL  RLR ONLY ..............................................................................................................................8

PARTS, TOOLS, AND SUPPLIES .................................................................................................................................................................................................................. 8

REMOTE CABLE AND HOUSING REMOVAL ...........................................................................................................................................................................................8

SHOCK EYELET SERVICE ...................................................................................................................................................................................9

MOUNTING HARDWARE AND BUSHING SERVICE .............................................................................................................................................................................. 9

MOUNTING HARDWARE REMOVAL ..........................................................................................................................................................................................................9

EYELET BUSHING REMOVAL ..................................................................................................................................................................................................................... 12

BEARING MOUNT SERVICE ........................................................................................................................................................................................................................ 13

BEARING REMOVAL ...................................................................................................................................................................................................................................... 13

BEARING INSTALLATION ............................................................................................................................................................................................................................ 15

DAMPER BEARING REPLACEMENT ......................................................................................................................................................................................................... 17

DELUXE™ SERVICE.............................................................................................................................................................................................18

PARTS, TOOLS AND SUPPLIES ................................................................................................................................................................................................................. 18

50/200 HOUR SERVICE

AIR CAN REMOVAL........................................................................................................................................................................................................................................ 19

BOTTO MLESS TUNING ............................................................................................................................................................................................................................... 22

AIR CAN SERVICE ......................................................................................................................................................................................................................................... 23

200 HOUR SERVICE

DAMPER BODY SERVICE ............................................................................................................................................................................................................................ 27

PISTON SERVICE ........................................................................................................................................................................................................................................... 29

IFP AND DAMPER BODY SERVICE .......................................................................................................................................................................................................... 35

SHOCK ASSEMBLY AND BLEED ..............................................................................................................................................................................................................37

REMOTE SPRING SERVICE  RLR ONLY ................................................................................................................................................................................................. 40

50/200 HOUR SERVICE

AIR CAN INSTALLATION ............................................................................................................................................................................................................................. 43

SHOCK EYELET ASSEMBLY ............................................................................................................................................................................ 45

EYELET BUSHING INSTALLATION .......................................................................................................................................................................................................... 45

MOUNTING HARDWARE INSTALLATION .............................................................................................................................................................................................. 46

REMOTE CABLE AND HOUSING INSTALLATION  RLR ONLY ..................................................................................................................48

REMOTE CABLE AND HOUSING INSTALLATION ............................................................................................................................................................................... 48

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5Exploded View - Deluxe™ RT3,RT,RL,R

Damper body eyelet

Damper air/nitrogen fill port

Damper body

IFP (Internal Floating Piston)

Counter Measure™

Main piston

Seal head / air piston

Bleed screw and compression ball

Compression lever

Deluxe RT3, RL, RT

Air valve

Shaft eyelet

Bottom out washer and o-ring

Exploded View - Deluxe™ RT3,RT,RL,R

Rebound adjuster

Deluxe R

Air can

Quad seal

Backup ring

Wiper seal

Sag indicator o-ring

Air Can

Rebound adjuster

Top hat assembly (RLR/RL/RT Only)

Top hat assembly

2019 Deluxe RL/RT

Main piston

IFP (Internal Floating Piston)

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6Exploded View - Deluxe™ RLR

Cable hanger

Deluxe RLR

Air valve

Shaft eyelet

Exploded View - Deluxe™ RLR

Preloader lock screw

Remote Spring

Rebound adjuster

Cable set screw

Ferrule lock screw Ferrule

Cable spool cap

Spring bushing

Remote spring

Spring tang

Spring preloader

Dust cover

Damper body

Exploded View - Deluxe Bearing Mount

Dust Cover

Bearing

Shaft eyelet

Bearing

Spacer

Bearing

Housing

Bearing

Dust Cover

Cap Screws

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7Getting Started

Getting Started

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 Maintenance Benefit

Every ride Clean dirt from shock damper body

Extends wiper seal lifespan

Minimizes damage to shock damper body

Minimizes air can contamination

Every 50 Hours Perform air can service

Reduces friction

Restores small bump sensitivity

Every 200 Hours Perform damper and spring service

Extends suspension lifespan

Restores damping performance

Record Your Settings

Use the charts below to record your shock settings to return your shock to its pre-service settings. Record your service date to track service intervals.

Service Hours

Interval

Date of Service Air Pressure

Rebound setting - count the number of clicks while turning the rebound adjuster fully counter-clockwise.

100

150

200

Torque Values

Part Tool Torque

Air can (shaft eyelet)

13 mm crowfoot

4.5 N•m (40 in-lb)

Piston nut

12 mm (RT3) or 10 mm (R) socket

4.5 N•m (40 in-lb)

Seal head/air piston

17 mm crowfoot

28 N•m (248 in-lb)

Ferrule lock screw (RLR only)

2 mm hex

0.9 N•m (7 in-lb)

Cable set screw (RLR only)

2 mm hex

0.8 N•m (7 in-lb)

Cable spool cap (RLR only)

T25 TORX®

0.75 N•m (6-7 in-lb)

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8Remote Cable and Housing Removal - RLR Only

RockShox® Suspension Service

We recommend that you have your RockShox suspension serviced by a qualified bicycle mechanic. Servicing RockShox suspension requires knowledge of suspension components, as well as the use of specialized tools and lubricants/fluids.

Visit www.sram.com/service for the latest RockShox Spare Parts catalog and technical information. For order information, please contact your local SRAM® distributor or dealer.

For recycling and environmental compliance information, please visit www.sram.com.

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.

Remote Cable and Housing Removal - RLR Only

Prior to servicing the rear shock, remove the remote cable and housing from the shock, then remove the shock from the bicycle frame according to the bicycle manufacturer's instructions. Replace the cable and housing after performing shock service (see the

Remote Cable and Housing Installation - RLR Only section).

Parts, Tools, and Supplies

Safety and Protection Supplies

• Safety glasses

• Nitrile gloves

Common Tools

• 2 mm hex wrench

• T25 TORX® wrench

• Cable and housing cutters

Remote Cable and Housing Removal

RLR: Use a T25 mm hex wrench to remove the cable spool cap.

The cable spool will rotate with the spool cap. Continue to rotate the spool cap counter-clockwise until it begins to loosen.

RLR: Use a 2 mm hex wrench to loosen the cable set screw, then use cable and housing cutters to cut the cable.

Use a 2 mm hex wrench to loosen the ferrule lock screw. Remove the ferrule, housing, and cable from the cable bracket.

Discard the cable, housing, and ferrule.

T25

2 mm

Cable and housing cutters

2 mm

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9Shock Eyelet Service

Shock Eyelet Service

Mounting Hardware and Bushing Service

Prior to servicing the rear shock, remove it from the bicycle frame according to the bicycle manufacturer's instructions. Once the shock is removed from the bicycle, remove the mounting hardware before performing any service.

Parts, Tools, and Supplies

Parts

• AM SVC kit 50h DLX/SDLX A1

• AM SVC kit 200h/1yr DLX A1

• AM SVC kit 200h/1yr DLX RMT A1

Safety and Protection Supplies

• Safety glasses

• Nitrile gloves

• Apron

• Clean, lint-free rags

RockShox Tools

• RockShox 1/2" x 1/2" rear shock bushing removal/installation tool

Lubricants and Fluids

• RockShox Dynamic Seal Grease

Common Tools

• Bench vise with aluminium soft jaws

• (2) 13 mm open end wrench

• Adjustable wrench

Mounting Hardware Removal

NOTICE

To prevent damage to the shock, use aluminium soft jaws and position the eyelet in the vise so that the adjustment knobs are clear of the vise jaws.

Some mounting hardware is easily removed using only your ﬁngers. Try to remove the end spacers with your ﬁngernail or small screwdriver, then push the bushing pin out of the bushing. If this works, continue to the next section.

If you are unable to remove the mounting hardware using your ﬁngers, use the RockShox® rear shock bushing removal/installation tool.

Thread the small end of the push pin onto the threaded rod until the rod is ﬂush or slightly protrudes from the hex-shaped end of the push pin.

Rear shock bushing removal/installation tool

Catcher

Threaded rod

Push pin

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10Mounting Hardware Removal

Insert the threaded rod through the shaft eyelet until the push pin rests against the bushing pin.

Thread the large, open end of the catcher along the rod until it rests on the end spacer.

Clamp the catcher in a vise or hold it secure with a 13 mm open end or adjustable wrench.

NOTICE

Do not scratch the air can as you turn the wrench.

Use a second 13 mm wrench to thread the push pin along the rod until it stops against the end spacer.

Unthread the push pin from the threaded rod to remove the end spacer and the bushing pivot pin.

If the bushing pin does not remove easily, reinsert the threaded rod and push pin through the eyelet shaft.

Thread the large, open end of the catcher along the rod until it rests against the shaft eyelet.

Use a 13 mm wrench to thread the push pin along the rod until it stops against the end spacer.

13 mm 13 mm

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11Mounting Hardware Removal

Unthread the catcher from the threaded rod.

Remove the end spacer and bushing pin from the tool.

Repeat steps 2-4 for the damper eyelet.

Set the mounting hardware aside until you have ﬁnished servicing the shock.

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12Eyelet Bushing Removal

Eyelet Bushing Removal

To replace damaged or worn out bushings, use the RockShox® rear shock bushing removal/installation tool.

Insert the threaded rod through the shaft eyelet until the base of the push pin rests against the bushing.

Thread the large, open end of the catcher onto the rod until it rests on the eyelet.

Clamp the catcher in a vise or hold it secure with a 13 mm wrench.

Use a second 13 mm wrench to thread the push pin along the rod until the push pin pushes the eyelet bushing out of the eyelet.

Unthread the catcher from the threaded rod. Remove the tool from the shaft eyelet and discard the old bushing.

Repeat steps 1-3 for the other eyelet.

Set the bushings aside until you have ﬁnished servicing your shock.

13 mm 13 mm

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13Bearing Mount Service

Bearing Mount Service

Replace the bearings if they are not spinning freely, or if they are making a creaking noise.

Parts, Tools, and Supplies

Parts

• Rear Shock Bearing kit DLX/SDLX BR

• Eyelet Bearing SDLX/DLX (Damper body only)

Safety and Protection Supplies

• Safety glasses

• Nitrile gloves

• Clean, lint-free rags

Common Tools

• Hammer

• Small diameter punch

• Vise with soft jaws

• 22 mm (OD) x 10 mm (ID) bearing press tool

Bearing Removal

Remove the dust cover.

To prevent damage to the air valve, remove the bearing on the side opposite of the air valve first. Place a punch against the back of the opposite bearing, and tap out the bearing.

Hammer Punch

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14Bearing Removal

Turn the shock over and place the punch against the back of the other bearing, and tap out the bearing.

NOTICE

Do not damage the air valve when tapping out the bearing.

Spray isopropyl alcohol in the bearing bores and clean them with a rag.

Punch Hammer

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15Bearing Installation

Bearing Installation

Install a new bearing into one bearing bore, then clamp the eyelet and bearing into a vise with soft jaws. Press the bearing into the bearing bore until it is flush with the eyelet.

Loosen the vise, and align the bearing press tool with the bearing, then tighten the vise. Press the bearing into the bearing bore until it stops.

NOTICE

Do not overtighten the bearing. Overtightening can damage the bearing and cause it to malfunction.

To prevent damage to the bearing, make sure that the bearing press tool contacts both the inner and outer races of the bearing.

Insert a new spacer into the eyelet, then install a new bearing into the other bearing bore. Clamp the eyelet and bearing into a vise with soft jaws, then press the bearing into the bearing bore until it is flush with the eyelet.

Loosen the vise, and align the bearing press tool with the bearing, then tighten the vise. Press the bearing into the bearing bore until it stops.

NOTICE

Do not overtighten the bearing. Overtightening can damage the bearing and cause it to malfunction.

To prevent damage to the bearing, make sure that the bearing press tool contacts both the inner and outer races of the bearing.

22 mm (OD) x 10 mm (ID) bearing press tool

Bearing press tool

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16Bearing Installation

Remove the shock from the vise. The bearings should sit approximately 1 mm below the outer edge of the bearing bore. Reinstall dust covers before installing the shock on the bicycle.

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17Damper Bearing Replacement

Damper Bearing Replacement

Loosen the cap screws and remove the bearing assembly from the shock.

The dust covers may fall off. This is normal.

NOTICE

If you are completing the 50 or 200 hour service, set the bearing assembly aside until service is complete. The air can cannot be removed with the bearing assembly installed.

Install the new bearing assembly and screws onto the shock. Tighten the cap screws to 6.2 N·m (55 in-lb).

3 mm

3 mm 6.2 N•m (55 in-lb)

3 mm TORQUE

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18Deluxe™ Service

Deluxe™ Service

Prior to servicing your rear shock, remove it from the bicycle frame according to the bicycle manufacturer's instructions. Once the shock is removed from the bicycle, remove the mounting hardware before performing any service (see the Mounting Hardware And Bushing Service section).

Parts, Tools and Supplies

Parts

• AM SVC kit 50h DLX/SDLX A1

• AM SVC kit 200h/1yr DLX A1

• AM SVC kit 200h/1yr DLX RMT A1

• RMT Spring kit DLX/SDLX/SDLXC

Safety and Protection Supplies

• Safety glasses

• Nitrile gloves

• Apron

• Clean, lint-free rags

Lubricants and Fluids

• Isopropyl alcohol

• RockShox® Dynamic Seal Grease

• Maxima® Maxum4 Extra 15w50

• RockShox 7wt suspension oil

• Loctite® Threadlocker Blue 242®

Bicycle Tools

• Schrader valve core tool

• High Pressure Shock Pump 600 psi

RockShox Tools

• RockShox Deluxe IFP Height Tool

• RockShox Rear Shock Vise Block

• RockShox Rear Shock Body Vise Block

• RockShox Air Valve Adapter Tool - Rear Shock

Common Tools

• Torque wrench

• 10 mm (RLR/R, 2018 RL/RT) and 12 mm (RT3, 2019 RL/RT) socket wrenches

• Bench vise with aluminium soft jaws

• 13 and 17 mm open end wrenches

• 13 and 17 mm crowfoot sockets

• 1.5, 2, and 3 mm hex wrenches

• 1.5, 2, and 3 mm hex bit sockets

• Strap wrench

• Pick

• Metric caliper or small metric ruler

⚠ WARNING

Before disassembly or service of any air system remove the air pressure from all air chambers and remove the air valve cores.

If your shock will not return to full extension, do not attempt to service or disassemble your shock. Attempting to service a shock that will not return to full extension can cause severe and/or fatal injuries.

SAFETY INSTRUCTIONS

Always wear safety glasses and nitrile gloves when working with suspension ﬂuid.

Place an oil pan on the ﬂoor underneath the area where you will be working on the shock.

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19Air Can Removal

50/200 Hour Service

Air Can Removal

NOTICE

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 rag. Apply grease to the new seal or o-ring. Only use RockShox® Dynamic Seal Grease when servicing RockShox shocks.

To prevent damage to the shock use aluminium soft jaws and position the eyelet in the vise so that the adjustment knobs are clear of the vise jaws. For bearing mount shocks, wrap a rag around the eyelet, then clamp the eyelet flat into the vise.

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

To record your adjustment settings, turn the rebound adjuster knob counter-clockwise until it stops, while counting the number of detent clicks. This will assist you with post-service set up.

RT3/RL/RT: Turn the compression lever to the unlocked position.

RLR: The compression circuit is unlocked by default once the remote

cable is removed.

RT3

RLR/RL/RT

Page 20

20Air Can Removal

Record your air pressure setting to assist with post-service set up.

Remove the air valve cap by hand. Use a small hex wrench to lightly depress the Schrader valve and slowly release all air pressure from the air can.

⚠ CAUTION

Do not disassemble a pressurized shock, this can cause suspension ﬂuid or debris to forcefully eject from the shock. Wear safety glasses.

Slowly release the air from the air can to make sure the air is removed from both chambers. Quickly releasing the air can trap air in the negative chamber and cause the air can to forcefully eject from the shock upon disassembly.

Use a Schrader valve tool to remove and reinstall the valve core from the valve body to make sure all air has been removed.

Clamp the shaft eyelet into a vise, with the shock positioned horizontally.

Remove the sag indicator.

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21Air Can Removal

Insert a rag through the damper body eyelet to prevent the air can from forcefully ejecting from the shock.

⚠ CAUTION EYE HAZARD

The air can may still have air pressure in the negative chamber, which may cause the air can to forcefully eject from the shock upon disassembly. Wear safety glasses.

Use a strap wrench to remove the air can. Wrap the strap around the section of the air can furthest from the shaft eyelet. Turn the wrench counter-clockwise to unthread the air can.

Once it is completely unthreaded, slowly pull the air can along the damper body to remove it and the Counter Measure™.

Remove the rag from the damper body eyelet.

Vacuum pressure will increase as you pull the air can along the damper body, and will suddenly release when the air can is pulled over the air piston.

NOTICE

Do not place the strap wrench on the air can decal.

Counter Measure

Page 22

22Bottomless Tuning

Bottomless Tuning

Bottomless Tokens™ and Gnar Dog™ Tokens reduce air volume in your rear shock and create greater progression at the end of the shock's travel. Add or remove tokens to tune your shock's bottomless feel. Gnar Dog Tokens are equivalent to 2.5 Bottomless Tokens.

Bottomless Tokens 3 Tokens Max

Gnar Dog Tokens 1 Gnar Dog Token + 2 Bottomless Tokens Max

Bottomless Tokens: Clamp the shaft eyelet into the vise.

Move the bottom out washer and o-ring away from the shaft eyelet, then snap the token onto the damper shaft with the tabbed side facing the air valve. Slide the token down the damper shaft until it contacts the other tokens or the eyelet. Slide the bottom out washer and o-ring onto the tokens.

Install up to three Bottomless Tokens.

Gnar Dog Token: Clamp the shaft eyelet into the vise.

Remove any existing tokens from the eyelet. Move the bottom out washer and o-ring away from the shaft eyelet, then snap the Gnar Dog Token onto the damper shaft with the flat side facing out of the eyelet. Slide the token down the damper shaft until it contacts the eyelet.

Only one Gnar Dog Token may be installed. If one Gnar Dog Token is installed, a maximum of two additional Bottomless Tokens can be installed. Slide the bottom out washer and o-ring onto the tokens.

NOTICE

The Gnar Dog Token must be the first token installed into the eyelet. Any additional Bottomless Tokens must be installed after the Gnar Dog Token is installed.

Token Removal: Clamp the shaft eyelet into the vise.

Move the bottom out washer and o-ring away from the shaft eyelet. Use a pick to separate the token from the other tokens or the shaft eyelet, then remove the token from the shaft.

NOTICE

Do not scratch the damper shaft, shaft eyelet, or the eyelet o-ring. Scratches can cause leaks.

Bottomless Tokens

Gnar Dog Tokens

Bottomless Tokens

Gnar Dog Tokens

Pick

Page 23

23Air Can Service

50/200 Hour Service

Air Can Service

NOTICE

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

Use your ﬁngers to remove the o-ring on the outside of the air can.

Spray isopropyl alcohol on the air can threads and eyelet body threads and clean them with a rag.

Install a new o-ring.

Use a pick to remove the air can wiper seal located in the top groove.

Page 24

24Air Can Service

Use a pick to remove the backup ring from the second groove inside the air can.

Use a pick to pierce and remove the quad seal from the bottom of the second groove in the air can.

Spray isopropyl alcohol inside the air can and clean it with a rag. Remove a glove and use your ﬁnger to inspect the inside and outside of the air can for scratches, dents, or other surface deformations. Replace the air can if it is scratched or damaged.

Install the quad seal by inserting one end into the deepest groove in the air can, then push the remainder of the ring into the groove.

Page 25

25Air Can Service

Install the backup ring by inserting one end into the air can, then push the remainder of the ring into the can, so that it rests on top of the quad seal.

Orient the new wiper seal step side up. Install it into the wiper seal groove at the top of the air can.

Spray isopropyl alcohol on the air can threads and eyelet body threads and clean them with a rag.

Apply a small amount of RockShox® Dynamic Seal Grease to the quad seal, backup ring, and wiper seal.

Set the air can aside.

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26Air Can Service

Clamp the eyelet vertically in the vise.

Use your fingers to remove the seal head/air piston seal and glide rings.

Spray isopropyl alcohol on the seal head/air piston and clean it with a rag.

Install the thicker glide ring below the seal head/air piston seal, and the thinner glide ring above.

To continue with the 50 Hour Service go to Air Can Installation.

To continue with the 200 Hour Service go to Damper Body Service.

Page 27

27Damper Body Service

200 Hour Service

Damper Body Service

NOTICE

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 rag. Apply grease to the new seal or o-ring. Only use RockShox® Dynamic Seal Grease when servicing RockShox shocks.

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

Use a Schrader valve tool to remove the damper air/nitrogen ﬁll port cap. Use a small hex wrench or pick to depress the Schrader valve and release all air pressure from the damper.

Once the pressure has been released, depress the Schrader valve a second time. If the Schrader valve is able to move, the shock has been completely depressurized.

If the Schrader valve does not move at all, the shock is still pressurized and will need to be sent to an authorized RockShox dealer for further service.

⚠ CAUTION  EYE HAZARD

Verify all pressure is removed from the shock before proceeding. Failure to do so can cause the damper body to separate from the shaft eyelet at a high velocity. Wear safety glasses.

Use a Schrader valve tool to remove and reinstall the Schrader valve core from the damper air/nitrogen ﬁll port to make sure all air has been removed.

Remove the shock from the vise. Turn the shock over and clamp the damper eyelet into the vise.

Page 28

28Damper Body Service

Use a 2 mm hex wrench to remove the bleed screw, located in the seal head/air piston.

Wrap a rag around the damper body.

Use a 17 mm open end wrench to loosen the seal head/air piston assembly from the damper body. Use your hand to remove the assembly.

⚠ CAUTION  EYE HAZARD

If fluid is foaming from the damper body when the seal head/air piston is loosened, the IFP seal has failed and the fluid inside the damper is pressurized. This can cause the seal head/air piston assembly and damper fluid to forcefully eject from the damper body. Cover the seal head/air piston assembly with a rag and slowly loosen the assembly to allow the pressurized fluid to leak out between the damper body and seal head/air piston assembly.

Fluid will spill from the damper body.

Remove the damper body from the vise and pour the ﬂuid into an oil pan.

2 mm

17 mm

Page 29

29Piston Service

200 Hour Service

Piston Service

NOTICE

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

Spray isopropyl alcohol on the shaft assembly and vice blocks and clean them with a rag.

Use a vise block with the 10 mm shaft clamp to clamp the shaft into a vise.

Do not remove the shaft from the eyelet.

NOTICE

To prevent damage to the seal head/air piston, position the shaft in the vise so that the piston is clear of the vise jaws.

RLR/RL/RT: Use your ﬁngers to remove the compression rod and top cap assembly.

Keep all the parts together and set them aside.

2019 RL/RT

2018 RLR/RL/RT

Page 30

30Piston Service

2019 RL/RT: Use a pick to remove the compression rod o-rings.

Install new o-rings onto the compression rod.

RT3 and 2019 RL/RT: Use a 12 mm socket wrench to remove the piston nut.

2018 RLR/RL/RT/R: Use a 10 mm socket wrench to remove the piston nut.

2019 RL/RT

2018 RLR/RL/RT

12 mm RT3

12 mm 2019 RL/RT

10 mm 2018 RLR/RL/RT

Page 31

31Piston Service

Use a small wrench or pick to slide the main piston assembly o the shaft and onto the tool.

NOTICE

Keep all the parts together and set them aside. If the main piston assembly is disassembled, it will need to be replaced.

Remove the seal head/air piston from the damper shaft.

Remove the bottom out o-ring from the damper shaft.

Install a new o-ring.

RT3

2019 RL/RT

2018 RLR/RL/RT

Page 32

32Piston Service

Use a pick to pierce and remove the internal seal o-ring located in the internal seal gland.

Install a new internal seal o-ring into the seal gland.

Use a pick to remove the inner o-ring, located at the base of the threads in the seal head/air piston.

Install a new inner o-ring into the seal head/air piston.

Use a 1.5 mm hex wrench to push the compression ball out of the backside of the seal head through the bleed port.

Do not replace the compression ball at this time; you will replace it later.

Do not reuse the compression ball.

Use your ﬁngers to remove the o-ring located inside the shaft eyelet threads.

Install a new o-ring inside the shaft eyelet threads.

1.5 mm

Page 33

33Piston Service

Install the seal head/air piston onto the damper shaft.

Use a vise block with the 10 mm shaft clamp to clamp the shaft into a vise.

NOTICE

To prevent damage to the seal head/air piston, position the shaft in the vise so that the piston is clear of the vise jaws.

Install the main piston assembly that was removed in step 5 onto the damper shaft. Use your ﬁngers to squeeze the shims and center the shim stack under the main piston. Use a small pick to center the shim stack along the inside edge of the main piston.

Be sure to keep the main piston assembly parts in the same order.

NOTICE

If the shims are not centered and in the correct order, the shock will not perform properly.

Page 34

34Piston Service

Spray isopropyl alcohol on the piston nut threads and clean it with a rag.

Apply a thin layer of Loctite® Threadlocker Blue 242® only on the threads of the piston nut, then thread the nut onto the damper shaft with the stepped side facing the shims.

RT3 and 2019 RL/RT: Use a torque wrench with a 12 mm socket to tighten the nut to 4.5 N·m (40 in-lb).

2018 RLR/RL/RT/R: Use a torque wrench with a 10 mm socket to tighten the nut to 4.5 N·m (40 in-lb).

Remove the assembly from the vise.

2019 RL/RT: Apply a small amount of grease to the tip of the compression rod. Install the compression rod and top hat into the main piston assembly.

2018 RLR/RL/RT: Install the top hat spring and top hat washer onto the compression rod. Hold the compression rod vertically so the spring is seated in the groove inside the top hat.

NOTICE

If the top hat spring is not seated in the groove inside the top hat, the shock will not perform properly.

Apply a small amount of grease to the tip of the compression rod. Install the compression rod and top hat into the main piston assembly.

Loctite Threadlocker Blue 242

12 mm 4.5 N·m (40 in-lb)

10 mm 4.5 N·m (40 in-lb)

2019 RL/RT

2018 RLR/RL/RT

Page 35

35IFP and Damper Body Service

200 Hour Service

IFP and Damper Body Service

NOTICE

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

Wrap a rag around the end of the damper body. Thread the air valve adapter tool into a shock pump. Thread the pump and adapter into the air fill port.

Pump air into the damper body to force the IFP out of the damper body, into the rag.

Spray isopropyl alcohol on the inside and outside of the damper body and clean it with a rag.

Remove a glove and use your finger to inspect the inside and outside of the damper body for scratches, dents, or other surface deformations. If any deformations are found, the damper body will need to be replaced.

Remove and replace the IFP o-ring. Apply RockShox Dynamic Seal Grease to the o-ring.

RockShox Air Valve Adapter Tool and shock pump

Page 36

36IFP and Damper Body Service

Install the IFP into the damper body with the stepped side visible. Use the Deluxe IFP Height Tool to push the IFP to the depth specified in the table below.

Measure the IFP depth from the lowest part of the IFP.

2018 RLR, RT3, RL, RT, R

Shock Stroke IFP insertion Depth

35 mm 48.1 mm

37.5 mm 50.2 mm

40 mm 52.3 mm

42.5 mm 54.5 mm

45 mm 56.6 mm

47.5 mm 58.7 mm

50 mm 60.8 mm

50 mm* 67. 2 mm

52.5 mm 62.9 mm

55 mm 65 mm

57.5 mm 67. 2 mm

60 mm 69.3 mm

62.5 mm 71.4 mm

65 mm 73.5 mm

*Trek® PowerFly®

2019 RL/RT

Shock Stroke IFP insertion Depth

35 mm 49.5 mm

37.5-45 mm 58 mm

47.5-55 mm 66.5 mm

57.5-65 mm 75 mm

2018 RLR/RT3/RL/RT/R

2019 RL/RT

Deluxe IFP Height Tool

Shock Stroke

Deluxe IFP Height Tool

Page 37

37Shock Assembly and Bleed

200 Hour Service

Shock Assembly and Bleed

NOTICE

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

Clamp the damper body into the RockShox Rear Shock Body Vise Block.

Tighten the vise firmly enough so that the IFP cannot move in the damper body. Check this by using your finger to push on the IFP.

If the IFP does move, use a shock pump to push out the IFP, and then reset it to the depth specified in the table.

Wrap a clean rag around the damper body.

Do not overtighten the vise so that the damper body gets crushed.

NOTICE

The RockShox Rear Shock Body Vise Block holds the IFP in place. Failure to use the vise block when clamping the damper body into the vise may result in improper IFP height. Improper IFP height can cause the damper to fail.

Pour new RockShox 7wt suspension oil into the damper body until it is level with the top.

RockShox 7wt suspension oil

Page 38

38Shock Assembly and Bleed

Check that the rebound adjuster knob is set to the fastest rebound setting. Rotate the rebound adjuster counter-clockwise until it stops.

Slide the seal head/air piston until it stops at the end of the damper shaft.

Use your hand to install the seal head/air piston onto the damper body.

Do not hold on to the shaft eyelet or damper shaft while inserting the seal head. It will move the piston/shaft assembly, causing too much ﬂuid to displace out of the damper body.

Check that the compression ball is removed from the seal head/air piston.

Fluid will be displaced out of the bleed port.

Use a torque wrench with 17 mm crowfoot to tighten the seal head/air piston to 28 N·m (248 in-lb).

Install the crowfoot onto the torque wrench at a 90° angle to the handle to ensure an accurate torque reading.

Allow air bubbles to escape from the bleed port in the seal head.

Insert the new compression ball into the bleed port.

17 mm

28 N

·m

(248 in-lb)

Page 39

39Shock Assembly and Bleed

Use a 2 mm hex wrench to thread the bleed screw into the bleed port until you feel it touch the compression ball, then tighten the bleed screw an additional ½ turn.

NOTICE

Overtightening the bleed screw can damage the compression ball.

RT3: Use a shock pump with the air valve adapter tool to pressurize the damper body to 350 psi.

RLR/RL/RT: Use a shock pump with the air valve adapter tool to pressurize the damper body to 500 psi.

R: Use a shock pump with the air valve adapter tool to pressurize the damper body to 250 psi.

If you have the proper fill equipment, you may substitute air with nitrogen.

Once you have pressurized the shock, remove the air valve adapter tool from the air fill port before removing it from the shock pump. Separating the pump from the adapter first will cause all of the air to escape from the shock.

Use a Schrader valve tool to install the damper air/nitrogen fill port cap.

Remove the shock from the vise.

Spray the damper assembly with isopropyl alcohol and clean it with a rag.

2 mm

350 psi (RT3) 500 psi (RLR/RL/RT) 250 psi (R)

Page 40

40Remote Spring Service - RLR only

200 Hour Service

Remote Spring Service - RLR only

The remote spring can be serviced on its own without completing air can or damper service.

RLR: Use a vise block with the 10 mm shaft clamp to clamp the shaft into a vise.

NOTICE

To prevent damage to the seal head/air piston, position the shaft in the vise so that the piston is clear of the vise jaws.

RLR: While holding the spring preloader in place, remove the preloader lock screw from the eyelet.

Remove the spring preloader, spring bushing, and remote spring from the eyelet.

⚠ CAUTION  EYE HAZARD

The preloader lock screw is spring loaded and can eject rapidly from the eyelet if the spring preloader is not held in place.

2 mm 3 mm

Page 41

41Remote Spring Service - RLR only

RLR: Apply a thick layer of grease to the inside and outside of a new

remote spring, then install the spring into the eyelet with the spring tang in the spring tang hole.

RLR: Install a new bushing into the eyelet, with the grooved edge facing out of the eyelet.

Grease

Page 42

42Remote Spring Service - RLR only

RLR: Install the spring preloader so that the spring tang slides into the spring tang hole in the preloader.

Use a 3 mm hex wrench to preload the spring counter-clockwise until the notch in the spring preloader lines up with the set screw hole, then tighten the set screw to 0.8 N·m (7 in-lb)

Use a T25 TORX® wrench to test the spring tension.

NOTICE

The spring preloader must be rotated counter-clockwise to preload the spring.

3mm 0.8 N·m (7 in-lb) 2 mm

3 mm

3 mm 2 mm

Page 43

43Air Can Installation

50/200 Hour Service

Air Can Installation

NOTICE

Inspect each part for scratches. Do not scratch any sealing surfaces when servicing your suspension. Scratches can cause leaks.

Clamp the shaft eyelet in the vise with soft jaws.

Install the Counter Measure™ onto the damper body. Apply RockShox Dynamic Seal Grease to the seal head/air piston seals.

Inject 1 mL of Maxima® Maxum4 Extra 15w50 into the air can before installing the air can onto the damper. Firmly press the air can down until the sealhead/air piston is inserted into the air can.

⚠ CAUTION EYE HAZARD

Fluid will eject out of the holes as you install the air can onto the damper. Wear safety glasses.

RockShox Dynamic Seal Grease

15w50 1 mL

Page 44

44Air Can Installation

Remove the shock from the vise, turn it over and clamp the damper body eyelet in the soft jaws.

Inject another 1 mL of Maxima® Maxum4 Extra 15w50 into the air can.

Clamp the air shaft eyelet into the vise. Press the air can onto the damper then thread it onto the shaft eyelet until it is hand tight.

Spray isopropyl alcohol on the outside of the air can and clean it with a rag.

Remove the shock from the vise. Turn it over and clamp the damper body eyelet in the vise.

Stabilize the air can with a strap wrench to prevent it from rotating. Use a torque wrench with a 13 mm crowfoot to tighten the air can to

4.5 N·m (40 in-lb).

Remove the shock from the vise. Spray isopropyl alcohol on the shock and clean it with a rag.

Install the sag indicator o-ring.

15w50 1 mL

13 mm

4.5 N

·m (40 in-lb)

Page 45

45Shock Eyelet Assembly

Shock Eyelet Assembly

Eyelet Bushing Installation

Apply a light layer of grease to the outside of the new bushing.

Position the shaft eyelet and eyelet bushing between the soft jaws of a vise. Slowly turn the vise handle to begin pressing the eyelet bushing into the shaft eyelet.

Check the alignment of the bushing as it enters the eyelet. If the bushing starts to enter the eyelet at an angle, remove the bushing from the eyelet, regrease the bushing, and repeat this step until the bushing enters the eyelet straight.

Continue to press the eyelet bushing until it is seated in the shaft eyelet.

Remove the shock from the vise and repeat the installation process for the other bushing and eyelet.

Page 46

46Mounting Hardware Installation

Mounting Hardware Installation

Some mounting hardware is easily installed using only your ﬁngers. Press the bushing pin into the shock eyelet bushing until the pin protrudes from both sides of the eyelet an equal amount. Next, press an end spacer, large diameter side ﬁrst, onto each end of the bushing pin. If this works, you have completed mounting hardware and bushing service.

If you are unable to install your mounting hardware using your ﬁngers, use the RockShox® rear shock bushing removal/installation tool.

Thread the small end of the push pin onto the threaded rod until the push pin is ﬂush or slightly protrudes from the hex-shaped end of the push pin.

Insert the threaded rod through the bushing pin then through the shaft eyelet so that the bushing pin is positioned between the push pin and the eyelet.

Thread the large, open end of the catcher onto the rod until it rests on the eyelet.

Clamp the catcher in a vise or hold it secure with a 13 mm wrench.

Use a second 13 mm wrench to thread the push pin along the rod until it pushes the bushing pin into the shock eyelet bushing.

Continue to thread the push pin until the bushing pin protrudes from both sides of the eyelet an equal amount.

You may need to unthread the catcher slightly to check the bushing pin spacing.

13 mm

Page 47

47Mounting Hardware Installation

Press an end spacer, large diameter side ﬁrst, onto each end of the bushing pin.

Reinstall the shock to your bicycle frame according to the bicycle manufacturer's instructions.

Use a shock pump to pressurize the shock to the desired air pressure. After adding air to the shock, the pressure will need to be equalized between the shock chambers.

Record the air pressure value on the pump, then unthread it from the shock. Slowly but firmly press or sit on the saddle to compress the shock until there is a hissing sound.

This sound indicates air transfer between chambers. Record the air pressure, then unthread it from the shock. Repeat this process until you reach the desired amount of sag, then install the valve cap.

NOTICE

When pressurizing the shock, do not exceed maximum pressure rating.

The pump must be removed from the shock prior to checking sag to avoid damage to the pump.

This concludes the service for the RockShox® Deluxe™ rear shock.

Page 48

48Remote Cable and Housing Installation - RLR Only

Remote Cable and Housing Installation - RLR Only

To install new cable and housing into the OneLoc™ remote, consult the OneLoc Remote User Manual on www.sram.com/service.

Parts, Tools, and Supplies

Parts

• AM SVC kit 200h/1yr DLX RMT A1

• RMT Spring kit DLX/SDLX/SDLXC

• Shift cable and housing

Safety and Protection Supplies

• Safety glasses

• Nitrile gloves

Common Tools

• 2 mm hex wrench

• 2 mm hex bit socket

• T25 TORX® wrench

• 5 mm open end wrench

• Torque wrench

• Cable and housing cutters

Remote Cable and Housing Installation

RLR: After the housing has been routed and installed on the bicycle, use a 5 mm open end wrench to thread a new ferrule onto the housing.

Do not push the housing into the ferrule.

RLR: Install the ferrule and housing into the reservoir, then use a 2 mm hex bit socket to tighten the ferrule lock screw to 0.9 N·m (8 in-lb).

RLR: Thread the cable through the housing, spool, and under the cable set screw. Pull the cable tight and use a torque wrench with a 2 mm hex bit socket to tighten the cable set screw to 0.9 N·m (8 in-lb).

5 mm

2 mm

0.9 N

·m (8 in-lb)

2 mm 0.9 N·m (8 in-lb)

Page 49

49Remote Cable and Housing Installation

RLR: Use cable and housing cutters to trim the cable, then install an end cap.

Tuck the cable into the pocket.

RLR: Install the spool cap, then use a torque wrench with a T25 TORX® bit socket to tighten the spool cap to .9 N·m (8 in-lb).

T25 TORX .9 N·m (8 in-lb)

Page 50

This publication includes trademarks and registered trademarks of the following companies:

Loctite® and 242® are registered trademarks of Henkel Corporation Maxima® Maxum4 Extra 15w 50 is a registered trademark of Maxima Racing Oils

Trek® and Powerfly® are registered trademarks of Trek Bicycle Corporation TORX® is a registered trademark of Acument Intellectual Properties, LLC

Page 51

tmplt 11.4.2016

www.sram.com

ASIAN HEADQUARTERS SRAM Taiwan No. 1598-8 Chung Shan Road Shen Kang Hsiang, Taichung City Taiwan R.O.C.

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