For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website atwww.rockshox.com.
Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website at www.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others.
· Perform service every 100 hours of riding (less depending on riding conditions and riding style).· Regular maintenance ensures your RockShox suspension fork performs as it should.· For bushing removal and installation, please reference the Bushing Service Guide.· Right side equals rider’s right; left side equals rider’s left.
1. Remove fork from bicycle.2. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes.3. Lay tools out on work bench and create a clean work area for internals service.4. Place oil pan under fork on floor.
· Safety Glasses· Clean Rags· Oil Pan or Bucket· Bicycle Stand / Clean Work
Table/Area· 24mm 6-point Socket· Plastic-Faced Mallet· Snap Ring Pliers (internal and external)· Shock Pump
1. TEAM/WORLD CUP: Remove air valve cover cap from left side air top cap (fig 1a).
Remove negative (bottom) air valvecap from lower air shaft (fig 1b).
Depress schrader valves and removeall air from air spring chambers(fig 1c/1d).
Using a 5mm hex wrench loosenrebound damper shaft bolt 3 to 4 fullturns (fig 2b).
Using an open-end 10mm wrench,loosen Dual Air shaft nut. Unthreadshaft nut by hand until nut extendsjust past threaded shaft end(figs 2c/2d).
2b 2c 2d
1b
2a
1a
PROCEDURES FOR 2006 SID RACE, TEAM AND WORLD CUP LOWER LEG AND DUAL AIR REMOVAL/INSTALLATION ARE THESAME FOR EACH MODEL. REFER TO THE 03-05 SID SERVICE GUIDE FOR SID RACE DAMPING INTERNALS SERVICEPROCEDURES
PN 95.4311.776.000, REV C 3
2006 SID Service Guide
3. With hex wrench in the rebound damper shaft bolt, tap the bolt free with plasticmallet. Tap the Dual Air shaft nut and free the shaft from the lower leg internally.You will feel the shaft release from the lower leg shaft bore (figs 3a/3b).
Remove both the shaft bolt and shaft nut completely.
4. Firmly pull the lower leg assembly down by holding eachleg or the brake arch (figs 4a/4b).
Remove lower leg assembly and allow all excess oil todrain into an oil pan (fig 4c). Place lower leg in oil pan todrain.
R E M O VA L6. Verify all air pressure is removed from air chamber before proceeding. Depress schrader air valve again to remove any remaining air
pressure.
Using a 24mm socket wrench,loosen air top cap assembly fromupper tube/crown (fig 6a).
Remove air top cap (fig 6b/6c).
Remove fork from bicycle workstand and pour any oil from positive air chamber into oil pan (fig 6d).
S I D D U A L A I R S P R I N G A S S E M B LY
7. Using the SID Dual Air upper tube retainer tool and an socket wrench, remove the threaded upper tube retainer. The retainer isreverse-threaded, so turn wrench CLOCKWISE to unthread (fig 7a). ‘Righty, Loosey...Lefty, Tighty.’
Pull Dual Air spring shaftassembly from upper tube(figs 7b/7c/7d). You may needto release additional negative airas you pull; pressure will build upwhile pulling.
3a 3b
6b 6c 6d
7c 7d
4a 4b 4c
5. Spray isopropyl alcohol onto each upper tube and wipe with a clean rag.
D I S A S S E M B LY & S E R V I C EPA R T K I T R E Q U I R E D: SID SE RV I C E KI T (11.4310.703.000)
10. Pinch the positive and negative air piston o-rings and remove. Replace with new o-rings (figs 10a/10b).
Using a sharp pick (a dental pickworks best) remove the innernegative air piston o-ring andreplace with a new o-ring.(fig 10c). Lubricate with 15wtsuspension oil or oil solublegrease (fig 10d).
IMPORTANT: REPLACEMENT OF AIR PISTON O-RINGS ENSURES THAT SID MAINTAINS A SOLID AIR SEAL. LUBRICATE ALL NEWO-RINGS THOROUGHLY WITH SUSPENSION OIL OR OIL SOLUBLE GREASE BEFORE INSTALLATION.
9. Slide the negative air piston sleeve from air spring shaft (fig9a/9b).
Spray air shaft with isopropyl alcohol and wipe clean.
Pinch the positive air piston o-ring and remove. Replacewith a new o-ring and lubricate with 15wt suspension oilor oil soluble grease (fig 9c).
11. Slide negative air spring sleeve back onto air spring shaft (figs 11a/11b).
ALL TRAVEL SPACER OPTION (DECREASE OR INCREASE TRAVEL)
Install one 20mm All Travel spacer to decrease travel from 80mm to 60mm.Remove the 20mm All Travel spacer to increase travel from 60mm to 80mm.
80mm travel configuration pictured here.
10b 10c
9b 9c
11b
10d
9a
THE SID DUAL AIR ALL TRAVEL SPACER IS LOCATED JUST ABOVE THE NEGATIVE SLEEVE TOP OUTBUMPER. TO INSTALL, SLIDE NEGATIVE SLEEVE DOWN AND SNAP ALL TRAVEL SPACER ONTO AIRSPRING SHAFT TO DECREASE TRAVEL.
A L L T R AV E L C O N F I G U R AT I O N S
80mm60mm
20mmSpacer
NoSpacer
11a
8. Spray the inside of the air spring upper tube with isopropylalcohol (fig 8a). Wrap a clean rag around a thin dowel,insert into upper tube and wipe the inside surface clean(8b/8c).
Look inside the upper tube using a light and check forscratches. If inside of upper tube is scratched, replaceCSU assembly. Scratches can cause air bypass.
8b 8c8a
10a
PN 95.4311.776.000, REV C 5
2006 SID Service Guide
12. Apply fresh 15wt suspension oil to new positive andnegative air piston o-rings (figs 12a/12b).
Insert positive air piston into bottom of upper tube.Push air piston/shaft assembly into upper tube (fig 12c).
13. Slide the negative air piston sleeve down air spring shaft and into bottom of uppertube (fig 13a). Continue to slide entire negative air spring sleeve into upper tube.You may need to press the negative schrader air valve as you push the negativesleeve into upper tube to release air pressure. This aids installation.
By hand, thread the air spring assembly threaded base retainer into upper tube(fig 13b). This part is reverse threaded, so turn counterclockwise to thread intoupper tube.
14. Using the SID Dual Air upper tube retainer tool and a socket wrench, press into retainer firm and squareand tighten the threaded upper tube/base retainer to 30 in-lb (fig 14).
Remember, turn counterclockwise to tighten!
12a 12b 12c
13a 13b
14
I N S TA L L AT I O N
15. Position fork upright in bicycle work stand.
Measure and pour, or inject, 3 to 5 cc/ml of 15wt suspension oil into positive air chamber, through crownand into upper tube (fig 15). Suspension oil on top of the positive air piston o-ring is critical to lubricationand maintenance of the air seal.
TIP: EVERY MONTH, RELEASE ALL POSITIVE AND NEGATIVE AIR PRESSURE AND REMOVE AIR TOP CAP.POUR OUT ANY REMAINING SUSPENSION OIL FROM POSITIVE AIR CHAMBER AND REFILL WITH 3 TO 5CC/ML OF FRESH 15WT SUSPENSION OIL. THIS REDUCES AIR SPRING SERVICE INTERVALS AND IMPROVESTHE FUNCTION OF YOUR FORK.
15
16. Clean the air top cap and upper tube threads with a cleanrag.
By hand, install the air top cap (fig 16a/16b). Using a24mm socket wrench, tighten to 60 in-lb (fig 16c).
Using a shock pump, inflate positive air chamber to about70 psi. This extends the Dual Air shaft and easeinstallation of the lower leg assembly.
17. Using a 2.5mm hex wrenchloosen and remove remote cablestop clamp set screw (fig 17a and17b).
Using a 1.5mm hex wrenchloosen and remove floodgateadjuster knob set screw (fig 17cand 17d).
18. Using external snap ring pliers, remove the compression spool retaining ring (fig 18a).
Remove the remote compressionadjust spool from topcap/compression damper (fig 18b).
Remove remote adjuster spoolreturn spring from under spool(fig 18c).
17c 17d
S I D M O T I O N C O N T R O L D A M P I N G A S S E M B LY ( S I D T E A M / W O R L D C U P )
17b
19. Using a 24mm socket wrench loosen and unthread Motion Control compression top cap (fig 19a).
By hand, pull up and removeMotion Control compressiondamper/damper tube/rebounddamper assembly from uppertube. The entire assembly willslide out of upper tube (figs19b/19c/19d).
Leave the threaded base retainer inside bottom of upper tube.
20. Gently pull the rebound damper/seal head assemblyfrom bottom of damping tube (figs 20a/20b). Oil willdrain so wrap a rag or paper towel around damper tubeas you remove damper.
Pour all oil from damper tube into an oil pan (fig 20c).
20b 20c20a
21. Pull the Motion Control damper from the damper tubeusing a slow twisting motion (figs 21a/21b). This assiststhe damper out of the damper tube.
Allow any excess oil to drain into an oil pan.
Spray entire compression damper with isopropyl alcoholand wipe all grease and oil from damper assembly.
17a
18c18b
19c 19d19b19a
18a
21b21a
THE 2006 SID MOTION CONTROL COMPRESSION DAMPER IS COMPATIBLE WITH THE PURE DAMPING SYSTEM. TO UPGRADE FROM PURE TO MOTIONCONTROL, FOLLOW STEPS 19-21, AND 27-44. KIT 11.4310.700.000 (SID DUAL AIR MOTION CONTROL UPGRADE KIT) REQUIRED.
R E M O VA L
PN 95.4311.776.000, REV C 7
2006 SID Service Guide
R E B O U N D D A M P E R S E R V I C E
23. Slide the rebound damper seal head from rebounddamper shaft (fig 23a/23b).
Replace the rebound damper glide ring if worn ordamaged (fig 23c).
23b 23c23a
24. Using a sharp pick remove the inner and outer seal head o-rings and replace withnew o-rings (figs 24a/24b).
Lubricate both new o-rings with 15wt suspension oil.
24a 24b
25. Slide rebound damper seal head back onto rebound dampershaft (fig 25a).
Using a 2.5mm hex wrench, or the rebound adjuster knob,insert hex into rebound damper adjuster at bottom ofshaft, and turn counterclockwise to open rebound dampervalve (fig 25b). This allows oil to flow into the dampervalve when re-filling damper tube with suspension oil.
Insert rebound damper and seal head into a container of 5wt suspension oil (fig 25c).
25b 25c
26. Pinch lower/primary damper piston o-ring and remove (fig 26a). Replace with new o-ring.
Pinch internal floating piston (IFP) o-ring (upper) andremove (fig 26b). Replace with new o-ring.
Pinch and remove top cap o-ring (fig 26c). Replace withnew o-ring.
Lubricate all new o-rings with 15wt suspension oil.
26b 26c26a
I N S TA L L AT I O N
25a
27. Place the gold floodgate adjuster knob back onto the compression damper (fig 27a)and tighten with a 1.5mm hex wrench (fig 27b). 27b27a
C O M P R E S S I O N D A M P E R S E R V I C E
22. Spray isopropyl alcohol into the damper tube and clean inside surface with a dry clean rag. Use a dowel with the clean rag wrappedaround the end. Insert into damper tube and clean.
30. Holding the damper tube with the open end of the tubefacing up, pour 5wt suspension oil into the damper tubeuntil the tube is approximately half-full (fig 30a).
Tap the compression damper/damper tube assembly on aflat surface lightly to release any air bubbles that may betrapped inside the damper (figs 30b/30c).
30a 30b 30c
29. Apply fresh 15wt suspension oil onto both the main piston o-ring and the IFP o-ring (figs 29a/29b).
Insert the compression damperback into the damper tube(fig 29c). Slide entire damperassembly into the tube (fig 29d).
Press the top cap firmly intoplace (fig 29e).
29d 29e29c
28. Turn the floodgate adjuster knob counterclockwise untilit stops (fig 28a). This is the full open position.
The floodgate adjustment affects the blow-off thresholdduring compression ‘lock-out’. The more open thefloodgate is, the lower the amount of force is required tocompress the fork in the ‘lock-out’ position.
Note the floodgate position orientations (figs 28b/28c).
28b 28c28a
Floodgate Closed Floodgate Open
29a
29b
31. Pour additional 5wt suspension oil into damper tube until completely full (fig 31a).
Remove the rebound damper/seal head assembly from the oil container(remember, the rebound damper/seal head assembly should be submerged in oil).
Wrap a rag around the damper tube to catch displaced oil. Insert the reboundpiston into the damper tube slowly (fig 31b). Slide the piston into the dampertube (fig 31c).
Insert the rebound damper seal head into the end of the damper tube and pressfirmly into place (fig 31d).
Wipe away all displaced oil from the damper tube.
IMPORTANT! DO NOT CYCLE THE REBOUND DAMPER INTO THE DAMPER TUBE. THE
COMPRESSION DAMPER IS NOT SECURE IN THE DAMPER TUBE UNTIL THREADED INTO THE
UPPER AND TIGHTENED WITH A SOCKET WRENCH.
31d
31a 31b
31c
PN 95.4311.776.000, REV C 9
2006 SID Service Guide
32. Inside the damper side upper tube (right) is an o-ring that sits in between the Motion Control dampertube/rebound seal head and the upper tube thread base retainer, ensure the o-ring is positioned flat on thethreaded upper tube base retainer.
If this o-ring came out with the damper tube assembly, apply a small amount of grease to the o-ring andplace it on the bottom of the rebound damper seal head (fig 32).
32
33. Insert Motion Control damper assembly back into the upper tube, rebound shaft first (fig 33a). Guide the end of the rebounddamper through the center of the threaded base retainer. Be careful and do not allow the rebound damper shaft to scrape theretainer.
Slide the damper completely intothe upper tube (fig 33b). Byhand, thread the compressiondamper top cap into the uppertube (fig 33c).
Using a 24mm socket wrench,tighten to 60 in-lb. (fig 33d)
33b 33c 33d
o-ring
33a
34. Using a 1.5mm hex wrench, loosen floodgate adjuster knob set screw. Remove the floodgate adjuster knob.
35. Using a 2.5mm hex wrench, loosen the cable stop clamp screw. Place the cable stop clamp on to the Motion Control top cap withthe cable top positioned approximately 90 degrees forward toward the steerer tube,as pictured (fig 35a).
Turn the compression spool adjuster shaft counterclockwise until it stops. This isthe open position (fig 35b).
Place the remote spool onto the compression spool adjuster shaft (hex) and turnclockwise until it stops (fig 35c). This is the closed (lockout) position. The spoolstop should be in the position pictured (fig 35c).
With one hand, hold the remote spool closed and rotate the cable stop clampcounterclockwise with your free hand until the cable stop touches the remote spoolstop (fig 35d). The cable stop clamp should be loose enough to turn freely on thetop cap hex detents.
Using a 2.5mm hex wrench, tighten the cable stop clamp screw (fig 35e).
Rotate the remote spool counterclockwise to the full open (unlocked) position. Theset screw should be positioned in line with the open mark on the cable stop clamp(fig 35f).
Remove the remote spool while in the compression adjuster rod is in the openposition (fig 35g).
Apply a small amount of grease to the remote spool torsion return spring. Greasewill hold the torsion spring in the remote spool during installation. Insert thetorsion spring into the underside of the remote spool knob, with the prong facingout (figs 35g & 35h).
Place the remote spool and torsion spring back onto the compression damperadjuster hex. The torsion spring prong fits into one detent hole in the top cap(fig 35i). The cable set screw in the remote spool should be positioned in line withthe alignment mark on the cable set screw (fig 35j).
Turn the remote spool clockwise until spool-stop stops in the closed positionagainst the cable stop clamp stop (fig 35k) If the stop on the remote spool doesnot touch the stop on the cable stop clamp, rotate the clamp counterclockwise untilthe two stops touch.
Release the spool and test the return to the open position.
Secure the remote spool with a new remote spool retaining ring using external snapring pliers (fig 35l).
35h
35i 35j
35g
35k 35l
36. Place the gold floodgate adjuster knob back onto the compression damper spool shaft.
Tighten the floodgate adjuster knob set screw to the flat surface of the black adjuster rod with a 1.5mm hexwrench (fig 36).
.
36
S I D R E M O T E S P O O L / C A B L E S T O P C L A M P O R I E N TAT I O N
Torque to:1.4 N-m +/- 0.2 N-m
Torque to:1.0 N-m +/- 0.2 N-m
Ensure snap ring is fully seated andengaged in spool shaft groove.
Always use a new snap ring.
Position torsion spring with longerend pointing down into top capdetent hole.
Turn spool shaft counterclockwise(open position) BEFORE installingremote spool and torsion spring.
1
2
3
4
5
open-mark on cablestop clamp
insert torsion springprong into top cap
detent hole
PN 95.4311.776.000, REV C 11
2006 SID Service Guide
INSTALL THE POPLOC LEVER ASSEMBLY ONTO YOUR HANDLEBAR IN THE DESIRED ORIENTATION BEFORE CABLE INSTALLATION. THEPOPLOC LEVER SHOULD BE IN THE OPEN POSITION.
37. Insert PopLoc shifter cable through cable stop clamp and position the cablehousing into the stop. Thread the shifter cable through the small cable guide holeon the remote spool (fig 37a).
Insert the end of the cable into the cable guide hole under the remote spool cableset screw (fig 37b).
Pull the shifter cable tight while rotating the remote spool into the position aspictured. Align the remote spool stop with the alignment mark on the cable stopclamp (figs 37c & 37d).
Using a 1.5mm hex wrench, tighten the cable set screw and secure cable (fig 37d).
Test the function of the PopLoc remote lever and remote spool (fig 37e).
When in the ‘locked out’ (closed position) the remote spool stop should touch thecable stop clamp, as pictured (fig 37f).
Press the PopLoc open button and test the return to open position.
37b
37c 37d
37a
37e 37f
P O P L O C R E M O T E L E V E R / C A B L E I N S TA L L AT I O N
alignment mark
remote spool shouldtouch cable stop
clamp
O P T I O N A L : R E M O T E A D J U S T T O N O N - R E M O T E A D J U S T
SWITCHING FROM REMOTE COMPRESSION ADJUST TO A CROWN-MOUNTED COMPRESSION ADJUSTER REQUIRES ONLYTHE REMOVAL OF THE REMOTE SPOOL AND CABLE STOP CLAMP ASSEMBLIES, AND INSTALLATION OF THE STANDARDCOMPRESSION ADJUSTER KNOB (11.4311.392.000 06 SID MOTION CONTROL COMP KNOB).
UNLIKE STANDARD MOTION CONTROL COMPRESSION DAMPERS, THE 06 SID MOTION CONTROL COMPRESSIONDAMPER REMOTE RETURN SPRING IS NOT DESIGNED INTO THE DAMPER ASSEMBLY.
THE REMOTE POPLOC LEVER ADJUSTER CAN EITHER BE REMOVED FROM THE HANDLEBAR, OR SIMPLY REMOVE THECABLE/CABLE HOUSING AND LEAVE THE POPLOC LEVER ON YOUR HANDLEBAR, IF YOU CHOOSE TO INSTALL THEREMOTE SPOOL IN THE FUTURE.
38. Thoroughly clean the dust seals and upper bushing with a clean rag and isopropyl alcohol. Replace dustseals and foam rings if worn or damaged. Refer to the ‘Bushing Service Guide’ for procedures atwww.rockshox.com.
Pour or inject 15wt suspension oil onto new or clean foam rings just under dust seal inside lower leg; eachside (fig 38). This provides additional lubrication during use.
40. Measure and pour (or inject...an oil syringe works best) 5cc/ml of 15wt suspension oil into lower legs (leftand right sides), through both shaft bolt holes (fig 40). This provides lubrication for the bushings duringuse.
Wipe all excess oil from lower legs.
40
39. Invert fork in bicycle stand to a 45-degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with aclean rag.
Slide lower leg assembly over and onto the ends of eachupper tube. Ensure both dust seals slide onto the tubescorrectly and do not fold under (fig 39a).
Continue sliding lower leg assembly onto upper tubes untilyou feel the lower bushings touch the end of the uppertubes (fig 39b). Pull lower leg assembly back off justslightly so lower bushing is not touching bottom of upper tube. Stop (fig 39c).
39a 39b 39c
41. Inspect and clean the rebound damper shaft bolt, Dual Air shaft nut and black nylon crush washers (fig 41).Replace crush washers and crush washer retainer if damaged. Damaged or dirty crush washers can cause oilto leak.
41
43. Spray entire fork with isopropyl alcohol and wipe down with a clean rag.
42. Slide lower leg assembly further down upper tubes until shaft ends are seated inside lower leg shaft holes. You may need to use asmall hex wrench or screw driver to guide the shaft ends into the holes (fig 42a)
Insert rebound damper shaft boltinto threaded shaft end (rightside), through lower leg shafthole. Hand thread into shaft andtighten with a 5mm hex wrenchto 60 in-lb (fig 42b).
Thread the Dual Air shaft nutonto the threaded air spring shaft. Tighten with an open end 10mm wrench to 60in-lb (fig 42c).
Insert external rebound damper knob into rebound damper shaft bolt. Push into bolt to secure (fig 42d). Adjust as desired.
42b 42c 42d42a
44. Inflate the positive (first) (fig 44a) and negative (second) (fig 44b) air chamberswith a shock pump to desired air pressures. See the air chart in this guide, or thedecal on the back of the fork lower leg for reference.
Thread both air valve cover caps back onto air top cap and negative air shaft.
44b44a
push to snap intoplace
PN 95.4311.776.000, REV C 13
2006 SID Service Guide
A I R
RIDER WEIGHTAIR PRESSURE
POSITIVE (TOP) NEGATIVE (BOTTOM)(XC SETTING)
NEGATIVE (BOTTOM)(RACING SETTING)
<120 lb (54 kg) 70-80 psi 70-80 psi 40-60 psi120-140 lb (54-64 kg) 80-100 psi 80-100 psi 60-80 psi140-160 lb (64-73 kg) 100-120 psi 100-120 psi 80-100 psi160-180 lb (73-82 kg) 120-140 psi 120-140 psi 100-120 psi
>180 lb (82 kg) 140-160 psi 140-160 psi 120-140 psi
O I LSID RACE DUAL AIR RIGHT LEG
PURE DELITE/MOTIONCONTROL
OIL WEIGHT BOTTOM VOLUME OIL WEIGHT
1/2 Full 5 wt 10cc/ml 15 wtSID RACE DUAL AIR LEFT LEG
SID TEAM/WORLD CUP DUAL AIR RIGHT LEGPURE DELITE/MOTION
CONTROLOIL WEIGHT BOTTOM VOLUME OIL WEIGHT
Full(fill from bottom of tube)
5 wt 10cc/ml 15 wt
SID TEAM/WORLD CUP DUAL AIR LEFT LEG
TOP VOLUME OIL WEIGHT BOTTOM VOLUME OIL WEIGHT
3cc/ml 15 wt 10cc/ml 15 wt
T R O U B L E - S H O O T I N GAIR LOSS
· Inspect air piston o-rings. Replace if necessary.· To avoid air loss, remove Dual Air top cap and check oil level inside air chamber, every 25 to 50 riding hours. If there is little or
no oil on top of air piston o-ring, pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. Oil will keep air seallubricated.
· Inspect schrader valve assembly. Replace if damaged or malfunctioning. Clean if clogged.
LOSS OF, OR VARIANCE IN DAMPING· Inspect all damper o-rings. Replace and lubricate.· Inspect damper oil volume. Remove damper top cap/compression damper assembly. Add or remove oil as needed.· Remote: Inspect remote cable tension. Cable may stretch, or become loose. Loosen cable screw, tension cable and tighten.
Test. Adjust as needed.
BUSHING PLAY· Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100 to 200
riding hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings! · See the 'Bushing Installation' guide at www.rockshox.com for procedures.
OIL LOSS· Inspect the air piston o-ring for air bypass. If there is a repeated loss of air pressure, air may be the cause of oil loss at the left
dust seal.· Inspect your shaft bolt crush washers. Replace if worn or damaged.· Inspect your top cap o-rings. Replace if torn or knicked.
