95-4012-950-000 A 06 Bushing Service Guide.pdf

For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at

www.rockshox.com.

Contact your local distributor or visit the RockShox website at www.rockshox.com for ordering information.

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.

PN 95.4012.950.000 Rev A

2006 Bushing Service Guide

W HY D O Y OU N EED TO R EPLACE Y OUR S USPENSION F ORK B USHINGS ?

Suspension fork bushings are considered ‘wear and tear’ parts and require regular maintenance, depending on frequency of riding, riding

terrain, rider body weight, use of disc brakes, and the type of fork you ride. The more you ride, the more frequently your bushings need

to be replaced.

S YMPTOMS OF W ORN B USHINGS

• Headset may feel loose

• Fork may knock when ridden

C HECK FOR L OOSE B USHINGS

1. 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.

2. Check the fork: Wrap your fingers around the dust seal and upper tube area. Rock the bike back and forth once again. Listen and feel if

there is any play between the upper tube and the dust seal. If so, the bushings are loose.

3. 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.

ROCK BIKE BACK

AND FORTH WHILE

SQUEEZING FRONT

BRAKE

P ARTS N EEDED

Visit your local SRAM dealer for the tools and parts you will need. If the parts are not in stock, your dealer can place an

order with their SRAM distributor. For a more comprehensive list of RockShox spare parts, check out the Spare Parts

Catalog at www.rockshox.com or www.sram.com.

DUST SEAL KITS

11.4307.250.000

Pilot/SID Dust Seal/Foam Ring Kit

11.4307.298.000

Psylo/Duke Dust Seal/Foam Ring Kit

11.4308.850.000

Reba/Pike Dust Seal/Oil Seal/Foam Ring Kit

11.4307.312.000

Boxxer Dust/Oil Seal Replacement Kit

11.4310.290.000

Tora/Recon/Revel Dust Seal/Foam Ring Kit

BUSHING KITS

11.4307.251.000

SID, Pilot, Judy Bushing Kit (10mm upr, 20mm lwr)

11.4307.280.000

Duke Bushing Kit (30mm upr/30mm lwr)

11.4307.296.000

Psylo Bushing Kit (30mm upr/45mm lwr)

11.4308.851.000

Reba/Pike/Tora/Recon/Revelation Bushing Kit (30mm upr/30mm lwr)

11.4305.621.000

00-04 Boxxer Bushing Kit (10mm upr/30mm lwr)

11.4310.006.000

05-06 Boxxer Bushing Kit (10mm upr/76mm lwr)

2006 Bushing Service Guide

T OOLS AND L UBRICANTS N EEDED

S TANDARD S HOP T OOLS

•

L UBRICANTS

• Isopropyl Alcohol/Spray Bottle

• Oil Soluable Grease

• 5, 10, or 15wt Suspension Oil

•

Plastic Mallet

•

Oil Pan

•

Work bench with mounted vice

•

24mm Socket Wrench

Air shock pump

(for re-assembly of air forks)

•

22mm Socket Wrench (00-02

Boxxer)

•

10mm Socket Wrench (All Dual Air

forks)

•

5mm hex wrench

•

Flat-head screw driver

•

Clean rags

•

Oil mixing syringe (MixMizer)

R OCK S HOX B USHING T OOLKITS

Part Number

Description

Use with:

11.4306.351.000 Fork Bushing Removal Tool (28mm/30mm/32mm)

All Forks

11.4307.499.000 Psylo/Duke Bushing Removal Plate (30mm)

11.4306.351.000

11.4306.352.000 Fork Bushing Install Tool (28mm/30mm Upr Tube)

Appropriate installation sleeve kit

11.4306.353.000 Fork Bushing Install Tool (32mm Upr Tube)

Appropriate installation sleeve kit

11.4307.498.000 Judy/Pilot/SID Bushing Install Sleeve

11.4306.352.000

11.4306.354.000 Psylo/Duke Bushing Install Sleeve

11.4306.352.000

11.4309.121.000 Reba/Pike Bushing Install Sleeve

11.4306.353.000

11.4310.701.000 Tora/Recon/Revel Bushing Install Sleeve

11.4306.353.000

11.4306.357.000 00-06 Boxxer Bushing Install Sleeve (sleeve only)

11.4306.353.000

05-06 Boxxer Lwr Bushing Install Spacer

(used with 00-05 Bushing Install Sleeve)

11.4310.014.000

11.4306.353.000 & 11.4306.357.000

00-06 Boxxer Bushing Install Sleeve/Spacer

(includes Sleeve and 05 Spacer)

11.4310.015.000

11.4306.353.000

11.4310.444.000 Dust Seal Install Tool (28mm/30mm)

11.4306.352.000

11.4308.722.000 Dust/Oil Seal Install Tool (32mm)

32mm dust seals, no other tool req’d

M ALLET D RIFT

28mm/30mm B USHING I NSTALLATION T OOL

T ORA /R ECON /R EVELATION

S LEEVE & S PACERS

R EBA /P IKE S LEEVE &

S PACER

32mm B USHING I NSTALLATION T OOL

P ILOT /SID

S LEEVE &

S PACERS

B OXXER /R EBA /P IKE

O IL S EAL /D UST S EAL

T OOL

D UKE /P SYLO

S LEEVE &

S PACERS

00-05 B OXXER

S LEEVE & 05

S PACER

R EBA /P IKE

S LEEVE &

S PACER

28mm/

30mm D UST

S EAL T OOL

U NIVERAL B USHING R EMOVAL T OOL

28mm

30mm

32mm

B USHING

R EMOVAL P LATES

95.4012.950.000 Rev A

2006 Bushing Service Guide

R EMOVAL : D UST S EALS , O IL S EALS & B USHINGS

D UST S EAL , F OAM R ING , O IL S EAL R EMOVAL

S EE THE APPROPRIATE COMPLETE SERVICE GUIDES FOR FORK DISASSEMBLY AND ASSEMBLY PROCEDURES .

( ALL FORK MODELS : PILOT , SID , DUKE , PSYLO , BOXXER , REBA , PIKE , TORA , RECON AND REVELATION )

Using a medium to large flat-head screwdriver, pry the old dust seal from the lower leg.

Remove the oil foam ring. Tora/Recon/Revelation and 06 Boxxer include foam rings under the dust seals.

Boxxer, Reba, Pike, 2000 and 2001 Judy, 2000-2001 SID and Psylo forks feature an inner oil seal, located just below the dust seal. To remove

this oil seal, use a flat-head screwdriver to pry the seal from the lower leg. To protect the lower leg paint, place a rag in between the lower leg

and the screwdriver The improved current Samurai dust seal eliminates the need to replace the oil seal.

• 2000 - 2002 B OXXER : Remove snap ring and large washer above oil seal.

DUST SEAL REMOVAL - ALL FORKS

OIL SEAL REMOVAL - ALL FORKS

OIL SEAL REMOVAL - B OXXER

OIL SEAL REMOVAL - R EBA /P IKE

B USHING R EMOVAL - A LL M ODELS

Clamp Bushing Removal Handle/Puller tool into bench vice. Clamp vice tight.

Install the correct bushing removal plate onto handle end and secure with handle plate screw.

•

28mm Plate (Judy/Pilot/SID)

•

30mm Plate (Duke/Psylo)

•

32mm Plate (Boxxer/Reba/Pike/Tora/Recon/Revelation)

Slide the removal plate past the upper bushing, pull lower leg away from puller, and hook the flat end of the plate secure under the

bushing. The removal plate pivots when inserted. When plate is secure under bushing, begin to remove.

REMOVE SCREW TO CHANGE PLATE

32mm

REMOVAL PLATE

30mm

REMOVAL PLATE

28mm

REMOVAL PLATE

BUSHING REMOVAL HANDLE AND PLATE

2006 Bushing Service Guide

3. To pull the upper bushing free from the lower leg use a plastic mallet to firmly and sqaurely hit the top of the lower leg on the flat dust seal

surface area until upper bushing pulls free.

B OXXER - Follow same procedure for Boxxer lower leg upper bushing and lower bushing removal.

SID/Pilot

Duke

Psylo

Reba/Pike

Tora/Recon/RVL

SID/Pilot

Duke

Psylo

Reba/Pike

Tora/Recon/RVL

4. 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 hit the top of the lower leg (flat dust seal surface) until bushing pulls free. Longer lower bushings

require more force.

5. Repeat other side. Wipe off any debris from lower leg inner surface.

SID/Pilot

Duke

Psylo

Reba/Pike

Tora/Recon/RVL

SID/Pilot

Duke

Psylo

Reba/Pike

Tora/Recon/RVL

B USHING I NSTALLATION

B USHING I NSTALLATION : (00-02 J UDY /03-05 P ILOT /99-06 SID) - 28 MM WIDTH

L OWER B USHING I NSTALLATION : 28 MM X 20 MM

1. Clamp 28mm/30mm bushing installation tool into bench-mounted vice.

2. Slide lower 28mm Pilot/SID bushing sleeve onto bushing installation post.

3. Slide 20mm lower bushing onto top of lower bushing installation sleeve.

4. Slide lower leg over installation post and rest on top of lower bushing.

5. Insert the mallet drift tool into the lower leg shaft hole, and hold in place with one hand.

95.4012.950.000 Rev A

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika: