ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM

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ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
ZEB, Lyrik, Pike
Ultimate Flight Attendant

SERVICE MANUAL

                            GEN.0000000006531 Rev A © 2021 SRAM, LLC
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
SRAM LLC WARRANTY
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AGAINST SRAM, LLC. YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM
STATE TO STATE, COUNTRY, OR PROVINCE. THIS WARRANTY DOES NOT AFFECT YOUR STATUTORY RIGHTS. TO THE EXTENT THIS
WARRANTY IS INCONSISTENT WITH THE LOCAL LAW, THIS WARRANTY SHALL BE DEEMED MODIFIED TO BE CONSISTENT WITH SUCH
LAW. FOR A FULL UNDERSTANDING OF YOUR RIGHTS, CONSULT THE LAWS OF YOUR COUNTRY, PROVINCE, OR STATE.
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its bicycle components to be free from defects in materials or workmanship for a period of two
(2) years after original purchase of the product.
SRAM warrants all Zipp MOTO Wheels and Rims to be free from defects in materials or workmanship for the lifetime of the product.
SRAM warrants all non-electronic Zipp branded bicycle components, Model Year 2021 or newer, to be free from defects in materials or workmanship
for the lifetime of the product.
GENERAL PROVISIONS
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 product was purchased or a SRAM authorized service location. Original proof of purchase is required. All SRAM warranty claims
will be evaluated by a SRAM authorized service location whereupon acceptance of the claim the product will be repaired, replaced, or refunded at
SRAM's discretion. To the extent allowed by local law claims under this warranty must be made during the warranty period and within one (1) year
following the date on which any such claim arises.
NO OTHER WARRANTIES
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT ALLOWED BY LOCAL LAW, SRAM MAKES NO OTHER WARRANTIES, GUARANTIES, OR
REPRESENTATIONS OF ANY TYPE (EXPRESS OR IMPLIED), AND ALL WARRANTIES (INCLUDING ANY IMPLIED WARRANTIES OF REASONABLE
CARE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE) ARE HEREBY DISCLAIMED.
LIMITATIONS OF LIABILITY
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL SRAM OR ITS THIRD PARTY SUPPLIERS BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. SOME STATES (COUNTRIES AND PROVINCES) DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL DAMAGES, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
LIMITATIONS OF WARRANTY
This warranty does not apply to products that have been incorrectly installed, adjusted, and/or maintained according to the respective SRAM user
manual. The SRAM user manuals can be found online at sram.com/service.
This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturer's
specifications of intended 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 modified, 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.
SRAM components are designed for use only on bicycles that are pedal powered or pedal assisted (e-Bike/Pedelec).
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 or parts that are not compatible or suitable for use with
SRAM components.
This warranty shall not cover damages resulting from commercial (rental) use.
WEAR AND TEAR
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 INCLUDE:
• Aero bar pads            • Chains                                        • Rear shock mounting                 • Stripped threads/bolts (aluminum,
• Air sealing o-rings      • Corrosion                                       hardware and main seals               titanium, magnesium or steel)
• Batteries                • Disc brake rotors                             • Rubber moving parts                 • Tires
• Bearings                 • Dust seals                                    • Shifter and Brake cables            • Tools
• Bottomout pads           • Free hubs, Driver bodies, Pawls                 (inner and outer)                   • Transmission gears
• Brake pads               • Foam rings, Glide rings                       • Shifter grips                       • Upper tubes (stanchions)
• Bushings                 • Handlebar grips                               • Spokes                              • Wheel braking surfaces
• Cassettes                • Jockey wheels                                 • Sprockets

ZIPP IMPACT REPLACEMENT POLICY
Zipp branded products, Model Year 2021 or newer, are covered under a lifetime impact-damage replacement policy. This policy can be used to obtain
a replacement of a product in the event of non-warranty impact damage occurring while riding your bicycle. See www.zipp.com/support for more
information.
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
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!
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
TABLE OF CONTENTS
ROCKSHOX SERVICE...........................................................................................................................................................................................5
       PART PREPARATION .......................................................................................................................................................................................................................................5
       SERVICE PROCEDURES..................................................................................................................................................................................................................................5
       PARTS, TOOLS, AND SUPPLIES...................................................................................................................................................................................................................6
       RECOMMENDED SERVICE INTERVALS..................................................................................................................................................................................................... 7
       RECORD YOUR SETTINGS............................................................................................................................................................................................................................. 7
       TORQUE VALUES.............................................................................................................................................................................................................................................. 7
       OIL VOLUME AND LUBRICANT....................................................................................................................................................................................................................8

EXPLODED VIEW - 2022 ZEB ULTIMATE FLIGHT ATTENDANT...................................................................................................................9

EXPLODED VIEW - 2022 LYRIK ULTIMATE FLIGHT ATTENDANT..............................................................................................................10

EXPLODED VIEW - 2022 PIKE ULTIMATE FLIGHT ATTENDANT.................................................................................................................11

EXPLODED VIEW - FLIGHT ATTENDANT CONTROL MODULE - ZEB, LYRIK, PIKE.................................................................................12

EXPLODED VIEW - LOWER LEG FEATURES - ZEB, LYRIK, PIKE................................................................................................................. 13

EXPLODED VIEW - BUTTERCUP - ZEB, LYRIK, PIKE....................................................................................................................................14

LOWER LEG REMOVAL AND SERVICE............................................................................................................................................................15
                                                                                                         50/200 HOUR SERVICE
       LOWER LEG REMOVAL.................................................................................................................................................................................................................................. 15
                                                                                                              50 HOUR SERVICE
       LOWER LEG SERVICE.................................................................................................................................................................................................................................... 17
                                                                                                            200 HOUR SERVICE
       LOWER LEG SEAL SERVICE......................................................................................................................................................................................................................... 19

AIR SPRING SERVICE - DEBONAIR+.............................................................................................................................................................. 22
                                                                                                            200 HOUR SERVICE
       AIR SPRING REMOVAL................................................................................................................................................................................................................................. 22
       BUTTERCUP REMOVAL - AIR SPRING SHAFT...................................................................................................................................................................................... 25
       DEBONAIR+ - AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS (OPTIONAL).................................................................................................... 27
       DEBONAIR+ - TRAVEL AND BOTTOMLESS TOKEN TUNING (OPTIONAL)................................................................................................................................. 27
       DEBONAIR+ - BOTTOMLESS TOKENS INSTALLATION (OPTIONAL)............................................................................................................................................ 27
       DEBONAIR+ - AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS (OPTIONAL).................................................................................................... 28
       AIR SPRING SERVICE.................................................................................................................................................................................................................................... 28
       AIR SPRING ASSEMBLY............................................................................................................................................................................................................................... 30
       BUTTERCUP INSTALLATION - AIR SPRING SHAFT............................................................................................................................................................................ 33
       AIR SPRING INSTALLATION........................................................................................................................................................................................................................ 35

DAMPER SERVICE............................................................................................................................................................................................. 39
                                                                                                            200 HOUR SERVICE
       FLIGHT ATTENDANT CONTROL MODULE REMOVAL....................................................................................................................................................................... 39
       DAMPER REMOVAL....................................................................................................................................................................................................................................... 42
       BUTTERCUP REMOVAL - DAMPER SHAFT........................................................................................................................................................................................... 43
       DAMPER SERVICE.......................................................................................................................................................................................................................................... 45
       DAMPER ASSEMBLY..................................................................................................................................................................................................................................... 48
       DAMPER BLEED..............................................................................................................................................................................................................................................50
       TEST LOCKOUT COMPRESSION.............................................................................................................................................................................................................. 53
       BUTTERCUP INSTALLATION - DAMPER SHAFT.................................................................................................................................................................................. 54
       DAMPER INSTALLATION.............................................................................................................................................................................................................................. 57
       CONTROL MODULE INSTALLATION....................................................................................................................................................................................................... 59
                                                                                                         50/200 HOUR SERVICE
       LOWER LEG INSTALLATION....................................................................................................................................................................................................................... 63
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
RockShox 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. Failure to follow the procedures outlined in this
service manual may cause damage to your component and void the warranty.
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.
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.
      For recycling and environmental compliance information, please visit: www.sram.com/en/company/about/environmental-policy-and-recycling.

 Part Preparation
Remove the component from the bicycle before service.
Disconnect and remove the remote cable or hydraulic hose from the fork or rear shock, if applicable. For additional information about RockShox
remotes, user manuals are available at www.sram.com.
Clean the exterior of the product with mild soap and water to avoid contamination of internal sealing part surfaces.

 Service Procedures
The following procedures should be performed throughout service, unless otherwise specified.

Clean the part with RockShox Suspension Cleaner or isopropyl alcohol and
a clean, lint-free shop towel. For hard to reach places (e.g. upper tube, lower
leg), wrap a clean, lint-free shop towel around a non-metallic dowel to clean
the inside.
Clean the sealing surface on the part and inspect it for scratches.

Replace the o-ring or seal with a new one from the service kit. Use your
fingers or a pick to pierce and remove the old seal or o-ring.
Apply grease to the new seal or o-ring.

                                  NOTICE
 Do not scratch any sealing surfaces when servicing the product. Scratches
 can cause leaks. Consult the spare parts catalog to replace the damaged
 part.

Use aluminum soft jaws when placing a part in a bench vise.
Tighten the part with a torque wrench to the torque value listed in the red bar.
When using a crowfoot socket and torque wrench, install the crowfoot socket
at 90 degrees to the torque wrench.

                                                                                                                         Specified torque value in N·m (in-lb)

                                                                                                                                RockShox Service                 5
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
P a r t s , To o l s , a n d S u p p l i e s
Parts                                                                  Bicycle Tools
• 2022 ZEB Ultimate Flight Attendant - 200 Hour Service Kit            • Bicycle work stand
• 2022 Lyrik Ultimate Flight Attendant - 200 Hour Service Kit          • Downhill tire lever
• 2022 Pike Ultimate Flight Attendant - 200 Hour Service Kit           • Shock pump
Safety and Protection Supplies                                         Common Tools
• Apron                                                                • Adjustable wrench or open end wench: 23, 25 mm
• Clean, lint-free shop towels                                         • Bench vise with aluminum soft jaw inserts
• Nitrile gloves                                                       • Crowfoot: 23, 25 mm
• Oil pan                                                              • Flat blade screwdriver
• Safety glasses                                                       • Hex bit sockets: 2, 2.5, 5 mm
Lubricants and Fluids                                                  • Hex wrenches: 2, 2.5, 5, 8 mm
• Maxima PLUSH 3wt Suspension Oil                                      • Internal retaining ring pliers (large) - air spring retaining ring (ZEB)
• Maxima PLUSH Dynamic Suspension Lube                                 • Long plastic or wooden dowel
• SRAM Butter Grease                                                   • Pick (metallic) - air spring retaining ring (Lyrik/Pike)
• RockShox Suspension Cleaner or isopropyl alcohol                     • Pick (non-metallic) - for all o-rings and seals
RockShox Tools                                                         • Plastic mallet
• RockShox Bleed Syringe                                               • Socket: 27 mm
• RockShox Dust Seal Installation Tool (38 mm) or RockShox x Abbey     • Socket wrench
  Bike Tools 38 mm Flangeless Dust Seal Installation Tool              • Soft jaws (flat, aluminum)
• RockShox Dust Seal Installation Tool (35 mm) or RockShox x Abbey     • Torque wrench
  Bike Tools 35 mm Flangeless Dust Seal Installation Tool
                                                                       • TORX bit socket: T10, T25
• RockShox Reverb Vise Blocks (10 mm slot) or
  RockShox Rear Shock Vise Blocks (10 mm slot)                         • TORX wrench: T10, T25

• RockShox Shock Pump
• RockShox Top Cap/Cassette tool (3/8" / 24 mm) or RockShox x
  Abbey Bike Tools Top Cap/Cassette Tool

                                                       SAFETY INSTRUCTIONS
Always wear safety glasses and nitrile gloves when working with suspension oil.
Place an oil pan on the floor underneath the area where you will be working on the shock or suspension fork.

                                                                                                                        Parts, Tools, and Supplies   6
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
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

                                                                                Extends wiper seal lifespan

  Every ride                     Clean dirt from upper tubes and wiper seals    Minimizes damage to upper tubes

                                                                                Minimizes lower leg contamination

                                                                                Restores small bump sensitivity

  Every 50 hours                 Perform lower leg service                      Reduces friction

                                                                                Extends bushing lifespan

                                                                                Extends suspension lifespan

  Every 200 hours                Perform damper and spring service              Restores small bump sensitivity

                                                                                Restores damping performance

 R e c o r d Yo u r S e t t i n g s
Use the table below to record your suspension settings to return your suspension to its pre-service settings. Record your service dates to track
service intervals.

                                                                                                                       Rebound setting - Count the
                                                                                                                       number of clicks while turning
  Service Hours Interval          Date of Service                                Air Pressure
                                                                                                                       the rebound adjuster fully
                                                                                                                       counter-clockwise.

  50

  100

  150

  200

 To r q u e Va l u e s
 Part                                                                           Tool                                  Torque
 Bleed screw - rebound damper seal head                                         TORX T10                              1.7 N•m (15 in-lb)
 Bottom bolt - air spring and damper                                            5 mm hex bit socket                   6.8 N•m (60 in-lb)
 Bottomless Tokens                                                              8 mm hex                              4 N•m (35 in-lb)
 ButterCup housing shaft end plate - end plate to shaft - air and damper        TORX T25                              3.3 N•m (29 in-lb)
 Seal head - rebound damper to damper cartridge tube                            23 mm crowfoot                        5 N•m (45 in-lb)
 Set screw (x2) - Flight Attendant Control Module to compression damper
                                                                                2 mm hex bit socket                   0.25 - 0.5 N•m (2.2 - 4.3 in-lb)
 top cap
 Set screw - rebound adjuster knob                                              2.5 mm hex bit socket                 0.84 N•m (7.5 in-lb)

 Top cap - air spring                                                           RockShox Top Cap/Cassette Tool
                                                                                (or standard cassette tool)           28 N•m (250 in-lb)
 Top cap - compression damper
                                                                                27 mm socket (optional)
 Upper ButterCup housing to lower ButterCup housing - air and damper            25 mm crow foot                       3.3 N•m (29 in-lb)

                                                                                                                  Recommended Service Intervals          7
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
Oil Volume and Lubricant

                                Damper                                                  Spring

                                             Upper Tube          Lower Leg                          Upper Tube              Lower Leg

Model
        Fork        Model       Damper       Oil                 Oil                    Spring      Oil
Year                                                   Volume                 Volume                              Volume    Oil Weight   Volume
                                             Weight              Weight                             Weight
                                                       (mL)                   (mL)                                (mL)      (wt)         (mL)
                                             (wt)                (wt)                               (wt)

        ZEB
                                                                                                    SRAM          Grease
                                                                                                    Butter        Air
                                                                                                    Grease*       Piston
                                                                 Maxima                                                     Maxima
                    Ultimate    Charger      Maxima              PLUSH                                                      PLUSH
2022    Lyrik       Flight      Flight       PLUSH     Bleed     Dynamic      30        DebonAir+                           Dynamic      15
                    Attendant   Attendant    3wt                 Suspension                                                 Suspension
                                                                 Lube                                                       Lube
                                                                                                    Maxima
                                                                                                    PLUSH
                                                                                                    Dynamic       3
                                                                                                    Suspension
        Pike                                                                                        Lube*

*Air Spring Oil / Grease - ZEB, Lyrik, and Pike Ultimate Flight Attendant forks are compatible with Maxima PLUSH Dynamic Suspension Lube and
SRAM Butter Grease.

                                                                                                                 Oil Volume and Lubricant      8
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
Exploded View - 2022 ZEB Ultimate Flight Attendant

                                                                                                                     Air Spring Assembly
        Steerer tube

                                                                                                                     Compression Damper
       Flight Attendant                                                                                              Assembly
        Control Module
                                                                                  Air cap
                                                                                                                     Rebound Damper
                                                                                   Air spring top cap                Assembly
                  Battery

              Battery block
                                                                                     Bottomless Token(s) 35 mm grey (optional)

 Compression damper top cap                                                            Sag o-ring

                          Crown

                                                                                            Upper tube
             Compression damper

                                                                                                 Lower leg arch

                              Damper tube

                                                                                                    Brake hose guide

                                Dust wiper seal

                                      Foam ring                                                          Air spring piston
                          Rebound damper piston
                                                                                                          Top out cup
                                                                                                           Top out bumper
                                                                                                            Air spring seal head

                                                                                                              Air seal head spacer

                                                                                                               Retaining ring

                              Rebound damper seal head
                                             Bleed port

                                                                                                                    Air spring shaft

                                                                                                                             ButterCup (air shaft)

                                            ButterCup (damper shaft)
                                                                                                                                 Crush washer
                                                        Maxle Stealth

                                                                                                                                   Air spring
                                                                                                                                   bottom bolt
                                                          Crush washer

                                                     Rebound bottom bolt

                                                        Rebound adjuster knob

                                                                                Exploded View - 2022 ZEB Ultimate Flight Attendant                   9
ZEB, Lyrik, Pike Ultimate Flight Attendant - SERVICE MANUAL - SRAM
Exploded View - 2022 Lyrik Ultimate Flight Attendant

                                                                                                                     Air Spring Assembly
        Steerer tube

                                                                                                                     Compression Damper
       Flight Attendant                                                                                              Assembly
        Control Module
                                                                               Air cap
                                                                                                                     Rebound Damper
                                                                                                                     Assembly
                  Battery                                                        Air spring top cap

              Battery block
                                                                                   Bottomless Token(s) 35 mm grey (optional)
 Compression damper top cap
                                                                                     Sag o-ring
                          Crown

                                                                                         Upper tube

              Compression damper

                                                                                            Lower leg arch

                            Damper tube
                                                                                                  Brake hose guide

                              Dust wiper seal

                                    Foam ring                                                          Air spring piston

                                                                                                        Top out cup
                                                                                                         Top out bumper

                            Rebound damper piston                                                         Air spring seal head

                                                                                                            Air seal head spacer

                                                                                                              Retaining ring

                              Rebound damper seal head
                                             Bleed port

                                                                                                                  Air spring shaft

                                                                                                                           ButterCup (air shaft)

                                          ButterCup (damper shaft)                                                            Crush washer

                                                      Maxle Stealth                                                             Air spring
                                                                                                                                bottom bolt
                                                        Crush washer

                                                  Rebound bottom bolt

                                                     Rebound adjuster knob

                                                                             Exploded View - 2022 Lyrik Ultimate Flight Attendant                  10
Exploded View - 2022 Pike Ultimate Flight Attendant

                                                                                                                       Air Spring Assembly
        Steerer tube

      Flight Attendant                                                                                                 Compression Damper
       Control Module                                                                                                  Assembly
                                                                                Air cap
                                                                                                                       Rebound Damper
                                                                                                                       Assembly
                  Battery                                                        Air spring top cap

              Battery block
                                                                                   Bottomless Token(s) 35 mm grey (optional)
 Compression damper top cap

                          Crown
                                                                                          Sag o-ring

                                                                                           Upper tube
             Compression damper

                                                                                              Lower leg arch

                                                                                                 Brake hose guide

                            Dust wiper seal
                                                                                                       Air spring piston
                                  Foam ring

                                                                                                         Top out cup
                                                                                                          Top out bumper
                         Rebound damper piston

                                                                                                             Air spring seal head

                                                                                                              Air seal head spacer

                                                                                                                Retaining ring
                          Rebound damper seal head
                                         Bleed port

                                                                                                                    Air spring shaft

                                                                                                                           ButterCup (air shaft)

                                       ButterCup (damper shaft)

                                                                                                                               Crush washer

                                                    Maxle Stealth
                                                                                                                                 Air spring bottom bolt
                                                       Crush washer

                                                 Rebound bottom bolt

                                                      Rebound adjuster knob

                                                                              Exploded View - 2022 Pike Ultimate Flight Attendant                    11
Exploded View - Flight Attendant Control Module - ZEB, Lyrik, Pike

                                                                                    Mode / Setting LED
                                          (−) Adjust button

                                           Menu button                                (+) Adjust button

                                                                                                    Flight Attendant Control Module

                                                                                           Set screw

                 AXS LED indicator
                       AXS button                                                         Output driver (compression damper adjuster)

                           SRAM battery

                                                                                                   Compression damper

 Battery latch
                                                                Battery block

SRAM battery

                                                              Exploded View - Flight Attendant Control Module - ZEB, Lyrik, Pike        12
Exploded View - Lower Leg Features - ZEB, Lyrik, Pike

                       Fender mount (x3)

                              Pressure Relief Valve (x2)

                                                      Bolt (x2)

                                             Dropout Adapter (x2)

                                                                  Exploded View - Lower Leg Features - ZEB, Lyrik, Pike   13
Exploded View - ButterCup - ZEB, Lyrik, Pike

                               Damper shaft                Air spring shaft

   Upper ButterCup housing                                            Upper ButterCup housing

                    Bushing                                           Bushing

              Upper bumper                                            O-ring

   ButterCup shaft end plate                                          ButterCup shaft end plate

   Lower ButterCup housing                                            Lower ButterCup housing

              Lower bumper                                            Bumper

                     O-ring
Lower housing alignment bolt

                                               Exploded View - ButterCup - ZEB, Lyrik, Pike       14
Lower Leg Removal and Service

  50/200 Hour Service Lower Leg Removal
ZEB is pictured in this section. Procedures are the same for Lyrik and Pike unless otherwise described.

 1    Remove the air valve cap.

 2    Depress the Schrader valve and release all air pressure.

                     ⚠ CAUTION - EYE HAZARD
       Verify all pressure is removed from the fork before proceeding.
       Failure to do so can result in injury and/or damage to the fork. Wear
       safety glasses.

 3    Turn the rebound adjuster knob counter-clockwise until it stops. This is
      the full open/fast rebound setting.

                                                                                   Counter-clockwise                   Rebound - Full Open Setting

 4    Loosen the set screw and remove the rebound damper adjuster knob.

                                                                                   2.5 mm

                                                                                                          Lower Leg Removal and Service          15
5   Place an oil pan beneath the fork to catch the draining oil.
    Loosen both bottom bolts 3 to 4 turns.

                                                                                   Spring side         5 mm     Damper side             5 mm

6   Strike each bolt head to dislodge the spring and damper shaft
    ButterCups from the lower leg. The bolt head should contact the
    bottom of the lower leg.
    Remove each bottom bolt. Clean each bolt and set them aside.
    Pike 27.5" and 29", Lyrik 29": Insert a 5 mm hex wrench into the bolt,
    and tap the wrench to avoid damage to the lower leg.

                                   NOTICE
     Do not strike the fork lower leg with mallet as this could damage the
     lower leg.

                                                                                   Mallet         Spring side                    Spring side

                                                                                   Mallet        Damper side                    Damper side

7   Firmly pull the lower leg downward until fluid begins to drain. Continue
    pulling downward to remove the lower leg.
    If the lower leg does not slide off of the upper tube or if oil does not
    drain from either side, the press fit of the shaft(s) into the lower leg may
    still be engaged. Reinstall the bottom bolts 2 to 3 turns and repeat the
    previous step.

                                   NOTICE
     Do not strike the fork arch with any tool when removing the lower
     leg as this could damage the lower leg.

    50 Hour Service Continue the 50 Hour Service with Lower Leg Service.
    200 Hour Service Continue the 200 Hour Service with Lower Leg Seal Service.

                                                                                                                    Lower Leg Removal      16
50 Hour Service                         Lower Leg Service

1   Remove the foam rings.

                                                                            Pick

2   Clean the foam rings.
    Replace the foam rings if worn, damaged, or excessively contaminated.

                                                                            RockShox Suspension Cleaner

3   Soak the foam rings in Maxima PLUSH Dynamic Suspension Lube.
                                                           Lube.

                                                                            Maxima PLUSH Dynamic Suspension Lube

                                                                                                                   Lower Leg Service   17
4   Clean the inside and outside of the lower leg.
    Clean the wiper seals.

                                                                                RockShox Suspension Cleaner   Dowel

5   Install the foam rings under the wiper seals.
    Confirm the foam rings are installed evenly and square in the space
    under the wiper seals and do not protrude out of the groove.

    50 Hour Service Continue the 50 Hour Service with Lower Leg Installation.

                                                                                                                      Lower Leg Service   18
200 Hour Service                           Lower Leg Seal Service

1   Remove and discard the foam rings.
    Remove the outer wire springs from the dust wiper seals.

                                                                             Pick

2   Stabilize the lower leg on a bench top. Place the tip of a downhill
    tire lever under the wiper seal. Press down on the downhill tire lever
    handle to remove the seal.
    Repeat on the other side. Discard the wiper seals.

                                  NOTICE
     Keep the lower leg stable. Do not allow the lower leg to twist in
     opposite directions, compress toward each other, or be pulled apart.
     This will damage the lower leg.

                                                                             Downhill tire lever

3   Clean the inside and outside of the lower leg.

                                                                             RockShox Suspension Cleaner   Dowel

                                                                                                           Lower Leg Seal Service   19
4   Soak new foam rings in Maxima PLUSH Dynamic Suspension Lube.
    Install the new foam rings into the lower leg.

                                                                                   Maxima PLUSH Dynamic Suspension
                                                                                   Lube

5   Remove the outer wire spring from each new dust wiper seal and set
    them aside.

6   Insert the narrow end of a new wiper seal into the recessed end of the
    RockShox Dust Seal Installation Tool.
    38 mm - ZEB
    35 mm - Lyrik and Pike

                                                                                   RockShox Dust Seal Installation Tool

7   Stabilize the lower leg on a bench top. Hold the lower leg steady and
    press, or tap with a mallet, the wiper seal into the lower leg until the top
    of the seal is flush with the top of the lower leg.
    Repeat on the other side.

                                   NOTICE
     Only press, or tap with a mallet, the wiper seal into the lower leg
     until it is flush with the top surface of the lower leg. Pressing the
     wiper seal below the top surface of the lower leg will compress the
     foam ring.

                                                                                   RockShox Dust Seal Installation Tool   Mallet

                                                                                                                          Lower Leg Seal Service   20
8   Install the outer wire springs.

                                      Lower Leg Seal Service   21
Air Spring Service - DebonAir+
A ZEB air spring assembly is pictured in this section. Procedures are the same for ZEB, Lyrik, and Pike unless otherwise described.

      200 Hour Service                               Air Spring Removal

                                                       ⚠ WARNING - EYE HAZARD
 Verify all pressure is removed from the fork before proceeding. Depress the Schrader valve again to remove any remaining air pressure. Failure to
 do so can result in injury and/or damage to the fork.

                                 NOTICE
 Inspect each part for scratches. Do not scratch any sealing surfaces when
 servicing your suspension. Scratches can cause leaks.
 When replacing seals and o-rings, use your fingers or a pick to remove the
 seal or o-ring. Spray RockShox Suspension Cleaner or isopropyl alcohol
 onto each part and clean with a clean lint-free shop towel.
 Apply SRAM Butter Grease to the new seals and o-rings.

                                                                                   SRAM Butter Grease

 1    Remove the air spring top cap. Press down firmly when loosening the
      top cap.

                                     NOTICE
       The fork top caps are tightened to a high torque value. Ensure
       the fork is held securely in the bicycle stand. To avoid damage
       to the top cap, press the top cap tool squarely and firmly down
       when loosening. Use a socket wrench with a long handle for extra
       leverage.

      Clean the upper tube threads.

                                                                                   Top cap / Cassette tool

 2    Remove the top cap o-ring and discard it.
      Apply grease to a new o-ring and install it.

                                                                                                                 Air Spring Service - DebonAir+   22
3   Remove the retaining ring.
    Use your finger to guide the retaining ring and protect the air spring
    shaft during removal.

                                   NOTICE
     Do not scratch the air spring shaft. Scratches on the air shaft will
     allow air to bypass the seal head into the lower leg, resulting in
     reduced spring performance.

                                                                                Retaining ring pliers          ZEB

    Lyrik/Pike: Wrap a shop towel tightly around the air shaft to protect it.

                                                                                Metal Pick              Lyrik / Pike

                                                                                                                       Air Spring Removal   23
4   Push the shaft half way into the upper tube, then quickly and firmly pull
    the shaft out to dislodge the seal head.
    Remove the air spring assembly and seal head spacer from the upper
    tube.

                                  NOTICE
     Do not scratch the inside of the upper tube. Scratches will allow air
     to bypass the seals resulting in reduced spring performance.

                                                                                ZEB                           Pike (pictured) and Lyrik

5   Clean the inside and outside of the upper tube.
    Inspect the inside and outside of the upper tube for damage.

                                  NOTICE
     Scratches on the inside surface of the upper tube can cause air to
     leak. If an internal scratch is visible, the crown steerer upper tube
     assembly may need to be replaced.

                                                                                RockShox Suspension Cleaner

                                                                                Dowel                         Dowel

                                                                                RockShox Suspension Cleaner

                                                                                                                      Air Spring Removal   24
200 Hour Service                          ButterCup Removal - Air Spring Shaft

1   Clamp the lower ButterCup housing into a vise with Reverb Vise Blocks
    or RockShox Rear Shock Vise Blocks on the wrench flats, with the air
    spring oriented upward.
    Hold the air spring shaft for support and unthread the upper ButterCup
    housing (25 mm) from the lower ButterCup housing.

                                                                             25 mm or adjustable open end wrench

2   Remove the air spring assembly from the lower ButterCup housing and
    set it aside.

3   Remove the ButterCup bumper from the lower ButterCup housing and
    discard it.

                                                                             Pick (non-metallic)

4   Remove the lower ButterCup housing from the vise. Clean the lower
    ButterCup housing.

                                                                                                        ButterCup Removal - Air Spring Shaft   25
5   Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise
    Blocks or RockShox Rear Shock Vise Blocks with the air piston oriented
    downward.
    Clamp the air spring shaft only tight enough so it does not spin when
    the ButterCup shaft end plate is removed.

                                   NOTICE
     Scratches on the air spring shaft can cause air to leak. If a scratch is
     visible the air spring assembly may need to be replaced.

    Unthread and remove the ButterCup shaft end plate from the air spring
    shaft.
                                                                                T25   RockShox Vise Blocks 10 mm

6   Remove the ButterCup shaft end plate o-ring (large) and discard it.
    The small o-ring does not need to be removed or replaced.

7   Remove the air spring shaft from the vise and vise blocks.
    Remove the upper ButterCup housing and bushing assembly from the
    air spring shaft and set it aside.

                                                                                                         ButterCup Removal - Air Spring Shaft   26
D e b o n A i r + - A i r S p r i n g Tr a v e l C h a n g e a n d B o t t o m l e s s To k e n s ( o p t i o n a l )
To increase or decrease the travel of your RockShox fork, the air spring must be replaced with the appropriate length air spring shaft assembly. For
example, to change a fork with a maximum of 140 mm of travel to a maximum of 160 mm of travel, a 160 mm air spring assembly must be installed.
Bottomless Tokens can be added to, or removed from the DebonAir+ (DA) top cap to fine-tune the bottom-out feel and spring curve. Use the table
below to help determine the number of Bottomless Tokens that can be used with each maximum fork travel option. If fork travel is changed from
stock, it may be necessary to add or remove Bottomless Tokens.
Refer to the RockShox Suspension Tuning and Setup Guide for more details.Refer to the RockShox Spare Parts Catalog at www.sram.com/service for
available air spring and Bottomless Token kits.
For part ordering information, please contact your local SRAM distributor or dealer.

 D e b o n A i r + - Tr a v e l a n d B o t t o m l e s s To k e n Tu n i n g ( o p t i o n a l )
                                                             ZEB - 27.5" Boost & 29" Boost
            Fork Travel                              Bottomless Tokens (grey)                                  Bottomless Tokens (grey)
               (mm)                                      Factory Installed                                            Maximum

                190                                              0                                                          4

                180                                              0                                                          4

                170                                              1                                                          4

                160                                              1                                                          5

                150                                              2                                                          5

                                                            Lyrik - 27.5" Boost & 29" Boost
            Fork Travel                              Bottomless Tokens (grey)                                  Bottomless Tokens (grey)
               (mm)                                      Factory Installed                                            Maximum

                160                                              0                                                          5

                150                                              0                                                          5

                140                                              1                                                          5

                                                             Pike - 27.5" Boost & 29" Boost
            Fork Travel                              Bottomless Tokens (grey)                                  Bottomless Tokens (grey)
               (mm)                                      Factory Installed                                            Maximum

                140                                              0                                                          4

                130                                              0                                                          5

                120                                              1                                                          5

 D e b o n A i r + - B o t t o m l e s s To k e n s I n s t a l l a t i o n ( o p t i o n a l )
Bottomless Tokens reduce air volume in your fork and create greater ramp at the end of the fork travel. Add or remove Tokens to tune your fork's
bottomless feel.
      Thread a Bottomless Token into another Bottomless Token, or into the
      the bottom of the top cap, and tighten.

                                                                                       8 mm              4 N∙m (35 in-lb)          Top cap / Cassette tool

                                                                         DebonAir+ - Air Spring Travel Change and Bottomless Tokens (optional)           27
D e b o n A i r + - A i r S p r i n g Tr a v e l C h a n g e a n d B o t t o m l e s s To k e n s ( o p t i o n a l )
It is optional to change maximum fork travel by replacing the stock air spring shaft assembly with a shorter or longer air spring shaft assembly. If
maximum travel is increased or reduced, use the new complete air spring shaft assembly in the following installation steps. It may also be necessary
to add or remove Bottomless Tokens. Refer to Air Spring Travel Change and Bottomless Tokens for details.
Refer to the RockShox Spare Parts Catalog at www.sram.com/service for available air spring and Bottomless Token kits.
For part ordering information, please contact your local SRAM distributor or dealer.

      200 Hour Service                             Air Spring Service

      A ZEB air spring assembly is pictured in this section. Procedures are
      the same for ZEB, Lyrik, and Pike air spring assemblies.

                                                                                       Lyrik                            Pike

 1    Remove the air seal head assembly and top out bumper from the air
      spring shaft.
      Discard the seal head assembly.

                                     NOTICE
       Scratches on the air spring shaft can cause air to leak. If a scratch is
       visible the air spring assembly may need to be replaced.

 2    Remove the top out bumper.
      Clean the top out bumper.
      Clean and inspect the air spring shaft for damage.

                                                                                       Pick (non-metallic)

                                                                           DebonAir+ - Air Spring Travel Change and Bottomless Tokens (optional)   28
3   Remove the glide ring (upper), quad ring, and backup ring (lower) from
    the air piston and discard them.

                                   NOTICE
     Do not scratch the air piston. Scratches will cause air to leak.

                                                                             Pick

4   Clean the air piston.

                                                                                    Air Spring Service   29
Air Spring Assembly

1   Install a new backup ring (thin, lower) onto the air piston.
    Apply grease to the new quad ring seal and install it onto the air piston
    above the backup ring.
    Install a new glide ring (thick, upper) tapered end upward, above the
    quad ring seal.

    Set the air spring assembly aside on a clean shop towel.

2   Apply a liberal amount of grease to the air spring shaft.

                                                                                SRAM Butter Grease

3   Apply a thin layer of grease to the new top out bumper and Install it
    onto the air spring shaft.

                                                                                SRAM Butter Grease

                                                                                                     Air Spring Assembly   30
4   Apply grease to the inner and outer seals on the new seal head.

                                                                              SRAM Butter Grease   SRAM Butter Grease

                                                                              SRAM Butter Grease

5   Install the new seal head assembly onto the air shaft, flat side first.

                                                                                                       Air Spring Assembly   31
6   Remove the grease from the inner shaft threads.

                                                      Air Spring Assembly   32
200 Hour Service                             ButterCup Installation - Air Spring Shaft

1   Install the ButterCup upper housing and bushing assembly onto the air
    spring shaft.

2   Apply grease to a new o-ring and install it onto the ButterCup shaft end
    plate, over the threads.
    Clean all grease from the threads.

                                                                                SRAM Butter Grease

3   Apply Loctite Threadlocker 2760 (red), or equivalent, to the first two to
    three full threads of the ButterCup shaft end plate.

                                                                                Threadlocker Loctite 2760 - Red

4   Position the upper ButterCup housing above the vise blocks.
    Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise
    Blocks or RockShox Rear Shock Vise Blocks.
    Clamp the air shaft only tight enough so it does not spin when the
    ButterCup is tightened.

                                   NOTICE
     Scratches on the air spring shaft can cause air to leak. If a scratch is
     visible the air spring assembly may need to be replaced.

    Thread the ButterCup shaft end plate into the air shaft and tighten it.

                                                                                T25     RockShox Vise Blocks 10 mm       T25          3.3 N∙m (29 in-lb)

                                                                                                          ButterCup Installation - Air Spring Shaft        33
5   Apply Loctite Threadlocker Blue 242, or equivalent, to three full outer
    threads on the lower ButterCup housing.

                                                                              Theadlocker Loctite 242 - Blue

6   Install a new ButterCup bumper into the lower ButterCup housing, wide
    end first.

7   Position the lower ButterCup housing and bumper onto the ButterCup
    end plate.
    Slide the upper ButterCup housing and bushing assembly up and
    thread it onto the lower ButterCup housing finger tight.

8   Remove the air shaft from the vise and vise blocks.
    Clamp the lower ButterCup housing into a vise with RockShox Vise
    Blocks on the wrench flats, air spring piston oriented upward.
    Tighten the upper ButterCup housing onto the lower housing.

                                                                                 25 mm                                8.5 N∙m (75 in-lb)

                                                                                                         ButterCup Installation - Air Spring Shaft   34
200 Hour Service                           Air Spring Installation

1   Apply a liberal amount of SRAM Butter grease evenly around the end
    of a clean plastic dowel, approximately 150 mm from one end. Use
    the dowel to apply the grease to the inside surface of the upper tube,
    approximately 150 mm into the tube.

                                                                              Dowel and grease     150 mm

2   Apply grease to the air piston and seal head outer o-rings.

                                                                              SRAM Butter Grease

3   With the crown steerer upper tube assembly clamped in the bicycle
    work stand, orient the upper tubes upward and the steerer tube
    oriented downward.
    Insert the air spring assembly into the upper tube. Firmly push the air
    piston into the upper tube.
    Inject 1 mL of Maxima PLUSH Dynamic Suspension Lube into the upper
    tube, on top of the air piston and into the negative air chamber.

                                                                                                            1 mL     PLUSH Dynamic Suspension Lube

                                                                                                                   Air Spring Installation     35
4   Insert the air seal head into the upper tube and firmly press it into the
    upper tube until it stops.

5   Apply grease to a new seal head spacer o-ring and install it onto the
    seal head spacer.
    Insert the seal head spacer into the upper tube, o-ring end first, and
    seat it into the upper tube step until it stops.

                                                                                Air Spring Installation   36
6   ZEB: Eyelet retaining
                 retaining rings have a sharper edged side and a rounder
    edged side. Installing retaining rings with the sharper edged side
    facing the tool will allow for easier installation and removal.
    Guide the retaining ring with your finger to prevent scratching the air
    shaft.
    Place the tips of the retaining ring pliers into the eyelets of the
    retaining ring, then use the pliers to push the seal head into the upper
    tube while installing the retaining ring into the groove.
    Confirm the retaining ring is properly seated in the retaining ring
    groove by using the retaining ring pliers to rotate the retaining ring
    and seal head back and forth a few times.

                                   NOTICE                                      Retaining ring pliers

     Do not scratch the air spring shaft. Scratches on the air shaft will
     allow air to bypass the seal head into the lower leg, resulting in
     reduced spring performance.

    Lyrik and Pike: Lift both prong ends from the center of the ring to open
    the retaining ring for installation.
    Use your fingers to protect and guide the ring over the air shaft.
    Insert the inner retaining ring prong end into the upper tube retaining
    ring gland.
    Using your thumb, guide and push the retaining ring edge, starting
    at the installed prong end, around the upper tube edge and into the
    gland.
    The retaining ring is installed completely when the outer prong end
    snaps into the gland.
    Confirm the retaining ring is properly seated completely in the
    retaining ring gland.

                                   NOTICE
     Do not scratch the air spring shaft. Scratches on the air shaft will
     allow air to bypass the seal head into the lower leg, resulting in
     reduced spring performance.

                                                                                                       Air Spring Installation   37
7   Inject or pour Maxima PLUSH Dynamic Suspension Lube into the air
    spring upper tube.

                                                                               Maxima PLUSH Dynamic Suspension Lube    RockShox Bleed Syringe      3 mL

8   Install the air spring top cap into the upper tube and tighten it. Press
    down firmly when tightening the top cap.

                                                                                                                      Top cap/           28 N∙m (250 in-lb)
                                                                                                                      Cassette tool

                                                                                                                         Air Spring Installation       38
Damper Service

    200 Hour Service                             Flight Attendant Control Module Removal

1   The compression damper must be in the OPEN position before
    removing the Control Module.
    Press and hold the Menu button until one LED pulses red.
    If necessary, press and release the (+
                                        (+) or (−
                                               (−) adjuster button until the
    red OPEN LED pulses.

2   Remove the SRAM battery and install the battery block.
    Install the battery cover on the SRAM battery and set it aside.
    Optional:: Insert the SRAM battery onto the battery charger.
    Optional

3   Loosen each Flight Attendant Control Module set screw.
    Do not remove the set screws.

                                                                               2 mm   2 mm

                                                                                             Damper Service   39
4   Carefully remove the Flight Attendant Control Module from the
    compression damper top cap. Use both thumbs to evenly push the
    Control Module straight up and out of the top cap.

                                    NOTICE
     Do not damage the internal mechanism when removing the Control
     Module.

5   Clean the underside of the Control Module with a damp clean shop
    towel.
    Set the Control Module aside.

                                    NOTICE
     Do not spray any cleaners onto the Control Module.

                                                                       Flight Attendant Control Module Removal   40
6   Carefully remove the inner damper top cap / Control Module o-ring
    seal.

                                 NOTICE
     Do not scratch the o-ring gland. Scratches can cause debris to enter
     the top cap under the Flight Attendant Control Module.

                                                                            Pick

    Clean the inside of the top cap and o-ring gland with a damp clean
    shop towel.

                                 NOTICE
     Do not spray any cleaners into the top cap or on top of the
     compression damper.

                                                                                   Flight Attendant Control Module Removal   41
200 Hour Service                          Damper Removal

1   Unthread the damper top cap and remove the damper assembly.

                                 NOTICE
     The fork top caps are tightened to a high torque value. Ensure
     the fork is held securely in the bicycle stand. To avoid damage
     to the top cap, press the top cap tool squarely and firmly down
     when loosening. Use a socket wrench with a long handle for extra
     leverage.

    Clean the upper tube threads.

                                                                        Top cap / Cassette tool

2   Clean the inside and outside of the upper tube.

                                                                        RockShox Suspension Cleaner

                                                                        Dowel                         Dowel

                                                                                                              Damper Removal   42
200 Hour Service                         ButterCup Removal - Damper Shaft

1   Clamp the lower ButterCup housing into a vise with Reverb Vise Blocks
    or RockShox Rear Shock Vise Blocks on the wrench flats, with the
    damper oriented downward.
    Hold the damper shaft for support and unthread the upper ButterCup
    housing from the lower housing.

                                                                            25 mm or adjustable open end wrench

2   Remove the damper assembly from the lower cup and set it aside.

3   Remove the lower ButterCup bumper from the lower ButterCup
    housing and discard it.
    Remove the lower ButterCup housing from the vise.
    Do not remove the alignment bolt.

                                                                            Pick (non-metallic)

4   Remove the lower ButterCup housing from the vise. Clean the lower
    ButterCup housing.

                                                                                                         ButterCup Removal - Damper Shaft   43
5   Clamp the damper shaft into the 10 mm slot of the RockShox Reverb
    Vise Blocks or RockShox Rear Shock Vise Blocks with the damper
    oriented downward.
    Clamp the damper shaft only tight enough so it does not spin when the
    ButterCup shaft end plate is removed.

                                  NOTICE
     Scratches on the damper shaft can cause oil to leak. If a scratch is
     visible the rebound damper assembly may need to be replaced.

    Unthread and remove the ButterCup shaft end plate from the damper
    shaft.
                                                                            T25   RockShox Vise Blocks 10 mm

6   Remove the upper ButterCup bumper and discard it.
    Remove the upper ButterCup housing and bushing assembly from the
    damper shaft.

                                                                                                       ButterCup Removal - Damper Shaft   44
200 Hour Service                             Damper Service

1   Clamp the cartridge tube wrench flats in a vise with flat soft jaw inserts,
    rebound damper oriented upward.
    Wrap a shop towel around the cartridge tube to absorb oil.

                                                                                  Vise and flat soft jaw inserts

2   Unthread and slowly remove the rebound damper and seal head
    assembly from the cartridge tube.

                                                                                  23 mm

3   Remove the seal head from the rebound damper shaft and discard it.

4   The solid band glide ring is not removable and only requires cleaning.
    Do not remove.

                                                                                                                   Damper Service   45
5   Apply grease to the new rebound damper seal head seals.

                                                                            SRAM Butter Grease

6   Install the new seal head onto the rebound damper shaft, threaded end
    first, and slide it towards the piston until it stops.

7   Remove the bleed screw from the seal head.

                                                                            TORX T10

8   Remove the cartridge tube from the vise and pour the oil into an oil
    pan.
    Squeeze the bladder to drain the oil from the compression damper
    assembly into an oil pan.

                                                                                                 Damper Service   46
9    Clamp the cartridge tube, on the bladder coupler wrench flats, back
     into the vise.
     Spray RockShox Suspension Cleaner or isopropyl alcohol into the
     cartridge tube.

     Squeeze the bladder 5-6 times to circulate the cleaner into the damper.

10   Remove the tube from the vise. Orient the tube downward and
     squeeze the bladder until the cleaner and any remaining oil is drained
     into an oil pan.
     Place the tube on a shop towel for a new minutes to allow any excess
     cleaner to drain.

11   Dry the cartridge tube and compression damper assembly with
     compressed air.

                                                                               Air compressor and air gun nozzle

                                                                                                                   Damper Service   47
200 Hour Service                            Damper Assembly

1   Clamp the cartridge tube wrench flats lightly into the vise and soft jaw
    inserts. Wrap a shop towel around the tube to absorb any oil.
    Pour Maxima PLUSH 3wt suspension oil into the cartridge tube until it
    is full.
    Squeeze the bladder until trapped bubbles stop purging. Pour
    additional oil into the cartridge tube until it is full.

                                                                               Maxima PLUSH 3wt Suspension Oil

2   The rebound damper must be in the full open/fastest rebound setting
    before installation.
    Insert the rebound adjuster knob, or 2.5 mm hex wrench, into the
    rebound damper shaft until it contacts the rebound adjuster screw.
    Turn the knob counter-clockwise until it stops.
    Remove the adjuster knob from the shaft.

                                                                                                                 Damper Assembly   48
3   Insert the rebound damper piston slowly into the cartridge tube and
    thread the sealhead into the tube.

    Tigthen the seal head.

                                                                          23 mm            5.1 N∙m (45 in-lb)

4   Thread the rebound bottom bolt into the shaft 3-4 turns.

                                                                                  Damper Assembly         49
200 Hour Service                           Damper Bleed

1   Draw Maxima PLUSH 3wt suspension oil into a RockShox Bleed
    Syringe until it is half full.

                                                                              Maxima PLUSH 3wt Suspension Oil   RockShox Bleed Syringe

2   Thread the syringe bleed fitting into the seal head bleed port.
    Depress the plunger to pressurize the damper assembly.

3   Push the rebound damper shaft into the cartridge tube while applying
    opposing pressure on the syringe plunger as the syringe fills with oil.

    Pull the rebound damper shaft slowly out of the cartridge tube while
    applying opposing pressure on the syringe plunger as oil fills the
    damper.
    Repeat this process until bubbles are no longer pulled from the damper
    into the syringe.

                                                                                                                Damper Bleed        50
4   Fully extend the rebound damper shaft. Push the syringe plunger
    down, then release the plunger. Allow the bladder to expand and
    retract until it stops in a resting position.

5   Unthread the syringe bleed fitting from the bleed port.

                                ⚠ CAUTION
     Oil may eject from the bleed port if the bladder is not in a resting
     position. Wear safety glasses.

6   Install the bleed screw and tighten it.
    Wipe away any excess oil.

                                                                            T10   1.7 N∙m (15 in-lb)

                                                                                                   Damper Bleed   51
7   Cycle the rebound shaft a few times.
    Remove the bottom bolt and clean the damper assembly.

                                                            Damper Bleed   52
200 Hour Service                           Te s t L o c k o u t C o m p r e s s i o n

1   Use a Schrader valve core tool to rotate the keyed adjuster clockwise
    until it lightly contacts the stop point, to the locked out or firmest
    position.

                                  NOTICE
     Do not over-rotate the keyed adjuster against the stop point. Over-
     rotation, or tightening, against the stop point can damage internal
     parts.

                                                                                                            Schrader valve core tool

2   Position the rebound damper shaft squarely on a flat surface while
    holding the compression circuit closed with the Schrader valve core
    tool.
    Push down on the damper assembly to test the bleed.
    Consistent resistance should be felt with no gaps in movement. If gaps
    are felt during compression, repeat the bleed process.
    If the bleed was successful, rotate the compression damper keyed
    adjuster counter clockwise to the open position, then rotate it one half
    turn clockwise.

                                                                               Schrader valve core tool     Schrader valve core tool

                                                                                                          Test Lockout Compression     53
200 Hour Service                            ButterCup Installation - Damper Shaft

1   Install the upper ButterCup housing and bushing assembly onto the
    damper shaft. Slide the assembly toward the rebound seal head until it
    stops.

2   Install a new upper ButterCup bumper, wide end first, onto the damper
    shaft.

                                                                                                                         SRAM Butter Grease

3   Apply Threadlocker Loctite 2760 (red), or equivalent, to the first three
    full threads on the end of the end plate.

                                                                               Threadlocker Loctite 2760 - Red

4   Clamp the damper shaft into the 10 mm slot of the Reverb Vise Blocks
    or RockShox Rear Shock Vise Blocks.
    Clamp the damper shaft only tight enough so it does not spin when the
    ButterCup housing is tightened.

                                   NOTICE
     Scratches on the damper shaft can cause oil to leak. If a scratch is
     visible the rebound damper assembly may need to be replaced.

    Thread the ButterCup shaft end plate into the damper shaft and tighten
    it.

                                                                               T25     RockShox Vise Blocks 10 mm        T25           3.3 N∙m (29 in-lb)

                                                                                                            ButterCup Installation - Damper Shaft           54
5   Install the lower ButterCup housing bumper into the lower ButterCup
    housing, wide side down, in alignment with the bolt.

6   Apply Threadlocker Loctite 242 (blue), or equivalent, to three full outer
    threads on the lower ButterCup housing.

                                                                                Theadlocker Loctite 242 - Blue

7   Position the upper ButterCup housing and bumper above the vise
    blocks.
    Install the lower ButterCup housing/bumper assembly onto the
    ButterCup shaft end plate; insert the bolt through the end plate bolt
    hole.
    Slide lower cup to the upper bumper end plate, and position the
    alignment bolt through the hole on the end plate.
    Thread the upper ButterCup housing onto the lower ButterCup housing
    finger tight.

                                                                                                             ButterCup Installation - Damper Shaft   55
8   Remove the damper shaft from the vise and vise blocks.
    Clamp the lower ButterCup housing into a vise with RockShox Vise
    Blocks on the wrench flats, damper oriented upward.

    Tighten the upper ButterCup housing onto the lower housing.

                                                                       25 mm             8.5 N∙m (75 in-lb)

                                                                               ButterCup Installation - Damper Shaft   56
200 Hour Service                               Damper Installation

1   Remove the o-ring from the top cap.
    Clean the top cap threads and o-ring groove.
    Apply grease to a new o-ring and install it.

                                                                                       SRAM Butter Grease

2   Apply grease to a new inner top cap o-ring and install it.

                                                                  SRAM Butter Grease

                                                                                            Damper Installation   57
3   Install the damper assembly into the damper side upper tube. Use
    your fingers to guide the damper and damper shaft into the upper tube
    without scratching the shaft.

    Thread the top cap into the upper tube and tighten it. Press down
    firmly when tightening the top cap.

                                                                            Top cap / Cassette tool   28 N∙m (250 in-lb)

                                                                                                      Damper Installation   58
200 Hour Service                           Control Module Installation

1   The keyed ends of the Control Module output driver and the
    compression damper adjuster must be aligned in the same orientation
    before installation.

                                  NOTICE
     Confirm the inside of the top cap is clean before installing the
     Flight Attendant Control Module. Contamination will affect the
     compression damper seal and function of the Control Module.

    Check key alignment before installation. If the keys are not aligned,
    rotate the adjuster key on the Control Module output driver to the
    same orientation as the adjuster key in the compression damper.

                                                                            Flat blade screwdriver

                                                                                                     Control Module Installation   59
2   Position the back of the Control Module parallel with the crown, and
    install the Control Module into the compression damper.
    With the keyed ends of the Control Module output driver and
    compression damper adjuster aligned, press the Control Module firmly
    into the damper and onto the top cap squarely.
    If the keyed ends are not aligned the Control Module will not snap
    into place inside the compression damper. If this occurs, remove the
    Control Module, align the keyed ends, and reinstall the Control Module.
                                                                              Parallel
                                  NOTICE
     For proper clearance and function, the Flight Attendant Control
     Module must be installed with the battery oriented to the BACK of
     the crown only, and parallel with the fork crown. Installation of the    Control Module parallel with crown
     Control Module with the battery oriented to the side or front of the
     crown will cause permanent damage.

3   Check and confirm the Control Module does not contact any part of
    the fork crown. Remove the Control Module, realign, and reinstall if
    needed.

                                                                                                                   Control Module Installation   60
4   Tighten each set screw evenly finger tight to center the Control Module
    position on the top cap.
    Tighten each set screw to the specified torque.

                                   NOTICE
     To avoid permanent damage to the compression damper top cap, do
     not over tighten the set screws.

                                                                              2 mm                                        2 mm

                                                                              2 mm   0.25 - 0.5 N•m (2.2 - 4.3 in-lb)     2 mm    0.25 - 0.5 N•m (2.2 - 4.3 in-lb)

5   Remove the battery block from the Control Module.
    Install the battery onto the Control Module.
    Control Module and Damper Homing: When the battery is installed,
    the Control Module motor will activate and automatically reset and
    adjust the compression damper to the full open position. If the Control
    Module is properly installed, the action should operate smoothly and
    quickly.

    If a clicking noise, or repeating motor actions are heard and felt,
    the Control Module is installed incorrectly. The output driver and
    compression damper keys may not be aligned correctly.
    Adjust Alignment:
    1. Remove the battery.
    2. Partially and evenly loosen each set screw. Do not remove the set
       screws or the Control Module.
    3. Reinstall the battery.
    4. The Control Module and damper adjuster keys should self align and
       reset the damper compression position.
    5. Tighten each set screw to the specified torque.

    If alignment adjustment was unsuccessful, remove the Control Module,
    align the output driver and compression keys, and reinstall the Control
    Module onto the compression damper top cap. Repeat Control Module
    Installation steps 1 - 5.

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