Rock Shox Yari Service Manual
User Manual: RockShoxYariServiceManual
Open the PDF directly: View PDF 
.
Page Count: 37
| Download | |
| Open PDF In Browser | View PDF |
2016-2017 Yari Service Manual GEN.0000000005021 Rev E © 2016 SRAM, LLC SRAM® LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase. This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased. Original proof of purchase is required. Except as described herein, SRAM makes no other warranties, guaranties, or representations of any type (express or implied), and all warranties (including any implied warranties of reasonable care, merchantibility, or fitness for a particular purpose) are hereby disclaimed. LOCAL LAW This warranty statement gives the customer specific legal rights. The customer may also have other rights which vary from state to state (USA), from province to province (Canada), and from country to country elsewhere in the world. To the extent that this warranty statement is inconsistent with the local law, this warranty shall be deemed modified to be consistent with such law, under such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the United States of America, as well as some governments outside of the United States (including provinces in Canada) may: a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer (e.g. United Kingdom). b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations. For Australian customers: This SRAM limited warranty is provided in Australia by SRAM LLC, 1000 W. Fulton Market, 4th Floor, Chicago, IL, 60607, USA. To make a warranty claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6 Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses incurred in making the warranty claim are your responsibility. The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. LIMITATIONS OF LIABILITY To the extent allowed by local law, except for the obligations specifically set forth in this warranty statement, in no event shall SRAM or its third party suppliers be liable for direct, indirect, special, incidental, or consequential damages. LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The SRAM user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com. This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design. This warranty does not apply when the product has been 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. This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal use, failure to service according to SRAM recommendations and/or riding or installation in conditions or applications other than recommended. Wear and tear parts are identified as: • Dust seals • Bushings • Air sealing o-rings • Glide rings • Rubber moving parts • Foam rings • Rear shock mounting hardware and main seals • Upper tubes (stanchions) • Stripped threads/bolts (aluminium, titanium, magnesium or steel) • Brake sleeves • Brake pads • Chains • Sprockets • Cassettes • Shifter and brake cables (inner and outer) • Handlebar grips • Shifter grips • Jockey wheels • Disc brake rotors • Wheel braking surfaces • Bottomout pads • Bearings • Bearing races • Pawls • Transmission gears • Spokes • Free hubs • Aero bar pads • Corrosion • Tools • Motors • Batteries Notwithstanding anything else set forth herein, the battery pack and charger warranty does not include damage from power surges, use of improper charger, improper maintenance, or such other misuse. This warranty shall not cover damages caused by the use of parts of different manufacturers. This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM components. This warranty shall not cover damages resulting from commercial (rental) use. TABLE OF CONTENTS EXPLODED VIEW - RC/DUAL POSITION AIR™ (DPA)......................................................................................................................................5 EXPLODED VIEW - RC/SOLO AIR™ (SA)............................................................................................................................................................6 ROCKSHOX SUSPENSION SERVICE.................................................................................................................................................................7 Parts, Tools, and Supplies.............................................................................................................................................................................................................................. 7 Recommended Service Intervals.................................................................................................................................................................................................................8 Record Your Settings........................................................................................................................................................................................................................................8 Torque Values.....................................................................................................................................................................................................................................................8 Fluid Volume.......................................................................................................................................................................................................................................................8 LOWER LEG ASSEMBLY.......................................................................................................................................................................................9 50/200 Hour Service Lower Leg Removal..........................................................................................................................................................................................................................................9 50 Hour Service Lower Leg Service............................................................................................................................................................................................................................................ 11 200 Hour Service Lower Leg Seal Service................................................................................................................................................................................................................................. 12 AIR SPRING SERVICE.........................................................................................................................................................................................15 200 Hour Service Air Spring Removal......................................................................................................................................................................................................................................... 15 Air Spring Travel Change and Bottomless Tokens (optional)........................................................................................................................................................... 20 Solo Air Travel Options and Bottomless Token Tuning...................................................................................................................................................................... 20 Dual Position Air Travel Options and Bottomless Token Tuning..................................................................................................................................................... 20 Bottomless Token Installation (optional).................................................................................................................................................................................................. 21 Air Spring Installation.................................................................................................................................................................................................................................... 22 DAMPER SERVICE............................................................................................................................................................................................. 25 200 Hour Service Compression Damper Removal................................................................................................................................................................................................................. 25 Rebound Damper Removal......................................................................................................................................................................................................................... 26 Rebound Damper Installation..................................................................................................................................................................................................................... 29 Compression Damper Installation.............................................................................................................................................................................................................. 31 LOWER LEG ASSEMBLY.................................................................................................................................................................................... 33 50/200 Hour Service Lower Leg Installation................................................................................................................................................................................................................................... 33 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! E x p l o d e d V i e w - R C / D u a l Po s i t i o n A i r ™ ( D PA ) Air Shaft Assembly Compression Damper Assembly Air Valve Cap Knob Retaining Nut Steerer Tube Rebound Damper Assembly DPA Adjuster Knob DPA Top Cap Compression Adjuster Knob Compression Top Cap Bottomless Token™(s) Compression Damper Upper Tube Lower Leg DPA Piston Top Out Bumper Backup Ring Wave Spring Rebound Piston DPA Seal Head Retaining Ring Damper Seal Head Air Shaft Retaining Ring Rebound Damper Shaft Bottom Bolt Bottom Bolt Rebound Adjuster Knob Exploded View - RC/Dual Position Air™ (DPA) 5 Exploded View - RC/Solo Air™ (SA) Air Shaft Assembly Compression Damper Assembly Steerer Tube Air Valve Cap Rebound Damper Assembly SA Top Cap Compression Adjuster Knob Bottomless Token™(s) Compression Top Cap Compression Damper Upper Tube Lower Leg SA Piston Top Out Bumper Backup Ring Wave Spring Rebound Piston SA Seal Head Retaining Ring Damper Seal Head Retaining Ring Air Shaft Rebound Damper Shaft Bottom Bolt Bottom Bolt Rebound Adjuster Knob Exploded View - RC/Solo Air™ (SA) 6 RockShox Suspension Service We recommend that you have your RockShox® suspension serviced by a qualified bicycle mechanic. Servicing RockShox suspension requires knowledge of suspension components, as well as the use of specialized tools and lubricants. Visit www.sram.com/service for the latest RockShox Spare Parts catalog and technical information. For order information, please contact your local SRAM® distributor or dealer. For recycling and environmental compliance information, please visit www.sram.com. Information contained in this publication is subject to change at any time without prior notice. Your product's appearance may differ from the pictures contained in this publication. P a r t s , To o l s , a n d S u p p l i e s Parts Bicycle Tools • Yari™ Service Kit - 200 Hour • Bicycle stand Safety and Protection Supplies • Downhill bicycle tire lever • Apron • Schrader valve removal tool • Clean, lint-free rags • Shock pump • Nitrile gloves • Park Tool® AV-4 or AV-5 Axle and Spindle Vise Insert • Oil pan Common Tools • Safety glasses • 2, 3 and 5 mm hex wrenches Lubricants and Fluids • 2, 3 and 5 mm hex bit sockets • Isopropyl alcohol • 10 and 24 mm socket wrenches • Loctite® Threadlocker Blue 242® • 15 mm open end wrench • RockShox suspension oil 0W-30 • 15 mm crow foot wrench • RockShox suspension oil 5wt • Flat blade screwdriver • SRAM® Butter (grease) • Graduated cylinder (mL) RockShox® Tools • Large internal retaining ring pliers • RockShox Bleed syringe • Long plastic or wooden dowel • RockShox 35 mm dust seal installation tool • Needle nose pliers • Pick • Plastic or Rubber mallet • Socket wrench • Torque wrench 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 fork. NOTICE For the most effective access to the fork while servicing, clamp the fork steerer tube into a bicycle work stand. RockShox Suspension Service 7 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 or yearly 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 charts below to record your shock settings to return your shock to its pre-service settings. Record your service date to track service intervals. Rebound setting - count the number of clicks while turning the rebound adjuster fully counter-clockwise. Compression setting - count the number of clicks while turning the compression adjuster fully counter-clockwise. Part Tool Torque Top caps (spring and compression damper) 24 mm socket 28 N•m (250 in-lb) Compression knob screw 2 mm hex bit socket 1.2 N•m (10.6 in-lb) DPA knob retainer nut 10 mm socket 1.7-2.6 N•m (15-20 in-lb) Bottom bolts 5 mm hex bit socket 7.3 N•m (65 in-lb) Service Hours Interval Date of Service Air Pressure 50 100 150 200 To r q u e Va l u e s Fluid Volume Damper Side Upper Tube Fork Model Damper Technology Fluid Volume (mL) Spring Side Lower Leg Fluid Volume (mL) Upper Tube Spring Technology Fluid Volume (mL) Lower Leg Fluid Volume (mL) 0w-30 10 Solo Air Yari RC Motion Control 5wt 180 0w-30 10 Dual Position Air Grease Recommended Service Intervals 8 Lower Leg Assembly 50/200 Hour Service 1 Lower Leg Removal Remove the air valve cap from the top cap located on the spring side fork leg. SA DPA 2 Use a small hex wrench to depress the Schrader valve and release all air pressure from the air chamber. SA ⚠ 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. DPA 3 Remove the rebound adjuster knob by pulling it from the bottom bolt. 4 Use a 5 mm hex wrench to loosen both bottom bolts 3 to 4 turns. 5 mm Lower Leg Assembly 9 5 Place an oil pan beneath the fork to catch any draining oil. 5 mm Use a rubber mallet to firmly strike each bottom bolt to dislodge the air and damper shafts from the lower leg. Use a 5 mm hex wrench to remove the bottom bolts from the lower leg. 6 Firmly pull the lower leg downward until oil begins to drain. Continue pulling downward to remove the lower leg from the fork. If the lower leg does not slide off of the upper tubes or if oil does not drain from either side, the press fit of the shaft(s) to the lower leg may still be engaged. Reinstall the bottom bolts 2 to 3 turns and repeat the previous step. NOTICE Do not hit the fork arch with any tool when removing the lower leg as this could damage the fork. 200 Hour Service Go to Lower Leg Seal Service to continue with the 200 Hour Service. Lower Leg Removal 10 50 Hour Service Lower Leg Service 1 Remove the foam rings and clean them with isopropyl alcohol and a clean rag. 2 Soak the foam rings in RockShox® 0w-30 suspension oil. 3 Spray isopropyl alcohol on the inside and outside of the lower leg and wiper seals. 4 Install the foam rings back into the lower leg under the wiper seals. 50 Hour Service To continue with the 50 Hour Service, proceed to Lower Leg Installation. Lower Leg Service 11 200 Hour Service 1 Lower Leg Seal Service Place the tip of a downhill tire lever underneath the lower lip of the dust wiper seal. NOTICE If using a flat blade screwdriver, make sure it has a round shaft. A screwdriver with a square shaft will damage the fork leg. Wrap a rag around the screwdriver to protect the lower leg. 2 Stabilize the lower leg on a bench top or on the floor. Press down on the tire lever handle to remove the dust wiper seal. Repeat on the other side. Discard the dust seals after they are removed. NOTICE Keep the lower leg assembly 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. 3 Use your fingers to remove and discard the foam rings from the lower leg. 4 Soak the new foam rings in RockShox 0w-30 suspension oil. Lower Leg Seal Service 12 5 Spray isopropyl alcohol on the inside and outside of the lower leg. Clean the outside of the lower leg with a rag. Wrap a rag around a long dowel and insert it into each lower leg to clean the inside of the lower leg. 6 Install the new foam rings into the lower leg. 7 Remove the wire spring from the new dust wiper seal and set it aside. 8 Insert the narrow end of a new dust wiper seal into the recessed end of the RockShox® 35 mm dust seal installation tool. RockShox Dust Seal Installation Tool Lower Leg Seal Service 13 9 Hold the lower leg steady and use the RockShox® 35 mm dust seal installation tool to press the dust wiper seal evenly into the lower leg until the seal surface is flush with the top of the lower leg surface. Reinstall the wire spring onto the dust wiper seal. Repeat steps 7, 8, and 9 for the other side of the lower leg. NOTICE Only press the dust wiper seal into the lower leg until it is flush with the top surface of the lower leg. Pressing the dust wiper seal past the top surface of the lower leg can damage the foam rings. Lower Leg Seal Service 14 Air Spring Service 200 Hour Service Air Spring Removal 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 isopropyl alcohol on each part and clean with a rag. Apply SRAM® Butter grease to the new seals and o-rings. 1 Dual Position Air™: Use a 10 mm socket wrench to remove the DPA travel adjuster knob retaining nut. Remove the DPA travel adjuster knob. 10 mm Air Spring Service 15 2 Use a 24 mm socket wrench to remove the top cap from the upper tube. Spray isopropyl alcohol on the upper tube threads and clean the threads with a rag. 24 mm SA DPA 3 Use your fingers or a pick to remove the top cap o-ring. SA Use your fingers to install a new o-ring. Do not apply grease to the top cap threads. DPA Air Spring Removal 16 4 Dual Position Air™: Push the air shaft into the upper tube to prevent it from getting scratched while removing the retaining ring. NOTICE Scratches on the air shaft will allow air to bypass the seal head into the lower leg, resulting in reduced spring performance. Use a flat blade screwdriver to push the DPA seal head tab under the retaining ring. DPA Place the tips of large internal retaining ring pliers into the eyelets of the retaining ring. Press firmly on the pliers to push the seal head into the upper tube enough to compress and remove the retaining ring. DPA DPA Solo Air™: Use a flat blade screwdriver to push the SA seal head tab under the retaining ring. SA Place your finger over the end of the air spring shaft to prevent it from getting scratched while removing the retaining ring. SA NOTICE Scratches on the air shaft will allow air to bypass the seal head into the lower leg, resulting in reduced spring performance. Place the tips of large internal retaining ring pliers into the eyelets of the retaining ring. Press firmly on the pliers to push the SA seal head into the upper tube enough to compress and remove the retaining ring. Slide the retaining ring onto your finger and release the air spring shaft. SA Air Spring Removal 17 5 Use your fingers to install the bottom bolt into the air shaft. DPA Firmly pull on the shaft and bottom bolt to remove the air shaft assembly from the upper tube. Unthread and remove the bottom bolt from the air shaft. Clean and inspect the assembly for damage. DPA SA SA 6 Spray isopropyl alcohol on the inside and outside of the upper tube and clean it with a rag. Wrap a rag around a long dowel and insert it into the upper tube to clean inside the upper tube. 7 Remove the seal head, wave spring, and backup ring from the air shaft. Discard the seal head assembly and wave spring. SA NOTICE Do not install a new seal head at this time. The seal head will be replaced in the Installation section. DPA Air Spring Removal 18 8 Dual Position Air™: Use your fingers or a pick to remove the outer air piston o-ring. Use a pick to pierce and remove the inner o-ring. Discard the o-rings. DPA Use your fingers to install new o-rings. DPA Solo Air™: Use your fingers or a pick to remove the air piston quad ring, and discard it. Use your fingers to install a new quad ring. SA Air Spring Removal 19 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 in your RockShox® Yari™ fork, the air spring must be replaced with the correct length air spring shaft assembly. For example, to change a Yari with a maximum of 140 mm of travel to a maximum of 160 mm of travel, a 160 mm air spring shaft assembly must be installed. Fork travel can be identified at the bottom of the air spring shaft. Bottomless Tokens™ can be added to, or removed from, the Solo Air™ (SA) top cap or the Dual Position Air™ (DPA) air spring assembly to fine-tune the bottom-out feel and spring curve. Use the chart 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. Red (DPA) and grey (SA) Bottomless Tokens are compatible with all Yari forks. SA air spring shaft identification DPA air spring shaft identification Refer to the RockShox Spare Parts Catalog available on our website at www.sram.com/service for spare part kit details. For part ordering information, please contact your local SRAM® distributor or dealer. S o l o A i r Tr a v e l O p t i o n s a n d B o t t o m l e s s To k e n Tu n i n g 29"+ Wheel 27.5"+ / 29" / 29" Boost Wheel 27.5" / 27.5" Boost Wheel Fork Travel (etched on air shaft) Bottomless Tokens Factory Installed Maximum Bottomless Tokens Fork Travel (etched on air shaft) Bottomless Tokens Factory Installed Maximum Bottomless Tokens Fork Travel (etched on air shaft) Bottomless Tokens Factory Installed Maximum Bottomless Tokens - - - LYRIK/YARI 180 0 4 LYRIK/YARI 180 0 4 - - - LYRIK/YARI 170 1 4 LYRIK/YARI 170 1 4 LYRIK/YARI 160 2 5 LYRIK/YARI 160 2 5 LYRIK/YARI 160 2 5 LYRIK/YARI 150 2 5 LYRIK/YARI 150 2 5 LYRIK/YARI 150 2 5 LYRIK/YARI 140 3 6 LYRIK/YARI 140 3 6 LYRIK/YARI 140 3 6 LYRIK/YARI 130 3 6 LYRIK/YARI 130 3 6 LYRIK/YARI 130 3 6 LYRIK/YARI 120 4 7 LYRIK/YARI 120 4 7 LYRIK/YARI 120 4 7 LYRIK/YARI 110 5 7 - - - - - - LYRIK/YARI 100 5 7 - - - - - - D u a l P o s i t i o n A i r Tr a v e l O p t i o n s a n d B o t t o m l e s s To k e n Tu n i n g 29"+ Wheel 27.5"+ / 29" / 29" Boost Wheel 27.5" / 27.5" Boost Wheel Fork Travel (etched on air shaft) Bottomless Tokens Factory Installed Maximum Bottomless Tokens Fork Travel (etched on air shaft) Bottomless Tokens Factory Installed Maximum Bottomless Tokens Fork Travel (etched on air shaft) Bottomless Tokens Factory Installed Maximum Bottomless Tokens - - - - - - LYRIK/YARI 180 0 4 - - - - - - LYRIK/YARI 170 0 5 LYRIK/YARI 160 1 5 LYRIK/YARI 160 1 5 LYRIK/YARI 160 1 5 LYRIK/YARI 150 1 6 LYRIK/YARI 150 1 6 LYRIK/YARI 150 1 6 Air Spring Travel Change and Bottomless Tokens (optional) 20 B o t t o m l e s s To k e n I n s t a l l a t i o n ( o p t i o n a l ) Bottomless Tokens™ reduce the air volume in your fork to create greater ramp at the end of the fork travel. Add tokens to maintain your fork's bottomless feel. See Air Spring Travel Change and Bottomless Tokens for the maximum number of tokens for your fork. 1 Solo Air™: Thread a Bottomless Token into another token or into the the bottom of the top cap. Use an 8 mm hex wrench and a torque wrench with a 24 mm socket to tighten the token to 3.4-4.5 N•m (30-40 in-lb). 8 mm 3.4-4.5 N•m (30-40 in-lb) 24 mm 8 mm 3.4-4.5 N•m (30-40 in-lb) 24 mm Dual Position Air™: Install additional Bottomless Tokens onto the DPA air spring shaft, as desired. Bottomless Token Installation (optional) 21 200 Hour Service Air Spring Installation NOTICE 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 page 20 for details. Refer to the RockShox® Spare Parts Catalog available at www.sram.com/service for the required spare part kit kits. For part ordering information, please contact your local SRAM® distributor or dealer. 1 Apply a liberal amount of SRAM Butter to the air piston and seal head seals. SA DPA 2 Install the backup ring, a new wave spring, and a new seal head assembly, in that order, onto the air shaft. SA DPA 3 Apply a liberal amount of SRAM Butter grease to the seal head. SA DPA Air Spring Installation 22 4 Firmly push the air shaft assembly into the bottom of the upper tube while gently rocking the air shaft side to side. Make sure the shaft remains fully extended. DPA Use your thumbs or fingers to firmly press the seal head into the upper tube until it snaps into place. DPA SA SA 5 Use your fingers to position the retaining ring into the bottom of the upper tube retaining ring groove. The seal head tab should be positioned between the retaining ring eyelets. SA Place the tips of large internal 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. Use your finger or thumb to hold the retaining ring in place while seating the retaining ring eyelets on either side of the seal head tab. 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. DPA 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, then firmly pull down on the air shaft. 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. Air Spring Installation 23 6 Install the air spring top cap into the top of the upper tube and tighten with a 24 mm socket wrench. SA Use a torque wrench with a 24 mm socket to tighten the top cap to 28 N·m (250 in-lb). DPA 24 mm 7 Dual Position Air™: Place the DPA adjuster knob and the knob retaining nut onto the top cap with the long tab near the front of the crown. Turn the DPA adjuster knob counter-clockwise until it engages the first detent space. 28 N•m (250 in-lb) DPA Thread the knob retaining nut onto the threaded air valve body. Use a torque wrench with a 10 mm socket to tighten the knob retaining nut to 1.7-2.2 N•m (15-20 in-lb). DPA 10 mm 1.7-2.2 N•m (15-20 in-lb) Air Spring Installation 24 Damper Service 200 Hour Service Compression Damper Removal 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 isopropyl alcohol on each part and clean with a rag. Apply SRAM® Butter grease to new seals and o-rings. 1 Use a 2 mm hex wrench to remove the compression adjuster knob screw. Remove the compression adjuster knob. 2 mm 2 Use a 24 mm socket wrench to loosen the compression damper top cap. Remove the compression damper by pulling up firmly while gently rocking side to side. Clean the upper tube threads with a rag. 24 mm 3 Use your fingers or a pick to remove the compression damper top cap o-ring. Use your fingers to install a new top cap o-ring. Use your fingers or a pick to remove the compression damper piston u-cup seal. Use your fingers to install a new u-cup seal. Damper Service 25 200 Hour Service Rebound Damper Removal 1 Remove the fork from the bicycle work stand and pour the suspension oil into an oil pan. 2 Push the rebound damper shaft into the seal head to avoid scratching the shaft while removing the retaining ring. Use internal retaining ring pliers to remove the retaining ring from the bottom of the upper tube. NOTICE Do not scratch the rebound damper shaft. Scratches will allow oil to bypass the seal head into the lower leg resulting in reduced spring performance. 3 Thread the rebound damper shaft bolt onto the rebound damper shaft 2 to 3 turns. Hold the bolt and pull the rebound damper shaft out of the seal head. Pull and remove the rebound damper and seal head assembly from the upper tube. 4 Spray isopropyl alcohol on the inside and outside of the upper tube and clean it with a rag. Wrap a rag around a long dowel and insert it into the upper tube to clean inside the upper tube. Rebound Damper Removal 26 5 Insert the rebound adjuster knob into the rebound damper shaft end and turn it counter-clockwise until it stops. This is the full-open position (fastest rebound damping). Remove the knob. NOTICE The rebound damper must be in the full-open position before the piston is removed. Failure to do so will cause damage to the rebound damper internals during piston removal. 6 The Yari™ rebound damper seal head cannot be removed from the end of the damper shaft. The rebound piston must be removed first. 15 mm Clamp the bottom of the rebound damper shaft into the 9/16" opening of a Park Tool® AV-4 or AV-5 aluminum axle and spindle vise insert. NOTICE Clamp the damper at the bottom of the shaft, near the threaded shaft bolt insert to avoid scratching or damaging the shaft. Use a 15 mm open end wrench and remove the rebound damper piston. Remove the seal head. Spray isopropyl alcohol on the rebound damper shaft and clean it with a rag. Inspect the shaft for scratches. If scratched, replace the rebound damper assembly. 7 Use your fingers or a pick to remove the outer seal head o-ring. Use a pick to pierce and remove the inner seal head shaft scraper seal. Use your fingers to install a new outer seal head o-ring and inner seal head wiper seal. Rebound Damper Removal 27 8 Use your fingers or a pick to remove the glide ring from the rebound damper piston. Use your fingers to install a new glide ring. Rebound Damper Removal 28 200 Hour Service 1 Rebound Damper Installation Install the seal head onto the rebound damper shaft with the flat end facing the rebound damper piston. Add a small drop of Loctite® Threadlocker Blue 242® to the rebound damper piston threads. Use your fingers to thread the rebound damper piston onto the rebound damper shaft. 15 mm 2.4-4 N•m (21.2-35.4 in-lb) Use a torque wrench with 15 mm crow foot wrench and tighten to 2.4-4 N•m (21.2-35.4 in-lb). 2 Insert the rebound damper piston into the bottom of the upper tube at an angle with the side opposite the glide ring entering first. Continue to angle and rotate the piston until the glide ring is in the upper tube. 3 Use your thumbs to push the rebound seal head into the upper tube until the retaining ring groove is visible. Rebound Damper Installation 29 4 Push the rebound damper shaft into the upper tube to prevent it from getting scratched while installing the retaining ring. Place the tips of the internal retaining ring pliers into the eyelets of the retaining ring and install the retaining ring into the groove. NOTICE Do not scratch the rebound damper shaft. Scratches will allow oil to bypass the seal head into the lower leg resulting in reduced spring performance. 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. Retaining rings have a sharper-edged side and rounder-edged side. Installing retaining rings with the sharper-edged side facing the tool will allow for easier installation and removal. 5 Pull the rebound damper shaft out to the fully extended position. Rebound Damper Installation 30 200 Hour Service 1 Compression Damper Installation Pour 180 mL RockShox® 5wt suspension oil into the damper side upper tube. NOTICE Suspension oil volume is critical. Too much suspension oil reduces available travel. Too little suspension oil decreases damping performance. 5wt 2 Turn the compression valve at the bottom of the compression damper to the open position. 3 Insert the compression damper into the upper tube. Press down slowly and rock side to side until the damper is installed. 4 Use a torque wrench with a 24 mm socket to tighten the compression top cap to 28 N•m (250 in-lb). 24 mm 180 mL 28 N•m (250 in-lb) Compression Damper Installation 31 5 Install the compression adjuster knob with the large tab toward the front of the crown (open position). 2 mm 1.2 N•m (10.6 in-lb) Use a torque wrench with a 2 mm hex bit socket to tighten the low speed compression adjuster knob retaining screw to 1.2 N•m (10.6 in-lb). Compression Damper Installation 32 Lower Leg Assembly 50/200 Hour Service Lower Leg Installation 1 Spray isopropyl alcohol on the upper tubes and clean them with a rag. 2 Apply a liberal amount of SRAM® Butter grease to the inner surfaces of the dust wiper seals. 3 Slide the lower leg assembly onto the upper tube assembly just enough to engage the upper bushing with the upper tubes. The lower leg bottom should not contact the spring or damper shaft. Make sure both dust wiper seals slide onto the tubes without folding the outer lip of either seal. 4 Position the fork at a slight angle with the bottom bolt holes oriented upward. Angle the syringe fitting into each lower leg bolt hole so the oil will only contact the inside of the lower leg and not fill the shaft. Using a RockShox® bleed syringe, inject 10 mL of RockShox 0w-30 suspension oil into the damper side leg, and 10 mL of RockShox 0w-30 suspension oil into the spring side leg shaft holes. NOTICE Do not exceed the recommended oil volume per leg as this can damage the fork. Lower Leg Oil Volume Spring Side 10 mL Damper Side 10 mL 0w-30 10 mL Lower Leg Assembly 33 5 Slide the lower leg assembly along the upper tubes until it stops and the spring and damper shafts are visible through the lower leg bolt holes. Use a rag to clean all excess oil from the outer surface of the lower leg. 6 Use a pick and needle nose pliers to remove the old crush washers from each bottom bolt. Hold the crush washer with needle nose pliers and unthread the crush washer from the bolt by turning the bolt counter-clockwise with a 5 mm hex wrench. NOTICE Dirty or damaged crush washers can cause leaks. Install a new crush washer on each bottom bolt. 7 Use a 5 mm hex wrench to install the black bottom bolt into the spring side lower leg. Use a 5 mm hex wrench to install the red bottom bolt into the damper side lower leg. 5 mm 7.3 N•m (65 in-lb) Use a torque wrench with a 5 mm hex bit socket to tighten each bolt to 7.3 N·m (65 in-lb). 5 mm Lower Leg Installation 34 8 Install the rebound adjuster knob onto the rebound damper bottom bolt. Press the knob firmly onto the bolt. 9 Refer to the air chart on the fork lower leg and pressurize the air spring to the appropriate pressure for your rider weight. You may see a drop in the indicated air pressure on the pump gauge while filling the air spring; this is normal. Continue to fill the air spring to the recommended air pressure. NOTICE Pressure in the positive and negative air chambers must be equalized after inflation to get an accurate pressure reading. Cycle the fork three to five times and re-check the pressure. Add air pressure as needed. 10 Thread the air valve cap onto the top cap of the spring side fork leg until it stops. SA DPA 11 Spray isopropyl alcohol on the entire fork and clean it with a rag. This concludes service for the RockShox® Yari™ front suspension fork. This publication includes trademarks and registered trademarks of the following companies: Loctite® and 242® are regsistered trademarks of Henkel Corp. Park Tool® is a registered trademark of Park Tool Co. www.sram.com ASIAN HEADQUARTERS SRAM Taiwan No. 1598-8 Chung Shan Road Shen Kang Hsiang, Taichung City Taiwan R.O.C. WORLD HEADQUARTERS SRAM LLC 1000 W. Fulton Market, 4th Floor Chicago, Illinois 60607 USA EUROPEAN HEADQUARTERS SRAM Europe Paasbosweg 14-16 3862ZS Nijkerk The Netherlands
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : Yes Language : en-US Tagged PDF : Yes XMP Toolkit : Adobe XMP Core 5.6-c137 79.159768, 2016/08/11-13:24:42 Instance ID : uuid:e0e2678c-db29-4eef-ad3f-70b4293342ed Original Document ID : adobe:docid:indd:303193db-afcc-11df-9ad9-821d9825a548 Document ID : xmp.id:2a422c13-bff7-3347-b05c-0de8ef1320da Rendition Class : proof:pdf Derived From Instance ID : xmp.iid:c1d6e1a0-34c5-f745-b5d5-e6176b7e262b Derived From Document ID : xmp.did:4e5d0a08-a51a-2a45-b8b2-b3725633223a Derived From Original Document ID: adobe:docid:indd:303193db-afcc-11df-9ad9-821d9825a548 Derived From Rendition Class : default History Action : converted History Parameters : from application/x-indesign to application/pdf History Software Agent : Adobe InDesign CC 2017 (Windows) History Changed : / History When : 2016:12:15 08:25:24-07:00 Create Date : 2016:12:15 08:25:24-07:00 Modify Date : 2016:12:15 08:26:30-07:00 Metadata Date : 2016:12:15 08:26:30-07:00 Creator Tool : Adobe InDesign CC 2017 (Windows) Format : application/pdf Producer : Adobe PDF Library 15.0 Trapped : False Page Count : 37 Creator : Adobe InDesign CC 2017 (Windows)EXIF Metadata provided by EXIF.tools