2018 RockShox Lyrik Service - Manual Rev - D

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2018

Lyrik™ & Yari™


service
manual

GEN.0000000005295 Rev D
© 2018 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:
Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer
(e.g. United Kingdom).
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 Stripped threads/bolts (aluminium, Handlebar grips Transmission gears
Bushings titanium, magnesium or steel) Shifter grips Spokes
Air sealing o-rings Brake sleeves Jockey wheels Free hubs
Glide rings Brake pads Disc brake rotors Aero bar pads
Rubber moving parts Chains Wheel braking surfaces Corrosion
Foam rings Sprockets Bottomout pads Tools
Rear shock mounting Cassettes Bearings Motors
hardware and main seals Shifter and brake cables Bearing races Batteries
Upper tubes (stanchions) (inner and outer) Pawls

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.
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!
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 - LYRIK™ RCT3 - DEBONAIR™ (DA)......................................................................................................................................9


LYRIK RCT R........................................................................................................................................................................................................................................................9

EXPLODED VIEW - LYRIK RC - DUAL POSITION AIR™ (DPA).......................................................................................................................10


LYRIK RC R.........................................................................................................................................................................................................................................................10

EXPLODED VIEW - YARI™ RC - DEBONAIR (DA).............................................................................................................................................11

EXPLODED VIEW - YARI RC - DUAL POSITION AIR (DPA)...........................................................................................................................12

LOWER LEG REMOVAL AND SERVICE............................................................................................................................................................ 13


50/200 HOUR SERVICE
LOWER LEG REMOVAL.................................................................................................................................................................................................................................. 13
50 HOUR SERVICE
LOWER LEG SERVICE.................................................................................................................................................................................................................................... 15
200 HOUR SERVICE
LOWER LEG SEAL SERVICE......................................................................................................................................................................................................................... 17

AIR SPRING SERVICE........................................................................................................................................................................................ 20


200 HOUR SERVICE
AIR SPRING REMOVAL................................................................................................................................................................................................................................. 20
AIR SPRING TRAVEL CHANGE AND BOTTOMLESS TOKENS™ (OPTIONAL).............................................................................................................................. 25
DEBONAIR - TRAVEL AND BOTTOMLESS TOKEN TUNING - LYRIK............................................................................................................................................. 25
DEBONAIR - TRAVEL AND BOTTOMLESS TOKEN TUNING - YARI............................................................................................................................................... 25
BOTTOMLESS TOKENS INSTALLATION (OPTIONAL)........................................................................................................................................................................ 26
AIR SPRING INSTALLATION........................................................................................................................................................................................................................ 27

CHARGER 2™ DAMPER SERVICE - LYRIK....................................................................................................................................................... 33


200 HOUR SERVICE
DAMPER REMOVAL....................................................................................................................................................................................................................................... 33
DAMPER SERVICE.......................................................................................................................................................................................................................................... 35
DAMPER ASSEMBLY..................................................................................................................................................................................................................................... 39
DAMPER BLEED............................................................................................................................................................................................................................................... 41
TEST LOCKOUT.............................................................................................................................................................................................................................................. 44
DAMPER INSTALLATION.............................................................................................................................................................................................................................. 45

MOTION CONTROL™ DAMPER SERVICE - YARI............................................................................................................................................ 49


200 HOUR SERVICE
DAMPER REMOVAL....................................................................................................................................................................................................................................... 49
DAMPER SERVICE........................................................................................................................................................................................................................................... 51
REBOUND DAMPER INSTALLATION........................................................................................................................................................................................................ 53
COMPRESSION DAMPER INSTALLATION.............................................................................................................................................................................................. 55

LOWER LEG ASSEMBLY.................................................................................................................................................................................... 57


50/200 HOUR SERVICE
LOWER LEG INSTALLATION....................................................................................................................................................................................................................... 57
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/company/environment.

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/service.
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 rag. For hard to reach places (e.g. upper tube, lower leg), wrap
a clean, lint-free rag 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. Specified torque value in N·m (in-lb)
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.

RockShox® Service 5
P a r t s , To o l s , a n d S u p p l i e s
Parts Bicycle Tools
• RockShox® Lyrik™ or Yari™ 200 Hour Service Kit • Bicycle work stand
Safety and Protection Supplies • Cassette tool
• Apron • Downhill tire lever
• Clean, lint-free rags • Park Tool® AV-4 or AV-5 aluminum axle and spindle vise insert
• Nitrile gloves • Shock pump
• Oil pan Common Tools
• Safety glasses • Air compressor with air gun nozzle
Lubricants and Fluids • Bench vise and aluminum soft jaw inserts
• Isopropyl alcohol or RockShox Suspension Cleaner • Crowfoot: 15, 23 mm
• Loctite® Threadlocker Blue 242® • Flat blade screwdriver
• RockShox 0w-30 Suspension Oil • Hex bit sockets: 2, 2.5, 5 mm
• RockShox 3wt Suspension Oil (Lyrik) • Hex wrenches: 2, 2.5, 5 mm
• RockShox 5wt Suspension Oil (Yari) • Internal retaining ring pliers - large and small
• SRAM® Butter grease • Long plastic or wooden dowel
RockShox Tools • Needle nose pliers
• RockShox Bleed Syringe • Open end wrenches: 15, 23 mm
• RockShox Dust Seal Installation tool (35 mm) • Pick
• RockShox Shock Pump • Rubber or plastic mallet
• RockShox Top Cap/Cassette tool (3/8" / 24 mm) • Sockets: 13, 24 mm
• Socket wrench
• TORX® bit socket: T10
• TORX wrench: T10
• 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 suspension fork.

Parts, Tools, and Supplies 6


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.

Low Speed Compression


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

50

100

150

200

To r q u e Va l u e s

Part Tool Torque


Top caps 24 mm socket or 28 N•m (250 in-lb)
RockShox Top Cap/Cassette
Tool (or standard cassette tool)
Bottom bolts 5 mm hex bit socket 7.3 N•m (65 in-lb)
Bottomless Tokens™ 8 mm hex and 3.4-4.5 N•m (30 - 40 in-lb)
24 mm or RockShox Top Cap/
Cassette Tool (or standard
cassette tool)
Retaining nut - Dual Position Air™ adjuster knob 10 mm socket 1.7 - 2.2 N•m (15 - 20 in-lb)
Seal head - Charger 2™ rebound damper (Lyrik™) 23 mm crowfoot 5.1 N•m (45 in-lb)
Bleed screw - Charger 2 rebound damper seal head (Lyrik) T10 TORX® bit socket 1.1 - 2.3 N•m (10 - 20 in-lb)
Rebound damper piston (Yari™) 15 mm crowfoot 2.4 - 4.0 N•m (21 - 35 in-lb)
Set screw - remote cable stop clamp (Lyrik) 2 mm hex bit socket 0.25 - 0.6 N•m (2.2 - 5.3 in-lb)
Retaining screw - low speed compression adjuster knob and remote spool 2 mm hex bit socket 1.2 N•m (10 in-lb)
knobs (Lyrik)
Retaining screw - compression adjuster knob (Lyrik) 2 mm hex bit socket 1.2 N•m (10 in-lb)
Retaining screw - compression adjuster knob (Yari) 2 mm hex bit socket 1.2 N•m (10 in-lb)
Set screw - rebound adjuster knob (Lyrik) 2.5 mm hex bit socket 0.85 N•m (7.5 in-lb)

Recommended Service Intervals 7


Oil Volume and Lubricant

Damper Spring

Upper Tube Lower Leg Upper Tube Lower Leg

Model
Fork Model Damper Oil Spring
Year Oil Volume Oil Volume Oil Volume Oil Volume
Height*
Weight (mL) Weight (mL) Weight (mL) Weight (mL)
(mm)

RCT3

DebonAir™
RCT R

2018 Lyrik™ Charger 2™ 3wt - Bleed


Grease Air
RC 0w-30 10 0w-30 10
Dual Pistons
Position
Air™
RC R

Motion
2018 Yari™ RC 5wt 100-106 180 DebonAir
Control™

*Oil Height - Measure from the top of the crown (above the upper tube) down to the oil.
Consult the 2016-2017 Lyrik Service Manual at www.sram.com/service for Charger Damper™ technical specifications.

Oil Volume and Lubricant 8


Exploded View - Lyrik™ RCT3 - DebonAir™ (DA)

Air Spring Assembly


Steerer tube

Air cap Compression Damper


Knob retaining screw Assembly
Air valve
Low speed compression
adjuster knob Air spring top cap Rebound Damper
Crown Assembly
Compression mode
adjuster knob
Bottomless Token™
Compression
damper top cap
Compression damper

Bladder
Upper tube

Coupler

Cartridge tube Brake hose guide

Air spring piston

Top out bumper


Dust wiper seal
Foam ring
Air spring shaft

Rebound damper piston Retaining washer


Wave spring
Bleed port Air spring seal head

Rebound damper seal head Retaining ring

Rebound damper shaft

Lyrik RCT R
Lower leg
Retaining screw

Low speed
adjuster knob
Top cap seal
Cable set screw
Maxle™ Ultimate
Remote spool
Crush washer
Remote cable
stop collar Bottom bolt
Set screw
Crush washer

Bottom bolt

Rebound
adjuster knob

Exploded View - Lyrik™ RCT3 - DebonAir™ (DA) 9


E x p l o d e d V i e w - Ly r i k ™ R C - D u a l Po s i t i o n A i r ™ ( D PA )

Air cap Air Spring Assembly

Steerer tube Travel adjuster knob


Compression Damper
Air valve
Assembly
Knob retaining screw Air spring top cap
Rebound Damper
Assembly
Compression
adjuster knob Crown
Compression
damper top cap
Bottomless Token™
Compression damper

Upper tube
Bladder

Upper air spring shaft

Coupler

Cartridge tube

Brake hose guide

Dust wiper seal Air spring piston


Foam ring
Top out bumper

Retaining washer
Rebound damper piston Wave spring
Bleed port Air spring seal head
Retaining ring
Rebound damper seal head

Lower air spring shaft


Rebound damper shaft

Lyrik RC R
Lower leg
Spool retaining screw
Cable set screw
Remote spool

Remote cable
stop collar

Set screw
Crush washer

Maxle™ Stealth Bottom bolt

Crush washer

Bottom bolt

Rebound
adjuster knob
Exploded View - Lyrik™ RC - Dual Position Air™ (DPA) 10
E x p l o d e d V i e w - Ya r i ™ R C - D e b o n A i r ™ ( D A )

Steerer tube Air Spring Assembly

Air cap Compression Damper


Assembly
Knob retaining screw Air valve
Air spring top cap Rebound Damper
Compression Assembly
adjuster knob

Bottomless Tokens™
Compression
damper top cap

Crown

Upper tube

Compression damper

U-cup seal

Brake hose guide

Air spring piston

Top out bumper


Dust wiper seal
Foam ring

Rebound damper piston


Retaining washer
Wave spring
Rebound damper shaft Air spring seal head
Retaining ring

Rebound damper seal head


Lower leg
Retaining ring

Air spring shaft

Crush washer
Maxle™ Ultimate
Bottom bolt

Crush washer

Bottom bolt

Rebound
adjuster knob

Exploded View - Yari™ RC - DebonAir™ (DA) 11


E x p l o d e d V i e w - Ya r i ™ R C - D u a l P o s i t i o n A i r ™ ( D PA )

Air cap Air Spring Assembly

Steerer tube
Travel adjuster knob
Compression Damper
Air valve
Assembly
Retaining screw
Air spring top cap
Rebound Damper
Compression Assembly
adjuster knob
Crown
Compression
damper top cap
Bottomless Token™

Upper tube

Compression damper
Upper air spring shaft

U-cup seal

Brake hose guide

Air spring piston


Dust wiper seal
Foam ring Top out bumper

Rebound damper piston Retaining washer

Wave spring
Air spring seal head
Retaining ring

Rebound damper seal head

Retaining ring Lower air spring shaft

Rebound damper shaft


Lower leg

Crush washer

Maxle™ Stealth Bottom bolt

Crush washer

Bottom bolt

Rebound adjuster knob

Exploded View - Yari™ RC - Dual Position Air™ (DPA) 12


Lower Leg Removal and Service
50/200 Hour Service Lower Leg Removal
Remove the air valve cap.
1 Dual Position Air™

DebonAir™

Depress the Schrader valve and release all air pressure.


2 Dual Position Air

⚠ 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.

DebonAir

Turn the rebound adjuster knob counter-clockwise until it stops. This is


3 the full open/fast rebound setting.
2.5 mm Lyrik

Lyrik™: Loosen the rebound adjuster knob screw and remove the
rebound adjuster knob.
Yari™: Remove the rebound adjuster knob by pulling it from the bottom
bolt.

Yari

Lyrik

Lower Leg Removal and Service 13


Place an oil pan beneath the fork to catch the draining oil.
4 Damper Side
Loosen both bottom bolts 3 to 4 turns.

Spring Side

Strike each bottom bolt to dislodge the shafts from the lower leg on
5 each side. The bolt head should contact the bottom of the lower leg.
Spring Side

Remove each bottom bolt. Clean each bolt and set them aside.

Spring Side

Damper Side

Damper Side

Firmly pull the lower leg downward until fluid begins to drain. Continue
6 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 14


50 Hour Service Lower Leg Service
Remove the foam rings.
1

Clean the foam rings.


2

Isopropyl Alcohol

Soak the foam rings in RockShox® suspension oil.


3

0w-30

Lower Leg Service 15


Clean the inside and outside of the lower leg.
4
Clean the wiper seals.

Install the foam rings under the wiper seals.


5
Confirm the foam rings are installed evenly in the space under the
wiper seals and do not protrude over the bushings.

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

Lower Leg Service 16


200 Hour Service Lower Leg Seal Service
Remove and discard the foam rings.
1
Remove the outer wire springs from the dust wiper seals.

Stabilize the lower leg on a bench top. Place the tip of a downhill
2 tire lever under the wiper seal. Press down on the downhill tire lever
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.

Clean the inside and outside of the lower leg.


3

Lower Leg Seal Service 17


Soak the new foam rings in RockShox® suspension oil.
4
Install the new foam rings into the lower leg.

0w-30

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

Insert the narrow end of a new wiper seal into the recessed end of the
6 Dust Seal Installation tool.

RockShox 35 mm Dust Seal Installation Tool

Stabilize the lower leg on a bench top. Hold the lower leg steady and
7 press 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 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.

Lower Leg Seal Service 18


Install the outer wire springs.
8

Lower Leg Seal Service 19


Air Spring Service
Consult the 2016-2017 Lyrik Service Manual at www.sram.com/service for Solo Air™ service procedures.

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 isopropyl alcohol on each part and clean with
a clean lint-free rag.
Apply SRAM® Butter grease to the new seals and o-rings.

SRAM Butter

Dual Position Air™: Remove the travel adjuster knob retaining nut.
1
Remove the travel adjuster knob.

10 mm Dual Position Air

Air Spring Service 20


Remove the air spring top cap.
2 DebonAir™ Lyrik™
Clean the upper tube threads.

RockShox® Top Cap / Cassette Tool

DebonAir Yari™

24 mm

Dual Position Air™

24 mm

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

DebonAir

Dual Position Air

Dual Position Air

Air Spring Removal 21


Dual Position Air™: Push the air shaft into the upper tube to prevent it
4 from getting scratched while removing the retaining ring.
Push the seal head tab (A) into the upper tube and under the A
retaining ring.
Remove the retaining ring.

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.

Dual Position Air

Dual Position Air

Dual Position Air

DebonAir™: Firmly push the air shaft into the upper tube with your
thumb. Push the seal head tab (A) into the upper tube and under the
retaining ring.
Trapped negative air pressure creates increased resistance when
pushing the shaft in. Wear a thicker glove to protect your thumb if A
needed.

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.

DebonAir

Push the air shaft into the upper tube with your thumb. While holding DebonAir
the shaft in, remove the retaining ring. Slide the retaining ring onto your
thumb and carefully release the air spring shaft.

DebonAir

Air Spring Removal 22


Thread the shaft bolt into the end of the air spring shaft for added grip.
5 Dual Position Air
With the shaft pushed half way into the upper tube, quickly and firmly
pull the shaft out to remove the seal head and air spring assemblies
from the upper tube.
Remove the bolt.

Dual Position Air™

DebonAir

DebonAir™

Remove the seal head, wave spring, retaining washer, and top out
6 bumper from the air spring shaft.
Dual Position Air

Discard the seal head and wave spring.


Clean and inspect the shaft for damage.
Clean the top out bumper.

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.

Dual Position Air

DebonAir

DebonAir

Air Spring Removal 23


Dual Position Air™: Remove the inner and outer air piston o-rings and
7 discard them. Clean the air piston.
Dual Position Air

Apply grease to new o-rings and install them.

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

Dual Position Air

DebonAir™: Remove the quad ring seal from the air piston and
discard it.
Clean the air piston.
Apply grease to a new quad ring seal and install it.

DebonAir

Clean the inside and outside of the upper tube.


8
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.

Air Spring Removal 24


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® Lyrik™ or Yari™ fork, the air spring must be replaced with the appropriate length air spring shaft
assembly. For example, to change a Lyrik with a maximum of 160 mm of travel to a maximum of 180 mm of travel, a 180 mm air spring shaft assembly
must be installed.
Bottomless Tokens can be added to, or removed from, the DebonAir™ (DA) 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.
Refer to the RockShox Spare Parts Catalog available at www.sram.com/service for spare part kit details.
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 - Ly r i k

29" BOOST™ 27.5" BOOST

Bottomless Tokens Bottomless Tokens Bottomless Tokens Bottomless Tokens


Fork Travel Fork Travel
Factory Installed Maximum Factory Installed Maximum

180 0 4 180 0 4

170 1 4 170 1 4

160 2 5 160 2 5

150 2 5 150 2 5

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 - Ya r i

29" BOOST 27.5" BOOST

Bottomless Tokens Bottomless Tokens Bottomless Tokens Bottomless Tokens


Fork Travel Fork Travel
Factory Installed Maximum Factory Installed Maximum

180 0 4 180 0 4

170 1 4 170 1 4

160 2 5 160 2 5

150 2 5 150 2 5

D u a l P o s i t i 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 - L y r i k a n d Ya r i

29" BOOST 27.5" BOOST

Fork Travel Fork Travel Bottomless Tokens Bottomless Tokens Fork Travel Fork Travel Bottomless Tokens Bottomless Tokens
(Lyrik) (Yari) Factory Installed Maximum (Lyrik) (Yari) Factory Installed Maximum

180 180 0 4 180 180 0 4

170 170 0 5 170 170 0 5

160 160 1 5 160 160 1 5

- 150 1 6 150 150 1 4

Air Spring Travel Change and Bottomless Tokens™ (optional) 25


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 tokens to tune your fork's bottomless feel.
See Air Spring Travel Change and Bottomless Tokens for the maximum number of Tokens for your fork.

DebonAir™: Thread a Bottomless Token into another Bottomless Token,


or into the the bottom of the top cap, and tighten.

8 mm 3.4-4.5 N•m (30-40 in-lb) 24 mm or Top Cap / Cassette Tool

8 mm 3.4-4.5 N•m (30-40 in-lb) 24 mm or Top Cap / Cassette Tool

Dual Position Air™: Install Bottomless Tokens onto the DPA air spring
shaft, as desired.

Bottomless Tokens™ Installation (optional) 26


200 Hour Service Air Spring Installation
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 available at www.sram.com/service for the required spare part kits. For part ordering information, please
contact your local SRAM® distributor or dealer.

Apply a liberal amount of grease to the inside of the upper tube, from
1 the end of the tube to approximately 60 mm into the tube.

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


2 Dual Position Air™

DebonAir™

Apply grease to the new seal head inner o-ring and wiper seal.
3 Dual Position Air

DebonAir

Air Spring Installation 27


Install the top out bumper onto the shaft.
4 DebonAir
Install the retaining washer/backup ring, a new wave spring, and the
new seal head assembly, in that order, onto the air shaft.

DebonAir™

Dual Position Air

Dual Position Air™

Apply grease to the air piston and seal head outer o-rings/seals.
5

DebonAir

Dual Position Air

Air Spring Installation 28


Insert the air spring assembly into the upper tube. Firmly push the air
6 piston into the upper tube.
DebonAir

Position the flat retaining washer (A) into the upper tube, followed by
the wavy washer (B). A
Use your fingers to firmly press the seal head into the upper tube until
it stops.

B
DebonAir™

DebonAir

Dual Position Air


A

Dual Position Air™

Dual Position Air

Air Spring Installation 29


Retaining rings have a sharper-edged side and a rounder edged side.
7 Installing retaining rings with the sharper-edged side facing the tool
DebonAir

will allow for easier installation and removal.


DebonAir™: Guide the retaining ring with your finger to prevent
scratching the air shaft.
Dual Position Air™: Push the air shaft into the upper tube to prevent it
from getting scratched while installing the retaining ring.
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.
Hold the retaining ring in place and seat the retaining ring eyelets A
on either side of the seal head tab (A). The seal head tab should be DebonAir
positioned between the retaining ring eyelets.
Confirm the retaining ring is properly seated in the retaining ring DebonAir

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.

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.

DebonAir

Dual Position Air

Dual Position Air

Dual Position Air

Air Spring Installation 30


Dual Position Air™: Thread a bottom bolt onto the shaft 2 to 3 turns and
8 pull the shaft out until it stops.
Remove the bolt.

Dual Position Air

Dual Position Air: Apply a liberal amount of grease to the top cap
9 upper air spring shaft.

Dual Position Air

Install the air spring top cap into the upper tube and tighten it.
10 24 mm 28 N•m (250 in-lb)

Dual Position Air

24 mm or Top Cap Tool 28 N•m (250 in-lb)

DebonAir™

Air Spring Installation 31


Dual Position Air™: Place the adjuster knob onto the top cap with the
11 long tab near the back of the crown. Turn the adjuster knob counter-
Dual Position Air

clockwise until it engages the first detent space.


Thread the knob retaining nut onto the threaded air valve body and
tighten the knob retaining nut.

Dual Position Air

10 mm 1.7-2.2 N•m (15-20 in-lb)

200 Hour Service To continue with Lyrik™ damper service, go to Charger 2™ Damper Service.
200 Hour Service To continue with Yari™ damper service, go to Motion Control™ Damper Service.

Air Spring Installation 32


Charger 2™ Damper Service - Lyrik™
Consult the 2016-2017 Lyrik Service Manual at www.sram.com/service for Charger Damper™ service procedures.

200 Hour Service Damper Removal


The compression damper must be in the full open position in order to
1 perform bleed procedure.
RCT3 Compression Mode

RCT3: Turn the compression adjuster knobs counter-clockwise, to the


full open position, until they stop.

RCT3 Low Speed

RCT R: Turn the low speed compression adjuster knob counter-


clockwise, to the full open position, until it stops.

RCT R Low Speed

RC: Turn the compression adjuster knob counter-clockwise, to the full


open position, until it stops.

RC

Remove the knob retaining screw.


2 2 mm RC / RC R

2 mm RCT3 / RCT R

Charger 2™ Damper Service - Lyrik™ 33


RCT R / RC R: Loosen the remote cable stop collar set screw and
3 remove the collar.
RCT R

2 mm RCT R

RC R

2 mm RC R

RCT R: Remove the low speed knob/remote spool assembly.


4 RC R
RC R: Remove the remote spool.

RCT R

Unthread the damper top cap and remove the Charger 2™ damper
5 assembly.
24 mm RCT R / RC R

Clean the upper tube threads.

RockShox® Top Cap Tool RCT3 / RC

Damper Removal 34
200 Hour Service Damper Service
Remove the o-ring from the top cap. Clean the top cap threads and
1 o-ring groove. Apply grease to a new o-ring and install it.

Clamp the cartridge tube wrench flats in a vise with flat soft jaw inserts,
2 with the rebound damper oriented upwards.
Wrap a rag around the cartridge tube to absorb oil.

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

23 mm

Remove the seal head from the rebound damper shaft and discard it.
4

Damper Service 35
Remove the glide ring from the rebound damper piston. Install a new
5 glide ring.

Apply grease to the new rebound damper seal head seals.


6

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

Remove the bleed screw from the seal head.


8

T10

Damper Service 36
Remove the cartridge tube from the vise and pour the oil into an
9 oil pan.
Squeeze the bladder to drain the oil from the compression damper
assembly into an oil pan.

Clamp the cartridge tube, on the bladder coupler wrench flats, back
10 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.

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

Damper Service 37
Dry the cartridge tube and compression damper assembly with
12 compressed air.

Air Compressor and Air Gun Nozzle

Damper Service 38
200 Hour Service Damper Assembly
Clamp the cartridge tube wrench flats lightly into the vise and soft jaw
1 inserts. Wrap a rag around the tube to absorb any oil.
Pour RockShox® 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 full.

3wt

The rebound damper must be in the full open/fastest rebound setting


2 before installation.
Insert the rebound adjuster knob 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 39
Insert the rebound damper piston slowly into the cartridge tube and
3 thread the sealhead into the tube.

Tighten the seal head.


23 mm 5.1 N·m (45 in-lb)

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

Damper Assembly 40
Damper Bleed
Draw 3wt RockShox® suspension oil into a RockShox Bleed syringe
1 until it is half full.
Hold the syringe upright, cover the tip with a rag, and gently depress
the plunger to purge any air bubbles from the syringe.

NOTICE
Only use a RockShox bleed syringe.
Do not use syringes that have been in contact with DOT brake fluid.
DOT brake fluid will permanently damage the seals and will cause the
fork to malfunction.

3wt RockShox Bleed Syringe

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

Push the rebound damper shaft into the cartridge tube while applying
3 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 41
Fully extend the rebound damper shaft. Push the syringe plunger
4 down, then release the plunger. Allow the bladder to expand and
retract until it stops in a resting position.

Unthread the syringe bleed fitting from the bleed port.


5
⚠ CAUTION - EYE HAZARD
Oil may eject from the bleed port if the bladder is not in a resting
position. Wear safety glasses.

Install the bleed screw and tighten it.


6 T10 1.1-2.3 N·m (10-20 in-lb)
Wipe away any excess oil.

T10

Damper Bleed 42
Cycle the rebound shaft a few times.
7
Remove the bottom bolt and clean the Charger 2™ damper assembly.

Damper Bleed 43
Te s t L o c k o u t
RCT3 / RCT R: Rotate the compression cam clockwise until it stops, to
1 the locked out position.
RCT R / RC R: Use the 13 mm wrench to hold the cam locked out while
compressing the damper.
Push down on the damper assembly to test the bleed.
RCT3 / RCT R: The rebound damper shaft should not move more than
2 mm. If the shaft moves more than 2 mm while locked out, repeat the
bleed process. If the bleed was successful, rotate the compression cam
counter-clockwise until it stops, to the unlocked position.
RC / RC R: Consistent resistance should be felt with no gaps in
movement.
13 mm

Test Lockout 44
200 Hour Service Damper Installation
Install the Charger 2™ damper assembly into the damper side upper
1 tube. Thread the top cap into the upper tube.

24 mm RCT R / RC R

Top Cap / Cassette Tool RCT3 / RC

Tighten the top cap.


2

Top Cap / Cassette Tool 28 N·m (250 in-lb) RCT3 / RC

24 mm 28 N·m (250 in-lb) RCT R / RC R

Damper Installation 45
3a RCT3: Install the compression mode adjuster knob onto the top cap
with the tab in the forward, unlocked position.

RCT3

Install the low speed compression adjuster knob onto the hex
2 mm 1.2 N·m (10 in-lb)
adjuster rod.
Install and tighten the retaining screw.

RC: Install the compression adjuster knob onto the top cap with the tab
in the forward, unlocked, position.

RC

Install and tighten the retaining screw.

2 mm 1.2 N·m (10 in-lb)

Damper Installation 46
3b RCT R: Install the cable stop collar with the housing guide in the 6
o'clock forward position, angled ≈20° degrees from center.

87°

20°
RCT R

Push the low speed adjuster knob spring retainer (A) in and push the
knob out of the remote spool.
Remove the top cap seal.
Clean each part.

Install the remote spool onto the hex adjuster with the spool cable set
screw oriented within the 87° range zone.
Install the knob seal.

Install the low speed adjuster knob onto the hex adjuster. Install and
2 mm 1.2 N·m (10 in-lb)
tighten the knob retaining screw.

Damper Installation 47
RC R: Install the cable stop collar with the housing guide in the
6 o'clock forward position, angled ≈20° degrees from center.

87°

RC R 20°

Install the remote spool onto the hex adjuster with the spool cable set 2 mm 1.2 N·m (10 in-lb)
screw oriented within the 87° range zone.
Tighten the spool retaining screw.

RCT R / RC R: Tighten the cable stop collar set screw.


4 2 mm 0.25 - 0.6 N·m (2.2 - 5.3 in-lb)
Consult the OneLoc™ user manual at www.sram.com/rockshox/
products/oneloc for cable and remote installation instructions.

2 mm 0.25 - 0.6 N·m (2.2 - 5.3 in-lb)

200 Hour Service Continue the 200 Hour Service with Lower Leg Installation.

Damper Installation 48
M o t i o n C o n t r o l ™ D a m p e r S e r v i c e - Ya r i ™
200 Hour Service Damper Removal
Turn the compression adjuster knob counter-clockwise, to the full open
1 position, until it stops.
Remove the retaining screw and remove the knob.

2.5 mm

Unthread the compression damper top cap.


2
Remove the compression damper by pulling up firmly and slowly, while
gently rotating the damper in a circular motion.

NOTICE
Do not force the damper out of the upper tube if there is resistance.
This can cause separation of the piston from the damper tube.

24 mm

Remove the fork from the work stand and pour the suspension oil into
3 an oil pan.

Clamp the fork into the work stand.


4
Push the shaft into the upper tube to avoid scratching the shaft while
removing the retaining ring. Remove the retaining ring.

Motion Control™ Damper Service - Yari™ 49


Thread the bottom bolt into the damper shaft 2-3 turns.
5
Remove the rebound damper and seal head.

Clean the inside and outside of the upper tube.


6
Inspect the inside and outside of the upper tube for scratches.

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

Damper Removal 50
200 Hour Service Damper Service
Remove the compression damper top cap o-ring and piston u-cup seal.
1
Apply grease to the new o-ring and seal, and install them.

The Yari™ rebound damper seal head cannot be removed from the end
2 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.
Clean the rebound damper shaft and inspect it for scratches. If
scratched, replace the rebound damper assembly.

Remove the outer seal head o-ring and inner shaft scraper seal and
3 discard them.
Apply grease to the new o-rings and install them.

Damper Service 51
Remove the glide ring and discard it.
4
Install a new glide ring.

Damper Service 52
200 Hour Service Rebound Damper Installation
Install the seal head onto the rebound damper shaft with the flat end
1 facing the rebound damper piston.
Loctite Threadlocker Blue 242

Add a small drop of Loctite® Threadlocker Blue 242® to the rebound


damper piston threads.

Thread the damper piston onto the shaft and tighten it. 15 mm 2.4-4.0 N·m (21-35 in-lb)

Insert the rebound damper and seal head into the upper tube.
2
Push the seal head into the upper tube until the retaining ring groove
is visible.

Rebound Damper Installation 53


Push the rebound damper shaft into the upper tube to prevent it from
4
3 getting scratched while installing the retaining ring.
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.
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.

Pull the rebound damper shaft out to the fully extended position.
6
5

Rebound Damper Installation 54


200 Hour Service Compression Damper Installation
Pour RockShox® 5wt suspension oil into the upper tube.
1
NOTICE
Suspension oil volume is critical. Too much oil reduces available travel
and can damage the fork. Too little suspension oil decreases damping
performance.

5wt 180 mL

Use the compression adjuster knob to open the valve (A).


2
A closed compression valve will restrict oil flow during installation.

Insert the compression damper into the upper tube. Press down slowly
3 and rotate in a circular motion until the damper is installed.
Thread the top cap into the upper tube.

24 mm

Compression Damper Installation 55


Tighten the top cap.
4

24 mm 28 N·m (250 in-lb)

Install the adjuster knob with the tab in the 7-8 o'clock, unlocked
5 position.

RC

Install and tighten the retaining screw.

2 mm 1.2 N·m (10 in-lb)

200 Hour Service Continue the 200 Hour Service with Lower Leg Installation.

Compression Damper Installation 56


Lower Leg Assembly
50/200 Hour Service Lower Leg Installation
Clean the upper tubes.
1

Apply grease to the inner surfaces of the dust wiper seals.


2

Install the lower leg assembly onto the upper tubes and slide it just
3 enough to engage the upper bushings with the upper tubes.

NOTICE
Make sure both wiper seals slide onto the tubes without folding the
outer lip of either seal.

The inside bottom of the lower leg should not contact the spring or
damper shafts. A gap between the shaft ends and the lower leg bolt
holes should be visible.

Lower Leg Assembly 57


Position the fork at an angle with the bolt holes oriented upward.
4
Inject RockShox® 0w-30 suspension oil into each lower leg through the
bottom bolt holes.

NOTICE
Do not exceed the recommended oil volume per leg as this can
damage the fork.

0w-30 RockShox Bleed Syringe 10 mL

Slide the lower leg assembly toward the crown until it stops.
5

The spring and damper shafts should be visible through the bottom
bolt holes.
Verify each shaft is centered and seated in the lower leg shaft/bolt hole
and no gap is visible between the lower leg and the shaft end.

Lower Leg Installation 58


200 Hour Service Remove the old crush washers from each
6 bottom bolt.
5 mm

Hold the crush washer with needle nose pliers and unthread it from the
bolt by turning the bolt counter-clockwise. Discard the crush washers.
Clean the bolts and install new crush washers.

NOTICE
Dirty or damaged crush washers can cause oil to leak from the fork.

Yari™

Lyrik

Lyrik™

Lyrik

Lyrik

Lower Leg Installation 59


Install the black bottom bolt into the spring side shaft.
7 5 mm 7.3 N·m (65 in-lb)
Install the silver or red bottom bolt into the damper side shaft.

5 mm Spring Side

5 mm 7.3 N·m (65 in-lb)

5 mm Damper Side

Lyrik™: Install the rebound damper knob and tighten the set screw.
8 2.5 mm 0.85 N·m (7.5 in-lb)
Do not over-tighten the set screw. Over-tightening will seize the
adjuster knob and it will not turn.
Yari™: Install the rebound adjuster knob and press it firmly onto the bolt.
Refer to your pre-service recorded rebound setting to adjust the
rebound damping.

Lyrik

Yari

Lower Leg Installation 60


Refer to your pre-service recorded settings, or use the air chart on the
9 fork's lower leg, and pressurize the air spring.
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.
Cycling the fork will equalize the positive and negative air chambers.
After the fork is cycled 3-4 times, check the pressure and add air as
needed.

Install the air valve cap.


Dual Position Air™

DebonAir™

Clean the entire fork.


10

This concludes the service of your RockShox® Lyrik™ or Yari™ suspension fork.

Lower Leg Installation 61


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

BOOST™ is a trademark owned by Trek Bicycle Corporation.


Park Tool® is a registered trademark of Park Tool Co.
TORX® is a registered trademark of Acument Intellectual Properties, LLC.
www.sram.com

ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS


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No. 1598-8 Chung Shan Road 1000 W. Fulton Market, 4th Floor Paasbosweg 14-16
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