1212

For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.rockshox.com. Contact your local distributor or visit the RockShox website at www.rockshox.com for ordering information. Information contained in this publication is subject to change at anytime without prior notice. For the latest technical information, visit our website atwww.rockshox.com. Names used in this manual may be trademarks or registered trademarks of others. © SRAM Corporation • October 2003 PN 95.4308.711.000, Rev. A

BUSHING SERVICE GUIDE

Bushing Service Guide

W HY D O Y OU N EED

TO

R EPLACE Y OUR S USPENSION F ORK B USHINGS ?

Suspension fork bushings are considered a 'wear and tear' part and require regular replacement depending on frequencyof rdn,tranrde,rdrbd wih,ueo ds bae,adtetp o fr yurd. iig eri idn ie oy egt s f ic rks n h ye f ok o ie

S YM P TO M S
• Loose headset feel • Knocking noise when you ride

O F WO R N BUS HI N G S :

HOW

TO

CHECK

FOR

LOOSE BUSHINGS

1. Hold the front brake lever tight, and rock the bike back and forth. See fig. 1. 2. Wrap your fingers around the dust seal and upper tube area,and feel for the lower legs rocking on the upper tubes. See fig. 2. 3. Wrap your fingers/hand around the upper headset cup. Rock the bike back and forth and feel for a loose headset. If the headset is tight, check for loose disc brake pads if you ride disc brakes. See fig. 3. 4. Listen and feel for the lower legs rocking on the upper tubes.

1

2

3

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© SRAM Corporation • BUSHINGSERVICE GUIDE

Bushing Service Guide

TOOLS
• • • • • • •

AND

LUBRICANT NEEDED

Universal Bushing Installation Post and Plate kit (Judy/Pilot/SID/Duke/Psylo) 11.4306.352.000 Universal Bushing Removal Handle/Puller kit (All Forks) 11.4306.351.000 30mm Duke/Psylo Bushing Installation Sleeve Kit (Duke/Psylo) 11.4306.354.000 28mm Judy/Pilot/SID Bushing Installation Sleeve kit(Judy/Pilot/SID) 11.4307.498.000 Boxxer Bushing Installation Post and Plate Kit (Boxxer) 11.4306.353.000 Boxxer Bushing Installation Sleeve Kit (Boxxer) 11.4306.357.000 Dust Seal Installation Kit (All forks) 11.4308.585.000

4a

4b

PN 95.4308.711.000, REV. A

119

Bushing Service Guide S T A N D A R D S H O P T O O L S ( S EE
• • • • • • • • • • • •
FI G .

4 C)
• • •

L U B R I C A NT S ( SEE

FI G .

4 C)

Plastic Mallet Oil Pan Bike work stand Work bench with mounted vice 24mm Socket Wrench 22mm Socket Wrench (00-02 Boxxer) 10mm Socket Wrench (SID DualAir fork, 02 Duke Race, 02 Psylo Race) 5mm hex wrench Flat-head screw driver Shock Pump (Air forks only) Clean rags Oil mixing syringe

5wt Suspension Fork Oil Isopropyl Alcohol/Spray Bottle RedRum or 15wt suspension fork oil4c

P A R T K I T S N EE D E D JUDY / P I LO T / SI D
• • • • • • • Judy/Pilot/SID Dust Seal and Foam Ring Revive Kit (11.4307.250.000) Judy/Pilot/SID Bushing Revive Kit (11.4307.251.000)

D UKE / P S YLO
Duke/Psylo Dust Seal and Foam Ring Revive Kit (11.43407.298.000) Duke Bushing Revive Kit (11.4307.280.000) Psylo Bushing Revive Kit (11.4307.296.000)

B O X XE R
Boxxer Dust/Oil SealReplacement Kit (11.4307.312.000) Boxxer Bushing Replacement Kit (11.4305.621.000)

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© SRAM Corporation • BUSHING SERVICE GUIDE

Bushing Service Guide

F O R K D I S A S S E M B LY P R O C E D U R E S
SEE
THE APPROPRIATE COMPLETE SERVICE GUIDES FOR FORK DISASSEMBLY AND ASSEMBLY PROCEDURES.

D U S T SE A L R E MO V A L ( A LL

F O R K M O D EL S :

SI D

P I C T U R ED )1. Using a medium to large flat-head screwdriver, pry the old dust seal from the lower leg (fig. 5). 2. Remove the oil foam ring (fig. 6) 3. 2000 and 2001 Judy, SID, and Psylo forks feature an inner oil seal, located just below the dust seal. To remove this oil seal, use a flathead screwdriver to pry the seal from the lower leg. The improved current Samurai dust seal eliminates the need for the...