RockShox SID Dual Air Motion Control Remote Upgrade Kit Installation and Setup Guide

PLEASE READ THE SAFETY AND WARRANTY INFORMATION INSIDE

95.4012.220.000 Rev. B © SRAM Corporation, 2006

CONGRATULATIONS!

You have selected the 2006 SID Dual Air Motion Control Upgrade Kit! This manual contains important information for installation, set-up and adjusting your (1999-2006) SID Dual Air fork. To ensure that your SID fork performs properly, carefully follow each step. For more detailed disassembly, service and re-assembly information refer to the 2006 SID Service Guide at www.rockshox.com.

First, here is some information to get you started:

TOOLS NEEDED

• 24mm socket wrench
• Cable cutters
• 5wt suspension oil
• Hex wrenches (1.5mm, 2.0mm, 2.5mm, 3mm, 5mm)
• External snap ring pliers
• Safety glasses
• Grease
• Plastic mallet/hammer
• Clean rags

KIT CONTENTS

DAMPER

1. 2006 SID Motion Control compression damper, qty 1

REMOTE COMPRESSION ADJUST

2. Remote spool, qty 1
3. Remote torsion spring, qty 1
4. SID cable-stop clamp, qty 1
5. Poploc Remote lever assembly, qty 1
6. Shifter cable (not shown), qty 1
7. Cable housing (not shown), qty 1

STANDARD COMPRESSION ADJUST

8. Crown mount compression knob, qty 1
9. Detent ball bearing, qty 1
10. Detent spring, qty 1
11. Top cap detent pins, qty 2

OTHER

12. External knob retaining ring, qty 1
13. Shaft bolt/knob retainer clip/crush washer/retainer, qty 1
14. Aluminum Red Rebound Adjuster Knob, qty 1

PRIOR TO INSTALLATION

(This procedure can be performed with fork either mounted on bicycle, or removed from bicycle. This procedure involves installation with fork mounted on a bicycle.)

• Secure bicycle into bicycle work stand.
• Thoroughly clean your fork around the compression damper top cap and crown.
• Remove the rider's left handlebar grip, shifter and brake lever.
• Loosen stem and turn handlebars 90 degrees.
• Use a cable-tie, or similar, to secure handlebar to frame. This allows for easier access to fork.

1. REMOVAL - BLACKBOX REMOTE LEVER

If your SID Dual Air fork already has the BlackBox Pure Remote lever installed, remove before you begin this installation procedure.

A. Using a 3mm hex wrench, remove the BlackBox Remote lever assembly from handlebar.

2. REMOVAL - BLACKBOX REMOTE SPOOL

A. Using a 1.5mm hex wrench loosen the BlackBox Remote compression spool cable set-screw. Pull cable from spool and remove.

B. Using a 2.5mm hex wrench, loosen and remove the BlackBox Remote compression spool screw and remove spool from the compression damper hex adjuster rod. Remove spool torsion spring.

C. Using a 2mm hex wrench, loosen the cable stop-clamp screw.

D. Remove cable stop-clamp from top cap.

3. REMOVAL - STANDARD COMPRESSION/LOCKOUT KNOB

A. Using a 2.5mm hex wrench, loosen and remove the compression knob screw from the compression damper hex adjuster rod. Remove knob.

B. Remove the detent ball bearing and detent spring from top cap. A magnet works best.

4. REMOVAL - PURE COMPRESSION DAMPER

A. Remove external rebound adjuster knob from damper shaft bolt. Pull to remove.

B. Using a 5mm hex wrench, loosen the rebound damper shaft bolt 3-4 turns counterclockwise.

C. Remove negative air cap. Using a 10mm open end wrench, loosen Dual Air shaft nut. Unthread nut just past end of Dual Air spring shaft.

D. Using a plastic mallet, tap the shaft bolt and Dual Air shaft nut until you feel the shafts break free from the inside of the lower leg shaft bores. Remove both the shaft bolt and nut.

E. Firmly pull the lower leg assembly down, by holding each leg or the brake arch. Allow oil to drain from the lower legs and remove lower legs completely.

F. Remove the rebound damper shaft bottom-out bumper (right side on 2001-2003 models).

G. Using a 24mm socket wrench press down firmly and unthread compression damper top cap (counterclockwise). Pull damper assembly out of upper tube.

H. Holding the damper assembly over an oil pan, pull rebound damper seal head and rebound damper from damper tube. Pour oil into oil pan.

I. Using the external rebound adjuster knob, insert the hex into the bottom of the rebound damper and turn counterclockwise to open the rebound damper to the full open position. Place rebound damper (piston end) into a cup of 5wt suspension oil. Damper piston should be submerged in suspension oil.

J. Pull the compression damper/top cap out of the damper tube. Pour excess oil into oil pan.

5. INSTALLATION - MOTION CONTROL COMPRESSION DAMPER

A. Turn the hex adjuster rod counterclockwise to the full open position.

B. Place the gold floodgate adjuster knob back onto the compression damper and tighten with a 2mm hex wrench. Turn the floodgate adjuster knob counterclockwise until it stops. This is the full open position.

C. Coat the compression damper o-ring seals with grease. Insert the Motion Control compression damper assembly into either end of the damper tube and press in tightly.

D. Holding the damper tube with the open end of the tube facing up, pour 5wt suspension oil into the damper tube until the tube is approximately half-full. Tap the compression damper/damper tube assembly on a flat surface lightly to release any air bubbles that may be trapped inside the damper.

E. Pour additional 5wt suspension oil into damper tube until completely full.

F. Remove the rebound damper/seal head assembly from the oil container (remember, the rebound damper/seal head assembly should be submerged in oil). Wrap a rag around the damper tube to catch displaced oil. Insert the rebound piston into the damper tube slowly.

G. Slide the piston onto the damper tube. Insert the rebound damper seal head into the end of the damper tube and press firmly into place. IMPORTANT! Do NOT cycle the rebound damper into the damper tube. The compression damper is not secure in the damper tube until threaded into the upper and tightened with a socket wrench.

H. Apply grease to the bottom of the rebound damper seal head. Place seal head o-ring on bottom of seal head. This o-ring protects the seal head inside the upper tube.

I. Insert Motion Control damper assembly back into the upper tube, rebound shaft first. Guide the end of the rebound damper through the center of the threaded base retainer. Ensure the rebound damper shaft does not scrape the retainer. Slide the damper completely into the upper tube.

J. By hand, thread the compression damper top cap into the upper tube. Using a 24mm socket wrench, tighten to 60 in-lb.

6. INSTALLATION - LOWER LEGS

A. Slide the rebound damper shaft bottom-out bumper back onto the rebound damper shaft (SID Dual Air 2001-2003). Coat the inner surface with suspension oil to aid installation.

B. Install the lower leg assembly back onto bottom of upper tubes. Slide the lower legs up and engage just the lower bushings. You will feel the lower bushing touch the bottom of the upper tubes. At this point, slide the lower legs back down the upper tubes about and inch.

C. Invert the bicycle in the bicycle stand about 45 degrees. This will allow easy access when filling the bottom of lower legs with suspension oil.

D. Pour or inject (an oil mixing syringe works best) 10cc/ml of 15wt suspension oil into bottom of both lower leg shaft bolt holes. This provides bushing lubrication.

E. Pull the lower legs down onto upper tubes and guide the Dual Air spring shaft through the left side shaft hole. Guide the rebound damper shaft (right side) into the lower leg shaft hole bore.

F. Install the Dual Air threaded shaft nut onto Dual Air threaded shaft end. Hand-thread and tighten to 60in-lb with a 10mm open-end wrench.

G. Insert the NEW rebound damper shaft bolt (includes a steel c-ring on end of bolt) into rebound damper shaft end. Handthread and tighten to 60in-lb with a 5mm hex wrench.

H. Insert the NEW external rebound adjuster knob (red/aluminum) into the rebound damper shaft bolt. Push to snap onto bolt.

I. Install the negative air valve cover cap onto thread Dual Air shaft end. Inflate fork to correct air pressure, according to decal on the back of the lower leg, after final assembly.

7. INSTALLATION - MOTION CONTROL REMOTE ADJUST SPOOL

A. Using a 1.5mm hex wrench, loosen floodgate adjuster knob set screw. Remove the floodgate adjuster knob.

B. Using a 2.5mm hex wrench, loosen cable stop clamp screw. Place new cable stop clamp on to Motion Control top cap with cable stop positioned approximately 90 degrees forward, as pictured.

C. Turn compression spool adjuster shaft counterclockwise until it stops. This is the open position.

D. Place Motion Control blue Remote spool onto compression spool adjuster shaft (hex) and turn clockwise until it stops. This is the closed (lockout) position. The spool stop should be in the position pictured.

E. With one hand, hold Remote spool closed and rotate cable stop clamp counterclockwise with your free hand until cable stop touches blue Remote spool stop. The cable stop clamp should be loose enough to turn freely on the top cap hex detents.

F. Using a 2.5mm hex wrench, tighten the cable stop clamp screw.

G. Rotate Remote spool counterclockwise to the full open (unlocked) position. The set screw should be positioned in line with the ‘open’ mark on the cable stop clamp.

H. Remove Remote spool while compression adjuster rod is in open position. Apply grease to Remote spool torsion return spring. Grease will secure torsion spring in the Remote spool during installation.

I. Insert the torsion spring into the underside of the Remote spool, prong facing out (figs H & I).

J. Place the Remote spool and torsion spring back onto the compression damper adjuster hex. The torsion spring prong fits into one detent hole in the top cap.

K. The cable set screw in the Remote spool should be positioned in line with the alignment mark on the cable set screw.

L. Turn the Remote spool clockwise until spool-stop stops in the closed position against the cable stop's clamp stop If the stop on the Remote spool does not touch the stop on the cable stop clamp, rotate the clamp counterclockwise until the two stops touch.

M. Release the spool and test the return to the open position. If the spool does not return to the open position, repeat step J.

N. Secure the Remote spool with a new Remote spool retaining ring using external snap ring pliers.

O. Place the gold floodgate adjuster knob back onto the compression damper spool shaft. Tighten the floodgate adjuster knob set screw to flat surface of black adjuster rod with a 1.5mm hex wrench.

8. INSTALLATION - POPLOC REMOTE LEVER

A. Slide the PopLoc lever assembly onto handlebar in the desired position (inside or outside brake lever clamp) and tighten lightly with a 3mm hex wrench. Your final position/orientation should be confirmed when shifter, brake lever and grip are installed so you do not need to tighten completely at this point.

B. Re-install brake lever, shifter and grip onto handlebar. You may need to try various shifter and brake lever positions to determine the preferred position of the Remote lever. For example, PopLoc lever inside or outside of brake lever.

9. INSTALLATION - REMOTE CABLE (POPLOC LEVER TO COMPRESSION DAMPER)

A. Insert PopLoc shifter cable through cable stop clamp and position the cable housing into the stop. Thread the shifter cable through the small cable guide hole on the Remote spool.

B. Insert the end of the cable into the cable guide hole under the Remote spool cable set screw. Pull the shifter cable tight while rotating the Remote spool into the position as pictured.

C. Using a 1.5mm hex wrench, tighten the cable set screw and secure cable. Test the function of the PopLoc Remote lever and Remote spool.

D. Press the PopLoc open button and test the return to open position.

E. When in the `locked out', closed position, the Remote spool stop should touch the cable stop clamp, as pictured.

F. Adjust position of shifter, brake lever and PopLoc lever to desired positions and tighten according to manufacturer's recommended torque settings.

G. Install the gold floodgate adjuster knob back onto the compression damper adjuster shaft. Tighten with a 1.5mm hex wrench.

H. Cut excess cable and finish with a cable end cap.

10. OPTIONAL INSTALLATION - MOTION CONTROL COMPRESSION KNOB - STANDARD

A. Turn compression shaft (hex) fully clockwise until it stops. This is the closed, or lockout, position.

B. Place the standard adjust Motion Control compression knob on the damper hex adjuster, as shown. This is the lockout position where the knob stops when the damper is locked out.

C. Remove knob and note the location of the knob window (7-8 o'clock). This is where the first Stop Pin will need to be placed. Install Stop Pin 1 into top cap detent hole, as shown.

D. Install Stop Pin 2 and leave three detent holes empty, to the right of Stop Pin 1, as shown.

E. Install the detent spring and ball bearing into any of the four detent holes, opposite the range of motion of the knob window, as shown.

F. Install standard compression knob onto hex shaft with the window positioned directly over Stop Pin 1, as shown.

G. Rotate knob counterclockwise approximately 20 degrees and push the knob down firmly. Turn the knob left and right and feel for the stop points in the full open and full closed positions.

H. Using external snap ring pliers, install adjuster knob retaining clip. Check for secure fit.

I. Install the gold floodgate knob and tighten set screw with a 1.5mm hex wrench.

J. Turn both knobs and test function.

11. FINAL CHECK

A. Test the function of either the Remote compression adjuster spool and PopLoc Remote lever, or the standard crown-mount compression adjuster knob. Close the knob (clockwise), push on the fork. Then open the knob (counterclockwise), push on the fork. In the open position, the fork should have no compression damping resistance. In the closed position the fork should have a firm, to platform, resistance to compression force.

B. Check to ensure knob retaining ring is securely fit.

C. Re-install brake caliper (rim or disc). Secure disc brake hose/cable. Re-attache from wheel.

D. Turn handlebars back to center and tighten stem bolt(s) to manufacturer's recommended torque settings.

E. Re-adjust shifter, brake lever, and PopLoc and tighten. Re-install handlebar grip.

F. Wipe all excess oil or grease from fork.

SRAM CORPORATION WARRANTY

EXTENT OF LIMITED WARRANTY

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.

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.

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 thirdparty 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 technical installation manual. The SRAM installation manuals can be found online at www.SRAM.com, www.rockshox.com or www.avidbike.com.
• This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturer's specifications of 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.
• 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
• Stripped threads/bolts (aluminum, titanium, magnesium or steel)
• Upper tubes (stanchions)
• Brake sleeves
• Brake pads
• Chains
• Sprockets
• Cassettes
• Shifter and brake cables (inner and outer)
• Handlebar grips
• Shifter grips
• Jockey wheels
• Disc brake rotors
• Tools

• 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 authorized by SRAM for use with SRAM components.

SRAM Corporation

1333 North Kingsbury, 4th Floor, Chicago, Illinois 60622

1-312-664-8800 fax 1-312-664-8826

www.rockshox.com