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MTB 06SID SVC Guide Rev C HQ PDF
MTB 06SID SVC Guide Rev C HQ PDF
For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at
www.rockshox.com.
Information contained in this publication is subject to change at anytime without prior notice.
For the latest technical information, visit our website at www.rockshox.com.
Names used in this manual may be trademarks or registered trademarks of others.
· Perform service every 100 hours of riding (less depending on riding conditions and riding style).
· Regular maintenance ensures your RockShox suspension fork performs as it should.
· For bushing removal and installation, please reference the Bushing Service Guide.
· Right side equals rider’s right; left side equals rider’s left.
G E T T I N G S TA R T E D
1. Remove fork from bicycle.
2. Spray entire fork with isopropyl alcohol and wipe all dirt and mud from fork. Clean around dust seals and upper tubes.
3. Lay tools out on work bench and create a clean work area for internals service.
4. Place oil pan under fork on floor.
TOOLS
· Safety Glasses · 1.5mm, 2mm, 2.5mm, 5mm Hex Wrench
· Clean Rags · SID Dual Air Upr Tube Retainer
· Oil Pan or Bucket Removal Tool
· Bicycle Stand / Clean Work · Long and Short Plastic or Wood
Table/Area Dowel, 3/4" Diameter (non-metallic)
· 24mm 6-point Socket · Torque Wrench
· Plastic-Faced Mallet · Sharp Pick/Dental Pick
· Snap Ring Pliers (internal and external) · Oil Mixing Syringe & Measuring cup
· Shock Pump · Isopropyl Alcohol/Spray Bottle
· 5wt and 15wt Suspension Oil
L O W E R L E G R E M O VA L
PROCEDURES FOR 2006 SID RACE, TEAM AND WORLD CUP LOWER LEG AND DUAL AIR REMOVAL/INSTALLATION ARE THE
SAME FOR EACH MODEL. REFER TO THE 03-05 SID SERVICE GUIDE FOR SID RACE DAMPING INTERNALS SERVICE
PROCEDURES
1. TEAM/WORLD CUP: Remove air valve cover cap from left side air top cap (fig 1a).
2. Firmly pull external rebound adjuster knob from rebound damper shaft bolt (fig 2a).
3. With hex wrench in the rebound damper shaft bolt, tap the bolt free with plastic
mallet. Tap the Dual Air shaft nut and free the shaft from the lower leg internally. 3a 3b
You will feel the shaft release from the lower leg shaft bore (figs 3a/3b).
5. Spray isopropyl alcohol onto each upper tube and wipe with a clean rag.
S I D D U A L A I R S P R I N G A S S E M B LY
R E M O VA L
6. Verify all air pressure is removed from air chamber before proceeding. Depress schrader air valve again to remove any remaining air
pressure.
6a 6b 6c 6d
Using a 24mm socket wrench,
loosen air top cap assembly from
upper tube/crown (fig 6a).
7. Using the SID Dual Air upper tube retainer tool and an socket wrench, remove the threaded upper tube retainer. The retainer is
reverse-threaded, so turn wrench CLOCKWISE to unthread (fig 7a). ‘Righty, Loosey...Lefty, Tighty.’
PN 95.4311.776.000, REV C 3
2006 SID Service Guide
8. Spray the inside of the air spring upper tube with isopropyl
alcohol (fig 8a). Wrap a clean rag around a thin dowel, 8a 8b 8c
insert into upper tube and wipe the inside surface clean
(8b/8c).
Look inside the upper tube using a light and check for
scratches. If inside of upper tube is scratched, replace
CSU assembly. Scratches can cause air bypass.
D I S A S S E M B LY & S E R V I C E
PA R T KIT REQUIRED: SID S E R V I C E K I T (11.4310.703.000)
9. Slide the negative air piston sleeve from air spring shaft (fig
9a/9b). 9a 9b 9c
10. Pinch the positive and negative air piston o-rings and remove. Replace with new o-rings (figs 10a/10b).
IMPORTANT: REPLACEMENT OF AIR PISTON O-RINGS ENSURES THAT SID MAINTAINS A SOLID AIR SEAL. LUBRICATE ALL NEW
O-RINGS THOROUGHLY WITH SUSPENSION OIL OR OIL SOLUBLE GREASE BEFORE INSTALLATION.
11. Slide negative air spring sleeve back onto air spring shaft (figs 11a/11b).
11a 11b
ALL TRAVEL SPACER OPTION (DECREASE OR INCREASE TRAVEL)
Install one 20mm All Travel spacer to decrease travel from 80mm to 60mm.
Remove the 20mm All Travel spacer to increase travel from 60mm to 80mm.
A L L T R AV E L C O N F I G U R AT I O N S
THE SID DUAL AIR ALL TRAVEL SPACER IS LOCATED JUST ABOVE THE NEGATIVE SLEEVE TOP OUT
BUMPER. TO INSTALL, SLIDE NEGATIVE SLEEVE DOWN AND SNAP ALL TRAVEL SPACER ONTO AIR
20mm No
SPRING SHAFT TO DECREASE TRAVEL. Spacer Spacer
60mm 80mm
I N S TA L L AT I O N
12. Apply fresh 15wt suspension oil to new positive and
negative air piston o-rings (figs 12a/12b). 12a 12b 12c
13. Slide the negative air piston sleeve down air spring shaft and into bottom of upper
tube (fig 13a). Continue to slide entire negative air spring sleeve into upper tube. 13a 13b
You may need to press the negative schrader air valve as you push the negative
sleeve into upper tube to release air pressure. This aids installation.
By hand, thread the air spring assembly threaded base retainer into upper tube
(fig 13b). This part is reverse threaded, so turn counterclockwise to thread into
upper tube.
14. Using the SID Dual Air upper tube retainer tool and a socket wrench, press into retainer firm and square
and tighten the threaded upper tube/base retainer to 30 in-lb (fig 14). 14
TIP: EVERY MONTH, RELEASE ALL POSITIVE AND NEGATIVE AIR PRESSURE AND REMOVE AIR TOP CAP.
POUR OUT ANY REMAINING SUSPENSION OIL FROM POSITIVE AIR CHAMBER AND REFILL WITH 3 TO 5
CC/ML OF FRESH 15WT SUSPENSION OIL. THIS REDUCES AIR SPRING SERVICE INTERVALS AND IMPROVES
THE FUNCTION OF YOUR FORK.
16. Clean the air top cap and upper tube threads with a clean
rag. 16a 16b 16c
PN 95.4311.776.000, REV C 5
2006 SID Service Guide
S I D M O T I O N C O N T R O L D A M P I N G A S S E M B LY ( S I D T E A M / W O R L D C U P )
THE 2006 SID MOTION CONTROL COMPRESSION DAMPER IS COMPATIBLE WITH THE PURE DAMPING SYSTEM. TO UPGRADE FROM PURE TO MOTION
CONTROL, FOLLOW STEPS 19-21, AND 27-44. KIT 11.4310.700.000 (SID DUAL AIR MOTION CONTROL UPGRADE KIT) REQUIRED.
R E M O VA L
17. Using a 2.5mm hex wrench
loosen and remove remote cable 17a 17b 17c 17d
stop clamp set screw (fig 17a and
17b).
19. Using a 24mm socket wrench loosen and unthread Motion Control compression top cap (fig 19a).
Pour all oil from damper tube into an oil pan (fig 20c).
21. Pull the Motion Control damper from the damper tube
using a slow twisting motion (figs 21a/21b). This assists 21a 21b
the damper out of the damper tube.
22. Spray isopropyl alcohol into the damper tube and clean inside surface with a dry clean rag. Use a dowel with the clean rag wrapped
around the end. Insert into damper tube and clean.
REBOUND DAMPER SERVICE
24. Using a sharp pick remove the inner and outer seal head o-rings and replace with
new o-rings (figs 24a/24b). 24a 24b
25. Slide rebound damper seal head back onto rebound damper
shaft (fig 25a). 25a 25b 25c
Using a 2.5mm hex wrench, or the rebound adjuster knob,
insert hex into rebound damper adjuster at bottom of
shaft, and turn counterclockwise to open rebound damper
valve (fig 25b). This allows oil to flow into the damper
valve when re-filling damper tube with suspension oil.
Insert rebound damper and seal head into a container of 5wt suspension oil (fig 25c).
Pinch and remove top cap o-ring (fig 26c). Replace with
new o-ring.
PN 95.4311.776.000, REV C 7
2006 SID Service Guide
29. Apply fresh 15wt suspension oil onto both the main piston o-ring and the IFP o-ring (figs 29a/29b).
30. Holding the damper tube with the open end of the tube
facing up, pour 5wt suspension oil into the damper tube 30a 30b 30c
until the tube is approximately half-full (fig 30a).
31. Pour additional 5wt suspension oil into damper tube until completely full (fig 31a).
31a 31b
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 (fig 31b). Slide the piston into the damper
tube (fig 31c).
Insert the rebound damper seal head into the end of the damper tube and press 31c 31d
firmly into place (fig 31d).
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.
32. Inside the damper side upper tube (right) is an o-ring that sits in between the Motion Control damper
tube/rebound seal head and the upper tube thread base retainer, ensure the o-ring is positioned flat on the 32
threaded upper tube base retainer.
If this o-ring came out with the damper tube assembly, apply a small amount of grease to the o-ring and
place it on the bottom of the rebound damper seal head (fig 32).
o-ring
33. Insert Motion Control damper assembly back into the upper tube, rebound shaft first (fig 33a). Guide the end of the rebound
damper through the center of the threaded base retainer. Be careful and do not allow the rebound damper shaft to scrape the
retainer.
33a 33b 33c 33d
Slide the damper completely into
the upper tube (fig 33b). By
hand, thread the compression
damper top cap into the upper
tube (fig 33c).
Turn the compression spool adjuster shaft counterclockwise until it stops. This is
the open position (fig 35b).
Place the remote spool onto the compression spool adjuster shaft (hex) and turn
clockwise until it stops (fig 35c). This is the closed (lockout) position. The spool
stop should be in the position pictured (fig 35c).
With one hand, hold the remote spool closed and rotate the cable stop clamp 35c 35d
counterclockwise with your free hand until the cable stop touches the remote spool
stop (fig 35d). The cable stop clamp should be loose enough to turn freely on the
top cap hex detents.
Using a 2.5mm hex wrench, tighten the cable stop clamp screw (fig 35e).
Rotate the 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 35e cable set-screw 35f
(fig 35f).
open-mark on cable
stop clamp
PN 95.4311.776.000, REV C 9
2006 SID Service Guide
Remove the remote spool while in the compression adjuster rod is in the open
position (fig 35g). 35g 35h
Apply a small amount of grease to the remote spool torsion return spring. Grease
will hold the torsion spring in the remote spool during installation. Insert the
torsion spring into the underside of the remote spool knob, with the prong facing
out (figs 35g & 35h).
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
(fig 35i). The cable set screw in the remote spool should be positioned in line with 35i 35j
the alignment mark on the cable set screw (fig 35j).
Turn the remote spool clockwise until spool-stop stops in the closed position
against the cable stop clamp stop (fig 35k) If the stop on the remote spool does
not touch the stop on the cable stop clamp, rotate the clamp counterclockwise until insert torsion spring
prong into top cap open-mark on cable
the two stops touch. stop clamp
detent hole
Release the spool and test the return to the open position.
35k 35l
Secure the remote spool with a new remote spool retaining ring using external snap
ring pliers (fig 35l).
36. Place the gold floodgate adjuster knob back onto the compression damper spool shaft.
36
Tighten the floodgate adjuster knob set screw to the flat surface of the black adjuster rod with a 1.5mm hex
wrench (fig 36).
S I D R E M O T E S P O O L / C A B L E S T O P C L A M P O R I E N TAT I O N
Torque to:
1.4 N-m +/- 0.2 N-m 5
Torque to:
1.0 N-m +/- 0.2 N-m 4
P O P L O C R E M O T E L E V E R / C A B L E I N S TA L L AT I O N
INSTALL THE POPLOC LEVER ASSEMBLY ONTO YOUR HANDLEBAR IN THE DESIRED ORIENTATION BEFORE CABLE INSTALLATION. THE
POPLOC LEVER SHOULD BE IN THE OPEN POSITION.
37a 37b
37. 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 (fig 37a).
Insert the end of the cable into the cable guide hole under the remote spool cable
set screw (fig 37b).
Pull the shifter cable tight while rotating the remote spool into the position as 37c 37d
pictured. Align the remote spool stop with the alignment mark on the cable stop pull cable
clamp (figs 37c & 37d).
Using a 1.5mm hex wrench, tighten the cable set screw and secure cable (fig 37d).
Test the function of the PopLoc remote lever and remote spool (fig 37e). alignment mark alignment mark
When in the ‘locked out’ (closed position) the remote spool stop should touch the 37e 37f
cable stop clamp, as pictured (fig 37f).
Press the PopLoc open button and test the return to open position.
UNLIKE STANDARD MOTION CONTROL COMPRESSION DAMPERS, THE 06 SID MOTION CONTROL COMPRESSION
DAMPER REMOTE RETURN SPRING IS NOT DESIGNED INTO THE DAMPER ASSEMBLY.
THE REMOTE POPLOC LEVER ADJUSTER CAN EITHER BE REMOVED FROM THE HANDLEBAR, OR SIMPLY REMOVE THE
CABLE/CABLE HOUSING AND LEAVE THE POPLOC LEVER ON YOUR HANDLEBAR, IF YOU CHOOSE TO INSTALL THE
REMOTE SPOOL IN THE FUTURE.
L O W E R L E G I N S TA L L AT I O N
38. Thoroughly clean the dust seals and upper bushing with a clean rag and isopropyl alcohol. Replace dust
seals and foam rings if worn or damaged. Refer to the ‘Bushing Service Guide’ for procedures at 38
www.rockshox.com.
Pour or inject 15wt suspension oil onto new or clean foam rings just under dust seal inside lower leg; each
side (fig 38). This provides additional lubrication during use.
PN 95.4311.776.000, REV C 11
2006 SID Service Guide
39. Invert fork in bicycle stand to a 45-degree angle, upper tubes facing up. Spray upper tubes with isopropyl alcohol and wipe with a
clean rag.
39a 39b 39c
Slide lower leg assembly over and onto the ends of each
upper tube. Ensure both dust seals slide onto the tubes
correctly and do not fold under (fig 39a).
41. Inspect and clean the rebound damper shaft bolt, Dual Air shaft nut and black nylon crush washers (fig 41).
Replace crush washers and crush washer retainer if damaged. Damaged or dirty crush washers can cause oil 41
to leak.
42. Slide lower leg assembly further down upper tubes until shaft ends are seated inside lower leg shaft holes. You may need to use a
small hex wrench or screw driver to guide the shaft ends into the holes (fig 42a)
Insert external rebound damper knob into rebound damper shaft bolt. Push into bolt to secure (fig 42d). Adjust as desired.
43. Spray entire fork with isopropyl alcohol and wipe down with a clean rag.
44. Inflate the positive (first) (fig 44a) and negative (second) (fig 44b) air chambers
with a shock pump to desired air pressures. See the air chart in this guide, or the 44a 44b
decal on the back of the fork lower leg for reference.
Thread both air valve cover caps back onto air top cap and negative air shaft.
AIR
AIR PRESSURE
RIDER WEIGHT POSITIVE (TOP) NEGATIVE (BOTTOM) NEGATIVE (BOTTOM)
(XC SETTING) (RACING SETTING)
<120 lb (54 kg) 70-80 psi 70-80 psi 40-60 psi
120-140 lb (54-64 kg) 80-100 psi 80-100 psi 60-80 psi
140-160 lb (64-73 kg) 100-120 psi 100-120 psi 80-100 psi
160-180 lb (73-82 kg) 120-140 psi 120-140 psi 100-120 psi
>180 lb (82 kg) 140-160 psi 140-160 psi 120-140 psi
OIL
SID RACE DUAL AIR RIGHT LEG
PURE DELITE/MOTION
OIL WEIGHT BOTTOM VOLUME OIL WEIGHT
CONTROL
1/2 Full 5 wt 10cc/ml 15 wt
SID RACE DUAL AIR LEFT LEG
TOP VOLUME OIL WEIGHT BOTTOM VOLUME OIL WEIGHT
3cc/ml 15 wt 10cc/ml 15 wt
SID TEAM/WORLD CUP DUAL AIR RIGHT LEG
PURE DELITE/MOTION
OIL WEIGHT BOTTOM VOLUME OIL WEIGHT
CONTROL
Full 5 wt 10cc/ml 15 wt
(fill from bottom of tube)
SID TEAM/WORLD CUP DUAL AIR LEFT LEG
TOP VOLUME OIL WEIGHT BOTTOM VOLUME OIL WEIGHT
3cc/ml 15 wt 10cc/ml 15 wt
TROUBLE-SHOOTING
AIR LOSS
· Inspect air piston o-rings. Replace if necessary.
· To avoid air loss, remove Dual Air top cap and check oil level inside air chamber, every 25 to 50 riding hours. If there is little or
no oil on top of air piston o-ring, pour 3 to 5cc RockShox 15wt suspension oil into air spring chamber. Oil will keep air seal
lubricated.
· Inspect schrader valve assembly. Replace if damaged or malfunctioning. Clean if clogged.
L O S S O F, O R VA R I A N C E I N D A M P I N G
· Inspect all damper o-rings. Replace and lubricate.
· Inspect damper oil volume. Remove damper top cap/compression damper assembly. Add or remove oil as needed.
· Remote: Inspect remote cable tension. Cable may stretch, or become loose. Loosen cable screw, tension cable and tighten.
Test. Adjust as needed.
B U S H I N G P L AY
· Inspect and replace worn bushings. Bushings are a wear and tear item, and need to be replaced after approximately 100 to 200
riding hours, depending your riding style, condition, riding time and body weight. If you ride a lot, check those bushings!
· See the 'Bushing Installation' guide at www.rockshox.com for procedures.
OIL LOSS
· Inspect the air piston o-ring for air bypass. If there is a repeated loss of air pressure, air may be the cause of oil loss at the left
dust seal.
· Inspect your shaft bolt crush washers. Replace if worn or damaged.
· Inspect your top cap o-rings. Replace if torn or knicked.
PN 95.4311.776.000, REV C 13