Rock Shox Reverb Stealth User manual

2014
REVERB STEALTH
Service Manual

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 specic 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 modied to be consistent with such law, under
such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the United States
of America, as well as some governments outside of the United States (including provinces in Canada) may:
a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer
(e.g. United Kingdom).
b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.
For Australian customers:
This SRAM limited warranty is provided in Australia by SRAM LLC, 1000 W. Fulton Market, 4th Floor, Chicago, IL, 60607, USA. To make a warranty
claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6
Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses incurred in
making the warranty claim are your responsibility. The benets 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 specically 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
specications 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 modied, 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 identied as:
• Dust seals
• Bushings
• Air sealing o-rings
• Glide rings
• Rubber moving parts
• Foam rings
• Rear shock mounting hardware and main seals
• Upper tubes (stanchions)
• Stripped threads/bolts (aluminium, titanium,
magnesium or steel)
• Brake sleeves
• Brake pads
• Chains
• Sprockets
• Cassettes
• Shifter and brake cables (inner and outer)
• Handlebar grips
• Shifter grips
• Jockey wheels
• Disc brake rotors
• Wheel braking surfaces
• Bottomout pads
• Bearings
• Bearing races
• Pawls
• Transmission gears
• Spokes
• Free hubs
• Aero bar pads
• Corrosion
• Tools
• Motors
• Batteries
Notwithstanding anything else set forth herein, the battery pack and charger warranty does not include damage from power surges, use of improper
charger, improper maintenance, or such other misuse.
This warranty shall not cover damages caused by the use of parts of different manufacturers.
This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM
components.
This warranty shall not cover damages resulting from commercial (rental) use.
(English)

TABLE OF CONTENTS
EXPLODED VIEW - REVERB STEALTH .......................................................................................................................................... 5
ROCKSHOX REVERB STEALTH SEATPOST SERVICE ................................................................................................................. 6
PARTS AND TOOLS............................................................................................................................................................................................................................. 6
REVERB STEALTH DISASSEMBLY................................................................................................................................................................................................ 8
TOP CAP ASSEMBLY SERVICE......................................................................................................................................................................................................16
REVERB STEALTH REASSEMBLY ................................................................................................................................................................................................21
REMOTE AND HOSE BLEED.......................................................................................................................................................................................................... 27

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!

Bleed Screw
Air Cap
Air Fill Valve
Schrader
Valve
IFP Tube
Upper Post
Inner Seal Head
Internal Floating
Piston (IFP)
Brass
Keys
(x3)
Inner Shaft
Piston
Inner Shaft
Seal Head
Post Head
Poppet Valve
Cover
OR
Saddle Clamp
Assembly
Top Cap
Assembly
Lower Post
Bottom Out O-ring
Travel Spacer (not in
all configurations)
Foam Washer
Snap Ring
Poppet Valve
5EXPLODED VIEW - REVERB STEALTH
EXPLODED VIEW - REVERB STEALTH
Hose Barb
Connectamajig
Hose
Strain
Relief
► ►

ROCKSHOX REVERB STEALTH SEATPOST SERVICE
We recommend that you have your RockShox Reverb Stealth seatpost serviced by a qualified bicycle mechanic. Servicing RockShox
products requires knowledge of suspension components as well as the special tools and fluids used for service.
For exploded diagram and part number information, please refer to the Spare Parts Catalog available on our web site at www.sram.com.
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. For the latest technical information,
please visit our website at www.sram.com/service.
Your product‘s appearance may dier from the pictures/diagrams contained in this publication.
PARTS AND TOOLS
• Safety glasses
• Nitrile gloves
• Apron
• Clean, lint-free rags
• Isopropyl alcohol
• SRAM Butter bicycle grease
• Bench vise with aluminum or plastic soft jaws
• Reverb I.F.P. Height Tool
• Reverb Hydraulic Bleed Kit
• Reverb Stealth Complete Seal Service Kit
• Fluid level gauge
• Fluid pan
• Small drip container
• 7-9 20 cm cable ties
• Suspension pump
• T10 TORXwrench
• 1.5, 3, and 4 mm hex wrenches
• 6, 7, 9, 10, and 11 mm open end wrenches
• 10, 11, 23, and 34 mm crowfoot sockets
• 23 mm box end wrench
• 34 mm open end wrench
• 9 mm socket, and socket wrench
• Torque wrench
• Downhill tire lever
• Needle nose pliers
• Internal snap ring pliers
• Plastic or wooden dowel
• Metric tape measure or ruler
• Schrader valve tool
• Plastic-tip hammer
• Pick
6ROCKSHOX REVERB STEALTH SEATPOST SERVICE

SAFETY INSTRUCTIONS
Always wear safety glasses and nitrile gloves when working with suspension fluid.
Place an fluid pan on the floor underneath the area where you will be working on the Reverb.
NOTICE
When servicing the Reverb Stealth seatpost, do not scratch any sealing surfaces, the upper post, the inside of the lower post, the inner
seal head, or damage any replacement o-rings or bushings. Damage to any of these parts can cause leaks and reduce performance of
the seatpost.
Use aluminum soft jaws to prevent damage to the seatpost or any seatpost components when clamping into a vise. Clamp the shaft
only tight enough to prevent it from spinning in the soft jaws.
CAUTION- EYE HAZARD
If you are able to compress the Reverb Stealth without pressing the
remote actuator, the seatpost must be returned to an authorized
RockShox service center for repair. Do not attempt to disassemble or
service the seatpost.
7PARTS AND TOOLS

REVERB STEALTH DISASSEMBLY
1 Record your saddle settings before beginning service. Use a 4mm
hex wrench to remove the saddle and saddle clamps from the top
of the seatpost.
2 Use a 9mm socket to remove the air cap from the upper post.
3 Use a 3 mm hex wrench to depress the Schrader valve and release
all air pressure from the air chamber.
CAUTION- EYE HAZARD
Verify all pressure is removed from the Reverb Stealth before
proceeding. Failure to do so can cause the inner seal head and
inner shaft to separate from the upper post assembly at high
velocity. Wear safety glasses.
4 Use a Schrader valve tool to remove the Schrader valve
from the upper post.
9 mm
4 mm
8REVERB STEALTH DISASSEMBLY

5 Use a Schrader valve tool to install a new Schrader valve
into the air fill valve.
6 Open the seatpost clamp or loosen the seatpost collar binder bolt
and remove the Reverb Stealth from the bicycle. It is not necessary
to remove the Reverb remote from the handlebar unless the
remote housing is too short to allow the Reverb to be removed
from the frame.
NOTICE
Use aluminum soft jaws to prevent damage to the seatpost or any seatpost components when clamping into a vise. Clamp the shaft
only tight enough to prevent it from spinning in the soft jaws.
7 Clamp the post head into a vise with soft jaws.
Standard: Use a 7mm and a 10mm open end wrench to
disconnect the hose from the poppet cover.
Connectamajig: Hold the Connectamajig coupler on the wrench
flats with a 9 mm wrench. Use a 6 mm wrench on the crimped
fitting on the hose. Unscrew the coupler from the crimped fitting
to disconnect.
8 Use internal snap ring pliers to remove the snap ring from the
bottom of the lower post.
7 mm 10 mm
Standard
6 mm
Connectamajig
9 mm
9REVERB STEALTH DISASSEMBLY

9 Remove the seatpost from the vise. Tap the seat clamp end of the
upper post with your hand or a plastic-tip hammer to expose the
inner shaft.
10 Clamp the inner shaft close to the seal head in a vise
with soft jaws.
11 Use an 11 mm open end wrench to hold the seal head in place and
use a 10 mm open end wrench to unthread and remove the poppet
cover from the seal head.
NOTICE
To prevent damage to the poppet cover bleed screw, do not allow
the 10mm wrench to contact the bleed screw.
12 Use needle nose pliers to pull the poppet valve
from the inner shaft.
11 mm 10 mm
10 REVERB STEALTH DISASSEMBLY

13 Use an 11mm open end wrench to unthread and remove
the seal head from the inner shaft.
14 Remove the foam washer from the air shaft.
NOTICE
Do not scratch any sealing surfaces when servicing your Reverb
Stealth. Scratches can cause leaks.
15 Use a pick to remove the bottom out o-ring from the lower post.
16 Clamp the lower post horizontally in a vise with soft jaws.
11 mm
11 REVERB STEALTH DISASSEMBLY

17 Use a 34 mm open end wrench to unthread the top cap assembly
from the lower post.
18 Remove the upper post from the lower post.
19 355 & 420 mm Reverb Stealth with 100 mm travel, and 420 mm
Reverb Stealth with 125 mm travel: Use a long wooden or plastic
dowel to push the false bottom insert from the lower post.
20 Remove the three brass keys from the upper post.
12 REVERB STEALTH DISASSEMBLY

21 Point the shaft at an oil pan and slowly push the inner shaft into
the upper post. Oil will eject out of the center of the inner shaft.
Leave the inner shaft in the upper post. Leave a small amount of
inner shaft exposed.
CAUTION- EYE HAZARD
Fluid will be ejected from the center of the inner shaft. Wear safety
glasses.
22 Clamp the post head in a vise with soft jaws.
23 Use a 23mm box end wrench to unthread the inner seal head from
the bottom of the upper post.
NOTICE
To prevent damage to the internal seal head wrench flats, make
sure the wrench is firmly tightened against the wrench flats while
unthreading the seal head from the upper post. Be careful not to
scratch the inner shaft as this is a critical sealing surface.
24 Remove the inner seal head from the upper post by hand.
23 mm
13 REVERB STEALTH DISASSEMBLY

25 Pull the inner shaft from the upper post by hand.
26 Remove the top cap assembly from the upper post.
27 Insert a 1.5 mm hex wrench into one of the cross holes of the IFP
tube. Use pliers to carefully pull the IFP tube out of the upper post.
28 Remove the upper post from the vise and pour the fluid into a
container. Clamp the post head back into the vise with soft jaws.
1.5 mm
14 REVERB STEALTH DISASSEMBLY

29 Insert seven to nine 20 cm long cable ties, one at a time, into the
upper post through the IFP. Pull all of the cable ties simultaneously
out of the upper post, removing the IFP in the process.
15 REVERB STEALTH DISASSEMBLY

TOP CAP ASSEMBLY SERVICE
NOTICE
Use caution when servicing the Reverb Stealth seatpost not to scratch any sealing surfaces, being especially careful not to scratch the
upper post, the inside of the lower post, the inner seal head, or damage any o-rings or bushings.
Use aluminum soft jaws to prevent damage to the seatpost or any seatpost components when clamping into a vise. Clamp the shaft
only tight enough to prevent it from spinning in the soft jaws.
1 Clamp the top cap assembly by the wrench flats into a flat section
of the soft jaws. Use a downhill tire lever to pry the dust wiper from
the top cap. Remove the top cap from the vise. Use a pick to
remove the o-ring and foam ring.
NOTICE
Tighten the vice only enough to hold the top cap securely in place
to prevent the top cap from becoming misshaped.
2 Install a new o-ring into the top cap.
16 TOP CAP ASSEMBLY SERVICE

3 Soak a new foam ring in Reverb Hydraulic Fluid. Install it into the
top cap above the bushing.
4 Carefully remove the energizer ring from the new dust wiper.
5 Insert the small end of the new dust wiper into the end of the
lower post. Orient the top cap on the bench with the logo facing
up, and use the lower post to press the dust wiper into the top cap.
Reinstall the energizer ring.
17 TOP CAP ASSEMBLY SERVICE

6 Use your fingers to remove the o-rings from the seal head. Clean
any dirt or debris from the seal head, and install new o-rings.
7 Use your fingers or a pick to remove the o-rings from the poppet
valve. Clean the poppet valve, then install new o-rings.
18 TOP CAP ASSEMBLY SERVICE

8 Use your fingers to remove the two backup rings and the o-ring
from the inner shaft piston.
Use a pick to remove the poppet o-ring from inside the main
piston, then install a new o-ring.
Clean the inner shaft piston and install two new backup rings and a
new o-ring. The o-ring must be located between the backup rings.
9 Use your fingers to remove the two external backup rings and
o-ring. Use a pick to remove the two internal backup rings and
o-ring.
Clean the IFP and install two new external backup rings and o-ring,
and two new internal backup rings and a new o-ring. The o-rings
must be located between the backup rings.
19 TOP CAP ASSEMBLY SERVICE

10 Remove the bushing from the inner seal head by hand. Use your
fingers or a pick to remove the two external o-rings, the internal
U-cup, and the internal top out bumper. Be careful not to scratch
any of the surfaces of the inner seal head.
Clean the inner seal head.
Install the internal U-cup with the open end facing away from
the wrench flats on the seal head. Install external o-rings and the
bushing.
20 TOP CAP ASSEMBLY SERVICE