SRAM RockShox DebonAir Quick start guide

DebonAir Upgrade and
Travel Change Kit
UPGRADE MANUAL
GEN.0000000005734 Rev E © 2022 SRAM, LLC

SRAM LLC WARRANTY
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AGAINST SRAM, LLC. YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM
STATE TO STATE, COUNTRY, OR PROVINCE. THIS WARRANTY DOES NOT AFFECT YOUR STATUTORY RIGHTS. TO THE EXTENT THIS
WARRANTY IS INCONSISTENT WITH THE LOCAL LAW, THIS WARRANTY SHALL BE DEEMED MODIFIED TO BE CONSISTENT WITH SUCH
LAW. FOR A FULL UNDERSTANDING OF YOUR RIGHTS, CONSULT THE LAWS OF YOUR COUNTRY, PROVINCE, OR STATE.
THIS WARRANTY APPLIES TO SRAM PRODUCTS MADE UNDER THE SRAM, ROCKSHOX, TRUVATIV, ZIPP, QUARQ, AVID AND TIME
BRAND NAMES.
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its bicycle components to be free from defects in materials or workmanship for a period of two
(2) years after original purchase of the product.
SRAM warrants all Zipp MOTO Wheels and Rims to be free from defects in materials or workmanship for the lifetime of the product.
SRAM warrants all non-electronic Zipp branded bicycle components, Model Year 2021 or newer, to be free from defects in materials or workmanship
for the lifetime of the product.
GENERAL PROVISIONS
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 product was purchased or a SRAM authorized service location. Original proof of purchase is required. All SRAM warranty claims
will be evaluated by a SRAM authorized service location whereupon acceptance of the claim the product will be repaired, replaced, or refunded at
SRAM's discretion. To the extent allowed by local law claims under this warranty must be made during the warranty period and within one (1) year
following the date on which any such claim arises.
NO OTHER WARRANTIES
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT ALLOWED BY LOCAL LAW, SRAM MAKES NO OTHER WARRANTIES, GUARANTIES, OR
REPRESENTATIONS OF ANY TYPE (EXPRESS OR IMPLIED), AND ALL WARRANTIES (INCLUDING ANY IMPLIED WARRANTIES OF REASONABLE
CARE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE) ARE HEREBY DISCLAIMED.
LIMITATIONS OF LIABILITY
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL SRAM OR ITS THIRD PARTY SUPPLIERS BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. SOME STATES (COUNTRIES AND PROVINCES) DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL DAMAGES, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
LIMITATIONS OF WARRANTY
This warranty does not apply to products that have been incorrectly installed, adjusted, and/or maintained according to the respective SRAM user
manual. The SRAM user manuals can be found online at sram.com/service.
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 intended 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.
SRAM components are designed for use only on bicycles that are pedal powered or pedal assisted (e-Bike/Pedelec).
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 dierent manufacturers or parts that are not compatible or suitable for use with
SRAM components.
This warranty shall not cover damages resulting from commercial (rental) use.
WEAR AND TEAR
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 INCLUDE:
• Aero bar pads
• Air sealing o-rings
• Batteries
• Bearings
• Bottomout pads
• Brake pads
• Bushings
• Cassettes
• Chains
• Cleats
• Corrosion
• Disc brake rotors
• Dust seals
• Free hubs, Driver bodies, Pawls
• Foam rings, Glide rings
• Handlebar grips
• Jockey wheels
• Rear shock mounting
hardware and main seals
• Rubber moving parts
• Shifter and Brake cables
(inner and outer)
• Shifter grips
• Spokes
• Sprockets
• Stripped threads/bolts (aluminum,
titanium, magnesium or steel)
• Tires
• Tools
• Transmission gears
• Upper tubes (stanchions)
• Wheel braking surfaces
ZIPP IMPACT REPLACEMENT POLICY
Zipp branded products, Model Year 2021 or newer, are covered under a lifetime impact-damage replacement policy. This policy can be used to obtain
a replacement of a product in the event of non-warranty impact damage occurring while riding your bicycle. See www.zipp.com/support for more
information.

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
MODEL CODE IDENTIFICATION .......................................................................................................................................................................7
LYRIK / PIKE / REVELATION / YARI / ZEB UPGRADE KIT COMPATIBILITY................................................................................................7
SEAL HEAD ONLY UPGRADE .....................................................................................................................................................................................................................7
DEBONAIR UPGRADE, TRAVEL CHANGE, AND BOTTOMLESS TOKENS ....................................................................................................................................7
LYRIK / PIKE / REVELATION / YARI / ZEB DEBONAIR UPGRADE KIT INSTALLATION.............................................................................9
LOWER LEG REMOVAL...................................................................................................................................................................................................................................9
AIR SPRING REMOVAL.................................................................................................................................................................................................................................. 11
BOTTOMLESS TOKENS INSTALLATION OPTIONAL......................................................................................................................................................................... 11
DEBONAIR SEAL HEAD ONLY UPGRADE ............................................................................................................................................................................................. 14
DEBONAIR SPRING INSTALLATION.........................................................................................................................................................................................................16
LOWER LEG ASSEMBLY ............................................................................................................................................................................................................................... 19
BOXXER DEBONAIR SPRING UPGRADE KIT COMPATIBILITY ................................................................................................................ 22
DEBONAIR UPGRADE, TRAVEL CHANGE, AND BOTTOMLESS TOKENS ................................................................................................................................. 22
PARTS, TOOLS, AND SUPPLIES ............................................................................................................................................................................................................... 22
BOXXER DEBONAIR UPGRADE AND TRAVEL CHANGE KIT INSTALLATION ....................................................................................... 23
FORK REMOVAL ............................................................................................................................................................................................................................................ 23
LOWER LEG REMOVAL................................................................................................................................................................................................................................ 27
DEBONAIR SPRING REMOVAL................................................................................................................................................................................................................. 29
BOTTOMLESS TOKENS OPTIONAL....................................................................................................................................................................................................... 31
DEBONAIR  TRAVEL AND BOTTOMLESS TOKEN TUNING............................................................................................................................................................ 31
BOTTOMLESS TOKENS INSTALLATION OPTIONAL........................................................................................................................................................................ 31
DEBONAIR SPRING INSTALLATION........................................................................................................................................................................................................ 32
LOWER LEG INSTALLATION ...................................................................................................................................................................................................................... 35
FORK INSTALLATION....................................................................................................................................................................................................................................37

5
RockShox Service
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/en/company/about/environmental-policy-and-recycling.
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 andClean the part with RockShox Suspension Cleaner or isopropyl alcohol and
a clean, lint-free shop towel. For hard to reach places (e.g. upper tube, lowera clean, lint-free shop towel. For hard to reach places (e.g. upper tube, lower
leg), wrap a clean, lint-free shop towel around a non-metallic dowel to cleanleg), wrap a clean, lint-free shop towel around a non-metallic dowel to clean
the inside.the inside.
Clean the sealing surface on the part and inspect it for scratches.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 yourReplace 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.fingers or a pick to pierce and remove the old seal or o-ring.
Apply grease to the new 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.Use aluminum soft jaws when placing a part in a bench vise.
Tighten the part with a torque wrench to the torque value listed in the red bar.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 socketWhen using a crowfoot socket and torque wrench, install the crowfoot socket
at 90 degrees to the torque wrench.at 90 degrees to the torque wrench.
Specified torque value in N·m (in-lb)

6
Parts, Tools, and Supplies
Parts, Tools, and Supplies
Parts
• RockShox DebonAir Seal Head Kit
• RockShox DebonAir Upgrade Kit
Safety and Protection Supplies
• Apron
• Clean, lint-free shop towels
• Nitrile gloves
• Oil pan
• Safety glasses
Lubricants and Fluids
• Loctite 2760 or 270 High Strength Threadlocker Red
• Maxima PLUSH Dynamic Suspension Lube Light or
RockShox 0w-30 Suspension Oil
• Maxima PLUSH Dynamic Suspension Lube Heavy or
RockShox 0w-30 Suspension Oil
• RockShox Dynamic Seal Grease or SRAM Butter grease‡
• RockShox Suspension Cleaner or Isopropyl alcohol
RockShox Tools
• RockShox Bleed Syringe
• RockShox Top Cap/Cassette tool (3/8" / 24 mm) or RockShox x
Abbey Bike Tools Top Cap/Cassette Tool
Bicycle Tools
• Bench vise
• Bicycle work stand
• Cassette tool
• Shock pump
Common Tools
• Hex bit sockets: 2.5, 5, 8 mm
• Hex wrenches: 2.5, 5, 8 mm
• Internal retaining ring pliers - large
• Long plastic or wooden dowel
• Needle nose pliers
• Open end wrenches: 12 mm
• Rubber or plastic mallet
• Small flat blade screwdriver
• Sockets: 12mm, 24 mm or RockShox x Abbey Bike Tools 24 mm Socket
• Socket wrench
• 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.
‡Air Spring Oil / Grease - Pike, Revelation, Lyrik, Yari, ZEB, and BoXXer forks are compatible with RockShox Dynamic Seal Grease and SRAM Butter.

7
Model Code Identification
Model Code Identification
Product model code and specification details can be identified with the serial number on the product. Model codes can be used to identify the
product type, series name, model name, and product version associated with the production model year. Product details can be used to identify spare
parts, service kit, and lubricant compatibility.
Model Code example: FS-PIKE-SEL-B3
FS = Product Type - Front Shock
PIKE = Platform/Series - Pike
SEL = Model - Select
B3 = Version - (B- second generation, 3- third iteration)
To identify the model code, locate the serial number on the product and enter it into the Search by Model Name or Serial Number field at
www.sram.com/service.
Lyrik / Pike / Revelation / Yari / ZEB Upgrade Kit Compatibility
DebonAir C1 upgrade kits are NOT compatible with ZEB (A2), Lyrik (D1), and Pike (C1), including Ultimate Flight Attendant.
The following 35mm and 38 mm fork models are compatible with the new DebonAir C1 upgrade kit:
Lyrik A1-C3
(2016-2022)
Pike 29+ A2-B1
(2017-2020)
Pike B1-B4
(2018-2022)
Revelation A1+
(2018+)
Yari A1+
(2016+)
ZEB A1
(2021-2022)
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.
Seal Head Only Upgrade
The following kit can be used to upgrade the seal head on a fork with a 2019+ DebonAir air spring previously installed.
Lyrik / Pike / Revelation / Yari (2019-2020) 00.4020.573.000 AM UPGR DB C1 - 35MM SEAL HEAD
DebonAir Upgrade, Travel Change, and Bottomless Tokens
It is possible to change maximum fork travel by replacing the stock air spring with a shorter or longer DebonAir spring assembly. Refer to the chart
below for travel options. If maximum travel is increased or reduced it may also be necessary to add or remove Bottomless Tokens. Use the chart
below to help determine the number of Bottomless Tokens that can be used with each maximum fork travel option.
Use ONLY RockShox, SRAM, and Maxima suspension oils/fluids and grease, unless otherwise specified. Use of any other lubricants can damage seals
and decrease performance.
Suspension oil/fluid - Maxima PLUSH Dynamic Suspension Lube and RockShox 0w-30 suspension oils/fluids are forward and backward compatible
with RockShox Dynamic Seal Grease and SRAM Butter Grease.
Refer to the appropriate RockShox suspension fork service manual, available at www.sram.com/service, for service specifications and procedures.
Fork Model
Year Generation
Wheel
Size
(in)
Desired Max
Travel (mm) Upgrade Kit Max Bottomless Tokens
Lower Leg Oil
Damper Side Spring Side
Oil Volume
(mL) Oil Volume (mL)
LYRIK 2016-
2022 A1-C3 27.5
29
180 00.4020.572.000 ‡ 4
PLUSH
Light* 10 PLUSH Light* 10
170 00.4020.572.001 ‡ 4
160 00.4020.572.002 ‡ 5
150 00.4020.572.003 ‡ 5
† Pike 2014-2017 forks are not compatible with DebonAir C1 air springs.
‡ Not compatible with ZEB (A2), Lyrik (D1), and Pike (C1), including Ultimate Flight Attendant.
* Maxima PLUSH Dynamic Suspension Lube

8
DebonAir Upgrade, Travel Change, and Bottomless Tokens
Fork Model
Year Generation
Wheel
Size
(in)
Desired Max
Travel (mm) Upgrade Kit Max Bottomless Tokens
Lower Leg Oil
Damper Side Spring Side
Oil Volume
(mL) Oil Volume (mL)
PIKE
2014-
2017 †A1-A2
26
160 00.4019.931.008 ‡ 4
PLUSH
Light* 10 PLUSH Light* 10
150 00.4019.931.009 ‡ 4
140 00.4019.931.010 ‡ 5
130 00.4019.931.011 ‡ 6
120 00.4019.931.012 ‡ 6
27.5
160 00.4019.931.007 ‡ 4
150 00.4019.931.008 ‡ 4
140 00.4019.931.009 ‡ 5
130 00.4019.931.010 ‡ 6
120 00.4019.931.011 ‡ 6
29
160 00.4019.931.005 ‡ 4
150 00.4019.931.006 ‡ 4
140 00.4019.931.007 ‡ 5
130 00.4019.931.008 ‡ 6
120 00.4019.931.009 ‡ 6
2018-
2022 B1-B4 27.5
29
160 00.4020.552.000 ‡ 4
150 00.4020.552.001 ‡ 4
140 00.4020.552.002 ‡ 5
130 00.4020.552.003 ‡ 6
120 00.4020.552.004 ‡ 6
2017-
2020 A2-B1 29+
160 00.4020.572.002 ‡ 5
150 00.4020.572.003 ‡ 5
140 00.4020.572.004 ‡ 6
130 00.4020.572.005 ‡ 6
120 00.4020.572.006 ‡ 7
REVELATION 2018+ A1+ 27.5
29
160 00.4020.552.000 4
PLUSH
Light* 10 PLUSH Light* 10
150 00.4020.552.001 4
140 00.4020.552.002 5
130 00.4020.552.003 6
120 00.4020.552.004 6
YARI 2016+ A1+
27.5
29
180 00.4020.572.000 4
PLUSH
Light* 10 PLUSH Light* 10
170 00.4020.572.001 4
160 00.4020.572.002 5
150 00.4020.572.003 5
140 00.4020.572.004 6
130 00.4020.572.005 6
120 00.4020.572.006 7
29+
160 00.4020.572.002 5
150 00.4020.572.003 5
140 00.4020.572.004 6
130 00.4020.572.005 6
120 00.4020.572.006 7
ZEB 2021-
2022 A1 27.5
29
190 00.4020.574.006 ‡ 4
PLUSH
Light* 20 PLUSH Light* 20
180 00.4020.574.007 ‡ 4
170 00.4020.574.008 ‡ 4
160 00.4020.574.009 ‡ 5
150 00.4020.574.010 ‡ 5
† Pike 2014-2017 forks are not compatible with DebonAir C1 air springs.
‡ Not compatible with ZEB (A2), Lyrik (D1), and Pike (C1), including Ultimate Flight Attendant.
* Maxima PLUSH Dynamic Suspension Lube

9
Lyrik / Pike / Revelation / Yari / ZEB DebonAir Upgrade Kit Installation
Lyrik / Pike / Revelation / Yari / ZEB DebonAir Upgrade Kit Installation
Lower Leg Removal
Remove the air valve cap from the top cap located on the non-drive
side fork leg.
Use a small 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 fork before proceeding.
Failure to do so can result in injury and/or damage to the fork. Wear
safety glasses.
Use a 2.5 mm hex wrench to loosen the set screw and remove the
rebound adjuster knob located at the bottom of the drive side fork leg.
Use a 5 mm hex wrench to loosen both bottom bolts 3 to 4 turns.
1
2
3
2.5 mm
Spring Side
Damper Side
4

10
Lower Leg Removal
Place an oil pan beneath the fork to catch any draining oil.
Use a rubber or plastic mallet to firmly strike each bottom bolt, or a hexor a hex
wrench inserted into the bottom bolt for hollow bottom lower legs,wrench inserted into the bottom bolt for hollow bottom lower legs, to
dislodge the air and damper shafts from the lower leg.
Use a 5 mm hex wrench to remove the bottom bolts from the lower leg.
Firmly pull the lower leg downward until oil begins to drain. Continue
pulling downward to remove the lower leg from the fork.
If the lower leg does not slide o of the upper tubes or if oil does
not drain from either side, the press fit of the shaft(s) to the lower
leg may still be engaged. Reinstall the bottom bolts 2 to 3 turns and
repeat step 5.
NOTICE
Do not hit the fork arch with any tool when removing the lower leg
as this could damage the fork.
5
Spring Side
Spring Side
Damper Side
Damper Side
6

11
Air Spring Removal
Air Spring Removal
Use a 24 mm socket wrench or RockShox Top Cap/Cassette tool to
remove the top cap.
Spray isopropyl alcohol on the upper tube threads and clean the
threads with a shop towel.
Bottomless Tokens Installation (optional)
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 Travel Change and Bottomless Tokens for the maximum number of Tokens for your fork.
Thread a Bottomless Token into another Bottomless Token, or into theThread a Bottomless Token into another Bottomless Token, or into the
the bottom of the top cap, and tighten.the bottom of the top cap, and tighten.
Top Cap/Cassette Tool
DebonAir
24 mm / RockShox Top Cap/Cassette Tool
Solo Air
1
8 mm 4 N•m (35 in-lb) 24 mm or Top Cap/Cassette Tool
8 mm 4 N•m (35 in-lb) 24 mm or Top Cap/Cassette Tool

12
Bottomless Tokens Installation (optional)
Solo Air: Use a flat blade screwdriver to push the SA seal head tab
under the retaining ring.
NOTICE
Scratches on the air shaft will allow air to bypass the seal head into
the lower leg, resulting in reduced spring performance.
Place the tips of large internal retaining ring pliers into the eyelets of
the retaining ring.
2018 DebonAir and Solo Air: Press firmly on the pliers to push the SA
seal head into the upper tube enough to compress and remove the
retaining ring. Slide the retaining ring onto your finger and release the
air spring shaft.
2019-2022 DebonAir: Push the air shaft into the upper tube with your
thumb. While holding the shaft in, remove the retaining ring. Slide the
retaining ring onto your thumb and carefully release the air spring
shaft.
2
2
2018 DebonAir and Solo Air
DebonAir
2018 DebonAir and Solo Air
2021-2022 DebonAir
2021-2022 DebonAir

13
Bottomless Tokens Installation (optional)
2018 DebonAir and Solo Air: Use your fingers to install the bottom bolt
into the air shaft. Firmly pull on the bottom bolt to remove the air shaft
assembly from the upper tube. Unthread and remove the bottom bolt
from the air shaft.
2019-2022 DebonAir: Wrap a shop towel around the end of the air
shaft for extra grip. Push the shaft half way into the upper tube, then
quickly and firmly pull the shaft out to dislodge the seal head. Remove
the air spring assembly from the upper tube.
A build up of negative air pressure may prevent the air spring from
being pulled out of the upper tube. If the air spring is dicult to
remove, use a clean plastic dowel to push the air spring piston down
while pulling the air shaft out.
Spray isopropyl alcohol on the inside and outside of the upper tube
and clean it with a shop towel. Wrap a shop towel around a long dowel
and insert it into the upper tube to clean inside the upper tube.
Continue with DebonAir Seal Head Only Upgrade if upgrading the seal head on a 2019-2020 DebonAir assembly.
Continue with DebonAir Spring Installation if installing a DebonAir Upgrade kit.
DebonAir
DebonAir
3
2019-2020 DebonAir
2019-2020 DebonAir
2021-2022 DebonAir
2021-2022 DebonAir
4

14
DebonAir Seal Head Only Upgrade
DebonAir Seal Head Only Upgrade
The following kit can be used to upgrade the seal head on a fork with a 2019+ DebonAir air spring previously installed.
Lyrik / Pike / Revelation / Yari (2019-2020) 00.4020.573.000 AM UPGR DB C1- 35MM SEAL HEAD
Clamp an 8 mm hex wrench into a vise. Position the air piston onto theClamp an 8 mm hex wrench into a vise. Position the air piston onto the
hex wrench. While holding the air shaft, unthread and remove the airhex wrench. While holding the air shaft, unthread and remove the air
shaft nut from the air spring shaft.shaft nut from the air spring shaft.
Remove the seal head from the air spring shaft. Discard the seal head.Remove the seal head from the air spring shaft. Discard the seal head.
Clean and inspect the shaft for damage.Clean and inspect the shaft for damage.
Clean the top out bumper.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.
Remove the air assembly from the vise.Remove the air assembly from the vise.
Apply grease to the new seal head inner seal.Apply grease to the new seal head inner seal.
Install the new seal head assembly onto the air shaft.Install the new seal head assembly onto the air shaft.
Remove the quad ring seal from the air piston and discard it.Remove the quad ring seal from the air piston and discard it.
Clean the air piston.Clean the air piston.
Apply grease to a new quad ring seal and install it.Apply grease to a new quad ring seal and install it.
NOTICE
Do not scratch the air piston. Scratches will cause air to leak.
1
8 mm 12 mm
2019-2020 19.3 mm
Loctite2760
2
3
4

15
DebonAir Seal Head Only Upgrade
Apply red Loctite 2760 or 270 to the first two to three full threads onApply red Loctite 2760 or 270 to the first two to three full threads on
the end of the air shaft.the end of the air shaft.
Clamp an 8 mm hex wrench into a vise. Insert the air piston onto theClamp an 8 mm hex wrench into a vise. Insert the air piston onto the
wrench to secure it. Install the new, red air shaft nut onto the air shaftwrench to secure it. Install the new, red air shaft nut onto the air shaft
and tighten it.and tighten it.
NOTICE
To ensure compatibility and correct performance, during reassembly
ONLY use the shaft nut that is compatible with the new seal head.
The silver shaft nut is compatible only with the 2019-2020 seal head.
The red shaft nut is compatible only with the 2021-2022 seal head.
Continue with DebonAir Spring Installation.
Loctite 2760 or 270
5
8 mm
8 mm / 12 mm 3.3 N•m (29 in-lb)

16
DebonAir Spring Installation
DebonAir Spring Installation
Apply a liberal amount of grease evenly around the end of a cleanApply a liberal amount of grease evenly around the end of a clean
plastic dowel, approximately 150 mm from one end. Use the dowel toplastic dowel, approximately 150 mm from one end. Use the dowel to
apply the grease to the inside surface of the upper tube, approximatelyapply the grease to the inside surface of the upper tube, approximately
150 mm into the tube.150 mm into the tube.
Apply grease to the air piston and seal head outer o-rings/seals.Apply grease to the air piston and seal head outer o-rings/seals.
Apply suspension oil to the spring shaft, above the seal head.Apply suspension oil to the spring shaft, above the seal head.
Fork Oil
Pike
Maxima PLUSH Dynamic
Suspension Lube Heavy
Revelation
Lyrik
Yari
ZEB
1
Dowel 150 mm
Grease
2
PLUSH Heavy 1 mL
Loctite2760

17
DebonAir Spring Installation
Insert the air spring assembly into the upper tube. Firmly push the airInsert the air spring assembly into the upper tube. Firmly push the air
piston into the upper tube.piston into the upper tube.
Insert the seal head into the upper tube and firmly press it into theInsert the seal head into the upper tube and firmly press it into the
upper tube until it stops.upper tube until it stops.
Retaining rings have a sharper-edged side and a rounder edged side.Retaining rings have a sharper-edged side and a rounder edged side.
Installing retaining rings with the sharper-edged side facing the toolInstalling retaining rings with the sharper-edged side facing the tool
will allow for easier installation and removal.will allow for easier installation and removal.
Place the tips of the retaining ring pliers into the eyelets of the retainingPlace the tips of the retaining ring pliers into the eyelets of the retaining
ring. Guide the retaining ring with your finger to prevent the shaft fromring. Guide the retaining ring with your finger to prevent the shaft from
from getting scratched while installing the retaining ring.from getting scratched while installing the retaining ring.
Use the pliers to push the seal head into the upper tube while installingUse the pliers to push the seal head into the upper tube while installing
the retaining ring into the groove. Release the retaining ring pliersthe retaining ring into the groove. Release the retaining ring pliers
when the ring is fully seated in the groove.when the ring is fully seated in the groove.
Confirm the retaining ring is properly seated in the retaining ringConfirm the retaining ring is properly seated in the retaining ring
groove by using the retaining ring pliers to rotate the retaining ringgroove by using the retaining ring pliers to rotate the retaining ring
and seal head back and forth a few times, then firmly pull down onand seal head back and forth a few times, then firmly pull down on
the air shaft.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.
Pull the shaft out until it stops.Pull the shaft out until it stops.
Inject or pour suspension oil into the air spring upper tube.Inject or pour suspension oil into the air spring upper tube.
Fork Oil
Pike
Maxima PLUSH Dynamic
Suspension Lube Heavy
Revelation
Lyrik
Yari
ZEB
3
4
5
6
PLUSH Heavy RockShox Bleed Syringe 3 mL

18
DebonAir Spring Installation
Install the air spring top cap into the upper tube and tighten it. PressInstall the air spring top cap into the upper tube and tighten it. Press
down firmly when tightening the top cap.down firmly when tightening the top cap.
7
24 mm or Top cap/
Cassette tool 28 N•m (250 in-lb)

19
Lower Leg Assembly
Lower Leg Assembly
Spray isopropyl alcohol on the upper tubes and clean them with a shop
towel.
Apply grease to the inner surfaces of the dust wiper seals.
Install the lower leg assembly onto the upper tubes and slide it justInstall the lower leg assembly onto the upper tubes and slide it just
enough to engage the upper bushings with the upper tubes.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 orThe inside bottom of the lower leg should not contact the spring or
damper shafts. A gap between the shaft ends and the lower leg boltdamper shafts. A gap between the shaft ends and the lower leg bolt
holes should be visible.holes should be visible.
1
2
3

20
Lower Leg Assembly
Position the fork at an angle with the bolt holes oriented upward.Position the fork at an angle with the bolt holes oriented upward.
Inject suspension oil into each lower leg through the bottom bolt holes.Inject suspension oil into each lower leg through the bottom bolt holes.
Consult theConsult the DebonAir Upgrade, Travel Change, and Bottomless TokenDebonAir Upgrade, Travel Change, and Bottomless Token
section for fork oil volumes.section for fork oil volumes. Use the oil weight and volume for yourUse the oil weight and volume for your
fork model and year.fork model and year.
NOTICE
Do not exceed the recommended oil volume per leg as this can
damage the fork.
Slide the lower leg assembly along the upper tubes until it stops and
the spring and damper shafts are visible through the lower leg bolt
holes.
Use a shop towel to clean all excess oil from the outer surface of the
lower leg.
Thread the black bottom bolt into the non-drive side lower leg. Thread
the silver bottom bolt into the drive side shaft of the lower leg.
Use a torque wrench with a 5 mm hex bit socket to tighten the bolts to
7.3 N·m (65 in-lb).
Install the rebound adjuster knob onto the rebound damper bottom
bolt.
Use a torque wrench with a 2.5 mm hex bit socket to tighten the set
screw to 0.9 N·m (8 in-lb).
NOTICE
Hold the rebound adjuster knob in place during installation to
prevent damage to the bottom bolt.
4
Maxima PLUSH Dynamic Suspension Lube Light RockShox Bleed Syringe
5
6
5 mm 7.3 N·m (65 in-lb)
5 mm 7.3 N·m (65 in-lb)
7
2.5 mm 0.9 N·m (8 in-lb)