vorsprung Luftkappe Air Piston Kit Installation Guide

: June 5, 2024
: vorsprung

Table of Contents

Key things to note before you start:
Tools required:
SETUP
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

Luftkappe
FORK AIR PISTON UPGRADE
INSTALLATION MANUAL – ROCKSHOX ZEB & DOMAIN
REVISION A

The Luftkappe can be installed by anyone who already possesses the tools and the know-how to service their own fork – or by anybody who has the tools and can follow instructions closely.

Key things to note before you start:

You need a torque wrench. Don’t try it without one. Beg, borrow, rent, buy or steal one from a friend.
You will need 10mm shaft clamps to hold the air spring shaft. Please don’t try grabbing the shaft in a vice or in V-blocks, you WILL damage it.
We refer to the Rockshox service manuals for all aspects of the servicing OTHER than the specific installation of the Luftkappe to the Debonair Air Shaft.
Record your air pressure and rebound settings before you start doing anything else.
Don’t do it drunk. Even if you’re Australian.
The Luftkappe only replaces the piston – not the entire air shaft. We will be removing the existing piston from the air shaft, and replacing it with the Luftkappe.

Tools required:

NOTE: Do not proceed unless you have the following tools and supplies on hand.

15mm socket / wrench
18mm socket/wrench
Torque wrench
Slickoleum (Slick Honey) grease
20wt WPL ShockBoost oil or Rockshox 0W30 oil
Red Loctite
Blue Loctite
Isopropyl alcohol
Clean, lint-free shop towels.

See manufacturer’s service instructions for removing the stock air spring from your fork.
ROCKSHOX: https://www.sram.com/en/service/manuals–documents/service- manuals?filters=&showRecent=false&page=1
Refer to the relevant factory service instructions up until you have removed the air spring from the stanchion.
Refer to the Factory service instructions for torque specifications, lubrication specifications, and general disassembly/reassembly.
Clamp shaft in 10mm shaft clamps.
Use an 18mm socket or wrench to remove the old (red) piston.
Clean off the Loctite residue from the shaft threads.
Apply fresh red Loctite to the shaft thread and thread the Luftkappe stud into place by hand.
Slide plastic Luftkappe piston onto the stud, and ensure the o-ring on the outside/top of the piston is greased. Lightly grease inside surface of Luftkappe dome.
Apply blue Loctite to thread on piston stud
Thread dome onto piston by hand, and torque to 50in.lbs (5.5Nm).
Thoroughly coat piston & dome with Slick Honey

Luftkappe installation is now complete.
Continue servicing the fork as per Rockshox’s instructions if you are servicing the damper or replacing the wiper seals, or skip to the reassembly instructions.
Follow the factory instructions for reassembly, but do not repressurize yet.
Note: ensure foot bolts are done up with the fork fully extended. If they’re done up with it partly or completely compressed, the fork will suck it down into its travel.

SETUP

Step One
Your token configuration should start with two tokens less than you had previously. The maximum number of tokens you can safely run is TWO LESS than what is specified by Rockshox for the configuration of fork you have when it is in stock guise.

Step Two
Your starting air pressure should be approximately the same as your air pressure was before installing the Luftkappe, however, it’s easiest to get there in two or three steps.
a) Pressurise the fork to roughly 1/3 of the final pressure you are aiming for. You will notice the fork is now very stiff at the start of the travel and is topped out quite hard.
b) Compress the fork several times, very slowly, to allow pressure to equalize between the positive and negative chambers. You will feel a soft notch in the motion near the start of the stroke – if you hold the fork at that position you will feel it get softer over the space of a couple of seconds at most.
c) Once the two chambers are equalized fully, the fork will top out more gently.
d) After the two chambers are equalized, pump the fork up to roughly 2/3 the pressure you are aiming for and repeat the equalization process there.
e) Repeat the equalization process at full pressure.

Step Three
Ride your bike and adjust pressure and volume configurations as you see fit.

Questions?
Email steve@vorsprungsuspension.com
www.vorsprungsuspension.com