COMPRESSION STACK, BOOTS, & COMPRESSION ROD REMOVAL:
1 Remove outer leg assembly.
2 Slide fork boots off of inner legs.
3 Press the bottom clip off the compression rod.
4 Slide off the bottom out elastomer from left leg compression rod.
5 Using a 15/16 wrench or socket unscrew the left inner leg cap. Then remove the compression
rod, elastomer and push rod.
AIR SPRING DISASSEMBLY:
1 Remove compression rod.
2 Let air out of air spring and remove top cap.
3 Push piston out top of left leg, with a 1/2 or smaller rod. Push through the center of the air
piston stop. (Air piston stop is not removable).
COMPRESSION ROD & AIR SPRING INSPECTION
1. Check the compression rod for obvious damage.
2. Check the fork boots for obvious damage.
3. Check all springs for obvious damage. Replace if necessary
4. Clean and inspect piston and seals, replace if seals are worn, nicked or torn.
5. Check all other parts for obvious damage, replace if necessary.
6. Replace all seals that have been removed.
COMPRESSION ROD & BOOTS REASSEMBLY:
1. Clean all parts thoroughly.
2. Grease compression rod lightly. Be sure rebound elastomer is installed onto compression rod.
3. Slide on end cap, second stage elastomer, and install bottom clip.
4. Install into left leg. Torque to 10-20 in-lbs (1.1-2.5 N-m).
5. Slide boots onto inner leg.
AIR SPRING REASSEMBLY:
1. Grease piston seals and threads in top of left leg.
2. Push the piston into the leg with the smaller hole facing down. Make certain piston is straight
and gently rock it back and forth while pushing down until it is past threads.
3. Install compression rod as described above.
4. Install outer leg assembly as described in section 10.
5. Pour 2.5 CC of 40-wt oil on top of air piston.
6. Install air cap, pressurize system and install knob.
WARNING:
Do not fill air spring with more than 190 psi.
REBOUND DAMPER DISASSEMBLY:
Note: Disassembly of the damping stack is not required unless you want to change or replace the
shim stack.
1. Remove outer leg assembly.
2. Remove the right compression damping assembly from the top of the right fork leg and pour
the oil out of the top of the fork and discard appropriately.
3. Using a 15/16 open end wrench or socket, unscrew the plastic end cap and pull the lower
shaft out of the inner leg.
