FIT
. R
EPLACEMENT OF THE ASSEMBLY MUST BE DONE TO CHANGE LENGTH
,
DIAMETER
,
OR HEADSET TYPE
(
THREADED OR
THREADLESS
). DO NOT
REMOVEORREPL ACETHESTEERERTUBE
,
THIS COULDRESULT IN LOSSOF CONTROLOFTHEBICYCLEWITH
POSSIBLESERIOUSAND
/
OR FATALINJURIES
.
4. Install the headset race firmly against the
top of the fork crown once the steerer tube
has been cut to proper length.
5 . Install the upper tubes into the lower crow n
and locate the lower crown so that 170mm of
u p per tubes extends above the lower crow n .
To rque the lower crown bolts to 60in-lb.
I M P O RTA N T: DO NOT EXCEED 170MM OF
EXPOSED UPPER TUBES ABOVE THE LOW E R
C ROW N , DOING THIS CAN CAUSE THE BOTTOM OF THE LOWER CROWN TO HIT THE FRONT T I R E
R E S U LTING IN THE LOSS OF CO N T ROL OF THE BICYCLE WITH POSSIBLE SERIOUS AND/OR FATAL INJURIES
6. Assemble the headset, upper crown and stem on the bic ycle. Adjust the headset so you feel no play or
drag. Complete the installation of the headset and stem according to the manufacturer ’s instructions.
Torque all the upper crown bolts to 60in-lb.
7. Complete the rest of the XL/XLC installation by following steps three through seven under “Installation
Instructions (Judy XC/SL),” page 5.
Tuning Your Fo rk
RockShox (JUDY) forks can be tuned to your particular weight, riding style, and terrain. Our forks are set up
for the 160 to 180lb (65 to 80Kg), all-around rider who spends equal time riding every off-road terrain
imaginable. Because you’re probably not that rider, you can benefit by making tuning adjustments to suit
your specific needs.For maximum tuning flexibility, purchase a RockShox Type 3 Tuning Kit (includes primary
and secondary coil springs).
When tuning suspension,always make one change at a time and write it down. Keeping a record lets you
know what changes you have tried and suggests what changes you might try. Ask a shop or local riders what
they have found works well. These resources are typically your best bet, but don’t hesitate to call RockShox
about specific tuning needs. A list of phone numbers is on Page 19.
R
IDE
H
EIGHT AND
S
PRING
P
RELOAD
A
DJUSTMENT
Judy is designed to compress (sag) when you are sitting on the bike. This sag allows the front wheel to stay
in contact with the ground when braking and cornering over rough and uneven terrain. The optimum settings
are 7 to 15mm sag for 63mm travel;13 to 20mm for 80mm travel;and 18 to 25mm for 100mm travel.
Changing the preload alters the sag and firmness of the initial fork movement.To measure sag,install a zip tie
on the upper tube so that it is flush against the Resi-wiper seal;sit on the bike with normal riding apparel;
then step off your bike and measure the bottom of the zip tie to the top of the wiper. This measurement is the
amount of sag. For example, heavier, more aggressive riders need more spring preload to maintain proper ride
Fig.3
use any cantilever brake other than those intended by the brake manufacturer to work with a
hangerless brace. Do not route the cable through the stem or any other mounts or cable stops! The cable
should make a direct route from the brake lever to the RockShox fork brace mount and be able to freely
move up and down with the suspension movement. It may be necessary to install a whole new cable.
MPORTANT
: T
HE DISTANCEFROMTHE TOP OFTHE BRAKE CABLE HANGER TO THE BOTTOMOFTHE BRACE CABLE HOUSING STOP
MUSTBE A MINIMUMOF
12
MMWITHTHE BRAKES APPLIED
. A
N IMPROPERLY INSTALLEDFRONTBRAKE CABLE COULDRESULT
IN LOSSOF CONTROLOFTHEBICYCLEWITHPOSSIBLESERIOUSAND
/
OR FATALINJURIES
.
6. Adjust the front wheel quick release to clear the dropout ’s counter bore. The quick release nut must be
tightened after the wheel is properly seated into the dropouts counter bore. Make sure four or more
threads are engaged in the quick release nut when it is closed. Orient the quick release lever in front of
and parallel to the lower tube in the locked position.
7. Keep in mind tire clearance as you choose tires. Maximum tire size is 2.2”wide or 342mm radius. Be
sure to check this radius whenever you change tires. To do this, remove the spring stack (per the
instructions on following pages),and compress fork completely to make sure at least 5 mm of clearance
exists between the top of the tire and the bottom of the crown. Exceeding this maximum will cause the
tire to jam against the crown when the forks are fully compressed. The upper tubes must always be fully
engaged in the crown. The upper tubes, on clamp type crowns, must not extend above the crown more
than 1mm and must always be engaged in the crown.
Ju dy XL/XLC Installation Instru ct i o n s
1. Remove the existing fork and lower headset race from the bicycle.
2 . Be fo re you install a Ju dy XL/XLC on the
b i cyc l e,ve rify that the fo rk has been supplied
with the co rre ct upper crow n . Re fer to Fi g.2
for upper crowns available for Ju dy XL/XLC
and to maximize fo rk stiffness by pro pe r
s e l e ction and ori e nt ation of the upper crow n .
3 . The ste e rer tube may need cutting to
p ro per length.To cut the ste e rer tube,
re m oval of the upper tubes are re q u i re d.
This is nece s s a ry otherwise the uppe r
t u bes will be in the way when cutting
the ste e rer tube to pro per length. Th e
s te e rer tube length is dete rmined by the
fo l l owing part s : Ju dy XL/XLC uppe r
c rown ste e rer clamp length, s te m
s te e rer tube clamp length, f rame head
t u be length and top and bo t to m
headset stack height (see Fi g.3 ,n ext
p a g e ) . To ease in the assembly, do not install the JUDY XL/XLC upper crown on to the upper tubes unt i l
the ste e rer has been cut to the pro per length and the lower crown has been fastened in the re q u i re d
po s i t i o n .
H I N T: MEASURE TWICE AND CUT ONCE!
IMPORTANT: D
O NOT ADDTHREADS TO
R
OCK
S
HOX STEERERS
. T
HESTEERERTUBECR OWNASSEMBLY IS A ONE
-
TIMEPRESS
Fig.2
