T
YPE
3 S
PRING
R
EPLACEMENT
The Ty pe 3 spring sys tem in Ju dy fo rks provide cutting edge pe rfo rm a n ce with the lively action of a coil spri n g
Howeve r, over time the springs can wear out, co m p romising pe rfo rm a n ce. This is ev i d e nt in co m p ression set
when the coil springs are shorter in a resting state than they we re when new. Fo l l ow the table listed be l ow as
a guide to kn ow when to re p l a ce the Ty pe 3 Sp ring Sys te m . Fo l l ow the dire ctions to clean and grease the spri n g
stack found on page 10, “After eve ry week or 8 hours of ri d i n g,” for re m oval and installat i o n .
T
YPE
3 S
PRING
S
YSTEM
S
PECIFICATION
T
ABLE
Travel
Primary Coil
Secondary Coil
Optimum
Replace
Optimum
Replace
XC and SL 63,80mm
67mm
65mm
92mm
90mm
XL/XLC 80mm
67mm
65mm
92mm
90mm
XL/XLC 100
117mm
114mm
180mm
176mm
C
ARTRIDGE
S
ERVICE
This is a no-maintenance cartridge . It is designed as a sealed unit with no serviceable parts inside. If the
cartridge fails it will be replaced by RockShox in accordance with the RockShox Warranty on page 19. To
receive a replacement cartridge contact your local R ockShox dealer or call RockShox direct (see “Warranty
Repair”,page 19 for the phone number).Cartridge removal can be done by following the steps under “Service:
Changing Travel” on page 12.
The cartridge is sealed at each end of the shaft. Apply a small amount of oil on the shaft to lubricate the seals
Over time, small amounts of oil leaving the cartridge may cause an air gap to form inside. The cartridge can
be refilled with oil if an air gap forms by following the instructions below.
1. To refill the cartridge, remove the screw in the damper shaft with a No. 2 Phillips head screwdriver.
2. Use a 4 to 5mm head syringe without a needle. Fill the syringe with RockShox 5wt.oil and insert it into
the cavity of the top of the damper shaft.
3. Apply pressure on the syringe plunger while c ycling the cartridge up and down.
4. Continue to cycle the cartridge until the air is removed from the system. Air no longer exists when the
gurgling noise stops while you are cycling the cartridge.
5. Remove the syringe tip from the top of damper shaft. A small amount of oil will flow back out of the
shaft—this is normal.
6. Insert the screw back into the damper shaft.
B
USHING
R
EPLACEMENT
The high quality bushings in RockShox forks are designed to last many months of hard riding. Protective
boots,a clean fork,and timely greasing are the keys to high performance and long bushing life. However,like
all moving parts, bushings will eventually wear and need replacement. Increased fore and aft movement of
seal groove at the rear and rotate boot around the upper tube to fully engage its lower edge behind the
brace. Compressing the boot and twisting as well as applying a small amount of oil on the mating
surfaces helps.
15.Install the external damping adjuster by applying a light coating of oil to the o-ring and pushing it onto
the shaft bolt with an upward twisting motion.
Se rv i ce
he following section contains detailed service procedures for all individual components of the Judy fork.
C
HANGING
T
RAVEL
he suspension travel on Judy forks can be changed by installing the matching Type 3 spring and damper
artridge kit (for spring selection,see basic spring tuning guide). First,remove one-piece lower tube assembly
by following the procedure described in,“To Clean and Grease Bushings and Resi-wiper Seal”,page 11.
HENFOLLOW THESEINSTRUCTIONS TO CHANGETRAVEL
:
1. Unscrew top cap using a 22mm or 24mm wrench or socket wrench. Remove the spring stack assemblies.
2. Remove the snap rings at the bottom of the upper tubes with small tip
internal snap ring pliers (see Fig. 8).
3. Pull the cartridge assembly free from the right upper tube. Note
orientation of parts, (top to bottom):shaft-end plate, cartridge, cartridge
shim (very important) and snap ring (see Fig. 9). The shaft-end plate on
the top of the cartridge shaft may remain in the upper tubes. Remove the
spring stack assembly as described above and tap the plate out the
bottom of the tube with the long socket extension.
4 . Pull the neutral shaft assembly free from the left lower tube. No te
o ri e nt ation of part s, ( top to bo t to m ) :s h a ft end plate, u p per shaft guide
with o-ri n g, wa s h e r, top-out bumpe r, l ower shaft guide, and snap ring (see
Fi g. 1 0 ) . The shaft-end plate and upper shaft guide on the top of the
n e u t ral shaft may remain in the upper tube. Re m ove the spring stack
assembly as descri bed above. Tap the plate and guide out the bo t tom of
the tube with the long soc ket extension (see ex p l oded diagra m s, pages 16
to 19).
5. Install new cartridge kit (cartridge assembly and neutral shaft assembly)
into upper tubes. Make sure all parts are clean,greased, and installed in
the proper order (see exploded diagrams, pages 16 to 19). Replace the
spring spacer with the new spacer provided in the kit.
6. Install snap rings with the sharp outside edge facing out into upper tube
ring grooves. Make certain snap rings are oriented correctly, and the snap
rings are fully seated in the ring groove of the upper tubes.
IMPORTANT: T
HE SNAPRINGSMUSTBEPROPERL Y ORIENTED
,
SHARPOUTSIDEEDGE FACINGOUT
,
ANDFULLY SEATEDINTHE
RINGGROOVE OFTHEUPPERTUBES
.
7 . Fo l l ow proce d u res “After Eve ry Mo nth or Twe nty - Fi ve Hours of Ri d i n g,”page 10, to co m p l e te the assembly.
Fig. 8
Fig. 9
Fig. 10
