2004 Black Service Manual


Bushing Installation (CONT.)



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Bushing Installation (CONT.)





  1. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet until proper depth is achieved. If using depth gage, slide gage onto rod before installing weighted handle and let it settle on of Mandrel. Tap rod until appropriate line on gage is even with top of casting leg.




  1. Remove weighted handle and gage (if applicable).




  1. For sizing of the lower bushing:




  1. Use slotted top cap from sizer kit and set it into the top of the casting leg, straddling the threaded rod. Spin the extra nut with washer down to the top cap and using a wrench, socket, or speeder wrench, tighten the nut in a clockwise direction. This will cause the Mandrel to be pulled through the bushing, thus sizing it. Keep turning the nut until the tool is all the way through the bushing and can be pulled out of the leg.




  1. To install top bushings, repeat steps B-E. Note that the top bushing gets inserted until it stops against the step inside of the casting. The extra sleeve that comes with the sizer kit is used to space the top cap off of the casting, so that there is enough room to pull the sizers out of the casting without bottoming on the cap.




  1. If you find that the bushings are too tight after installing them, use the sizer Mandrel that does not have a stop on it to hold the bushing while installing it into the casting. This is available in the 25.4mm leg kit (85-5191) to go back in and resize the bushings.




  1. To resize bushings, Choose the next larger size rings and repeat the above process.




  1. When satisfied with the results, reinstall Dust/wiper seals and then reassemble fork



TROUBLESHOOTING


Symptom

Cause

Solution

Service Manual Page

Air Loss

Schrader Valve leaks

Tighten Valve core, replace bad parts as needed.

 

 

Air Cap O-ring leaks

Make sure O-ring is seated properly, replace parts as needed.

 

 

Air Piston leaks

Check oil volume on top of piston, replace parts as needed.

 

 

Air Top Cap leaks

Check O-ring, tighten cap to proper Torque, replace parts as needed.

 

Oil leaks from Wiper Seals

Seal not seated properly

Remove Casting from Inner Legs, reinstall or replace seals

 

 

Nicks or scratches on inner legs

Replace Crown/Steerer/Inner Leg Assembly

 

 

Too much Semi Bath oil

Follow instructions for removal and installation of Outer Casting

 

 

Wear

Remove Casting from Inner Legs, reinstall or replace seals

 

Oil leaks from bottom of Casting

Rebound damper shaft leaks

Replace Rebound Damping assembly

 

 

Rebound damper shaft O-ring damaged

Replace O-ring on threaded end of Rebound Damping assembly

 

 

Compression Rod Bolt leaks

Check O-ring on bolt to see if it is damaged and then reinstall

 

Lack of Travel

Tight Bushings

Resize bushings or replace with new ones if damaged

 

 

Hydraulic lock out

Replace Rebound Damping assembly

 

 

Semi Bath oil volume

Follow instructions for removal and installation of Outer Casting

 

 

Damper oil volume

Check oil level, Replace Rebound Damping assembly if needed

 

 

Fork alignment

Visually inspect fork, call Answer Products Customer Service

 

Loss of SPV damping

SPV valve not functioning

Inspect for damage, check valve gap, replace assembly if needed

 

 

Damper oil volume

Check oil level, refer to "Oil leaks from bottom of Casting"

 

 

Rebound knob does not turn

Replace Rebound Damping Assembly

 

 

Loss of SPV air pressure

Refer to "Air Loss- Schrader valve leaks and Air Cap O-ring Leaks"

 


TROUBLESHOOTING (CONT.)


Symptom

Cause

Solution

Service Manual Page

Fork Top out

Loss of Rebound Damping

Replace Rebound Damping assembly

 

 

SPV Valve not functioning

Refer to " Loss of SPV Damping - SPV valve not functioning"

 

 

Top out spring damaged

Inspect and replace Top out spring if needed.

 

 

Damping oil volume not correct

Check oil level, Replace Rebound Damping assembly if needed

 

Fork Bottom out

Too much SAG

Refer to SAG Set up in Tuning section of Owners Manual

 

 

Bottom out Bumper damaged

Inspect and replace Bottom out Bumper if needed

 

 

Damping oil volume not correct

Check oil level, Replace Rebound Damping assembly if needed

 

Play in Fork

Loose bushings

Resize bushings or replace with new ones if damaged

 

 

Loose Compression Rod bolt

Tighten bolt to specified torque

 

 

Loose Rebound damping shaft

Tighten Shaft to specified torque

 

 

Loose press fit tolerances

Call Answer Products Customer Service

 



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