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FTER EVERY MONTH OR
A
25
FTER EVERY MONTH OR
HOURS OF RIDING
T
O CLEAN AND GREASE THE SPRING STACKS
1. Unscrew the top cap using 22mm wrench or socket wrench. Remove the spring stack assembly and
clean the stack with degreaser. Wipe dry.
2. Inspect Type II spring for compression set. (See Spring Stack Specification Table under Type II Spring
Replacement Section, page 14.) Replace as needed.
3. Apply a thin coating of Judy Butter to the MCU.
4. Install assembly in upper tube, starting top cap threads by hand.
5. Torque top cap to 20-30 in-lb (2.3-3.4 Nm). This should be between 30-60 degrees of clockwise wrench
movement after cap is flush with upper tube.
6. Repeat procedure on other leg.
T
O CLEAN AND GREASE BUSHINGS AND DOUBLE SEAL
1. Mount the bike in a stand, disconnect the front brake cable, and remove
the front wheel. (The brakes do not need to be removed. Avoid
disassembling brakes unless absolutely necessary.).
2. Pull red external damping adjustment knob from left shaft bolt of Judy SL
with a downward twisting motion. (The external adjuster is press fit in
the shaft bolt.)
3. Partially loosen shaft bolts with a 6 or 8mm hex wrench, tap bolts firmly
with a mallet breaking shafts free from lower tube, and remove bolts
completely. (See Fig.5)
4. Slide off one-piece lower tube assembly. Remove fork boots. (See Fig. 6)
5. Clean upper tubes and inspect for wear and/or damage (nicks, scratches,
or dings).
6. Clean fork boots and slide onto uppers, and clean internals of lower tubes,
bushings (two per leg), and double seal. A lint-free rag wrapped to a long
3/8" drive socket extension wrapped with cloth tape works well.
IMPORTANT: C
LEAN LOWER BUSHINGS
7. Apply Judy Butter to the surface of the four bushings, the inside of the
lower tubes and fill the pocket between the lips of the double seal
completely. Use a socket extension wrapped with cloth tape dipped in
Judy Butter to reach inside the lower tubes. (See Fig. 7)
DO NOT
-
USE LITHIUM
BASED GREASE
Smear teflon based oil, 5wt oil or a thin layer of Judy Butter to the upper
tubes under the fork boots.
8. Install one-piece lower assembly onto upper tubes, carefully engage upper double seal lip with the
upper tubes, and gently rock the one-piece lower assembly to engage the lower bushings with the
upper tubes. When installed properly, the cartridge and neutral shaft threads are visible through the
25
HOURS OF RIDING
,
CLEAN AND GREASE THE SPRING STACKS
,
:
FOLLOW THIS PROCEDURE
,
:
DO THE FOLLOWING
,
6" (150
)
APPROXIMATELY
MM
FROM TOP
. I
T WILL REACT WITH THE COATING ON THE BUSHINGS
,
,
BUSHINGS
AND DOUBLE SEAL
Fig. 5
.
Fig. 6
.
Fig. 7
.
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