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holes in the lower tubes.
9. Refit shaft bolts, apply blue Loc-tite on steel bolts, and use anti-seize on titanium bolts. Use 6 or 8mm
hex wrench to torque shaft bolts to 60 in-lb (7 Nm).
NOTE: I
T IS VERY EASY TO OVER TIGHTEN THIS BOLT WITH AN
10. Refit fork boot into double seal groove using small blade screwdriver. Engage boot with double seal
groove at the rear and rotate boot around the upper tube to fully engage its lower edge behind the
brace. A small amount of oil on the mating surfaces helps.
11. Repeat procedure on other leg.
12. On Judy SL, re-install the red external damping adjuster by applying a light coating of oil to the O-ring
and pushing it into the shaft bolt with an upward twisting motion.
The following section contains detailed service procedures for all individual components of the Judy fork.
The suspension travel on Judy forks can be changed by installing a different travel cartridge kit. First, remove
one-piece lower tube assembly by following the procedure described in To Clean and Grease Bushings and
Double Seal, page 12,to remove one-piece lower tube assembly.
T
HEN FOLLOW THESE DIRECTIONS TO CHANGE TRAVEL
1. Unscrew top cap using a 22mm 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 left upper tube. Note orientation
of parts, top to bottom: shaft-end plate, cartridge, cartridge washer (very
important), wave washer, 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. (For DH, repeat this
procedure on right leg to remove rebound damping cartridge.)
4. Pull the neutral shaft assembly free from the right lower tube. Note
orientation of parts, top to bottom:shaft end plate, upper shaft guide with
o-ring, washer, top-out bumper, lower shaft guide, and snap ring. (See Fig.
10) The shaft-end plate and upper shaft guide on the top of the neutral
shaft may remain in the upper tube. Remove the spring stack assembly as
described above. Tap the plate and guide out the bottom of the tube with
the long socket extension. (See exploded diagram, pages 7-10)
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 diagram, pages 7-10)
CAUTION: B
E SURE TO PROPERLY INSTALL CARTRIDGE WASHER AND WAVE WASHER
BETWEEN THE CARTRIDGE AND SNAP RING
8
MM HEX WRENCH
Service
C
T
HANGING
RAVEL
:
.
. U
.
SE A TORQUE WRENCH
Fig. 8
Fig. 9
Fig. 10
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