srsuntour workshop book

SR SUNTOUR workshop book, version 2008/Mar/25 page 3

workshop bookworkshop book

English

Warning!Only trained bike mechanics are allowed to carry out repairs and service work on SR SUNTOUR suspension forks.

DeutschGerman

Achtung!Es ist ausschließlich ausgebildeten Zweiradmechaniker erlaubt Reparatur- und Servicearbeiten an SR SUNTOUR Federgabeln vorzunehmen.

FrançaisFrench

Attention!Uniquement les mécaniciens cycle certifiés sont autorisés à réparer et entretenir les fourches SR SUNTOUR

ItalianoItalian

Attenzione:Escluso persone istruiti e qualificati in meccanico di biciclette e permesso di aggiustare le SR SUNTOUR forcelle, non appena i lavori di servizi.

ČeskyCzech

*POZOR!Opravy a servisní práce na vidlicích SR SUNTOUR jsou povoleny pouze proškoleným mechaniku*m

PolskiPolish

Uwaga!Tylko przeszkolonym mechanikom rowerów wolno dokonywać napraw i serwisu widelców amortyzowanych firmy SR SUNTOUR

Español Spanish

ATENCION!Sólo se permite llevar a cabo trabajos de reparación y servicio en las horquillas de suspension de SR SUNTOUR a mecánicos de bicicleta competentes.

РусскийRussian

Внимание!Ремoнт и сервисные работы по вилкам SR SUNTOUR разрешается производить исключительно специализированным и обученным механикам.

中文Chinese

注意 !只有接受過訓練的技工才會被允許進行修補 SR SUNTOUR 的避震前叉及服務性質的工作.

日本語Japanese

注意 !SR SUNTOUR のサスペンションホークは訓練を受けたメカニックのみ修理およびサービスが許されています。

Български език

Bulgarian

Внимание! Амортисьорните вилки SR SUNTOUR, могат да бъдат ремонтирани и поддръжани, само от оторизирани механици преминали курсовете за обучение!

Disclaimer


workshop bookworkshop bookTable Of Contents

Disclaimer ..........................................................................................3

I. Introduction ................................................... 7Introduction .....................................................................................8Abbreviations ...................................................................................9Addresses ....................................................................................... 10

SR SUNTOUR corporate ..................................................................................10

Worlwide Distributors ....................................................................................10

II. Owner’s manuals ......................................... 13Suspension Front Fork with Coil Spring or MCU .............. 14Suspension Front Fork with <Air/Air> / <air/hydraulic> or <coil spring/hydraulic> system ...................................... 16Rear Shock: Suntour RS6-XC PRO-LO, RS6-XC Pro-RL, RS7-EPICON-DA ............................................................................ 21DH-CT-600-Series Hub Dynamo............................................. 25

III. Service manuals ......................................... 27Mounting the remote lock-out single lever ....................... 28

Lock-out function setting ..............................................................................30

Mounting the remote lock-out single lever ....................... 31Lock-out function setting: .............................................................................33

Mounting and Operating the remote travel adjust control – New TA Lever................................................. 34Mounting and Operating the remote travel adjust control – Old TA Lever .................................................. 36

Travel adjustment setting .............................................................................38

Operating the hydraulic rebound damping ...................... 39Use and function of the hydraulic rebound damping ...........................39

Increase rebound speed .................................................................................39

Fork Model: Duro 2006 ...................................................................................39

Fork Model: Duro DJ 2007 - 2008.................................................................39

Fork Model: Axon / Epicon ............................................................................39

Decrease rebound speed ...............................................................................40

Fork Model: Duro DJ 2006 .............................................................................40

Setting the SAG for SR Suntour Forks ................................... 41Setting SAG for air spring forks ....................................................................41

Setting sag for rear suspension ....................................................................44

Use and function of the Lock-Out system .......................... 45Function of the Lock-Out knob: ...................................................................45

IV. Instruction Sheet for Suspension seat post SP-NCX-D3and SP-NEX-D4 ............. 47

Suspension Seat Post Instruction Sheet .............................. 48Before using the suspension seat post .......................................................48

Installation of the Suspension Seat Post ...................................................49

Installation of the saddle ...............................................................................49

Performance Tuning .......................................................................................51

How to increase the preload of the suspension seat post? ...................51

How to change coil springs ...........................................................................52

V. Charts ........................................................... 55Overview of the fork systems .................................................. 56Suspension Fork Air Pressure and Oil Level Chart ........... 58Rear Shock Pressure and Oil Level Chart ............................. 61Coil Spring Chart .......................................................................... 62Maximum possible rotor diameter ....................................... 71Serial Number Explanation ...................................................... 72Tightening Torque Chart ........................................................... 73Oil Type Chart ............................................................................... 74

VI. Fork Maintenance Manuals ...................... 75Fork Maintenance ........................................................................ 76Maintenance ................................................................................. 76Regular Maintenance: ................................................................ 76Important advice for fork service........................................... 77How to Replace Remote-Lock-Out + Damping (RLD) cartridge .......................................................... 78How to replace Remote-Lock-Out + Damping (RLD) cartridge ........................................................ 82How to replace Lock-Out (LO) cartridge ............................ 85How to replace the Travel-Adjust (TA) cartridge .............. 89

Old travel adjust top cap unit .......................................................................89

New travel adjust top cap unit .....................................................................92

How to solve air leaking problems ....................................... 94How to solve hydraulic Lock-Out issues .............................. 96How to solve Mechanical-Lock-Out (MLO) issues ............ 98How to convert the travel of an Axon fork .......................103How to convert the travel of an Epicon Suspension fork ...........................................................108How to change slider sleeves (plugged dust seals) .....113How to change slider sleeves (pressed-in dust seals) .116

VII. Exploded views SR SUNTOUR Suspension Forks ................... 119

SF7AXON-RLD .........................................................................................................120

SF7CR-8R ..................................................................................................................121

SF7CR-8R-MLO .......................................................................................................122

SF7CR-8V-MLO........................................................................................................123

SF7CR-8V ..................................................................................................................124

SF8DUROLUX20-TS ................................................................................................125

SF8DUROLUX 20-1.5 ..............................................................................................126

SF8 DURO FR20-160...............................................................................................127

SF7DURO-DJ-D .......................................................................................................128

SF7DURO-DJ-E .......................................................................................................129

SF8EPICON-RLD ......................................................................................................130

SF7EPICON-RL .........................................................................................................131

SF8EPICON-LOD .....................................................................................................132

SR SUNTOUR workshop book, version 2008/Mar/25, page 6


SF7EPICON-LO ........................................................................................................133

SF7EPICON-RLD ......................................................................................................134

SF7NEX4610-HLO-700-63 ....................................................................................135

SF8NEX4610-MLO-700-63 ...................................................................................136

SF8NEX4100-26-63 ................................................................................................137

SF8NEX4110-700-63 ..............................................................................................138

SF8NEX4600-HLO-26-63 ......................................................................................139

SF8NEX4600-MLO-26-63 .....................................................................................140

SF8NEX4510-MLO 700c ........................................................................................141

SF7NCX-E-RL-700-75 .............................................................................................142

SF8NCX-E-LO-700-63 ............................................................................................143

SF7NCX-D-RL-700-63 ........................................................................................... 144

SF7NCX-D-LO-700-63 ...........................................................................................145

SF7NCX-D-700-63 ..................................................................................................146

SF8NRX S-RLD .........................................................................................................147

SF8NRX S-RL ............................................................................................................148

SF8NRX S-LOD-63 ..................................................................................................149

SF8NRX S-LO............................................................................................................150

SF8NRX E-RL ............................................................................................................151

SF8NRX E-LO-63 .....................................................................................................152

SF7NRX-LO-63 ........................................................................................................153

SF8RAIDON-RL-air .................................................................................................154

SF8RAIDON-LO-air ................................................................................................155

SF8RAIDON-RLD ....................................................................................................156

SF8RAIDON-LOD ....................................................................................................157

SF8RAIDON-LO .......................................................................................................158

SF7X1-LO ..................................................................................................................159

SF7XCM-HLO ...........................................................................................................160

SF7XCM-MLO 26” ...................................................................................................161

SF7XCM-DA 26” ......................................................................................................162

SF7XCM 26” ..............................................................................................................163

SF7XCR-RL ............................................................................................................... 164

SF7XCR-LO ...............................................................................................................165

SF7XCR-DA ...............................................................................................................166

SF7XCR ......................................................................................................................167

SF8XCT V2 ............................................................................................................... 168

SF8XCT V2-MLO ......................................................................................................169

SF7 RL Remote Assembly......................................................................................170

chapter IIntroduction


workshop bookworkshop bookIntroduction

Dear Customer,

We would like to present you our new workshop book. It was developed to provide you with all necessary technical information about our products. Additionally it will give you a better understanding how our forks are designed and how they can be serviced.

Pictures are always just a snapshot, therefore it’s sometimes hard to understand what the working step really tries to explain. Moreover it’s a fact that not everyone speaks English! This led us to the decision to produce video manuals in which every little working step is explained. We consciously avoided nearly 100% of any written working instruction within these videos and worked instead with symbols which are known international. The “video manuals” will give you the opportunity to learn how to repair SR SUNTOUR forks step by step. In addition these videos can be used as an educational film during workshops for local dealers. We have enclosed a DVD at the last page of the workshop book. On this DVD you will find 10 video manuals which cover all major service issues plus it includes all exploded views of our 2006/2007/2008 suspension fork line up. In combination with the videos they will give you a powerful tool to maintain SR SUNTOUR forks.

Nevertheless not everybody has a computer in their bike workshop to watch the videos and repair the fork at the same time. Because of that we have additionally converted all videos into picture stories which you will find in chapter V.

We would like to give you a short overview about what you will find within this workshop book. In chapter II you will find all fork and rear suspension instruction sheets. Chapter number III provides you with all nec-essary information about the assembling of our different remote levers. Additionally it will give you better understandings how our lock out and rebound systems are working. One very important subitem within chapter number III is the instruction “How to set SAG”. In combination with the oil and air pressure chart it will help you to set the proper SAG for each of your customer’s forks. In chapter number VI we have put together all necessary technically information about SR SUNTOUR forks. You will find all picture stories in chapter number V. It also includes instructions how to convert the travel of EPICON and AXON forks. All questions regarding our suspension seat posts can be answered in chapter number IV. And within the chapter VII you will find all exploded views of our 2007-2008 suspension fork models.

A workshop book can never be finished as you always have small changes of the systems even during the year. Moreover some people might have some needs which are not covered within this book. Any time you may feel to have an idea which could contribute to an improvement of this book you are welcome to let us know!

We would like to thank you for the trust in SR SUNTOUR products and wish you the best for the 2008 bike season!

Best Regards

YOUR SR SUNTOUR TEAM


workshop bookworkshop bookAbbreviations

All Suspension ForksDA DAMPING ADJUST

ELDELECTRONICAL LOCK OUT + DAMPING ADJUST

HLO HYDRAULIC LOCK OUTLO LOCK OUTLOD LOCK OUT + DAMPING ADJUSTMLO MECHANICAL LOCK OUTRL REMOTE LOCK OUTRLD REMOTE LOCK OUT + DAMPING ADJUSTTAD TRAVEL ADJUST + DAMPING ADJUSTTR TRAVEL ADJUST + REMOTE LOCK OUT

NRX MODELSS AIRE COIL SPRING

NCX MODELSS AIRE AIRD COIL SPRING

DURO DJ E CroMo STEERER TUBEDJ D STKM STEERER TUBE

AXON MODELSS AIRE AIRD COIL SPRING

RADOMCW CHAIN WHEELCS CASSETTESL SHIFT LEVERRD REAR DERAILLEURFD FRONT DERAILLEURDB DISC BRAKESP SEAT POSTFT FIRM TECH



Worlwide Distributors

AUSTRIA KTM FAHRRAD GMBHHarlochner Str. 135230 MattighofenAustriaTel.: +43 7742 4091-34Fax: +43 7742 4094-26email: [email protected]: www.ktm-bikes.at

BENELUXJuncker Bike PartsFokkerstraat 253905 KV VeenendaalThe NetherlandsTel.: +31 (0) 318 553030Fax: +31 (0) 318 553211email: [email protected]: www.juncker.nl

BRAZILIntacRue alba; 1737-V. Santa; Catarina04346-000, Sao PauloBraziliaTel.: +55 11 55 65 21 00

COLOMBIAHA BICICLETASCalle 14 No. 52A-187ApartadoAero 368MedellinColombiaTel.: +57 4 28 55 04 0Fax: +57 4 25 53 34 3email: [email protected]

CZECH REPUBLICBP LUMENMr. Lukas BartaPuskinova 546542 32 UpiceCzech RepublicTel.: +420 49 9 88 13 27Fax: +420 49 9 88 27 93email: [email protected]: www.bplumen.cz

FRANCEWinora FranceFrancetel.: 0800 64 65 66Fax: +33 (0)38 052 8122email: [email protected]

FRANCESAV SR Suntour France (Service)Allee Ruby 1038500 VoironFranceTel.: +33 (0) 87 044 7093Fax: +33 (0) 47 605 1650email: [email protected]

GERMANYE.Wiener Bike Parts GmbHMax-Planck-Str. 897526 SennfeldPostfach 15 61, 97405 SchweinfurtGermanytel.: +49 9721 6501 88fax: +49 9721 6501 73

GERMANYZweirad-Einkaufs-Genossenschaft ZEGLongericher Str. 250739 KölnGermanytel.: +49 221 17959 - 20fax: +49 221 17959 - 31

Addresses

SR SUNTOUR corporate

EUROPESR SUNTOUR Europe GmbHAm Marschallfeld 6a83626 ValleyGermanyTel.: +49 8024 3038152Fax: +49 8024 4730984email: [email protected]

TAIWANSR SUNTOUR Inc.#7 Hsing Yeh RdFu Hsing Industrial ZoneChang HuaTaiwan, R.O.C.Tel.: +886 4 7695115Fax: +886 4 7694028email: [email protected]: www.srsuntour-cycling.com

CHINASR SUNTOUR (Shen Zhen) Inc.Suibei Industrial Zone Suibei RoadGongming Town, Baoan DistrictShen ZhenTel.: +86 755 27 10 55 33Fax: +86 755 27 10 56 33

CHINASR SUNTOUR Machinery (Kunshan) Co.Ltd.388 Matang Road PengLang, KunShandevelopment zone JiangSu Province CHINAZIP 215333Tel.: +86 512 578 12 53 0Fax: +86 512 578 12 56 1

USASR SUNTOUR USA503 Columbia street, Vancouver, WA 98660USATel.: +1 (360) 737 6450Fax: +1 (360) 60 737 6452email: [email protected]


workshop bookworkshop bookHUNGARYNeuzer KFTH-1211 Budapest, Csepel Muvek,Gyepsor UT 1Hungarytel.: +361 420 3760fax: +361 420 0847email: [email protected]: www.neuzer-bike.hu

ITALYSAIM S.P.A.Via Leon Battista Alberti 1020149 MilanoItalyTel.: +39 02 3491616Fax: +39 02 3491613email: [email protected]

JAPANRiteway Products Japan102 Ikebukuro city-hights3-18-34 Minami IkebukuroToshima-ku, TokyoJapanTel.: +81 (03) 59 50 60 02Fax: +81 (03) 59 56 80 28email: [email protected]: www.riteway-jp.com

MEXICOBICICLO S.A. DE C.V.Eje 126, No. 265 zona ind. del potosiSan luis potosi, S.L.P. 78395Mexicotel.: +52 444 824 0139fax: +52 444 824 0279email: [email protected]: www.turbo.com.mx

POLANDEuro Bike Productsul. Starolecka 1861 361 PoznanPolandtel. +48 61 87 87 368,web: www.eurobike.pl

RUSSIAAlna-Bike Co.Sokolnicheskaya square 4Moscow 107 113Russiatel / fax: +7 495 775 14 09email: [email protected]

SLOVAKIAKCK CYKLOSPORT-MODE s.r.o.Mierova 854/37972 47 OslanySlovakiaTel.: +421-46-549-2200Fax: +421-46-549-2350email: [email protected]: www.kck-oslany.sk

SPAINBH, S.A. BICICLETAS DE ALAVA S.A.Arcacha 101006 VitoriaSpainTel.: +34 (9)45 13 52 02 / 13 57 08Fax: +34 (9)45 13 93 21 / 23 48 10

SWITZERLANDSUSPENSION CENTERGurnigelstr. 113132 RiggisbergSwitzerlandtel.: +41 31 8093020fax: 41 31 8093022email: [email protected]: www.suspensioncenter.ch

U.K.GREYVILLE ENTERPRISES20 Europa way britannia enterprise parkLichfield, Staffs. WS14 9TZU.K.Tel.: +44 (0)1543 25 13 28Fax: +44 (0)1543 25 62 60E-MAIL: [email protected]

U.K.MOORE LARGE & CO. LTDDerby DE24 9GLSinfin laneSinfin lane industrial estateU.K.Tel.: +44 133 22 74 238Fax: +44 133 22 74 201email: [email protected]

chapter IIOwner’s manuals

Owner‘s Manual

Suspension front fork w. coil spring or MCU

1.) Before riding the bicycle, be sure the brakes are properly installed and adjusted. If the brakes do not work properly, the rider could suffer serious injuries. 2.) Do not ride the bicycle if you notice bent or broken parts at the fork, especially after a collision, sounds of excessive topping out, or other indications of a possible fork failure. In these cases, take your bike to a qualified bicycle mechanic for inspection and repair. 3.) Always use genuine SR Suntour parts. Use of other replacement parts voids the warranty and could cause structural failure to the suspension fork.

Read this instruction sheet thoroughly before using the suspension fork. Using the suspension fork inappropiately may cause serious injuries. Be sure to follow all warnings and caution indications. The instruction sheet contains important information on the correct installation and usage of the fork. After reading this instruction sheet, please be sure to keep it in a safe place for future reference. When transferring ownership of the suspension fork, give this instruction sheet to the new owner. As with any new suspension fork, there is a short period within moving parts will break in. During the first 300-500 km, the ride dynamics of the fork may change slightly. One of the things you may notice, is a small amount of play in the lower tubes. This movement is normal. Suspension forks can dramatically improve the comfort and control of your bicycle, but they can also change the way it handles, so always exercise caution and good judgement when getting used to your new setup.

IMPORTANT SAFETY INFORMATION

SR SUNTOUR recommends that your suspension fork be installed by a qualified bicycle mechanic, because it must be properly installed, adjusted and checked for safety. - The steerer tube must be cut to proper length correctly- Special tools and skills are required- If you install the fork by yourself, the completed installation must be inspected by a qualified bicycle mechanic and signed off to validate your warranty.

Installation instructions:The SR Suntour suspension forks are available both with threadless steerer and threaded ones: choose the right headset depending on the type of steerer you have. See manufacturer‘s installation guide for the headset and handlebar stem you are using!

- The SR SUNTOUR steerer tube may need cutting to the proper length. - To cut the steerer tube is not a job for untrained people, so let a professional mechanic install the fork. If you are going to tackle this job, get a good book on repairing bicycles and read it carefully. But in this case our warranty is void and SR SUNTOUR is not liable for incidental or consequential damages.

Tire clearance: Maximum tire size for the SR Suntour suspension forks is to be checked depending on the outer diameter for 28“/26”/24“ wheel size. Also, you have to check the tire width and you have to allow a minimum of 5mm between tire and the fork‘s lowers. Please keep in mind that the narro-west point at the lowers is usually at the height of the brake bosses - so you may have to deflate the tire in case you have to remove the wheel, depending on the tire width.Be sure to check the tire diameter and width whenever you change tires. To check the tire diameter, remove the top caps/or adjuster knobs and spring stack assemblies and compress the fork completely to make sure at least 10 mm of clearance exists between the top of the tire and the bottom of the crown. Exceeding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed.If you want to retrofit the bike with mudguards, you have to take into account that the clearance between tire and mudguard is now changed. Please check the clearance again as described above.

INSTALLATION

Handlebar Stems:- Minimum insertion of handlebar stem (for threaded steerers) There are two requirements: First, always insert the handlebar stem past the minimum insertion mark, as indicated on the stem. Second, make sure that the handlebar stem is inserted at least 10mm beyond the threaded length of the fork (see Fig 1.).- When using a Ahead type handlebar stem, be sure to never clamp the stem onto the threaded section of the steerer tube. Use a threadless steerer or cut off all the threads and use the threadless portion of a standard steerer.

Handlebarstem

Minimum insertion mark

Threaded length

More than 10mm

Steerer tube

Fig. 1

Headsets: Make sure that the headset you use matches the dimensions of your fork and frame. Refer to the instruction sheet that comes with your headset and carefully follow its instructions.Brakes:The SR Suntour suspension forks are designed to be used either only with V-type brakes or both with V-brake and discbrake. The use of discbrake can be seen on the left side lower, where the discbrake mounting tabs are present. Max. rotor diameter 160mm. Only XCM & XCR = 185mm. Please check the instruction manual of the brake manufacturer for technical details and dimensions. You need to make sure that the cable housing of your brakes can move freely and does not come in contact with any part of the fork while moving.

Intended use These types (only coil spring or MCU) of SR Suntour suspension forks are designed for leisure riding(swept blades type) and for sports and exercise (leading axle type). These forks are not intended to be used in downhill racing (see warning sticker on the fork)!!!

Notes on usage of the fork

LIMITED WARRANTY SR SUNTOUR warrants the suspension front fork to be free from defects in materials and workmanship under normal use for a period of two years from the date of purchase. In no event shall this limited warranty apply to any defect of the suspension fork caused by: improper installation, disassembly, re-assembly, intentional breakage or damage, alterations or modifications to the suspension fork by the user or other party or any unreasonable use or abuse of the product or any use for which this product was not intended. Plastic slider sleeves have only a limited warranty of 6 months from purchase.The obligation of this limited warranty shall be limited to repairing or replacing the suspension fork or any part for which there is a defect in materials or workmanship during the two years following the date of purchase. To validate this limited warranty the purchaser must submit this warranty card to SR SUNTOUR within 30 days after purchase of the suspension fork. Any alteration of, or tampering with the warranty card automatically terminates this limited warranty.SR SUNTOUR makes no express or implied warranties of fitness or merchatability of any kind, except as set forth above. SR SUNTOUR’s liability he-reunder is expressly limited to repair or replacement of the product. Under no circumstances will SR SUNTOUR be liable for incidental or consequential damages. Some jurisdictions do not allow the exclusion or limitation of liability of incidental or consequential damages, so the above exclusion may not apply to you. This warranty gives you specific rights and you may have other rights which vary from jurisdiction to jurisdiction.

In all places, the purchaser should contact the place of purchase for information about warranty service.

Date of purchase: Fork model name Serial no.

Term of limited warranty: Two years from the date of purchase

Dealer Name: Phone#:

Address:

Purchaser Name: Phone#:

Address:

This warranty is void without proof of purchase.

SR SUNTOUR EUROPE GMBHAm Marschallfeld 6a, 83626 Valley / GermanyPhone: 49-8024-3038152 / Fax: 49-8024-4730984E-mail: [email protected]

SR SUNTOUR USA 503 Columbia street, Vancouver WA 98660, USA Tel: 1-360-737-6450 / Fax: 1-360-737-6452 / E-mail: [email protected]

SR SUNTOUR INC. Specifications are subject to change without notice. Printed in TAIWAN.

Suspension Fork Warranty Card:

Adjusting Preload (where it applies) The preload adjustment allows the user to tune the response of the suspension fork as riding conditions demand and in accordance to his weight. The more preload you have, the more thrust it takes to get the fork to first move. The preload is adjusted by turning the preload adjustment knob at the top of the stanchion tube.Turning the adjustment knob clockwise increases the amount of preload, while turning the knob counterclockwise reduces the preload . Please turn the adjustment knobs first fully counter-clockwise and then count the full turns you make clockwise. Please adjust always by the same amount of turns on both sides.

SR Suntour website: www.srsuntour-cycling.com

If for any reason you feel that there is something wrong with the fork, by the way it handles or by unusual topping sounds, you must immediately stop using it and you have to take it to the dealer from which it was purchased, for inspection.

FOR DETAILED INFORMATION, TARGET CATEGORY AND EXPLODED VIEW OF YOUR FORK, PLEASE VISIT OUR WEB-SITE < WWW.SRSUNTOUR-CYCLING.COM> AND DOWNLOAD THIS INSTRUCTION SHEET FOR FUTURE REFERENCE!

After 25 hours

After every ride

After 50 hours

MAINTENANCEClean the stanchion tubes and the dustseal area (models w/o dustboots)Check for proper torque the main fixing bolts (10Nm) and top caps (3-4Nm)

Teflon oilbushings at the dealer

FOR MORE TUNING OPTIONS - HARDER/SOFTER SPRINGS AND MCU - PLEASE CONTACT YOUR LOCAL DEALER

Oil the dustseal area with

SR SUNTOUR INC. No.7 Hsing Yeh Road, Fu Hsing Industrial Zone,ChangHua,50606, Taiwan, R.O.C. Tel:00886-4-7695115 / Fax: 00886-4-769 4028 / E-mail: [email protected]

SERVICE AT THE DEALER1st. service Date:___________________ Signature of the dealer: ______________________ Stamp: __________________

2nd. service Date:___________________ Signature of the dealer: ______________________ Stamp: __________________You may use also the dealer‘s own business stationary in order to prove the date and frequency of the service intervals.

Function check of the fork and clean and grease service of

Instruction SheetSuspension front fork with <air/air> / <air/hydraulic> or < coil spring/hydraulic> system

1.) Before riding the bicycle, be sure the brakes are properly installed and adjusted. If the brakes do not work properly, the rider could suffer serious injuries.2.) Do not ride the bicycle if you notice bent or broken parts at the fork, especially after a collusion, sounds of excessive topping out, or other indications of a possible fork failure. In these cases, take your bike to a qualified bicycle mechanic for inspection and repair. 3.) Always use genuine SR Suntour parts. The use of other replacement parts voids the warranty and could cause structural failure to the suspension fork.

Read this instruction sheet thoroughly before using the suspension fork. Using the suspension fork inappropiately may cause serious injuries. Be sure to follow all warnings and caution indications. The instruction sheet contains important information on the correct installation and usage of the fork. After reading this instruction sheet, please be sure to keep it in a safe place for future reference. When transferring ownership of the suspension fork, give this instruction sheet to the new owner. As with any new suspension fork, there is a short period within moving parts will break in. During the first 300-500 km, the ride dynamics of the fork may change slightly. One of the things you may notice, is a small amount of play in the lower tubes. This movement is normal. Suspension forks can dramatically improve the comfort and control of your bicyc-le, but they can also change the way it handles, so always exercise caution and good judgement when getting used to your new setup.

IMPORTANT SAFETY INFORMATION

SR SUNTOUR recommends that your suspension fork be installed by a qualified bicycle mechanic, because it must be properly installed, adjusted and checked for safety. - The steerer tube must be cut to proper length correctly- Special tools and skills are required- If you install the fork by yourself, the completed installation must be inspected by a qualified bicycle mechanic and signed off to validate your warranty.

Installation instructions:The SR Suntour suspension forks with hydraulic system are available only with threadless steerer: choose the right headset for this „Ahead“ type of steerer. See manufacturer‘s installation guide for the headset and handlebar stem you are using!- The SR SUNTOUR steerer tube may need cutting to the proper length. - To cut the steerer tube is not a job for untrained people, so let a professional mechanic install the fork. If you are going to tackle this job by yourself, get a good book on repairing bicycles and read it carefully. But in this case our warranty is void and SR SUNTOUR is not liable for incidental or consequential damages.

INSTALLATION

1. Remove the existing fork and lower headset race from the bicycle. - Measure the length of the fork steerer tube against the length of the SR SUNTOUR steerer tube to determine whether it may need cutting to the proper length 2. In order to find out the proper length of the steering tube, you have to add up the following dimensions:- Head tube of the frame + stack height of the headset + stack height of the Clip on handlebar stem 3. Install the headset race firmly against the top of the fork crown. Install the fork assembly back on the bike. 4. Assemble the headset and handlebar stem on the bicycle. Adjust the headset so you feel no play or drag. - Complete the installation of the headset and stem according to the manufacturer‘s instructions. 5. Reinstall the handlebar.6. Install the brakes as per the manufactures instruction, making sure to adjust the brake properly. - Use the fork only with V-type brakes mounted to the existing cantilever bosses. Mount the disc brake only to the tabs provided at the left lower of the forks 7. Run the brake cable from the brake lever to the brake (V-type brake or Disc brake) making sure to leave enough cable housing to allow full travel of the fork.

Handlebar Stems:- Please use only “Ahead-type” handlebar stems for 1 1/8” (28.6mm) steerer diameter.- Follow the handlebar stem manufacturer’s installation manual and please mind to use the proper torque for this safety item.Headsets: Make sure that the headset you use matches the dimensions of your fork and frame. Refer to the instruction sheet or installation manual that comes with your headset and carefully follow its instructions.

Tire clearance: Maximum tire size for the SR Suntour suspension forks is to be checked depending on the outer diameterfor 28“or 26” wheel size. Also, you have to check the tire width and you have to allow a minimum of 5mm between tire and the fork‘s lowers. Please keep in mind that the narrowest point at the lowers is usually at the height of the brake bosses - so you may have to deflate the tire in case you have to remove the wheel, depending on the tire width.Be sure to check the tire diameter and width whenever you change tires. To check the tire diameter, remove the top caps/or adjuster knobs and spring stack assemblies and compress the fork completely to make sure at least 10 mm of clearance exists between the top of the tire and the bottom of the crown. Exceeding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed.If you want to retrofit the bike with mudguards, you have to take into account that the clearance between tire and mudguard is now changed. Please check the clearance again as described above.

Brakes:The SR Suntour suspension forks are designed to be used with V-brake and Discbrake. The use of discbrake can be seen on the left side lower, where the Discbrake mounting tabs are present. Please check the instruction manual of the brake manufacturer for technical details and dimensions. You need to make sure that the cable housing of your brakes can move freely and does not come in contact with any part of the fork.

- 1 -

MOUNTING OF THE REMOTE TRAVEL ADJUSTER AND REMOTE LOCK-OUT CONTROL

Mounting of the remote travel adjuster controlYou have the choice of two remote travel adjuster controls, depending on the drive train and shifter types you are using. Note: The travel adjustment cartridge is located on the left side of the fork.1.) If you use „Rapid Fire“ type of shifters you have to use the single remote travel adjuster lever included in the fork set (see photo # 1).a.) Mount first the remote travel adjustment lever on the handlebar. Use a 3mm Allen key for fastening of the lever bracket (see # 2). After that, you can mount the brake lever and the shifting levers.b.) Choose the right length of outer casing, in order to allow the unrestricted function of the fork. c.) Turn the cable tension adjustment barrel (see # 2) two turns counter-clock-wise in order to have adjustment clearance for the travel adjustment function.d.) Thread the cable through the outer casing stopper at the guide pulley and push the outer casing cap firmly in the outer casing stopper (see photo # 3).e.) Lead the cable around the guide pulley and thread it through the hole in the fixing bolt. The fixing bolt, washer and nut have to be placed into the hook of the cam lever. Tension the cable lightly and tighten the nut on the fixing bolt.f,) Now press the lever and at the same time push on the handlebar in order to compress the fork. At the end of this movement, release the lever and then the handlebar. Check if the fork stays in that position. If not, then you have to adjust the tension of the cable. To release the fork from that position, push the lever again and pull the handlebar (see photo # 4). Travel adjustment settinga.) If the cable tension is too high, the cam lever will be pushed all the time down. As such you will feel that the compression of the fork is too easy and the fork will extend eventually too slow. In such case, decrease the cable tension by turning the adjustment barrel (#5) clockwise (-), until the fork stops at the desired level and it will extend when you push the remote action lever again.b.) If the cable tension is too low, then the fork will not stay in the preselected position after you release the lever. In order to increase the cable tension, turn the adjustment barrel counter-clockwise (+), until the fork will stay in the preselected position (see photo #5).c.) In case you cannot adjust the fork using the adjustment barrel, you have to open the cable fixing nut and increase or decrease the cable tension at this point. After that, you can make the fine tuning again as described at a.) and b.).

Air pressure adjustmentIn case it is necessary to increase or decrease the air pressure in the travel adjustment cartridge, please proceed after the following steps:a.) Turn the adjustment barrel fully clockwise (-) and unhook the fixing bolt unit from the cam lever (see photo #7). b.) Remove the travel adjust push button. You will see now the „Schrader“ valve.c.) Using a fork pump with pressure gauge, increase or decrease the air pressure in accordance with the chart displayed on the next page. If you have a fork with air cartridge on the other side, please use the setting of the air chart on the SR Suntour website, attached to your fork model.2.) There is an option to use the I.C.E. (Integrated Control Equipment) type of lever - model DSM-XCR60-SC - for travel adjustment and remote lock-out.

Mounting of the lock-out control1.) If you use „Rapid Fire“ type of shifters you have to use the single remote lock-out lever included in the fork set (see photo #9).a.) Mount first the remote lock-out lever on the handlebar. Use a 3mm Allen key for fastening of the lever bracket (see #9). After that, you can mount the brake lever and the shifting levers.b.) Choose the right length of outer casing, in order to allow the unrestricted function of the fork. c.) Turn the cable tension adjustment barrel two turns counter-clockwise (#14)in order to have adjustment clearance for the lock-out adjustment function.d.) Thread the cable through the outer casing stopper and trough the cover cap hole and push the outer casing cap firmly in the outer casing stopper (#11).e.) Tension the cable lightly and tighten the fixing screw using a slot or cross type screwdriver.f,) Now push the lever to the right (see photo # 10) in order to lock the fork. Check if the fork is now locked, by pushing down the handlebar. If not, you have to adjust the tension of the cable.To unlock the fork, push the lever to the left and check if the fork is now unlocked. Lock-out function settinga.) If the cable tension is too high, the lock-out lever will not stay engaged and keep the fork in locked position. In such case, decrease the cable tension by tur-ning the adjustment barrel (#14) clockwise (-), until the lever will stay engaged.b.) If the cable tension is too low, then the fork will not be locked when you engage the lever. In order to increase the cable tension, turn the adjustment barrel counter-clockwise (+), until the fork will stay locked and the lever is still engaged.c.) In case you cannot adjust the fork using the adjustment barrel, you have to open the cable fixing screw and increase or decrease the cable tension at this point (see #13). After that, you can make the fine tuning again as described at a.) and b.).Don‘t forget to put an end cap on the cable for your protection (see #11).

Fixing bolt. Use a 3mm Allen key.

Cable tension adjustment barrel.

Cable nipple. Shifting cable type.

Cable fixing bolt

Cable guide pulley

Cam lever Press the lever and then the handlebar to check the function.

For your protection, insert an end cap at the cable end.

Decrease tension.

Increase tension.

Cam lever released.

Travel adjust push button.

„Schrader“ valve for air pressure adjust.

-

+

In this position, the fork is now locked.

Lever bracket fixing bolt.

Outer casing stopper

Cable clamping screw.

Cable tension adjustment barrel.

Here, the barell is screwed in completely. The support spring has to have space between the coils, in order to allow less cable tension adjustment.

Less tension.

More tension.

Cable clamping screw.

Pass the cable through this hole below the cable clamping screw.

For your protection, insert an end cap at the cable end.

12

3

4

5 6

7

8

9

10

11 12

13 14

- 2 -

Fork performance tuning

The SR Suntour suspension forks can be tuned for your particular weight, in accordance with the terrain and your personal preferences.

Setting SagSuspension forks will sag(dive in) more or less, depending on your weight and fork setting, when you mount the saddle and sit on your bike. The proper adjustment of sag allows the front wheel to keep contact with the ground during the ride. Sag is adjusted byincreasing or decreasing (depending of the fork model) - a.) the positive air pressure / b.) the preload on the spring stacks.

Travel Intended use Sag 80 mm Racing 8-12 mm 80 mm XC 12-16 mm 100 mm Racing 10-14 mm 100 mm XC 14-18mm 130 mm Freeride 20-25mm

To measure the amount of sag your fork is diving in, install a zip tie on the stanchion tube, at the level of the lower tube seal. Now, mount the saddle and sit on the bike in normal riding position, ride a short distance on flat ground and stepoff the bike. Measure the distance between the lower seal and the zip tie and you will find out the sag. In case of travel adjustment forks, set the fork to maximum travel (120mm) and check as described above. a.) Setting Sag by air pressure

f

Check following points:a) Visible damage of the fork - on upper or lower tubes, fork crown, brace, dropouts - like cracks, dents, as effects of a crash during the ride or of other causes.b) Tightness of the headset by pressing the braking lever of the front brake and pushing and pulling the bike in order to see if there is play.c) Brake pad adjustment on the rim and distance to the rim ( 1-2 mm is optimal)d) Brake lever travel - ideally the contact of the brake pad and rim should occur after 1/3 of lever travel rangee) Firmness of the brake assembly - apply the brakes several times and check carefully for loose nuts, bolts, etc.f) Front wheel must be centred within the fork tubes. Check proper torque on wheel quick release mechanism.

Check the fork before each ride and contact your dealer if you have any questions.

Dropout

Fork lowers

ForkCrown

Steerer

Travel adjus-ter/ Air system/

preload adj.

Lock-Out system /

Hydraulicsystem/

Air system

In order to adjust the air pressure, please be sure to use the following steps (Right and left side from rider’s perspective):1.) unscrew by hand the cover cap on the left or right side of the fork crown. In case of a travel adjustment fork, please follow the procedure described on the previous page in order to access the air valve.2.) attach the suspension fork air pump at the “Schrader” valve.3.) pump up the fork to the desired hardness level -> see chart.4.) remove the pump from the valve.5.) replace the cover cap.

b) Setting Sag by spring preload

In order to adjust the Sag by spring preload, measure first - as described above - the initial Sag, using the zip tie method.After you found out the amount of Sag you have, reduce or increase it, by using the preload knob on the top of the fork crown. By turning the preload knob clockwise, you increase the preload and reduce the Sag.By turning the preload knob counter-clockwise, you reduce the preload and increase the Sag. Please adjust the Sag in accordance with your personal preferences and use the values indicated above as guidance. If you are not able to adjust the optimum Sag, you need to change the fork‘s springs, to harder or softer ones.

Reboundadjuster

Stanchion

NOTE: Your fork‘s apperance may vary from the images shown in

this instruction sheet.For latest information please visit

our website:WWW.SRSUNTOUR-CYCLING.COM

Air valve cover cap

For more information and for ordering the suitable springs, please contact you authorized local dealer or visit our website at - WWW.SRSUNTOUR-CYCLING.COM. - to see the list of authorized international distributors.

The I.C.E. type control DSM-XCR60-SC

The remote lock-out control

The remote travel adjusterThe remote lock-out control

The remote lock-out control can be used separately, without the remote travel adjuster.

Rider weight Air pressure lb. kg. psi kgf/cm2

80 36 51 3,6100 45 64 4,5120 54 77 5,4140 64 91 6,4160 73 104 7,3180 82 117 8,2200 91 130 9,1220 100 143 10

Max. air pressure = 180psi/12.7kg/cm2

AIR PRESSURE CHART

Note: This chart is just for your reference and the values may vary depending on your riding style and terrain.For your specific suspension fork, please visit our website on: www.srsuntour-cycling.com, where you can find under your fork‘s model name a detailed air pressure chart as downloadable pdf document.

- 3 -

Fork features and function

Travel adjustment

This feature allows you to adjust the travel of your fork depending on your preferences and the terrain you’re riding.The travel adjustment allows you to change the way the bike handles, when you ride uphill or downhill. When you ride uphill, you push the lever (which is mounted on the handlebar) and push down the handlebar. You release the lever at the desired travel level of the fork. Now you can ride uphill in a more comfortable body position.When you ride downhill, you push the lever and pull the handlebar and the fork extends its travel to the maximum travel level. Now you can ride downhill in a more comfortable and safer body position.The infinitely variable travel can be adjusted from 60-120mm (130mm - depending on the fork model) steplessly.Remark: The changement of the travel of the fork doesn’t change the air spring rate. You have the same comfort at all travel levels.

HydraLock (lock-out feature)

This feature allows you to reduce bobbing while riding uphill or sprinting. In order to activate this function, you have either to push the “wishbone” shaped lever to the right - in case of a remote lock-out fork or to turn the lock-out knob located on the right side of the fork crown clockwise up to stop. In order to open the system for normal damping, you have to push the “wishbone” lever to the left in the case of a remote lock-out fork or turn the lock-out knob counter-clockwise. To perform both functions - lock or un-lock -> you need only one flip of your thumb in the case of the remote lock-out fork or a full turn of the lock-out knob for a standard lock-out fork.This function allows you only to have the hydraulic damping fully open or fully closed.

WARNING: Please don’t forget to un-lock your system when you’re riding rough terrain. Riding rough terrain with a locked system may damage your lock-out cartridge.

Preload adjustment

The preload adjustment allows the user to tune the response of the suspension fork as riding conditions demand and in accordance to his weight. The more preload you have, the more thrust it takes to get the fork to first move. The preload is adjusted by turning the preload adjustment knobs located on the fork crown.Turning the adjustment knob clockwise increases the amount of preload, while turning the knob counter-clockwise reduces the preload . Please check the chapter “Setting Sag” described before.

MaintenanceSR SUNTOUR forks are designed to be nearly maintenance free. However, as long as moving parts are exposed to moisture and contamination, performance may be reduced. To maintain high performance, safety and long life, periodic maintenance is required. The recommended intervals for maintenance are listed below.Lubricants and Cleaners:- Teflon fortified oil- SR SUNTOUR special grease (SRS No.9170-001) / high quality Teflon fortified grease.Damping oil:- SR SUNTOUR special damping oil (SR SUNTOUR special damper oil #PSF01-033 / Viscosity 11).Regular Maintenance:Before every ride, inspect the following parts:a) Front wheel and quick release for proper installation and adjustmentb) Fork for any obvious damage (crown, brace, upper tubes, lower tubes, and dropouts)c) Front brake cable for proper routingd) Front brake pads for proper contact with the rime) Front brake lever for proper adjustmentf) Headset for proper function and adjustment g) Stanchion tubes for scratches. In case of deeper scratches contact your local dealer for advice.

If you ride in extreme weather or terrain conditions, we recommend a more frequent maintenance.

(

RemoteTravel

AdjusterRemote

Lock-out System

Air system

Lock-out Air system

or coil spring

Coil spring

Open oil + coil spring

RemoteLock-out System

RemoteTravel

AdjusterAIR

System

We recommend the service after 50 and 100 hours of riding to be performed by a qualified bicycle mechanic. He has all necessary tools for this servíce and the necessary know-how.

After 25 hours

After every ride

After 50 hours

After 100 hours

After 200 hours

MAINTENANCEClean the stanchion tubes and the dustseal area Check for proper torque the main fixing bolts (10Nm) Oil the dustseal area with Teflon oilFunction check of the fork and clean and grease service of bushings at the dealerChange oil bath and lubricate remote lock-out cap from outside with Teflon oil Inspection and service of the complete fork at the dealer

In any case, if you feel that your fork’s performance has changed or it handles differently as normal - please contact immediately your local dealer to inspect your fork.

- 4 -

Notes on usage of the fork

LIMITED WARRANTY

SR SUNTOUR warrants the suspension front fork to be free from defects in materials and workmanship under normal use for a period of two years from the date of purchase. In no event shall this limited warranty apply to any defect of the suspension fork caused by: improper installation, disassembly, re-assembly, intentional breakage or damage, alterations or modifications to the suspension fork by the user or other party or any unreasonable use or abuse of the product or any use for which this product was not intended. The obligation of this limited warranty shall be limited to repairing or replacing the suspension fork or any part for which there is a defect in materials or workmanship during the two years following the date of purchase. To validate this limited warranty the purchaser must submit this warranty card to SR SUNTOUR within 30 days after purchase of the suspension fork. Any alteration of, or tampering with the warranty card automatically terminates this limited warranty.SR SUNTOUR makes no express or implied warranties of fitness or merchatability of any kind, except as set forth above. SR SUNTOUR’s liability he-reunder is expressly limited to repair or replacement of the product. Under no circumstances will SR SUNTOUR be liable for incidental or consequential damages. Some jurisdictions do not allow the exclusion or limitation of liability of incidental or consequential damages, so the above exclusion may not apply to you. This warranty gives you specific rights and you may have other rights which vary from jurisdiction to jurisdiction.

In all places, the purchaser should contact the place of purchase for information about warranty service.

SR SUNTOUR INC. No.7 Hsing Yeh Road, Fu Hsing Industrial Zone.Changhua.50606. Taiwan, R.O.C. Tel:00886-4-7695115 / Fax: 00886-4-769 4028 / E-mail: [email protected]

This warranty is void without proof of purchase.

SR SUNTOUR EUROPE S.A. Chaussee de Tervueren,43,1410 Waterloo. Belgium Tel: 0032-2-3544676 / Fax: 0032-2-354 7835 / E-mail: [email protected]

SR SUNTOUR USA P.O. Box 61988 Vancouver WA 98666 Tel: 1- 360 737 6450 / Fax: 1 360 737 6452 / E-mail: [email protected]

SR SUNTOUR INC. Specifications are subject to change without notice. Printed in TAIWAN.

Intended use The SR Suntour suspension forks are designed for Endurance/Freeride and moderate downhill riding (air system/hydraulic type forks) and Cross Country and All Road sports (hydraulic system/spring type forks). These forks are not intended to be used in downhill racing!!! Detailed information about the target category of your fork you can find on our website at - WWW.SRSUNTOUR-CYCLING.COM - where you can download this instruction sheet as interactive pdf. file.

If for any reason you feel that there is something wrong with the fork, by the way it handles or by unusual topping sounds, you must immediately stop using it and you have to take it to the dealer from which it was purchased, for inspection.

Date of purchase: Fork model name Serial number

Term of limited warranty: Two years from the date of purchase

Dealer Name: Phone#:

Address:

Purchaser Name: Phone#:

Address:

Suspension Fork Warranty Card:

SR Suntour website: www.srsuntour-cycling.com

- 5 -

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-DA

Alu

min

ium

bus

hing

body

Owne

rs Ma

nual

RS6

-XC

PRO-

LO / -

RL +

RS7

-EPI

CON-

DA, P

age 2

Upg

rade

you

r bik

e w

ith a

new

rear

sho

ckTo

repl

ace

a re

ar s

hock

on

an e

xist

ing

bike

whe

re it

has

not

bee

n eq

uipp

ed o

rigi-

nally

it is

impo

rtant

to fo

llow

sev

eral

ste

ps:

1.

Mak

e su

re th

at th

e ey

e-to

-eye

leng

th is

the

sam

e as

the

orig

inal

equ

ippe

d sh

ock.

Info

rmat

ion:

The

eye-

to-ey

e len

gth is

the d

istan

ce fr

om th

e cen

tre of

the b

olt at

the

head

of th

e sho

ck to

the c

entre

of th

e othe

r bolt

at th

e bas

e of th

e sho

ck.

WAR

NING

! If a

long

er sh

ock i

s ins

talle

d th

e geo

met

ry o

f you

r bike

is ch

ang-

ing.

Thi

s can

lead

to st

eerin

g pr

oblem

s and

a hi

gher

bot

tom

bra

cket

whi

ch

prev

ents

you

touc

hing

the g

roun

d wi

th yo

ur fe

et. T

his c

an re

sult

in lo

ss o

f co

ntro

l and

serio

us in

jury

or d

eath

2.

Rem

ove

your

old

sho

ck a

nd c

lean

the

insi

de s

urfa

ces

of th

e fra

me

and

swin

g ar

m, r

emov

e an

y di

rt an

d m

ake

sure

that

the

surfa

ces

are

clea

n.

3.

Mak

e su

re th

at y

ou a

re h

avin

g th

e co

rrec

t wid

th a

nd b

ore

diam

eter

alu

min

ium

bu

shin

gs a

t eith

er e

nd o

f the

sho

ck to

con

nect

the

shoc

k pr

oper

ly a

nd p

lay

free

to

the

fram

e an

d sw

ing

arm

. If y

our b

ike

and

prev

ious

sho

ck a

re h

avin

g a

diffe

rent

se

t up

you

may

nee

d to

con

sult

your

SR

SU

NTO

UR

dea

ler.

4.

Che

ck th

e m

ovem

ent b

y le

tting

out

the

air o

f the

sho

ck a

nd m

ove

the

swin

garm

th

roug

h th

e co

mpl

ete

shoc

k st

roke

. Mak

e su

re th

at y

ou h

ave

suffi

cien

t cle

aran

ce

betw

een

all c

ompo

nent

s to

acc

omm

odat

e th

e fu

ll tra

vel o

f the

rea

r sw

ing

arm

. K

eep

in m

ind

to c

heck

pro

blem

s in

con

sequ

ence

of l

ower

ed s

eatp

osts

and

diff

er-

ent s

hock

mou

ntin

g bo

res!

E

stab

lish

whi

ch w

ay y

ou a

re g

oing

to p

ositi

on th

e sh

ock

take

into

con

side

ratio

n ac

cess

to th

e ad

just

ers.

WAR

NING

! In

suffi

cient

clea

ranc

e be

twee

n th

e sh

ock,

seat

post

, sw

inga

rm,

fram

e or r

ocke

r can

resu

lt in

loss

of c

ontro

l and

serio

us in

jury

or d

eath

5.

The

tight

enin

g pr

oces

s re

quire

s on

ly a

med

ium

am

ount

of p

ress

ure,

as

the

alu-

min

ium

spa

cers

are

a to

lera

nce

fi t.

7.

Set

-up

the

shoc

k as

des

crib

ed in

the

set-u

p in

stru

ctio

ns

Set-u

p In

stru

ctio

ns

For

max

imum

per

form

ance

from

you

r S

R S

UN

TOU

R s

hock

, it i

s ne

cess

ary

to a

d-ju

st t

he s

ag a

nd t

he r

ebou

nd d

ampi

ng.

The

way

of

setu

p is

the

sam

e on

all

the

SR

SU

NTO

UR

RS

6-X

C P

RO

and

RS

7-E

PIC

ON

-DA

rear

sho

ck m

odel

s in

clud

ed in

th

is m

anua

l.A

djus

t the

sag

The

sag

is a

djus

ted

by v

aryi

ng t

he a

ir pr

essu

re a

nd h

as t

o be

det

erm

ined

by

the

rider

’s w

eigh

t, rid

ing

styl

e, fr

ame

desi

gn a

nd p

erso

nal p

refe

renc

e. In

crea

sing

the

Air

pres

sure

will

mak

e th

e sh

ock

com

pres

s le

ss d

urin

g th

e rid

e - t

hat m

eans

it w

ill fe

el

hard

er. D

ecre

asin

g th

e A

ir pr

essu

re w

ill m

ake

the

shoc

k to

com

pres

s m

ore,

it fe

els

softe

r.Th

e ai

r pre

ssur

e is

adj

uste

d w

ith a

sta

ndar

d sc

hrad

er v

alve

sho

ck p

ump

on th

e m

ain

air v

alve

.Ow

ners

Manu

al R

S6-X

C PR

O-LO

/ -RL

+ R

S7-E

PICO

N-DA

, Pag

e 3

The

reco

mm

ende

d am

ount

of s

ag is

as

follo

ws:

To

set

up

the

sag

you

will

nee

d to

mea

sure

how

muc

h th

e sh

ock

com

pres

ses

whe

n yo

u si

t on

your

bik

e in

a n

orm

al ri

ding

pos

ition

. You

r wei

ght s

houl

d be

on

the

sadd

le

and

your

feet

on

the

peda

ls. I

t may

be

nece

ssar

y to

hol

d yo

urse

lf up

aga

inst

som

e th

ing

stea

dy a

s a

wal

l. N

ow th

e ey

e-to

-eye

dis

tanc

e ha

s to

be

mea

sure

d. T

he p

er-

cent

ual d

iffer

ence

bet

wee

n th

e un

com

pres

sed

eye-

to-e

ye le

ngth

and

the

just

mea

-su

red

one

is c

alle

d sa

g. W

e re

com

men

d ge

tting

ass

itanc

e fro

m a

noth

er p

erso

n du

r-in

g th

at m

easu

rem

ent.

Incr

ease

or d

ecre

ase

the

air p

ress

ure

and

repe

at th

e m

easu

rem

ent t

o ge

t the

des

ired

amou

nt o

f sag

.

Info

rmat

ion:

The p

ress

ure r

ange

is 50

-200

psi. N

ever

exce

ed an

air p

ress

ure o

f 200

psi in

the

unco

mpre

ssed

shoc

k.

WAR

NING

! Rid

ing w

ith im

prop

er ai

r pre

ssur

e can

resu

lt in l

oss o

f con

trol a

nd re

sult

in s

erio

us in

jury

or d

eath

. Exc

eedi

ng th

e m

axim

um a

ir pr

essu

re o

f 200

lbs/i

nch

will

resu

lt in

serio

us in

jury

.

Adj

ust t

he re

boun

d da

mpi

ngR

ebou

nd d

ampi

ng c

ontro

ls th

e ra

te a

t whi

ch th

e sh

ock

deco

mpr

esse

s. T

he a

mou

nt

of n

eede

d re

boun

d da

mpi

ng is

var

ying

dep

endi

ng o

n th

e rid

ers

wei

ght r

espe

ctiv

ely

the

sprin

g ra

te w

hich

is s

et b

y th

e ai

r pre

ssur

e, th

e am

ount

of t

rave

l, th

e rid

ing

styl

e an

d pe

rson

al p

refe

renc

es.

The

best

way

to a

djus

t the

rebo

und

dam

ping

is to

dec

reas

e it

com

plet

ely

by tu

rnin

g on

the

red

adju

ster

whe

el a

nd te

st ri

de. I

ncre

ase

the

dam

ping

unt

il yo

u fe

el c

omfo

rt-ab

le a

nd s

afe

with

out t

he s

uspe

nsio

n ki

ckin

g yo

u ou

t of t

he s

addl

e.

WAR

NING

! Rid

ing

with

impr

oper

rebo

und

dam

ping

can

resu

lt in

loss

of c

ontro

l and

re

sult

in se

rious

inju

ry o

r dea

th.

Use

the

Lock

out

Whe

n yo

u ar

e rid

ing

uphi

ll so

met

imes

it g

ets

nece

ssar

y to

lock

the

mov

emen

t of t

he

susp

ensi

on s

yste

m t

o ha

ve le

ss p

ower

loss

in t

he t

rans

mis

sion

. W

ith t

he lo

ckou

t sy

stem

on

the

SR

SU

NTO

UR

RS

6-X

C P

RO

LO

you

can

sim

ply

lock

the

syst

em b

y sw

itchi

ng th

e le

ver f

rom

the

“lock

ed” t

o “u

nloc

ked”

pos

ition

on

the

blue

leve

r on

the

shoc

k. O

n th

e S

R S

UN

TOU

R R

S6-

XC

PR

O R

L it

is e

ven

easi

er b

y sw

itchi

ng th

e ha

ndle

bar r

emot

e le

ver.

Be

sure

to o

pen

the

lock

out w

hen

ridin

g in

roug

h te

rrai

n. T

his

ensu

res

you

the

max

i-m

um c

omfo

rt, ri

ding

con

trol a

nd p

reve

nts

the

oil p

ress

ure

in th

e in

side

of t

he s

hock

to

cau

se d

amag

es to

the

shoc

k.

WAR

NING

! Rid

ing

in lo

ckou

t pos

ition

und

er h

eavy

and

roug

h co

nditi

ons c

an re

sult

a sho

ck b

low

off a

nd i

n lo

ss th

e of c

ontro

l and

resu

lt in

serio

us in

jury

or d

eath

.

Cro

ss C

ount

ry:

10-2

5% s

agFr

eerid

e:

25-3

0% s

ag

Owne

rs Ma

nual

RS6

-XC

PRO-

LO / -

RL +

RS7

-EPI

CON-

DA, P

age 4

Mai

nten

ance

SR

SU

NTO

UR

RS

6-X

C P

RO

and

RS

7-E

PIC

ON

-DA

rear

sho

cks

need

s a

min

imum

of

mai

nten

ance

onl

y:•

Nev

er u

se a

hig

h pr

essu

re c

lean

er to

cle

an th

e sh

ock

• To

cle

an th

e sh

ock

it is

reco

mm

ende

d to

use

wat

er a

nd s

oap

only.

• Th

e ex

tens

ive

serv

ice

of

the

shoc

k in

tern

als

mus

t on

ly

be

done

by

a

AU

THO

RIZ

ED

SR

SU

NTO

UR

SE

RV

ICE

CE

NTE

R

WAR

NING

! Ope

ning

the

shoc

k wi

thou

t hav

ing

the

know

ledge

how

to d

o wi

ll re

sult

in se

rious

inju

ry.

• A

fter 2

500k

m o

f rid

ing,

take

out

the

mou

nt b

earin

g sl

eeve

on

both

sid

es o

f you

r sh

ock

for

insp

ectio

n an

d se

rvic

e. C

lean

the

m a

nd g

reas

e or

rep

lace

if n

eces

-sa

ry.

• G

et t

he s

ervi

ce d

one

on t

he in

tern

al p

arts

of

the

shoc

k do

ne m

ore

frequ

ently

w

hen

it is

use

d m

ainl

y un

der e

xtre

me

cond

ition

s.

Mai

nten

ance

She

dule

New

inst

alle

d sh

ock

/ new

bik

e:•

Che

ck m

ount

ing

hard

war

e to

rque

acc

ordi

ng to

the

bike

or f

ram

e m

anua

l•

Che

ck th

e ai

r pre

ssur

e•

Che

ck th

e re

boun

d da

mpi

ngB

efor

e ev

ery

ride:

• C

heck

Air

pres

sure

(it

is n

orm

al th

at th

e sh

ock

is lo

osin

g ai

r pre

ssur

e ov

er th

e tim

e)•

Mou

ntin

g ha

rdw

are

torq

ueEv

ery

2500

km:

• B

ring

the

shoc

k to

an

AU

THO

RIZ

ED

SR

SU

NTO

UR

SE

RV

ICE

CE

NTE

R f

ordo

ing

an e

xten

sive

ser

vice

on

the

inte

rnal

par

ts

Owne

rs Ma

nual

RS6

-XC

PRO-

LO / -

RL +

RS7

-EPI

CON-

DA, P

age 5

Owne

rs Ma

nual

RS6-

XC P

RO-L

O / -

RL +

RS7

-EPI

CON-

DA, P

age 6

LIM

ITED

WA

RR

AN

TYS

R S

UN

TOU

R w

arra

nts

the

rear

sho

cks

to b

e fre

e fro

m d

efec

ts in

mat

eria

ls a

nd

wor

kman

ship

und

er n

orm

al u

se fo

r a p

erio

d of

two

year

s fro

m th

e da

te o

f pur

chas

e.

In n

o ev

ent

shal

l thi

s lim

ited

war

rant

y ap

ply

to a

ny d

efec

t of

the

sus

pens

ion

fork

ca

used

by:

impr

oper

inst

alla

tion,

dis

asse

mbl

y, re

asse

mbl

y, in

tent

iona

l bre

akag

e or

da

mag

e, a

ltera

tions

or m

odifi

catio

ns to

the

rear

sho

ck b

y th

e us

er o

r oth

er p

arty

or

any

unre

ason

able

use

or a

buse

of t

he p

rodu

ct o

r any

use

for w

hich

this

pro

duct

was

no

t int

ende

d.Th

e ob

ligat

ion

of th

is li

mite

d w

arra

nty

shal

l be

limite

d to

rep

airin

g or

rep

laci

ng th

e su

spen

sion

fork

or a

ny p

art f

or w

hich

ther

e is

a d

efec

t in

mat

eria

ls o

r wor

kman

ship

du

ring

the

two

year

s fo

llow

ing

the

date

of p

urch

ase.

To

valid

ate

this

lim

ited

war

rant

y th

e pu

rcha

ser m

ust s

ubm

it th

is w

arra

nty

card

to S

R S

UN

TOU

R w

ithin

30

days

afte

r pu

rcha

se o

f the

rea

r sh

ock.

Any

alte

ratio

n of

, or

tam

perin

g w

ith th

e w

arra

nty

card

au

tom

atic

ally

term

inat

es th

is li

mite

d w

arra

nty.

SR

SU

NTO

UR

mak

es n

o ex

pres

s or

impl

ied

war

rant

ies

of fi

tnes

s or

mer

chat

abili

ty

of a

ny k

ind,

exc

ept

as s

et f

orth

abo

ve.

SR

SU

NTO

UR

’s li

abili

ty h

ereu

nder

is e

x-pr

essl

y lim

ited

to re

pair

or re

plac

emen

t of t

he p

rodu

ct. U

nder

no

circ

umst

ance

s w

ill

SR

SU

NTO

UR

be

liabl

e fo

r inc

iden

tal o

r con

sequ

entia

l dam

ages

. Som

e ju

risdi

ctio

ns

do n

ot a

llow

the

excl

usio

n or

lim

itatio

n of

liab

ility

of i

ncid

enta

l or c

onse

quen

tial d

am-

ages

, so

the

abov

e ex

clus

ion

may

not

app

ly to

you

. Thi

s w

arra

nty

give

s yo

u sp

ecifi

c rig

hts

and

you

may

hav

e ot

her

right

s w

hich

var

y fro

m ju

risdi

ctio

n to

juris

dict

ion.

In

all p

lace

s, th

e pu

rcha

ser s

houl

d co

ntac

t the

pla

ce o

f pur

chas

e fo

r inf

orm

atio

n ab

out

war

rant

y se

rvic

e.

Con

tact

and

Ser

vice

add

ress

Che

ck o

ur w

eb s

ite h

ttp://

ww

w.s

rsun

tour

-cyc

ling.

com

for l

ocal

dis

truto

rs a

nd s

ervi

ce

cent

res.

TA

IWA

NS

R S

UN

TOU

R IN

C.

No.

7 H

sing

Yeh

Roa

dFu

Hsi

ng In

dust

rial Z

one

Cha

ng H

uaTa

iwan

, R.O

.C.

Tel.:

+ 8

86 /

(0) 4

/ 76

95

115

Fax:

+88

6 / (

0) 4

/ 76

94

028

e-M

ail:

orde

rs@

srsu

ntou

r.com

.tw

EU

RO

PE

SR

SU

NTO

UR

EU

RO

PE

GM

BH

Am

Mar

scha

llfel

d 6a

, 836

26 V

alle

yG

erm

any

Tel.:

+49

/ (0

) 80

24 /

30 3

8 15

2Fa

x: +

49 /

(0) 8

0 24

/ 47

30

984

e-M

ail:

serv

ice@

srsu

ntou

reur

ope.

com

US

AS

R S

UN

TOU

R U

SA

P.O

. Box

619

88Va

ncou

ver,

WA

9866

6Te

l.: +

1 (3

60) 7

37 6

450

Fax:

+1

(360

) 737

645

2E

-mai

l: se

rvic

e@us

ulco

rp.c

om

SR S

UN

TOU

R D

H-C

T-60

0-Se

ries

Hub

Dyn

amo

Ow

ner’s

Man

ual

The

DH

-CT6

00-s

erie

s hu

b dy

nam

o is

a c

ompa

ct li

ght a

nd e

ffici

ent b

icyc

le d

ynam

o hu

b. It

is

deve

lopp

ed to

mat

ch th

e le

gal r

equi

rem

ents

, suc

h as

the

germ

an re

gula

tions

StV

ZO §

22a.

S

ome

of th

e re

quire

men

ts a

re in

crea

sed

effic

ianc

y, v

olta

ge li

mita

tion

and

a ch

arac

teris

tic o

f the

vo

ltage

to s

peed

rela

tion

whi

ch re

duce

s fli

cker

ing

whe

n rid

ing

at v

ery

low

spe

eds.

It is

opt

imiz

ed

in w

eigh

t and

rolli

ng re

sist

ance

. The

hub

is in

clud

ing

a st

ate

of th

e ar

t con

nect

or w

hich

mak

es

the

whe

el a

ssem

bly

as e

asy

as p

ossi

ble.

The

DH

-CT6

00-s

erie

s hu

b dy

nam

o gi

ves

you

one

of

the

best

fitte

d pr

oduc

ts w

hich

has

bee

n de

licat

ely

desi

gned

and

has

pas

sed

seve

re fi

eld

and

lab

test

s to

ach

ieve

the

best

per

form

ance

.U

sual

ly th

e hu

b dy

nam

o yo

u pu

rcha

sed

has

been

cor

rect

ly in

stal

led

and

prop

erly

adj

uste

d in

you

r bik

e by

aut

horiz

ed m

anuf

actu

rers

, dea

lers

or r

etai

lers

. In

som

e ca

ses

you

may

hav

e bo

ught

the

hub

dyna

mo

pack

age

inde

pend

ently

to re

plac

e yo

ur e

xist

ing

non

dyna

mo

front

w

heel

hub

or a

s re

plac

emen

t for

ano

ther

dyn

amo

hub.

In th

at c

ase

the

hub

mus

t be

asse

mbl

ed

into

the

front

whe

el b

y a

prof

essi

onal

whe

elbu

ilder

.A

lthou

gh th

e S

R S

UN

TOU

R h

ub d

ynam

o is

des

igne

d fo

r eas

y in

stal

latio

n, it

is n

eces

sary

to

know

som

e ba

sics

whi

ch a

re d

escr

ibed

in th

e fo

llow

ing

page

s. It

is in

any

cas

e re

com

men

ded

to re

ad a

nd fo

llow

the

man

ual’s

inst

ruct

ions

car

eful

ly b

efor

e in

stal

latio

n an

d us

age.

This

man

ual p

rovi

des

you

impo

rtant

info

rmat

ion

abou

t ins

talla

tion,

ope

ratio

n an

d m

aint

enan

ce.

If yo

u ha

ve a

ny p

robl

ems

with

inst

alla

tion

or th

e el

ectri

c pe

rform

ance

, ple

ase

stop

inst

allin

g or

rid

ing

and

cont

act y

our n

eare

st a

utho

rized

reta

iler f

or a

ssis

tanc

e.

If th

e m

anua

l will

not

be

unde

rsto

od p

rope

rly b

y th

e rid

er, p

leas

e co

nsul

t you

r dea

ler o

r ano

ther

sp

ecia

list.

In c

ase

child

ren

are

goin

g to

use

the

prod

uct,

the

pare

nts

shou

ld e

xpla

in th

e co

nten

t of

the

man

ual.

Kee

p th

is m

anua

l as

long

as

your

SR

SU

NTO

UR

DH

-CT6

00-S

erie

s hu

b dy

nam

o is

in u

se. O

n th

is w

ay y

ou c

an re

fer t

o th

e m

anua

l for

upc

omin

g qu

estio

ns d

urin

g us

e.Th

is m

anua

l cov

ers

the

follo

win

g S

R S

UN

TOU

R h

ub d

ynam

os:

• SR

SU

NTO

UR

DH

-CT6

24-3

2H (6

V, 2

.4W

, 32

spok

es)

• SR

SU

NTO

UR

DH

-CT6

24-3

6H (6

V, 2

.4W

, 36

spok

es)

• SR

SU

NTO

UR

DH

-CT6

30-3

2H (6

V, 3

.0W

, 32

spok

es)

• SR

SU

NTO

UR

DH

-CT6

30-3

6H (6

V, 3

.0W

, 36

spok

es)

War

ning:

Befor

e ins

tallat

ion of

the S

R SU

NTOU

R DH

-CT6

00-se

ries h

ub dy

namo

eq

uippe

d fro

nt wh

eel a

nd rid

ing yo

ur bi

ke re

ad th

is ma

nual

care

fully.

This

will

help

you

avoid

injur

y and

dama

ge on

your

hub d

ynam

o and

your

bike

. Eve

n if y

ou ar

e a ex

peri-

ence

d bicy

cle rid

er or

bicy

cle m

echa

nic an

d hav

e bee

n doin

g bicy

cle se

rvice

your

self f

or

year

s, it i

s imp

ortan

t to re

ad th

e man

ual c

omple

tely b

efore

you r

ide yo

ur bi

ke.

Infor

matio

n: Ch

eck o

ut we

b site

http:

//www

.srsu

ntour

-cycli

ng.co

m oc

casio

nally

for u

pdate

s on t

his

manu

al an

d safe

ty no

tices

. If yo

u hav

e any

ques

tions

after

read

ing th

is ma

nual

or th

e info

rmati

on

prov

ided o

n our

web

site

pleas

e con

tact y

our S

R SU

NTOU

R de

aler.

If you

r dea

ler ca

n’t ha

ndle

it plea

se co

ntact

us by

using

mail

, pho

ne or

the i

ntern

et (a

dres

ses a

re

show

n on t

he ba

cksid

e of th

e man

ual).

Dyn

amo H

ub O

wner

’s Ma

nual

DH-C

T600

-Ser

ies, p

age 1

fork

Inst

alla

tion

of th

e fr

ont w

heel

To in

stal

l the

fron

t whe

el fo

llow

the

step

s de

scrib

ed b

elow

:1.

loos

e th

e nu

ts (F

G9.

5) a

nd w

ashe

r whi

ch a

re p

lace

d on

the

left

and

the

right

sid

e of

the

axle

2. in

sert

the

front

whe

el in

to th

e fo

rk o

n th

at w

ay th

at th

e co

nnec

tor t

erm

inal

is lo

cate

d at

the

right

dro

pout

(whe

n lo

okin

g fro

m th

e bi

cycl

e ba

ck in

forw

ard

mov

ing

drec

tion)

. R

otat

e th

e te

rmin

al s

o th

at it

is a

ligne

d w

ith th

e le

g of

the

fork

.

Infor

matio

n: If t

he te

rmina

l con

necto

r is no

t alig

ned w

ith th

e low

er le

gs th

e cab

le ca

n be

dama

ged e

asier

. The

light

syste

m wi

ll not

prop

erly

work

then.

3. C

heck

if fr

ont w

heel

has

bee

n in

serte

d co

mpl

etel

y in

to th

e dr

opou

ts. T

ight

en th

e nu

ts o

n th

e rig

ht a

nd th

e le

ft si

de a

ltern

atel

y in

ste

ps u

ntil

you

reac

h th

e tig

hten

ing

torq

ue o

f 20N

m.

Mak

e su

re th

at th

e w

heel

is c

ente

red

betw

een

the

brak

es p

rope

rly a

fter t

ight

enin

g th

e nu

ts. I

f th

e w

heel

is o

ff-ce

nter

unt

ight

the

nuts

and

sta

rt th

e tig

hten

ing

proc

edur

e fro

m n

umbe

r 1 o

f th

is d

escr

iptio

n ag

ain.

WAR

NING

: Nev

er rid

e you

r bike

with

a off

-cente

r fixe

d fro

nt wh

eel. A

off-c

enter

fixed

fron

t wh

eel c

an ca

use a

malf

uncti

on of

the b

rake

or in

dama

ging t

he tir

e and

resu

lt in l

oss o

f co

ntrol

and s

eriou

s inju

ry or

death

.

dyna

mo

hub

conn

ectio

n te

rmin

al

fork

nut

was

her

was

her

dyna

mo

hub

nut

Dyn

amo H

ub O

wner

’s Ma

nual

DH-C

T600

-Ser

ies, p

age 2

Inst

alla

tion

of th

e el

ectr

ic c

able

s an

d co

nnec

tors

Infor

matio

n: De

pend

ing on

the h

ub sp

ecific

ation

s the

lamp

can o

nly be

used

with

a fro

nt-lam

p (6V

/ 2

,4W) o

nly or

a fro

nt- an

d rea

r lamp

(6V

/ 2.4W

+ 0.

6W).

Whe

reby

the D

H-CT

624-

xx hu

bs ar

e for

fron

t-lamp

use o

nly an

d the

DH-

CT63

0-xx

are f

or fr

ont-

and r

ear-l

amp u

se. D

epen

ding o

n the

lega

l requ

ireme

nts th

e typ

e of h

ub m

ust b

e cho

osen

.

Infor

matio

n: Th

e SR

SUNT

OUR

DH-C

T-60

0-Se

ries D

ynam

o Hub

is pr

epar

ed to

be co

nnec

ted

with

the la

mp sy

stem

throu

gh a

2-wi

re ca

ble. T

he re

comm

ende

d cab

le typ

e is h

aving

a se

ction

of

1mm2 an

d a to

tal di

amete

r of 1

.8 to

2mm

includ

ing th

e ins

ulatio

n.

War

ning:

Do no

t touc

h unis

olated

lectr

ic co

mpon

ents

(fx. u

nfixe

d cab

les, c

onne

ctor t

er-

mina

ls an

d mor

e) du

ring r

iding

or ro

tation

of th

e whe

el. To

uchin

g elec

tric pa

rts ca

n cau

se

electr

ic sh

ocks

and b

urns

.

front

lam

p

cabl

e (g

roun

d)

conn

ecto

r pl

ug

dyna

mo

hub

cabl

e

To c

onne

ct th

e la

mps

with

the

hub

follo

w th

e sh

own

inst

ruct

ion.

Stri

p 18

mm

of t

he in

sula

tion

on th

e lo

wer

end

of b

oth

cabl

es.

Gui

de th

e en

ds in

to th

e co

nnec

tor p

lug

whe

reas

the

right

cab

le

is th

e gr

ound

cab

le.

Con

nect

the

uppe

r end

of t

he c

able

with

the

conn

ecto

rs o

f the

la

mp.

Not

e: D

o no

t sw

itch

over

the

two

cabl

es. I

f the

y ar

e sw

itche

d ov

er th

en th

e la

mp

will

sho

w n

o fu

nctio

n.

If th

e la

mp

man

ufac

ture

r

If a

rear

lam

p is

con

nect

ed to

the

syst

em, t

his

is u

sual

ly c

on-

nect

ed d

irect

ly to

the

front

lam

p. C

heck

the

man

ual o

f the

fron

t la

mp

for f

urth

er in

form

atio

n. If

ther

e is

any

diffi

culty

or m

alfu

nc-

tion

plea

se a

sk y

our d

eale

r for

ass

ista

nce.

Dyn

amo H

ub O

wner

’s Ma

nual

DH-C

T600

-Ser

ies, p

age 3

LIM

ITED

WA

RR

AN

TYS

R S

UN

TOU

R w

arra

nts

the

dyna

mo

hub

to b

e fre

e fro

m d

efec

ts in

mat

eria

ls a

nd

wor

kman

ship

und

er n

orm

al u

se fo

r a p

erio

d of

two

year

s fro

m th

e da

te o

f pur

chas

e.

In n

o ev

ent s

hall

this

lim

ited

war

rant

y ap

ply

to a

ny d

efec

t of t

he s

uspe

nsio

n fo

rk

caus

ed b

y: im

prop

er in

stal

latio

n, d

isas

sem

bly,

reas

sem

bly,

inte

ntio

nal b

reak

age

or

dam

age,

alte

ratio

ns o

r mod

ifica

tions

to th

e dy

nam

o hu

b by

the

user

or o

ther

par

ty

or a

ny u

nrea

sona

ble

use

or a

buse

of t

he p

rodu

ct o

r any

use

for w

hich

this

pro

duct

w

as n

ot in

tend

ed.

The

oblig

atio

n of

this

lim

ited

war

rant

y sh

all b

e lim

ited

to re

pairi

ng o

r rep

laci

ng th

e dy

nam

o hu

b or

any

par

t for

whi

ch th

ere

is a

def

ect i

n m

ater

ials

or w

orkm

ansh

ip

durin

g th

e tw

o ye

ars

follo

win

g th

e da

te o

f pur

chas

e. T

o va

lidat

e th

is li

mite

d w

ar-

rant

y th

e pu

rcha

ser m

ust s

ubm

it th

e w

arra

nty

card

to S

R S

UN

TOU

R w

ithin

30

days

af

ter p

urch

ase

of th

e pr

oduc

t. A

ny a

ltera

tion

of, o

r tam

perin

g w

ith th

e w

arra

nty

card

au

tom

atic

ally

term

inat

es th

is li

mite

d w

arra

nty.

SR

SU

NTO

UR

mak

es n

o ex

pres

s or

impl

ied

war

rant

ies

of fi

tnes

s or

mer

chat

abili

ty

of a

ny k

ind,

exc

ept a

s se

t for

th a

bove

. SR

SU

NTO

UR

’s li

abili

ty h

ereu

nder

is e

x-pr

essl

y lim

ited

to re

pair

or re

plac

emen

t of t

he p

rodu

ct. U

nder

no

circ

umst

ance

s w

ill

SR

SU

NTO

UR

be

liabl

e fo

r inc

iden

tal o

r con

sequ

entia

l dam

ages

. Som

e ju

risdi

c-tio

ns d

o no

t allo

w th

e ex

clus

ion

or li

mita

tion

of li

abili

ty o

f inc

iden

tal o

r con

sequ

entia

l da

mag

es, s

o th

e ab

ove

excl

usio

n m

ay n

ot a

pply

to y

ou. T

his

war

rant

y gi

ves

you

spec

ific

right

s an

d yo

u m

ay h

ave

othe

r rig

hts

whi

ch v

ary

from

juris

dict

ion

to ju

risdi

c-tio

n. In

all

plac

es, t

he p

urch

aser

sho

uld

cont

act t

he p

lace

of p

urch

ase

for i

nfor

ma-

tion

abou

t war

rant

y se

rvic

e.

Con

tact

and

Ser

vice

add

ress

chec

k ou

r web

site

http

://w

ww

.srs

unto

ur-c

yclin

g.co

m fo

r loc

al d

istru

tors

and

ser

vice

ce

ntre

s.

SR

SU

NTO

UR

INC

. N

o.7

Hsi

ng Y

eh R

oad,

Fu

Hsi

ng In

d. Z

one.

C

hang

hua.

5060

6 Ta

iwan

, R.O

.C.

Pho

ne: +

886

(4) 7

6951

15

Fax:

+88

6 (4

) 769

402

8 E

-mai

l: or

ders

@sr

sunt

our.c

om.tw

SR

SU

NTO

UR

EU

RO

PE

GM

BH

A

m M

arsc

hallf

eld

6a

8362

6 Va

lley

Ger

man

y

Pho

ne: +

49 /

(0)8

024

/ 3 0

3 81

52

Fax:

+49

/ (0

)802

4 / 4

73

09 8

4 E

-mai

l: se

rvic

e@sr

sunt

oure

urop

e.co

m

SR

SU

NTO

UR

US

A P.

O. B

ox 6

1988

Va

ncou

ver W

A 98

666

Can

ada

Pho

ne: +

1 (3

60) 7

37 6

450

Fax:

+1

(360

) 737

645

2 E

-mai

l: se

rvic

e@us

ulco

rp.c

om

Dyn

amo H

ub O

wner

’s Ma

nual

DH-C

T600

-Ser

ies, p

age 4

chapter IIIService manuals


workshop bookworkshop bookMounting the remote lock-out single lever

Models: AXON / EPICON / NRX

a. Mount the remote lock-out lever on your handlebar. Use a 2.5mm allen key to fasten the lever. Afterwards you can mount your brake and shifting lever back on again

pict

ure

RL1.

1

b. Choose the right length of the cable casing in order to not interfere the function of the fork

c. Turn the cable tension adjustment barrel two turns counter-clockwise in order to have adjustment clearance for the lock-out function

pict

ure

RL1.

7


workshop bookworkshop bookd. Take off the plastic cover using a Allen

key

pict

ure

RL1.

2

e. Unscrew the cable fixing bolt with a 2.0mm Allen key. Thread the cable through the outer casing stopper and through the cover unit hole. Tension the cable slightly and tighten it.

pict

ure

RL1.

4

f. Cut the cable to a proper length

pict

ure

RL1.

5


workshop bookworkshop bookg. Make sure the fork is set to the “Un-

locked position” and the little plastic toothed wheel sits like shown on picture no. 6

pict

ure

RL1.

6

h. Reassemble the plastic cover again us-ing a 2.5mm Allen key

pict

ure

RL1.

2

i. Pull the remote lever to the “lock” position. Check if the fork is locked by pushing down your handlebar. If the fork is not locked, you have to adjust the tension of the cable. To unlock the fork, push the red knob upwards

Lock-out function setting

“Though the lock-out lever is on unlocked position, the fork stays locked”It means that the cable tension is too high. In such a case decrease the tension of the cable by turning the adjustment barrel clockwise until the fork stays unlocked.

“The remote lock-out lever stays not engaged”Again it means that the cable tension is too high. In such a case decrease the tension of the cable by turning the adjustment barrel clockwise until the lever stays engaged.

If the fork does not open up even after you decreased the tension of the cable it’s more likely that the cartridge it self has defect in material. In a case like this please be so kind and inform the distributor of SR SUNTOUR products or get directly in contact with SR SUNTOUR EUROPE GmbH.


workshop bookworkshop bookMounting the remote lock-out single lever

Models: Raidon / XCR / NCX

a. Mount the remote lock-out lever on your handlebar. Use a 2.5mm allen key to fasten the lever. Afterwards you can mount your brake and shifting lever back on again

pict

ure

RL2.

1


c. Turn the cable tension adjustment barrel two turns counter-clockwise in order to have adjustment clearance for the lock-out function

pict

ure

RL2.

2


workshop bookworkshop bookd. Take off the plastic cover

pict

ure

RL2.

3

e. Unscrew the cable fixing bolt with a 1.5mm Allen key.

pict

ure

RL2.

4

Thread the cable through the outer casing stopper and through the cover unit hole. Tension the cable slightly and tighten it

pict

ure

RL2.

5

f. Cut the cable to a proper length(approx 12mm)

pict

ure

RL2.

6


workshop bookworkshop bookg. Reassemble the plastic cover again

pict

ure

RL2.

7

h. Install a cable end cap at the end of the cut cable using a needle nose pliers pi

ctur

e RL

2.8

i. Pull the remote lever to the “lock” position. Check if the fork is locked by pushing down your handlebar. If the fork is not locked, you have to adjust the tension of the cable. To unlock the fork, push the red knob upwards

Lock-out function setting:

“Though the lock-out lever is on unlocked position, the fork stays locked”It means that the cable tension is too high. In such a case decrease the tension of the cable by turning the adjustment barrel clockwise until the fork stays unlocked.

“The remote lock-out lever stays not engaged”Again it means that the cable tension is too high. In such a case decrease the tension of the cable by turning the adjustment barrel clockwise until the lever stays engaged.

If the fork does not open up even after you decreased the tension of the cable it’s more likely that the cartridge it self has defect in material. In case like this please be so kind and inform the distributor of SR SUNTOUR products or get directly in contact with SR SUNTOUR EUROPE GmbH.


workshop bookworkshop bookMounting and Operating the remote travel adjust control – New TA Lever

Models: SF8 EPICON XC TAD SF8 DUROLUX SERIES

Note: The travel adjust cartridge sits within the left stanchion tube

a. Mount the remote travel adjust lever on your handlebar. Use a 2.5mm Allen key to fasten the lever. Afterwards you can mount your brake and shifting lever back on again

pict

ure

TAL2

.1

b. Choose the right length of the cable cas-ing in order to not interfere the function of the fork

c. Thread the cable through the outer casing stopper and through the cable clamp: Tension the cable slightly and tighten the cable firmly with the fixing bolt using a 2.5mm Allen key

pict

ure

TAL

2.2

d. Cut the cable to a proper length (approx. 12mm)

pict

ure

TAL2

.3


workshop bookworkshop bookworkshop bookworkshop booke. Install a cable end cap at the end of the

cut cable using needle nose pliers

pict

ure

TAL2

.4

f. To decrease the travel of the fork you have to press the lever and simultaneously compress the fork. Afterwards release the lever. To increase the travel, you have to press the lever again and the fork will come up itself


workshop bookworkshop bookMounting and Operating the remote travel adjust control – Old TA Lever

Note: The travel adjust cartridge sits within the left stanchion

a. Mount the remote travel adjust lever on your handlebar. Use a 2.5mm Allen key to fasten the lever. Afterwards you can mount your brake and shifting lever back on again

pict

ure

TAL1

.1


c. Turn the cable tension adjustment barrel two turns counter-clockwise in order to have adjustment clearance for the travel adjustment function

pict

ure

TAL1

.7d. Remove the plastic cover cap, using a

2.5mm Allen key.pi

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L1.2


workshop bookworkshop booke. Thread the cable through the outer

casing stopper and through the cable clamp. Tension the cable slightly and tighten the cable firmly with the fixing bolt using a Phillips screwdriver

pict

ure

TAL1

.3

f. Cut the cable to a proper length (approx. 12mm)

pict

ure

TAL1

.4

g. Reassemble the plastic cover cap using a 2.5mm Allen key

pict

ure

TAL1

.5


workshop bookworkshop bookh. Install a cable end cap at the end of

the cut cable using a needle nose pliers pi

ctur

e TA

L1.6

i. To decrease the travel of the fork you have to press the lever and simultane-ously compress the fork. Afterwards release the lever. If the fork does not stay in the lower position you have to adjust the tension of the cable. To increase the travel, you have to press the lever again and the fork will come up itself

Travel adjustment setting

If the cable tension is too low, the fork will not stay in the position pre-selected. In order to increase the cable tension, turn the adjustment barrel counter-clockwise (+), until the fork will stay in the pre-selected position.

In case you cannot adjust the fork using the adjustment barrel, you have to open the cable clamp-ing screw and increase or decrease the cable tension at this point. Afterwards you are able to perform the fine tuning like described above.


workshop bookworkshop bookOperating the hydraulic rebound damping

Use and function of the hydraulic rebound damping

The rebound damping function of SR SUNTOUR hydraulic forks allows you to tune your fork according to your personal preferences and weight as well as the terrain you are riding on. The rebound damp-ing function makes it possible to control the speed of the rebound of the fork after its compression. The degree of the required rebound damping varies according to the weight of the rider, the spring stiffness, style of riding and travel of the fork.

If the rebound of the fork is set to slow on a terrain with lots of small bumps, it will start bouncing and the front wheel can lose its contact to the ground. So if you are going to ride on terrain like this we rec-ommend increasing the rebound speed of the fork, so that it can keep its contact to the ground.

On the other hand you should lower the speed of the rebound while riding on terrain with bigger bumps. If the rebound speed of the fork is too fast on terrains like this, the fork will rebound too fast after being compressed. This contains the risk of losing control of your bicycle.

Increase rebound speed

In order to increase the speed of the rebound, you have to turn the rebound knob, which is located at the right lower dropout, counter-clockwise.

Fork Model: Duro 2006

In case the rebound speed is still to slow, there is the option of changing the standard oil (5W) to oil with a lower viscosity (2.5W). This fork tuning has to be carried out by an authorized and trained bike mechanic.

Fork Model: Duro DJ 2007 - 2008

In case the rebound speed is still to slow, there is the option of changing the standard oil (10W) to oil with a lower viscosity (7.5W). This fork tuning has to be carried out by an authorized and trained bike mechanic.

Fork Model: Axon / Epicon

Please note that the 7.5W oil can result into a failure of the lock out if it’s warmer than 5 degrees Celsius. According to the cold temperatures in winter season the 10W oil can slow down the reaction of the fork. In this case you have the possibility of changing the 10W to 7.5W oil.


workshop bookworkshop bookworkshop bookworkshop bookDecrease rebound speed

In order to decrease the speed of the rebound you have to turn the rebound knob clockwise. In case the rebound is still to fast, there is the possibility of changing the standard oil (10W) to oil with a higher viscosity (12.5W). This fork tuning has to be carried out by an authorized and trained bike mechanic.

Fork Model: Duro DJ 2006

In case the rebound is still to fast, there is the possibility of changing the standard oil (5W) to oil with a higher viscosity (7.5W). This fork tuning has to be carried out by an authorized and trained bike mechanic.


workshop bookworkshop bookSetting the SAG for SR Suntour Forks

Suspension forks will sag (dive-in) depending on the weight and seating position of the rider while you are sitting on your bike. The SAG is the compression which is just caused by the weight and seating position of the rider and not as a result of riding. Every rider has a different weight and seating position, therefore the fork will sag more or less. We deliberately renounced to give you an “air pressure chart by rider weight”, because we think that it makes no sense to give you a chart which carries just standard values though we know that every rider has a different weight and seating position which influences the fork in a different way. To assure a proper function of the fork and to not interfere the performance of it, setting a proper SAG is the only way to find the right air pressure for your fork. Moreover an adequate adjusted SAG enables the front wheel to keep contact with the ground during the ride.

Setting SAG for air spring forks

To set the SAG on a bike with an air spring fork, we recommend inflating the fork with a standard pres-sure of 73 psi (5 bar). Forks which come with travel adjust option have to be set to the maximum travel.

Warning: It is not allowed using any kind of compressor, normal bicycle pump or air pressure pump at gas stations to inflate your fork. Inflating the fork with a compressor will cause seri-ous damage which is not covered by warranty! SR SUNTOUR forks have to be inflated with special suspension fork air pumps.

63-100mm travel --> 15-20% sag120-180mm travel --> 20-25% sag

a. Place your bike on a flat ground (lean it against a wall so that you have something to hold on to)

b. Install a zip tie on the stanchion tube, at the level of the lower tube seal Pi

ctur

e 1


workshop bookworkshop bookworkshop bookworkshop bookc. Get on your bike – try to avoid any

bouncing of the fork Pict

ure

2

d. According to your own weight and seating position the fork will sag Pi

ctur

e 3

e. Get off your bike again – try to avoid compressing your fork while you’re getting off

f. Measure the distance between the lower tube seal and the zip tie Pi

ctur

e 4

140mm total travel60mm sag = 45%

Too Much!


workshop bookworkshop bookworkshop bookworkshop bookg. Inflate the fork until you have reached

the proper pressure Pict

ure

5

h. Get on you bike once more try to avoid any bouncing Pi

ctur

e 6

i. Measure the distance between the lower tube seal and the zip tie again. If you have achieved a proper SAG, take of the zip tie

Pict

ure

7

140mm total travel35mm sag = 25%

Proper SAG

The distance between your lower tube seal and the zip tie is the “SAG”. In our air pressure chart you will find the recommended “SAG” for each SR SUNTOUR fork. If you need to adjust the SAG once more please repeat the steps stated below until the fork is set to the right SAG.


workshop bookworkshop bookworkshop bookworkshop bookSetting sag for rear suspension

Warning: It is not allowed using any kind of compressor, normal bicycle pump or air pres-sure pump at gas stations to inflate your fork. Inflating the fork with a compressor will cause serious damage which is not covered by warranty! SR SUNTOUR forks have to be inflated with special suspension fork air pumps.

How to Inflate the fork:Unscrew the cover of the Schraeder valve on the left side of your fork. Regarding travel adjust 1. forks, please note that the “Schraeder” valve is being located at the lower drop out.

Mount the suspension fork air pump at the “Schraeder” valve (please only use a special suspen-2. sion fork air pump, do not use any kind of compressor, normal bicycle pump or air pressure pumps at gas stations).

adjust the air pressure according to your own weight and seating position, so that you achieve the SAG 3. which is recommended for your fork.

Dismount the pump from the valve4.

Reinstall the cover cap again5.


workshop bookworkshop bookUse and function of the Lock-Out system

Note: The Remote-Lock/Lock-Out cartridge is located at the right side of the fork

The lock out function of SR SUNTOUR forks is intended to reduce swaying during rides out of saddle or uphill riding. Every fork will sway according to the movements of your body. By locking the fork this can be almost eliminated. SR SUNTOUR forks will never be locked 100%. There will be a few millimeters of remaining travel even if the fork is locked. We call this sys-tem “Anti-Blow-Off-System”. It was developed to prevent you in case you have forgotten to unlock your fork while riding in rough terrain. Additionally it ensures that the fork will not get damaged when being compressed under high load.

Nevertheless we recommend not using the fork in the “Lock-Out-Mode” while riding in rough terrain, going down hill or jumping. There is always the possibility that the fork which is set to the locked position will get damaged when being compressed with a high load. That may also lead into a breakage of the hydraulic cartridge it self.

Function of the Lock-Out knob:

Locked PositionThis is the standard position of the LO knob if the fork is being set to the “Lock-Out-Mode”. We recommend to install the lock out knob like shown above if the fork is being set to the “Lock-Out-Mode”

Pict

ure

LO1

Note: There are two different lock-out cartridges available!

LO-cartridge Type 1:Picture No. 2 shows the position of the LO knob if the fork is being set to the “Unlock-Mode”. To set the fork into the “Unlock-Mode” you have to turn the LO knob 90°degree counter-clockwise until the stopper tab.

Pict

ure

LO2

LO-cartridge Type 2:Picture No. 3 shows the position of the LO knob if the fork is being set to the “Unlock-Mode”. To set the fork into the “Unlock-Mode” you have to turn the LO knob 180°degree counter-clockwise until the stopper tab.

Pict

ure

LO3

Note: If the fork doesn’t lock even if the LO knob is set to the “Lock-Out-Mode” or if the fork doesn’t unlock if even if the LO knob is set to the “Unlock-Mode”, please be so kind and take a lock at Chapter V sub-item 5.6. This instruction will show you how to reset the lock out system.

chapter IVInstruction Sheet

for Suspension seat post

SP-NCX-D3 and SP-NEX-D4


workshop bookworkshop bookSuspension Seat Post Instruction Sheet

Models: SP8-NCX and SP8-NEX

Before using the suspension seat post

Read this instruction sheet thoroughly before using the suspension seat post. The inappropriate use of the suspension seat post may cause serious injuries. Make sure to follow all warning and caution indications. This instruction sheet contains important information on the correct installation and usage of the suspension seat post. Please make sure to keep this instruction sheet in a safe place for future references after read-ing it. If the ownership of the seat post is transferred to another person, this instruction sheets has to be given to the owner.

Important Safety Information1. Do not ride your seat post, if it is only inserted until

the “minimum insertion mark” which visibly indicated on the front side of the seat post tube. Due to the high leverage of any seat post, it needs to be inserted approximately 10mm past the joint of the top tube and the seat tube in order to protect the frame from breaking.

2. Before each ride please make sure that the seat clamp is tightened to the proper torque value. Not securing the clamp can cause serious accidents, as the saddle may move during the ride. Follow the bicycle manu-facturer’s specification for the clamp torque value.

3. Always use genuine SR SUNTOUR parts. The usage of other replacement parts voids the warranty and could cause structural failure to the suspension seat post.

4. If you are going to use the suspension seat post in combination with a child seat, make sure to use a SR SUNTOUR neoprene protection cover to avoid any injuries to the child’s hand.


workshop bookworkshop bookInstallation of the Suspension Seat Post

SR SUNTOUR recommends your NCX or NEX suspension seat post is being installed by a trained and qualified bicycle mechanic. Only a qualified bike mechanic is able to assure a proper installed and adjusted suspension seat post.

If you are upgrading your bike by using a SR SUNTOUR suspension seat post, please follow the steps mentioned below:

1. Remove your old seat post

2. Clean the inside of the seat tube and check it for any burrs at the end of the seat tube slot

3. Grease the inside of the seat tube. If you are going to use a seat post shim, grease it in- and outside

4. Install the seat post and insert it past the “minimum insertion mark” and appox. 10mm past the joint of top and seat tube

Installation of the saddle

a. Unscrew the two fixing bolts using a 5mm Allen Key pi

ctur

e 1

b. Take off the upper clamp platepi

ctur

e 2


workshop bookworkshop bookc. Place the upper clamp plate on to

the saddle rail. Afterwards direct the gripper clamp through the two saddle rails and over the upper clamp plate.

pict

ure

4

d. Tighten the two fixing bolts until the saddle is already fixed but can still be adjusted.

pict

ure

5

e. Adjust the saddle that it is centered horizontal like shown in picture no. 6. pi

ctur

e 6

f. Tighten the two fixing bolts with a torque value of 12Nm.


workshop bookworkshop bookPerformance Tuning

SR SUNTOUR suspension seat posts can be tuned according to your personnel weight, riding style and the terrain you are riding on by adjusting the preload. The preload can be adjusted to fit the needs of riders between 144 to 220 lbs (65 to 100kg). If you are less than 144lbs (65kg) or more than 220lbs (100kg) you have the possibility to replace the standard springs to a softer one or a harder one. To change the springs of your suspension seat post, please follow the instructions stated un-der “How to change coil springs”.

If the SAG of your suspension seat post is too high (the saddle moves down and back) while you’re just sitting on your bike, you have to increase the preload of your seat post. A certain amount of SAG is OK. We recommend an SAG between 0mm-10mm travel, but this is an individual setting and depends as well on your weight, seating position and the terrain you are going to ride on. Chang-ing the preload will alter the SAG and breakaway torque.

How to increase the preload of the suspension seat post?

1. Reinstall the suspension seat post of your frame

2. To adjust the preload you have to turn the adjuster bolt clock-wise using a 6mm Allen key.

pict

ure

1

Do not turn the adjuster bolt counter-clockwise beyond the initial position at delivery. This can cause a failure to the preload adjuster bolt and can strip the threads. In this original position, around 10mm of the seat post thread should be visible.


workshop bookworkshop bookHow to change coil springs

1. Reinstall the suspension seat post of your frame

2. Unscrew the preload adjuster bolt

pict

ure

1

3. Slide out the coil springs

pict

ure

2Please find the different

coil spring setting combinations here:

weight [lbs]

weight [kg] Picture

Soft 99 – 165 45 – 75 SP3.1Standard 144 – 220 65 - 100 SP3.2

Hard 176 – 265 80 - 120 SP3.3

picture SP 3.1 picture SP 3.2 picture SP 3.3


workshop bookworkshop book4. Reassemble the coil springs back into

the seat post pict

ure

3

5. Tighten the preload adjuster bolt at least until 10mm of the whole thread is visible

pict

ure

4

6. Install the suspension seat back to your bike again

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2007

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UN

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, ver

sion

200

8/M

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5, p

age

60

wor

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2006

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UN

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200

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2008

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UN

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sion

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7,4

Soft

FEP2

01-2

020

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53,

420

4,7

SF8-

DU

RO F

R20

R

3510

0H

ard

on re

ques

t

Stan

dard

FEP2

0016

,620

02,

821

3,9

Soft

on re

ques

t

2008

/200

7 m

odel

s

MTB

For

ks 2

6”

A

B

C

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

63

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

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r

(A)

Inne

r di

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(B)

Ove

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leng

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(C)

Wire

di-

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)

Tu

rn o

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ire

Sprin

g ra

te

[mm

][m

m]

[mm

][N

/mm

][m

m]

[mm

]

SF7-

DU

RO D

J E

L35

80H

ard

FEP2

74-1

020

,620

94

1412

Stan

dard

FEP2

7420

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14

179,

9

Soft

on re

ques

t

SF7-

DU

RO D

J E

R35

80H

ard

on re

ques

t

Stan

dard

FEP2

7516

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02,

822

3,7

Soft

on re

ques

t

SF7-

DU

RO D

J E

L35

100

Har

d FE

P201

-10

20,6

230

417

10,5

Stan

dard

FEP2

0120

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23,

819

7,4

Soft

FEP2

01-2

020

,623

53,

420

4,7

SF7-

DU

RO D

J E

R35

100

Har

d on

requ

est

Stan

dard

FEP2

0016

,620

02,

821

3,9

Soft

on re

ques

t

SF7-

DU

RO D

J E

L35

130

Har

d FE

P173

-10

20,6

262

4,2

258

Stan

dard

FEP1

7320

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43,

824

5,9

Soft

on re

ques

t

SF7-

DU

RO D

J E

R35

130

Har

d on

requ

est

Stan

dard

FEP1

7216

,623

22,

827

3,1

Soft

on re

ques

t

SF7-

DU

RO D

J D

L35

80H

ard

FEP2

74-1

020

,620

94

1412

Stan

dard

FEP2

7420

,621

14

179,

9

Soft

on re

ques

t

SF7-

DU

RO D

J D

R35

80H

ard

on re

ques

t

Stan

dard

FEP2

7516

,618

02,

822

3,7

Soft

on re

ques

t

A

B

C

MTB

For

ks 2

6” c

ontin

ued

from

pre

viou

s pa

ge

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

64

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

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r

(A)

Inne

r di

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(B)

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di-

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)

Tu

rn o

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Sprin

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te

[mm

][m

m]

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][N

/mm

][m

m]

[mm

]

SF7-

DU

RO D

J D

L35

100

Har

d FE

P201

-10

20,6

230

417

10,5

Stan

dard

FEP2

0120

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23,

819

7,4

Soft

FEP2

01-2

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53,

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4,7

SF7-

DU

RO D

J D

R35

100

Har

d on

requ

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Stan

dard

FEP2

0016

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02,

821

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Soft

on re

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SF7-

DU

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130

Har

d FE

P173

-10

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262

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258

Stan

dard

FEP1

7320

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Soft

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SF7-

DU

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R35

130

Har

d on

requ

est

Stan

dard

FEP1

7216

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827

3,1

Soft

on re

ques

t

SF8-

RAID

ON

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3210

0H

ard

on re

ques

t

Stan

dard

FEP3

5919

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24,

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11,2

Soft

on re

ques

t

SF8-

RAID

ON

-RLD

3212

0H

ard

on re

ques

t

Stan

dard

FEP3

6319

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44,

327

9,2

Soft

on re

ques

t

SF8-

RAID

ON

-LO

D32

100

Har

d on

requ

est

Stan

dard

FEP3

5919

,525

24,

526

11,2

Soft

on re

ques

t

SF8-

RAID

ON

-LO

D32

120

Har

d on

requ

est

Stan

dard

FEP3

6319

,527

44,

327

9,2

Soft

on re

ques

t

A

B

C

MTB

For

ks 2

6” c

ontin

ued

from

pre

viou

s pa

ge

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

65

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

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r

(A)

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r di

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(B)

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(C)

Wire

di-

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)

Tu

rn o

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ire

Sprin

g ra

te

[mm

][m

m]

[mm

][N

/mm

][m

m]

[mm

]

SF8-

RAID

ON

-LO

3210

0H

ard

on re

ques

t

Stan

dard

FEP3

8119

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92,

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8,5

Soft

on re

ques

t

SF8-

RAID

ON

-LO

3212

0H

ard

on re

ques

t

Stan

dard

FEP3

8019

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04

267,

4

Soft

on re

ques

t

SF7-

XCR-

RL30

80H

ard

on re

ques

t

Stan

dard

FEP2

52-7

019

216

3,8

218,

2

Soft

FEP2

52-4

019

217

3,2

204,

7

SF7-

XCR-

RL30

100

Har

d FE

P251

-90

18,7

237

428

7,7

Stan

dard

FEP2

51-8

019

236

3,8

266,

6

Soft

FEP2

51-3

019

239

3,2

253,

8

SF7-

XCR-

RL30

120

Har

d on

requ

est

Stan

dard

FEP2

36-8

019

236

3,8

266,

6

Soft

FEP2

36-5

019

264

3,2

303,

1

SF7-

XCR-

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80H

ard

on re

ques

t

Stan

dard

FEP2

52-7

019

216

3,8

218,

2

Soft

FEP2

52-4

019

217

3,2

204,

7

SF7-

XCR-

LO30

100

Har

d FE

P251

-90

18,7

237

428

7,7

Stan

dard

FEP2

51-8

019

236

3,8

266,

6

Soft

FEP2

51-3

019

239

3,2

253,

8

SF7-

XCR-

LO30

120

Har

d on

requ

est

Stan

dard

FEP2

36-8

019

236

3,8

266,

6

Soft

FEP2

36-5

019

264

3,2

303,

1

A

B

C

MTB

For

ks 2

6” c

ontin

ued

from

pre

viou

s pa

ge

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

66

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

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r

(A)

Inne

r di

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(B)

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leng

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(C)

Wire

di-

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)

Tu

rn o

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ire

Sprin

g ra

te

[mm

][m

m]

[mm

][N

/mm

][m

m]

[mm

]

SF7-

XCR-

DA

3080

Har

d on

requ

est

Stan

dard

FEP2

52-7

019

216

3,8

218,

2

Soft

FEP2

52-4

019

217

3,2

204,

7

SF7-

XCR-

DA

3010

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ard

FEP2

51-9

018

,723

74

287,

7

Stan

dard

FEP2

51-8

019

236

3,8

266,

6

Soft

FEP2

51-3

019

239

3,2

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8

SF7-

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DA

3012

0H

ard

on re

ques

t

Stan

dard

FEP2

36-8

019

236

3,8

266,

6

Soft

FEP2

36-5

019

264

3,2

303,

1

SF7-

XCR

3080

Har

d FE

P252

-50

1921

53,

820

8,6

Stan

dard

FEP2

52-3

019

217

3,5

206,

5

Soft

FEP2

52-4

019

217

3,2

204,

7

SF7-

XCR

3010

0H

ard

FEP2

51-4

019

236

3,8

256,

9

Stan

dard

FEP2

51-2

019

238

3,5

255,

2

Soft

FEP2

51-3

019

239

3,2

253,

8

SF7-

XCR

3012

0H

ard

FEP2

36-4

019

257

3,8

296

Stan

dard

FEP2

36-3

019

260

3,5

304,

3

Soft

FEP2

36-5

019

264

3,2

303,

1

SF7-

XCM

-HLO

3080

Har

d FE

P327

-40

18,6

225,

53,

618

8,4

Stan

dard

FEP3

27-3

018

,623

7,5

3,5

216,

5

Soft

FEP3

27-5

018

,622

9,5

3,2

205

SF7-

XCM

-HLO

3010

0H

ard

FEP3

19-4

018

,624

7,5

3,6

236,

5

Stan

dard

FEP3

19-3

018

,624

9,5

3,5

265,

2

Soft

FEP3

19-5

018

,624

9,5

3,2

263,

8

A

B

C

MTB

For

ks 2

6” c

ontin

ued

from

pre

viou

s pa

ge

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

67

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

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r

(A)

Inne

r di

amet

er

(B)

Ove

rall

leng

th

(C)

Wire

di-

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er(D

)

Tu

rn o

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ire

Sprin

g ra

te

[mm

][m

m]

[mm

][N

/mm

][m

m]

[mm

]

SF7-

XCM

-DA

30m

m80

mm

Har

dFE

P236

-40

18,6

225,

53,

618

8,4

Stan

dard

FEP2

36-3

018

,623

7,5

3,5

216,

5

Soft

FEP2

36-5

018

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9,5

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SF7-

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30m

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0mm

Har

dFE

P319

-40

18,6

247,

53,

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6,5

Stan

dard

FEP3

19-3

018

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9,5

3,5

265,

2

Soft

FEP3

19-5

018

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9,5

3,2

263,

8

SF7-

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-MLO

30m

m80

mm

Har

don

requ

est

Stan

dard

FEP3

2618

283

425

9,4

Soft

on re

ques

t

SF7-

XCM

-MLO

30m

m10

0mm

Har

dFE

P323

-10

1828

24,

228

10

Stan

dard

FEP3

2318

285

431

7,6

Soft

FEP3

23-2

018

285

3,7

345,

3

SF7-

XCM

30m

m80

mm

Har

dFE

P327

-10

1922

63,

821

8,2

Stan

dard

FEP3

2719

227,

53,

520

6,5

Soft

FEP3

27-2

019

228,

53,

218

5,2

SF7-

XCM

30m

m10

0mm

Har

dFE

P319

-10

1924

7,5

3,8

256,

9

Stan

dard

FEP3

1919

249,

53,

525

5,2

Soft

FEP3

19-2

019

249,

53,

225

3,8

SF8-

XCT

V2 M

LO 2

6”28

mm

80m

mH

ard

FEP2

89-4

016

282

427

11,6

Stan

dard

FEP2

89-3

016

282

431

10,1

Soft

FEP2

89-5

016

284

3,6

297,

5

SF8-

XCT

V2 2

6”28

mm

80m

mH

ard

on re

ques

t

Stan

dard

FE

P350

-30

1527

94,

536

,514

,8

Soft

FEP3

50-5

015

279

435

10,5

A

B

C

MTB

For

ks 2

6” c

ontin

ued

from

pre

viou

s pa

ge

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

68

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

ombe

r

(A)

Inne

r di

amet

er

(B)

Ove

rall

leng

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(C)

Wire

di-

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er(D

)

Tu

rn o

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ire

Sprin

g ra

te

[mm

][m

m]

[mm

][N

/mm

][m

m]

[mm

]

A

B

C

Trek

king

Bik

e Fo

rks

700c

SF8-

NRX

-E-R

L 70

0C30

mm

63m

m

Har

d on

requ

est

Stan

dard

FEP3

9115

,621

03,

422

8,7

Soft

on re

ques

t

SF8-

NRX

-E-L

O 7

00C

30m

m63

mm

Har

d on

requ

est

Stan

dard

FEP3

9115

,621

03,

422

8,7

Soft

on re

ques

t

SF8-

NRX

-LO

700

c30

mm

63m

m

Har

d FE

P335

-10

1921

03,

816

,510

,4

Stan

dard

FEP3

3519

211

3,6

187,

9

Soft

on re

ques

t

SF7-

NCX

-FT-

D-R

L 28

mm

63m

m

Har

d FE

P212

-70

1720

03,

822

10,3

Stan

dard

FEP2

12-1

017

197

3,5

218,

1

Soft

FEP2

12-6

017

203

3,2

225,

7

SF7-

NCX

-FT-

D-L

O28

mm

63m

m

Har

d FE

P291

1520

63,

219

9

Stan

dard

FEP2

5815

206

3,2

237,

4

Soft

on re

ques

t

SF7-

NCX

-D-R

L28

mm

63m

m

Har

d FE

P212

-70

1720

03,

822

10,3

Stan

dard

FEP2

12-1

017

197

3,5

218,

1

Soft

FEP2

12-6

017

203

3,2

225,

7

SF7-

NCX

-D-L

O25

.4m

m63

mm

Har

d FE

P291

1520

63,

219

9

Stan

dard

FEP2

5815

206

3,2

237,

4

Soft

on re

ques

t

SR S

UN

TOU

R w

orks

hop

book

, ver

sion

200

8/M

ar/2

5, p

age

69

wor

ksho

p bo

okw

orks

hop

book

Coil

Spri

ng C

hart

Mod

el

Stan

chio

n tu

be

diam

eter

Trav

elTy

pe o

f sp

ring

Part

s co

de N

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r

(A)

Inne

r di

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er

(B)

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leng

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(C)

Wire

di-

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)

Tu

rn o

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ire

Sprin

g ra

te

[mm

][m

m]

[mm

][N

/mm

][m

m]

[mm

]

SF7-

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-D25

.4m

m63

mm

Har

d FE

P291

1520

63,

219

9

Stan

dard

FEP2

5815

206

3,2

237,

4

Soft

on re

ques

t

SF8-

NEX

4610

-HLO

25

.4m

m63

mm

Har

d on

requ

est

Stan

dard

FEP2

6415

211

3,4

30-1

97.

0-11

.1

Soft

on re

ques

t

SF8-

NEX

4610

-MLO

25.4

mm

63m

m

Har

d on

requ

est

Stan

dard

FEP2

6415

211

3,4

30-1

97.

0-11

.1

Soft

on re

ques

t

SF8-

NEX

-411

025

.4m

m63

mm

Har

d FE

P335

-10

14,3

206

426

15,7

Stan

dard

FEP3

5514

,420

83,

829

11,7

Soft

on re

ques

t

SF8-

NEX

4600

-HLO

26”

25.4

mm

63m

m

Har

d on

requ

est

Stan

dard

FEP2

3815

209

3,2

34-2

15.

0-8.

1

Soft

on re

ques

t

SF8-

NEX

4600

-MLO

26”

25.4

mm

63m

m

Har

d on

requ

est

Stan

dard

FEP2

6415

211

3,4

30-1

97.

0-11

.1

Soft

on re

ques

t

SF8-

NEX

-410

0 26

”25

.4m

m63

mm

Har

d FE

P335

-10

14,3

206

426

15,7

Stan

dard

FEP3

5514

,420

83,

829

11,7

Soft

on re

ques

t

SF7-

CT-

SA 7

00c

25.4

mm

63m

m

Har

d FE

P181

1518

93,

426

8,1

Stan

dard

FEP1

6315

192

2,9

27-1

94.

5-6.

4

Soft

on re

ques

t

A

B

C

Trek

king

Bik

e Fo

rks

700c

con

tinue

d fr

om p

revo

ius

page

SR S

UN

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workshop bookworkshop bookworkshop bookworkshop bookMaximum possible rotor diameter

2008 MTB ForksDuro Series 210mmDurolux Series 210mmAxon Series 185mmEpicon Series 185mmRaidon Series 185mmXCR Series 185mmXCM Series 185mmXCT Series 160mmXCU Series 160mmM2000 Series 160mm

2008 Trekking ForksNRX Series 185mmNCX Series 185mmNCX FT Series 180mmNEX Series 180mm

2007 MTB ForksDuro Series 210mmRux Series 210mmXC-Pro Series 185mmAxon Series 185mmEpicon Series 185mmRaidon Series 180mmXCR Series 185mmXCM Series 185mmXCT Series 160mmXCU Series 160mmM2000 Series 160mmNEX 26” Series 180mm

2007 Trekking ForksNRX Series 185mmNCX Series 185mmNCX FT Series 180mmNEX Series 180mmM2000N Series 160mm


workshop bookworkshop bookworkshop bookworkshop bookSerial Number Explanation

country of origin year production

line month day

T 07 D 06 21

C 07 E 05 15

C = ChinaT = Taiwan


workshop bookworkshop bookworkshop bookworkshop bookTightening Torque Chart

Pos. Part to be tightened Tightening torque [Nm]*

1 Fork top cap (alloy) 102 Fork top cap (plastic) 53 Lower fixing bolt/nut 104 V-brake pivot 155 Upper and Lower crown fixing bolts 76 Through axle fixing bolt (Durolux 20/Duro FR20) 117 axle nut (BB XCR FX, Hexagon 28mm) 7-108 BB XCR FX crank fixing bolt (BB XCR FX) 40-45

* Tolerance: ±10%

1/2

3

4

sche

mat

ic g

raph

ic s

how

ing

nuts

and

bo

lts fo

r tig

hten

ing

torq

ue c

hart

5


workshop bookworkshop bookworkshop bookworkshop book

Oil Type Chart

Oil type Viscosity (40deg.c) wtKCE202 11cSt 5KCE207 31cSt 10

Oil type Viscosity ccAir chamber sealing oil 150 cSt 6

6

sche

mat

ic g

raph

ic s

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nuts

and

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sem

bly

BB-X

RC F

X

7

8

chapter VIFork Maintenance

Manuals


workshop bookworkshop bookFork Maintenance

Check your fork before each ride! Contact your dealer immediately if you recognize any dam-ages at your fork.

The following points need to be checked:

Visible damage(e.g. cracks, dents etc.) at the fork – on upper or lower tubes, fork •crown, brace, dropouts, as a result of a downfall, crash or other causes.The forks preload – The preload of the fork has to be set according to your weight and seating •position. For more information please take a look at the category: Setting the SAGTightness of the headset by pressing the brake lever of the front brake and pushing and pulling •the bike front- and backwards in order to figure out if there is any kind of play within the head-set.Brake pads adjustment on the rim and distance to the rim (1-2mm is optimal)•Brake lever travel – the brake pads and rim should contact each other after 1/3 of the whole •lever travel range.Check the firmness of the brake assembly – apply the brakes several times and check it carefully •for loose nuts, bolts etc.The front wheel has to be centered within the fork lower tubes. Check the proper torque for the •quick release mechanism.

Maintenance

SR SUNTOUR forks are designed to be nearly maintenance free. However, as long as moving parts are exposed to moisture and contamination, the performance of your fork might be reduced after several rides. To maintain a high performance, safety and a long life of your fork, a periodic mainte-nance is required.

Regular Maintenance:

Before every ride we recommend to check the following parts!a. Front wheel and quick release for a proper installation and adjustmentb. Fork for any obvious damage (crown, brace, upper, bottom case, drop outs)c. Front brake cable for proper routingd. Front brake pads for proper contact with the rim / abrasion of disc brake padse. Brake levers for proper adjustment and functionf. Headset for proper function and adjustmentg. Stanchion tubes for scratches. In case of deeper scratches contact your dealer immediately for an advice.

In any case, if you feel that your fork’s performance has changed or it handles differently as normal – please contact your dealer immediately to inspect your fork.


workshop bookworkshop bookWe recommend servicing the fork after 50 and 100hours of riding. This service has to be performed by a trained and qualified bike mechanic. If you ride in extreme weather and terrain conditions, we recommend carrying out the service more frequently.

Maintenance Schedule after every ride

after 25 hours

after 50 hours

after 100 hours

clean the stanchion tube and the dust seal areacheck the main fixing bolts for proper torque (Nm)oil the dust seal area with teflon oil or other fork oilcheck the function of your fork / clean and grease the bushings at the dealerchange oil and lubricate the remote lock and travel adjust beneath the top cap with teflon oilinspection and service of the complete fork at the dealer

Important advice for fork service

Your suspension fork requires periodic maintenance, as moisture and contamination may build up inside the fork depending on the weather conditions during your ride. In order to maintain the forks proper performance, we recommend to get it serviced (disassembling, cleaning, lubricating, adjusting) periodically by a trained and qualified bike mechanic. We strongly recommend this ser-vice if you intend to not using the fork for a long period of time.

Never use a high pressure spray gun for cleaning your fork, as water may enter the fork at the dust seal level.

The periodic greasing of the dust seals is very important, as it is linked directly to smooth function of the fork. At any time you may feel that your fork isn’t moving as smooth as before (even if you oiled the fork after each 25 hours) please contact your dealer to disassemble the fork and clean and grease the dust seals and metal bushings.

For each fork service at a dealer you should clean your fork!

Please keep in mind that a fork which has not been serviced in accordance with the maintenance recommendations will loose it’s warranty!


workshop bookworkshop bookHow to Replace Remote-Lock-Out + Damping (RLD) cartridge

Models:AXON / EPICON / NRX

a. Pull out the rebound adjuster knob using a needle nose pliers pi

ctur

e 1

b. Unscrew the fixing bolt half way using an 8mm Allen key pi

ctur

e 2

c. Hit the fixing bolt with plastic tip ham-mer slightly pi

ctur

e 3

d. Unscrew the fixing bolt full way and take it out pi

ctur

e 4


workshop bookworkshop booke. Unscrew the fixing bolt of the remote

lock cover cap using a 2.5mm Allen key

pict

ure

5

f. Unfasten the remote lock unit fixing bolt using a Phillips screwdriver No. 2 pi

ctur

e 6

g. Unfasten the remote lock cartridge us-ing a 27mm socket wrench pi

ctur

e 7

h. Take out the old cartridgepi

ctur

e 8


workshop bookworkshop booki. Before assembling the new cartridge

make sure that it is set to the unlocked position

pict

ure

9

j. Pull out the support tube assy full way

pict

ure

10

k. Tighten the new cartridge with 10Nm using a 27mm socket wrench pi

ctur

e 11

l. Fasten the damper fixing bolt with 6Nm using an 8mm Allen key pi

ctur

e 12

90° unlock


workshop bookworkshop bookm. Reassemble the rebound adjuster

knob pict

ure

13

n. Reinstall the remote lock out unit us-ing a Phillips screwdriver No.2 pi

ctur

e 14

o. Reinstall the toothed wheel and spring unit like shown on picture No. 15

pict

ure

15

p. Assemble the remote lock unit cover cap using a 2.5mm Allen key pi

ctur

e16

open position


workshop bookworkshop bookHow to replace Remote-Lock-Out + Damping (RLD) cartridge

Models: RAIDON RL / XCR RL / NCX RL

a. Unscrew the two fixing bolts half way using a 5mm Allen key pi

ctur

e 1

b. Hit the fixing bolts with plastic tip hammer slightly pi

ctur

e 2

c. Unscrew the fixing bolts full way and take them out pi

ctur

e 3

d. Separate upper and bottom case

pict

ure

4


workshop bookworkshop booke. Take off the remote look out unit us-

ing a 2.5mm Allen key pict

ure

5

f. Unscrew cartridge fixing bolt using a 10mm socket wrench / NCX RL: 5mm Allen key

pict

ure

6

g. Hit the fixing bolt slightly using a plas-tic tip hammer pi

ctur

e 7

h. Take out the old cartridge and install the new one pi

ctur

e 8

i. Tighten the cartridge fixing bolt again using a 10mm socket wrench / NCX RL: 5mm Allen key

pict

ure

9


workshop bookworkshop bookj. Reinstall the remote-lock-out unit us-

ing a 2.5mm Allen key pict

ure

10

k. Reassemble the upper and bottom case pi

ctur

e 11

l. Before fastening the left fixing bolt you have to pull up the fork pi

ctur

e 12

m. Fasten the fixing bolts with 10Nm us-ing a 5mm Allen key pi

ctur

e 13


workshop bookworkshop bookHow to replace Lock-Out (LO) cartridge

Models: RAIDON LO / RAIDON LO air / XCR LO / XCM HLO NCX D LO / NCX E LO / NCX FT D LO / NEX4610 HLO


ctur

e 1


ctur

e 2


ctur

e 3


pict

ure

4


workshop bookworkshop booke. Take off the lock-out knob

pict

ure

5

f. Take out the adjust core using a needlenose pliers pi

ctur

e 6

g. Unfasten the cartridge fixing bolt half way using a 5mm Allen key pi

ctur

e 7

h. Hit the fixing bolt slightly using a plas-tic tip hammer pi

ctur

e 8


workshop bookworkshop booki. Unscrew the cartridge fixing bolt full

way and take out the cartridge pict

ure

9

j. Install the new cartridge and fasten the fixing bolt with 10Nm pi

ctur

e 10

k. Set the cartridge to the unlocked posi-tion before continuing. To do so use a 4mm Allen key

pict

ure

11

l. Reassemble the adjust corepi

ctur

e 12

m. Reassemble the upper and bottom case


workshop bookworkshop bookn. Before fastening the left fixing bolt

you have to pull up the fork. pict

ure

13

o. Tighten the fixing bolts with 10Nm using a 5mm Allen key pi

ctur

e 14


workshop bookworkshop bookHow to replace the Travel-Adjust (TA) cartridge

Models: DUROLUX SERIES / EPICON TAD / XC-PRO TAD / XC-PRO TA

Old travel adjust top cap unit

a. Unscrew the fixing bolt using a 10mm socket wrench pi

ctur

e 1

b. Take off the travel adjust unit cover cap using a 2.5mm Allen key pi

ctur

e 2

c. Take off the travel adjust core using a Phillips screwdriver No.2 pi

ctur

e 3

d. Take out the circlip using a small screwdriver pi

ctur

e 4


workshop bookworkshop booke. Take out the travel adjust core

pict

ure

5

f. Unscrew the cartridge using a 27mm socket wrench pi

ctur

e 6

g. Hit the cartridge slightly using a plas-tic tip hammer and take it out pi

ctur

e 7

h. Assemble the new cartridge and fas-ten it with 10Nm using a 27mm socket wrench

pict

ure

8


workshop bookworkshop booki. Reinstall the travel adjust core

pict

ure

9

j. Reassemble the circlip using a small screwdriver pi

ctur

e 10

k. Fasten then travel adjust core using a Philips screwdriver No.2 pi

ctur

e 11

l. Reinstall the travel adjust unit cover cap using a 2.5mm Allen key pi

ctur

e 12


workshop bookworkshop bookm. Fasten the fixing bolt with 6Nm using

a 10mm socket wrench pict

ure

13

New travel adjust top cap unit

The working steps which need to be carried out are very similar between the old and the new travel adjust. The only big difference is the new travel adjust top cap unit. Therefore we are just concentrating on how to replace the new top cap unit. The other working steps are identical with the ones described above.

a. Unscrew the two fixing bolts using a 2mm Allen key pi

ctur

e 1


workshop bookworkshop bookb. Take out the circlip using a small

screwdriver pict

ure

2

c. Take out the travel adjust core using a circlip pliers pi

ctur

e 3


workshop bookworkshop bookHow to solve air leaking problems

Models: All air cartridge forks

a. Release all air

pict

ure

1

b. Unscrew the air top cap using a 27mm/21mm Allen key pi

ctur

e 2

c. Take out all remaining old oil

pict

ure

3

d. Refill the fork with 6ml of 80W gear oil

pict

ure

4


workshop bookworkshop booke. Grease the O-ring of the air top cap

pict

ure

5

f. Tighten the air top cap with 10Nm us-ing a 27mm/21mm Allen key pi

ctur

e 6

g. Inflate the fork according to the per-sonal settings of the customer pi

ctur

e 7

We recommend inflating the fork over night with a test pressure of 150psi (10.3 bar) and to test it again the next day.


workshop bookworkshop bookHow to solve hydraulic Lock-Out issues

Models: RAIDON air LO / RAIDON LO / XCR LO / XCM HLO NXE E LO / NCX D LO / NEX4610 HLO / CR990 LO / CR940 LO

The fork does not lock even after turning the lock out knob to the locked position

a. Take off the lock-out knob

pict

ure

1

b. Take out the adjust core using a needle nose pliers pi

ctur

e 2

c. Test if the cartridge fixing bolt is tightened properly with 10Nm using a 5mm Allen key

pict

ure

3

d. Turn the core clockwise until the stop-per using a 4mm Alllen key. The fork should now be completely locked!

pict

ure

4


workshop bookworkshop booke. Make sure the adjust core is installed

properly pict

ure

5pi

ctur

e 6

f. The lock-out knob’s nose has to be installed like shown in picture no.7 pi

ctur

e 7

g. To test if the fork unlocks, turn the lock out knob counter-clockwise pi

ctur

e 8


workshop bookworkshop bookHow to solve Mechanical-Lock-Out (MLO) issues

Models: XCM MLO / XCT V2 MLO / NEX MLO SERIES / CR8V MLO / CR 8R MLO

a. Pull out the lock out knob using a needle nose pliers pi

ctur

e 1

b. Unscrew the lock out top cap using a 27mm/21mm socket wrench pi

ctur

e 2

c. Take out the upper stopper using a needle nose pliers pi

ctur

e 3

d. Unscrew the two fixing bolts using a 10mm socket wrench pi

ctur

e 4


workshop bookworkshop booke. Separate the upper and the bottom

case

pict

ure

5

f. Slide out the sup spring, lower index and lower stopper pi

ctur

e 6

g. Take out the fixing bolts using an ex-tra long 5mm Allen key and a monkey wrench

pict

ure

7

h. Make sure the main fixing bolt is a hexagon screw and not an Allen screw. Otherwise the lock out mecha-nism can not work

pict

ure

8


workshop bookworkshop booki. The hexagon screw has to fit into the

lower spring stopper pict

ure

9

j. Picture No. 10 shows how upper stop-per and lower index fit together pi

ctur

e 10

k. Reinstall the main fixing bolt using a extra long 5mm Allen key and a mon-key wrench

pict

ure

11

l. Slide the sup spring, lower index and lower stopper back in pi

ctur

e 12


workshop bookworkshop bookm. Slide in the upper stopper

pict

ure

13

n. Reinstall the lock out top cap with 10Nm using a 27mm/21mm socket wrench

pict

ure

14

o. Install the adjust stopper like shown on picture No. 15 pi

ctur

e 15

p. Reinstall the lock out knob back again. Make sure it is set to the unlocked position (green)

pict

ure

16


workshop bookworkshop bookq. Reassemble upper and bottom case

with 10Nm using a 10mm socket wrench

pict

ure

17


workshop bookworkshop bookHow to convert the travel of an Axon fork

a. Release all air

b. Unscrew the fixing bolt using a 10mm socket wrench

pict

ure

AX01

c. Pull out the rebound adjust knob

pict

ure

AX02


workshop bookworkshop bookworkshop bookworkshop bookd. Unscrew the fixing bolt half way

pict

ure

AX03

e. Hit the fixing bolt slightly using a plas-tic tip hammer

pict

ure

AX04

f. Separate upper and bottom case

pict

ure

AX05


workshop bookworkshop bookworkshop bookworkshop bookg. Unscrew the fork nose using a monkey

wrench

pict

ure

AX06

h. Slide out the support tube assy

pict

ure

AX07

i. To convert the travel you have to re-move the pin and reset the spacer

pict

ure

AX09

pict

ure

AX08100mm 80mm


workshop bookworkshop bookworkshop bookworkshop bookj. Reassamble the support tube assy

back into the upper

pict

ure

AX07

k. Grease the fork nose and fasten it

pict

ure

AX06

l. Reassemble upper and bottom case

pict

ure

AX05


workshop bookworkshop bookworkshop bookworkshop bookm. Fasten the fixing bolt with 4Nm using

a 10mm socket wrench

pict

ure

AX01

n. Fasten the fixing bolt with 10Nm using a 5mm Allen key

pict

ure

AX03

o. Reassemble the rebound adjuster knob

pict

ure

AX02


workshop bookworkshop bookHow to convert the travel of an Epicon Suspension fork

a. Release all air

pict

ure

EP1

b. Unscrew the fixing bolt half way using a 5mm Allen key

pict

ure

EP2

c. Hit the fixing bolts with plastic tip ham-mer slightly

pict

ure

EP3


workshop bookworkshop bookd. Unscrew the fixing bolts full way and take

them out

pict

ure

EP4

e. Unscrew the air valve top cap using a 27mm socket wrench

pict

ure

EP5

f. Pull out the air semi cartridge

pict

ure

EP6

g. Take off the air valve top cap

pict

ure

EP7


workshop bookworkshop bookh. Slide out the air piston, support tube,

rebound springs and spring guides

Make sure the air piston does not get dirty

pict

ure

EP8

i. Convert the travel:

0 Spacer = 140mm travel pict

ure

EP9

1 Spacer = 120mm travel

pict

ure

EP10

2 Spacer = 100mm travelpi

ctur

e EP

11

3 Spacer = 80mm travel

pict

ure

EP12


workshop bookworkshop bookj. Reassemble the support tube, rebound

springs, spring guides and air piston back into the air cylinders

pict

ure

EP13

k. Seal the air piston with 6ml of a 80W gear oil

pict

ure

EP14

l. Seal the air valve top cap with SR SUNTOUR Con Panna grease. After-wards reassemble the air valve top cap and the semi air cartridge

pict

ure

EP15


workshop bookworkshop bookm. Reinstall the semi air cartridge to the fork

pict

ure

EP16

n. Fasten the semi air cartridge with 10Nm using a 27mm socket wrench

pict

ure

EP17

o. Reinstall the fixing bolt and fasten it with 10Nm using a 5mm Allen key

pict

ure

EP18

p. Inflate the fork


workshop bookworkshop bookHow to change slider sleeves (plugged dust seals)

Models: XCM SERIES / XCT V2 SERIES / NCX D / NCX D LO / NEW SERIES / CR980 LW / CR920 / CR 8V SERIES / CR 8R SERIES

a. Unscrew the top cap using a preload adjuster tool preload adjuster remover pi

ctur

e 1

b. Take out the coil springs

pict

ure

2

c. Unscrew the two main fixing bolts us-ing a 5mm extra long Allen key pi

ctur

e 3


pict

ure

4


workshop bookworkshop booke. Take off the plugged dust seals using

a screwdriver

pict

ure

5

f. Take out the old dust seals using a pliers. Turn the sleeve approximately 90 degrees counter clock wise

pict

ure

6

g. The clip of the slider sleeve has to be clicked into the notch of the fork lower

pict

ure

7

h. After installing the sleeves, plug the dust seals back onto the fork lower pi

ctur

e 8


workshop bookworkshop booki. Reassemble the upper and bottom

case again and fasten with 10Nm us-ing a 5mm extra long Allen key

pict

ure

9

j. Reinstall the coil springs

pict

ure

10

k. Fasten the top cap using a preload adjuster tool preload adjuster remover tool

pict

ure

11


workshop bookworkshop bookHow to change slider sleeves (pressed-in dust seals)

Models: XCR SERIES / XCP 75 DJ


ctur

e 1


ctur

e 2


ctur

e 3


pict

ure

4


workshop bookworkshop booke. Take out the dust seals using a nail

lifter

pict

ure

5

f. Take out the old dust seals

pict

ure

6

g. The clip of the slider sleeve has to be clicked into the notch of the fork lower

pict

ure

7pi

ctur

e 8


workshop bookworkshop bookh. Reinstall the dust

seals using a dust seal installer(28mm/30mm/32mm/35mm) and plastic tip hammer

pict

ure

9

i. Reassemble the upper and bottom case pi

ctur

e 10

j. Before fastening the left fixing bolt you have to pull up the fork pi

ctur

e 11

k. Tighten the fixing bolts with 10Nm using a 5mm Allen key pi

ctur

e 12

chapter VIIExploded views

SR SUNTOUR Suspension Forks

SF6, english, 2006/01/21, V1.0

Pos.D

escr

iptio

nPa

rt-N

o.

26”

700c / 50mm

700c / 63mm

Qty.

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ider

sle

eve

see

Pos.

42

Pos.

Des

crip

tion

Part

-No.

26”

700c / 50mm

700c / 63mm

Qty.

5FA

A06

82

6FA

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92

7FS

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51

12

18

8

4b

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10

5

6

3

9

11

25a

19

20

2117

7

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23

22

24

25b

13

14

15

16

4

25

SF7-

NEX

4510

MLO

700

C26

” + 7

00c

(50m

m +

63m

m)

2

explosion drawing sr suntour XCM-LO, SF6, english, 2006/01/09, V1.0

1

2

7

4a5

01

8

21

31

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0.99b

Pos

.

Description Part-No. Qty

.

1 RL remote assembly FKE112 11a RL remote assembly part “a” see pos. 1 11b Snap ring see pos. 1 11c RL remote assembly part “c” see pos. 1 11d RL remote assembly part “d” see pos. 1 11e RL remote assembly part “e” see pos. 1 11f RL remote assembly part “f” see pos. 1 11g RL remote assembly part “g” see pos. 1 11h RL remote assembly part “h” see pos. 1 11i RL remote assembly part “i” see pos. 1 11i RL remote assembly part “j” see pos. 1 12 cable assembly not part of the set 1

2a cable housing see pos. 2 12b cable housing end cap see pos. 2 12c cable (std. bicycle shifting cable) see pos. 2 1

1c

1

1b

1f 1g

1i

1h

1j

1e

1d

2c

2a2b

1a

RL REMOTE ASSEMBLY modelyear 2007

srsuntour workshop book

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