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1998 Judy Owner’s Manual
Judy XC, SL,XL and XLC models
SHOH

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At A Glance Maintenance Interval Checklist
heck the following for each maintenance interval. For further details see page 8.
Every Ride (Inspect)
Front wheel
Quick release
Check for damage
Cable routing
Brake pads
Brake levers
Headset
Eight Hours of Riding
Clean upper tubes
Oil upper tubes
Check crown and brace bolts
Check brake posts
Twenty-five hours of Riding
Clean and grease spring stacks
Inspect spring system for compression set
Clean and grease bushings and Resi-wiper
Clean upper tubes and inspect for damage
Clean fork boots
PORTANT: TO MAINTAIN HIGH PERFORMANCE, SAFETY AND LONG LIFE, PERIODIC MAINTENANCE
REQUIRED. PERFORM MAINTENANCE MORE OFTEN IF YOU RIDE IN EXTREME CONDITIONS.
Table of Contents
Introduction
Features
Safety Instructions
Installation
Tuning
Maintenance
Exploded Diagram
Service
Glossary of Terms
Warranty
International Distributor List
2
3
4
5
7
9
16
12
15
19
19

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ROCK
Congratulations! You have purchased
HOH
the best in mountain bike
suspension. RockShox forks are
made of lightweight, high-strength
materials, and are designed to balance high
performance with ease of maintenance. This
manual contains important information about
the safe installation, operation, and
maintenance of your purchase. We urge you to
read it carefully, become familiar with its
contents, and follow our recommendations to
help make your mountain bike experience
enjoyable and trouble free.
Steerer Tube
per Fork Crown (XLIXLC only)
Fork Crown
Ipper Fork Tube (w/dust boot)
Brake Post
idge Adjuster (XC,SL,XLIXLC)
Preload Adjuster Knob
Fork Stop (XLIXLC only)
One Piece Fork Brace
and Lower Tube Assembly
Disk Brake Mount
Shaft Bolt
Juay reatures
• True “One-Piece” lower tube assembly.
• New Type 3 Spring System. Very easy to tune for different riders. Lively action of a progressive coil
spring system.
• New Type 3 aluminum hydraulic damper cartridge with adjustable rebound and compression. More
consistent damping, better heat dissipation and improved reliability.
Unique Resi-wiper seal. Cleans and lubricates the upper fork tubes.
28mm diameter Easton tapered aluminum upper tubes (XC,SL,XL/XLC).
Lightweight construction on SL steerer, crown and upper tubes.
• Increased slider overlap.
• Super stiff alloy crown.
• External cartridge adjuster knob (XC,SL,XL/XLC).
• New top cap with external preload.
• Disc brake ready
• Oil bath lubrication system.
• Dual crowns on Judy XLIXLC for increased rigidity.
STANDARD EQUIPMENT (SUPPLIEDWITH JUDY)
63mm travel standard equipment (XC & SL)
(2) medium primary springs
(2) medium secondary springs
80mm travel standard equipment (XC,SL & XLIXLC)
(2) medium primary springs
(2) soft secondary springs
100mm travel standard equipment (XLIXLC)
(2) medium primary springs
(2) medium secondary springs
Judy Butter (All models)
Bolt-on brake cable hanger (for those without ‘V’ style brakes)
OPTIONAL EQUIPMENT
63 and 80mm Travel Spring Tuning Kits (Judy
Spring Kit Description
Extra Soft
Soft
Medium
Firm
Primary Springs
Extra Soft
Soft
Medium
Firm
Secondary Springs
Extra Soft
Soft
Medium
Firm
* For spring selection suggestions, see Basic Spring Tuning Guide.

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Spring Kit Description
Soft
Medium
Firm
Extra Firm
Primary Springs
Soft
Medium
Firm
Extra Firm
Secondary Springs
Soft
Medium
Firm
Extra Firm
4.
5.
d rop-out failure could result in loss of control of the bicycle with possible serious and/or fatal injuries.
If the fork ever loses oil or if it makes sounds of excessive topping out, stop riding the bicycle
immediately and have the fork inspected by a dealer or call RockShox. Continuing to ride with the fork
in either of these conditions could result in loss of control of the bicycle with possible serious and/or
fatal injuries.
Always use genuine RockShox parts. Use of non-RockShox after-market replacement parts voids the
warranty and could cause structural failure to the fork. Structural failure could result in loss of control of
the bicycle with possible serious and/or fatal injuries.
* For spring selection suggestions, see Basic Spring Tuning Guide.
Judy XCISL 63mm Travel Damper Cartridge Kit
Judy XCISL 80mm Travel Damper Cartridge Kit
Judy XLIXLC 100mm Travel Damper Cartridge Kit
(Judy XLIXLC 80mm travel to 100mm travel conversion requires a 100mm travel spring kit)
Judy XL/XLC short, tall and extra tall crowns
(for selection of Judy XLIXLC upper crown,see Judy XL/XLC installation instructions)
Bolt-on brake cable hanger (for those without V-style bakes)
VARNING: 1-114″ STEERERFORKSTHAT REQUIRE A BUKE CABLEHANGERMUSTUSE LOWERTUBEASSEMBLIESTHAT HAVETHE
RAKE CABLEHANGERMOLDEDINT O THEFORK LOWERTUBES (AVAILABLETHROUGH YOURDEALER). THEBOLT-ONBRAKE CABLE
ANGER IS NOT COMPATIBLE WITH 1-114″ FORKS. DO NOT A BOLT-ON BUKE CABLE HANGER WITH 1-114″ STEERER
ORKS, ASI TMA Y CABLEHANGEUSSEMBL HITTHEHEADSET LOWERCUPAND IORFORKCR ,
ESULTINGIN LOSSOF CONTROLOFTHEBICYCLEWITHPOSSIBLESERIOUSAND IOR FATALINJURIES.
CONSUMER SAFETY INFORMATION
A BIKEISDANGEROUS . NOT PROPERLY MAINTAININGORINSPECTING YOURBIKEIS EVENMOREDANGEROUS . IT’s ALSO
ANGEROUSNOTTO READTHESEINSTRUCTIONS. So IF YOUUSEOURSTUFF , DON’T BE A DUMMY—READTHEINSTRUCTIONS !
. Before riding the bicycle,be sure the brakes are properly installed and adjusted. If the brakes don’t work
properly, the rider could suffer serious and/or fatal injuries.
Use this fork with cantilever-type bra kes mounted to the existing mounting posts or a disc brake mounted
to the disc brake tab provided. Forks with hangerless style braces were only designed for ‘V- style, hydraulic
cantilever or disc brakes. Do not use any cantilever brake other than those intended by the brake
manufacturer to work with a hangerless brace.Do not route the front brake cable and/or cable housing
through the stem or any other mounts or cable stops. Do not use a front brake cable leverage device
mou nted to the brae. Do not use disc-style brakes with any other attachment to the lower tube other than
those supplied with the fork. The lower tubes were designed to have a disc brake mounted, only, at the tab
provided. Do not use the disc brake cable mounts with any other fork or disc brake other than a
RockShox fork or disc bra ke. Any other kind of mount could lead to stru ctural failure of the fork.
Structural failure could result in loss of control of the bicycle with possible serious and/or fatal injuries.
Use extreme caution not to tilt the bicycle to either side when mounting the bicycle to a carrier by the
fork drop-outs (front wheel removed). The fork legs may suffer structural damage if the bicycle is tilted
while the drop-outs are in the carrier. Make sure the front wheel is securely fastened down with a quick
release. Make sure the rear wheel is fastened down when using ANY bike carrier that secures the fork’s
drop-outs. Not securing the rear wheel can allow the bike’s mass to side-load the drop-outs, causing them
to break or crack. If the bicycle tilts or falls out of its carrier, do not ride the bicycle until the fork is properly
examined for possible damage. Return the fork to your dealer for inspection or call RockShox if there is
IMPORTANT: ROCKSHOX FORKS ARE DESIGNED FOR COMPETITIVE OFF-RCAD RIDING AND DO NOT COME WITH THE PROPEI
REFLECTORSFOR ON-ROADUSE. YOURDEALERSHOULDINSTALLPROPERREFLECTORS TOMEETTHE CONSUMER PRODUCT SAFET’
COMMISSION’S (CPSC) REQUIREMENTS FOR BICYCLE STANDARD SIFT HEFORKI GOING TO BEUSEDONPUBLIC ROADS AT ANYTIME
Installation Instructions (Judy XCISL)
IT IS EXTREMELY IMPORTANT THAT ROCKSHOX JUDY FORK IS INSTALLED CORRECTLY BY A QUALIFIED TECHNICIAN
PROPER TOOLS. IMPROPERLY IN STALLEDFORKSAREEXTREMELY DANGEROUSAND CANRESULT INSEVEREAND/OR FATALINJURIES
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 RockShox steerec The RockShox steerer tube may need cutting to
the proper length. On threadless steerers (Aheadset design),make sure there is sufficient length to
properly clamp the stem (refer to stem manufacturer’s instructions). Remember to measure twice
and cut once.
IMPORTANT: Do NOT ADDTHREADS TO ROCKSHOX STEERERS.
REPLACEMENTOFTHEASSEMBLY STBEDONE TO CHANGELENGTH, DIAMETER, ORHEADSET TYPE (THREADEDORTHREADLESS)
DO NOT REMOVE OR REPLACE THE STEERER TUBE, BECAUSE THIS COULD RESULT IN Loss OF CONTROL OF THE BICYCLE
POSSIBLESERIOUSAND/ORFATALINJURIES.
2.
3.
4.
5.
Install the headset race (26.4 mm inner diameter for l”steerers, 29.9mm inner diameter for 1-118″
steerers) firmly against the top of the fork crown. Install the fork assembly on the bike. Make sure there
are sufficient threads to properly lock the headset in place. On threadless steerers (Aheadset design),
make sure there is sufficient length to properly clamp the stem (refer to stem manufacturerS
instructions). Adjust the headset so you feel no play or drag.
Install the brakes according to the manufacturer’s instructions and adjust brake pads properly. Use the
fork only with cantilever-type brakes mounted to the existing mounting posts or disc style brakes
mounted to the tabs provided. Do not use any other mounting system that does not utilize the tab:
provided. Do not use these tabs with any other fork or brace.
On threaded steerers, insert stem to a minimum depth according to CPSC and JIS
standards. The stem must be inserted to a minimum engaging length not less
than 2.5 times the stem diameter from the lowest end of the stem,not the
wedge (see Fig. 1).
Fit a brake cable to the RockShox fork brace mount. Forks with hangerless style
braces were designed for V-type, hydraulic cantilever or disc style brakes. Do not
Fig. 1

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hangerless brace. Do not route the cable through the stem or any other mounts or cable stops! The cable
should make a direct route from the brake lever to the RockShox fork brace mount and be able to freely
move up and down with the suspension movement. It may be necessary to install a whole new cable.
PORTANT: THE DISTANCEFROMTHE TOP OFTHE BRAKE CABLE HANGER TO THE BOTTOMOFTHE BRACE CABLE HOUSING STOP
IUSTBE A MINIMUMOF 12 MMWITHTHE BUKES APPLIED. AN IMPROPERLY INSTALLEDFRONTBRAKE CABLE COULDRESULT
LOSSOF CONTROLOFTHEBICYCLEWITHPOSSIBLESERIOUSAND IOR FATALINJURIES.
Adjust the front wheel quick release to clear the dropout ‘s counter bore. The quick release nut must be
tightened after the wheel is properly sea ted into the dropouts counter bore. Make sure four or more
threads are engaged in the quick release nut when it is closed. Orient the quick release lever in front of
and parallel to the lower tube in the locked position.
Keep in mind tire clearance as you choose tires. Maximum tire size is 2.2″wide or 342mm radius. Be
sure to check this radius whenever you change tires. To do this, remove the spring stack (per the
instructions on following pages),and compress fork completely to make sure at least 5 mm of clearance
exists between the top of the tire and the bottom of the crown. Exceeding this maximum will cause the
tire to jam against the crown when the forks are fully compressed. The upper tubes must always be fully
engaged in the crown. The upper tubes, on clamp type crowns, must not extend above the crown more
than Imm and must always be engaged in the crown.
Judy XLIXLC Installation Instructions
. Remove the existing fork and lower headset race from the bicycle.
HI. or AS*MbLY MUSI 10 CHANGE LENCIH, UIAMEIEN, ON (IHNEAUEU ur
THREADLESS). DO NOT , THIS COULDRESULT IN LOSSOF CONTROLOFTHEBICYCLEWITH
POSSIBLESERIOUSAND IOR FATALINJURIES.
4
5.
Install the headset race firmly against the
top of the fork crown once the steerer tube
has been cut to proper length.
Install the upper tubes into the lower crown
and locate the lower crown so that 170mm of
upper tubes extends above the lower crown.
Torque the lower crun bolts to 60in-lb.
IMPORTANT: DO NOT EXCEED 170MM OF
EXPOSED UPPER TUBES ABOVE THE LOWER
Fig. 3
Before you install a Judy on the
bicycle, verify that the fork has been supplied
wth the correct upper crown. Refer to Fig.2
for upper crowns available for Judy XbXLC
and to maximize fork stiffness by proper
selection and orientation the upper crown
The steerer tube may need cutting to
proper length.To cut the steerer tube,
removal of the upper tubes are required.
This is necessary otherwise the upper
tubes will be in the way when cutting
the steerer tube to proper length. The
steerer tube length is determined by the
following parts: Judy XL/XLC upper
crown steerer clamp length, stem
steerer tube clamp length, frame head
tube length and top and bottom
headset stack height (see Fig.3 ext
SbJtUgø (nxn Irwertd
< tanrn (rc*.n Fig. 2 page). To ease in the assembly, do not install the JUDY XLIXLC upper crown on to the upper tubes until the steerer has been cut to the proper length and the lower crown has been fastened in the required position. HINT: MEASURE TWICE AND CUT ONCE! PORTANT: Do NOT ADDTHREADS TO ROCKSHOX STEERERS. THESTEERERTUBECR OWNASSEMBLY IS A ONE-TIMEPRESS CROWN, DOING THIS CAN CAUSE THE BOTTOM OF THE LOWER CROWN TO HIT THE FRONT TIRE RESULTING IN THE LOSS OF CON TROL OF THE BICYCLE WITH POSSIBLE SERIOUS AND/OR FATAL INJURIES 6 Assemble the headset, upper crown and 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 Torque all the upper crown bolts to 60in-Ib. 7. Complete the rest of the XLIXLC installation by following steps three through seven under "Installation Instructions (Judy XCISL)," page 5. Tuning Your Fork RockShox (JUDY) forks can be tuned to your particular weight, riding style, and terrain. Our forks are set for the 160 to 1801b (65 to 80Kg), all-around rider who spends equal time riding every off-road terrair imaginable. Because you're probably not that rider, you can benefit by making tuning adjustments to sui your specific needs. For maximum tuning flexibility, purchase a RockShoxType 3 Tuning Kit (includes priman and secondary coil springs). When tuning suspension,always make one change at a time and write it down. Keeping a record lets know what changes you have tried and suggests what changes you might try. Ask a shop or local riders wha they have found works well. These resources are typically your best bet, but don't hesitate to call RockSho about specific tuning needs. A list of phone numbers is on Page 19. RIDE HEIGHT AND SPRING PRELOAD ADJUSTMENT Judy is designed to compress (sag) when you are sitting on the bike. This sag allows the front wheel to sta) in contact with the ground when braking and cornering over rough and uneven terrain. The optimum setting are 7 to 15mm sag for 63mm travel;13 to 20mm for 80mm travel;and 18 to 25mm for 100mm travel. Changing the preload alters the sag and firmness of the initial fork movement. To measure sag, install a zip on the upper tube so that it is flush against the Resi-wiper seal;sit on the bike with normal riding apparel then step off your bike and measure the bottom of the zip tie to the top of the wiper. This measurement is amount of sag For example, heavier, more aggressive riders need more spring preload to maintain proper ricft ****** Result for Image/Page 6 ****** o Change Preload: The top cap adjustment knob on each leg adjusts the sag of the fork (the preload on the pring stack). When the adjustment knobs are turned full clockwise, the fork will sag the least and be the rmest. Turning the adjustment knobs full counterclockwise makes the fork sag the most and be the softest. 10 NOTTURNTHE PRELOAD ADJUSTERS PASTTHEIRLIMITSTOPS. THEREAREONLY 3 FULLTURNSFROMMINIMUM TOMAXIMUM COULDRESULTINPREMATUREFAIWREOFTHEPRELOADADJUSTERCAPASSEMBLY. BASIC SPRING TUNING GUIDE he Type 3 spring system can be tuned for various riding styles and weight. There are four springs in the Judy Jk that can be interchanged allowing up to 32 tuning combinations. For example, aggressive riders may lant to increase their spring rate over those recommended and can do so by changing out the springs rovided in the fork with those that better meet their needs. The table below indicates rider weight and the ±commended spring kits for those weights Kits may be purchased through your dealer. 3mm,80mm and 100mm Travel for XC,SL and XLIXLC maintenance Judy forks are designed to be nearly maintenance free. However, as long as moving parts are exposed to tm elements, moisture and contamination can reduce performance. To maintain high performance, safety, anc long life, periodic maintenance is required. RockShox forks are engineered for easy service to help you the fork clean,greased , and performing like new. Performing maintenance more often is necessary if you ridf in extreme conditions. The recommended tools and intervals for maintenance are listed below. IMPORTANT: ALWAYS WEARSAFETY GLASSESWHEN WORKINGON ROCKSHOX FORKS. MAINTENANCE TOOLS 2.5,3,4,5,6 and 8mm hex wrenches • 8mm open-end wrench • Small tip internal snap ring pliers • Plastic face mallet 22mm and 24mm socket (6 point preferred) or wrench • Ratchet, for socket • Small straight blade screwdriver • Long (8"+1200mm) socket extension,end wrapped with cloth tape Rider Weight (lb.) Under 110 130 130 to 150 150 to 170 170 to 190 190 to 210 Above 210 Left Leg ( Spring Kit) Extra Soft Extra Soft Soft Soft Medium Medium Firm Right Leg (Spring Kit) Extra Soft Soft Soft Medium Medium Firm Firm • Safety glasses Crown Bolts Top Cap Assemblies Fork Brace Bolts Brake Posts Shaft Bolts TORQUE TIGHTENING TABLE 60 in-lb (6.8Nm) 3040 in-lb (3.4Nm) 60 in-lb (6.8Nm) 60 in-lb (6.8Nm) 50 in-lb (6.8Nm) Yuick Tip: Right and left side is determined when straddling the bicycle frame facing forward. REBOUND AND COMPRESSION DAMPING CARTRIDGE ADJUSTMENT single aluminum damping cartridge in the left leg provides compression and rebound damping for the ntire fork by turning the external adjuster knob. This cartridge has a rebound/compression damping djustment. The compression adjustment controls the speed that the fork will collapse and covers a wide ange. It may take several times to achieve the correct damping rates. To adjust, follow this procedure: . Turn the external adjuster knob clockwise to increase the damping (slower) and counterclockwise to decrease the damping (faster). Small changes make a big difference on the trail. There are three full turns of adjustment available from full clockwise. QUICK TIP: Less is generally better. Lightly damped systems are more active and less harsh when riding. PORTANT: DO NOT TURN ADJUSTMENT MORE THAN THREE TURNS FROM FULL CLOCKWISE. LUBRICANTS, CLEANERS AND MAINTENANCE PARTS: Degreaser RockShox 15wt oil (or fork oil without seal-sweller additives) Judy Butter or high quality teflon fortified grease Oil Bath Crush Washer IMPORTANT: FOR BEST PERFORMANCE, AVOID LITHIUM-BASED GREASES. SOME LITHIUM GREASES CAN BECOME STICKY, GRAY AND CAKEUPWHENUSED TO BUSHINGS. WHENTHISHAPPENS , SMOOTHFORK ACTIONISGREATLY LIMITED AND PERFORMANCE IS GREATLY REDUCED. IF you LITHIUM GREASE, CHECK GREASE QUALITY AND CONDITION AT EACI 25-HOURSERVICEINTER VAL TO ENSUREGREASEISPERFORMINGPROPERL Y. IF YOUEXPERIENCEPROBLEMS , TRY USINGANOTHEF TYPEOF LUBRICANT. ****** Result for Image/Page 7 ****** MAIN BEFORE EVERY RIDE EVERY RIDE, INSPECTTHEFOLLOWING PARTS: Front wheel and quick release for proper installation and adjustment Fork for any obvious damage (crown, brace, upper tubes, lower tubes, and dropouts) . Front brake cable for proper routing Front brake pads for proper contact with the rim Front brake lever for proper adjustment . Headset for proper function and adjustment FTER EVERY RIDECLEANANDDR Y THEFORK, TAKING CARENOTTO GET WATERINTHEFORK AT THE RESI-WIPERSEAL. AFTER EVERY WEEK OR EIGHT HOURS OF RIDING FTER EVERY WEEKOREIGHTHOJRSOFRIDING , CLEANANDOILTHEJPPERTUBESANDCHECK FASTENERSFORPROPER TORQUE. FOLLOW IU ±USHINGSANU , UU 2 3. 4. 5. 6. 7. Mount the bike in a stand, disconnect the front brake cable, and remove the front wheel (the brakes do not need to be removed). Pull external damping adjustment knob from left shaft bolt with a downward twisting motion (the shaft bolt is press fit into the external adjuster). Partially loosen shaft bolts with a 6 or 8mm hex wrench,tap bolts firmly with a mallet breaking shafts free from lower tube (see Fig. 5) ,and remove bolts completely. Oil from the open oil bath will pour out of the bottom of the lower tube when you take the shaft bolts off. Use a rag to catch the oil. Slide off one-piece lower tube assembly (see Fig. 6). Remove fork boots . Clean upper tubes and inspect for wear and/or damage (nicks, scratches, or dings). Clean fork boots and slide onto upper tubes. Pour oil out from lower tubes. Then clean internals of lower tubes, bushings (two per leg),and Resi-wiper seal. A long 3/8"drive socket extension wrapped in a lint-free rag works well. ROCEDURE: . Lift fork boots from lower tubes. Then wipe exterior surfaces, Resi- wiper seal area and upper tube clean. Apply 2-3 drops of Teflon- fortified oil to the upper tubes at the Resi-wiper. (See Flg. 4) Refit fork boots into Resi-wiper seal groove using small blade screwdriver. Engage the boot with Resi-wiper seal groove at the rear and rotate boot around the upper tube to fully engage its lower edge behind the brace. A small amount of oil on the mating surfaces helps. . Check crown bolts, brace bolts, and brake posts for proper torque. (Refer toTorque Tightening Values, above.) Repeat procedure on other leg. Fig. 4 IMPORTANT: CLEAN LOWER BUSHINGS, APPROXIMATELY 6"(150MM) FROM TOP. Apply Judy Butter to the surface of the four bushings, the inside of the lower tubes and fill the pocket between the lips of the Resi-wiper seal completely. Use a socket extension wrapped with cloth tape dipped in Judy Butter to reach inside the lower tubes (see Fig. 7). IMPORTANT: DO NOT USELITHIUM-BASEDGREASE. IT COATINGON THE BUSHINGS. 8. Smear RockShox fork oil or a thin layer of Judy Butter to the upper tubes under the fork boots. Fig. 5 Fig. 6 Fig. 7 AFTER EVERY MONTH OR TWENTY-FIVE HOURS OF RIDING HER EVERY MONTHOR TWENTY-FIVEHOURSOFRIDING , CLEANANDGREASETHESPRINGST uS, BUSHINGS, AND RESI-WIPERSEAL. O CLEANANDGREASETHESPRINGST ACKS, FOLLOW THISPROCEDURE: . Unscrew the top cap using 22mm or 24mm wrench or socket wrench. Remove the spring stack assembly and clean the stack with degreaser. Wipe dry. . Inspect Type 3 spring for compression set (see "Type 3 Spring Specification"table, page 13.) Replace as needed. Apply a thin coat of Judy Butter to the Type 3 spring. . Install assembly in upper tube, starting top cap threads by hand. Torque top cap to 30 to 40 in-lb (2.3-3.4 Nm). This should be between 30 and 60 degrees of clockwise wrench movement after cap is flush with upper tube. Repeat procedure on other leg. 9. Install lower tubes onto upper tubes,carefully engaging upper Resi-wiper seal lip with the upper tubes and gently rock the one-piece lower assembly to engage lower bushings with upper tubes. Stop short of engaging the neutral shafts into the counterbore. 10. Turn the fork upside down and fill each lower leg with 10cc of 15 wt. RockShox oil by pouring the oil through the shaft bolts holes in the bottom of the lower legs. I I. Now, fully engage the lower tubes with upper tubes by engaging the neutral shafts into the cou nterbore of the lower tubes. 12. Install new crush washer onto each of the shaft bolts. IMPORTANT: THECRUSH WASHERSEALSTHEOILINT O STBEREPL T ISREMOVED 13. Refit shaft bolts, apply blue Loc-tite on steel bolts. Use a 6 or 8mm hex wrench to torque shaft bolts to 60 in-lb. (6.8Nm) IMPORTANT: IT ISVERY EASY TO OVERTIGHTENTHISBOL TWITHAN 8MMHEXWRENCH . USE A TORQUEWRENCH. 14. Refit fork boot into Resi-wiper seal groove using a small blade screwdriver. Engage boot with Resi-wipe ****** Result for Image/Page 8 ****** brace. Compressing the boot and twisting as well as applying a small amount of oil on the mating surfaces helps. 5.1nstall the external damping adjuster by applying a light coating of oil to the O-ring and pushing it onto the shaft bolt with an upward twisting motion. Service he following section contains detailed service procedures for all individual components of the Judy fork. CHANGING TRAVEL he suspension travel on Judy forks can be changed by installing the matching Type 3 spring and damper artridge kit (for spring selection,see basic spring tuning guide). First, remove one-piece lower tube assembly y following the procedure described in, "To Clean and Grease Bushings and Resi-wiper Seal'; page 11. HENFOLLOW THESEINSTRUCTIONS TO CHANGETRA/EL: Unscrew top cap using a 22mm or 24mm wrench or socket wrench. Remove the spring stack assemblies. I YPE é SPRING NE-PLACEMENT The Type 3 spring system in Judy forks provide cutting edge performance with the lively action of a coil spring However, over time the springs can wear out, compromising performan ce. This is evident in compression set when the coil springs are shorter in a resting state than they were when new. Follow the table listed below a guide to know when to replace the Type 3 Sp ring System. Follow the directions to clean and grease the sprin! stack found on page 10, "After every week or 8 hours of riding," for removal and installation TYPE 3 SPRING SYSTEM SPECIFICATION TABLE Travel XC and SL 63,80mm XL/XLC 80mm XLIXLC IOO Primary Coil Optimum 67mm 67mm 117mm Replace 65mm 65mm 114mm Secondary Coil Optimum 92mm 92mm 180mm Replace 90mm 90mm 176mm . Remove the snap rings at the bottom of the upper tubes with small tip internal snap ring pliers (see Fig. 8). Pull the cartridge assembly free from the right upper tube. Note orientation of parts, (top to bottom):shaft-end plate, cartridge,cartridge shim (very important) and snap ring (see Fig. 9). The shaft-end plate on the top of the caNridge shaft may remain in the upper tubes. Remove the spring stack assembly as described above and tap the plate out the bottom of the tube with the long socket extension. Pull the neutral shaft assembly free from the left lower tube. Note orientation of parts, (top to end plate, upper shaft guide with O-ring, washer, top-out bumper, lower shaft guide, and snap ring (see Fig. 10). The shaft-end plate and upper shaft guide on the top of the neutral shaft may remain in the upper tube. Remove the spring stack assembly as described above. Tap the plate and guide out the bottom of the tube with the long socket extension (see exploded diagrams, pages 16 to 19). I. Install new caNridge kit (cartridge assembly and neutral shaft assembly) into upper tubes. Make sure all parts are clean,greased, and installed in the proper order (see exploded diagrams, pages 16 to 19). Replace the spring spacer with the new spacer provided in the kit. . Install snap rings with the sharp outside edge facing out into upper tube ring grooves. Make certain snap rings are oriented correctly, and the snap rings are fully seated in the ring groove of the upper tubes. Fig. 8 CARTRIDGE SERVICE This is a no-maintenance cartridge. It is designed as a sealed unit with no serviceable parts inside. If the cartridge fails it will be replaced by RockShox in accordance with the RockShox Warranty on page 19. Tt receive a replacement cartridge contact your local RockShox dealer or call RockShox direct (see "Warrant) Repaid', page 19 for the phone number). Cartridge removal can be done by following the steps under"Service Changing Travel" on page 12. The cartridge is sealed at each end of the shat. Apply a small amount of oil on the shaft to lubricate the seals Over time, small amounts of oil leaving the cartridge may cause an air gap to form inside. The cartridge car be refilled with oil if an air gap forms by following the instructions below. Fig. 9 Fig. 10 2 3 4. 5. 6. To refill the cartridge, remove the screw in the damper shaft with a No. 2 Phillips head screwdriver. Use a 4 to 5mm head syringe without a needle. Fill the syringe with RockShox 5wt oil and insert it into the cavity of the top of the damper shaft. Apply pressure on the syringe plunger while cycling the cartridge up and down. Continue to cycle the cartridge until the air is removed from the system. Air no longer exists when the gurgling noise stops while you are cycling the cartridge. Remove the syringe tip from the top of damper shaft. A small amount of oil will flow back out of the shaft—this is normal. Insert the screw back into the damper shaft. BUSHING REPLACEMENT PORTANT: THE SNAPRINGSMUSTBEPROPERL Y ORIENTED, SHARPOUTSIDEEDGE FACINGOUT, ANDFULLY SEATEDINTHE INGGROOVE OFTHEUPPERTUBES . Follow procedures "After Every Month or Twenty-Five Hours of Riding,"page 10, to complete the assembly. The high quality bushings in RockShox forks are designed to last many months of hard riding. ProtectM boots, a clean fork,and timely greasing are the keys to high performance and long bushing life. However, 1k all moving parts, bushings will eventually wear and need replacement. Increased fore and aft movement o ****** Result for Image/Page 9 ****** ppel IUL)es Ill IUV'EI IUUes a luuse Ileuusel) UllU/Ul SIUW UUIIUII, even anel a II esm 91 easing, le need to remove and replace the bushings. VIPORTANT: THISSERVICEREQUIRES ROCKSHOX SPECIALTY TOOLS. WE A UALIFIEDBIKESHOPORMECHANIC Glossary OT lerms Bottoming Out- the condition when all suspension travel has been used up. Compression Stroke - the 'upward" motion of a fork which is moving in response to a bump impact. Damping Force - the force required to move a shock absorber I damper (general oil) at any given speed. Forged- a metal forming process which optimizes material structure using very large forces acting on a die mold in which material to formed is placed. Geometry- Descriptive term for the lengths and angles used in a bicycle design. Head angle - Angle the steering axis leans back from vertical. Oil bath - oil reservoir system used for lubricating internal parts in the fork. One piece- unitized lower leg assembly with both fork legs and fork brace cast as one piece. Preload- The amount either in pounds or inches , a spring is compressed when fitted to an extended shock absorber. Rebound- The extension or return direction of the shocks or suspension. Sag - compression of the suspension caused by the rider's weight. Spring rate - The amount of force required to deflect a spring a given distance. Tapered - varying wall thickness of a tube.A design to optimize placement of material,allowing most efficient design considering the loads. Topping out- the position of the fork at the "top" of the travel,or when the fork is fully extended. The action of complete extension of the fork. Follow the NORBA Code I will yield the right of way to other non-motorized recreationalists. I will use caution when overtaking another and will make my presence be known well in ad vance. I will maintain control of my speed at all times. I will stay on designated trails. I will not disturb wildlife or livestock. I will not litter. I will respect public and private property. I will always be self sufficient. I will not travel solo when bikepacking in remote areas. I will observe the practice of minimum impact bicycling. I will always wear a helmet whenever riding. ****** Result for Image/Page 10 ****** exploaea L.nagrams O 1998 Judy XC Reflector Bracket Bolt 2 Reflector Bracket Hangerless 3 Reflector Bracket Lock washer 4 Nut 5 Brake Post Washer 6 Brake Post 7 I-OKW Leg Assembly, Hangrlss 8 Resiwiper top seal 9 Upper Bushing 10 Lower Bushing 11 Bottom Bumper 12 Judy XC Panel Decal 13 Judy XC (L & R) 14 Washer Sealing, M6 15 Hollow Shaft Bolt 16 Damping Hand Adjuster O-ring -o O -t 0 Damping Hand Adjuster Washer Sealing, M8 Shaft Bolt Shaft End Plate Cartridge Assembly Cartridge Lock Ring Wave Washer Cartridge Retaining Ring Upper Shaft Guide Upper Shaft Guide O-ring Neutral Shaft FlatWasher Top Out Bumper Lower Shaft Guide Bottom Out Bumper Upper Tube Available in a—mbly onbr 1998 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Fork Boot Crown/Steerer Crown/Steerer/UpperTubes Top Cap Assembly Type 3 Primary Spring Type 3 Spring Spacer Type 3 Secondary Spring Crown Bolts Lower Leg Assembly, Hanger Reflector Bracket, Hanger-style Reflector Bracket Bolt 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Reflector Bracket Bolt Reflector Bracket Hangerless Reflector Bracket Lock washer Nut Brake Post Washer Brake Post Lower Leg Assembly, Hangrlss Resiwiper top seal Upper Bushing Lower Bushing Bottom Bumper Judy SL Panel Decal Judy SL Decal (L & R) Washer Sealing, M8 Hollow Shaft Bolt o 2nd bumper 16 Damping Hand Adjuster O-ring 17 Damping Hand Adjuster 18 Washer Sealing, M6 19 Shaft Bolt 21 Shaft End Plate 22 Cartridge Assembly 23 Cartridge Lock Ring 24 Wave Washer 25 Cartridge Retaining Ring 26 Upper Shaft Guide 27 Upper Shaft Guide O-ring 28 Neutral Shaft 29 FlatWasher 30 Top Out Bumper 31 Lower Shaft Guide 32 Bottom Out Bumper 33 Fork Boot 34 Crown/Steerer/Upper Tubes 35 Top Cap Assembly 36 Type 3 Primary Spring 37 Type 3 Spring Spacer 38 Type 3 Secondary Spring 39 Lower Leg Assembly, Hanger 40 Reflector Bracket, Hanger-style 41 Reflector Bracket Bolt t Indicates Threadless Steerer t Indicates Threadless Steerer * Crownlsteerer includes four crown bolts