96 Judy Service
Contents
1. CARTRIDGE S Y S T E M SERVICE MANUAL 19 96 For Judy XC SL DH and FSX Forks RockShox Inc 1 800 677 7177 INTRODUCTION ROCK SHOX JUDYS The Judys are designed as a modular system The multicellular urathane MCU springs and damper cartridge are easy to tune remove and replace With the adjustment available almost any ride quality can be achieved Steerer Tube Preload Adjuster Knob Fork Crown Bolts 2 side none on SL Fork Crown Upper Fork Tube w dust boot Fork Brace Fork Brace Bolt Brake Post Lower Tube Hollow Shaft Bolt all Shaft Bolt hollow on DH model only REQUIRED TOOLS COMMON HAND TOOLS e 2 4 amp 5mm hex keys Snap ring pliers e Small straight blade screwdriver e Soft face mallet Safety glasses SPECIAL ROCK SHOX TOOLS Bushing installer tool Bushing remover tool Judy bushing puller adapter ring Mag seal puller tool Cartridge Service Tool Kit e Shaft Guide Tool MISCELLANEOUS High quality bearing grease Judy Butter or Non Lithium Fishing line or Mag 21 Seal O ring RockShox Fork Oil 8 or 5 wt page 1 REGULAR MAINTENANCE 1 Routine maintenance of Judy forks consists of keeping the forks clean externally After every ride wipe down the outside of the fork 2 Approximately once a month and or every 40 hours of riding inspect the fork for damage crown brace upper tubes lower tubes 3 Also check2. check to see if upper tubes have engaged lower bushings It may be necessary to spread lower tube brace assembly apart slightly or gently rock assembly side to side while getting lower bushings to mate with upper tubes DO NOT FORCE Be sure to push protective boots into their retaining grooves on the lower tubes TUNING VARIABLES Judy forks can be tuned to your particular weight riding style and terrain Start by tuning the spring stack to achieve the correct ride height Please refer to the illustration in the back as a reference for the parts used in the following descriptions page 3 RIDE HEIGHT ADJUSTMENT Judys are designed to compress droop or sag when you are sitting with your weight on the bike Sag allows the front wheel to stay in contact with the ground when braking and cornering over rough and uneven terrain Adjust preload and or change spring stack to maintain correct ride height For example set preload adjusters to zero full counter clockwise and sit on the bike If fork compresses 15mm too much sag turn preload adjusters clockwise one click on each side at a time until desired ride height is achieved The nominal sag dimensions are 7 10mm for 75 and 80mm travel 5 8mm for 60mm travel 2 5mm for 50mm travel SPRING TUNING To tune the MCU spring unscrew p A 5 firm solid the top cap assembly see 0 150 B 6 firm exploded view in Small Parts R 100 C 5 firm Tsoft Catalog or Owner s Manual
3. replace the O ring and inspect rebound plate white plastic washer for freedom of movement If plate is not free replace assembly For pistons with a glide ring inspect ring for nicks and scratches and that it shuttles freely on the piston Replace as needed Note The piston shaft is available in assembly form only Do not disassemble 10 Remove and replace adjuster rod O ring Grease liberally prior to installation onto adjuster rod 11 For 50 and 60mm cartridge assemblies determine which cartridge body you have 50mm 4 59 body PN43101 and 1 spacer PN42265 or 3 59 body PN43105 60mm 4 59 body PN43101 and 1 2 spacer PN42266 or 4 09 body PN43104 This will help you determine which cartridge body you may need to order CARTRIDGE ASSEMBLY 1 Lightly coat inside of cartridge body with RockShox oil If a spacer was used reinstall it into the cartridge Apply grease to a new upper cartridge seal inside and out Slide seal pocket side down onto upper seal installation tool Press the seal into seal bore of cartridge until fully seated Fig 8B Remove upper seal installation tool 2 For DH cartridges reinstall retaining ring sharp side out and make sure it is fully seated into its groove Next reinstall plastic shaft guide and then press upper seal into cartridge bore as previously described Make sure seal is fully seated as plastic shaft guide should not be loose in the cartridge Figure 8B Continue
4. the torque of the crown bolts lower tube bolts brace bolts and brake posts 4 The aluminum upper tubes the MCU spring stacks and the bushings in the lower tubes should be lubed at this interval REMOVING MCU STACKS 1 To lube MCU spring assembly first loosen the 5 or 6mm crown bolts using a 4 or 5mm allen wrench respectively then unscrew top cap assembly counter clockwise and pull top cap and MCU spring stack out fig 2A and 2B 2 Unsnap the MCU springs and or spacers from the Judy Jax and clean off old grease with a rag and degreaser such as Pedro s fig 2C 3 Now reassemble the stack and using a rag or your fingers apply a coating of grease to the entire MCU spring stack Reassemble by screwing top cap assembly back into upper tube and tighten crown Figure 2A bolts to 60 in Ibs of torque very snug but not super tight Figure 2B Figure 2C REMOVING AND GREASING LOWER TUBES 1 To lube upper tubes and bushings the lower tube brace assembly must be removed First disconnect front brake cable and remove front wheel 2 Using a 5mm hex wrench remove 6mm bolt at bottom of each lower tube See fig 2D It may be necessary to add preload to the spring stack in order to break the 6mm bolt loose Add preload by turning Figure 2D the adjuster knobs clockwise and or compress the fork 3 After removing both 6mm bolts pull lower tube brace assembly free of upper tub
5. 50 D 4 firm 2 soft Remove spring stack By using I 0 He E 3 firm 3 soft Pere 0 15 30 45 60 75 different combinations of the soft TRAVEL MM red the firm blue springs and figure 4A the solid spacer almost any spring rate you desire is possible Simply separate the standard springs from the JUDY JAX then reassemble the new combination of firm and soft springs you would like to try SPRING PRELOAD The preload adjuster knobs control the amount of fork sag preload on the spring stack Turn the adjuster knob clockwise to increase the preload on the microcellular spring and reduce sag Turn the adjuster knob counter clockwise to reduce the preload on the spring and increase sag COMPRESSION DAMPER TUNING A single cartridge in the left leg provides the damping for the entire fork except the DH Kits with different travel options 2 5bOmm adjustable 2 5 60mm adjustable and 3 75mm adjustable are available for XC and SL models only The DH is available in 80mm adjustable only The damper unit has a wide range of adjustment Insert the enclosed 2mm hex key through the hollow shaft bolt in the bottom of the left leg see exploded view at end of English section Turn the hex key clockwise to increase the compression damping Turning the hex key counterclockwise will decrease the compression damping There are two full turns of adjustment available from full clockwise DO NOT TURN ADJUSTER MORE THAN TWO FULL TURNS COUNTER CLOCK
6. IALS OR WORKMANSHIP ANY RockSHOX FORK THAT IS RETURNED TO THE FACTORY AND IS FOUND BY ROCKSHOX TO BE DEFECTIVE IN MATERIALS OR WORKMANSHIP WILL BE REPAIRED OR REPLACED AT THE OPTION OF ROCKSHOX INC THIS WARRANTY IS THE SOLE AND EXCLUSIVE REMEDY ROCKSHOX SHALL NOT BE HELD LIABLE FOR ANY INDIRECT SPECIAL OR CONSEQUENTIAL DAMAGES THE WARRANTY DOES NOT APPLY TO FORKS WHICH HAVE NOT BEEN PROPERLY INSTALLED AND ADJUSTED ACCORDING TO ROCKSHOX INSTALLATION INSTRUCTIONS THE WARRANTY DOES NOT COVER ANY FORK THAT HAS BEEN SUBJECT TO MISUSE OR WHOSE SERIAL NUMBER HAS BEEN ALTERED DEFACED OR REMOVED THIS WARRANTY DOES NOT COVER PAINT DAMAGE OR MODIFICATIONS TO FORKS PROOF OF PURCHASE IS REQUIRED WARRANTY REPAIR IF FOR ANY REASON IT SHOULD BE NECESSARY TO HAVE WARRANTY WORK DONE RETURN THE FORK TO THE PLACE OF PURCHASE IN THE USA DEALERS SHOULD CALL FOR A RETURN AUTHORIZATION RA PRIOR TO RETURNING PRODUCT PRODUCTS RETURNED FOR INSPECTION MUST BE SENT FREIGHT PREPAID TO ROCKSHOX INC 401 CHARCOT Ave San Jose CA 95131 408 435 7469 FAX 408 435 7468 CUSTOMERS IN COUNTRIES OTHER THAN THE USA SHOULD CONTACT THEIR DEALER OR LOCAL DISTRIBUTOR page 10
7. MPORTANT THAT THE SNAP RING IS CORRECTLY INSTALLED AND FULLY ENGAGED IN THE UPPER TUBE IF THE SNAP RING Figure 7A WORKS ITSELF LOOSE THERE WILL BE A SEAL FAILURE IN THE CARTRIDGE AND THE HYDRAULIC FLUID WILL LEAK OUT 7 Repeat this entire procedure to install neutral shaft assembly of matching travel length in right upper tube See figure 7A for the correct sequence of neutral shaft assembly parts 8 After installing cartridge and matching neutral shaft assembly reinstall lower tubes See REINSTALLING LOWER TUBES CARTRIDGE SERVICE SECTION INTRODUCTION ROCK SHOX JUDY CARTRIDGE The Judy damper cartridge is designed to be fully servicable and tuneable Use the proper tools and procedures to keep Judy cartridges operating properly The best performing cartridges have the least amount of air inside Keep this in mind when servicing your cartridge CARTRIDGE DISASSEMBLY AND OIL CHANGE 1 Remove the cartridge from the fork See previous section Changing Travel for details on removal 2 Slide off the plastic cartridge washer Hold the cartridge over an oil recepticle with the exposed seal end down and tap the damper shaft with a mallet firmly holding the cartridge body to press the seal out of the cartridge body Fig 7B Once the seal is exposed drain the oil from the cartridge into the oil container 3 Pull the damper shaft free of the cartridge body Inspect the damper shaft for nicks or scratches that may c
8. WISE REBOUND DAMPER TUNING DH only A cartridge in the right leg provides the rebound damping for the DH fork The damper unit has a wide range of adjustment Insert the enclosed 2mm hex key through the hollow shaft bolt in the bottom of the right leg see exploded view at end of English section Turn the hex key clockwise to increase the rebound damping slow the return stroke Turning the hex key counterclockwise will decrease the rebound damping speed the return stroke There are four full turns of adjustment available from full clockwise page 4 BUSHING REMOVAL The high quality Garlock DU bushings are designed to outlast many months of hard riding The protective boots a clean fork and timely greasing are keys to long bushing life However like all moving parts bushings will eventually wear and need replacement Increased fore and aft movement of upper tubes in lower tubes similar to a loose headset and slow action even after a fresh greasing signals the need to remove and replace bushings 1 First remove lower tube brace assembly as detailed in Figure SA previous section REMOVING LOWER TUBES Figure 5C 2 Remove brakes as per manufacturer s instructions 3 Next remove fork brace by unscrewing 6mm fork brace bolts with an appropriate hex wrench and unscrew 8mm brake boss bolts with an open end wrench Remove the dust seal with a small flat blade screwdriver 4 Slide J
9. anged MCU spring kit part number 59043 includes 2 solid 4 blue 4 red springs See previous REMOVING MCU STACKS section for details on changing MCU spring stack Figure 6C 1 To change damper cartridge and neutral shaft start by removing lower tube brace assembly see previous section REMOVING LOWER TUBES for details With lower tubes removed use internal snap ring pliers to remove snap ring on end of each upper tube See figure 6C CAUTION MAKE SURE THE FORK HAS BEEN AT REST FOR A MINIMUM OF 15 MINUTES BEFORE REMOVING SNAP RING 2 Next grab end of each shaft and gently pull cartridge and neutral shaft assembly free of each upper tube one at a time Figure 6D 3 Prior to installing new damping cartridge into left upper tube make certain that cone shaped shaft end plate is installed on shaft end that is NOT threaded to accept a 6mm bolt 4 Install a plastic cartridge washer onto other end CAUTION BE SURE TO PROPERLY INSTALL CARTRIDGE WASHER BETWEEN THE CARTRIDGE AND RETAINING CLIP page 6 CHANGING TRAVEL Cont 5 Slide cartridge into upper tube with end plate side first NOTE On 96 SL forks make sure the cartridge stop clip is properly seated in its groove within the upper tube 6 Reinstall snap ring sharp outside edge facing out Make certain cartridge washer is in place snap ring is oriented correctly and fully engaged in groove of upper tube CAUTION IT IS VERY I
10. ause oil leakage Replace assembly as needed Figure 7B 4 Inspect the inside bore of the cartridge body for scoring or scratches that may cause oil leakage Replace cartridge body as needed Continued on next page page 7 CARTRIDGE DISASSEMBLY CONT 5 For adjustable compression cartridges unscrew the adjuster rod completely with a 2mm hex and remove from the damper shaft Fig 8A CAUTION REMOVE THE ADJUSTER ROD GENTLY TO AVOID DAMAGING THE ADJUSTER ROD O RING ON THE THREADS OF THE SHAFT WHEN REMOVING Note The adjuster rod in the DH rebound cartridge is not removable 6 Clean the following parts with a clean lint free rag damper shaft seal cartridge body 7 Press upper seal out of cartridge body by using a 2mm hex key alternating through the four access holes in cartridge body Finish seal removal using a flat blade screwdriver through the shaft hole Figure 8A WARNING USE EXTREME CARE NOT TO DAMAGE THE CARTRIDGE BORE 8 For DH cartridges remove top retaining clip and plastic shaft guide washer to allow seal to be pressed out through top of cartridge using upper seal installation tool Note Some 50mm and 60mm cartridges use a plastic spacer located inside or outside upper seal 9 Identify whether piston has an O ring or a piston glide ring pistons with three ports have an O ring pistons with four ports have a glide ring For pistons with an O ring remove and
11. d on next page page 8 CARTRIDGE REASSEMBLY CONT 1s Figure 9A Figure 9C Figure 9E ge 3 Figure 9G 3 Insert shaft guide tool into cartridge body and seal Fig 9A Place assembly into cartridge body fixture Fig 9B Fill cartridge 1 2 full with RockShox oil Apply oil to piston O ring or glide ring and insert piston shaft assembly into cartridge mating shaft with shaft guide tool Then push piston shaft assembly through the upper seal forcing shaft guide tool out Fig 9C 4 Lift entire cartridge body fixture and remove shaft guide tool from bottom side taking care not to lose any oil from the cartridge Fig 9D 5 Push piston shaft assembly into cartridge body until it stops Add more oil until it s about 2 3 full using care not to pull shaft back through the seal and the piston out of the oil Cycle piston shaft assembly several times until no air bubbles are seen in the oil Fig 9D 6 Push piston shaft assembly fully into cartridge body until it stops 7 Install top out O ring and seal washer onto shaft 8 Fill cartridge body fully with RockShox oil 9 Apply grease to new seal inside and out fully filling pocket of seal with grease 10 Using your fishing line or cut main seal O ring PN 51104 place in I D of seal Fig 9E 11 Carefully install this seal assembly pocket side down over shaft being careful not to damage sealing
12. es See fig 2E ETT S 4 Use a clean lint free rag and degreaser to clean the aluminum upper M osi tubes Clean bushing surfaces inside magnesium lower tube with a clean lint free rag Be certain to reach lower bushings cont next page Figure 2E page 2 REMOVING AND GREASING LOWER TUBES Cont located 7 inside lower tube a long 3 8 drive extension or screwdriver works well for this 5 Apply a light coating of grease such as Judy Butter to the clean bushings again a long 3 8 extension without the rag this time works well for lower bushings See fig 3A t Es NOTE DO NOT USE LITHIUM BASED GREASE 6 Next apply a light coating of grease to upper tubes Fig 3B and internal lip of dust wiper located on top of each lower tube Fig 3C The primary cause Figure 3A I for a sticky Judy is a dry and or dirty dust seal rubbing on a dry and or dirty upper tube 4 md Figure 3B Figure 3C REINSTALLING THE LOWER TUBES 1 Slide lower tube brace assembly gently over upper tubes taking care not to damage dust wiper or lower bushing Fig 3D 2 Apply medium threadlock such as blue Loctite 242 to threads of 6mm bolts and using a 5mm allen key reinstall them through the lower tubes engaging threads in cartridge and or neutral shafts Figure 3D 3 Torque to 60in Ibs If bolts do not thread into cartridge and or neutral shafts
13. ift until lower tube bottoms on bushing installer tool base See figure 6A page 5 BUSHING REPLACEMENT Cont 5 Remove lower tube and slide sleeve and spacer off of the end of the installer tool Slide a new greased upper bushing with the larger O D onto the installer tool See figure 6B 6 Use a soft mallet to gently tap upper bushing into lower tube until lower tube bottoms on bushing installer tool base H 7 Repeat this entire procedure for other lower tube a 8 See the previous section REINSTALLING THE LOWER Figure 6A TUBES for details on reinstalling the lower tubes Figure 6B 9 After installing lower tubes reassemble fork brace being sure to use medium strength threadlock blue 242 Loc tite on fork brace bolt and brake post threads CAUTION USE ANTI SEIZE ON ALL TITANIUM FASTENERS 10 Torque all bolts to 60 in Ibs Remember to check torque every month or every 40 hours of riding Reinstall brakes per manufacturer s instructions CHANGING TRAVEL Judy XC SL and FSX models are capable of having any of three travels that are available 2 50mm 2 5 60mm or 3 75mm The list below gives part numbers for different cartridge kits available cartridge kit cartridge and neutral shaft 2 0 50mm adj cartridge kit 59053 2 5 60mm adj cartridge kit 59054 3 0 75mm adj cartridge kit 59055 The standard MCU spring stack may need to be adjusted when travel is ch
14. lips on the flats of shaft and maintaining orientation of fishing line between seal and shaft Fig 9F Note Make sure fishing line does not get caught between cartridge body and seal O D Figure 9B Figure 9D Figure 9F 12 Place seal installation tool over exposed shaft and press seal into cartridge body leaving 1mm of seal exposed above cartridge body lip Fig 9G CAUTION HOLD A RAG AROUND LOWER SEAL INSTALLATION TOOL AS OIL WILL BE FORCED OUT THROUGH THE VENT HOLES OF THE TOOL Note The lower seal can be pressed in too far Leave 1mm exposed 13 Remove fishing line from seal Continued on next page page 9 CARTRIDGE REASSEMBLY Cont rj 14 Adjustable cartridges only Fill exposed adjuster rod shaft full with oil Fig 10A j 15 Using a 2mm hex key install adjuster rod with new O ring that is liberally greased Thread into exposed m shaft until rod bottoms out CAUTION USE CARE WHILE INSTALLING ADJUSTER ROD TO PREVENT DAMAGE TO O RING THREADS IN SHAFT Hint Spin adjuster rod as O ring contacts shaft effectively threading O ring through the 6mm threads Figure 10A 16 See Changing Travel for reinstalling cartridge into upper tube Note Be sure to properly install a cartridge washer between cartridge and retaining clip Warranty ROCKSHOX INC WARRANTS ITS FORKS FOR A PERIOD OF ONE YEAR FROM ORIGINAL DATE OF PURCHASE TO BE FREE FROM DEFECTS IN MATER
15. udy bushing puller adapter tool over aluminum end of a Mag seal puller tool Insert bushing puller tool inside lower tube and engage lower edge of upper bushing with lever of tool See figure 5A 5 Slide seal puller tool over handle of the bushing puller until it sits on lower Figure 5B tube See figure 5b 6 Invert the entire assembly with tool engaged with bushing and clamp puller tool handle in vise Now unscrew seal puller tool by hand or by using 32 and 36mm headset wrenches until the upper bushing has pulled free See figure 5C 7 Repeat this procedure for lower bushing 8 Repeat this entire procedure for other lower tube Clean the inside of each lower tube to remove dirt and old grease BUSHING REPLACEMENT 1 Looking at your replacement bushings determine which luo cB bushings have the large outer diameter These are upper Bushing Post bushings set them aside I 2 Take one smaller outer diameter lower bushing and Sleeve lube interior and exterior surfaces with Judy Butter or other non lithium high quality bearing grease Place bushing over end of bushing installer post with sleeve Spacer and spacer in place See figure 5D and illustration 5E 4 Pase 3 Place lower tube without dust wiper over this assembly Figure 5D Figure 5E and insert mallet drift into counter bore of lower tube 4 Using a soft mallet gently tap dr
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