K2 Bike Chubby LT User manual

1998 CHUBBY / CHUBBY LT OWNER'S MANUAL - PDF
Noleen
Chubby / Chubby LT
Owner’s Manual

TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Your Noleen Chubby and Chubby LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Read This Manual!
Precautions
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Frame Preparation
Fork Preparation / Installation
Suspension Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tuning Variables
Tuning Adjustments
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Tools Needed
Lubrication
Seal and O-Ring Replacement
Bearing Replacement
Maintenance Schedule
Torque and Lubrication Table
Service Kits

INTRODUCTION
YOUR NOLEEN
CHUBBY AND
CHUBBY LT
Congratulations! You’ve just purchased the Noleen Chubby or Chubby LT Suspension Fork! With it’s unique dual triple clamp design,
and four inches of elastomer, spring, and air travel, the Chubby is designed to let you dive into the gnarliest terrain and come out
unrattled and unscathed.
So ride the Chubby and let it Rip!
GENERAL
INFORMATION
In this section:
• Read this Manual!
• Precautions
Note: The Noleen Chubby and Chubby LT come in a Standard size (for bicycles with 90mm to 125mm head tubes) and a Long size (for
bicycles with 126mm to 160mm head tubes). Make sure that you have the correct size Chubby. If you have further questions about
the correct size, see the Installation section. Also, for any other sizing questions, please contact your K2 Bike / Noleen Dealer.
NOTE : Read this manual carefully before attempting to install or service you Chubby Fork. It is important that you follow proper
proceduretoensuremaximumperformance.
CAUTION: K2 Bike strongly recommends that your Chubby Fork be installed by a K2 Bike dealer or other
qualified technician. These instructions are for a qualified installer who possesses proper training and tools.
Improperly installed forks can be extremely dangerous, and can result in failure during use and severe injury.
CAUTION: The Noleen Chubby Fork is a competition off road fork, and as such does not come with reflectors
or lights for road use. Adapt proper reflectors and lights if bicycle will be used in low light conditions.
CAUTION: Installation of an incorrect length steerer tube could result in fork failure and severe injury. See
your authorized K2 Bike / Noleen dealer or other qualified technician to ensure proper installation.
CAUTION: In the event of a crash, there could be damage to your Chubby Fork that may not be visible.
Damaged forks can be extremely dangerous, and can result in failure during use and severe injuries. After a
crash, take your fork to an authorized K2 Bike/Noleen dealer or qualified technician to verify its integrity.
!
!
!
!
2

Frame Preparation
ProperframepreparationwillmakeinstallingyournewNoleenChubbyforkeasierandallowyourforktofunctionproperly.
Notes : All Noleen suspension forks require the use of a threadless headset, such as a Dia-Compe Aheadset. If you do not have a
threadless headset, you will need to install one before you install your new Noleen fork.
1. Removetheoldstemandforkfromyourbicycle.IfyouareinstallingtheNoleenforkonanewframethathasnever
hadaforkinstalled,moveontothenextstep.
2. Inorderfortheheadsetonyourframetofunctionproperly,theends oftheheadtubeshouldbeperpendiculartothe
sidesoftheheadtube.Someheadtubesneedtobe“faced”inordertoholdtheheadsetcupsproperly.Ifyoubelieve
thatyourheadtubeneedstobefaced,consultyourlocalK2Bike/Noleendealerorotherqualifiedbicycledealer.
3. Lubricatetheinsideoftheframe'sheadtubeaswellastheheadsetcupsandpresstheupperandlowerheadsetcups
intoyourframe.Makesurethattheheadtubeandheadsetcupsarefreeofdirtandgrime.
NOTE: Headset cups should be installed using a headset press. Do not substitute this tool for anything else. See your local Noleen
dealer for assistance installing headset cups. Damage to the frame and/or headset can occur if not installed properly.
Fork Preparation / Installation - 6 Easy Steps!
Onceyouhaveaproperlypreparedframe,youcannowinstallyourNoleenfork.WhileyourNoleenChubbyhasbeenassembledwithcareatthe
factory, partial disassembly and reassembly is required for mounting.Follow these steps:
Step #1 - Remove the Upper Triple Clamp from the fork.
1. Loosenthethreeboltsontheuppertripleclamp.
2. UsingtheChubbyWrench(preloadadjusterremovaltool),loosenandremovethepreloadadjustersandspringstack.
2. Slidetheuppertripleclampoffofthetopofthefork.
Step #2 - Check the ”Critical Measurement“ for the Chubby / Chubby LT.
CAUTION: The lower triple clamp on the Chubby and Chubby LT must remain a certain distance above the
front tire. The Chubby needs this amount of room allow the suspension to compress fully without the tire
striking the lower triple clamp. Improper fork installation could result in a loss of control and severe injury.
As stated in the caution above, the Chubby needs this amount of room allow the suspension to compress fully without the tire
strikingthelower triple clamp.ThismeasurementisdifferentforthetwoChubbyforks.ThismeasurementDOESNOTchangeforthedifferent
sizes ofeach fork model. This measurement should be taken from the middle of the dropout (or the middle of the front hub axle) to the
bottom of the lower triple clamp. We call this measurement the “Critical Measurement.” See below for the Critical Measurement for
the Chubby and Chubby LT forks.
Dim A: Chubby (both Standard and Long sizes) = 442mm
Chubby LT (both Standard and Long sizes) = 467mm
Follow these instructions to set the ”Critical Measurement“ on your Chubby or Chubby LT:
1. Using a tape measure or ruler, measure the distance from the center of the fork dropout to the bottom of
the lower triple clamp.
2. Checkthis measurement against the ”Critical Measurement“ above.
3. Loosen the two bolts on the lower triple clamp and slide the triple clamp up or down so that both sides
are set to the ”Critical Measurement.“ Torque all of the lower triple clamp bolts to 85 in-lbs.
INSTALLATION
In this section:
• Frame Preparation
• Fork Preparation /
Installation
!
Dim A
”CriticalMeasurement“
Dim A
RemoveUpper
TripleClamp
3

NOTE: AFter you set the ”Critical Measurement,“ you will be left with a certain amount of room between the triple clamps for your
bike's headtube and the headset. You will need to know the headtube length and the headset stack height to find this measurement.
This is VERY IMPORTANT! The maximum amount of room between the triple clamps for our Chubby and Chubby LT forks are:
Dim B: Standard Size Long Size Example: Headtube Length 125mm
+
Chubby/ChubbyLT 156mm 191mm Headset Stack Height 27mm
Total Height 152mm*
*Intheexample above, thiscombinationwillfitaChubby or Chubby LT Standardsizefork.
Step #3 - Install the crown race seat and steerer tube.
1. MakesurethatthecrownraceforyourthreadlessheadsetwillfitontothecrownraceseatontheChubbysteerer
tube.Thecrownraceshouldhaveaninsidediameterof30.0mm(11/8“Standard).Thecrownraceshouldbeslightly
smallerthanthecrownraceseatsothatapress-fitisrequiredtosettheracefirmlyontothefork.
2. Make sure that the lower triple clamp is sitting flush with the lip on the bottom of the steerer tube. If it is
not,loosenthesteererclampboltandslidethesteererupuntilthebottomliponthesteererisagainstthebottom
sideofthelowertripleclamp.Retorquethesteererclampboltto85in-lbs.
3. Slidethecrownraceontothesteerertubeandinstalltheraceusinga slidehammerorotherraceinstallationtool.
4. Inspecttheraceandmakesurethatthebottomoftheracesitsflushwiththecrownraceseatonthelowertriple
clampandthattheraceisfirmlyinplace.
Step #4 - Install the fork.
1. Slidethesteerertubeintotheheadtubeofthebikeand,whilesupportingthebottomofthesteerertubeandlower
tripleclampwithyourhand,slidetheuppercuporraceoftheheadsetontothesteerer.
2. Route both derailleur and rear brake cables between the two triple clamps and in between stanchion
tubeand head tube.
CAUTION: DO NOT route cables outside of fork legs. Loss of control and serious injury may result. Always
route cables between fork leg and head tube.
3. Slide the upper triple clamp onto the steerer tube and the stanchion tubes and temporarily tighten the
steerer cinch bolt. Important! Do not cut the steerer tube at this point.
Headtube/Headset
Measurement - Dim B
Dim B
!
Proper Steerer Tube
Installation
Install steerer and fork
CrownRace
Installation
Proper Cable Routing
4

Step #5 - Decide where you want the upper triple clamp mounted.
Thepositionoftheuppertripleclamp ontheChubbyforks issomewhatflexible.Youcanplacetheupper triple clampdirectlyontop of the
headset, or you can space it up so that it clamps up higher on the stanchions. Remember: the position of the lower triple clamp is
FIXED,andshouldnot be moved upordown. Thestepsbelow willshowyouhowto mounttheuppertripleclampproperlyinanylocation.
1. Withtheuppertripleclamptemporarilyinstalled,slidethestem(withhandlebarattached)ontothesteererand
position itwhereyou wouldlike it. Tighten the stem cinch bolts and sit on the bike to check the handlebar
height. Do not ride the bike like this. You are only checking handlebar position now. Note: If you want a
lower stem position, the stanchion tubes will probably extend above the top of the upper triple clamp.
Make sure this is what you want before making any alterations to the steerer tube.
2. Ifyouwouldprefertohavethetopofthestanchiontubesflushwiththetopoftheuppertripleclamp,youwillneed
toplaceenoughheadsetspacersontopoftheheadsetinordertodoso.Measuretheamountofexposedstanchion
tubewiththeuppertripleclampinstalleddirectlyontopoftheheadset.Thisistheamountofheadsetspacersyou
willneed.
3. Installtheheadsetspacersanduppertripleclampintothedesiredpositionandtightensteererclampboltto85in-lbs.
4. InsertthetwospringstacksandpreloadadjustersintothestanchiontubesandtightenwiththeChubbyWrench.
5. Tightentheremainingboltsontheupperclampto85in-lbs.
6. Rotatetheforkandcheckforanybindingorgrindingintheheadset.Iftheforkrotatessmoothly,continueontothe
nextstep.Iftheforkbindsortheheadsetfeelsrough,loosentheuppertripleclampandrepeatstep3.
Step #6 - Install the star-fangled nut, stem, handlebar and brakes. That's it!
1. If you will want to cut the steerer tube, make sure that you have enough room for your stem. DO NOT cut
the steerer tube too short! Also, make sure the star-fangled nut is properly placed in the steerer tube
before you do any cutting.
2. Installthestar-fanglednutintotopofsteerertube10-12mmfromtheuppersurfacewithstarfanglednutinstalla-
tiontool,ifitisnotinstalledalready.Donotattempttoinstallthestar-fanglednutwithoutthepropertool.
3. Wheninstallingyourstem,thedistancebetweenthetopedgeofthestemclampmustextendabovethetopofthe
steerertube1-3mm.Ifthedistanceisincorrect,removethestemandaddorremovespacersontopoftheupper
tripleclamptoachievea1-3mmdistance.
CAUTION: Assembly with the top of the stem extending more than 3mm above the top of the top of the
steerer tube can result in fork failure during use and severe injury.
4. InserttheAheadsetcapandscrewthroughthetopofthestemandintothestar-fanglednut.Usethethreadless
headsetcaptoadjusttheheadsetasperthemanufacturer'sinstructions.Remember:Youwillneedtoloosenallof
theuppertripleclampboltsandthestemclampboltstoadjusttheheadset.
5. Tightenthetwostemboltsto90-120in-lbsorrefertothestemmanufacturer'storquespecsforthestem.Installthe
handlebarandbrake/shiftercontrols.Positionasdesiredandtightenallboltstomanufacturer'storquespecification.
CAUTION: If the two steerer pinch bolts are not securely tightened, the stem may rotate or pull off of the
steerer tube, resulting in loss of control and severe injury.
CAUTION: All Chubby fork bolts should be tightened to the proper torque when installation is completed.
Failure to torque all bolts properly can result in failure during use and severe injury. Refer to Maintenance:
Service Table for all torque, lubrication, and Loc-tite specifications for all Chubby bolts.
Option 2
Option 1
!
!
Proper Star-Fangled
Nut Installation
10-12mm
!
Proper Stem
Installation
1-3mm
5

Tuning Variables
Allridersaredifferent.Therefore,bicyclesuspensionneedstobeabletoadjusttothedifferentneedsanddesiresofdifferentriders.Thefollowing
factorsshouldbeconsideredwhenadjustingthesuspensionofaNoleenfork:
Rider Weight
Lighterridersneedtohavesofterspringsinordertotakefulladvantageofthetravelofthefork.HeavierridersneedtousestifferMCUspringsto
keepthe forkfrombottomingout.Youmayneed toadjustthestiffnessofspringsinyourforkforyourbodyweight. See Suspension Variables:
SpringRateforthecorrect springstouse.
Type of Riding
Asuspensionforkusedforhigh-performanceoff-roadridingshouldhavestiffersuspensionthanoneintendedforrecreationalroaduse.Thesevere
impactsandhighspeedsofserious off-roadridingdemandstiffersprings,while morecasualridingismorecomfortablewithsoftersprings.In
general,theforkshouldbesetuptomaximizetheuseofsuspensiontravelintheconditionstobeencountered.
Personal Preference
Newsuspensionridersoftenpreferstiffersuspensionsthatfeelmorelikearigidbikes.However,suspensionforksworkbestwhenarideradapts
theirstyletousethesuspensionfully.Aspringthatfeelssoft atfirstmaybeexactlywhatyouwantafteraweekofriding.
Tuning Adjustments
Once you have an understanding of the variables affecting suspension tuning, you can now move on to actually adjusting your
suspension to fit your needs. The Tuning Adjustments of your Noleen Chubby suspension are:
Spring Rate
TheSpringRateofaspring istheamountofloadrequiredtocompressthatspringoneinch. Thisdefinitionappliesmainlytocoilspringsandnot
toMCUsprings.SincetheChubbyandChubbyLTuseacombinationofMCUspringsandacoilspring,thespringchartbelowreferstocombina-
tionsofMCUspringsandnotactualspringrates.Wesuggestdifferentspringratesforourbikesandforksbecausedifferentridersplacedifferent
loadsonbicycles.
Springselectionisalsoaffectedgreatlybyriderpreference. Moreaggressiveridersmaydesiretheirspringstobestiffer, whileamorerecreationally
orientedridermaylikeasofterridewithsoftersprings. Experimentationwithdifferentspringratesmaybenecessarytofindthecorrectsetup.
Spring Selection Tables
Consultthetablesbelowtoselectthespringsetthat’sbestforyou.Remember,thesearerecommendations.You
maywishtotrystifferorsofterspringsthanrecommendedduetotheterrainyouride,yourridingstyle,andpersonalpreference.
Rider Weight Chubby(each leg) ChubbyLT(eachleg)
upto140 3Blue,3Tan 4Blue,4Tan
130-170 1Blue, 5 Tan 2Blue, 6Tan
160-200 6Tan 8Tan
190-230 5Tan, 1 Pink 7 Tan, 1 Pink
over230 4 Tan,2 Pink 6 Tan, 2 Pink
Replacing Springs on the Chubby and Chubby LT
The Chubby comes equipped with six elastomers and one coil spring per leg, and the Chubby LT has eight MCU springs and
one coil spring.
NOTE: Aftermarket forks are supplied with two additional pink Springs for modification of your Chubby. Your Chubby can be
stiffened by replacing a standard tan spring with a stiff pink spring. To change springs, simply follow the instructions below.
1. Loosenuppertripleclampstanchionbolts.
2. UnscrewpreloadadjusterswiththeChubbyWrenchandremovespringstack.
3. Tochangesprings,pullstackapartandreplaceMCUspringswithharderspringstowardsthetopofthestack.
SUSPENSION
TUNING
In this section:
• Tuning Variables
• Tuning
Adjustments
Changing MCU Springs
6

4. Reinstallspringstackandpreloadadjusterintostanchiontube
5. Retorquealltripleclampboltsto85in-lbs.
CAUTION: All Chubby fork bolts should be tightened to the proper torque when servicing your fork. Failure
to torque all bolts properly can result in failure during use and severe injury.
WARNING: Make sure preload adjuster is installed fully. Failure to do so could lead to fork bottoming out and
serious injury.
Preload
Preload is the amount of load placed on a spring to increase the spring rate in the initial part of the travel. All of our Chubby forks
feature adjustable preload. Preload is used to help achieve the proper amount of suspension sag for your bike or fork.
Suspensionsag is the amount a shock compresses underthe weight of the rider. All suspension systems should exhibit some amount of
suspensionsag. Noleenforksshouldallbesetupproperlywithacertainamountofsag. Theoptimumsagamountforallofour frontsuspension
systems is 20% of the total wheel travel. For example:
Our Chubby LT has 125mm / 5 in. of travel. To calculate the optimum sag for this fork, multiply 125mm by .2. The answer
gives you a suggested sag , which for the Chubby is 25mm / 1 in.
Optimum suspension sag: Chubby 20mm ChubbyLT 25mm
Tomeasuretheamountofsag:
1. Beforeyoubeginmeasuring,Ithelpstocompresstheforkafewtimestoovercomeanyinitialfrictiontheremaybe
intheshock. Thiswillhelpinobtaininganaccuratemeasurement.
2. Measure the distance between a point on the lower leg of the fork (bottom edge of the fork boot, for
example) and a point on the upper part of the fork (The bottom of the lower triple crown) with no weight
on the bike.
3. Then measure from the same two points with a rider on the bike.(You will need some help with this). The
difference between the two measurements is the amount of suspension sag.
4. To increase preload on the Chubby, turn preload adjustercaps clockwise. To decrease the preload on the
Chubby,turnpreloadadjustercapscounterclockwise.
5. Ifyouhaveincreasedthepreloadfullyandarestillgettingtoomuchsag,youmayneedtochangethespringstackin
thefork.Remember:Thecorrectamountofpreloadcanonlybeachievedwiththepropersuggestedspringstack.
Damping
Dampingisthe actionofcontrolling the rateatwhich ashockcompressesand extends.Therateatwhichaspringcompressesandextends
canbecontrolled byanumberofways. The Chubby forksuseanairdamper in eachlegtocontrolthe rate ofreboundandcompression.
Airdampersworkverywelliftunedproperlyandarealsoverylight.IntheChubbyfork,thecombinationMCU/coilspringstackworkswellwith
theairdamper.
Thefirsttypeofdampingisrebounddamping. Rebounddampingcontrolstherateatwhichthespringextendsbacktoitsoptimumsag
length. Ifthespringextendstooquickly,thesuspensionwillexhibita"bouncy"or"lively"feel.Toomuchrebounddampingwillcausetheshock
tofeel"dead"or"unresponsive".The other type of dampingiscompression damping. Compressiondampingassiststhespringtocontrol
therateof shock compression.Aforkthathastoomuchcompressiondamping willfeelstifforinactiveoversmallbumps,andaforkwithtoo
littlecompressiondampingwillfeeltoosoftandtendtobottomoutquickly.
The compression and rebound damping in our Chubby forks are nonadjustable. The air dampers provide ample rebound and com-
pression damping for many different riders.
!
!
Adjusting Preload
Measuring Optimum
Suspension Sag
7

TheNoleenChubbyandChubbyLTaredesignedtobemaintainedeasily.Simplelubricationisusuallyallthatisrequiredtokeeptheforkworking
smoothly.ThefollowingmaintenanceshouldbeperformedwheneveryoufeeltheperformanceofyourChubbyisdeteriorating.
CAUTION: K2 Bike strongly recommends that your Noleen suspension components be disassembled and
adjustedby your authorized Noleen dealer. Your authorized Noleen dealer possesses theproper training and
toolsto serviceyour bicycle.Improperly assembledor adjustedbicycles canbe extremelydangerous, andcan
result in failure during use and severe injuries. These instructions are provided for owners having sufficient
knowledge and the proper tools to do the job.
WARNING: Following any maintenance on your fork, be sure all bolts are checked and torqued to proper
spececfication. Failure to do so could result in fork failure and serious injury.
Tools Needed:
• 4,5and6mmHexWrench • In-lbTorqueWrenchwith4,5and6mmhexbits
• K2Goo(orotherTeflon-fortifiedgrease) • Thread-lockingcompound-LoctiteBlue#242
• 8mmHexWrenchwithlongextension • Internalsnap-ringpliers
Lubrication
Sliders and Stanchions
Lubricationoftheslidersandstanchiontubesisasimpleprocedurethatshouldbedoneeverymonthduringnormalridingconditions.Thiswill
allowthetwoforktubestomovesmoothly,andwillreducefrictionbetweenthestanchionandsliders.
1. Cleanoffalldirtandgrimefromforkandremovefrontwheel.
2. Disconnectfrontbrakecable frombrakelever.Thiswillallowyoutoleavethebrakesonwhileremovingsliders.
3. Remove4mmhexboltslocatedonbottomofforklegs.Youmayexperiencedifficultywhendoingthis.
Note: If you have trouble removing the bottom slider bolts, increase the preload on the spring stack and try again. If this doesn't
work, remove the spring stack and the x-shaped spacer and insert an 8 mm wrench with a long extension into the spring seat to
prevent the spring seat from rotating. See Chubby diagram on page_____ for part explanations.
4. Pushrubberforkbootiesup offofsliders.
5. Separateslidersfromstanchiontubeswithadownwardtug.
6. Cleantheoutsideofthestanchiontubesandtheinsideofthesliderswithcleanrag.
7. Applythinlayerofgreasetostanchiontubesandalsototheinsideofthewipersealonthesliders.
8. Pushsliderupontostanchionsandreinstalllowersliderbolts.Torqueto80in-lbs.
Elastomer Stack and inner Stanchion Tubes
Regularcleaningandregreasingofthespringstackwillensuresmoothspringmovementandconsistentperformance.
1. Loosenuppertripleclampstanchionboltsandremovepreloadadjusterswithspringstack.
2. Cleantheinsideofthestanchiontubeswithacleanrag.Youmayneedalong,thinrodtohelppushtheragintothe
stanchiontubes.
3. Wipeawayoldgreasefromspringstackwithcleanragandapplyanewlayerofgreasetoallsprings.
4. Reinsertspringstackintostanchiontube.Retightenpreloadadjusterandtorqueuppertripleclampboltsto85in-lbs.
MAINTENANCE
In this section:
• Tools Needed
• Lubrication
• Seal and O-Ring
Replacement
• Bearing
Replacement
• Maintenance
Schedule
• Torque and
Lubrication Table
• Service Kits
!
Removing Sliders
Regreasing Fork Legs
Removing Spring Stack
8

Air Damper
IfyouareexperiencinginconsistentrebounddampingwithyourChubbyfork,youshouldchecktheairdamperforproperfunction.
1. Removeslidersandspringstack.Forinstructions on this,seeLubrication:Sliders andSpring Stack.
2. Removeinternalsnapringlocatedatthebottomoftheexposedstanchiontubeswithinternalsnapringpliers.
3. Nowpulldownwardonairthedamperwithafirmtugtoseparateairdamperfromstanchiontubes.
NOTE: The o-rings around the air damper and the aluminium stopper may be worn and need to be replaced. See Maintenance: Seal
and O-ring Replacement for full instructions.
4. Remove all grease and dirt from air damper unit with clean rag. It is very important to clean the air
damper and surrounding parts thoroughly to allow the proper flow of air through the damper holes.
5. Nowapplyathin layerofnewgreasetoO-ringsonly.Donotput anygreaseoverdamper holes.Thiscould clog
the damper and prevent it from operating properly.
6. Cleantherestoftheforkthoroughlyandlightlygreaseslidersandstanchions.
7. Reinstallairdamperintobottomofstanchion. Installaluminiumstopperintoleguntilitstops.
8. Usinginternalringpliers,replaceinternalringontobottomofairdamper.Lightlygreasetheendofthestanchion
tubearoundtheextendedrodspacer.
9. Installsliders(torquelowerboltsto60in-lbs)andspringstackandtorqueuppertripleclampboltsto85in-lbs.
Seal and O-Ring Replacement
Youmayfinditnecessarytoreplacethetopwipersealsando-ringsintheChubbyandChubbyLTaftersometime.Theo-ringswillbegintowear
andlosetheireffectiveness.Youmaynoticeinconsistentdampingsuchasaquickrebound,andreplacingtheo-ringswillhelpfixthis.Therearea
totaloffouro-ringsineachleg:twoaroundtheairdamper,oneontheoutsideofthealuminiumstopper,andoneoftheinsideofthealuminium
stopper.Theyshouldallbereplacedatthesametime.
1. FollowthestepsinLubrication: AirDampertodisassembletheforkandtheairdamper.
2. Removethealuminiumstopperfromthedamperrodandcleanthoroughly.
3. Removetheo-ringsfromthedamperandtheouterandinnneraluminiumstoppero-ringsusingasmallscrewdriver
orpaperclip. Beverycarefulnottoscratchorotherwisedamagethesurfacethatholdstheo-rings.
4. Replacetheoldo-ringswithnewones,beingcarefulto putthenewo-ringsintotheirproperposition.Lightlygrease
thenewo-rings.
5. Reinstallthe aluminium stopper withtheflat side downandfollow the stepsinLubrication: Air Damper for
reinstallationoftheairdamper.
6. Toreplacethewipersealsonthesliders,pryofftheoldwiperswithasmallscrewdriver,beingcarefulnottodamage
thetopsofthemagnesiumsliders.
7. Installthenewwiper sealsandgreasetheinsideedge.SeeLubrication:Slidersforinstructionsonreinstallation.
Bearing Replacement
ThebearingsintheChubbyandChubbyLTarepress-fitmetalbearingsthatareinstalledineachslider.Servicingthesebearingscanonlybedone
byyourNoleen/K2BikeDealerorotherqualifiedmechanicwiththepropertrainingandthepropertools.
CAUTION: Do not attempt to service the bearings that are installed in the sliders of your Chubby or Chubby
LT fork. Improperly serviced Noleen forks can be extremely dangerous, and can result in failure during use
and severe injuries.
Reinstall Air Damper
ReplacingAir Damper
O-Rings
Removing Air Damper
9

Maintenance Schedule
ThefollowingtableisaguidelineforservicingyourNoleenfork.Morefrequentridingandwetter,muddierconditionswillincreasethefrequency
ofrequiredservice.PleasetakeyourridinghabitsandconditionsintoaccountwhenservicingyourNoleensuspensionfork.
RequiredInspection/Service Every Ride Monthly Yearly
Checktorqueonallbolts 4
Checkheadsetadjustment 4
Checkshockfunction 4
Greasesealsandbearings 4
Check/greasebrakepivotposts 4
Check/adjustSuspensionSag 4
Inspect/serviceallsealando-rings 4
Torque / Lubrication
Product PartName/Location Size/Description Torque(in-lbs) Lubrication Loctite
Chubbyfork TripleCrown M6 x 1 x 18 SHCS 85 Yes Blue
BrakeBridge M6 x 1 x 14 FHCS 60 Yes Blue
Brakepivot M8 BrakePivotPost 60 No Red
Sliderbottom M5 x .8 x 15 SHCS 60 Yes None
Service Kits
ThefollowingReplacement/ServiceKitisavailablefromyourK2Bike/NoleenAuthorizedDealer.ItisintendedtobeusedbyyourK2Bike/Noleen
dealerorotherqualifiedmechanicpossessingthepropertrainingandtools.
NoleenChubbySealKit Containswipersealsando-ringsneededforservicingfork RK007
10

Item # Part # Qty Description
15 M5FKQ-2Y40-000 2 Nut
16 M5FKU-2Y10-000 2 M5x.8x15SHCS(sliderbottom)
17 M5FR5-2141-000 14 FoamSpringConnectors(10inChubby)
18 M5FK5-2142-000 2 Bearing(upper)
19 M5FR5-2143-000 2 Bearing(lower)
20 M5FR5-2144-000 2 SpringSeatSupport
21 M5FR5-2163-000 2 AluminumStopper
22 M5FR5-2168-000 2 AirValveDamper
23 M5FR5-2312-000 16 FoamSpring,Tan(Med)40mm(12inChubby)
M5FR5-2315-000 - FoamSpring,Blue(Soft)40mm
M5FR5-2317-000 - FoamSpring,Pink(Hard)40mm
24 M5FR5-2350-000 2 CoilSpring
25 M5FR5-2610-000 2 Seal(wiper)
26 M5FR7-2166-000 2 TopSpringRetainer
27 M5FRY-2167-000 2 BottomSpringRetainer
28 M5FR5-2143-000 2 ReboundBumper
Item # Part # Qty Description
1 15150-x 1 SliderAssy,Right
2 15151-x 1 SliderAssy,Left
3 15244-x 2 StanchionTube,Chubby
15735-x 2 Stanchion,TubeChubbyLT
4 15245 2 EndSpacer,Chubby
15734 2 EndSpacer,ChubbyLT
5 15246-x 2 MiddleSpacer
6 15249 2 RodSpacer
7 3952B-25000 2 RetainingRing
8 8064A-01100 2 O-Ring(AluminiumStopper-inner)
9 8064A-02000 4 O-Ring(AirDamper)
10 8064A-02500 2 O-Ring(AluminiumStopper-outer)
11 H5FRT-2161-000 2 PreloadAdjuster
12 M5FK5-2310-000 2 Bumper
13 M5FKD-2310-000 2 RubberCylinder
14 M5FKP-2360-000 2 ReboundSpring
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Item # Part # Qty Description
1 15083-1 1 ForgedTripleClamp(upper)
2 15083-2 1 ForgedTripleClamp(lower)
3 15181 1 StarFangledNut
4 15247-x 1 SteererTube
5 15344 2 StanchionBumper
6 M5FKF-2340-000 2 WireTie
7 M5FKH-2Y20-000 2 BrakePivotPostWasher
8 M5FKP-2Y10-000 4 M6x1x14FHCS(BrakeBridge)
9 M5FKZ-2720-000 2 M8BrakePivotPost
10 15650-x 1 BrakeBridge
11 M5FRA-2310-000 2 4inchboot
12 MTFK1-2Y14-100 6 M6x1x18SHCS(tripleclamps)
12