Rock Shox Judy cartridge 1997 Installation and operating instructions

1997 Cartridge
Service Addendum
Judy Fork Models
®

Cartridge Service
The Judy cartridge is designed to be fully serviceable.The oil in the cartridge provides the damping for the entire fork and over time will break down.At least once a season,
have the cartridge rebuilt (oil change) to maintain optimal performance.When servicing the cartridge,keep in mind that the best performing cartridges have the least amount
of air.Cartridge service is easiest with a RockShox cartridge tool kit available from your dealer.The following instructions are written for use with the cartridge service tool kit,
but the cartridge can be serviced without these tools.
RockShox forks are designed to be nearly maintenance free. However, as long as moving parts are exposed to the elements, moisture and contamination can reduce
performance.To maintain high performance, safety, and long life, periodic maintenance is required. RockShox forks are engineered for easy service to help you keep the fork
clean,greased, and performing like new.
NOTE: ROCKSHOX RECOMMENDS REPLACING BOTH SHAFT SEALS AND ADJUSTER ROD O-RING DURING EVERY SERVICE.
IMPORTANT: ALWAYS WEAR SAFETY GLASSES WHEN WORKING ON ROCKSHOX FORKS.
MAINTENANCE TOOLS
The recommended tools and intervals for maintenance are listed below. Remember, performing maintenance more often is always better and
necessary if you ride in extreme conditions.
3mm and 8mm hex wrenches
8mm open-end wrench
Small tip internal snap ring pliers
Plastic face mallet
22mm socket (6 point preferred) or wrench
Ratchet, for socket
Small straight blade screwdriver
Long (8”minimum) socket extension,end wrapped with cloth tape
LUBRICANTS AND CLEANERS:
Degreaser
Judy Butter or high quality teflon fortified grease*
RockShox 5wt or 8wt oil (or fork oil without seal sweller additives)
*NOTE: FOR BEST PERFORMANCE,AVOID LITHIUM-BASED GREASES. SOME LITHIUM GREASES CAN BECOME
STICKY,TURN GRAY AND CAKE UP WHEN USED TO LUBRICATE THE BUSHINGS.WHEN THIS HAPPENS,SMOOTH
FORK ACTION IS GREATLY LIMITED,AND PERFORMANCE IS GREATLY REDUCED. IF YOU USE LITHIUM GREASE,
CHECK GREASE QUALITY AND CONDITION AT EACH 25-HOUR SERVICE INTERVAL TO ENSURE GREASE IS PER-
FORMING PROPERLY. IF YOU EXPERIENCE PROBLEMS,TRY USING ANOTHER TYPE OF LUBRICANT.
97 CARTRIDGE INTERNALS (SEE DIAGRAM TO RIGHT)
1 Shaft Guide Retaining Ring 50133
2 Shaft Guide 43089
3 Cartridge Body, 63mm 43175
4 Cartridge Seal (2) 56404
5 Piston Shaft Assembly, 63mm 20864
6* Piston Glide Ring 51227
7* Adjuster Rod O-ring 51216
8* Adjuster Rod 43080
9 Top-out O-ring 51119
10 Seal Washer 52236
* included with piston/shaft assembly (see Small Parts Catalog
for other cartridge configurations)
1
10
6
3
2
4
5
7
8
9
4

Cartridge Disassembly
1. Mount the bike in a stand, disconnect the front brake cable,and remove the front wheel. (The brakes do
not need to be removed.Avoid disassembling brakes unless absolutely necessary.).
2. Pull red external damping adjustment knob from left shaft bolt of Judy SL with a downward twisting
motion.(The external adjuster is press fit in the shaft bolt.) (See Fig.1)
3. Partially loosen shaft bolts with a 6 or 8mm hex wrench, tap bolts firmly with a mallet breaking shafts
free from lower tube,and remove bolts completely.(See Fig.2)
4. Slide off one-piece lower tube assembly.(See Fig.3) Remove fork boots.
5. Clean upper tubes and inspect for wear and/or damage (nicks,scratches,or dings).
6. Clean fork boots and slide onto uppers,and clean internals of lower tubes,and double seal.
7. Remove the snap rings at the bottom of the upper tubes with small tip internal snap ring pliers.(see
Fig.4)
8. Pull the cartridge assembly free from the left upper tube.Note orientation of parts,top to bottom:
shaft-end plate,cartridge,cartridge washer (very important), wave washer,and snap ring.The shaft-
end plate on the top of the cartridge shaft may remain in the upper tubes.Remove the spring stack
assembly as described in owner’s manual and tap the plate out the bottom of the tube with the
long socket extension.(For DH,repeat this procedure on right leg to remove rebound damping cartridge.)
9. Pull the neutral shaft assembly free from the right lower tube.Note orientation of parts,top to bottom:
shaft end plate,upper shaft guide with o-ring,pressed-on washer, top-out bumper,lower shaft guide, and
snap ring. (See Fig.6) 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 in owner’s manual.Tap the plate
and guide out the bottom of the tube with the long socket extension.
10. Slide off the plastic cartridge washer.Hold the cartridge over an oil receptacle with the exposed seal end
down and tap the top damper shaft end with a mallet,firmly holding the cartridge body, to press the lower
seal out of the cartridge body.(See Fig.7) Once the seal is exposed, drain the oil from the cartridge into the
oil container.If the seal is difficult to remove you may need to support cartridge body in fixture tool.
3. Pull the damper shaft free of the cartridge body.Inspect the damper shaft for nicks or scratches that may
cause oil leakage.Replace assembly as needed.
4. Inspect the inside bore of the cartridge body for scoring or scratches that may cause oil leakage.Replace
cartridge body as needed.
5. For adjustable compression cartridges,unscrew the adjuster rod completely with a 3mm hex wrench and
remove from the damper shaft.(See Fig.8)
CAUTION: REMOVE THE ADJUSTER ROD GENTLY TO AVOID DAMAGING THE ADJUSTER ROD O-RING ON THE THREADS OF THE SHAFT
WHEN REMOVING.
6. Clean the following parts with a lint-free rag: damper shaft,seal, and cartridge body.
7. Remove top snap ring and plastic shaft guide washer from cartridge body to remove upper seal out of
cartridge body.
WARNING: USE EXTREME CARE NOT TO DAMAGE THE CARTRIDGE BORE.
8. Inspect glide ring for nicks and scratches,making certain it shuttles freely on the piston.Replace as needed.
9. Remove and inspect adjuster rod o-ring for cuts and damage.Grease liberally prior to installation onto
adjuster rod.
NOTE: ROCKSHOX RECOMMENDS REPLACING ADJUSTER ROD O-RING DURING EVERY SERVICE.
CARTRIDGE ASSEMBLY
1. Install snap ring,sharp outside edge up, and plastic shaft guide washer into upper end of cartridge body.
2. Lightly coat inside of cartridge body with RockShox oil.Apply grease to 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.(See Fig.9) Remove upper seal
installation tool.
3. Invert (turn upside down) cartridge body, and insert greased shaft guide tool into cartridge body and seal. (See Fig.10) Place
assembly into cartridge body fixture.(See Fig.11) Fill cartridge 1/2 full with RockShox oil (5wt stock,8wt optional). Apply oil to
piston glide ring and carefully insert piston shaft assembly,internal threaded shaft end up,into cartridge,mating shaft end with
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 6
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5

shaft guide tool.Then push piston shaft assembly through the upper seal forcing shaft guide tool out of upper seal.
4. Remove shaft guide tool by lifting entire cartridge body fixture.Take care not to spill any oil.
5. Push piston shaft assembly into cartridge body until it stops.Add more oil until it’s about 2/3 full (see Fig.12), taking care
not to pull shaft back through the seal and the piston out of the oil.
6. Let assembly set for minimum of 5 minutes to allow any residual air to escape.
7. Install top-out o-ring and seal washer onto shaft.
8. Fill cartridge body with RockShox oil to within 5mm of body edge.
9. Apply grease to upper seal,inside and out, fully filling pocket of seal with grease.
10. Using fishing line,cut main seal o-ring (PN 51104) or equivalent, place in I.D. of seal.(See Fig.13)
11. Carefully install this seal assembly,pocket side down, over shaft, being careful not to damage sealing lips on the flats of
shaft and maintaining orientation of line between seal and shaft. The line provides a leak path for the excess oil when seal
is pressed into cartridge body.
NOTE: MAKE SURE LINE DOES NOT GET CAUGHT BETWEEN CARTRIDGE BODY AND SEAL O.D.
12. Place Cartridge Lower Bushing Installation Spacer (PN 70181) step side down over exposed shaft.Place Lower Seal
Installation tool (PN 70138) over shaft.Press fully into cartridge body leaving 1mm of exposed cartridge body above
top of seal.(See Fig.14)
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 SHOULD BE PRESSED IN TO BODY UNTIL 1MM OF CARTRIDGE BODY WALL IS EXPOSED.
13. Remove line from seal.(See Fig.15)
14. Adjustable cartridge only:Fill exposed adjuster rod shaft full with oil.(See Fig.16)
15. Using a 3mm hex wrench,install adjuster rod with o-ring that is liberally greased.Thread into exposed shaft until rod
bottoms out.
CAUTION: TAKE 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 THREADS.
16. Install rebuilt cartridge assembly and neutral shaft assembly into upper tubes.Make sure all parts are clean,greased, and installed in the proper
order.
NOTE: BE SURE TO PROPERLY INSTALL A CARTRIDGE WASHER AND WAVE WASHER BETWEEN CARTRIDGE AND SNAP RING.
17. Install snap rings,sharp outside edge facing out into upper tube ring grooves.Make certain cartridge washer,wave washer, and snap ring are
oriented correctly, and the snap rings are fully seated in the ring groove of the upper tubes.
CAUTION: SNAP RINGS MUST BE PROPERLY ORIENTED,SHARP OUTSIDE EDGE FACING OUT,AND FULLY SEATED IN RING GROOVE OF THE UPPER TUBES.
18. Clean fork boots and slide onto uppers,and clean internals of lower tubes,bushings (two per leg), and double seal. A lint-free rag wrapped to a
long 3/8”drive socket extension wrapped with cloth tape works well.
IMPORTANT: CLEAN LOWER BUSHINGS,APPROXIMATELY 6” (150MM) FROM TOP.
19. 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 double seal
completely. Use a socket extension wrapped with cloth tape dipped in Judy Butter to reach inside the lower tubes.(See Fig. 17)
Fig. 12
Fig. 13
Fig. 15
Fig. 14
Fig. 16
Fig. 17
Fig. 18
Fig. 19
NOTE: FOR BEST PERFORMANCE,AVOID LITHIUM-BASED GREASES.SOME LITHIUM GREASES CAN BECOME STICKY,TURN GRAY AND CAKE UP WHEN USED TO LUBRICATE THE BUSHINGS.WHEN THIS HAPPENS,
SMOOTH FORK ACTION IS GREATLY LIMITED,AND PERFORMANCE IS GREATLY REDUCED. IF YOU USE LITHIUM GREASE,CHECK GREASE QUALITY AND CONDITION AT EACH 25-HOUR SERVICE INTERVAL TO ENSURE
GREASE IS PERFORMING PROPERLY. IF YOU EXPERIENCE PROBLEMS,TRY USING ANOTHER TYPE OF LUBRICANT.
Smear teflon based oil,5wt oil or a thin layer of Judy Butter to the upper tubes under the fork boots.
19. Install one-piece lower assembly onto upper tubes,carefully engage upper double seal lip with the upper tubes,and gently rock the one-piece lower assembly to
engage the lower bushings with the upper tubes. When installed properly, the cartridge and neutral shaft threads are visible through the holes in the lower tubes.
20. Refit shaft bolts, apply grease to steel bolts or anti-seize on titanium bolts. Use 6 or 8mm hex wrench to torque shaft bolts to 60 in-lb (7 Nm). (See Fig.18)
NOTE: IT IS VERY EASY TO OVER TIGHTEN THIS BOLT WITH AN 8MM HEX WRENCH. USE A TORQUE WRENCH.
21. Refit fork boot into double seal groove using small blade screwdriver. (See Fig.19) Engage boot with double seal groove at the rear and rotate boot around the upper
tube to fully engage its lower edge behind the brace. A small amount of oil on the mating surfaces helps.
22. Repeat procedure on other leg.
23. On Judy SL, re-install red external damping adjuster by applying a light coating of oil to the O-ring and pushing it into the shaft bolt with an upward twisting motion.

Tightening Torque Table
Crown Bolts 60 in-lb 6.8Nm
Top Cap Assemblies 30 in-lb 3.4Nm
Fork Brace Bolts 60 in-lb 6.8Nm
Brake Posts 60 in-lb 6.8Nm
Shaft Bolts 60 in-lb 6.8Nm
Warranty
ROCKSHOX, INC.WARRANTS ITS FORKS FOR A PERIOD OF ONE YEAR FROM ORIGINAL DATE OF PURCHASE TO BE FREE FROM DEFECTS IN MATERIALS 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 NUMBER (RA#) PRIOR
TO RETURNING PRODUCT. PRODUCTS RETURNED FOR INSPECTION MUST BE SENT FREIGHT PREPAID TO:
ROCKSHOX,INC. 408.435.7469
401 CHARCOT AVE. FAX [phone]
SAN JOSE,CA 95131 TOLL-FREE TECHNICAL SUPPORT IN THE USA 800.677.7177
CUSTOMERS IN COUNTRIES OTHER THAN THE USA SHOULD CONTACT THEIR DEALER OR LOCAL DISTRIBUTOR.
WorldWide Distributors
Argentina
Broni S.A.
Phone: [phone]
FAX: [phone]
Australia
Steve Cramer Products
Phone: [phone]
FAX: [phone]
Austria
Barisitz-Austria
Phone: [phone]
FAX: [phone]
Belgium
Vertex Cycle Systems BV
Phone: [phone]
FAX: [phone]
Brazil
Pacific Bicycle Company
Phone: [phone]
FAX: [phone]
Canada
Bell Sports Canada
Phone: [phone]
FAX: [phone]
Chile
Bicicletas Belda Limitada
Phone: [phone]
FAX: [phone]
Colombia
Disandina Ltda.
Phone: [phone]
FAX: [phone]
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SPC Bicicletas
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FAX: [phone]
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Finland
Mr. Cool OY
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FAX: [phone]
France
Philamy S.A.
Phone: [phone]
FAX: [phone]

Germany
Sport Import GmbH
Phone: [phone]
FAX: [phone]
Greece
Gatsoulis Stefanos Imports
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Guatemala
BYS Importaciones S.A.
Phone: [phone]
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Holland
Vertex Cycle Systems BV
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Hong Kong
Flying Ball Bicycle Company
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Hungary
Prokero KFT
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Orninn Hjol Ltd.
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Motorquality
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Yoshigai Corporation
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KS Trading
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Vertex Cycle Systems BV
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W.H. Worrall & Co. Ltd.
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Bicimax
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Sportex
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Tri-Sport International
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Singapore
Treknology Bikes 3
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Slovakia
Velo Gepard Ltd.
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Slovenia
Proloco Trade
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South Africa
Coolheat (SA) (PTY) Ltd.
Phone: [phone]
FAX: [phone]
Spain
K. Motor Dealer S.L.
Phone: [phone]
FAX: [phone]
Sweden
Hallman Sports
Phone: [phone]
FAX: [phone]
Switzerland
CILO Bike Service
Phone: [phone] (French)
Phone: [phone] (German)
FAX: [phone]
Taiwan
Biketech Co. Ltd.
Phone: [phone]
FAX: [phone]
Thailand
Probike Co. Ltd.
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FAX: [phone]
Trinidad
Let’s Ride Instead
Phone: [phone]
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Turkey
EBSAT
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FAX: [phone]
United Kingdom
Caratti Sport Ltd.
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FAX: [phone]
Uruguay
International Sports
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FAX: [phone]
USA
RockShox, Inc.
401 Charcot Avenue
San Jose,CA 95131
Sales & Tech Support
Phone: [phone]
FAX: [phone]
Venezuela
Bike Sports
Phone: [phone]
FAX: [phone]

®
Bushing Service Addendum,PN 950-000187-00 © RockShox,Inc. January 1997