Rock Shox Judy T2 User manual

1998 JudyT2 Owner’s Manual
®

Table of Contents
Introduction ............................................................. 2
Features ................................................................ 3
ConsumerSafetyInformation .............................................. 4
Installation .............................................................. 5
Tuning YourFork ......................................................... 6
Maintenance ............................................................ 7
Service ................................................................. 10
ExplodedDiagram ........................................................ 13
Glossary ................................................................. 14
NORBACode ............................................................. 14
Warranty ............................................................... 15
InternationalDistributorList ............................................... 15
At A Glance Maintenance Interval Checklist
heckthefollowingforeachmaintenanceinterval. Forfurtherdetailsseepage8.
EveryRide(Inspect) EightHoursofRiding Twenty-fivehoursofRiding
Frontwheel Cleanuppertubes Cleanandgreasespringstacks
Quickrelease Oiluppertubes Inspectspringsystemforcompressionset
Checkfordamage Checkcrownandbracebolts CleanandgreasebushingsandResi-wiper
Cablerouting Checkbrakeposts Cleanuppertubesandinspectfordamage
Brakepads Cleanforkboots
Brakelevers
Headset
IMPORTANT: TOMAINTAINHIGHPERFORMANCE,SAFETYANDLONGLIFE,PERIODICMAINTENANCE
ISREQUIRED. PERFORMMAINTENANCEMOREOFTENIF YOURIDEINEXTREMECONDITIONS.

JUDYT2 Features
• True“one-piece”lowertubeassembly.
• T2SpringSystem. Livelyactionofaprogressivecoilspringsystem.Veryeasytotunefordifferentriders.
• UniqueResi-wiperseal.Cleansandlubricatestheupperforktubes.
• 28mmdiameterEastontaperedaluminumuppertubes.
• Modularforksystem: upgradeabletonewType3springsystemandnewC3dampercartridge
• Superstiffalloycrown.
• Newtopcapwithexternalpreload.
STANDARD EQUIPMENT (SUPPLIED WITH JUDY)
63and80mmtravel*:
(2)Springrateadjusters(beige/soft)
NewandImprovedJudyButter
*63mmtravelversionisonlyofferedwithoriginalequipmentmanufacturersandisnotavailabletothe
after-market.
**80mmtravelversionisofferedasbothanafter-marketandoriginalequipmentmanufacturer’sfork.
OPTIONAL EQUIPMENT
63and80mmTravelT2SpringTuningKits
ExtraSoft
Soft
Medium
Firm
63and80mmTravelT2MCUSpringTuningKit
63and80mmTravelType3SpringTuningKits
Extrasoft
Soft
Medium
Firm
Type2SpringRateAdjusterKit
JudyXC/SL63mmC3TravelCartridgeKit
JudyXC/SL80mmC3LongTravelCartridgeKit
Congratulations! You have purchased
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.
®
SteererTube
ForkCrown
BrakePost
ShaftBolt
UpperForkTube(w/dustboot)
PreloadAdjusterKnob
OnePieceForkBrace
andLowerTubeAssembly

Installation Instructions
ITISEXTREMELYIMPORTANTTHAT YOUR ROCKSHOXJUDYT2FORKISINSTALLED CORRECTLYBY AQUALIFIEDTECHNICIANWITH
PROPER TOOLS. IMPROPERLYINSTALLEDFORKSAREEXTREMELYDANGEROUSAND CANRESULTINSEVEREAND/OR FATALINJURIES
1. Removetheexistingforkandlowerheadsetracefromthebicycle. Measurethelengthoftheforksteerer
tubediameteragainstthelengthoftheRockShoxsteerer. TheRockShoxsteerertubemayneedcuttingto
theproperlength. Onthreadlesssteerers(Aheadsetdesign),makesurethereissufficientlengthtoproperly
clampthestem(refertostemmanufacturer’sinstructions).Remembertomeasuretwiceandcutonce.
IMPORTANT: DO NOT ADDTHREADS TO ROCKSHOX STEERERS. THESTEERERTUBECROWNASSEMBLY IS A ONE-TIMEPRESSFIT
REPLACEMENTOFTHEASSEMBLYMUSTBEDONE TOCHANGELENGTH,DIAMETER,ORHEADSET TYPE(THREADEDORTHREADLESS).
DONOT REMOVE OR REPLACE THE STEERER TUBE,THIS COULD RESULT IN LOSS OF CONTROL OFTHE BICYCLEWITH POSSIBLE
SERIOUSAND/OR FATALINJURIES.
2. Installtheheadsetrace(26.4mmfor1”steerers,29.9mmfor1-1/8”steerers)firmlyagainstthetopof
theforkcrown. Installtheforkassemblyonthebike. Makesuretherearesufficientthreadstoproperly
locktheheadsetinplace. Onthreadlesssteerers(Aheadsetdesign),makesurethereissufficientlength
toproperlyclampthestem(refertostemmanufacturer’sinstructions). Adjusttheheadsetsoyoufeel
noplayordrag.
3. Installthebrakesaccordingtothemanufacturer’sinstructionsandadjustbrakepadsproperly. Usethe
forkonlywithcantilever-typebrakesmountedtotheexistingmountingpostsordisc-stylebrakes
mountedtothetabsprovided.
4. Onthreadedsteerers,insertstemtoaminimumdepthaccordingtoCPSCandJISstandards. Thestem
mustbeinsertedtoaminimumengaginglengthnotlessthan2.5timesthestem
diameterfromthelowestendofthestem,notthewedge(seeFig.1).
5. FitabrakecabletotheRockShoxforkbracemount. Forkswithhangerlessstyle
bracesweredesignedforV-type,hydrauliccantileverbrakesordisc-stylebrakes.
Donotuseanycantileverbrakeotherthanthoseintendedbythebrake
manufacturertoworkwithahangerlessbrace. Donotroutethecablethroughthe
stemoranyothermountsorcablestops!Thecableshouldmakeadirectroute
fromthebrakelevertotheRockShoxforkbracemountandbeabletofreelymove
upanddownwiththesuspensionmovement. Itmaybenecessarytoinstallawholenewcable.
NOTE:THE DISTANCEFROMTHE TOPOFTHEBRAKE CABLE HANGER TO THEBOTTOMOFTHEBRACE CABLEHOUSINGSTOPMUST
BE AMINIMUMOF 12MMWITHTHEBRAKESAPPLIED. AN IMPROPERLYINSTALLEDFRONTBRAKE CABLE COULDRESULT INLOSS
OF CONTROLOFTHEBICYCLEWITHPOSSIBLESERIOUSAND /OR FATALINJURIES.
6. Adjustthefrontwheelquickreleasetoclearthedropout’scounterbore. Thequickreleasenutmustbe
tightenedafterthewheelisproperlyseatedintothedropoutscounterbore. Makesurefourormore
threadsareengagedinthequickreleasenutwhenitisclosed. Orientthequickreleaseleverinfrontof
andparalleltothelowertubeinthelockedposition.
7. Keepinmindtireclearanceasyouchoosetires. Maximumtiresizeis2.2”wideor335mmradius.
Besuretocheckthisradiuswheneveryouchangetires.Todothis,removethespringstack(perinstructions
onfollowingpages),andcompressforkcompletelytomakesureatleast5mmofclearanceexistsbetween
thetopofthetireandthebottomofthecrown. Exceedingthismaximumwillcausethetiretojamagainst
thecrownwhentheforksarefullycompressed.Theuppertubesmustalwaysbefullyengagedinthecrown.
Theuppertubes,onclamptypecrowns,mustnotextendabovethecrownmorethan1mm.
Fig. 1
Consumer Safety Information
RIDING A BIKEISDANGEROUS. NOT PROPERLY MAINTAININGORINSPECTING YOURBIKEIS EVENMOREDANGEROUS. IT’S ALSO
DANGEROUSNOT TO READTHESE INSTRUCTIONS. SO IF YOUUSEOURSTUFF,DON’T BE A DUMMY—READTHE INSTRUCTIONS!
1. Beforeridingthebicycle,besurethebrakesareproperlyinstalledandadjusted. Ifthebrakesdon’twork
properly,theridercouldsufferseriousand/orfatalinjuries.
2. Usethisforkwithcantilever-typebrakesmountedtotheexistingmountingposts.Forkswithhangerless
stylebraceswereonlydesignedfor‘V’-styleorhydrauliccantileverbrakes.Donotuseanycantilever
brakeotherthanthoseintendedbythebrakemanufacturertoworkwithahangerlessbrace.Donot
routethefrontbrakecableand/orcablehousingthroughthestemoranyothermountsorcablestops.
Donotuseafrontbrakecableleveragedevicemountedtothebrace.Donotusedisc-stylebrakes
mountedtotheouterlowertube.Thelowertubeswerenotdesignedto sustainthestressessuchbrakes
couldplaceonthem,andstructuralfailuretotheforkmayresultifanydevicesortypesofbrakeother
thanacantileveraremountedonthefork.Structuralfailurecouldresultinlossofcontrolofthebicycle
withpossibleseriousand/orfatalinjuries.
3. Useextremecautionnottotiltthebicycletoeithersidewhenmountingthebicycletoacarrierbythe
forkdrop-outs(frontwheelremoved).Theforklegsmaysufferstructuraldamageifthebicycleistilted
whilethedrop-outsareinthecarrier.Makesurethefrontwheelisfasteneddownwithaquickrelease.
MakesuretherearwheelisfasteneddownwhenusingANYbikecarrierthatsecuresthefork’sdrop-
outs.Notsecuringtherearcanallowthebike’smasstoside-loadthedrop-outs,causingthemtobreak
orcrack.Ifthebicycletiltsorfallsoutofitscarrier,donotridethebicycleuntiltheforkisproperly
examinedforpossibledamage.ReturntheforktoyourdealerforinspectionorcallRockShoxifthereis
anyquestionofpossibledamage(SeeInternationalDistributorslistedbycountryonPage15).Aforkleg
ordrop-outfailurecouldresultinlossofcontrolofthebicyclewithpossibleseriousand/orfatalinjuries.
4. Iftheforkeverlosesoilorifitmakessoundsofexcessivetoppingout,stopridingthebicycle
immediatelyandhavetheforkinspectedbyadealerorcallRockShox. Continuingtoridewiththefork
ineitheroftheseconditionscouldresultinlossofcontrolofthebicyclewithpossibleseriousand/or
fatalinjuries.
5. AlwaysusegenuineRockShoxparts. Useofafter-marketreplacementpartsvoidsthewarrantyand
couldcausestructuralfailuretothefork. Structuralfailurecouldresultinlossofcontrolofthebicycle
withpossibleseriousand/orfatalinjuries.
IMPORTANT: ROCKSHOXFORKSAREDESIGNEDFOR COMPETITIVEOFF-ROADRIDINGANDDONO TCOMEWITHTHEPROPER
REFLECTORS FOR ON-ROAD USE. YOUR DEALER SHOULD INSTALL PROPER REFLECTORS TO MEET THE CONSUMER PRODUCT
SAFETYCOMMISSION’S(CPSC)REQUIREMENTSFORBICYCLESTANDARDSIFTHEFORKISGOING TOBEUSEDONPUBLIC ROADS
TANYTIME.

performance. Inthis case the greyorfirmspringrateadjusterprovidesmoreresistancetolargebumpsand
preventsbottomoutforheavierormoreaggressiveriders.
Thetablebelowindicatesriderweightandtherecommendedcoilspringkitsforthoseweights.
RiderWeight CoilSpringKit
Under140 ExtraSoft
140to160 Soft
160to180 Medium
Above180 Firm
DOTHEFOLLOWING TO CHANGETHE T2COILSPRINGS:
IMPORTANT: THESPRINGRATEADJUSTERSMUSTBETHESAMEINEACHLEG.
1. Unscrewthetopcapassemblyusinga22or24mmwrenchorsocket.
2. Removethespringstackassembly(topcap,coilspring,springrateadjuster,spacerandMCU). SeeFig.2.
3. RemovetheMCUspacerfromthespringrateadjuster,coilspringandtopcap.
4. Unsnapthespringrateadjusterfromthespacer. Byusingasofterorfirmerspringrateadjusterthan
stock,youcanchangetheoverallspringrate.
5. Snaptheappropriatespringrateadjusterintoeachcoilspring.
6. CleanandgreasetheMCUandreassemblethespringstack.
7. Installthespringstackassembliesintotheuppertubes,startingtopcapthreadsbyhand.
8. Tightenthetopcapuntilitisflushwiththeuppertube.Torquetopcapsto30or40IN-LB. Afterriding
youmayneedtoadjustthetopcapknobstoobtainthesamesag/pre-loadfeel.
Maintenance
Aslongasmovingpartsareexposedtotheelements,moistureandcontaminationcanreduceperformance
JudyT2forksaredesignedtobeeasytomaintain.Tomaintainhighperformance,safety,andlonglife,periodic
maintenance is required. RockShox forks are engineered for easy service to help you keep the fork clean,
greased,andperforming like new.Performingmaintenance more often is necessary if you ride in extreme
conditions. Therecommendedtoolsandintervalsformaintenancearelistedbelow.
IMPORTANT:ALWAYS WEARSAFETYGLASSESWHEN WORKINGON ROCKSHOX FORKS.
MAINTENANCE TOOLS
•5,6and8mmhexwrenches
• 8mmopen-endwrench
• Smalltipinternalsnapringpliers
• Plasticfacemallet
Fig.2
Tuning Your Fork
RockShox(JUDYT2)forkscanbetunedtoyourparticularweight,ridingstyle,andterrain. Ourforksaresetup
or the 140 to 180lb (65 to 80kg), all-around rider who spends equal time riding every off-road terrain
imaginable. Becauseyou’re probably not that rider,you can benefit by making tuning adjustments to suit
ourspecificneeds.Formaximumtuningflexibility,T2SpringTuningKitsandT2SpringRateAdjusterKitsare
vailable.
When tuning suspension,alwaysmake one change at a time and write itdown. Keeping a record lets you
nowwhatchangesyouhavetriedandsuggestswhatchangesyoumighttry. Askashoporlocalriderswhat
theyhavefoundworkswell. Theseresourcesaretypically your best bet,butdon’thesitate to call RockShox
aboutspecifictuningneeds. AlistofphonenumbersisonPage15.
RIDE HEIGHT AND SPRING PRELOAD ADJUSTMENT
udyT2isdesignedtocompress(sag)whenyouaresittingonthebike.Thissagallowsthefrontwheeltostay
incontactwiththegroundwhenbrakingandcorneringoverroughanduneventerrain.Theoptimumsettings
are5to8mmsagfor63mmtraveland7to10mmfor80mmtravel.
hangingthepreloadaltersthesagandfirmnessoftheinitialforkmovement.Tomeasuresag,installaziptie
onthe upper tubeso that itis flush against the Resi-wiper seal;sit on thebike with normalriding apparel;
thenstepoffyourbikeandmeasurethebottomoftheziptietothetopofthewiper.Thismeasurementisthe
amountofsag.Forexample,heaviermoreaggressiveridersneedmorespringpreloadtomaintainproperride
heightandallowmoreofthefork’straveltobeusedduringbumpimpact.
oChangePreload: Thetopcapadjustmentknoboneachlegadjuststhesagofthefork(thepreloadonthe
springstack). When the adjustment knobs are turned full clockwise,the fork will sag the least and be the
firmest. Turningtheadjustmentknobsfullcounterclockwisemakestheforksagthemostandbethesoftest.
MPORTANT: DONOTTURNTHE PRELOAD ADJUSTERS PASTTHEIR LIMIT STOPS.THEREARE APPROXIMATELY 5FULL TURNS
FROMMINIMUM TO MAXIMUMPRELOAD.FAILURE TO OBSERVETHISINSTRUCTION COULDRESULTINPREMATURE FAILUREOFTHE
PRELOADADJUSTER CAPASSEMBLY.
QUICK TIP: RIGHTANDLEFTSIDEISDETERMINEDWHENSTRADDLINGTHEBICYCLEFRAME FACINGFORWARD
BASIC SPRING TUNING GUIDE
oinsurethatyouaregettingthebenefitofallavailabletravel,yourforkshouldoccasionallyhittheendofit’s
travel(bottomout). Ifyouarebottomingouttoooftenornot usingalltheavailabletravel thentheoverall
springrateshouldbechanged.
herearetwocoilspringsandtwospringrateadjustersintheJudyT2thatcanbeinterchanged. Forexample,
aggressiveridersmaywanttoincreasetheirspringrateoverthoserecommendedandcandosobychanging
outthespringsandspringrateadjustersprovidedintheforkwiththosethatbettermeettheirneeds.
hecoil springs modify the fork for small bump performance. Forexample,softer springswill improvethe
small bump performance for lighter riders. The spring rate adjusters modify the fork for large bump

AFTER EVERY WEEK OR EIGHT HOURS OF RIDING
AFTEREVERYWEEKOREIGHTHOURSOFRIDING ,CLEANANDOILTHEUPPERTUBESANDCHECK FASTENERSFORPROPER TORQUE. FOLLOWTHIS
PROCEDURE:
1. Liftforkbootsfromlowertubes.Thenwipeexteriorsurfaces,Resi-wipersealareaanduppertubeclean.
Apply2-3dropsofTeflon-fortifiedoiltotheuppertubesattheResi-wiper.(SeeFig.3)
2. RefitforkbootsintoResi-wipersealgrooveusingsmallblade
screwdriver. EngagethebootwithResi-wipersealgrooveattherear
androtatebootaroundtheuppertubetofullyengageitsloweredge
behindthebrace. Asmallamountofoilonthematingsurfaceshelps.
3. Checkcrownbolts,bracebolts,andbrakepostsforpropertorque.
(RefertoTorqueTighteningValues,above.)
4. Repeatprocedureonotherleg.
AFTER EVERY MONTH OR TWENTY-FIVE HOURS OF RIDING
AFTER EVERY MONTHOR TWENTY-FIVEHOURSOFRIDING,CLEANANDGREASETHESPRINGST ACKS,BUSHINGS,AND RESI-WIPERSEAL.
TOCLEANANDGREASETHESPRINGST ACKS,FOLLOW THISPROCEDURE:
1. Unscrewthetopcapusing22or24mmwrenchorsocketwrench. Removethespringstackassembly
andcleanthestackwithdegreaser. Wipedry.
2. InspectT2springforcompressionset(see“T2SpringSpecification”table,page11).Replaceasneeded.
3. ApplyNewandImprovedJudyButtertoentirespringstack,completely
coveringtheMCUandcoilspring.
4. Installassemblyinuppertube,startingtopcapthreadsbyhand.
5. Torquetopcapto30or40in-lb(3.4-4.5Nm). Thisshouldbebetween30
and60degreesofclockwisewrenchmovementaftercapisflushwith
uppertube.
6. Repeatprocedureonotherleg.
TOCLEANAND GREASE BUSHINGSAND RESI-WIPERSEAL,DOTHEFOLLOWING:
1. Mountthebikeinastand,disconnectthefrontbrakecable,andremove
thefrontwheel(thebrakesdonotneedtoberemoved).
2. Partiallyloosenshaftboltswitha6or8mmhexwrench,tapboltsfirmly
withamalletbreakingshaftsfreefromlowertube,andremovebolts
completely(seeFig.4).
IMPORTANT: OILFROMTHEOPENOIL BATHSYSTEMWILLLEAKOUTOFTHEBO TTOMOFTHE
LOWERTUBES,WHENTHESHAFTBOLTS AREREMOVED. USE A RECYCLING CONTAINER LARGE
ENOUGH TO CATCHTHEOILFROMBOTH LEGS.
3. Slideoffone-piecelowertubeassembly(seeFig.5). Removeforkboots.
Fig. 4
Fig. 5
Fig. 3
• 22and24mmsocket(6pointpreferred)orwrench
• Ratchet,forsocket
• Smallstraightbladescrewdriver
• Long(8”+/200mm) socket extension,end wrapped with cloth tape
TORQUE TIGHTENING VALUES
CrownBolts 60IN-LB(6.8Nm)
TopCapAssemblies 30-40IN-LB(3.4to4.5Nm)
ForkBraceBolts 60IN-LB(6.8Nm)
BrakePosts 60IN-LB(6.8Nm)
ShaftBolts 50IN-LB(5.6Nm)
LUBRICANTS AND CLEANERS:
• Degreaser
• RockShox15wtoil(orforkoilwithoutseal-swelleradditives)
• NewandImprovedJudyButterorhighqualityTeflonfortifiedgrease(nolithiumgrease)
MPORTANT: FOR BEST PERFORMANCE,AVOID LITHIUM-BASED GREASES.SOME LITHIUM GREASES CAN BECOME STICKY,TURN
GRAY AND CAKEUPWHENUSED TO LUBRICATETHE BUSHINGS.SMOOTHFORK ACTIONISGREATLYLIMITEDANDPERFORMANCEIS
GREATLY REDUCEDWHENTHISHAPPENS.IFYOUUSELITHIUMGREASE,CHECKGREASEQUALITYANDCONDITIONATEACH25-HOUR
SERVICEINTERVAL TO ENSURE GREASEISPERFORMINGPROPERLY.TRY USINGANOTHER TYPEOF LUBRICANTIF YOUEXPERIENCE
PROBLEMS.
Regular Maintenance
BEFORE EVERY RIDE
BEFORE EVERYRIDE,INSPECTTHEFOLLOWING PARTS:
1. Frontwheelandquickreleaseforproperinstallationandadjustment
2. Forkforanyobviousdamage(crown,brace,uppertubes,lowertubes,anddropouts)
3. Frontbrakecableforproperrouting
4. Frontbrakepadsforpropercontactwiththerim
5. Frontbrakeleverforproperadjustment
6. Headsetforproperfunctionandadjustment
AFTER EVERY RIDECLEANANDDRYTHEFORK,TAKING CARENOT TO GET WATERINTHEFORK ATTHEUPPERTUBE/LOWERTUBEJUNCTION.

TYPE 2SPRING REPLACEMENT
TheT2spring system inJudyT2forksprovidecuttingedgeperformance with the lively actionof acoilspring
However,overtimethespringscanwearout,compromisingperformance.Thisisevidentincompressionset,when
thecoilspringsareshorterinarestingstatethantheywerewhennew. Followthetablelistedbelowasaguide
toknowwhentoreplacetheT2SpringSystem. Followthe directionstocleanandgreasethespringstackfound
inMaintenanceprocedures,“AftereveryweekorEighthoursofriding,”page9,forremovalandinstallation.
TYPE 2SPRING SYSTEM SPECIFICATION TABLE
Travel OptimumCoil ReplaceCoil OptimumMCU ReplaceMCU
63mm 51mm 46mm 100mm 94mm
80mm 51mm 46mm 115mm 108mm
UPGRADING TO TYPE 3 SPRING SYSTEM AND C3 DAMPER CARTRIDGE
ThesuspensiontravelonJudyT2forkscanbechangedbyupgradingtotheType3springsystemanddamper
cartridgekit. Whenupgrading,RockShoxrecommends installingboththeType3 Spring System and theC3
damper cartridge because these systems were specifically designed to work together to provideoptimum
performance.
First,removeone-piecelower tube assemblyby following the proceduredescribedin,“ToClean and Grease
BushingsandResi-wiperseal”,page9toremoveone-piecelowertubeassembly.
THENFOLLOWTHESEDIRECTIONS TO CHANGETRAVEL:
1. Unscrewtopcapusinga22mmwrenchorsocketwrench.Removethe
springstackassemblies.
2. Removethesnapringsatthebottomoftheuppertubeswithsmalltip
internalsnapringpliers(seeFig.7).
3. Pulltheneutralshaftassemblyfreefromtherightlowertube. Note
orientationofparts,toptobottom:shaftendplate,uppershaftguidewith
o-ring,washer,top-outbumper,lowershaftguide,andsnapring(seeFig.
8). Theshaft-endplateanduppershaftguideonthetopoftheneutral
shaftmayremainintheuppertube. Removethespringstackassemblyas
describedabove. Taptheshaftendplate (throughtopofuppertube)and
guideoutthebottomofthetubewiththelongsocketextension.
4. InstallnewC3CartridgeKit(cartridgeassemblyandneutralshaft
assembly)intouppertubes. Makesureallpartsareclean,greased,and
installedintheproperorder(seeFigs.8&9). Replacethespringspacer
withthenewspacerprovidedinthekit.
IMPORTANT:BE SURETOPROPERLY INSTALLCARTRIDGE LOCKRINGBETWEEN CARTRIDGEAND
SNAPRING.
5. Installsnapringswiththesharpoutsideedgefacingoutintouppertube
ringgrooves. Makecertainsnapringsareorientedcorrectly,andthesnap
ringsarefullyseatedintheringgrooveoftheuppertubes.
Fig. 7
Fig. 8 Fig. 9
4. Thoroughlycleanuppertubesandinspectforwearordamage(nicks,scratches,ordings).
5. Cleanforkbootsandslideontouppertubes.
6. Thencleaninternalsoflowertubes,bushings(twoperleg),andResi-wiper seal. A long 3/8”drive socket
extensionwrappedinalint-freeragworkswell(seeFig.6).
IMPORTANT: CLEAN LOWER BUSHINGS,APPROXIMATELY 6”(150MM)FROM TOP.
7. ApplyNewandImprovedJudyButtertothesurfaceoftheupperbushings
andfillthepocketbetweenthelipsoftheResi-wipersealcompletely.
MPORTANT: FOR BEST PERFORMANCE,AVOID LITHIUM-BASED GREASES. SOME LITHIUM
GREASES CAN BECOME STICKY,TURNGRAY AND CAKE UPWHEN USED TO LUBRICATETHE BUSHINGS.SMOOTH FORK ACTION IS
GREATLY LIMITEDAND PERFORMANCEIS GREATLY REDUCEDWHEN THIS HAPPENS.IF YOUUSE LITHIUM GREASE,CHECK GREASE
QUALITY AND CONDITION AT EACH 25-HOUR SERVICE INTERVAL TO ENSURE GREASE IS PERFORMING PROPERLY.TRY USING
ANOTHERTYPEOF LUBRICANTIF YOUEXPERIENCEPROBLEMS.
8. SmearRockShoxforkoilorathinlayerofNewandImprovedJudyButtertotheuppertubesunderthe
forkboots.
9. Installlowertubesontouppertubes,carefullyengagingupperResi-wiperseallipwithuppertubes.
Gentlyrocktheone-piecelowerassemblytoengagethelowerbushingswithuppertubes.Stopshortof
engagingtheneutralshaftsintothecounterboreinthebottomofthelowerlegs.
10.Turntheforkupsidedownandfilleachlowerlegwithexactly10ccof15wt.RockShoxforkoilbypouring
theoilthroughtheshaftboltholesinthebottomofthelowerlegs.
11.Now,fullyengagethelowertubeswiththeuppertubesbyengagingtheneutralshaftsintothe
counterboresofthelowertubes.Wheninstalledproperly,thecartridgeandneutralshaftthreadsare
visiblethroughtheholesinthebottomofthelowertubes.
12.Installnewcrushwashers ontotheshaftbolts.
MPORTANT: THECRUSH WASHERSEALSTHEOILINTOTHELEGANDMUSTBEREPL ACEDEACHTIMETHESHAFTBOLTISREMOVED.
13.Refitshaftbolts,applyblueLoc-titeonsteelbolts. Usea6or8mmhexwrenchtotorqueshaftboltsto
50in-lb.(5.6Nm).
IMPORTANT: IT IS VERY EASY TO OVER TIGHTEN THIS BOLTWITH AN 8MM HEX WRENCH. USE A
TORQUEWRENCH.
14.RefitforkbootintoResi-wipersealgrooveusingasmallbladescrewdriver. EngagebootwithResi-wiper
sealgrooveattherearandrotatebootaroundtheuppertubetofullyengageitsloweredgebehindthe
brace.Compressingthebootandtwistingaswellasapplying asmallamountofoilonthemating
surfaceshelps.
15.Install the externaldampingadjusterbyapplyingalightcoatingofoiltotheo-ringandpushingitonto
theshaftboltwithanupwardtwistingmotion.
Service
hefollowingsectioncontainsdetailedserviceproceduresforallindividualcomponentsoftheJudyT2fork.
Fig. 6

1 ReflectorBracketScrew
2 ReflectorBracket
3 LockWasher
4 BrakePostWasher
5 BrakePost
6 LowerLegAssembly,Hangerless
7 DustWiper
8 UpperBushing
9 LowerBushing
10 BottomBumper
11 PanelDecal
12 JudyT2Decal(leftandright)
13 ShaftBolt
14 ShaftEndPlate
15 UpperShaftGuide
16 UpperShaftGuideO-ring
17 NeutralShaftAssembly
18 FlatWasher
19 TopOutBumper
20 LowerShaftGuide
21 WaveWasher
22 CartridgeRetainingRing
23 BottomOutBumper
24 UpperTube
25 ForkBoot
26 Crown/Steerer
27 CrownBolts
28 Crown/Steerer/UpperTubes
29 TopCapAssembly
30 Type2Spring
31 Spacer
32 MCUSpacer,63mmtravel
33 MCUSpacer,80mmtravel
34 MCU
35 LowerLegAssembly,Hanger
36 ReflectorBracket,Hanger-type
1998JudyT2
MPORTANT: THESNAPRINGSMUSTBEPROPERL YORIENTED,SHARPOUTSIDEEDGE FACINGOUT,ANDFULLYSEATEDINTHERING
GROOVEOFTHEUPPERTUBES .
6. ApplyathincoatofNewandImprovedJudyButtertotheType3spring
7. ReplaceT2springassemblywiththenewType3assembly. Placerubberpadatthebottomofthespring
stack.
8. Installtheassemblyinuppertube,startingtopcapthreadsbyhand.
9. Torquetopcapto30or40in-lb.(3.4to4.5Nm). Thisshouldbebetween30and60degreesofclockwise
wrenchmovementafterthecapisflushwithuppertube.
10.Repeatprocedureonotherleg.
11.Followprocedures“AfterEveryMonthorTwenty-fiveHoursofRiding,”page9,tocompleteassembly.
BUSHING REPLACEMENT
he high quality bushings in RockShox forks are designed to last many months of hard riding. Protective
boots,acleanfork,andtimelygreasingarethekeystohighperformanceandlongbushinglife. However,like
allmovingparts,bushingswilleventuallywearandneedreplacement. Increasedforeandaftmovementof
uppertubesinlowertubes(similartoalooseheadset)and/orslowaction,evenafterafreshgreasing,signal
theneedtoremoveandreplacethebushings.
MPORTANT: THIS SERVICE REQUIRES ROCKSHOX SPECIALTY TOOLS. WE RECOMMEND THIS LEVEL OF SERVICE BE DONE BY A
QUALIFIEDBIKESHOPMECHANIC FAMILIARWITHOURPRODUCTSANDTHISPROCEDURE.

Warranty
ROCKSHOX,INC.WARRANTS ITS FORKS FOR A PERIOD OF ONEYEAR FROM ORIGINAL DATE OF PURCHASE TO BE FREE FROM DEFECTS IN
MATERIALSOR WORKMANSHIP. ANY ROCKSHOX FORKTHATISRETURNED TOTHE FACTORY ANDISFOUNDBY ROCKSHOXTO BEDEFECTIVEIN
MATERIALS OR WORKMANSHIPWILL BE REPAIRED OR REPLACED AT THE OPTION OF ROCKSHOX, INC. THIS WARRANTY IS THE SOLE AND
EXCLUSIVEREMEDY. ROCKSHOX SHALLNOTBEHELDLIABLEFORANYINDIRECT,SPECIAL,ORCONSEQUENTIALDAMAGES.
THE WARRANTY DOES NOT APPLY TO FORKS WHICH HAVE NOT BEEN PROPERLY INSTALLED AND ADJUSTED ACCORDING TO ROCKSHOX
INSTALLATION INSTRUCTIONS. THE WARRANTY DOES NOT COVERANY FORKTHATHASBEENSUBJECT TO MISUSE ORWHOSESERIAL NUMBER
HAS BEEN ALTERED,DEFACED OR REMOVED. THIS WARRANTY DOES NOT COVER PAINTDAMAGE OR MODIFICATIONS TO FORKS. PROOF OF
PURCHASEISREQUIRED.WARRANTY REPAIR
IFFORANYREASONITSHOULDBENECESSAR YTO HAVEWARRANTYWORKDONE,RETURNTHEFORK TOTHEPLACEOFPURCHASE.INTHE USA,
DEALERS SHOULD CALL FOR A RETURN AUTHORIZATION NUMBER (RA#) PRIOR TO RETURNING PRODUCT. PRODUCTS RETURNED FOR
INSPECTIONMUSTBESENTFREIGHTPREPAID TO:
RockShox,Inc.
2713N. FirstStreetFAX408.953.7569
SanJose,CA95131
Toll-FreeTechnicalSupportintheUSA800.694.0668
CUSTOMERSIN COUNTRIES OTHERTHANTHE USASHOULD CONTACTTHEIR LOCALDEALERORDISTRIBUTOR.
International Distributor List
Africa
CoolHeatS.A.
Phone[phone]
FAX [phone]
Argentina
BroniS.A.
Phone[phone]
FAX[phone]
Australia
SportsPlus
Phone[phone]
FAX[phone]
Austria
BarisitzAustria
Phone[phone]
FAX[phone]
Belgium
VertexCycleSystemsBV
Phone[phone]
FAX[phone]
Brazil
PacificBicycleCompany
Phone[phone]
FAX[phone]
Canada
CanadaLtd.
Phone[phone]
FAX[phone]
ChileBicicletasBelda
Phone[phone]
FAX[phone]
Colombia
DisandinaLtda.
Phone[phone]
FAX[phone]
CostaRica
CobicondorS.A.
Phone[phone]
FAX[phone]
CostaRica
SPCBicicletas
Phone[phone]
FAX[phone]
CzechRepublic
veloGepardLtd.
Phone[phone]
FAX[phone]
Denmark
Ettol
Phone[phone]
FAX[phone]
Ecuador
BiciSportSierra
Phone[phone]
FAX[phone]
Finland
Mr.CoolOY
Phone[phone]
FAX[phone]
Glossary
BottomingOut–theconditionwhenallsuspensiontravelhasbeenusedup.
ompressionStroke–the“upward”motionofaforkwhichismovinginresponsetoabumpimpact.
DampingForce–theforcerequiredtomoveashockabsorber/damper(generaloil)atanygivenspeed.
orged–ametalformingprocesswhichoptimizesmaterialstructureusingverylargeforcesactingonadie
moldinwhichmaterialtoformedisplaced.
Geometry–Descriptivetermforthelengthsandanglesusedinabicycledesign.
Headangle–Anglethesteeringaxisleansbackfromvertical.
Oilbath– oilreservoirsystemusedforlubricatinginternalpartsinthefork.
Onepiece–unitizedlowerlegassemblywithbothforklegsand forkbracecastasonepiece.
Preload–Theamounteitherinpoundsorinches,aspringiscompressedwhenfittedtoanextendedshock
absorber.
Rebound–Theextensionorreturndirectionoftheshocksorsuspension.
ag–compressionofthesuspensioncausedbytherider’sweight.
pringrate–Theamountofforcerequiredtodeflectaspringagivendistance.
apered–varyingwallthicknessofatube.Adesigntooptimizeplacementofmaterial,allowing most
efficientdesignconsideringtheloads.
oppingout–thepositionoftheforkatthe“top”ofthetravel,orwhentheforkisfully extended.The
actionofcompleteextensionofthefork.
Follow the NORBA Code
• Iwillyieldtherightofwaytoothernon-motorizedrecreationalists.
•Iwillusecautionwhenovertakinganotherandwillmakemypresencebeknownwillinadvance.
• Iwillmaintaincontrolofmyspeedatalltimes.
• Iwillstayondesignatedtrails.
• Iwillnotdisturbwildlifeorlivestock.
• Iwillnotlitter
• Iwillrespectpublicandprivateproperty.
• Iwillalwaysbeselfsufficient.
• Iwillnottravelsolowhenbikepackinginremoteareas.
• Iwillobservethepracticeofminimumimpactbicycling
• Iwillalwayswearahelmetwheneverriding.

Liste de vérification aide-mémoire
d’intervalles de maintenance
Vérifiezlespointssuivantsàchaqueintervalledemaintenance.Pourdeplusamplesdétails,consultezlapage26
Achaquerandonnée Après8heuresderandonnée Après25heuresderandonnée
(Inspectez)
Roueavant Nettoyeztubessupérieurs Nettoyezetgraissezpilesderessort
Manettedeblocage Huileztubessupérieurs Inspectezsystèmederessortsde
l’ensembledecompression
Vérifiezdétérioration Vérifiezboulonsdetêteet Nettoyezetgraissezgaineset
debéquille Resi-wiper
Acheminementdescâbles Vérifieztigesdefreins Nettoyeztubessupérieursetinspectez
pourvoirs’ilyadétérioration
Patinsdefreins Nettoyezgainesdefourche
Leviersdefreins
Jeudedirection
IMPORTANT : POUR MAINTENIR UN HAUT NIVEAU DE PERFORMANCE,DE SÉCURITÉ ET DE LONGÉVITÉ,UNE MAINTENANCE
PÉRIODIQUEESTNÉCESSAIRE.N’OUBLIEZPASQU’UNEMAINTENANCEFRÉQUENTEESTINDISPENSABLE LORSQUEL’ONUTILISEUNE
BICYCLETTEDANSDES CONDITIONSEXTRÊMES.
rance
PhilamyS.A.
Phone[phone]
FAX[phone]
ermany
SportImportGmbH
Phone[phone]
FAX[phone]
reece
Gatsoulis
Phone[phone]
FAX [phone]
uatemala
BikeCenter
Phone[phone]
FAX[phone]
Holland
VERTEXCycleSystemsBV
Phone[phone]
FAX[phone]
HongKong
FlyingBallBicycleCo.
Phone[phone]
FAX[phone]
srael
C.T.C.Ltd.
Phone[phone]
Fax[phone]
talyMotorquality
Phone[phone]
FAX[phone]
uxumbourg
VertexCycleSystemsBV
Phone[phone]
FAX[phone]
Mexico
GrupoScandl
Phone[phone]
FAX [phone]
Japan
YoshigaiCorporation
Phone[phone]
FAX[phone]
NewZealand
W.H.Worrall&Co.Ltd.
Phone[phone]
FAX[phone]
Norway
FossSykler
Phone[phone]
FAX[phone]
Panama
DistribuidoraRali,S.A.
Phone[phone]
FAX[phone]
PeruFabisadeBicicletasS.A.
Phone[phone]
FAX[phone]
Poland
GiantPolska
Phone[phone]
FAX[phone]
Portugal
Bicimax,
ArtigosDesportivos,Lda.
Phone/Fax[phone]
St.Maarten
Tri-SportInternational
Phone[phone]
FAX[phone]
Singapore
TreknologyBikes3
Phone[phone]
FAX[phone]
Slovenia
ProlocoTrade
Phone[phone]
FAX [phone]
Spain
MotorDealer
Phone[phone]
FAX[phone]
Sweden
HallmanSports
Phone[phone]
FAX[phone]
Switzerland
MTBCycletech,A.G.
Phone [phone]
FAX[phone]
UnitedKingdom
CarattiSportLimited
Phone[phone]
FAX[phone]
Taiwan
BiketechCo.,Ltd.
Phone[phone]
FAX[phone]
Thailand
ProbikeCo.,Ltd
Phone[phone]
FAX[phone]
USARockShox,Inc.
401CharcotAve.
SanJose,CA95131
DealerSales
[phone]
TechServices
[phone]
Questions&Catalogs
[phone]
OtherPeople
[phone]
WorldWideWebsite
www.rockshox.com
Venezuela
Bicimont
Phone/FAX[phone]