Rock Shox JUDY C User manual

1997 Judy
Owner’s Manual
Judy C,XC,DH,and SL models
®
RockShox, Inc.
401 Charcot Ave.
San Jose, CA 95131
Dealer Sales [phone]
Tech Services [phone]
Questions & Catalogs [phone]
Other People [phone]
www.rockshox.com

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 its
recommendations to help make your mountain
bike experience enjoyable and trouble free.
®
SteererTube
ForkCrown
BrakePost
ShaftBolt(HollowonDHonly)
UpperForkTube(w/dustboot)
PreloadAdjusterKnob
OnePieceForkBrace
andLowerTubeAssembly
(XC,SL,DH)
HollowShaftBolt(XC,SL,DH)

Judy Features
• NewTrue“One-Piece”MonocoqueCastingLowerTubeBraceAssembly(XC,SL,DH)
• NewTypeIISpringSystem. LivelyactionofacoilspringandlightweightprogressiveMCU. Veryeasyto
tunefordifferentriders. AvailableonallJudyforks.
• Adjustablecompressionaluminumhydraulicdampercartridge. Moreconsistentdamping,betterheat
dispersion,andimprovedreliability. AvailableonallJudyforks.
• UniqueResiwiperSeal.Cleansandlubricatestheupperforktubes(XC,SL,DH).
• 28mmdiameterEastontaperedaluminumuppertubes(XC,SL).
• LightweightconstructiononSLcrownandsteerer.
• 6inchesofslideroverlap.
• Superstiffalloycrown.
• DHequippedwithadjustablerebounddampingcartridge.
• ExternalcompressiondampingadjusterknobonJudySL.
STANDARD EQUIPMENT (SUPPLIED WITH JUDY/FORK PURCHASED SEPARATELY)
63mmTravelversion—(2X) SpringStop,SpringRateAdjuster,beige(soft)
63mmTravelversion—(2X) SpringStop,SpringRateAdjuster,gray(hard)
80mmTravelversion—(2X) SpringStop,SpringRateAdjuster,black(medium)
80mmTravelversion—(2X) SpringStop,SpringRateAdjuster,gray(hard)
AllJudymodels—(1X)JudyButter,1oz
AllJudymodels—(1X)3mmHexKeytoadjustcartridge(notapplicableonJudySL)
OPTIONAL EQUIPMENT
SoftCoilSpringSet—SpringRate100-LB(45.5Kg)
Soft/MediumCoilSpringSet—SpringRate120-LB(54.5Kg)
HardCoilSpringSet—SpringRate160-LB(72.7Kg)
ExternalCompressionAdjuster(s)forJudyXCandDH(x2)
80mmLongTravelCartridgeKit(JudyC/XC/SL)
TypeII TuningKits
100-140#(45.4-63.6Kg)
140-200#(63.6-90.9Kg)

CONSUMER SAFETY INFORMATION
RIDING A BIKE IS DANGEROUS.NOT PROPERLY MAINTAINING OR INSPECTING YOUR BIKE IS EVEN MORE DANGEROUS.IT’S ALSO
DANGEROUS NOT TO READ THESE DIRECTIONS.SO IF YOU USE OUR STUFF,DON’T BE A DUMMY—READ THE DIRECTIONS!
1. Brakesmustbeproperlyinstalledandadjusted. Ifthebrakesdon’tworkproperly,theridercouldsuffer
seriousand/orfatalinjuries. Beforeridingthebicycle,besurethebrakesareproperlyinstalledandadjusted.
2. Usetheforkonlywithcantilever-typebrakesmountedtotheexistingmountingposts. Thisforkis
intendedandapprovedforuseonlywithcantilever-typebrakesmountedtotheexistingmounting
posts. ForkswithhangerlessstylebracesweredesignedforV-typeorhydrauliccantileverbrakes. Do
notuseanycantileverbrakeotherthanthoseintendedbythebrakemanufacturertoworkwitha
hangerlessbrace. Donotroutethefrontbrakecableand/orcablehousingthroughthestemorany
othermountsorcablestops!Donotuseafrontbrakecableleveragedevicemountedtothebrace. Do
notusedisc-typebrakesmountedtotheouterlowertube. Thelowertubeswerenotdesignedto
sustainthestressessuchbrakescouldplaceuponthem,andstructuralfailuretotheforkmayresultif
anydevicesortypeofbrakeotherthancantileveraremountedonthefork. Structuralfailurecould
resultinlossofcontrolofthebicyclewithpossibleseriousand/orfatalinjuries.
3. Useextremecautionwhenmountingbicycletoacarrier. Whenmountingthebicycletoacarrierbythe
forkdrop-outs(frontwheelremoved),donottiltthebicycletoeitherside. Ifthebicycleistiltedwhile
thedrop-outsareinthecarrier,theforklegsmaysufferstructuraldamage. Youmustalsosecurethe
rearwheel. Notsecuringtherearwheelcanallowthebike’smasstoside-loadthedrop-outs,causing
themtobreakorcrack. Makesuretherearwheelisfasteneddown(thisincludesBikeTitetruck-style
mountsalso). Ifthebicycletiltsorfallsoutofthecarrier,donotridethebicycleuntiltheforkisproperly
examinedforpossibledamage. Ifthereisanyquestionofpossibledamage,returntheforktoyour
dealerforinspectionorcallRockShox. (SeeTechnicalServiceslistbycountryonlastpage.)Aforklegor
drop-outfailurecouldresultinlossofcontrolofthebicyclewithpossibleseriousand/orfatalinjuries.
4. Iftheforkeverlosesoilorifitmakessoundsofexcessivetoppingout,stopridingthebicycle
immediatelyandhavetheforkinspectedbyyourdealerorcallRockShox. Continuingtoridewiththe
forkineitheroftheseconditionscouldresultinlossofcontrolofthebicyclewithpossibleseriousand/or
fatalinjuries.
5. AlwaysusegenuineRockShoxparts. Useofafter-marketreplacementpartsvoidsthewarrantyand
couldcausestructuralfailuretothefork. Structuralfailurecouldresultinlossofcontrolofthebicycle
withpossibleseriousand/orfatalinjuries.
IMPORTANT: ROCKSHOX FORKS ARE DESIGNED FOR COMPETITIVE OFF-ROAD RIDING AND DO NOT COME WITH THE PROPER
REFLECTORS FOR ON-ROAD USE.YOUR DEALER SHOULD INSTALL PROPER REFLECTORS TO MEET THE CONSUMER PRODUCT SAFETY
COMMISSION’S(CPSC)REQUIREMENTSFORBICYCLES STANDARDIFTHEFORK ISGOINGTOBE USEDONPUBLIC ROADSATANYTIME.

Installation Instructions
IT IS EXTREMELY IMPORTANT THAT YOUR ROCKSHOX FORK IS INSTALLED CORRECTLY BY A QUALIFIED TECHNICIAN WITH PROPER
TOOLS.IMPROPERLY INSTALLED FORKS ARE EXTREMELY DANGEROUS AND CAN RESULT IN SEVERE INJURIES.
1. Removetheexistingforkandlowerheadsetracefromthebicycle. Measurethelengthofthefork
steerertubediameteragainstthelengthoftheRockShoxfork. TheRockShoxsteerertubemayneed
cuttingtotheproperlength. Onthreadlesssteerers(Aheadsetdesign),makesurethereissufficient
lengthtoproperlyclampstem. (Refertostemmanufacturer’sinstructions.)
NOTE: DO NOT ADD THREADS TO ROCKSHOX STEERERS.THE STEERER TUBE CROWN ASSEMBLY IS A ONE-TIME PRESS FIT.
REPLACEMENT OF THE ASSEMBLY MUST BE DONE TO CHANGE LENGTH,DIAMETER,OR HEADSET TYPE (THREADED OR THREADLESS).
DO NOT REMOVE OR REPLACE THE STEERER TUBE,BECAUSE THIS COULD RESULT IN LOSS OF CONTROL OF THE BICYCLE WITH
POSSIBLE SERIOUS AND/OR FATAL INJURIES.
2. Installtheheadsetrace(Ø26.4mmfor1”steerers)firmlyagainstthetopoftheforkcrown. Installthe
forkassemblyonthebike. Makesuretherearesufficientthreadstoproperlylocktheheadsetinplace.
Onthreadlesssteerers(Aheadsetdesign),makesurethereissufficientlengthtoproperlyclampstem
(refertostemmanufacturer’sinstructions). Adjusttheheadsetsoyoufeelnoplayordrag.
3. Installthebrakesaccordingtothemanufacturer’sinstructionsandadjustbrakepadsproperly. Usethe
forkonlywithcantilever-typebrakesmountedtotheexistingmountingposts.
4. Onthreadedsteerers,insertstemtoaminimumdepthaccordingtoCPSCandJIS
standards. Thestemmustbeinsertedtoaminimumengaginglengthnotless
than2.5timesthestemdiameterfromthelowestendofthestem,notthe
wedge. (SeeFig. 1).
5. FitabrakecabletotheRockShoxforkbracemount. Forkswithhangerlessstyle
bracesweredesignedforV-typeorhydrauliccantileverbrakes. Donotuseany
cantileverbrakeotherthanthoseintendedbythebrakemanufacturertoworkwitha
hangerlessbrace. Donotroutethecablethroughthestemoranyothermountsorcablestops!Thecable
shouldmakeadirectroutefromthebrakelevertotheRockShoxforkbracemountandbeabletofreely
moveupanddownwiththesuspensionmovement. Itmaybenecessarytoinstallawholenewcable.
NOTE:THE DISTANCE FROMTHE TOP OF THE BRAKE CABLE HANGER TO THE BOTTOM OFTHE BRACE CABLE HOUSING STOP MUST
BE A MINIMUM OF 12MM WITH THE BRAKES APPLIED.AN IMPROPERLY INSTALLED FRONT BRAKE CABLE COULD RESULT IN LOSS
OF CONTROL OF THE BICYCLEWITH POSSIBLE SERIOUS AND/OR FATAL INJURIES.
6. Adjustthefrontwheelquickreleasetoclearthedropoutscounterbore. Thequickreleasenutmustbe
tightenedafterthewheelisproperlyseatedintothedropoutscounterbore. Makesurefourormore
threadsareengagedinthequickreleasenutwhenitisclosed. Orientthequickreleaseleverinfrontof
andparalleltothelowertubeinthelockedposition.
7. Keepinmindtireclearanceasyouchoosetires. Maximumtiresizeis2.2”wideor335mmradius. Be
suretocheckthisradiuswheneveryouchangetires. Todothis,removethespringstack(asper
instructionsonfollowingpages),andcompressforkcompletelytomakesureatleast5mmofclearance
existsbetweenthetopofthetireandthebottomofthecrown. Exceedingthismaximumwillcausethe
tiretojamagainstthecrownwhentheforksarefullycompressed. Theuppertubesmustalwaysbefully
engagedinthecrown. Theuppertubesmustnotextendabovethecrownmorethan1mm.
Fig. 1

TuningYour Fork
RockShox(JUDY)forkscanbetunedtoyourparticularweight,ridingstyle,andterrain. Ourforksaresetupforthe
140-180lb(65-80Kg),all-aroundriderwhospendsequaltimeridingeveryoff-roadterrainimaginable. Because
you’re probably not that rider,you can benefit by making tuning adjustments to suit your specific needs.For
maximumtuningflexibility,purchaseaRockShoxTypeIITuningKit(includescoilsprings,springstops&MCU’s).
Ideally the fork performs best when occasionally bottoming out,but not too harshly nor too often. When
tuningyoursuspension,alwaysmakeonechangeatatimeandwriteitdown. Thistakespatiencebutallows
youtounderstandhoweachchangefeelsontheterrainyouride. Keepingarecordletsyoualwaysknowwhat
changesyouhavetriedandsuggestswhatchangesyoumighttry. Askyourshopand/orlocalriderswhatthey
have found works well. These resources are typically your best bet,but don’t hesitate to call us about your
specifictuningneedsifnecessary. Alistofphonenumbers,bycountry,areinthebackofthismanual.
RIDE HEIGHT AND SPRING PRELOAD ADJUSTMENT
Judyisdesignedtocompress(sag)whenyouaresittingonthebike. Thissagallowsthefrontwheeltostayin
contactwiththegroundwhenbrakingandcorneringoverroughanduneventerrain. Thenominalsettingsby
travelare7-10mmsagfor80mmtravel;5-8mmfor63mmtravel. Thetopcapadjustmentknoboneachleg
adjuststhesagofthefork(thepreloadonthespringstack). Changingthepreloadaltersthesagandfirmness
oftheinitialforkmovement.Whentheadjustmentknobisturnedfullclockwise,theforkwillsagtheleastand
bethefirmestinitially. Turningtheadjustmentknobsfullcounterclockwisemakestheforksagthemostand
bethesoftestinitially. Typically,heavier,moreaggressiveridersneedmorespringpreloadtoholdtheforkup
inthetravelandallowmoreoftheforktraveltobeusedduringbumpimpact. Lighter,lessaggressiveriders
need less preload on the spring system to allow the fork to move easier and be more supple over smaller
bumps. Forthe idealpreloadfor you,turn thetopcap adjustmentknobs toyour desired setting,keeping in
mindsagandinitialforkmovement.
DO NOT TURN THE PRELOAD ADJUSTERS PAST THEIR LIMIT STOPS.THERE ARE ONLY 3 FULL TURNS FROM MINIMUM TO
MAXIMUM PRELOAD.FAILURE TO OBSERVE THIS INSTRUCTION COULD RESULT IN PREMATURE FAILURE OF THE PRELOAD ADJUSTER
CAP ASSEMBLY.
OVERALL SPRING RATE ADJUSTMENT
Remember you want the fork to occasionally bottom out,but not too harshly nor too often. If you are
bottomingouttoooftenornotusingalltheavailabletravel,andifthepreloadandsagfeelgood(seeabove),
thenthe overallspring rateshould bechanged. Bychangingthe coilspringstops,youcan altertheoverall
springrate. Tochangethecoilspringstopineachleg,followthisprocedure:
NOTE:THE COIL SPRING STOPS MUST BE THE SAME IN EACH LEG.
1. Unscrewthetopcapassemblyusinga22mmwrenchorsocket.
2. Removethespringstackassembly(topcap,coilspring,coilspring
stop,spacer,andMCU).(SeeFig.2)
3. RemovetheMCUspacerfromthecoilspringstop,coilspring,andtop
capusinganunscrewingmotion.
4. Nowunsnapthecoilspringstopfromthespacer. Byusingshorter Fig.2

(softer)orlonger(firmer)coilspringstopsthanstock,youcanchangetheoverallspringrate.
5. Snaptheappropriatecoilspringstopintoeachcoilspring,cleanandgreasetheMCU,andreassemble
thespringstackassembly.
6. Installthecleanandgreasedspringstackassembliesintotheuppertubes,startingthetopcapthreads
byhand. Donotcrossthread.
7. Tightenthetopcapuntilitisflushwiththeuppertube.
8. Nowusinga22mmsocketandbeam-styletorquewrench,torquetopcapassemblyto20-30in-lb(2.3-
3.4Nm). Thisshouldbebetween30-60degreesofclockwisewrenchmovementoncethecapisflush
withtheuppertube. Afterridingyoumayneedtoadjustthetopcapknobstoobtainthesame
sag/preloadfeel. (SeePreloadabove)
COMPRESSION DAMPING CARTRIDGE ADJUSTMENT (XC,SL,DH)
A single aluminum damping cartridge in the left leg provides compression and rebound damping for the
entire fork (the DH has an adjustable rebound damping cartridge in the right leg). This cartridge has a
compressiondampingadjustment.Thecompressionadjustmentcontrolsthespeedthattheforkwillcollapse
andcoversaverywiderange. Toadjust,followthisprocedure:
1. Inserta3mmhexwrenchthroughthehollowshaftboltinthebottomof
theleftleg(turntheredexternalknobontheJudySL). (SeeFig.3)
2. Turnthe3mmhexwrenchclockwisetoincreasethecompression
damping(slower)andcounterclockwisetodecreasethecompression
damping(faster). Smallchangesmakeabigdifferenceonthetrail. There
aretwofullturnsofadjustmentavailablefromfullclockwise.
WARNING:DO NOT TURN ADJUSTER MORE THAN TWO TURNS FROM FULL CLOCKWISE.
DH REBOUND DAMPING CARTRIDGE ADJUSTMENT
Aredaluminumrebounddamping cartridgein therightlegprovidestherebounddampingadjustment for
thefork. Thereboundadjustmentcontrolsthespeedthattheforkwillextendandcoversaverywiderange.
Toadjusttherebound,followthisprocedure:
1. Inserta3mmhexwrenchthroughthehollowshaftboltinthebottomoftherightleg.
2. Turnthe3mmhexwrenchclockwisetoincreasetherebounddamping(slower)andcounterclockwiseto
decreaserebounddamping(faster). Therearethreefullturnsofadjustmentavailablefromfullclockwise.
IMPORTANT:DO NOT TURN ADJUSTMENT MORE THAN THREE TURNS.
Maintenance
RockShoxforksaredesignedtobenearlymaintenancefree. However,aslongasmovingpartsareexposedto
theelements,moisture andcontaminationcan reduceperformance. Tomaintain highperformance,safety,
andlonglife,periodic maintenanceis required. RockShox forksare engineered foreasy serviceto helpyou
keeptheforkclean,greased,andperforminglikenew.
Therecommendedtoolsandintervalsformaintenancearelistedbelow. Remember,performingmaintenance
moreoftenisalwaysbetterandnecessaryifyourideinextremeconditions.
IMPORTANT:ALWAYS WEAR SAFETY GLASSES WHEN WORKING ON ROCKSHOX FORKS.
Fig. 3

1
2
3
1
4
5
6
8
9
11
10
12
31
24
26
27
28
29
30
32
33
25
13
7
AVAILABLE IN
ASSEMBLY ONLY
14
15
16
17
18
19
20
14
21
22
23
20
1 ReflectorBracketScrew
2 ReflectorBracket
3 ForkBrace
4 BraceBolt
5 BrakePost
6 DustWiper
7 UpperBushing
8 LowerBushing
9 BottomBumper
10 PanelDecal
11 JudyCDecal(leftandright)
12 ShaftBolt
13 LowerTubeAssembly(leftandright)
14 ShaftEndPlate
15 UpperShaftGuide
16 UpperShaftGuideO-ring
17 NeutralShaftAssembly(63mm)
18 TopOutBumper
19 LowerShaftGuide
20 CartridgeRetainingRing
21 CartridgeAssembly(63mm)
22 CartridgeWasher
23 WavyWasher
24 ForkBoot
25 Crown/Steerer/UpperTubeAssembly
26 TopCapAssembly
27 TuningSpring
28 SpringStopSpacer
29 MCUStop
30 MCUBumper
31 HangerlessForkBrace
32 HangerlessReflectorBracket
33 MCUStopfor80mmTravelSetup
1997JudyC
3,4,5,6and8mmhexwrenches
8mmopen-endwrench
Smalltipinternalsnapringpliers
Plasticfacemallet
22mmsocket(6pointpreferred)orwrench
Ratchet,forsocket
Smallstraightbladescrewdriver
Long(8”+/200mm)socketextension,
endwrappedwithclothtape
MAINTENANCE TOOLS

3
5
8
9
6
12
14
25 31
30
29
28
27
26
34
15
16
17
19
18
20
21
13
4
7
1
2
10
11
14
22
23
24
21
132
33
Available in
assembly only
1 ReflectorBracketScrew
2 ReflectorBracket
3 BrakePost
4 One-PieceLowerLegAssembly
5 Resi-WiperTopSeal
6 Spacer
7 UpperBushing
8 LowerBushing
9 BottomBumper
10 PanelDecal
11 JudyXCDecal(leftandright)
12 HollowShaftBolt
13 ShaftBolt
14 ShaftEndPlate
15 UpperShaftGuide
16 UpperShaftGuideO-ring
17 NeutralShaftAssembly(63mm)
18 FlatWasher
19 TopOutBumper
20 LowerShaftGuide
21 CartridgeRetainingRing
22 CartridgeAssembly
23 CartridgeWasher
24 WavyWasher
25 ForkBoot
26 Crown/Steerer/UpperTubeAssembly(OEM)
27 TopCapAssembly
28 TuningSpring
29 SpringStopSpacer
30 MCUStop
31 MCUBumper
32 One-PieceLowerLegAssembly(Hangerless)
33 HangerlessReflectorBracket
34 MCUStopfor80mmTravelSetup
1997JudyXC

3
5
8
9
6
12
14
13
20
26
28
25
24
23
22
21
27
4
7
1
2
10
11
14
19
16
17
18
15
16
17
18
129
30
Available in
assembly only
1 ReflectorBracketScrew
2 ReflectorBracket
3 BrakePost
4 One-PieceLowerLegAssembly
5 Resi-WiperTopSeal
6 Spacer
7 UpperBushing
8 LowerBushing
9 BottomBumper
10 PanelDecal
11 JudyDHDecal(leftandright)
12 HollowShaftBolt
13 UpperTube
14 ShaftEndPlate
15 CartridgeAssembly(80mmRebound)
16 CartridgeWasher
17 WavyWasher
18 CartridgeRetainingRing
19 CartridgeAssembly(80mmCompression)
20 ForkBoot
21 TopCapDecal
22 TopCapAssembly
23 TuningSpring
24 SpringStopSpacer
25 MCUStop
26 MCUBumper
27 Crown/SteererAssembly
28 CrownBolts(4)
29 One-PieceLowerLegAssembly(Hangerless)
30 HangerlessReflectorBracket
1997JudyDH

3
5
8
9
6
12
36
37
14
25 32
31
30
29
28
26
35
15
16
17
13
4
7
1
2
10
11
14
22
23
24
21
133
34
19
18
20
21
Available in
assembly only
27
1 ReflectorBracketScrew
2 ReflectorBracket
3 BrakePost
4 One-PieceLowerLegAssembly
5 Resi-WiperTopSeal
6 Spacer
7 UpperBushing
8 LowerBushing
9 BottomBumper
10 JudySLPanelDecal
11 JudySLDecal(leftandright)
12 HollowShaftBolt
13 ShaftBolt
14 ShaftEndPlate
15 UpperShaftGuide
16 UpperShaftGuideO-ring
17 NeutralShaftAssembly(63mm)
18 FlatWasher
19 TopOutBumper
20 LowerShaftGuide
21 CartridgeRetainingRing
22 CartridgeAssembly
23 CartridgeWasher
24 WavyWasher
25 ForkBoot
26 Crown/Steerer/UpperTubeAssembly
27 TopCapDecal
28 TopCapAssembly
29 TuningSpring
30 SpringStopSpacer
31 MCUStop
32 MCUBumper
33 One-PieceLowerLegAssembly(Hangerless)
34 HangerlessReflectorBracket
35 MCUStopfor80mmTravelSetup
36 DampingAdjusterO-ring
37 DampingAdjusterKnob
1997JudySL

TIGHTENING TORQUE TABLE
CrownBolts 60in-lb(6.8Nm)
TopCapAssemblies 30in-lb(3.4Nm)
ForkBraceBolts 60in-lb(6.8Nm)
BrakePosts 60in-lb(6.8Nm)
ShaftBolts 60in-lb(6.8Nm)
LUBRICANTS AND CLEANERS:
Degreaser
JudyButterorhighqualityteflonfortifiedgrease(nolithiumgrease)
RockShox5wtor8wtoil(orforkoilwithoutseal-swelleradditives)
REGULAR MAINTENANCE
BEFORE EVERY RIDE
Beforeeveryride,inspectthefollowingparts:
1. Frontwheelandquickreleaseforproperinstallationandadjustment
2. Forkforanyobviousdamage(crown,brace,uppertubes,lowertubes,anddropouts)
3. Frontbrakecableforproperrouting
4. Frontbrakepadsforpropercontactwiththerim
5. Frontbrakeleverforproperadjustment
6. Headsetforproperfunctionandadjustment
AFTER EVERY RIDE CLEAN AND DRY FORK,TAKING CARE NOT TO GET WATER IN FORK ATTHE UPPER TUBE/LOWER TUBE JUNCTION.
AFTER EVERY WEEK OR 8 HOURS OF RIDING
AFTER EVERY WEEK OR 8 HOURS OF RIDING,CLEAN AND OIL THE UPPER TUBES AND CHECK FASTENERS FOR PROPER TORQUE.
FOLLOW THIS PROCEDURE:
1. Liftforkbootsfromlowertubes,andwipedoublesealareaandupper
tubeclean. Apply2-3dropsofteflon-fortifiedoiltotheuppertubesat
theseal.(SeeFig.4)
2. Refitforkbootsintodouble-sealgrooveusingsmallbladescrewdriver.
Engagebootwithdoublesealgrooveattherearandrotateboot
aroundtheuppertubetofullyengageitsloweredgebehindthebrace.
Asmallamountofoilonthematingsurfaceshelps.
3. Checkcrownbolts,bracebolts,andbrakepostsforpropertorque.
(RefertoTighteningTorqueTable,above.)
4. Repeatprocedureonotherleg.
Fig. 4

AFTER EVERY MONTH OR 25 HOURS OF RIDING
AFTER EVERY MONTH OR 25 HOURS OF RIDING,CLEAN AND GREASE THE SPRING STACKS,BUSHINGS,AND DOUBLE SEAL.
TO CLEAN AND GREASE THE SPRING STACKS,FOLLOW THIS PROCEDURE:
1. Unscrewthetopcapusing22mmwrenchorsocketwrench. Removethespringstackassemblyand
cleanthestackwithdegreaser. Wipedry.
2. InspectTypeIIspringforcompressionset. (SeeSpringStackSpecificationTableunderTypeIISpring
ReplacementSection,page14.)Replaceasneeded.
3. ApplyathincoatingofJudyButtertotheMCU.
4. Installassemblyinuppertube,startingtopcapthreadsbyhand.
5. Torquetopcapto20-30in-lb(2.3-3.4Nm). Thisshouldbebetween30-60degreesofclockwisewrench
movementaftercapisflushwithuppertube.
6. Repeatprocedureonotherleg.
TO CLEAN AND GREASE BUSHINGS AND DOUBLE SEAL,DO THE FOLLOWING:
1. Mountthebikeinastand,disconnectthefrontbrakecable,andremove
thefrontwheel. (Thebrakesdonotneedtoberemoved. Avoid
disassemblingbrakesunlessabsolutelynecessary.).
2. PullredexternaldampingadjustmentknobfromleftshaftboltofJudySL
withadownwardtwistingmotion. (Theexternaladjusterispressfitin
theshaftbolt.)
3. Partiallyloosenshaftboltswitha6or8mmhexwrench,tapboltsfirmly
withamalletbreakingshaftsfreefromlowertube,andremovebolts
completely.(SeeFig.5)
4. Slideoffone-piecelowertubeassembly. Removeforkboots. (SeeFig.6)
5. Cleanuppertubesandinspectforwearand/ordamage(nicks,scratches,
ordings).
6. Cleanforkbootsandslideontouppers,andcleaninternalsoflowertubes,
bushings(twoperleg),anddoubleseal. Alint-freeragwrappedtoalong
3/8”drivesocketextensionwrappedwithclothtapeworkswell.
IMPORTANT: CLEAN LOWER BUSHINGS,APPROXIMATELY 6”(150MM)FROM TOP.
7. ApplyJudyButtertothesurfaceofthefourbushings,theinsideofthe
lowertubesandfillthepocketbetweenthelipsofthedoubleseal
completely. Useasocketextensionwrappedwithclothtapedippedin
JudyButtertoreachinsidethelowertubes.(SeeFig.7)
DONOTUSE LITHIUM-BASEDGREASE.ITWILLREACTWITHTHE COATINGONTHE BUSHINGS.
Smearteflonbasedoil,5wtoilorathinlayerofJudyButtertotheupper
tubesundertheforkboots.
8. Installone-piecelowerassemblyontouppertubes,carefullyengageupperdoubleseallipwiththe
uppertubes,andgentlyrocktheone-piecelowerassemblytoengagethelowerbushingswiththe
uppertubes. Wheninstalledproperly,thecartridgeandneutralshaftthreadsarevisiblethroughthe
Fig. 5
Fig. 7
Fig. 6

holesinthelowertubes.
9. Refitshaftbolts,applyblueLoc-titeonsteelbolts,anduseanti-seizeontitaniumbolts. Use6or8mm
hexwrenchtotorqueshaftboltsto60in-lb(7Nm).
NOTE:IT IS VERY EASY TO OVER TIGHTEN THIS BOLT WITH AN 8MM HEX WRENCH.USE A TORQUE WRENCH.
10.Refitforkbootintodoublesealgrooveusingsmallbladescrewdriver. Engagebootwithdoubleseal
grooveattherearandrotatebootaroundtheuppertubetofullyengageitsloweredgebehindthe
brace. Asmallamountofoilonthematingsurfaceshelps.
11.Repeatprocedureonotherleg.
12.OnJudySL,re-installtheredexternaldampingadjusterbyapplyingalightcoatingofoiltotheO-ring
andpushingitintotheshaftboltwithanupwardtwistingmotion.
Service
ThefollowingsectioncontainsdetailedserviceproceduresforallindividualcomponentsoftheJudyfork.
CHANGING TRAVEL
Thesuspensiontravelon Judyforkscanbechanged byinstallinga differenttravelcartridgekit. First,remove
one-piecelowertube assemblybyfollowing theproceduredescribedinToCleanandGreaseBushings and
DoubleSeal,page12,toremoveone-piecelowertubeassembly.
THEN FOLLOW THESE DIRECTIONS TO CHANGE TRAVEL:
1. Unscrewtopcapusinga22mmwrenchorsocketwrench.Removethespringstackassemblies.
2. Removethesnapringsatthebottomoftheuppertubeswithsmalltip
internalsnapringpliers. (SeeFig.8)
3. Pullthecartridgeassemblyfreefromtheleftuppertube. Noteorientation
ofparts,toptobottom:shaft-endplate,cartridge,cartridgewasher(very
important),wavewasher,andsnapring. (SeeFig.9) Theshaft-endplate
onthetopofthecartridgeshaftmayremainintheuppertubes. Remove
thespringstackassemblyasdescribedaboveandtaptheplateoutthe
bottomofthetubewiththelongsocketextension. (ForDH,repeatthis
procedureonrightlegtoremoverebounddampingcartridge.)
4. Pulltheneutralshaftassemblyfreefromtherightlowertube. Note
orientationofparts,toptobottom:shaftendplate,uppershaftguidewith
o-ring,washer,top-outbumper,lowershaftguide,andsnapring. (SeeFig.
10) Theshaft-endplateanduppershaftguideonthetopoftheneutral
shaftmayremainintheuppertube. Removethespringstackassemblyas
describedabove. Taptheplateandguideoutthebottomofthetubewith
thelongsocketextension. (Seeexplodeddiagram,pages7-10)
5. Installnewcartridgekit(cartridgeassemblyandneutralshaftassembly)
intouppertubes. Makesureallpartsareclean,greased,andinstalledin
theproperorder. (Seeexplodeddiagram,pages7-10)
CAUTION: BE SURE TO PROPERLY INSTALL CARTRIDGE WASHER AND WAVE WASHER
BETWEEN THE CARTRIDGE AND SNAP RING.
Fig. 8
Fig. 9 Fig. 10

6. Installsnaprings,sharpoutsideedgefacingoutintouppertuberinggrooves. Makecertaincartridge
washer,wavewasher,andsnapringareorientedcorrectly,andthesnapringsarefullyseatedinthering
grooveoftheuppertubes.
CAUTION:THE SNAP RINGS MUST BE PROPERLY ORIENTED,SHARP OUTSIDE EDGE FACING OUT,AND FULLY SEATED IN THE RING
GROOVE OF THE UPPER TUBES.
7. FollowproceduresunderMaintenanceprocedures,Aftereverymonthor25hoursofriding,page12,
tocompleteassembly.
TYPE II SPRING REPLACEMENT
TheTypeIIspringsysteminJudyforksprovidecuttingedgeperformancewiththelivelyactionofacoilspring
andthelightweightprogressivenessofanMCU. However,overtimethespringscanwearout,compromising
performance. This is evident in compression set,when the coil spring and the MCU are shorter in a resting
statethantheywerewhennew. FollowthetablelistedbelowasaguidetoknowwhentoreplacetheTypeII
SpringSystem.FollowdirectionstocleanandgreasespringstackfoundintheMaintenanceprocedures,After
everyweekor8hoursofriding,page11,forremovalandinstallation.
TYPE II SPRING SYSTEM SPECIFICATION TABLE
Model Coil MCU
Nominal Replace Nominal Replace
63mmJUDYs 51mm 46mm 100mm 94mm
80mmJudys 51mm 46mm 115mm 108mm
CARTRIDGE SERVICE
TheJudycartridgeisdesigned tobe fullyserviceable. The oilinthecartridgeprovidesthedamping forthe
entirefork andovertimewill breakdown. Atleastonceaseason,havethe cartridgerebuilt(oilchange) to
maintain optimal performance. The best performing cartridges are those with the least amount of air.The
cartridge canberemovedbyfollowingChangingTravelsectionaboveinordertocheckforairpocketsand
oilloss.
NOTE:CARTRIDGE SERVICE REQUIRES ROCKSHOX SPECIALTY TOOLS.WE RECOMMEND THIS LEVEL OF SERVICE BE DONE BY A
QUALIFIED BIKE SHOP OR MECHANIC FAMILIAR WITH OUR PRODUCTS AND THIS PROCEDURE.
NOTE:CARTRIDGE SERVICE MANUAL ADDENDUMS ARE AVAILABLE THROUGH YOUR DEALER OR THROUGH ROCKSHOX DIRECT.
BUSHING REPLACEMENT
ThehighqualitybushingsinRockShoxforksaredesignedtolastmanymonthsofhardriding. Theprotective
boots,acleanfork,andtimelygreasingarethekeystohighperformanceandlongbushinglife. However,like
allmovingparts,bushingswilleventuallywearandneedreplacement. Increasedforeandaftmovementof
uppertubesinlowertubes(similartoalooseheadset)and/orslowaction,evenafterafreshgreasing,signal
theneedtoremoveandreplacethebushings.
NOTE:THISSERVICE REQUIRES ROCKSHOX SPECIALTYTOOLS.WERECOMMENDTHIS LEVEL OFSERVICE BE DONE BYA QUALIFIED
BIKE SHOP OR MECHANIC FAMILIAR WITH OUR PRODUCTS AND THIS PROCEDURE.

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 FORKTHAT IS RETURNED TO THE FACTORY AND IS FOUND BY ROCKSHOXTO 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 FORKTHAT HAS BEEN SUBJECTTO 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
IFFOR ANY REASON ITSHOULDBE NECESSARYTOHAVEWARRANTYWORKDONE,RETURNTHE FORKTOTHEPLACEOF PURCHASE.INTHEUSA,
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. 408.433.5815
2713N. FIRST STREET FAX[phone]
SAN JOSE,CA95131 TOLL-FREETECHNICAL SUPPORT INTHE USA800.694.0668
CUSTOMERS IN COUNTRIES OTHERTHAN THE USASHOULD CONTACT THEIR LOCAL DEALER OR DISTRIBUTOR.
Worldwide 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]
France
PhilamyS.A.
Phone[phone]
FAX[phone]
Germany
SportImportGmbH
Phone[phone]
FAX[phone]
Greece
Gatsoulis
Phone[phone]
FAX [phone]
Guatemala
BikeCenter
Phone[phone]
FAX[phone]
Holland
VERTEXCycleSystemsBV
Phone[phone]
FAX[phone]
HongKong
FlyingBallBicycleCo.
Phone[phone]
FAX[phone]
Israel
C.T.C.Ltd.
Phone[phone]
Fax[phone]
ItalyMotorquality
Phone[phone]
FAX[phone]
Luxumbourg
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]

Félicitations! Vous voici propriétaire d’une
suspension RockShox, la meilleure qui soit
sur le marché, en ce qui concerne les cycles
tout terrain. Les fourches RockShox sont
fabriquées avec des matériaux légers et extrêmement
résistants et elles sont conçues pour joindre aux exigences
de hautes performances une facilité d’entretien. Le
présent manuel contient d’importantes informations
concernant l’installation, le fonctionnement et l’entretien
de votre nouvelle fourche, en toute sécurité. Nous vous
recommandons de lire attentivement ces instructions, de
vous familiariser avec leurs directives et de suivre celles-ci
afin que votre cycle tout terrain vous donne un maximum
de satisfactions et un minimum de désagréments.
®
TubeduGuidon
TêtedelaFourche
MontantduFrein
BoulondelaTige
(concaveuniquement
danslaversionDH)
TubeSupérieurdelaFourche
(jointanti-poussière)
BoutondeRéglagedePrécharge
ÉtrierÉlastiquedela
FourcheenUnePièceet
EnsembleduTubeInférieur
(XC,SL,DH)
BoulonConcavedelaTige
(XC,SL,DH)

CaractéristiquesTechniques des Fourches Judy
• VéritableNouvelEnsembled’ÉtrierÉlastiquedeTubeInférieurFonduenCoquilleen“UnePièce”
(XC,SL,DH)
• NouveauSystèmedeRessortsdeTypeII.ActionvigoureuseduressortàboudinetduMCUlégeràaction
progressive.Trèsfacileàréglerpourtoustypesdecyclistes.DisponiblesurtouteslesfourchesJudy.
• Cartouched’amortisseurhydrauliqueenaluminiumàcompressionréglable.Amortissementplus
résistant,meilleuredispersiondelachaleuretperfectionnementdelafiabilité.Disponiblesurtoutes
lesfourchesJudy.
• JointResiwiperExceptionnel.Nettoieetlubrifielestubesdelafourchesupérieure.(XC,SL,DH)
• TubesEastonsupérieursconiquesenaluminiumde28mmdediamètre(XC,SL,)
• ConstructionlégèredelatêtedelafourcheetdutubeduguidondelaversionSL.
• 15.24cmderecouvrementdecontactàglissement
• Têtedefourcheenalliageparticulièrementrenforcé
• LaversionDHestéquipéed’unecartouched’amortisseurdevibrationsréglable
• SurlaversionJudySL,boutonderéglagedelacompressionexternedel’amortisseur.
ÉQUIPEMENT STANDARD (FOURNI AVEC JUDY/FOURCHE ACHETÉE SÉPARÉMENT)
VersiondeDébattementde63mm-(2x)ArrêtdeRessort,RégleurdeTensiondeRessort,Beige(tendre)
VersiondeDébattementde63mm-(2x)ArrêtdeRessort,RégleurdeTensiondeRessort,Gris(dur)
VersiondeDébattementde80mm-(2x)ArrêtdeRessort,RégleurdeTensiondeRessort,Noir(moyen)
VersiondeDébattementde80mm-(2x)ArrêtdeRessort,RégleurdeTensiondeRessort,Gris(dur)
PourtouslesmodèlesJudy-(1x)GraisseJudy,28.35grammes
PourtouslesmodèlesJudy-(1x)Cléhexagonalede3mmpourréglerlacartouche
(nepeuts’appliqueraumodèleJudySL)
ÉQUIPEMENT EN OPTION
SetdeRessortàBoudinTendre-TensiondeRessort100LB(45.5kg)
SetdeRessortàBoudinTendre/Moyen-TensiondeRessort120LB(54.5kg)
SetdeRessortàBoudinDur-TensiondeRessort160LB(72.7kg)
Régleur(s)deCompressionExternepourversionsJudyXCetDH(x2)
KitdeCartoucheLongDébattementde80mm(JudyC/XC/SL)
KitsdeRéglagedeTypeII
100-140#(45.4-63.6kg)
140-200#(63.6-90.9kg)

CONDITIONS D’USAGE
MONTER SUR UN CYCLE NE VA PAS SANS DANGER.IL EST ENCORE PLUS DANGEREUX DE NE PAS EFFECTUER D’INSPECTION OU
D’ENTRETIEN RÉGULIERS DE VOTRE CYCLE.IL EST DANGEREUX ÉGALEMENT DE NE PAS LIRE LES INSTRUCTIONS SUIVANTES.C’EST
POURQUOI,SI VOUS DÉCIDEZ D’UTILISER NOTRE FOURCHE,NE PRENEZ PAS DE RISQUES :LISEZ CES INSTRUCTIONS !
1. Lesfreinsdoiventêtreinstallésetrégléscorrectement.Silesfreinsdevaientnepasfonctionner
correctement,lecyclistepourraitencourirdesblessuresgraveset/oumortelles.Avantdemonteren
selle,assurez-vousquelesfreinssoientinstallésetrégléscorrectement.
2. N’utilisezlafourchequ’avecdesfreinsdetypeàcantilevermontéssurlesmontantsdemontageprévusà
ceteffet.Cettefourcheestconçueethomologuéeuniquementpourlesfreinsdetypeàcantilevermontés
surlesmontantsprévusàceteffet.Lesfourchesavecdesétriersélastiquessanssupportontétéconçues
pourletypeenVoupourdesfreinsàcantileverhydrauliques.N’utilisezpasdefreinsàcantilever
différentsdeceuxquiontétéprévusparlefabriquantpourlesétriersélastiquessanssupport.Nefaites
paspasserlecâbledufreinavantet/oul’ensembleducâbleàtraverslabarreoutoutautremontantou
arrêtdecâble!N’utilisezpasdesystèmedelevierdecâbledefreinavant,montésurl’étrierélastique.
N’utilisezpasdefreinsàdisquesmontéssurletubeinférieurexterne.Eneffet,lestubesinférieursn’ont
pasétéconçuspoursoutenirleseffortsquedetelsfreinspourraientleurimposeretilsepourraitquedes
défaillancesdespartiesportantessevérifientaucasoùd’autressystèmesoutypesdefreinsqueceuxà
cantileversoientmontéssurlafourche.Detellesdéfaillancesmécaniquespourraientprovoqueruneperte
decontrôleducycleetrisquerdecauserd’éventuellesblessuresgraveset/oumortelles.
3. Prenezlesplusgrandesprécautionsquandvousplacezvotrecycledansunporte-cycle.Lorsquevous
placezuncycledansunporte-cycleparlemoyeudelafourche(roueavantôtée),faitesattentionànepas
inclinerlecycled’uncôtéoudel’autre.Aucasoùlecyclesetrouvaitinclinépendantquelesmoyeuxsont
engagésdansleporte-cycle,lebranchementdelafourcherisquedesubirdesdommagesstructurels.La
rouearrièredoitelleaussiêtrefixée.Nepaslafixerpourraitsignifierquelamasseducyclesedéplace
latéralementsurlesmoyeux,cequipourraitlesbriseroulesfêler.Vérifiezquelarouearrièresoitfixéeen
place(cecivautaussipourlesmontantsdesBikeTite).Silecycles’inclinelatéralementoutombedu
porte-cycle,nepasmontersurcelui-ciavantd’avoireffectuéuncontrôleappropriédelafourche,pour
détecterd’éventuelsdommages.Encasd’éventuelsdommages,renvoyezlafourcheàvotre
concessionnairepourqu’illavérifieouappelezdirectementlaSociétéRockShox.(Veuillezconsulterla
listedenosServicesTechniquesénumérésparpays,quevoustrouverezàladernièrepagedece
manuel).Toutdommageaubranchementdelafourcheouaumoyeupourraitdonnerlieuàunepertede
contrôleducycleetrisquerdeprovoquerd’éventuellesblessuresgraveset/oumortelles.
4. Aucasoùlafourchedevaitdonnerdessignesdeperted’huileoudecompressionexcessive,descendez
immédiatementdeselleetfaitescontrôlerlafourcheparvotreconcessionnaireouappelezdirectement
laSociétéRockShox.Lefaitdecontinueràutiliservotrecycledansl’uneoul’autredecesconditions
pourraitdonnerlieuàunepertedecontrôleducycleetrisquerdeprovoquerd’éventuellesblessures
graveset/oumortelles.
5. N’utilisezquedespiècesderechangeRockShox.Lefaitd’utiliserdespiècesderechanged’occasion
annulelagarantieetpourraitêtreàl’origined’unepertedecontrôleducycleetrisquerdeprovoquer
d’éventuellesblessuresgraveset/oumortelles.
ATTENTION : LES FOURCHES ROCKSHOX SONT CONÇUES POUR UN CYCLISME COMPÉTITIF TOUT TERRAIN ET CE TYPE DE CYCLE N’EST PAS FOURNI DES
CATAPHOTES APPROPRIÉS À L’USAGE SUR ROUTE.VOTRE CONCESSIONNAIRE DEVRA DONC LES INSTALLER AFIN QUEVOTRE CYCLE SOIT CONFORME AUX NORMES DE
LA CPSC(COMMISSION DE PROTECTION DU CONSOMMATEUR),SI VOUS AVEZ L’INTENTION D’UTILISER VOTRE CYCLE SUR DES ROUTES PUBLIQUES.