SUNTOUR RS6-XC PRO-LO User manual

SR SUNTOUR workshop book, version 2008/Mar/25 page 3
workshop bookworkshop book
English
Warning!
Only trained bike mechanics are allowed to carry out repairs and service work on
SR SUNTOUR suspension forks.
Deutsch
German
Achtung!
Es ist ausschließlich ausgebildeten Zweiradmechaniker erlaubt Reparatur- und
Servicearbeiten an SR SUNTOUR Federgabeln vorzunehmen.
Français
French
Attention!
Uniquement les mécaniciens cycle certiés sont autorisés à réparer et entretenir
les fourches SR SUNTOUR
Italiano
Italian
Attenzione:
Escluso persone istruiti e qualicati in meccanico di biciclette e permesso di
aggiustare le SR SUNTOUR forcelle, non appena i lavori di servizi.
Česky
Czech
*POZOR!
Opravy a servisní práce na vidlicích SR SUNTOUR jsou povoleny pouze
proškoleným mechaniku*m
Polski
Polish
Uwaga!
Tylko przeszkolonym mechanikom rowerów wolno dokonywać napraw i serwisu
widelców amortyzowanych rmy SR SUNTOUR
Español
Spanish
ATENCION!
Sólo se permite llevar a cabo trabajos de reparación y servicio en las horquillas de
suspension de SR SUNTOUR a mecánicos de bicicleta competentes.
Русский
Russian
Внимание!
Ремoнт и сервисные работы по вилкам SR SUNTOUR разрешается
производить исключительно специализированным и обученным механикам.
中文
Chinese
注意 !
只有接受過訓練的技工才會被允許進行修補 SR SUNTOUR 的避震前叉及服務性
質的工作.
日本語
Japanese
注意 !
SR SUNTOUR のサスペンションホークは訓練を受けたメカニックのみ修理およ
びサービス
が許されています。
Български
език
Bulgarian
Внимание!
Амортисьорните вилки SR SUNTOUR, могат да бъдат ремонтирани и
поддръжани, само от оторизирани механици преминали курсовете за
обучение!
Disclaimer

SR SUNTOUR workshop book, version 2008/Mar/25 page 5
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Table Of Contents
Disclaimer..........................................................................................3
I. Introduction ................................................... 7
Introduction .....................................................................................8
Abbreviations...................................................................................9
Addresses .......................................................................................10
SR SUNTOUR corporate..................................................................................10
Worlwide Distributors ....................................................................................10
II. Owner’s manuals ......................................... 13
Suspension Front Fork with Coil Spring or MCU.............. 14
Suspension Front Fork with <Air/Air> / <air/hydraulic>
or <coil spring/hydraulic> system ......................................16
Rear Shock: Suntour RS6-XC PRO-LO, RS6-XC Pro-RL,
RS7-EPICON-DA............................................................................ 21
DH-CT-600-Series Hub Dynamo.............................................25
III. Service manuals ......................................... 27
Mounting the remote lock-out single lever.......................28
Lock-out function setting..............................................................................30
Mounting the remote lock-out single lever.......................31
Lock-out function setting:.............................................................................33
Mounting and Operating the remote travel
adjust control – New TA Lever.................................................34
Mounting and Operating the remote travel
adjust control – Old TA Lever ..................................................36
Travel adjustment setting .............................................................................38
Operating the hydraulic rebound damping......................39
Use and function of the hydraulic rebound damping ...........................39
Increase rebound speed.................................................................................39
Fork Model: Duro 2006...................................................................................39
Fork Model: Duro DJ 2007 - 2008.................................................................39
Fork Model: Axon / Epicon ............................................................................39
Decrease rebound speed ...............................................................................40
Fork Model: Duro DJ 2006.............................................................................40
Setting the SAG for SR Suntour Forks...................................41
Setting SAG for air spring forks....................................................................41
Setting sag for rear suspension....................................................................44
Use and function of the Lock-Out system..........................45
Function of the Lock-Out knob:...................................................................45
IV. Instruction Sheet for Suspension
seat post SP-NCX-D3and SP-NEX-D4 ............. 47
Suspension Seat Post Instruction Sheet.............................. 48
Before using the suspension seat post .......................................................48
Installation of the Suspension Seat Post ...................................................49
Installation of the saddle...............................................................................49
Performance Tuning .......................................................................................51
How to increase the preload of the suspension seat post? ...................51
How to change coil springs...........................................................................52
V. Charts ........................................................... 55
Overview of the fork systems..................................................56
Suspension Fork Air Pressure and Oil Level Chart ........... 58
Rear Shock Pressure and Oil Level Chart............................. 61
Coil Spring Chart..........................................................................62
Maximum possible rotor diameter .......................................71
Serial Number Explanation......................................................72
Tightening Torque Chart...........................................................73
Oil Type Chart ...............................................................................74
VI. Fork Maintenance Manuals ...................... 75
Fork Maintenance........................................................................ 76
Maintenance .................................................................................76
Regular Maintenance:................................................................76
Important advice for fork service...........................................77
How to Replace Remote-Lock-Out +
Damping (RLD) cartridge..........................................................78
How to replace Remote-Lock-Out +
Damping (RLD) cartridge ........................................................82
How to replace Lock-Out (LO) cartridge ............................ 85
How to replace the Travel-Adjust (TA) cartridge .............. 89
Old travel adjust top cap unit.......................................................................89
New travel adjust top cap unit.....................................................................92
How to solve air leaking problems .......................................94
How to solve hydraulic Lock-Out issues..............................96
How to solve Mechanical-Lock-Out (MLO) issues............98
How to convert the travel of an Axon fork.......................103
How to convert the travel of an
Epicon Suspension fork...........................................................108
How to change slider sleeves (plugged dust seals) .....113
How to change slider sleeves (pressed-in dust seals) .116
VII. Exploded views
SR SUNTOUR Suspension Forks ................... 119
SF7AXON-RLD.........................................................................................................120
SF7CR-8R..................................................................................................................121
SF7CR-8R-MLO .......................................................................................................122
SF7CR-8V-MLO........................................................................................................123
SF7CR-8V ..................................................................................................................124
SF8DUROLUX20-TS................................................................................................125
SF8DUROLUX 20-1.5..............................................................................................126
SF8 DURO FR20-160...............................................................................................127
SF7DURO-DJ-D.......................................................................................................128
SF7DURO-DJ-E .......................................................................................................129
SF8EPICON-RLD......................................................................................................130
SF7EPICON-RL.........................................................................................................131
SF8EPICON-LOD .....................................................................................................132

SR SUNTOUR workshop book, version 2008/Mar/25, page 6
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SF7EPICON-LO ........................................................................................................133
SF7EPICON-RLD......................................................................................................134
SF7NEX4610-HLO-700-63....................................................................................135
SF8NEX4610-MLO-700-63 ...................................................................................136
SF8NEX4100-26-63 ................................................................................................137
SF8NEX4110-700-63 ..............................................................................................138
SF8NEX4600-HLO-26-63......................................................................................139
SF8NEX4600-MLO-26-63 .....................................................................................140
SF8NEX4510-MLO 700c ........................................................................................141
SF7NCX-E-RL-700-75 .............................................................................................142
SF8NCX-E-LO-700-63............................................................................................143
SF7NCX-D-RL-700-63........................................................................................... 144
SF7NCX-D-LO-700-63...........................................................................................145
SF7NCX-D-700-63..................................................................................................146
SF8NRX S-RLD.........................................................................................................147
SF8NRX S-RL ............................................................................................................148
SF8NRX S-LOD-63..................................................................................................149
SF8NRX S-LO............................................................................................................150
SF8NRX E-RL ............................................................................................................151
SF8NRX E-LO-63 .....................................................................................................152
SF7NRX-LO-63 ........................................................................................................153
SF8RAIDON-RL-air.................................................................................................154
SF8RAIDON-LO-air................................................................................................155
SF8RAIDON-RLD ....................................................................................................156
SF8RAIDON-LOD....................................................................................................157
SF8RAIDON-LO.......................................................................................................158
SF7X1-LO ..................................................................................................................159
SF7XCM-HLO...........................................................................................................160
SF7XCM-MLO 26” ...................................................................................................161
SF7XCM-DA 26” ......................................................................................................162
SF7XCM 26”..............................................................................................................163
SF7XCR-RL............................................................................................................... 164
SF7XCR-LO ...............................................................................................................165
SF7XCR-DA...............................................................................................................166
SF7XCR ......................................................................................................................167
SF8XCT V2 ............................................................................................................... 168
SF8XCT V2-MLO......................................................................................................169
SF7 RL Remote Assembly......................................................................................170

chapter I
Introduction

SR SUNTOUR workshop book, version 2008/Mar/25, page 8
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Introduction
Dear Customer,
We would like to present you our new workshop book. It was developed to provide you with all necessary
technical information about our products. Additionally it will give you a better understanding how our
forks are designed and how they can be serviced.
Pictures are always just a snapshot, therefore it’s sometimes hard to understand what the working step
really tries to explain. Moreover it’s a fact that not everyone speaks English! This led us to the decision to
produce video manuals in which every little working step is explained. We consciously avoided nearly
100% of any written working instruction within these videos and worked instead with symbols which are
known international.
The “video manuals” will give you the opportunity to learn how to repair SR SUNTOUR forks step by step.
In addition these videos can be used as an educational lm during workshops for local dealers. We have
enclosed a DVD at the last page of the workshop book. On this DVD you will nd 10 video manuals which
cover all major service issues plus it includes all exploded views of our 2006/2007/2008 suspension fork
line up. In combination with the videos they will give you a powerful tool to maintain SR SUNTOUR forks.
Nevertheless not everybody has a computer in their bike workshop to watch the videos and repair the fork
at the same time. Because of that we have additionally converted all videos into picture stories which you
will nd in chapter V.
We would like to give you a short overview about what you will nd within this workshop book. In chapter
II you will nd all fork and rear suspension instruction sheets. Chapter number III provides you with all nec-
essary information about the assembling of our dierent remote levers. Additionally it will give you better
understandings how our lock out and rebound systems are working. One very important subitem within
chapter number III is the instruction “How to set SAG”. In combination with the oil and air pressure chart it
will help you to set the proper SAG for each of your customer’s forks.
In chapter number VI we have put together all necessary technically information about SR SUNTOUR forks.
You will nd all picture stories in chapter number V. It also includes instructions how to convert the travel
of EPICON and AXON forks. All questions regarding our suspension seat posts can be answered in chapter
number IV. And within the chapter VII you will nd all exploded views of our 2007-2008 suspension fork
models.
A workshop book can never be nished as you always have small changes of the systems even during the
year. Moreover some people might have some needs which are not covered within this book. Any time
you may feel to have an idea which could contribute to an improvement of this book you are welcome to
let us know!
We would like to thank you for the trust in SR SUNTOUR products and wish you the best for the 2008 bike
season!
Best Regards
YOUR SR SUNTOUR TEAM

SR SUNTOUR workshop book, version 2008/Mar/25 page 9
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Abbreviations
All Suspension Forks
DA DAMPING ADJUST
ELD
ELECTRONICAL LOCK OUT + DAMPING
ADJUST
HLO HYDRAULIC LOCK OUT
LO LOCK OUT
LOD LOCK OUT + DAMPING ADJUST
MLO MECHANICAL LOCK OUT
RL REMOTE LOCK OUT
RLD REMOTE LOCK OUT + DAMPING ADJUST
TAD TRAVEL ADJUST + DAMPING ADJUST
TR TRAVEL ADJUST + REMOTE LOCK OUT
NRX MODELS
SAIR
E COIL SPRING
NCX MODELS
SAIR
EAIR
D COIL SPRING
DURO
DJ E CroMo STEERER TUBE
DJ D STKM STEERER TUBE
AXON MODELS
SAIR
EAIR
D COIL SPRING
RADOM
CW CHAIN WHEEL
CS CASSETTE
SL SHIFT LEVER
RD REAR DERAILLEUR
FD FRONT DERAILLEUR
DB DISC BRAKE
SP SEAT POST
FT FIRM TECH

SR SUNTOUR workshop book, version 2008/Mar/25, page 10
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Worlwide Distributors
AUSTRIA
KTM FAHRRAD GMBH
Harlochner Str. 13
5230 Mattighofen
Austria
Tel.: [phone]
Fax: [phone]
email: o[e-mail]
web: www.ktm-bikes.at
BENELUX
Juncker Bike Parts
Fokkerstraat 25
3905 KV Veenendaal
The Netherlands
Tel.: [phone]
Fax: [phone]
email: [e-mail]
web: www.juncker.nl
BRAZIL
Intac
Rue alba; 1737-V. Santa; Catarina
04346-000, Sao Paulo
Brazilia
Tel.: [phone]
COLOMBIA
HA BICICLETAS
Calle 14 No. 52A-187
Apartado
Aero 368
Medellin
Colombia
Tel.: [phone]
Fax: [phone]
email: [email protected]
CZECH REPUBLIC
BP LUMEN
Mr. Lukas Barta
Puskinova 546
542 32 Upice
Czech Republic
Tel.: [phone]
Fax: [phone]
email: [email protected]
web: www.bplumen.cz
FRANCE
Winora France
France
tel.: [phone]
Fax: [phone]
email: [e-mail]
FRANCE
SAV SR Suntour France (Service)
Allee Ruby 10
38500 Voiron
France
Tel.: [phone]
Fax: [phone]
email: [e-mail]
GERMANY
E.Wiener Bike Parts GmbH
Max-Planck-Str. 8
97526 Sennfeld
Postfach 15 61, 97405 Schweinfurt
Germany
tel.: [phone]
fax: [phone]
GERMANY
Zweirad-Einkaufs-Genossenschaft ZEG
Longericher Str. 2
50739 Köln
Germany
tel.: [phone] - 20
fax: [phone] - 31
Addresses
SR SUNTOUR corporate
EUROPE
SR SUNTOUR Europe GmbH
Am Marschallfeld 6a
83626 Valley
Germany
Tel.: [phone]
Fax: [phone]
email: [email protected]
TAIWAN
SR SUNTOUR Inc.
#7 Hsing Yeh Rd
Fu Hsing Industrial Zone
Chang Hua
Taiwan, R.O.C.
Tel.: [phone]
Fax: [phone]
email: [e-mail]
web: www.srsuntour-cycling.com
CHINA
SR SUNTOUR (Shen Zhen) Inc.
Suibei Industrial Zone Suibei Road
Gongming Town, Baoan District
Shen Zhen
Tel.: [phone]
Fax: [phone]
CHINA
SR SUNTOUR Machinery (Kunshan)
Co.Ltd.
388 Matang Road PengLang, KunShan
development zone JiangSu Province
CHINA
ZIP 215333
Tel.: [phone]
Fax: [phone]
USA
SR SUNTOUR USA
503 Columbia street,
Vancouver, WA 98660
USA
Tel.: [phone]
Fax: [phone]
email: [email protected]

SR SUNTOUR workshop book, version 2008/Mar/25 page 11
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HUNGARY
Neuzer KFT
H-1211 Budapest, Csepel Muvek,
Gyepsor UT 1
Hungary
tel.: [phone]
fax: [phone]
email: neuzer[email protected]
web: www.neuzer-bike.hu
ITALY
SAIM S.P.A.
Via Leon Battista Alberti 10
20149 Milano
Italy
Tel.: [phone]
Fax: [phone]
email: [e-mail]
JAPAN
Riteway Products Japan
102 Ikebukuro city-hights
3-18-34 Minami Ikebukuro
Toshima-ku, Tokyo
Japan
Tel.: [phone]
Fax: [phone]
email: [e-mail]
web: www.riteway-jp.com
MEXICO
BICICLO S.A. DE C.V.
Eje 126, No. 265 zona ind. del potosi
San luis potosi, S.L.P. 78395
Mexico
tel.: [phone]
fax: [phone]
email: [email protected]
web: www.turbo.com.mx
POLAND
Euro Bike Products
ul. Starolecka 18
61 361 Poznan
Poland
tel. [phone],
web: www.eurobike.pl
RUSSIA
Alna-Bike Co.
Sokolnicheskaya square 4
Moscow 107 113
Russia
tel / fax: [phone]
email: [email protected]
SLOVAKIA
KCK CYKLOSPORT-MODE s.r.o.
Mierova 854/37
972 47 Oslany
Slovakia
Tel.: [phone]
Fax: [phone]
email: [e-mail]
web: www.kck-oslany.sk
SPAIN
BH, S.A. BICICLETAS DE ALAVA S.A.
Arcacha 1
01006 Vitoria
Spain
Tel.: [phone] / 13 57 08
Fax: [phone] / 23 48 10
SWITZERLAND
SUSPENSION CENTER
Gurnigelstr. 11
3132 Riggisberg
Switzerland
tel.: [phone]
fax: [phone]
email: suspension.cent[email protected]
web: www.suspensioncenter.ch
U.K.
GREYVILLE ENTERPRISES
20 Europa way britannia enterprise park
Licheld, Stas. WS14 9TZ
U.K.
Tel.: [phone]
Fax: [phone]
E-MAIL: [e-mail]
U.K.
MOORE LARGE & CO. LTD
Derby DE24 9GL
Sinn lane
Sinn lane industrial estate
U.K.
Tel.: [phone]
Fax: [phone]
email: [email protected].uk

chapter II
Owner’s manuals

Owner‘s Manual
Suspension front fork w. coil spring or MCU
1.) Before riding the bicycle, be sure the brakes are properly installed and adjusted.
If the brakes do not work properly, the rider could suffer serious injuries.
2.) Do not ride the bicycle if you notice bent or broken parts at the fork, especially after a collision,
sounds of excessive topping out, or other indications of a possible fork failure.
In these cases, take your bike to a qualified bicycle mechanic for inspection and repair.
3.) Always use genuine SR Suntour parts. Use of other replacement parts voids the warranty
and could cause structural failure to the suspension fork.
Read this instruction sheet thoroughly before using the suspension fork. Using the suspension fork inappropiately may cause serious injuries. Be sure to
follow all warnings and caution indications. The instruction sheet contains important information on the correct installation and usage of the fork. After
reading this instruction sheet, please be sure to keep it in a safe place for future reference. When transferring ownership of the suspension fork, give this
instruction sheet to the new owner. As with any new suspension fork, there is a short period within moving parts will break in. During the first 300-500
km, the ride dynamics of the fork may change slightly. One of the things you may notice, is a small amount of play in the lower tubes. This movement
is normal. Suspension forks can dramatically improve the comfort and control of your bicycle, but they can also change the way it handles, so always
exercise caution and good judgement when getting used to your new setup.
IMPORTANT SAFETY INFORMATION
SR SUNTOUR recommends that your suspension fork be installed by a qualified bicycle mechanic, because it must be properly installed,
adjusted and checked for safety.
- The steerer tube must be cut to proper length correctly
- Special tools and skills are required
- If you install the fork by yourself, the completed installation must be inspected by a qualified
bicycle mechanic and signed off to validate your warranty.
Installation instructions:
The SR Suntour suspension forks are available both with threadless steerer and threaded ones:
choose the right headset depending on the type of steerer you have.
See manufacturer‘s installation guide for the headset and handlebar stem you are using!
-The SR SUNTOUR steerer tube may need cutting to the proper length.
-To cut the steerer tube is not a job for untrained people, so let a professional mechanic install the fork.
If you are going to tackle this job, get a good book on repairing bicycles and read it carefully. But in this
case our warranty is void and SR SUNTOUR is not liable for incidental or consequential damages.
Tire clearance:
Maximum tire size for the SR Suntour suspension forks is to be checked depending on the outer diameter for 28“/26”/24“ wheel size. Also, you
have to check the tire width and you have to allow a minimum of 5mm between tire and the fork‘s lowers. Please keep in mind that the narro-
west point at the lowers is usually at the height of the brake bosses - so you may have to deflate the tire in case you have to remove the wheel,
depending on the tire width.
Be sure to check the tire diameter and width whenever you change tires. To check the tire diameter, remove the top caps/or adjuster knobs and
spring stack assemblies and compress the fork completely to make sure at least 10 mm of clearance exists between the top of the tire and the
bottom of the crown. Exceeding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed.
If you want to retrofit the bike with mudguards, you have to take into account that the clearance between tire and mudguard is now changed.
Please check the clearance again as described above.
INSTALLATION
Handlebar Stems:
- Minimum insertion of handlebar stem (for threaded steerers)
There are two requirements: First, always insert the handlebar stem past the minimum insertion mark, as
indicated on the stem. Second, make sure that the handlebar stem is inserted at least 10mm beyond the
threaded length of the fork (see Fig 1.).
- When using a Ahead type handlebar stem, be sure to never clamp the stem onto the threaded section of the steerer
tube. Use a threadless steerer or cut off all the threads and use the threadless portion of a standard steerer.
Handlebar
stem
Minimum
insertion mark
Threaded
length
More than
10mm
Steerer
tube
Fig. 1
Headsets:
Make sure that the headset you use matches the dimensions of your fork and frame. Refer to the instruction
sheet that comes with your headset and carefully follow its instructions.
Brakes:
The SR Suntour suspension forks are designed to be used either only with V-type brakes or both with V-brake and discbrake. The use of discbrake
can be seen on the left side lower, where the discbrake mounting tabs are present. Max. rotor diameter 160mm. Only XCM & XCR = 185mm.
Please check the instruction manual of the brake manufacturer for technical details and dimensions.
You need to make sure that the cable housing of your brakes can move freely and does not come in contact with any part of the fork while moving.

Intended use
These types (only coil spring or MCU) of SR Suntour suspension forks are designed for leisure riding(swept blades type) and for
sports and exercise (leading axle type). These forks are not intended to be used in downhill racing ( see warning sticker on the fork )!!!
Notes on usage of the fork
LIMITED WARRANTY
SR SUNTOUR warrants the suspension front fork to be free from defects in materials and workmanship under normal use for a period of two years from
the date of purchase. In no event shall this limited warranty apply to any defect of the suspension fork caused by: improper installation, disassembly, re-
assembly, intentional breakage or damage, alterations or modifications to the suspension fork by the user or other party or any unreasonable use or abuse
of the product or any use for which this product was not intended. Plastic slider sleeves have only a limited warranty of 6 months from purchase.
The obligation of this limited warranty shall be limited to repairing or replacing the suspension fork or any part for which there is a defect in materials
or workmanship during the two years following the date of purchase. To validate this limited warranty the purchaser must submit this warranty card to
SR SUNTOUR within 30 days after purchase of the suspension fork. Any alteration of, or tampering with the warranty card automatically terminates this
limited warranty.
SR SUNTOUR makes no express or implied warranties of fitness or merchatability of any kind, except as set forth above. SR SUNTOUR’s liability he-
reunder is expressly limited to repair or replacement of the product. Under no circumstances will SR SUNTOUR be liable for incidental or consequential
damages. Some jurisdictions do not allow the exclusion or limitation of liability of incidental or consequential damages, so the above exclusion may not
apply to you. This warranty gives you specific rights and you may have other rights which vary from jurisdiction to jurisdiction.
In all places, the purchaser should contact the place of purchase for information about warranty service.
Date of purchase: Fork model name Serial no.
Term of limited warranty: Two years from the date of purchase
Dealer Name: Phone#:
Address:
Purchaser Name: Phone#:
Address:
This warranty is void without proof of purchase.
SR SUNTOUR EUROPE GMBH
Am Marschallfeld 6a, 83626 Valley / Germany
Phone: [phone] / Fax: [phone]
E-mail: [email protected]
SR SUNTOUR USA
503 Columbia street, Vancouver WA 98660, USA
Tel: [phone] / Fax: [phone] / E-mail: [email protected]
SR SUNTOUR INC.
Specifications are subject to change without notice.
Printed in TAIWAN.
Suspension Fork Warranty Card:
Adjusting Preload (where it applies)
The preload adjustment allows the user to tune the response of the suspension fork as riding conditions demand and in accordance to his
weight. The more preload you have, the more thrust it takes to get the fork to first move. The preload is adjusted by turning the preload
adjustment knob at the top of the stanchion tube.
Turning the adjustment knob clockwise increases the amount of preload, while turning the knob counterclockwise reduces the preload .
Please turn the adjustment knobs first fully counter-clockwise and then count the full turns you make clockwise. Please adjust always by the
same amount of turns on both sides.
SR Suntour website: www.srsuntour-cycling.com
If for any reason you feel that there is something wrong with the fork, by the way it handles or by unusual topping sounds, you
must immediately stop using it and you have to take it to the dealer from which it was purchased, for inspection.
FOR DETAILED INFORMATION, TARGET CATEGORY AND EXPLODED VIEW OF YOUR FORK, PLEASE VISIT OUR WEB-
SITE < WWW.SRSUNTOUR-CYCLING.COM> AND DOWNLOAD THIS INSTRUCTION SHEET FOR FUTURE REFERENCE!
After25hours
Afterevery ride
After50hours
MAINTENANCE
Clean the stanchion tubes and the dustseal area (models w/o dustboots)
Check for proper torque the main fixing bolts (10Nm) and top caps (3-4Nm)
Teflon oil
bushings at the dealer
FOR MORE TUNING OPTIONS - HARDER/SOFTER SPRINGS AND MCU - PLEASE CONTACT YOUR LOCAL DEALER
Oil the dustseal area with
SR SUNTOUR INC.
No.7 Hsing Yeh Road, Fu Hsing Industrial Zone,ChangHua,50606, Taiwan, R.O.C.
Tel:[phone] / Fax: [phone] / E-mail: [email protected]
SERVICE AT THE DEALER
1st. service Date:___________________ Signature of the dealer: ______________________ Stamp: __________________
2nd. service Date:___________________ Signature of the dealer: ______________________ Stamp: __________________
You may use also the dealer‘s own business stationary in order to prove the date and frequency of the service intervals.
Function check of the fork and clean and grease service of

Instruction Sheet
Suspension front fork with <air/air> / <air/hydraulic> or < coil spring/hydraulic> system
1.) Before riding the bicycle, be sure the brakes are properly installed and adjusted. If the brakes do not work properly, the rider could suffer serious injuries.
2.) Do not ride the bicycle if you notice bent or broken parts at the fork, especially after a collusion, sounds of excessive topping out, or other indications of
a possible fork failure. In these cases, take your bike to a qualified bicycle mechanic for inspection and repair.
3.) Always use genuine SR Suntour parts. The use of other replacement parts voids the warranty and could cause structural failure to the suspension fork.
Read this instruction sheet thoroughly before using the suspension fork. Using the suspension fork inappropiately may cause serious injuries.
Be sure to follow all warnings and caution indications. The instruction sheet contains important information on the correct installation and
usage of the fork. After reading this instruction sheet, please be sure to keep it in a safe place for future reference. When transferring ownership
of the suspension fork, give this instruction sheet to the new owner. As with any new suspension fork, there is a short period within moving
parts will break in. During the first 300-500 km, the ride dynamics of the fork may change slightly. One of the things you may notice, is a small
amount of play in the lower tubes. This movement is normal. Suspension forks can dramatically improve the comfort and control of your bicyc-
le, but they can also change the way it handles, so always exercise caution and good judgement when getting used to your new setup.
IMPORTANT SAFETY INFORMATION
SR SUNTOUR recommends that your suspension fork be installed by a qualified bicycle mechanic, because it
must be properly installed, adjusted and checked for safety.
- The steerer tube must be cut to proper length correctly
- Special tools and skills are required
- If you install the fork by yourself, the completed installation must be inspected by a qualified
bicycle mechanic and signed off to validate your warranty.
Installation instructions:
The SR Suntour suspension forks with hydraulic system are available only with threadless steerer:
choose the right headset for this „Ahead“ type of steerer. See manufacturer‘s installation guide for the headset and handlebar stem you are using!
-The SR SUNTOUR steerer tube may need cutting to the proper length.
-To cut the steerer tube is not a job for untrained people, so let a professional mechanic install the fork.
If you are going to tackle this job by yourself, get a good book on repairing bicycles and read it carefully. But in this
case our warranty is void and SR SUNTOUR is not liable for incidental or consequential damages.
INSTALLATION
1. Remove the existing fork and lower headset race from the bicycle.
- Measure the length of the fork steerer tube against the length of the SR SUNTOUR steerer tube to determine whether it may need cutting to the proper length
2. In order to find out the proper length of the steering tube, you have to add up the following dimensions:
- Head tube of the frame + stack height of the headset + stack height of the Clip on handlebar stem
3. Install the headset race firmly against the top of the fork crown. Install the fork assembly back on the bike.
4. Assemble the headset and handlebar stem on the bicycle. Adjust the headset so you feel no play or drag.
- Complete the installation of the headset and stem according to the manufacturer‘s instructions.
5. Reinstall the handlebar.
6. Install the brakes as per the manufactures instruction, making sure to adjust the brake properly.
-
Use the fork only with V-type brakes mounted to the existing cantilever bosses. Mount the disc brake only to the tabs provided at the left lower of the forks
7.
Run the brake cable from the brake lever to the brake (V-type brake or Disc brake) making sure to leave enough cable housing to allow full travel of the fork .
Handlebar Stems:
- Please use only “Ahead-type” handlebar stems for 1 1/8” (28.6mm) steerer diameter.
- Follow the handlebar stem manufacturer’s installation manual and please mind to use the proper torque for this safety item.
Headsets:
Make sure that the headset you use matches the dimensions of your fork and frame. Refer to the instruction
sheet or installation manual that comes with your headset and carefully follow its instructions.
Tire clearance:
Maximum tire size for the SR Suntour suspension forks is to be checked depending on the outer diameter
for 28“or 26” wheel size. Also, you have to check the tire width and you have to allow a minimum of 5mm between tire and the fork‘s lowers.
Please keep in mind that the narrowest point at the lowers is usually at the height of the brake bosses - so you may have to deflate the tire in case
you have to remove the wheel, depending on the tire width.
Be sure to check the tire diameter and width whenever you change tires. To check the tire diameter, remove the top caps/or adjuster knobs and
spring stack assemblies and compress the fork completely to make sure at least 10 mm of clearance exists between the top of the tire and the
bottom of the crown. Exceeding maximum tire size will cause the tire to jam against the crown when the fork is fully compressed.
If you want to retrofit the bike with mudguards, you have to take into account that the clearance between tire and mudguard is now changed.
Please check the clearance again as described above.
Brakes:
The SR Suntour suspension forks are designed to be used with V-brake and Discbrake. The use of discbrake can be seen on the left side lower, where
the Discbrake mounting tabs are present.
Please check the instruction manual of the brake manufacturer for technical details and dimensions.
You need to make sure that the cable housing of your brakes can move freely and does not come in contact with any part of the fork.
- 1 -

MOUNTING OF THE REMOTE TRAVEL ADJUSTER AND REMOTE LOCK-OUT CONTROL
Mounting of the remote travel adjuster control
You have the choice of two remote travel adjuster controls, depending on the
drive train and shifter types you are using.
Note: The travel adjustment cartridge is located on the left side of the fork.
1.) If you use „Rapid Fire“ type of shifters you have to use the single remote
travel adjuster lever included in the fork set (see photo # 1).
a.) Mount first the remote travel adjustment lever on the handlebar. Use a 3mm
Allen key for fastening of the lever bracket (see # 2). After that, you can mount
the brake lever and the shifting levers.
b.) Choose the right length of outer casing, in order to allow the unrestricted
function of the fork.
c.) Turn the cable tension adjustment barrel (see # 2) two turns counter-clock-
wise in order to have adjustment clearance for the travel adjustment function.
d.) Thread the cable through the outer casing stopper at the guide pulley and
push the outer casing cap firmly in the outer casing stopper (see photo # 3).
e.) Lead the cable around the guide pulley and thread it through the hole in the
fixing bolt. The fixing bolt, washer and nut have to be placed into the hook of
the cam lever. Tension the cable lightly and tighten the nut on the fixing bolt.
f,) Now press the lever and at the same time push on the handlebar in order
to compress the fork. At the end of this movement, release the lever and then
the handlebar. Check if the fork stays in that position. If not, then you have to
adjust the tension of the cable. To release the fork from that position, push the
lever again and pull the handlebar (see photo # 4).
Travel adjustment setting
a.) If the cable tension is too high, the cam lever will be pushed all the time
down. As such you will feel that the compression of the fork is too easy and the
fork will extend eventually too slow. In such case, decrease the cable tension
by turning the adjustment barrel (#5) clockwise (-), until the fork stops at the
desired level and it will extend when you push the remote action lever again.
b.) If the cable tension is too low, then the fork will not stay in the preselected
position after you release the lever. In order to increase the cable tension, turn
the adjustment barrel counter-clockwise (+), until the fork will stay in the
preselected position (see photo #5).
c.) In case you cannot adjust the fork using the adjustment barrel, you have
to open the cable fixing nut and increase or decrease the cable tension at this
point. After that, you can make the fine tuning again as described at a.) and b.).
Air pressure adjustment
In case it is necessary to increase or decrease the air pressure in the travel
adjustment cartridge, please proceed after the following steps:
a.) Turn the adjustment barrel fully clockwise (-) and unhook the fixing bolt
unit from the cam lever (see photo #7).
b.)
Remove the travel adjust push button. You will see now the „Schrader“ valve.
c.) Using a fork pump with pressure gauge, increase or decrease the air pressure
in accordance with the chart displayed on the next page.
If you have a fork with air cartridge on the other side, please use the setting
of the air chart on the SR Suntour website, attached to your fork model.
2.) There is an option to use the I.C.E. (Integrated Control Equipment) type of
lever - model DSM-XCR60-SC - for travel adjustment and remote lock-out.
Mounting of the lock-out control
1.) If you use „Rapid Fire“ type of shifters you have to use the single remote
lock-out lever included in the fork set (see photo #9).
a.) Mount first the remote lock-out lever on the handlebar. Use a 3mm Allen
key for fastening of the lever bracket (see #9). After that, you can mount the
brake lever and the shifting levers.
b.) Choose the right length of outer casing, in order to allow the unrestricted
function of the fork.
c.)
Turn the cable tension adjustment barrel two turns counter-clockwise
(#14)in order to have adjustment clearance for the lock-out adjustment function.
d.) Thread the cable through the outer casing stopper and trough the cover cap
hole and push the outer casing cap firmly in the outer casing stopper (#11).
e.) Tension the cable lightly and tighten the fixing screw using a slot or cross
type screwdriver.
f,) Now push the lever to the right (see photo # 10) in order to lock the fork.
Check if the fork is now locked, by pushing down the handlebar. If not, you
have to adjust the tension of the cable.To unlock the fork, push the lever to the
left and check if the fork is now unlocked.
Lock-out function setting
a.) If the cable tension is too high, the lock-out lever will not stay engaged and
keep the fork in locked position. In such case, decrease the cable tension by tur-
ning the adjustment barrel (#14) clockwise (-), until the lever will stay engaged.
b.) If the cable tension is too low, then the fork will not be locked when you
engage the lever. In order to increase the cable tension, turn the adjustment
barrel counter-clockwise (+), until the fork will stay locked and the lever is still
engaged.
c.) In case you cannot adjust the fork using the adjustment barrel, you have to
open the cable fixing screw and increase or decrease the cable tension at this
point (see #13). After that, you can make the fine tuning again as described at
a.) and b.).
Don‘t forget to put an end cap on the cable for your protection (see #11).
Fixing bolt. Use a 3mm Allen key.
Cable tension adjustment barrel.
Cable nipple. Shifting cable type.
Cable
fixing bolt
Cable guide
pulley
Cam lever Press the lever and then the
handlebar to check the function.
For your
protection,
insert an
end cap at
the cable end.
Decrease
tension.
Increase
tension.
Cam lever
released.
Travel adjust
push button.
„Schrader“
valve for air
pressure adjust.
-
+
In this position, the
fork is now locked.
Lever bracket
fixing bolt.
O u t e r
casing
stopper
Cable
clamping
screw.
Cable tension adjustment barrel.
Here, the barell is screwed in
completely. The support spring has to
have space between the coils, in order
to allow less cable tension adjustment.
Less
tension.
More
tension.
Cable
clamping
screw.
Pass the cable through
this hole below the cable
clamping screw.
For your
protection,
insert an
end cap at
the cable end.
1
2
3
4
5 6
7
8
9
10
11 12
13 14
- 2 -

Fork performance tuning
The SR Suntour suspension forks can be tuned for your particular weight, in accordance with the terrain
and your personal preferences.
Setting Sag
Suspension forks will sag(dive in) more or less, depending on your weight and fork setting, when you mount
the saddle and sit on your bike.
The proper adjustment of sag allows the front wheel to keep contact with the ground during the ride. Sag is adjusted by
increasing or decreasing (depending of the fork model) - a.) the positive air pressure / b.) the preload on the spring stacks .
Travel Intended use Sag
80 mm Racing 8-12 mm
80 mm XC 12-16 mm
100 mm Racing 10-14 mm
100 mm XC 14-18mm
130 mm Freeride 20-25mm
To measure the amount of sag your fork is diving in, install a zip tie on the stanchion tube, at the level of the lower
tube seal. Now, mount the saddle and sit on the bike in normal riding position, ride a short distance on flat ground and step
off the bike. Measure the distance between the lower seal and the zip tie and you will find out the sag. In case of travel
adjustment forks, set the fork to maximum travel (120mm) and check as described above.
a.) Setting Sag by air pressure
f
Check following points:
a) Visible damage of the fork - on upper or lower tubes, fork crown, brace, dropouts - like cracks, dents, as effects of a crash during
the ride or of other causes.
b)
Tightness of the headset by pressing the braking lever of the front brake and pushing and pulling the bike in order to see if there is play.
c) Brake pad adjustment on the rim and distance to the rim ( 1-2 mm is optimal)
d) Brake lever travel - ideally the contact of the brake pad and rim should occur after 1/3 of lever travel range
e) Firmness of the brake assembly - apply the brakes several times and check carefully for loose nuts, bolts, etc.
f) Front wheel must be centred within the fork tubes. Check proper torque on wheel quick release mechanism.
Check the fork before each ride and contact your dealer if you have any questions.
Dropout
Fork
lowers
Fork
Crown
Steerer
Travel adjus-
ter/ Air system/
preload adj.
Lock-Out
system /
Hydraulic
system/
Air system
In order to adjust the air pressure, please be sure to use the
following steps (Right and left side from rider’s perspective
):
1.) unscrew by hand the cover cap on the left or right side of the fork crown.
In case of a travel adjustment fork, please follow the procedure
described on the previous page in order to access the air valve.
2.) attach the suspension fork air pump at the “Schrader” valve.
3.) pump up the fork to the desired hardness level -> see chart.
4.) remove the pump from the valve.
5.) replace the cover cap.
b) Setting Sag by spring preload
In order to adjust the Sag by spring preload, measure first - as described above - the
initial Sag, using the zip tie method.
After you found out the amount of Sag you have, reduce or increase it, by using the
preload knob on the top of the fork crown.
By turning the preload knob clockwise, you increase the preload and reduce the Sag.
By turning the preload knob counter-clockwise, you reduce the preload and increase the Sag.
Please adjust the Sag in accordance with your personal preferences and use the values
indicated above as guidance. If you are not able to adjust the optimum Sag, you need to
change the fork‘s springs, to harder or softer ones.
Rebound
adjuster
Stanchion
NOTE: Your fork‘s apperance
may vary from the images shown in
this instruction sheet.
For latest information please visit
our website:
WWW.SRSUNTOUR-CYCLING.COM
Air valve
cover cap
For more information and for ordering the suitable springs, please contact you authorized local dealer or visit our website at -
WWW.SRSUNTOUR-CYCLING.COM. - to see the list of authorized international distributors.
The I.C.E. type control DSM-XCR60-SC
The remote lock-out control
The remote travel adjuster The remote lock-out control
The remote lock-out control
can be used separately, without
the remote travel adjuster.
Rider weight Air pressure
lb. kg. psi kgf/cm
2
80 36 51 3,6
100 45 64 4,5
120 54 77 5,4
140 64 91 6,4
160 73 104 7,3
180 82 117 8,2
200 91 130 9,1
220 100 143 10
Max. air pressure = 180psi/12.7kg/cm
2
AIR PRESSURE CHART
Note: This chart is just for your reference and the values
may vary depending on your riding style and terrain.
For your specific suspension fork, please visit our
website on: www.srsuntour-cycling.com, where you
can find under your fork‘s model name a detailed air
pressure chart as downloadable pdf document.
- 3 -

Fork features and function
Travel adjustment
This feature allows you to adjust the travel of your fork depending on your preferences and the terrain you’re riding.
The travel adjustment allows you to change the way the bike handles, when you ride uphill or downhill.
When you ride uphill, you push the lever (which is mounted on the handlebar) and push down the handlebar.
You release the lever at the desired travel level of the fork. Now you can ride uphill in a more comfortable body position.
When you ride downhill, you push the lever and pull the handlebar and the fork extends its travel to the maximum
travel level. Now you can ride downhill in a more comfortable and safer body position.
The infinitely variable travel can be adjusted from 60-120mm (130mm - depending on the fork model) steplessly.
Remark: The changement of the travel of the fork doesn’t change the air spring rate.
You have the same comfort at all travel levels.
HydraLock (lock-out feature)
This feature allows you to reduce bobbing while riding uphill or sprinting.
In order to activate this function, you have either to push the “wishbone” shaped lever to the right - in case of a remote
lock-out fork or to turn the lock-out knob located on the right side of the fork crown clockwise up to stop. In order to
open the system for normal damping, you have to push the “wishbone” lever to the left in the case of a remote lock-out
fork or turn the lock-out knob counter-clockwise. To perform both functions - lock or un-lock -> you need only one
flip of your thumb in the case of the remote lock-out fork or a full turn of the lock-out knob for a standard lock-out fork.
This function allows you only to have the hydraulic damping fully open or fully closed.
WARNING: Please don’t forget to un-lock your system when you’re riding rough terrain.
Riding rough terrain with a locked system may damage your lock-out cartridge.
Preload adjustment
The preload adjustment allows the user to tune the response of the suspension fork as riding conditions demand and in
accordance to his weight. The more preload you have, the more thrust it takes to get the fork to first move. The preload
is adjusted by turning the preload adjustment knobs located on the fork crown.
Turning the adjustment knob clockwise increases the amount of preload, while turning the knob counter-clockwise
reduces the preload . Please check the chapter “Setting Sag” described before.
Maintenance
SR SUNTOUR forks are designed to be nearly maintenance free. However, as long as moving parts are exposed to
moisture and contamination, performance may be reduced. To maintain high performance, safety and long life, periodic
maintenance is required.
The recommended intervals for maintenance are listed below.
Lubricants and Cleaners:
- Teflon fortified oil
- SR SUNTOUR special grease (SRS No.9170-001) / high quality Teflon fortified grease.
Damping oil:
- SR SUNTOUR special damping oil (SR SUNTOUR special damper oil #PSF01-033 / Viscosity 11).
Regular Maintenance:
Before every ride, inspect the following parts:
a) Front wheel and quick release for proper installation and adjustment
b) Fork for any obvious damage (crown, brace, upper tubes, lower tubes, and dropouts)
c) Front brake cable for proper routing
d) Front brake pads for proper contact with the rim
e) Front brake lever for proper adjustment
f) Headset for proper function and adjustment
g) Stanchion tubes for scratches. In case of deeper scratches contact your local dealer for advice.
If you ride in extreme weather or terrain conditions, we recommend a more frequent maintenance.
(
Remote
Travel
Adjuster
Remote
Lock-out
System
Air system
Lock-out
Air system
or coil spring
Coil
spring
Open oil +
coil spring
Remote
Lock-out
System
Remote
Travel
Adjuster
AIR
System
We recommend the service after 50 and 100 hours of riding to be performed by a qualified bicycle mechanic.
He has all necessary tools for this servíce and the necessary know-how.
After25hours
Afterevery ride
After50hours
After100 hours
After200 hours
MAINTENANCE
Clean the stanchion tubes and the dustseal area
Check for proper torque the main fixing bolts (10Nm)
Oil the dustseal area with Teflon oil
Function check of the fork and clean and grease service of bushings at the dealer
Change oil bath and lubricate remote lock-out cap from outside with Teflon oil
Inspection and service of the complete fork at the dealer
In any case, if you feel that your fork’s performance has changed or it handles differently as normal -
please contact immediately your local dealer to inspect your fork.
- 4 -

Notes on usage of the fork
LIMITED WARRANTY
SR SUNTOUR warrants the suspension front fork to be free from defects in materials and workmanship under normal use for a period of two years from
the date of purchase. In no event shall this limited warranty apply to any defect of the suspension fork caused by: improper installation, disassembly, re-
assembly, intentional breakage or damage, alterations or modifications to the suspension fork by the user or other party or any unreasonable use or abuse
of the product or any use for which this product was not intended.
The obligation of this limited warranty shall be limited to repairing or replacing the suspension fork or any part for which there is a defect in materials
or workmanship during the two years following the date of purchase. To validate this limited warranty the purchaser must submit this warranty card to
SR SUNTOUR within 30 days after purchase of the suspension fork. Any alteration of, or tampering with the warranty card automatically terminates this
limited warranty.
SR SUNTOUR makes no express or implied warranties of fitness or merchatability of any kind, except as set forth above. SR SUNTOUR’s liability he-
reunder is expressly limited to repair or replacement of the product. Under no circumstances will SR SUNTOUR be liable for incidental or consequential
damages. Some jurisdictions do not allow the exclusion or limitation of liability of incidental or consequential damages, so the above exclusion may not
apply to you. This warranty gives you specific rights and you may have other rights which vary from jurisdiction to jurisdiction.
In all places, the purchaser should contact the place of purchase for information about warranty service.
SR SUNTOUR INC.
No.7 Hsing Yeh Road, Fu Hsing Industrial Zone.Changhua.50606. Taiwan, R.O.C.
Tel:[phone] / Fax: [phone] / E-mail: [email protected]
This warranty is void without proof of purchase.
SR SUNTOUR EUROPE S.A.
Chaussee de Tervueren,43,1410 Waterloo. Belgium
Tel: [phone] / Fax: [phone] /
E-mail: [email protected]
SR SUNTOUR USA
P.O. Box 61988 Vancouver WA 98666
Tel: [phone] / Fax: [phone] /
E-mail: [email protected]
SR SUNTOUR INC.
Specifications are subject to change without notice.
Printed in TAIWAN.
Intended use
The SR Suntour suspension forks are designed for Endurance/Freeride and moderate downhill riding (air system/hydraulic type
forks) and Cross Country and All Road sports (hydraulic system/spring type forks).
These forks are not intended to be used in downhill racing!!!
Detailed information about the target category of your fork you can find on our website at - WWW.SRSUNTOUR-CYCLING.COM
- where you can download this instruction sheet as interactive pdf. file.
If for any reason you feel that there is something wrong with the fork, by the way it handles or by unusual
topping sounds, you must immediately stop using it and you have to take it to the dealer from which it was
purchased, for inspection.
Date of purchase: Fork model name Serial number
Term of limited warranty: Two years from the date of purchase
Dealer Name: Phone#:
Address:
Purchaser Name: Phone#:
Address:
Suspension Fork Warranty Card:
SR Suntour website: www.srsuntour-cycling.com
- 5 -