AIR Spring Travel and AC Length Modifications
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Before your first ride you should check if you have enough tire to crown clearance. Depending on the
model, this fork comes standard with either 100 mm (505 mm AC), 110 mm (530 mm AC) or 150 mm (570
mm AC) of travel from the factory. If you are using narrow rims and big tires, you must check if you have
enough clearance between your crown and tire before you ride with this fork. If you do not have enough
clearance, the air spring needs to be modified with a clip(s) that will give you the proper clearance. Clips
are now supplied with every fork. If you have an older fork, you may contact us to purchase clips. The
clips reduce travel or travel and AC Length in 10 mm increments. As an example:
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150 mm of travel - pre-set at factory
For 140 mm of travel - remove the pre-installed* 10 mm clip and insert 1 - 20 mm clip.
For 130 mm of travel - leave the 20 mm clip in place and add the 10 mm clip ABOVE the 20 mm clip. The 10 mm
clip must always be on top.
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110 mm of travel - pre-set at the factory
For 100 mm of travel - remove the pre-installed* 10 mm clip and insert 1 - 20 mm clip.
For 90 mm of travel - leave the 20 mm clip in place and add the 10 mm clip ABOVE. The 10 mm clip must be on
top.
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100 mm of travel - pre-set at the factory
For 90 mm of travel - remove the pre-installed* 10 mm clip and insert 1 - 20 mm clip.
For 80 mm of travel - leave the 20 mm clip in place and add the 10 mm clip ABOVE. The 10 mm clip must be on
top.
*
The pre-installed 10 mm clip does not reduce the advertised travel of the fork. It is installed to provide a safety
stop should the fork take a big hit. You should always ride with a clip in place on the TOP of the air spring. If you
take out the 10 mm clip and install a 20 mm clip, you will reduce the advertised travel by 10 mm as noted above.
If you decide to reduce the travel and AC length, leave the pre-installed 10 mm clip on the TOP of the air spring
and insert the correct clip INSIDE the air spring as noted on page 6.
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Checking for Crown to Tire Clearance:
1.
Install the front wheel on the fork being sure tire is properly inflated.
2.
Release air from the air spring to make fork easier to compress.
3.
Push down on the handlebars until the fork bottoms out and check for the amount of clearance between crown
and tire. A minimum of 5 mm is recommended, 10 mm is better if conditions might lead to snow or mud
buildup between the tire and crown.
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Air Spring Travel Only Modification and Assembly:
1. Place your bike in a work stand and remove the front wheel.
2. Remove the blue air cap from the left leg and release all the air from the system. If your fork is a TwinAir, be
sure to empty both top and bottom air chambers.
3. Loosen and carefully remove the air spring assembly nut (large silver nut below the blue air cap) with a 26 mm
socket. This nut is low profile and care should be taken to firmly engage the socket. DO NOT remove the red
air spring assembly cap.
4. Unscrew the collars on the stanchions by hand. Now the air spring can be pulled out including the air side
stanchion from the bottom of the fork.
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Warning: At this stage please absolutely make sure again that all the air has been released from the air
spring unit to avoid severe and/or fatal injuries.
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5. Select the correct clip(s) as discussed above.
6. Insert the proper clip size into the air spring at the TOP directly below the upper assembly cap and onto the
flattened sides of the rod. For a 10 mm clip, snap onto the rod and slide up over the flattened surfaces under
the upper assembly cap. For the 20 mm clip, be sure the wide-mouth end is at the top, facing up. This end is
chamfered to fit over the flattened surfaces. Lineup with the flattened surfaces and snap onto the rod. If using
both stoppers, be sure the 10 mm is on TOP.
7. Wipe any old grease off the upper bushing and the sliding bushing on the stanchion and lightly re-grease with
a grease suitable for the temperature you will be riding in. If your fork is keyed, lightly grease the keys. For
general use we recommend Slick Honey.
8. Reverse steps 1 to 4 for reassembly. If your fork is keyed, be sure to lineup the keys properly. Be sure the
sliding bushing is completely pressed into the upper before tightening the collars. Be sure to torque the air
spring assembly cap to 10 Nm. Be sure the fork collars are hand tight. Be sure to check your air pressure and
sag.
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