O W N E R S MA N UA L F O R 580 N. Westgate Dr. Grand Junction, CO 81505 USA 1.800.999.8277 www.whitebrotherscycling.com A division of PAGE 1 TABLE OF CONTENTS SAFETY.......................................................PAGE 2 INTRODUCTION........................................PAGE 2 FORK INSTALLATION..............................PAGE 3 TUNING.......................................................PAGE 4 MAINTENANCE........................................PAGE 5 TROUBLE SHOOTING..... ........................PAGE 6 EXPLODED VIEWS.............................PAGE 7,8,9 WARRANTY..............................................PAGE 10 IMPORTANT CONSUMER SAFETY INFORMATION WARNING: RIDING A BIKE IS DANGEROUS. NOT PROPERLY MAINTAINING OR INSPECTING YOUR BIKE AND IT'S COMPONENTS IS EVEN MORE DANGEROUS. IT IS ALSO DANGEROUS TO NOT READ AND FOLLOW THESE INSTRUCTIONS. 1. NEVER REMOVE STEERER TUBE FROM CROWN. THIS IS A PRESSED IN PART. REMOVING IT WILL RENDER BOTH THE CROWN AND STEERER TUBE INOPERABLE.* MAKE SURE THE FORK CAPS AND ALL FORK HARDWARE (pinch bolts, etc.) ARE TIGHT BEFORE EACH RIDE. 2. DO NOT PERFORM ANY MODIFICATIONS OR ADJUSTMENTS THAT ARE NOT OUTLINED IN THIS MANUAL. SEE THE TUNING SECTION FOR MORE DETAILS. 3. INSPECT YOUR FORK BEFORE EVERY RIDE. INSPECT THE CROWN, TUBES, AND AXLE SEAT AREAS FOR ANY SIGNS OF FATIGUE, BENDING, CRACKING OR OTHER DAMAGE. IF YOU NOTICE ANY TYPE OF DAMAGE, DO NOT RIDE IT. RETURN IT TO YOUR DEALER OR TO WHITE BROTHERS FOR A COMPLETE INSPECTION AND NECESSARY REPAIR. 4. THIS WHITE BROTHERS FORK IS DESIGNED WITH A LOCKOUT THA TURNS OFF THE FORK'S T SUSPENSION. THE LOCKOUT IS ONLY DESIGNED TO BE USED ON SMOOTH TERRAIN. USING THE LOCKOUT ON ROUGH TERRAIN, BUMPS OR DROP-OFFS CAN CAUSE SERIOUS DAMAGE TO THE FORK AND COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH. 5. PERFORM ALL RECOMMENDED MAINTENANCE ACCORDING TO THE MAINTENANCE SECTION OF THIS MANUAL. FAILURE TO PERFORM MAINTENANCE COULD DRASTICALLY REDUCE THE FORK'S LIFE, PERFORMANCE AND CAUSE YOUR FORK TO BE A SAFETY HAZARD. 6. WHITE BROTHERS RECOMMENDS THAT YOU WEAR PROPER SAFETY EQUIPMENT EVERY TIME YOU RIDE, INCLUDING AN APPROVED BICYCLE HELMET. NEVER RIDE AT NIGHT WITHOUT LIGHTS. 7. ALWAYS USE GENUINE WHITE BROTHERS PARTS. USE OF AFTERMARKET REPLACEMENT PARTS AND UPGRADES VOIDS THE WARRANTY AND COULD CAUSE STRUCTURAL FAILURE. 8.WHITE BROTHERS FORKS ARE DESIGNED FOR OFF ROAD USE ONLY. THEY ARE NOT EQUIPPED WITH REFLECTORS FOR ROAD USE. IF YOU ARE GOING TO USE YOUR FORK ON THE ROAD, HA A DEALER VE OR MECHANIC INSTALL REFLECTORS THAT MEET THE CONSUMER PRODUCT SAFETY COMMISSION'S REQUIREMENTS. *IF SERVICE BECOMES NECESSARY OR REMOVAL OCCURS, PLEASE CALL WHITE BROTHERS CUSTOMER SERVICE FOR PRODUCT EVALUATION AND DIAGNOSIS. INTRODUCTION Thank you for purchasing your new White Brothers fork. Our forks are designed to help you perform at your absolute peak. Your new White Brothers fork has oil damping and is air sprung for light weight performance. The air spring and damper is set stock to satisfy a wide range of rider weights and riding styles. Fine tuning can be easily accomplished by changing air pressure in the air spring cartridge. See the adjustment and maintenance section for rider weight verses air pressures settings. For very heavy or very light riders the external damper can be adjusted to give a wide range of compression and rebound damping. Steering accuracy is improved over conventional MTB forks by utilizing superior materials and design. These include oversized 32mm fork tubes, a torsion box design steering crown with pressed in tubes, a one piece billet brake arch and extra thick drop-outs. The WB forks bootless design allows a considerable amount more slider/stanchion overlap than competitor forks which increases the fork steering accuracy. Fork travel has been chosen to offer the best performance possible for each fork's intended use. To ensure peak performance, proper installation and periodic maintenance is required. When riding on public land, please respect the rights of others and stay on established paths and trails. By riding responsibly, you are helping ensure the future of our sport. PAGE 2 FORK INSTALLATION White Brothers forks feature a 1-1/8" threadless steer tube. If you have a threaded type fork on your bicycle, consult your dealer for the appropriate upgrade parts necessary to convert to a 1-1/8" threadless steer tube. 1. Remove your old fork from the bicycle. Measure the diameter and length of your old forks steerer tube to ensure that the White Brothers steerer tube is the correct diameter and sufficient length for the installation. 2. Remove the crown race from your old fork. 3. Press the crown race onto your new White Brothers fork.(see Figure #1) 4. Preassemble the headset by sliding the fork steerer tube through the bearings. Then install the headset upper race, headset spacer (optional), and stem onto the fork steerer tube. Adjust with optional spacers to your preferred height. (See Figure #2) Refer to the head set owner's manual if there are any questions about the pre-assembly. 5. Mark the steerer tube at the top of the stem. The steerer tube will now need to be cut to the correct length. Disassemble and cut 3mm (1/8") below the mark. Consult your dealer or mechanic if you don't have the proper tools to cut the steer tube. 6. The star fangled nut must now be installed into the steer tube. If you don't have the set tool, we recommend dealer installation of this part. (See Figure #3) 7. Clean and grease all headset bearings and races to prepare them for assembly. Note: Replace the bearings if there is any sign of wear or corrosion. 8. Now loosely assemble the headset, stem and handle bars as done in step four. 9. Install the headset top cap into the star fangled nut. Tighten until there is no play in the steering. The fork should rotate freely in the head tube. Straighten the stem in relation to the front tire and tighten the pinch bolts on the stem. If there are any questions consult your dealer or mechanic. 10. Install your front brake and adjust according to the manufacture's instructions. 11. Adjust the quick release on the hub to clear the secondary catches on the drop-outs. Tighten the quick release after the axle is properly seated in the drop-out. Ensure that there is sufficient thread engagement (5 or more threads with the quick release in the lock position) due to the thicker White Brothers drop-outs. Install the front wheel per manufactures specifications. 12. Check to see that the brakes are adjusted and properly working. Make sure that the brake cable does not interfere with any part of the bike when the fork is compressed and released. Warning: When installing the wheel or a new tire, check for minimum clearance. Measure from the highest point on the tire to the under side of the crown. There must be 1/8" or 3mm more clearance than the fork's travel to ensure adequate clearance in all riding conditions. Any less clearance can result in the tire hitting the crown resulting in serious injury or death. Steering Stem Optional Headset Spacer Headset Upper Race Star Fangled Nut Steerer Tube Frame with Headset Cups Headset Lower Race Fork Crown Figure #1 Figure #2 Figure #3 PAGE 3 TUNING To get the most out of your White Brothers fork, it is important that you tune the fork to fit your weight, riding style and the terrain you ride. INITIAL BREAK-IN PERIOD Your new fork is designed to break-in over a period of 10 hours or more of riding. As all the parts bed into each other, the stiction (friction) of the fork decreases and the sensitivity increases. After the initial brake-in period, fine tuning the air pressure and damping adjustments may be beneficial to achieve the best possible performance. TOOLS NEEDED: High pressure air pump 15/16" socket with ratchet. 6mm Allen wrench Air Spring Lockout / Compression Adjuster AIR SPRING /CARTRIDGE DAMPER Your new White Brothers fork is designed with an air cartridge for air sprung support. An air cartridge is a light weight, adjustable air sprung shock absorber, which screws into the fork stanchion at the crown. The following guidelines for checking and adjusting your cartridge will enable you to enjoy maximum performance from your fork. 1. First, test ride the fork over easy terrain. If after riding the fork over varied terrain you decide that more tuning is necessary, continue to the next step. 2. The compression or spring of the fork can be changed two ways: 1) by changing air pressure in the cartridge and 2) adjusting the settings of the damper cartridge. 3. To change the air pressure remove the snap in dust cap (use a finger nail or small screw driver) so that the schrader valve stem is exposed.(see Figure #4) 4. You will need a high pressure shock pump to inflate the cartridge. Start with the stock setting of 200 lbs. If the fork feels too soft or firm, fine tune the air pressure in five pound increments until the fork sag (support) is approximately 15 to 25 percent of the total travel. 5. Test ride after each adjustment until the air cartridge is at an adequate pressure. Generally you will want a higher pressure for a 80mm fork and a lower pressure for a 100mm fork. Reinstall the dust cap. 6. Compression adjustment (lockout) is done by turning the knob on the top of the right leg and is a lockout when turned full clockwise. WARNING: The lockout is designed to be used on smooth terrain only. DO NOT lockout the fork on rough terrain, bumps or dropoffs. Turning the knob counter-clockwise from lockout, will provide less and less compression damping. Less compression damping will increase the fork dive but will feel smoother over small bumps. More compression damping will feel stiffer over small bumps but will be more resistant to bottoming. The compression / lockout knob has ¾ of a turn of adjustment. If more damping range is needed, contact White Brothers. 7. Rebound adjustment is done by turning the adjuster on the bottom of the right leg. Turn the knob clockwise for slower rebound. To speed up rebound, turn the knob counterclockwise. Start with a middle setting and fine tune the rebound from there. Proper rebound will allow the tire to track the ground over consecutive bumps. Too slow of rebound will pack-up (feel stiff over consecutive bumps) while rebound set too fast will cause the fork to top out. Adjustment range is 6 turns. Rebound Adjuster Figure #4 PAGE 4 MAINTENANCE Your White Brothers fork requires periodic maintenance to ensure peak performance and long life. Neglecting proper maintenance will reduce the fork's life. Internal build up of water and dirt or a lack of lubrication will cause excessive wear and void the warranty. BEFORE EVERY RIDE: Visually inspect your fork for bent or broken parts, loss of oil, abnormal sounds or other indications of possible fork failure. Compress you fork to verify proper function. Check all other bicycle components to ensure proper working order. Warning: Check the air cartridge to ensure that it is tightly threaded into the fork crown. AFTER EVERY RIDE: Clean and dry the exterior of your fork. When cleaning the fork, do not direct the water spray at the seals. Visually inspect your fork for damage. *EVERY 30 HOURS OF RIDING: Your fork should be disassembled, inspected, cleaned and re-grease. If the fork appears to be relatively clean, you can go 40 hours between servicing. If the fork appears excessively dirty you should service it every 20 hours. The three things that will effect the service interval and performance of your fork are water, mud and dust. How much you use your fork in those conditions will determine how much service it requires. *EVERY 100 HOURS OF RIDING: Complete service should include removing the lower fork legs cleaning and re-greasing all shafts, bushings and seals. Check top cap assembly's, damper cartridge, stanchion plug, brake post bolts and shaft bolts for proper torque. At this time, the fork should be carefully inspected for wear and damage before reassembly. Contact White Brothers for replacement parts and service. We recommend that this service be performed by a certified White Brothers service center or by the factory. *White Brothers recommends that you consult with a qualified technician before performing major service. Maintenance (Air Cartridge) 1. Once a year (depending on riding style and frequency) the cartridge should be removed for annual maintenance. Deflate the cartridge. Un-thread the cartridge from the stanchion tube. 2. Remove the air cap from the cartridge body and push the shaft and piston assembly out the top of the cartridge. Inspect the air cap o-ring and piston o-ring for damage or dirt. If the o-rings are damaged see your local dealer or contact White Brothers for o-ring rebuild kit. Clean and lubricate the o-rings and shaft with Slick Honey. Re-assemble the cartridge. When inserting the shaft in the body, push the shaft end through the o-rings with a steady, grad ...