O W N E R S MA N UA L F O R BW 1.3 580 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 WARRANTY...............................................PAGE 8 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 (brake bolts, 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. 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. 5. WHITE BROTHERS RECOMMENDS THAT YOU WEAR PROPER SAFETY EQUIPMENT EVERY TIME YOU RIDE, INCLUDING APPROVED BICYCLE HELMET. NEVER RIDE AT NIGHT WITHOUT LIGHTS. 6. ALWAYS USE GENUINE WHITE BROTHERS PARTS. USE OF AFTERMARKET REPLACEMENT PARTS AND UPGRADES VOIDS THE WARRANTY AND COULD CAUSE STRUCTURAL FAILURE. 7.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 and external damper settings. See the tuning section for details. 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 bootless design allows a considerable amount more slider/stanchion overlap than competitor forks which increases fork steering accuracy. Every effort has been made to make White Brothers forks very light and perform at a level superior to other forks on the market. 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 steerer 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 headset owners manual if there is 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 steerer tube. 6. The star fangled nut must now be installed into the steerer 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 instructions. 11. Install and tighten the wheel in the front fork. Tighten the 20 mm thru axle nut and the pinch bolts. 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 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: 15/16" socket with ratchet. 4mm Allen wrench 6mm Allen wrench COIL SPRING / OIL DAMPER Your new White Brothers fork is designed with a air spring and oil damping. The following guidelines for adjusting and maintaining your fork will enable you to enjoy maximum performance and longevity 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 adjusting the air pressure 2)by adjusting the settings of the damper. 3. To adjust the air pressure remove the dust cap from the left leg to expose the air valve. Add or remove pressure using a high pressure air pump to achieve your desired spring support. 4. Compression adjustment is done by adding or removing air at the top of the right leg. Pressures can range from 50 to 150 lbs. Higher air pressure will provide more compression damping while lower air pressure will provide 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. 5. Rebound adjustment is done by turning the knob 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 harshly. Adjustment range is 6 turns. Air Pressure Adjustment Compression Adjustment Rebound Adjustment 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. 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, inspect, 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 regreasing all shafts, bushings and seals. Check top cap assembly's, damper cartridge, stanchion plug, brake 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: Basic Fork Disassembly and Inspection 1. Disconnect the front brake and remove the wheel as outlined in you bicycle owners manual. 2. Pop out the damping adjuster knob from the bottom of the right dropout. Loosen the allen bolts at the bottom of the fork legs(See figure #5). A light tap may be needed to free the control rod from the lower assembly. Finish removing the compression screws. 3. Simply slide the fork legs off the end of the inner stanchion tubes. 4. Check the air pressure in the damper. It should be between 50 and 150 psi. Inspect the damper leg for visible leakage. If none, grasp the shaft while in the stanchion tube and operate back and forth to insure smooth action. If the damper has visible leakage and/or the damping feels inconsistent as it is stroked, return the fork to White Brothers or a dealer familiar with rebuilding the damper for service. The damper is a sealed unit and should not be opened unless service is required. Damper service should be performed by White Brothers. 5. Clean all parts with a clean, non-abrasive rag. A mild grease cutting cleaner or solvent might make this an easier task. Once clean, inspect the seals for tears or cracks. If in good condition, re-grease them with Slick Honey or other suitable nonlithium grease. If your seals show signs of wear have them replaced. 6. Check the DU bushings carefully for wear. This is done by looking at the color of the bushings. If the bushings are dark gray, they are in good condition. If they are bronze/gold in areas, they are worn and can cause fork stanchion damage. If there is noticeable movement back and forth when the legs are fully engaged on the fork stanchions, the DU bushings may need to be replaced. Please note that special tools are required to remove and replace these bushings. This service can be performed by White Brothers. 7. Next, inspect the fork stanchion tubes for wear, nicks or scrapes. These will cause premature wear on the seals and DU bushings. Check again for noticeable play between the stanchion tubes and the fork lower. 8. If everything is free of problems, coat all parts with a liberal coat of Slick Honey or other non-lithium grease. Be sure to lube the DU bushings located inside the lower leg. Figure #5 PAGE 5 Basic Fork Reassembly 1. Make sure all the spacers and bottoming bumpers are installe ...