Service Instructions for Seat post service (27.2 or 26.8). Each size will use a separate kit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Prior to doing any service on the AP-1, you must remove all air from the seat post. WARNING failure to remove all air from the seat post may result in damage to the seat post and personal injury. Push the air cap (#5) into the lower seat post tube (#1). Remove the air cap retainer ring (#17) using a small awl or small screwdriver. Push the stanchion assembly (#14) into the lower tube (#1) and the air cap will pop out. WARNING make sure that the air cap is pointing away from any person during removal. Remove the valve body (#7) by inserting a 6mm Allen wrench up into the lower tube. Remove the flat head screw (#13) and push the brass guide pin (#2) out. You can now pull the stanchion assembly (#14) from the lower tube. Remove the piston (#6) from inside the lower tube by using a dowel or other non-sharp object to push it out through the bottom (end where air cap sits) of the lower tube. Clean the inside of the outer tube and the stanchion assembly. WARNING carefully inspect the lower tube (#1) and the stanchion assembly (#14) for any signs of wear or cracks. Inspect the upper DU bushing (#16) for wear (note the DU bushing is pressed into the top of the lower tube). If wear is noted, please contact White Brothers for service or service parts to replace the DU bushing. If no wear is detected, lube the DU bushing and the composite bushing (#19 pressed into lower tube at pin hole) with grease * (see note below). Apply a small amount of grease on the stanchion (#14) and insert the stanchion into the lower tube. Install a new o-ring (#9) onto the piston (#6). Apply grease to the piston o-rings and to the lower part of the lower tube. Insert the valve body (#7) through the piston (#6). WARNING Apply a small amount of Locktite 271 on the threads of the valve body (#7). Use an Allen wrench to carefully insert the piston and valve body into the lower tube. WARNING tighten the valve body, but do not over tighten. If the valve body is too tight, the stanchion assembly will bind when worked inside the lower tube. Work the stanchion assembly several times to make sure that the valve body is not too tight. Insert a new guide pin (#2) through the lower tube and stanchion assembly (Note you may need to rotate the stanchion assembly for the pin to fit properly). Apply Locktite 271 on the threads of the flat head screw (#13) and tighten the flat head screw into the guide pin. CAUTION do not over tighten the screw, as it will cause the stanchion to not work smoothly. Check to make sure that the stanchion assembly moves freely after tightening. Install a new o-ring (#15) onto the air cap (#5). Apply grease to the air cap o-rings. Apply a small amount of grease to the inside of the lower tube. Insert the air cap into the bottom of the lower tube and install the air cap retainer (#17). WARNING make sure that the air cap retainer is properly seated into the groove in the lower tube. Failure to properly seat the air cap retainer may result in damage to the seat post and personal injury. Push down on the stanchion assembly to properly seat the air cap. Insert the proper amount of air pressure. Using a mixture of soap and water, check for air leaks around the guide pin and air cap. Go Ride! * Only use a non-lithium based suspension grease on the AP-1. 580 N. Westgate Dr. Grand Junction, CO 81505 USA 1.800.999.8277 Service Instructions for Seat post service (27.2 or 26.8). 3 11 4 10 6 9 14 7 20 21 22 23 8 16 2 18 15 5 17 12 13 1 ITEM NO. QTY. PART NO. 1 1 P4702 2 1 P4711 3 1 P4718 4 1 P4710 5 1 P4713 6 1 P4712 7 1 P4709 8 1 P4700 9 1 P4706 10 1 ZTA-ORING-015 11 1 P4708 12 1 ZTA-TVALVE 13 1 P4705 14 1 P4715 15 1 P4707 16 1 P4714 17 1 P4701 18 1 ZTA-ORING-203 19 1 100251 20 1 ZTA-VSPNG 21 1 ZTA-CVLV 22 1 ZTA-ADJ-1 23 1 ZTA-ORING-006 DESCRIPTION AP-1 Lower Tube 27.2 Guide Pin AP-1 1/2" Topout Bumper Chamber Plug AP-1 Air Cap Piston AP-1 Valve Body AP-1 AP-1 Boot O-Ring 208 O-Ring 015 O-Ring 205 Tank Valve Flat Head Socket Cap Screw Stanchion & Bracket Assm. O-Ring 115 AP-1 Garlock Bushing AP-1 Air Cap Retainer O-Ring 203 Stanchion Bushing Delrin Valve Spring Compress-n-Valve #1 Adjuster O-Ring 006 19 580 N. Westgate Dr. Grand Junction, CO 81505 USA 1.800.999.8277 ...