SRSuntour Workshop Book

SR SUNTOUR workshop book, version 2008/Mar/25 page 3
workshop book workshop 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 ausschlielich ausgebildeten Zweiradmechaniker erlaubt Reparatur- und
Servicearbeiten an SR SUNTOUR Federgabeln vorzunehmen.
Franais
French
Attention!
Uniquement les mcaniciens cycle certifs sont autoriss rparer et entretenir
les fourches SR SUNTOUR
Italiano
Italian
Attenzione:
Escluso persone istruiti e qualifcati in meccanico di biciclette e permesso di
aggiustare le SR SUNTOUR forcelle, non appena i lavori di servizi.
esky
Czech
*POZOR!
Opravy a servisn prce na vidlicch SR SUNTOUR jsou povoleny pouze
prokolenm mechaniku*m
Polski
Polish
Uwaga!
Tylko przeszkolonym mechanikom rowerw wolno dokonywa napraw i serwisu
widelcw amortyzowanych frmy SR SUNTOUR
Espaol
Spanish
ATENCION!
Slo se permite llevar a cabo trabajos de reparacin y servicio en las horquillas de
suspension de SR SUNTOUR a mecnicos de bicicleta competentes.
Russian
!
o SR SUNTOUR
.
Chinese
!
SR SUNTOUR
.
Japanese
!
SR SUNTOUR
Bulgarian
!
SR SUNTOUR,
,
!
Disclaimer
Table Of Contents
Disclaimer ..........................................................................................3
I. Introduction ................................................... 7
Introduction .....................................................................................8
Abbreviations ...................................................................................9
Addresses ....................................................................................... 10
SR SUNTOUR corporate .................................................................................. 10
Worlwide Distributors .................................................................................... 10
II. Owners 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
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
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 its sometimes hard to understand what the working step
really tries to explain. Moreover its 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 flm during workshops for local dealers. We have
enclosed a DVD at the last page of the workshop book. On this DVD you will fnd 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 fnd in chapter V.
We would like to give you a short overview about what you will fnd within this workshop book. In chapter
II you will fnd all fork and rear suspension instruction sheets. Chapter number III provides you with all nec-
essary information about the assembling of our diferent 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 customers forks.
In chapter number VI we have put together all necessary technically information about SR SUNTOUR forks.
You will fnd 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 fnd all exploded views of our 2007-2008 suspension fork
models.
A workshop book can never be fnished 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
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
S AIR
E COIL SPRING
NCX MODELS
S AIR
E AIR
D COIL SPRING
DURO
DJ E CroMo STEERER TUBE
DJ D STKM STEERER TUBE
AXON MODELS
S AIR
E AIR
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
Worlwide Distributors
AUSTRIA
KTM FAHRRAD GMBH
Harlochner Str. 13
5230 Mattighofen
Austria
Tel.: +43 7742 4091-34
Fax: +43 7742 4094-26
email: ofce@ktm-bikes.at
web: www.ktm-bikes.at
BENELUX
Juncker Bike Parts
Fokkerstraat 25
3905 KV Veenendaal
The Netherlands
Tel.: +31 (0) 318 553030
Fax: +31 (0) 318 553211
email: info@juncker.nl
web: www.juncker.nl
BRAZIL
Intac
Rue alba; 1737-V. Santa; Catarina
04346-000, Sao Paulo
Brazilia
Tel.: +55 11 55 65 21 00
COLOMBIA
HA BICICLETAS
Calle 14 No. 52A-187
Apartado
Aero 368
Medellin
Colombia
Tel.: +57 4 28 55 04 0
Fax: +57 4 25 53 34 3
email: habici@elsitto.net.co
CZECH REPUBLIC
BP LUMEN
Mr. Lukas Barta
Puskinova 546
542 32 Upice
Czech Republic
Tel.: +420 49 9 88 13 27
Fax: +420 49 9 88 27 93
email: info@bplumen.cz
web: www.bplumen.cz
FRANCE
Winora France
France
tel.: 0800 64 65 66
Fax: +33 (0)38 052 8122
email: contact@winora-group.com
FRANCE
SAV SR Suntour France (Service)
Allee Ruby 10
38500 Voiron
France
Tel.: +33 (0) 87 044 7093
Fax: +33 (0) 47 605 1650
email: sav@srsuntoureurope.com
GERMANY
E.Wiener Bike Parts GmbH
Max-Planck-Str. 8
97526 Sennfeld
Postfach 15 61, 97405 Schweinfurt
Germany
tel.: +49 9721 6501 88
fax: +49 9721 6501 73
GERMANY
Zweirad-Einkaufs-Genossenschaft ZEG
Longericher Str. 2
50739 Kln
Germany
tel.: +49 221 17959 - 20
fax: +49 221 17959 - 31
Addresses
SR SUNTOUR corporate
EUROPE
SR SUNTOUR Europe GmbH
Am Marschallfeld 6a
83626 Valley
Germany
Tel.: +49 8024 3038152
Fax: +49 8024 4730984
email: service@srsuntoureurope.com
TAIWAN
SR SUNTOUR Inc.
#7 Hsing Yeh Rd
Fu Hsing Industrial Zone
Chang Hua
Taiwan, R.O.C.
Tel.: +886 4 7695115
Fax: +886 4 7694028
email: orders@srsuntour.com.tw
web: www.srsuntour-cycling.com
CHINA
SR SUNTOUR (Shen Zhen) Inc.
Suibei Industrial Zone Suibei Road
Gongming Town, Baoan District
Shen Zhen
Tel.: +86 755 27 10 55 33
Fax: +86 755 27 10 56 33
CHINA
SR SUNTOUR Machinery (Kunshan)
Co.Ltd.
388 Matang Road PengLang, KunShan
development zone JiangSu Province
CHINA
ZIP 215333
Tel.: +86 512 578 12 53 0
Fax: +86 512 578 12 56 1
USA
SR SUNTOUR USA
503 Columbia street,
Vancouver, WA 98660
USA
Tel.: +1 (360) 737 6450
Fax: +1 (360) 60 737 6452
email: service@usulcorp.com
HUNGARY
Neuzer KFT
H-1211 Budapest, Csepel Muvek,
Gyepsor UT 1
Hungary
tel.: +361 420 3760
fax: +361 420 0847
email: neuzer.info@neuzer-bike.hu
web: www.neuzer-bike.hu
ITALY
SAIM S.P.A.
Via Leon Battista Alberti 10
20149 Milano
Italy
Tel.: +39 02 3491616
Fax: +39 02 3491613
email: saim.ciclo@saim-group.com
JAPAN
Riteway Products Japan
102 Ikebukuro city-hights
3-18-34 Minami Ikebukuro
Toshima-ku, Tokyo
Japan
Tel.: +81 (03) 59 50 60 02
Fax: +81 (03) 59 56 80 28
email: rpjinfo@gt-japan.co.jp
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.: +52 444 824 0139
fax: +52 444 824 0279
email: bicicletas@turbo.com.mx
web: www.turbo.com.mx
POLAND
Euro Bike Products
ul. Starolecka 18
61 361 Poznan
Poland
tel. +48 61 87 87 368,
web: www.eurobike.pl
RUSSIA
Alna-Bike Co.
Sokolnicheskaya square 4
Moscow 107 113
Russia
tel / fax: +7 495 775 14 09
email: Alna-Bike@mail.ru
SLOVAKIA
KCK CYKLOSPORT-MODE s.r.o.
Mierova 854/37
972 47 Oslany
Slovakia
Tel.: +421-46-549-2200
Fax: +421-46-549-2350
email: kck@kck-oslany.sk
web: www.kck-oslany.sk
SPAIN
BH, S.A. BICICLETAS DE ALAVA S.A.
Arcacha 1
01006 Vitoria
Spain
Tel.: +34 (9)45 13 52 02 / 13 57 08
Fax: +34 (9)45 13 93 21 / 23 48 10
SWITZERLAND
SUSPENSION CENTER
Gurnigelstr. 11
3132 Riggisberg
Switzerland
tel.: +41 31 8093020
fax: 41 31 8093022
email: suspension.center@bluewin.ch
web: www.suspensioncenter.ch
U.K.
GREYVILLE ENTERPRISES
20 Europa way britannia enterprise park
Lichfeld, Stafs. WS14 9TZ
U.K.
Tel.: +44 (0)1543 25 13 28
Fax: +44 (0)1543 25 62 60
E-MAIL: sales@greyville.com
U.K.
MOORE LARGE & CO. LTD
Derby DE24 9GL
Sinfn lane
Sinfn lane industrial estate
U.K.
Tel.: +44 133 22 74 238
Fax: +44 133 22 74 201
email: sales@moorelarge.co.uk
chapter II
Owners manuals
Owners 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 qualied 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 rst 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 qualied 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 qualied
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 manufacturers 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 forks 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 deate 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 retrot 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 modications 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 tness or merchatability of any kind, except as set forth above. SR SUNTOURs 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 specic 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: 49-8024-3038152 / Fax: 49-8024-4730984
E-mail: service@srsuntoureurope.com
SR SUNTOUR USA
503 Columbia street, Vancouver WA 98660, USA
Tel: 1-360-737-6450 / Fax: 1-360-737-6452 / E-mail: service@usulcorp.com
SR SUNTOUR INC.
Specications 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 rst 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 rst 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!
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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:00886-4-7695115 / Fax: 00886-4-769 4028 / E-mail: orders@srsuntour.com.tw
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 dealers 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 qualied 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 rst 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 qualied 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 qualied
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 manufacturers 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 nd 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 rmly 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 manufacturers 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 manufacturers 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 28or 26 wheel size. Also, you have to check the tire width and you have to allow a minimum of 5mm between tire and the forks 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 deate 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 retrot 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 rst 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 rmly in the outer casing stopper (see photo # 3).
e.) Lead the cable around the guide pulley and thread it through the hole in the
xing bolt. The xing 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 xing 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 xing nut and increase or decrease the cable tension at this
point. After that, you can make the ne 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 xing 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 rst 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 rmly in the outer casing stopper (#11).
e.) Tension the cable lightly and tighten the xing 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 xing screw and increase or decrease the cable tension at this
point (see #13). After that, you can make the ne tuning again as described at
a.) and b.).
Dont 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
xing 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
xing bolt.
Outer
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 at ground and step
off the bike. Measure the distance between the lower seal and the zip tie and you will nd 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 riders 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 rst - 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 forks springs, to harder or softer ones.
Rebound
adjuster
Stanchion
NOTE: Your forks 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
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 specic suspension fork, please visit our
website on: www.srsuntour-cycling.com, where you
can nd under your forks 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 youre 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 innitely variable travel can be adjusted from 60-120mm (130mm - depending on the fork model) steplessly.
Remark: The changement of the travel of the fork doesnt 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
ip 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 dont forget to un-lock your system when youre 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 rst 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:
- Teon fortied oil
- SR SUNTOUR special grease (SRS No.9170-001) / high quality Teon fortied 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 qualied bicycle mechanic.
He has all necessary tools for this servce and the necessary know-how.
A
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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 forks 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 modications 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 tness or merchatability of any kind, except as set forth above. SR SUNTOURs 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 specic 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:00886-4-7695115 / Fax: 00886-4-769 4028 / E-mail: orders@srsuntour.com.tw
This warranty is void without proof of purchase.
SR SUNTOUR EUROPE S.A.
Chaussee de Tervueren,43,1410 Waterloo. Belgium
Tel: 0032-2-3544676 / Fax: 0032-2-354 7835 /
E-mail: service@srsuntoureurope.com
SR SUNTOUR USA
P.O. Box 61988 Vancouver WA 98666
Tel: 1- 360 737 6450 / Fax: 1 360 737 6452 /
E-mail: service@usulcorp.com
SR SUNTOUR INC.
Specications 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 nd on our website at - WWW.SRSUNTOUR-CYCLING.COM
- where you can download this instruction sheet as interactive pdf. le.

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 -
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4
chapter III
Service manuals
Mounting the remote lock-out single lever
Models: AXON / EPICON / NRX
a. Mount the remote lock-out lever on
your handlebar. Use a 2.5mm allen key
to fasten the lever. Afterwards you can
mount your brake and shifting lever
back on again
p
i
c
t
u
r
e

R
L
1
.
1
b. Choose the right length of the cable
casing in order to not interfere the
function of the fork
c. Turn the cable tension adjustment
barrel two turns counter-clockwise in
order to have adjustment clearance
for the lock-out function
p
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c
t
u
r
e

R
L
1
.
7
d. Take of the plastic cover using a Allen
key
p
i
c
t
u
r
e

R
L
1
.
2
e. Unscrew the cable fxing bolt with a
2.0mm Allen key. Thread the cable
through the outer casing stopper and
through the cover unit hole. Tension
the cable slightly and tighten it.
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f. Cut the cable to a proper length
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g. Make sure the fork is set to the Un-
locked position and the little plastic
toothed wheel sits like shown on
picture no. 6
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h. Reassemble the plastic cover again us-
ing a 2.5mm Allen key
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i. Pull the remote lever to the lock
position. Check if the fork is locked by
pushing down your handlebar. If the
fork is not locked, you have to adjust
the tension of the cable. To unlock the
fork, push the red knob upwards
Lock-out function setting
Though the lock-out lever is on unlocked position, the fork stays locked
It means that the cable tension is too high. In such a case decrease the tension of the cable by turning
the adjustment barrel clockwise until the fork stays unlocked.
The remote lock-out lever stays not engaged
Again it means that the cable tension is too high. In such a case decrease the tension of the cable by
turning the adjustment barrel clockwise until the lever stays engaged.
If the fork does not open up even after you decreased the tension of the cable its more likely that the
cartridge it self has defect in material. In a case like this please be so kind and inform the distributor of SR
SUNTOUR products or get directly in contact with SR SUNTOUR EUROPE GmbH.
Mounting the remote lock-out single lever
Models: Raidon / XCR / NCX
a. Mount the remote lock-out lever on
your handlebar. Use a 2.5mm allen key
mount your brake and shifting lever
back on again
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for the lock-out function
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d. Take of the plastic cover
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e. Unscrew the cable fxing bolt with a
1.5mm Allen key.
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4
Thread the cable through the outer
casing stopper and through the cover
unit hole. Tension the cable slightly
and tighten it
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f. Cut the cable to a proper
length(approx 12mm)
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g. Reassemble the plastic cover again
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h. Install a cable end cap at the end of
the cut cable using a needle nose
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8
i. Pull the remote lever to the lock
position. Check if the fork is locked by
pushing down your handlebar. If the
fork is not locked, you have to adjust
the tension of the cable. To unlock the
fork, push the red knob upwards
Lock-out function setting:
Though the lock-out lever is on unlocked position, the fork stays locked
It means that the cable tension is too high. In such a case decrease the tension of the cable by turning
the adjustment barrel clockwise until the fork stays unlocked.
The remote lock-out lever stays not engaged
Again it means that the cable tension is too high. In such a case decrease the tension of the cable by
turning the adjustment barrel clockwise until the lever stays engaged.
If the fork does not open up even after you decreased the tension of the cable its more likely that the
cartridge it self has defect in material. In case like this please be so kind and inform the distributor of SR
SUNTOUR products or get directly in contact with SR SUNTOUR EUROPE GmbH.
Mounting and Operating the remote travel adjust control New TA Lever
Models: SF8 EPICON XC TAD
SF8 DUROLUX SERIES
Note: The travel adjust cartridge sits within the left stanchion tube
a. Mount the remote travel adjust lever on
your handlebar. Use a 2.5mm Allen key
mount your brake and shifting lever back
on again
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b. Choose the right length of the cable cas-
ing in order to not interfere the function
of the fork
c. Thread the cable through the outer casing
stopper and through the cable clamp:
Tension the cable slightly and tighten the
cable frmly with the fxing bolt using a
2.5mm Allen key
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d. Cut the cable to a proper length (approx.
12mm)
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workshop book workshop book workshop book workshop book
e. Install a cable end cap at the end of the
cut cable using needle nose pliers
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f. To decrease the travel of the fork you have
to press the lever and simultaneously
compress the fork. Afterwards release
the lever. To increase the travel, you have
to press the lever again and the fork will
come up itself
Mounting and Operating the remote travel adjust control Old TA Lever
Note: The travel adjust cartridge sits within the left stanchion
a. Mount the remote travel adjust lever
on your handlebar. Use a 2.5mm Allen
key to fasten the lever. Afterwards you
can mount your brake and shifting
lever back on again
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for the travel adjustment function
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d. Remove the plastic cover cap, using a
2.5mm Allen key.
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e. Thread the cable through the outer
casing stopper and through the cable
clamp. Tension the cable slightly and
tighten the cable frmly with the fxing
bolt using a Phillips screwdriver
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f. Cut the cable to a proper length
(approx. 12mm)
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g. Reassemble the plastic cover cap
using a 2.5mm Allen key
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h. Install a cable end cap at the end of
the cut cable using a needle nose
pliers
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i. To decrease the travel of the fork you
have to press the lever and simultane-
ously compress the fork. Afterwards
release the lever. If the fork does not
stay in the lower position you have
to adjust the tension of the cable. To
increase the travel, you have to press
the lever again and the fork will come
up itself
Travel adjustment setting
If the cable tension is too low, the fork will not stay in the position pre-selected. In order to increase
the cable tension, turn the adjustment barrel counter-clockwise (+), until the fork will stay in the
pre-selected position.
In case you cannot adjust the fork using the adjustment barrel, you have to open the cable clamp-
ing screw and increase or decrease the cable tension at this point. Afterwards you are able to
perform the fne tuning like described above.
Operating the hydraulic rebound damping
Use and function of the hydraulic rebound damping
The rebound damping function of SR SUNTOUR hydraulic forks allows you to tune your fork according
to your personal preferences and weight as well as the terrain you are riding on. The rebound damp-
ing function makes it possible to control the speed of the rebound of the fork after its compression. The
degree of the required rebound damping varies according to the weight of the rider, the spring stifness,
style of riding and travel of the fork.
If the rebound of the fork is set to slow on a terrain with lots of small bumps, it will start bouncing and
the front wheel can lose its contact to the ground. So if you are going to ride on terrain like this we rec-
ommend increasing the rebound speed of the fork, so that it can keep its contact to the ground.
On the other hand you should lower the speed of the rebound while riding on terrain with bigger
bumps. If the rebound speed of the fork is too fast on terrains like this, the fork will rebound too fast after
being compressed. This contains the risk of losing control of your bicycle.
Increase rebound speed
In order to increase the speed of the rebound, you have to turn
the rebound knob, which is located at the right lower dropout,
counter-clockwise.
Fork Model: Duro 2006
In case the rebound speed is still to slow, there is the option
of changing the standard oil (5W) to oil with a lower viscosity
(2.5W). This fork tuning has to be carried out by an authorized
and trained bike mechanic.
Fork Model: Duro DJ 2007 - 2008
In case the rebound speed is still to slow, there is the option of
changing the standard oil (10W) to oil with a lower viscosity
Fork Model: Axon / Epicon
Please note that the 7.5W oil can result into a failure of the lock out if its warmer than 5 degrees Celsius.
According to the cold temperatures in winter season the 10W oil can slow down the reaction of the fork.
In this case you have the possibility of changing the 10W to 7.5W oil.
Decrease rebound speed
In order to decrease the speed of the rebound you have to
turn the rebound knob clockwise. In case the rebound is still to
fast, there is the possibility of changing the standard oil (10W)
to oil with a higher viscosity (12.5W). This fork tuning has to be
carried out by an authorized and trained bike mechanic.
Fork Model: Duro DJ 2006
In case the rebound is still to fast, there is the possibility of
changing the standard oil (5W) to oil with a higher viscosity
Setting the SAG for SR Suntour Forks
Suspension forks will sag (dive-in) depending on the weight and seating position of the rider while you
are sitting on your bike. The SAG is the compression which is just caused by the weight and seating
position of the rider and not as a result of riding. Every rider has a diferent weight and seating position,
therefore the fork will sag more or less. We deliberately renounced to give you an air pressure chart by
rider weight, because we think that it makes no sense to give you a chart which carries just standard
values though we know that every rider has a diferent weight and seating position which infuences the
fork in a diferent way. To assure a proper function of the fork and to not interfere the performance of it,
setting a proper SAG is the only way to fnd the right air pressure for your fork. Moreover an adequate
adjusted SAG enables the front wheel to keep contact with the ground during the ride.
Setting SAG for air spring forks
To set the SAG on a bike with an air spring fork, we recommend infating the fork with a standard pres-
sure of 73 psi (5 bar). Forks which come with travel adjust option have to be set to the maximum travel.
Warning: It is not allowed using any kind of compressor, normal bicycle pump or air pressure
pump at gas stations to infate your fork. Infating the fork with a compressor will cause seri-
ous damage which is not covered by warranty! SR SUNTOUR forks have to be infated with
special suspension fork air pumps.
63-100mm travel --> 15-20% sag
120-180mm travel --> 20-25% sag
a. Place your bike on a fat ground (lean
it against a wall so that you have
something to hold on to)
b. Install a zip tie on the stanchion tube,
at the level of the lower tube seal
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c. Get on your bike try to avoid any
bouncing of the fork
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d. According to your own weight and
seating position the fork will sag
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e. Get of your bike again try to avoid
compressing your fork while youre
getting of
f. Measure the distance between the
lower tube seal and the zip tie
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4
140mm total travel
60mm sag = 45%
Too Much!
g. Infate the fork until you have reached
the proper pressure
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h. Get on you bike once more try to
avoid any bouncing
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i. Measure the distance between the
lower tube seal and the zip tie again. If
you have achieved a proper SAG, take
of the zip tie
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7
140mm total travel
35mm sag = 25%
Proper SAG
The distance between your lower tube seal and the zip tie is the SAG. In our air pressure chart you will
fnd the recommended SAG for each SR SUNTOUR fork. If you need to adjust the SAG once more please
repeat the steps stated below until the fork is set to the right SAG.
Setting sag for rear suspension
Warning: It is not allowed using any kind of compressor, normal bicycle pump or air pres-
sure pump at gas stations to infate your fork. Infating the fork with a compressor will cause
serious damage which is not covered by warranty! SR SUNTOUR forks have to be infated with
special suspension fork air pumps.
How to Infate the fork:
Unscrew the cover of the Schraeder valve on the left side of your fork. Regarding travel adjust 1.
forks, please note that the Schraeder valve is being located at the lower drop out.
Mount the suspension fork air pump at the Schraeder valve (please only use a special suspen- 2.
sion fork air pump, do not use any kind of compressor, normal bicycle pump or air pressure
pumps at gas stations).
adjust the air pressure according to your own weight and seating position, so that you achieve the SAG 3.
which is recommended for your fork.
Dismount the pump from the valve 4.
Reinstall the cover cap again 5.
Use and function of the Lock-Out system
Note: The Remote-Lock/Lock-Out cartridge is located at the right side of the fork
The lock out function of SR SUNTOUR forks is intended to reduce swaying during rides out
of saddle or uphill riding. Every fork will sway according to the movements of your body. By
locking the fork this can be almost eliminated. SR SUNTOUR forks will never be locked 100%.
There will be a few millimeters of remaining travel even if the fork is locked. We call this sys-
tem Anti-Blow-Of-System. It was developed to prevent you in case you have forgotten to
unlock your fork while riding in rough terrain. Additionally it ensures that the fork will not get
damaged when being compressed under high load.
Nevertheless we recommend not using the fork in the Lock-Out-Mode while riding in rough
terrain, going down hill or jumping. There is always the possibility that the fork which is set
to the locked position will get damaged when being compressed with a high load. That may
also lead into a breakage of the hydraulic cartridge it self.
Function of the Lock-Out knob:
Locked Position
This is the standard position of the LO knob if the fork
is being set to the Lock-Out-Mode. We recommend to
install the lock out knob like shown above if the fork is
being set to the Lock-Out-Mode
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Note: There are two diferent lock-out
cartridges available!
LO-cartridge Type 1:
Picture No. 2 shows the position of the LO knob if the fork
is being set to the Unlock-Mode. To set the fork into the
Unlock-Mode you have to turn the LO knob 90degree
counter-clockwise until the stopper tab.
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LO-cartridge Type 2:
Picture No. 3 shows the position of the LO knob if the fork
is being set to the Unlock-Mode. To set the fork into the
Unlock-Mode you have to turn the LO knob 180degree
counter-clockwise until the stopper tab.
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Note: If the fork doesnt lock even if the LO knob is set to the Lock-Out-Mode or if the fork doesnt
unlock if even if the LO knob is set to the Unlock-Mode, please be so kind and take a lock at
Chapter V sub-item 5.6. This instruction will show you how to reset the lock out system.
chapter IV
Instruction Sheet
for
Suspension seat post
SP-NCX-D3
and SP-NEX-D4
Suspension Seat Post Instruction Sheet
Models: SP8-NCX and SP8-NEX
Before using the suspension seat post
Read this instruction sheet thoroughly before using the suspension seat post. The
inappropriate use of the suspension seat post may cause serious injuries. Make sure to
follow all warning and caution indications. This instruction sheet contains important
information on the correct installation and usage of the suspension seat post. Please
make sure to keep this instruction sheet in a safe place for future references after read-
ing it. If the ownership of the seat post is transferred to another person, this instruction
sheets has to be given to the owner.
Important Safety Information
1. Do not ride your seat post, if it is only inserted until
the minimum insertion mark which visibly indicated
on the front side of the seat post tube. Due to the
high leverage of any seat post, it needs to be inserted
approximately 10mm past the joint of the top tube
and the seat tube in order to protect the frame from
breaking.
2. Before each ride please make sure that the seat clamp
is tightened to the proper torque value. Not securing
the clamp can cause serious accidents, as the saddle
may move during the ride. Follow the bicycle manu-
facturers specifcation for the clamp torque value.
3. Always use genuine SR SUNTOUR parts. The usage of
other replacement parts voids the warranty and could
cause structural failure to the suspension seat post.
4. If you are going to use the suspension seat post in
combination with a child seat, make sure to use a SR
SUNTOUR neoprene protection cover to avoid any
injuries to the childs hand.
Installation of the Suspension Seat Post
SR SUNTOUR recommends your NCX or NEX suspension seat post is being installed by a trained
and qualifed bicycle mechanic. Only a qualifed bike mechanic is able to assure a proper installed
and adjusted suspension seat post.
If you are upgrading your bike by using a SR SUNTOUR suspension seat post, please follow the
steps mentioned below:
1. Remove your old seat post
2. Clean the inside of the seat tube and check it for any burrs at the end of the seat tube
slot
3. Grease the inside of the seat tube. If you are going to use a seat post shim, grease it in-
and outside
4. Install the seat post and insert it past the minimum insertion mark and appox. 10mm
past the joint of top and seat tube
Installation of the saddle

a. Unscrew the two fxing bolts using a
5mm Allen Key
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b. Take of the upper clamp plate
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c. Place the upper clamp plate on to
the saddle rail. Afterwards direct the
gripper clamp through the two saddle
rails and over the upper clamp plate.
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4
d. Tighten the two fxing bolts until the
saddle is already fxed but can still be
adjusted.
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5
e. Adjust the saddle that it is centered
horizontal like shown in picture no. 6.
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6
f. Tighten the two fxing bolts with a
torque value of 12Nm.
Performance Tuning
SR SUNTOUR suspension seat posts can be tuned according to your personnel weight, riding style
and the terrain you are riding on by adjusting the preload. The preload can be adjusted to ft the
needs of riders between 144 to 220 lbs (65 to 100kg). If you are less than 144lbs (65kg) or more than
220lbs (100kg) you have the possibility to replace the standard springs to a softer one or a harder
one. To change the springs of your suspension seat post, please follow the instructions stated un-
der How to change coil springs.
If the SAG of your suspension seat post is too high (the saddle moves down and back) while youre
just sitting on your bike, you have to increase the preload of your seat post. A certain amount of
SAG is OK. We recommend an SAG between 0mm-10mm travel, but this is an individual setting and
depends as well on your weight, seating position and the terrain you are going to ride on. Chang-
ing the preload will alter the SAG and breakaway torque.
How to increase the preload of the suspension seat post?
1. Reinstall the suspension seat post of
your frame
2. To adjust the preload you have to turn
the adjuster bolt clock-wise using a
6mm Allen key.
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1
Do not turn the adjuster bolt counter-clockwise beyond the initial position at delivery.
This can cause a failure to the preload adjuster bolt and can strip the threads. In this
original position, around 10mm of the seat post thread should be visible.
How to change coil springs
1. Reinstall the suspension seat post of
your frame
2. Unscrew the preload adjuster bolt
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3. Slide out the coil springs
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Please fnd the diferent
coil spring setting combinations
here:
weight
[lbs]
weight
[kg]
Picture
Soft 99 165 45 75 SP3.1
Standard 144 220 65 - 100 SP3.2
Hard 176 265 80 - 120 SP3.3
picture SP 3.1 picture SP 3.2 picture SP 3.3
4. Reassemble the coil springs back into
the seat post
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5. Tighten the preload adjuster bolt at
least until 10mm of the whole thread
is visible
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6. Install the suspension seat back to
your bike again
chapter V
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P
1
1
6
-
3
0
1
3
1
6
0
3
,
2
2
5
9
,
7
S
t
a
n
d
a
r
d
F
E
P
1
1
6
-
0
2
1
3
1
6
3
2
,
9
2
9
-
2
4
5
.
9
-
7
.
3
S
o
f
t
o
n

r
e
q
u
e
s
t
A
B
C
T
r
e
k
k
i
n
g

B
i
k
e

F
o
r
k
s

7
0
0
c

c
o
n
t
i
n
u
e
d

f
r
o
m

p
r
e
v
o
i
u
s

p
a
g
e
Maximum possible rotor diameter
2008 MTB Forks
Duro Series 210mm
Durolux Series 210mm
Axon Series 185mm
Epicon Series 185mm
Raidon Series 185mm
XCR Series 185mm
XCM Series 185mm
XCT Series 160mm
XCU Series 160mm
M2000 Series 160mm
2008 Trekking Forks
NRX Series 185mm
NCX Series 185mm
NCX FT Series 180mm
NEX Series 180mm
2007 MTB Forks
Duro Series 210mm
Rux Series 210mm
XC-Pro Series 185mm
Axon Series 185mm
Epicon Series 185mm
Raidon Series 180mm
XCR Series 185mm
XCM Series 185mm
XCT Series 160mm
XCU Series 160mm
M2000 Series 160mm
NEX 26 Series 180mm
2007 Trekking Forks
NRX Series 185mm
NCX Series 185mm
NCX FT Series 180mm
NEX Series 180mm
M2000N Series 160mm
Serial Number Explanation
country of
origin
year
production
line
month day
T 07 D 06 21
C 07 E 05 15
C = China
T = Taiwan
Tightening Torque Chart
Pos. Part to be tightened Tightening torque [Nm]*
1 Fork top cap (alloy) 10
2 Fork top cap (plastic) 5
3 Lower fxing bolt/nut 10
4 V-brake pivot 15
5 Upper and Lower crown fxing bolts 7
6 Through axle fxing bolt (Durolux 20/Duro FR20) 11
7 axle nut (BB XCR FX, Hexagon 28mm) 7-10
8 BB XCR FX crank fxing bolt (BB XCR FX) 40-45
* Tolerance: 10%

1/2

3

4
s
c
h
e
m
a
t
i
c

g
r
a
p
h
i
c

s
h
o
w
i
n
g

n
u
t
s

a
n
d

b
o
l
t
s

f
o
r

t
i
g
h
t
e
n
i
n
g

t
o
r
q
u
e

c
h
a
r
t

5
Oil Type Chart
Oil type Viscosity (40deg.c) wt
KCE202 11cSt 5
KCE207 31cSt 10
Oil type Viscosity cc
Air chamber sealing oil 150 cSt 6

6
s
c
h
e
m
a
t
i
c

g
r
a
p
h
i
c

s
h
o
w
i
n
g

n
u
t
s

a
n
d

b
o
l
t
s

f
o
r

t
i
g
h
t
e
n
i
n
g

t
o
r
q
u
e

c
h
a
r
t
b
o
t
t
o
m

b
r
a
c
k
e
t

c
r
a
n
k

a
s
s
e
m
b
l
y

B
B
-
X
R
C

F
X

7

8
chapter VI
Fork Maintenance
Manuals
Fork Maintenance
Check your fork before each ride! Contact your dealer immediately if you recognize any dam-
ages at your fork.
The following points need to be checked:
Visible damage(e.g. cracks, dents etc.) at the fork on upper or lower tubes, fork
crown, brace, dropouts, as a result of a downfall, crash or other causes.
The forks preload The preload of the fork has to be set according to your weight and seating
position. For more information please take a look at the category: Setting the SAG
Tightness of the headset by pressing the brake lever of the front brake and pushing and pulling
the bike front- and backwards in order to fgure out if there is any kind of play within the head-
set.
Brake pads adjustment on the rim and distance to the rim (1-2mm is optimal)
Brake lever travel the brake pads and rim should contact each other after 1/3 of the whole
lever travel range.
Check the frmness of the brake assembly apply the brakes several times and check it carefully
for loose nuts, bolts etc.
The front wheel has to be centered within the fork lower tubes. Check the proper torque for the
quick release mechanism.
Maintenance
SR SUNTOUR forks are designed to be nearly maintenance free. However, as long as moving parts
are exposed to moisture and contamination, the performance of your fork might be reduced after
several rides. To maintain a high performance, safety and a long life of your fork, a periodic mainte-
nance is required.
Regular Maintenance:
Before every ride we recommend to check the following parts!
a. Front wheel and quick release for a proper installation and adjustment
b. Fork for any obvious damage (crown, brace, upper, bottom case, drop outs)
c. Front brake cable for proper routing
d. Front brake pads for proper contact with the rim / abrasion of disc brake pads
e. Brake levers for proper adjustment and function
f. Headset for proper function and adjustment
g. Stanchion tubes for scratches. In case of deeper scratches contact your dealer immediately
for an advice.
In any case, if you feel that your forks performance has changed or it handles diferently as
normal please contact your dealer immediately to inspect your fork.
We recommend servicing the fork after 50 and 100hours of riding. This service has to be performed
by a trained and qualifed bike mechanic. If you ride in extreme weather and terrain conditions, we
recommend carrying out the service more frequently.

Maintenance Schedule
after
every ride
after
25 hours
after
50 hours
after
100 hours
clean the stanchion tube and the dust
seal area
check the main fxing bolts for proper
torque (Nm)
oil the dust seal area with tefon oil or
other fork oil
check the function of your fork / clean
and grease the bushings at the dealer
change oil and lubricate the remote lock
and travel adjust beneath the top cap
with tefon oil
inspection and service of the complete
fork at the dealer
Important advice for fork service
Your suspension fork requires periodic maintenance, as moisture and contamination may build
up inside the fork depending on the weather conditions during your ride. In order to maintain the
forks proper performance, we recommend to get it serviced (disassembling, cleaning, lubricating,
adjusting) periodically by a trained and qualifed bike mechanic. We strongly recommend this ser-
vice if you intend to not using the fork for a long period of time.
Never use a high pressure spray gun for cleaning your fork, as water may enter the fork at the dust
seal level.
The periodic greasing of the dust seals is very important, as it is linked directly to smooth function
of the fork. At any time you may feel that your fork isnt moving as smooth as before (even if you
oiled the fork after each 25 hours) please contact your dealer to disassemble the fork and clean and
grease the dust seals and metal bushings.
For each fork service at a dealer you should clean your fork!
Please keep in mind that a fork which has not been serviced in accordance with the maintenance
recommendations will loose its warranty!
How to Replace Remote-Lock-Out + Damping (RLD) cartridge
Models:AXON / EPICON / NRX
a. Pull out the rebound adjuster knob
using a needle nose pliers
p
i
c
t
u
r
e

1
b. Unscrew the fxing bolt half way using
an 8mm Allen key
p
i
c
t
u
r
e

2
c. Hit the fxing bolt with plastic tip ham-
mer slightly
p
i
c
t
u
r
e

3
d. Unscrew the fxing bolt full way and
take it out
p
i
c
t
u
r
e

4
e. Unscrew the fxing bolt of the remote
lock cover cap using a 2.5mm Allen
key
p
i
c
t
u
r
e

5
f. Unfasten the remote lock unit fxing
bolt using a Phillips screwdriver No. 2
p
i
c
t
u
r
e

6
g. Unfasten the remote lock cartridge us-
ing a 27mm socket wrench
p
i
c
t
u
r
e

7
h. Take out the old cartridge
p
i
c
t
u
r
e

8
i. Before assembling the new cartridge
make sure that it is set to the unlocked
position
p
i
c
t
u
r
e

9
j. Pull out the support tube assy full way
p
i
c
t
u
r
e

1
0
k. Tighten the new cartridge with 10Nm
using a 27mm socket wrench p
i
c
t
u
r
e

1
1
l. Fasten the damper fxing bolt with
6Nm using an 8mm Allen key p
i
c
t
u
r
e

1
2
90 unlock
m. Reassemble the rebound adjuster
knob p
i
c
t
u
r
e

1
3
n. Reinstall the remote lock out unit us-
ing a Phillips screwdriver No.2 p
i
c
t
u
r
e

1
4
o. Reinstall the toothed wheel and
spring unit like shown on picture No.
15
p
i
c
t
u
r
e

1
5
p. Assemble the remote lock unit cover
cap using a 2.5mm Allen key
p
i
c
t
u
r
e
1
6
open position
How to replace Remote-Lock-Out + Damping (RLD) cartridge
Models: RAIDON RL / XCR RL / NCX RL
a. Unscrew the two fxing bolts half way
using a 5mm Allen key
p
i
c
t
u
r
e

1
b. Hit the fxing bolts with plastic tip
hammer slightly
p
i
c
t
u
r
e

2
c. Unscrew the fxing bolts full way and
take them out
p
i
c
t
u
r
e

3
d. Separate upper and bottom case
p
i
c
t
u
r
e

4
e. Take of the remote look out unit us-
ing a 2.5mm Allen key
p
i
c
t
u
r
e

5
f. Unscrew cartridge fxing bolt using a
10mm socket wrench / NCX RL: 5mm
Allen key
p
i
c
t
u
r
e

6
g. Hit the fxing bolt slightly using a plas-
tic tip hammer
p
i
c
t
u
r
e

7
h. Take out the old cartridge and install
the new one
p
i
c
t
u
r
e

8
i. Tighten the cartridge fxing bolt again
using a 10mm socket wrench / NCX
RL: 5mm Allen key
p
i
c
t
u
r
e

9
j. Reinstall the remote-lock-out unit us-
ing a 2.5mm Allen key p
i
c
t
u
r
e

1
0
k. Reassemble the upper and bottom
case p
i
c
t
u
r
e

1
1
l. Before fastening the left fxing bolt
you have to pull up the fork p
i
c
t
u
r
e

1
2
m. Fasten the fxing bolts with 10Nm us-
ing a 5mm Allen key p
i
c
t
u
r
e

1
3
How to replace Lock-Out (LO) cartridge
Models: RAIDON LO / RAIDON LO air / XCR LO / XCM HLO
NCX D LO / NCX E LO / NCX FT D LO / NEX4610 HLO
p
i
c
t
u
r
e

1
hammer slightly
p
i
c
t
u
r
e

2
take them out
p
i
c
t
u
r
e

3
p
i
c
t
u
r
e

4
e. Take of the lock-out knob
p
i
c
t
u
r
e

5
f. Take out the adjust core using a
needlenose pliers
p
i
c
t
u
r
e

6
g. Unfasten the cartridge fxing bolt half
way using a 5mm Allen key
p
i
c
t
u
r
e

7
h. Hit the fxing bolt slightly using a plas-
tic tip hammer
p
i
c
t
u
r
e

8
i. Unscrew the cartridge fxing bolt full
way and take out the cartridge
p
i
c
t
u
r
e

9
j. Install the new cartridge and fasten
the fxing bolt with 10Nm p
i
c
t
u
r
e

1
0
k. Set the cartridge to the unlocked posi-
tion before continuing. To do so use a
4mm Allen key
p
i
c
t
u
r
e

1
1
l. Reassemble the adjust core
p
i
c
t
u
r
e

1
2
m. Reassemble the upper and bottom
case
n. Before fastening the left fxing bolt
you have to pull up the fork. p
i
c
t
u
r
e

1
3
o. Tighten the fxing bolts with 10Nm
using a 5mm Allen key p
i
c
t
u
r
e

1
4
How to replace the Travel-Adjust (TA) cartridge
Models: DUROLUX SERIES / EPICON TAD / XC-PRO TAD / XC-PRO TA
Old travel adjust top cap unit
a. Unscrew the fxing bolt using a 10mm
socket wrench
p
i
c
t
u
r
e

1
b. Take of the travel adjust unit cover
cap using a 2.5mm Allen key
p
i
c
t
u
r
e

2
c. Take of the travel adjust core using a
Phillips screwdriver No.2
p
i
c
t
u
r
e

3
d. Take out the circlip using a small
screwdriver
p
i
c
t
u
r
e

4
e. Take out the travel adjust core

p
i
c
t
u
r
e

5
f. Unscrew the cartridge using a 27mm
socket wrench
p
i
c
t
u
r
e

6
g. Hit the cartridge slightly using a plas-
tic tip hammer and take it out
p
i
c
t
u
r
e

7
h. Assemble the new cartridge and fas-
ten it with 10Nm using a 27mm socket
wrench
p
i
c
t
u
r
e

8
i. Reinstall the travel adjust core
p
i
c
t
u
r
e

9
j. Reassemble the circlip using a small
screwdriver p
i
c
t
u
r
e

1
0
k. Fasten then travel adjust core using a
Philips screwdriver No.2 p
i
c
t
u
r
e

1
1
l. Reinstall the travel adjust unit cover
cap using a 2.5mm Allen key p
i
c
t
u
r
e

1
2
m. Fasten the fxing bolt with 6Nm using
a 10mm socket wrench p
i
c
t
u
r
e

1
3
New travel adjust top cap unit
The working steps which need to be carried out are very similar between the old and the new
travel adjust. The only big diference is the new travel adjust top cap unit. Therefore we are just
concentrating on how to replace the new top cap unit. The other working steps are identical with
the ones described above.
a. Unscrew the two fxing bolts using a
2mm Allen key
p
i
c
t
u
r
e

1
b. Take out the circlip using a small
screwdriver
p
i
c
t
u
r
e

2
c. Take out the travel adjust core using a
circlip pliers
p
i
c
t
u
r
e

3
How to solve air leaking problems
Models: All air cartridge forks
a. Release all air
p
i
c
t
u
r
e

1
b. Unscrew the air top cap using a
27mm/21mm Allen key
p
i
c
t
u
r
e

2
c. Take out all remaining old oil
p
i
c
t
u
r
e

3
d. Refll the fork with 6ml of 80W gear oil
p
i
c
t
u
r
e

4
e. Grease the O-ring of the air top cap

p
i
c
t
u
r
e

5
f. Tighten the air top cap with 10Nm us-
ing a 27mm/21mm Allen key
p
i
c
t
u
r
e

6
g. Infate the fork according to the per-
sonal settings of the customer
p
i
c
t
u
r
e

7
We recommend infating the fork over night with a test pressure of 150psi (10.3 bar) and to test it again
the next day.
How to solve hydraulic Lock-Out issues
Models: RAIDON air LO / RAIDON LO / XCR LO / XCM HLO
NXE E LO / NCX D LO / NEX4610 HLO / CR990 LO / CR940 LO
The fork does not lock even after turning the lock out knob to the locked position
a. Take of the lock-out knob
p
i
c
t
u
r
e

1
b. Take out the adjust core using a
needle nose pliers
p
i
c
t
u
r
e

2
c. Test if the cartridge fxing bolt is
tightened properly with 10Nm using a
5mm Allen key
p
i
c
t
u
r
e

3
d. Turn the core clockwise until the stop-
per using a 4mm Alllen key.

The fork should now be completely
locked!
p
i
c
t
u
r
e

4
e. Make sure the adjust core is installed
properly
p
i
c
t
u
r
e

5
p
i
c
t
u
r
e

6
f. The lock-out knobs nose has to be
installed like shown in picture no.7
p
i
c
t
u
r
e

7
g. To test if the fork unlocks, turn the
lock out knob counter-clockwise
p
i
c
t
u
r
e

8
How to solve Mechanical-Lock-Out (MLO) issues
Models: XCM MLO / XCT V2 MLO / NEX MLO SERIES / CR8V MLO / CR 8R MLO
a. Pull out the lock out knob using a
needle nose pliers
p
i
c
t
u
r
e

1
b. Unscrew the lock out top cap using a
27mm/21mm socket wrench
p
i
c
t
u
r
e

2
c. Take out the upper stopper using a
needle nose pliers
p
i
c
t
u
r
e

3
d. Unscrew the two fxing bolts using a
10mm socket wrench
p
i
c
t
u
r
e

4
e. Separate the upper and the bottom
case

p
i
c
t
u
r
e

5
f. Slide out the sup spring, lower index
and lower stopper
p
i
c
t
u
r
e

6
g. Take out the fxing bolts using an ex-
tra long 5mm Allen key and a monkey
wrench
p
i
c
t
u
r
e

7
h. Make sure the main fxing bolt is
a hexagon screw and not an Allen
screw. Otherwise the lock out mecha-
nism can not work
p
i
c
t
u
r
e

8
i. The hexagon screw has to ft into the
lower spring stopper
p
i
c
t
u
r
e

9
j. Picture No. 10 shows how upper stop-
per and lower index ft together p
i
c
t
u
r
e

1
0
k. Reinstall the main fxing bolt using a
extra long 5mm Allen key and a mon-
key wrench
p
i
c
t
u
r
e

1
1
l. Slide the sup spring, lower index and
lower stopper back in p
i
c
t
u
r
e

1
2
m. Slide in the upper stopper
p
i
c
t
u
r
e

1
3
n. Reinstall the lock out top cap with
10Nm using a 27mm/21mm socket
wrench
p
i
c
t
u
r
e

1
4
o. Install the adjust stopper like shown
on picture No. 15 p
i
c
t
u
r
e

1
5
p. Reinstall the lock out knob back again.
Make sure it is set to the unlocked
position (green)
p
i
c
t
u
r
e

1
6
q. Reassemble upper and bottom case
with 10Nm using a 10mm socket
wrench
p
i
c
t
u
r
e

1
7
How to convert the travel of an Axon fork
a. Release all air
b. Unscrew the fxing bolt using a 10mm
socket wrench
p
i
c
t
u
r
e

A
X
0
1
c. Pull out the rebound adjust knob
p
i
c
t
u
r
e

A
X
0
2
d. Unscrew the fxing bolt half way
p
i
c
t
u
r
e

A
X
0
3
e. Hit the fxing bolt slightly using a plas-
tic tip hammer
p
i
c
t
u
r
e

A
X
0
4
f. Separate upper and bottom case
p
i
c
t
u
r
e

A
X
0
5
g. Unscrew the fork nose using a monkey
wrench
p
i
c
t
u
r
e

A
X
0
6
h. Slide out the support tube assy
p
i
c
t
u
r
e

A
X
0
7
i. To convert the travel you have to re-
move the pin and reset the spacer
p
i
c
t
u
r
e

A
X
0
9
p
i
c
t
u
r
e

A
X
0
8
100mm 80mm
j. Reassamble the support tube assy
back into the upper
p
i
c
t
u
r
e

A
X
0
7
k. Grease the fork nose and fasten it
p
i
c
t
u
r
e

A
X
0
6
l. Reassemble upper and bottom case
p
i
c
t
u
r
e

A
X
0
5
m. Fasten the fxing bolt with 4Nm using
a 10mm socket wrench
p
i
c
t
u
r
e

A
X
0
1
n. Fasten the fxing bolt with 10Nm using
a 5mm Allen key
p
i
c
t
u
r
e

A
X
0
3
o. Reassemble the rebound adjuster
knob
p
i
c
t
u
r
e

A
X
0
2
How to convert the travel of an Epicon Suspension fork
a. Release all air
p
i
c
t
u
r
e

E
P
1
b. Unscrew the fxing bolt half way using a
5mm Allen key
p
i
c
t
u
r
e

E
P
2
c. Hit the fxing bolts with plastic tip ham-
mer slightly
p
i
c
t
u
r
e

E
P
3
d. Unscrew the fxing bolts full way and take
them out
p
i
c
t
u
r
e

E
P
4
e. Unscrew the air valve top cap using a
27mm socket wrench
p
i
c
t
u
r
e

E
P
5
f. Pull out the air semi cartridge
p
i
c
t
u
r
e

E
P
6
g. Take of the air valve top cap
p
i
c
t
u
r
e

E
P
7
h. Slide out the air piston, support tube,
rebound springs and spring guides
Make sure the air piston does not get dirty
p
i
c
t
u
r
e

E
P
8
i. Convert the travel:
0 Spacer = 140mm travel
p
i
c
t
u
r
e

E
P
9
p
i
c
t
u
r
e

E
P
1
0
p
i
c
t
u
r
e

E
P
1
1
p
i
c
t
u
r
e

E
P
1
2
j. Reassemble the support tube, rebound
springs, spring guides and air piston back
into the air cylinders
p
i
c
t
u
r
e

E
P
1
3
k. Seal the air piston with 6ml of a 80W gear
oil
p
i
c
t
u
r
e

E
P
1
4
l. Seal the air valve top cap with
SR SUNTOUR Con Panna grease. After-
wards reassemble the air valve top cap
and the semi air cartridge
p
i
c
t
u
r
e

E
P
1
5
m. Reinstall the semi air cartridge to the fork
p
i
c
t
u
r
e

E
P
1
6
n. Fasten the semi air cartridge with 10Nm
using a 27mm socket wrench
p
i
c
t
u
r
e

E
P
1
7
o. Reinstall the fxing bolt and fasten it with
10Nm using a 5mm Allen key
p
i
c
t
u
r
e

E
P
1
8
p. Infate the fork
How to change slider sleeves (plugged dust seals)
Models: XCM SERIES / XCT V2 SERIES / NCX D / NCX D LO / NEW SERIES /
CR980 LW / CR920 / CR 8V SERIES / CR 8R SERIES
a. Unscrew the top cap using a preload
adjuster tool preload adjuster remover
p
i
c
t
u
r
e

1
b. Take out the coil springs
p
i
c
t
u
r
e

2
c. Unscrew the two main fxing bolts us-
ing a 5mm extra long Allen key
p
i
c
t
u
r
e

3
p
i
c
t
u
r
e

4
e. Take of the plugged dust seals using
a screwdriver

p
i
c
t
u
r
e

5
f. Take out the old dust seals using a
pliers. Turn the sleeve approximately
90 degrees counter clock wise
p
i
c
t
u
r
e

6
g. The clip of the slider sleeve has to
be clicked into the notch of the fork
lower
p
i
c
t
u
r
e

7
h. After installing the sleeves, plug the
dust seals back onto the fork lower
p
i
c
t
u
r
e

8
i. Reassemble the upper and bottom
case again and fasten with 10Nm us-
ing a 5mm extra long Allen key
p
i
c
t
u
r
e

9
j. Reinstall the coil springs
p
i
c
t
u
r
e

1
0
k. Fasten the top cap using a preload
adjuster tool preload adjuster remover
tool
p
i
c
t
u
r
e

1
1
How to change slider sleeves (pressed-in dust seals)
Models: XCR SERIES / XCP 75 DJ
p
i
c
t
u
r
e

1
hammer slightly
p
i
c
t
u
r
e

2
take them out
p
i
c
t
u
r
e

3
p
i
c
t
u
r
e

4
e. Take out the dust seals using a nail
lifter

p
i
c
t
u
r
e

5
f. Take out the old dust seals
p
i
c
t
u
r
e

6
g. The clip of the slider sleeve has to
be clicked into the notch of the fork
lower
p
i
c
t
u
r
e

7
p
i
c
t
u
r
e

8
h. Reinstall the dust
seals using a dust seal
installer(28mm/30mm/32mm/35mm)
and plastic tip hammer
p
i
c
t
u
r
e

9
i. Reassemble the upper and bottom
case p
i
c
t
u
r
e

1
0
j. Before fastening the left fxing bolt
you have to pull up the fork p
i
c
t
u
r
e

1
1
k. Tighten the fxing bolts with 10Nm
using a 5mm Allen key p
i
c
t
u
r
e

1
2
chapter VII
Exploded views
SR SUNTOUR
Suspension Forks
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.
Description Part-No. Q
t
y
.
1 RL remote assembly FKE112 1
1a RL remote assembly part a see pos. 1 1
1b Snap ring see pos. 1 1
1c RL remote assembly part c see pos. 1 1
1d RL remote assembly part d see pos. 1 1
1e RL remote assembly part e see pos. 1 1
1f RL remote assembly part f see pos. 1 1
1g RL remote assembly part g see pos. 1 1
1h RL remote assembly part h see pos. 1 1
1i RL remote assembly part i see pos. 1 1
1i RL remote assembly part j see pos. 1 1
2 cable assembly not part of the set 1
2a cable housing see pos. 2 1
2b cable housing end cap see pos. 2 1
2c cable (std. bicycle shifting cable) see pos. 2 1
1c
1
1b
1f
1g
1i
1h
1j
1e
1d
2c
2a
2b
1a
RL REMOTE ASSEMBLY
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