SRSuntour Workshop Book

workshop book
Disclaimer
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 certifis sont autoriss rparer et entretenir
les fourches SR SUNTOUR
Italiano
Italian
Attenzione:
Escluso persone istruiti e qualificati 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 firmy 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,
,
!
SR SUNTOUR workshop book, version 2008/Mar/25 page 3
workshop book
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
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
IV. Instruction Sheet for Suspension

seat post SP-NCX-D3and SP-NEX-D4 .............. 47
SF7CR-8V...................................................................................................................124
Before using the suspension seat post........................................................48
SF8 DURO FR20-160...............................................................................................127
Suspension Seat Post Instruction Sheet............................... 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
SF8DUROLUX20-TS.................................................................................................125
SF8DUROLUX 20-1.5...............................................................................................126
SF7DURO-DJ-D........................................................................................................128
SF7DURO-DJ-E........................................................................................................129
SF8EPICON-RLD.......................................................................................................130
SF7EPICON-RL..........................................................................................................131
SF8EPICON-LOD......................................................................................................132
workshop book
SF7EPICON-LO.........................................................................................................133
SF7NRX-LO-63.........................................................................................................153
SF7EPICON-RLD.......................................................................................................134
SF8RAIDON-RL-air..................................................................................................154
SF7NEX4610-HLO-700-63.....................................................................................135
SF8RAIDON-LO-air.................................................................................................155
SF8NEX4610-MLO-700-63....................................................................................136
SF8RAIDON-RLD.....................................................................................................156
SF8NEX4100-26-63.................................................................................................137
SF8RAIDON-LOD.....................................................................................................157
SF8NEX4110-700-63...............................................................................................138
SF8RAIDON-LO........................................................................................................158
SF8NEX4600-HLO-26-63.......................................................................................139
SF7X1-LO...................................................................................................................159
SF8NEX4600-MLO-26-63......................................................................................140
SF7XCM-HLO............................................................................................................160
SF8NEX4510-MLO 700c.........................................................................................141
SF7XCM-MLO 26....................................................................................................161
SF7NCX-E-RL-700-75..............................................................................................142
SF7XCM-DA 26.......................................................................................................162
SF8NCX-E-LO-700-63.............................................................................................143
SF7XCM 26...............................................................................................................163
SF7NCX-D-RL-700-63............................................................................................ 144
SF7XCR-RL................................................................................................................ 164
SF7NCX-D-LO-700-63............................................................................................145
SF7XCR-LO................................................................................................................165
SF7NCX-D-700-63...................................................................................................146
SF7XCR-DA................................................................................................................166
SF8NRX S-RLD..........................................................................................................147
SF7XCR.......................................................................................................................167
SF8NRX S-RL.............................................................................................................148
SF8XCT V2................................................................................................................ 168
SF8NRX S-LOD-63...................................................................................................149
SF8XCT V2-MLO.......................................................................................................169
SF8NRX S-LO............................................................................................................150
SF7 RL Remote Assembly......................................................................................170
SF8NRX E-RL.............................................................................................................151
SF8NRX E-LO-63......................................................................................................152
SR SUNTOUR workshop book, version 2008/Mar/25, page 6
chapter
Introduction
workshop book
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 film during workshops for local dealers. We have
enclosed a DVD at the last page of the workshop book. On this DVD you will find 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 find in chapter V.
We would like to give you a short overview about what you will find within this workshop book. In chapter
II you will find all fork and rear suspension instruction sheets. Chapter number III provides you with all necessary information about the assembling of our different 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 find 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 find all exploded views of our 2007-2008 suspension fork
models.
A workshop book can never be finished 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
workshop book
Abbreviations
All Suspension Forks
DA
ELD
HLO
LO
LOD
MLO
RL
RLD
TAD
TR
DAMPING ADJUST
ELECTRONICAL LOCK OUT + DAMPING
ADJUST
HYDRAULIC LOCK OUT
LOCK OUT
LOCK OUT + DAMPING ADJUST
MECHANICAL LOCK OUT
REMOTE LOCK OUT
REMOTE LOCK OUT + DAMPING ADJUST
TRAVEL ADJUST + DAMPING ADJUST
TRAVEL ADJUST + REMOTE LOCK OUT
NRX MODELS
S
E
AIR
COIL SPRING
NCX MODELS
S
E
D
AIR
AIR
COIL SPRING
DURO
DJ E
DJ D
CroMo STEERER TUBE

STKM STEERER TUBE
AXON MODELS
S
E
D
AIR
AIR
COIL SPRING
RADOM
CW
CS
SL
RD
FD
DB
SP
FT
CHAIN WHEEL
CASSETTE
SHIFT LEVER
REAR DERAILLEUR
FRONT DERAILLEUR
DISC BRAKE
SEAT POST
FIRM TECH
workshop book
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
Worlwide Distributors
AUSTRIA
KTM FAHRRAD GMBH
Harlochner Str. 13
5230 Mattighofen
Austria
Tel.: +43 7742 4091-34
Fax: +43 7742 4094-26
email: office@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
workshop book
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
Lichfield, Staffs. 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
Sinfin lane
Sinfin lane industrial estate
U.K.
Tel.: +44 133 22 74 238
Fax: +44 133 22 74 201
email: sales@moorelarge.co.uk
chapter
Owners manuals
II
Owners Manual
Suspension front fork w. coil spring or MCU
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

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.
INSTALLATION
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 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.
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.
Headsets:
Handlebar
stem
Minimum
insertion mark
Threaded
length
More than
10mm
Fig. 1
Steerer
tube
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.
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.
FOR MORE TUNING OPTIONS - HARDER/SOFTER SPRINGS AND MCU - PLEASE CONTACT YOUR LOCAL DEALER
Notes on usage of the fork

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)!!!
FOR DETAILED INFORMATION, TARGET CATEGORY AND EXPLODED VIEW OF YOUR FORK, PLEASE VISIT OUR WEBSITE < WWW.SRSUNTOUR-CYCLING.COM> AND DOWNLOAD THIS INSTRUCTION SHEET FOR FUTURE REFERENCE!
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)
Oil the dustseal area with Teflon oil
Function check of the fork and clean and grease service of bushings at the dealer
rs
ide hours
hou
ry r
eve fter 25 ter 50
r
e
t
f
A
A
Af
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.
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, reassembly, 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 hereunder 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.
Suspension Fork Warranty Card:

Date of purchase:
Fork model name
Serial no.
Term of limited warranty: Two years from the date of purchase

Dealer
Name:
Phone#:
Name:
Phone#:
Address:
Purchaser
Address:
This warranty is void without proof of purchase.
SR Suntour website: www.srsuntour-cycling.com

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.
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
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 EUROPE GMBH

Am Marschallfeld 6a, 83626 Valley / Germany
Phone: 49-8024-3038152 / Fax: 49-8024-4730984
E-mail: service@srsuntoureurope.com
SR SUNTOUR INC.
Specications are subject to change without notice.

Printed in TAIWAN.
Instruction Sheet
Suspension front fork with <air/air> / <air/hydraulic> or < coil spring/hydraulic> system
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

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.
INSTALLATION
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.
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-clockwise 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 turning 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).
-2-
Cable nipple. Shifting cable type.

Fixing bolt. Use a 3mm Allen key.
Cable tension adjustment barrel.
Cable guide
pulley
Cam lever
Press the lever and then the

handlebar to check the function.
Cable
xing bolt
6
Increase
tension.
For your
protection,
insert an
end cap at
the cable end.
Decrease
tension.
Travel adjust
push button.
Schrader
valve for air
pressure adjust.
Cam lever
released.
Lever bracket
xing bolt.
10
In this position, the

fork is now locked.
Outer
casing
stopper
11
For your
protection,
insert an
end cap at
the cable end.
Cable
clamping
screw.
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.
14
13
Pass the cable through
this hole below the cable
clamping screw.
12
More
tension.
Check the fork before each ride and contact your dealer if you have any questions.
Check following points:
a)
b)
c)
d)
e)
f)
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.
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.
Brake pad adjustment on the rim and distance to the rim ( 1-2 mm is optimal)
Brake lever travel - ideally the contact of the brake pad and rim should occur after 1/3 of lever travel range
Firmness of the brake assembly - apply the brakes several times and check carefully for loose nuts, bolts, etc.
Front wheel must be centred within the fork tubes. Check proper torque on wheel quick release mechanism.
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
fSuspension 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
80 mm
80 mm
100 mm
100 mm
130 mm
Intended use
Sag
Racing
XC
Racing
XC
Freeride
Lock-Out
system /
Hydraulic
system/
Air system
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.
Travel adjuster/ Air system/

preload adj.
Fork
Crown
Stanchion
Air valve
cover cap
8-12 mm
12-16 mm
10-14 mm
14-18mm
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
AIR PRESSURE CHART
Rider weight
Air pressure
lb.
kg.
psi
kgf/cm2
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/cm2
Steerer
Fork
lowers
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.
Dropout
In case of a travel adjustment fork, please follow the procedure
Rebound
described on the previous page in order to access the air valve.
adjuster
2.) attach the suspension fork air pump at the Schrader valve.
3.) pump up the fork to the desired hardness level -> see chart.
NOTE: Your forks apperance
4.) remove the pump from the valve.
may vary from the images shown in
5.) replace the cover cap.
this instruction sheet.
b) Setting Sag by spring preload
For latest information please visit

our website:
WWW.SRSUNTOUR-CYCLING.COM
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.
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 remote lock-out control
The remote travel adjuster
The I.C.E. type control DSM-XCR60-SC
-3-

can be used separately, without
the remote travel adjuster.
Fork features and function

Travel adjustment
Remote
Lock-out
System
Remote
Travel
Adjuster
Remote
Lock-out
System
Air system
Lock-out
Air system
or coil spring
Open oil +
coil spring
Coil
spring
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.
AIR
System
If you ride in extreme weather or terrain conditions, we recommend a more frequent maintenance.
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.
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.
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
-4-
rs
rs
ride
ours
hou
hou
ours
very er 25 h er 50 h er 100 er 200
e
r
t
t
e
t
t
ft
Af
Af
Af
Af
Remote
Travel
Adjuster
Notes on usage of the fork

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.
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, reassembly, 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 hereunder 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.
Suspension Fork Warranty Card:

Date of purchase:
Fork model name
Serial number
Term of limited warranty: Two years from the date of purchase

Dealer
Name:
Phone#:
Name:
Phone#:
Address:
Purchaser
Address:
SR Suntour website: www.srsuntour-cycling.com

This warranty is void without proof of purchase.
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
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 EUROPE S.A.

Chaussee de Tervueren,43,1410 Waterloo. Belgium
Tel: 0032-2-3544676 / Fax: 0032-2-354 7835 /
SR SUNTOUR INC.
Specications are subject to change without notice.

Printed in TAIWAN.
-5-
Stand: October 2006
Suntour RS7-EPICON-DA
Suntour RS6-XC PRO - RL
Suntour RS6-XC PRO - LO
Owners Manual
Rear Shock
Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 1
Do not modify your bike, frame or shock. Modication, improper service

or use of non-SR SUNTOUR spare parts voids the warranty and could
cause a shock malfunction resulting in serious injury or death.
Follow the maintainance schedule found inside this manual
If the shock is showing any malfunction such as loosing oil, doing
unusual sounds are anything is bent or broken stop riding immediately.
Contact you SR SUNTOUR dealer for assistance.
Never try to open or disassemble the shock. Opening the shock could
cause serious injury. Contact you SR SUNTOUR dealer for assistance.
The SR SUNTOUR RS6-XC Pro and RS7-EPICON-DA rear shocks are

intended to be used on marathon, cross country bikes and light freeride.
Do not use these shocks for heavy freeride, dirt jump or Downhill!!
Important Safety Information
Please check out web site http://www.srsuntour-cycling.com occasionally for updates

on this manual and safety notices. If you have any questions after reading this manual
or the information provided on our web site please contact your SR SUNTOUR dealer.
If your dealer cant handle it please contact us by using mail, phone or the internet
(adresses therefore are shown on the backside of the manual).
RS7-EPICON-DA, air spring with adjustable rebound damping

RS6-XC PRO-LO, air spring with adj. rebound damping, lockout
RS6-XC PRO-RL, air spring with adj. rebound damping, remote lockout
This manual covers the following SR SUNTOUR rear shocks:
Keep this manual as long as you are keeping your SR SUNTOUR rear shock. On this
way you can refer to the manual for upcoming questions.
Parents should explain it to their children. If the manual will not be understood properly
by the rider, please consult your dealer or another specialist.
Even if you are a experienced bicycle rider and have been doing bicycle service for years, it is important for EVERY person to read the manual completely before you ride your bike which is equipped with a
SR SUNTOUR RS6-XC PRO and RS7-EPICON-DA rear shock.
Before installation of the rear shock and riding your bike read this manual carefully. This
will help you avoid injury and damage on your new rear shock and your bike.
Congratulations on selecting a SR SUNTOUR RS6-XC PRO rear shock. This manual

explains how to choose, install, setup and maintain your new
SR SUNTOUR RS6-XC PRO and RS-7-EPICON-DA rear shock and keep it operating
safely. This manual does not contain a step-by-step details service instruction since
that kind of service is recommended to be done at a SR SUNTOUR AUTHORIZED
SERVICE CENTER only.
SR SUNTOUR RS6-XC PRO-LO/-RL and RS7-EPICON-DA
OWNERS MANUAL
Main air chamber valve
lock out controller
bend
cable
bushing
dust cap
RS6-XC PRO RL
rebound adjuster set (red)
lock out adjustment (blue)
RS6-XC PRO LO
RS7-EPICON-DA
Aluminium bushing
Aluminium bushing
RS6-XC PRO
-LO / -RL
+
RS7-EPICON-DA
Main air chamber
body
The air pressure is adjusted with a standard schrader valve shock pump on the main
air valve.
The sag is adjusted by varying the air pressure and has to be determined by the
riders weight, riding style, frame design and personal preference. Increasing the Air
pressure will make the shock compress less during the ride - that means it will feel
harder. Decreasing the Air pressure will make the shock to compress more, it feels
softer.
Adjust the sag
For maximum performance from your SR SUNTOUR shock, it is necessary to adjust the sag and the rebound damping. The way of setup is the same on all the
SR SUNTOUR RS6-XC PRO and RS7-EPICON-DA rear shock models included in
this manual.
Set-up Instructions
7. Set-up the shock as described in the set-up instructions
5. The tightening process requires only a medium amount of pressure, as the aluminium spacers are a tolerance t.
WARNING! Insufficient clearance between the shock, seatpost, swingarm,

frame or rocker can result in loss of control and serious injury or death
Establish which way you are going to position the shock take into consideration
access to the adjusters.
4. Check the movement by letting out the air of the shock and move the swingarm
through the complete shock stroke. Make sure that you have sufcient clearance
between all components to accommodate the full travel of the rear swing arm.
Keep in mind to check problems in consequence of lowered seatposts and different shock mounting bores!
3. Make sure that you are having the correct width and bore diameter aluminium
bushings at either end of the shock to connect the shock properly and play free to
the frame and swing arm. If your bike and previous shock are having a different
set up you may need to consult your SR SUNTOUR dealer.
2. Remove your old shock and clean the inside surfaces of the frame and swing
arm, remove any dirt and make sure that the surfaces are clean.
WARNING! If a longer shock is installed the geometry of your bike is changing. This can lead to steering problems and a higher bottom bracket which
prevents you touching the ground with your feet. This can result in loss of
control and serious injury or death
Information: The eye-to-eye length is the distance from the centre of the bolt at
the head of the shock to the centre of the other bolt at the base of the shock.
1. Make sure that the eye-to-eye length is the same as the original equipped
shock.
To replace a rear shock on an existing bike where it has not been equipped originally it is important to follow several steps:
Upgrade your bike with a new rear shock
25-30% sag
Freeride:
WARNING! Riding in lockout position under heavy and rough conditions can result
a shock blow off and in loss the of control and result in serious injury or death.
Be sure to open the lockout when riding in rough terrain. This ensures you the maximum comfort, riding control and prevents the oil pressure in the inside of the shock
to cause damages to the shock.
When you are riding uphill sometimes it gets necessary to lock the movement of the
suspension system to have less power loss in the transmission. With the lockout
system on the SR SUNTOUR RS6-XC PRO LO you can simply lock the system by
switching the lever from the locked to unlocked position on the blue lever on the
shock. On the SR SUNTOUR RS6-XC PRO RL it is even easier by switching the
handlebar remote lever.
Use the Lockout
WARNING! Riding with improper rebound damping can result in loss of control and
result in serious injury or death.
The best way to adjust the rebound damping is to decrease it completely by turning
on the red adjuster wheel and test ride. Increase the damping until you feel comfortable and safe without the suspension kicking you out of the saddle.
Rebound damping controls the rate at which the shock decompresses. The amount
of needed rebound damping is varying depending on the riders weight respectively
the spring rate which is set by the air pressure, the amount of travel, the riding style
and personal preferences.
Adjust the rebound damping
WARNING! Riding with improper air pressure can result in loss of control and result
in serious injury or death. Exceeding the maximum air pressure of 200lbs/inch will
result in serious injury.
Information: The pressure range is 50-200psi. Never exceed an air pressure of 200psi in
the uncompressed shock.
Increase or decrease the air pressure and repeat the measurement to get the desired
amount of sag.
To set up the sag you will need to measure how much the shock compresses when
you sit on your bike in a normal riding position. Your weight should be on the saddle
and your feet on the pedals. It may be necessary to hold yourself up against some
thing steady as a wall. Now the eye-to-eye distance has to be measured. The percentual difference between the uncompressed eye-to-eye length and the just measured one is called sag. We recommend getting assitance from another person during that measurement.
10-25% sag
Cross Country:
The recommended amount of sag is as follows:
To clean the shock it is recommended to use water and soap only.

The extensive service of the shock internals must only be done by a
AUTHORIZED SR SUNTOUR SERVICE CENTER
Get the service done on the internal parts of the shock done more frequently
when it is used mainly under extreme conditions.
Check the air pressure

Check the rebound damping
Check Air pressure
Mounting hardware torque
(it is normal that the shock is loosing air pressure over the time)
Bring the shock to an AUTHORIZED SR SUNTOUR SERVICE CENTER for

doing an extensive service on the internal parts
Every 2500km:
Before every ride:
Check mounting hardware torque according to the bike or frame manual
New installed shock / new bike:
Maintenance Shedule
After 2500km of riding, take out the mount bearing sleeve on both sides of your
shock for inspection and service. Clean them and grease or replace if necessary.
WARNING! Opening the shock without having the knowledge how to do will
result in serious injury.
Never use a high pressure cleaner to clean the shock
SR SUNTOUR RS6-XC PRO and RS7-EPICON-DA rear shocks needs a minimum

of maintenance only:
Maintenance
USA
SR SUNTOUR USA
P.O. Box 61988
Vancouver, WA 98666
Tel.: +1 (360) 737 6450
Fax: +1 (360) 737 6452
TAIWAN
SR SUNTOUR INC.
No.7 Hsing Yeh Road
Fu Hsing Industrial Zone
Chang Hua
Taiwan, R.O.C.
Tel.: + 886 / (0) 4 / 76 95 115
Fax: +886 / (0) 4 / 76 94 028
e-Mail: orders@srsuntour.com.tw
EUROPE
Am Marschallfeld 6a, 83626 Valley
Germany
Tel.: +49 / (0) 80 24 / 30 38 152
Fax: +49 / (0) 80 24 / 47 30 984
e-Mail: service@srsuntoureurope.com
Check our web site http://www.srsuntour-cycling.com for local distrutors and service
centres.
Contact and Service address
SR SUNTOUR makes no express or implied warranties of tness or merchatability

of any kind, except as set forth above. SR SUNTOURs liability hereunder 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.
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 rear shock. Any alteration of, or tampering with the warranty card
automatically terminates this limited warranty.
SR SUNTOUR warrants the rear shocks 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, reassembly, intentional breakage or
damage, alterations or modications to the rear shock 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.
LIMITED WARRANTY
Dynamo Hub Owners Manual DH-CT600-Series, page 1
If your dealer cant handle it please contact us by using mail, phone or the internet (adresses are
shown on the backside of the manual).
Information: Check out web site http://www.srsuntour-cycling.com occasionally for updates on this
manual and safety notices. If you have any questions after reading this manual or the information
provided on our web site please contact your SR SUNTOUR dealer.
Warning: Before installation of the SR SUNTOUR DH-CT600-series hub dynamo

equipped front wheel and riding your bike read this manual carefully. This will help you
avoid injury and damage on your hub dynamo and your bike. Even if you are a experienced bicycle rider or bicycle mechanic and have been doing bicycle service yourself for
years, it is important to read the manual completely before you ride your bike.
SR SUNTOUR DH-CT624-32H (6V, 2.4W, 32 spokes)

This manual covers the following SR SUNTOUR hub dynamos:
Keep this manual as long as your SR SUNTOUR DH-CT600-Series hub dynamo is in use. On
this way you can refer to the manual for upcoming questions during use.
This manual provides you important information about installation, operation and maintenance.
If you have any problems with installation or the electric performance, please stop installing or
riding and contact your nearest authorized retailer for assistance.
If the manual will not be understood properly by the rider, please consult your dealer or another
specialist. In case children are going to use the product, the parents should explain the content
of the manual.
Although the SR SUNTOUR hub dynamo is designed for easy installation, it is necessary to
know some basics which are described in the following pages. It is in any case recommended
to read and follow the manuals instructions carefully before installation and usage.
Usually the hub dynamo you purchased has been correctly installed and properly adjusted
in your bike by authorized manufacturers, dealers or retailers. In some cases you may have
bought the hub dynamo package independently to replace your existing non dynamo front
wheel hub or as replacement for another dynamo hub. In that case the hub must be assembled
into the frontwheel by a professional wheelbuilder.
To install the front wheel follow the steps described below:
The DH-CT600-series hub dynamo is a compact light and efcient bicycle dynamo hub. It is
developped to match the legal requirements, such as the german regulations StVZO 22a.
Some of the requirements are increased efciancy, voltage limitation and a characteristic of the
voltage to speed relation which reduces ickering when riding at very low speeds.It is optimized
in weight and rolling resistance. The hub is including a state of the art connector which makes
the wheel assembly as easy as possible. The DH-CT600-series hub dynamo gives you one of
the best tted products which has been delicately designed and has passed severe eld and
lab tests to achieve the best performance.
dynamo hub
connection
terminal
nut
washer
fork
dynamo hub
nut
washer
WARNING: Never ride your bike with a off-center xed front wheel. A off-center xed front
wheel can cause a malfunction of the brake or in damaging the tire and result in loss of
control and serious injury or death.
3. Check if front wheel has been inserted completely into the dropouts. Tighten the nuts on the
right and the left side alternately in steps until you reach the tightening torque of 20Nm.
Make sure that the wheel is centered between the brakes properly after tightening the nuts. If
the wheel is off-center untight the nuts and start the tightening procedure from number 1 of
this description again.
fork
Information: If the terminal connector is not aligned with the lower legs the cable can be
damaged easier. The light system will not properly work then.
2. insert the front wheel into the fork on that way that the connector terminal is located at the
right dropout (when looking from the bicycle back in forward moving drection).
Rotate the terminal so that it is aligned with the leg of the fork.
1. loose the nuts (FG9.5) and washer which are placed on the left and the right side of the axle
Installation of the front wheel
SR SUNTOUR DH-CT-600-Series Hub Dynamo Owners Manual
cable
front lamp
connector
plug
cable
(ground)
If a rear lamp is connected to the system, this is usually connected directly to the front lamp. Check the manual of the front dynamo
lamp for further information. If there is any difculty or malfunc- hub
tion please ask your dealer for assistance.
If the lamp manufacturer
Note: Do not switch over the two cables. If they are switched
over then the lamp will show no function.
Connect the upper end of the cable with the connectors of the
lamp.
Strip 18mm of the insulation on the lower end of both cables.

Guide the ends into the connector plug whereas the right cable
is the ground cable.
To connect the lamps with the hub follow the shown instruction.
Warning: Do not touch unisolated lectric components (fx. unxed cables, connector terminals and more) during riding or rotation of the wheel. Touching electric parts can cause
electric shocks and burns.
Information: The SR SUNTOUR DH-CT-600-Series Dynamo Hub is prepared to be connected

with the lamp system through a 2-wire cable. The recommended cable type is having a section of
1mm2 and a total diameter of 1.8 to 2mm including the insulation.
Information: Depending on the hub specications the lamp can only be used with a front-lamp (6V
/ 2,4W) only or a front- and rear lamp (6V / 2.4W + 0.6W).
Whereby the DH-CT624-xx hubs are for front-lamp use only and the DH-CT630-xx are for frontand rear-lamp use. Depending on the legal requirements the type of hub must be choosen.
Installation of the electric cables and connectors
Phone: +1 (360) 737 6450

Fax: +1 (360) 737 6452
SR SUNTOUR USA
P.O. Box 61988
Vancouver WA 98666
Canada
Phone: +886 (4) 7695115

Fax: +886 (4) 769 4028
E-mail: orders@srsuntour.com.tw
SR SUNTOUR INC.
No.7 Hsing Yeh Road,
Fu Hsing Ind. Zone.
Changhua.50606
Taiwan, R.O.C.
Phone: +49 / (0)8024 / 3 03 81 52

Fax: +49 / (0)8024 / 4 73 09 84

Am Marschallfeld 6a
83626 Valley
Germany
check our web site http://www.srsuntour-cycling.com for local distrutors and service
centres.
Contact and Service address
SR SUNTOUR makes no express or implied warranties of tness or merchatability

of any kind, except as set forth above. SR SUNTOURs liability hereunder 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.
The obligation of this limited warranty shall be limited to repairing or replacing the
dynamo hub 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 the warranty card to SR SUNTOUR within 30 days
after purchase of the product. Any alteration of, or tampering with the warranty card
automatically terminates this limited warranty.
SR SUNTOUR warrants the dynamo hub 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, reassembly, intentional breakage or
damage, alterations or modications to the dynamo hub 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.
LIMITED WARRANTY
chapter
Service manuals
III
workshop book
Mounting the remote lock-out single lever
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
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
picture RL1.7
a.
picture RL1.1
Models: AXON / EPICON / NRX
e.
Unscrew the cable fixing 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.
f.
Cut the cable to a proper length
picture RL1.4
Take off the plastic cover using a Allen

key
picture RL1.5
d.
picture RL1.2
workshop book
Make sure the fork is set to the Unlocked position and the little plastic
toothed wheel sits like shown on
picture no. 6
h.
Reassemble the plastic cover again using a 2.5mm Allen key
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
picture RL1.2
g.
picture RL1.6
workshop book
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.
workshop book
Mounting the remote lock-out single lever
Mount the remote lock-out lever on

your handlebar. Use a 2.5mm allen key
mount your brake and shifting lever
back on again
b.

c.

for the lock-out function
picture RL2.2
a.
picture RL2.1
Models: Raidon / XCR / NCX
Unscrew the cable fixing bolt with a

1.5mm Allen key.
Thread the cable through the outer

casing stopper and through the cover
unit hole. Tension the cable slightly
and tighten it
f.
Cut the cable to a proper

length(approx 12mm)
picture RL2.4
e.
picture RL2.5
Take off the plastic cover
picture RL2.6
d.
picture RL2.3
workshop book
Reassemble the plastic cover again
h.
Install a cable end cap at the end of

the cut cable using a needle nose
pliers
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
picture RL2.8
g.
picture RL2.7
workshop book
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.
workshop book
Mounting and Operating the remote travel adjust control New TA Lever
SF8 EPICON XC TAD
SF8 DUROLUX SERIES
Note:
The travel adjust cartridge sits within the left stanchion tube
b.
Choose the right length of the cable casing 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 firmly with the fixing bolt using a
2.5mm Allen key
d.
Cut the cable to a proper length (approx.

12mm)
picture TAL 2.2
Mount the remote travel adjust lever on

your handlebar. Use a 2.5mm Allen key
mount your brake and shifting lever back
on again
picture TAL2.3
a.
picture TAL2.1
Models:
e.
Install a cable end cap at the end of the

cut cable using needle nose pliers
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
picture TAL2.4
workshop book
workshop book
Mounting and Operating the remote travel adjust control Old TA Lever
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
b.

c.

for the travel adjustment function
d.
Remove the plastic cover cap, using a

2.5mm Allen key.
picture TAL1.7
a.
picture TAL1.1
The travel adjust cartridge sits within the left stanchion
picture TAL1.2
Note:
f.
Cut the cable to a proper length

(approx. 12mm)
g.
Reassemble the plastic cover cap

using a 2.5mm Allen key
picture TAL1.4
Thread the cable through the outer

casing stopper and through the cable
clamp. Tension the cable slightly and
tighten the cable firmly with the fixing
bolt using a Phillips screwdriver
picture TAL1.5
e.
picture TAL1.3
workshop book
h.
Install a cable end cap at the end of

the cut cable using a needle nose
pliers
i.
To decrease the travel of the fork you

have to press the lever and simultaneously 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
picture TAL1.6
workshop book
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 clamping screw and increase or decrease the cable tension at this point. Afterwards you are able to
perform the fine tuning like described above.
workshop book
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 damping 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 stiffness,
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 recommend 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.
workshop book
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
workshop book
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 different 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 different weight and seating position which influences the
fork in a different 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 find 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 inflating the fork with a standard pressure 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 inflate your fork. Inflating the fork with a compressor will cause serious damage which is not covered by warranty! SR SUNTOUR forks have to be inflated with
special suspension fork air pumps.
a.
Place your bike on a flat 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
Picture 1
63-100mm travel --> 15-20% sag

120-180mm travel --> 20-25% sag
d.
According to your own weight and

seating position the fork will sag
e.
Get off your bike again try to avoid

compressing your fork while youre
getting off
f.
Measure the distance between the

lower tube seal and the zip tie
Picture 3
Get on your bike try to avoid any

bouncing of the fork
Picture 4
c.
Picture 2
workshop book
140mm total travel

60mm sag = 45%
Too Much!
h.
Get on you bike once more try to

avoid any bouncing
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
Picture 6
Inflate the fork until you have reached

the proper pressure
Picture 7
g.
Picture 5
workshop book
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
find 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.
workshop book
Setting sag for rear suspension
Warning: It is not allowed using any kind of compressor, normal bicycle pump or air pressure pump at gas stations to inflate your fork. Inflating the fork with a compressor will cause
serious damage which is not covered by warranty! SR SUNTOUR forks have to be inflated with
special suspension fork air pumps.
How to Inflate the fork:
1. Unscrew the cover of the Schraeder valve on the left side of your fork. Regarding travel adjust
forks, please note that the Schraeder valve is being located at the lower drop out.
2. Mount the suspension fork air pump at the Schraeder valve (please only use a special suspension fork air pump, do not use any kind of compressor, normal bicycle pump or air pressure
pumps at gas stations).
3. adjust the air pressure according to your own weight and seating position, so that you achieve the SAG
which is recommended for your fork.
4. Dismount the pump from the valve

5. Reinstall the cover cap again
workshop book
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 system Anti-Blow-Off-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.
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
Note:
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.
Picture LO2
There are two different lock-out

cartridges available!
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.
Picture LO3
Note:
Picture LO1
Function of the Lock-Out knob:
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
Instruction Sheet
for
Suspension seat post
SP-NCX-D3
and SP-NEX-D4
IV
workshop book
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 reading 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 manufacturers specification 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.
workshop book
Installation of the Suspension Seat Post
SR SUNTOUR recommends your NCX or NEX suspension seat post is being installed by a trained
and qualified bicycle mechanic. Only a qualified 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
Grease the inside of the seat tube. If you are going to use a seat post shim, grease it inand outside
Install the seat post and insert it past the minimum insertion mark and appox. 10mm
past the joint of top and seat tube
3.
4.
Unscrew the two fixing bolts using a

5mm Allen Key
b.
Take off the upper clamp plate
picture 2
a.
picture 1
Installation of the saddle
d.
Tighten the two fixing bolts until the

saddle is already fixed but can still be
adjusted.
e.
Adjust the saddle that it is centered

horizontal like shown in picture no. 6.
f.
Tighten the two fixing bolts with a

torque value of 12Nm.
picture 5
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.
picture 6
c.
picture 4
workshop book
workshop book
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 fit 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 under 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. Changing the preload will alter the SAG and breakaway torque.
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.
picture 1
How to increase the preload of the suspension seat post?
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.
workshop book
Reinstall the suspension seat post of
your frame
2.
Unscrew the preload adjuster bolt
3.
Slide out the coil springs
Please find the different

coil spring setting combinations
here:
picture 2
1.
picture 1
How to change coil springs
weight
[lbs]
Soft 99 165
Standard 144 220
Hard 176 265
picture SP 3.1
weight
[kg]
45 75
65 - 100
80 - 120
picture SP 3.2
Picture
SP3.1
SP3.2
SP3.3
picture SP 3.3
Reassemble the coil springs back into

the seat post
5.
Tighten the preload adjuster bolt at

least until 10mm of the whole thread
is visible
6.
Install the suspension seat back to

your bike again
picture 4
4.
picture 3
workshop book
chapter
Charts
Hydraulical-Lock-Out
Remote-Lock-Out-Unit
NCX D LO
NCX FT S RL
NCX FT E RL
NCX FT D RL
NCX FT D LO
EPICON XC TAD
NCX D RL
EPICON DA
EPICON LO
EPICON RL
NCX E LO
EPICON LOD
NCX E RL
EPICON RLD
Preload Adjust
NCX S RL
Preload Adjust
VVC
DUROLUX 20 1.5
DURO DJ D
VVC
DUROLUX 20 TRIPLE
DURO DJ E
VVC
AXON RLD
DUROLUX 20TS
AXON RL
Preload Adjust
Preload Adjust
Air Pressure Adjust
Air Pressure Adjust
Preload Adjust
Preload Adjust
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Travel-Adjust-Unit
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Preload Adjust
Preload Adjust
Travel-Adjust-Unit
Travel-Adjust-Unit
Travel-Adjust-Unit
Air Pressure Adjust
Air Pressure Adjust
Rebound-Damping Adjust
C
-
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Schematic explanation of positions of adjusters and valves on SR SUNTOUR suspension forks.
Overview of the fork systems
workshop book
D
Mechnical-Lock-Out
Mechnical-Lock-Out
NRX S LO
NRX E RL
NRX E RL
RAIDON RL air
RAIDON LO air
RAIDON RLD
RAIDON LOD
RAIDON LO
XCM HLO
XCM MLO
XCR RL
XCR LO
XCT V2 MLO
Mechnical-Lock-Out
NEX4600 MLO
Mechnical-Lock-Out
NEX4610 MLO
NRX S RL
NRX S RLD
Preload Adjust
NEX4610 HLO
NEX4600 HLO
Preload Adjust
Preload Adjust
Preload Adjust
Preload Adjust
Preload Adjust
Preload Adjust
Air Pressure Adjust
Air Pressure Adjust
Preload Adjust
Preload Adjust
Air Pressure Adjust
Air Pressure Adjust
Air Pressure Adjust
Preload Adjust
workshop book
D
B
D
air spring
air spring
coil spring
coil spring
coil spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
air spring
SF8-AXON-RL
SF8-Duro FR20
SF7-Duro DJ E
SF7-Duro DJ D
SF8-Durolux 20 triple
SF8-Durolux 20 1.5
SF8-Durolux 20 TS
SF8-EPICON XC TAD
SF8-EPICON-RLD
SF8-EPICON-RL
SF8-EPICON-LOD
SF8-EPICON-LO
SF8-EPICON-DA
SF8-RAIDON-RL air
SF8-RAIDON-LO air
SF8-NRX S RLD 700C Ltd.
SF8-NRX S RLD 700C
SF8-NRX S RL 700C
SF8-NRX S LOD 700C
SF8-NRX S LO 700C
SF7-NCX -E- RL 700C
SF7-NCX-E LO 700C
SF-CR990 LO 700C
SF-Condor TA 26
System
SF7-AXON-RLD
Models 2008
45
45
45
45
45
80
80
80
80
Right
Left
Oil amount
[cm]
Suspension Fork Air Pressure and Oil Level Chart
workshop book
not decided
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
Oil type
20 - 25
15
15
15
15
15
15
15
15
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
15 - 20
20 - 25
20 - 25
20 - 25
15 - 20
15 - 20
[%]
SAG
29
29
75
75
150
150
150
150
150
150
150
150
150
180
180
180
180
180
180
180
180
150
150
150
165
165
Air pressure
[psi]
Right
Left
min max min max
2,0
2,0
10,5
10,5
10,5
10,5
10,5
10,5
10,5
10,5
10,5
12,6
12,6
12,6
12,6
12,6
12,6
12,6
12,6
10,5
10,5
10,5
11,6
11,6
2,0
2,0
5,1
5,1
10,3
10,3
10,3
10,3
10,3
10,3
10,3
10,3
10,3
12,4
12,4
12,4
12,4
12,4
12,4
12,4
12,4
10,3
10,3
10,3
11,4
11,4
Air pressure
[bar]
Right
Left
min max min max
5,3
5,3
Air pressure
[kgf/cm]
Right
Left
min max min max
air spring
open oil bath
open oil bath
open oil bath
open oil bath
open oil bath
open oil bath
coil spring
coil spring
coil spring
air spring
air spring
air spring
air spring
air spring
air spring
SF7-RUX triple
SF7-RUX-S
SF7-RUX-E
SF7 XC PRO TAD
SF7 XC PRO TA
SF7 XC PRO TR
SF7 DURO DJ E
SF7 DURO DJ D
SF7 DURO DJ TRIPLE
SF7-EPICON-RLD
SF7-EPICON-RL
SF7-EPICON-LOD
SF7-EPICON-DA
SF7-NRX S RLD 700C Ltd.
SF7-NRX S RLD 700C
System
SF7-AXON-RLD
Models 2007
45
45
85
85
85
85
80
80
90
150
150
220
75
Right
120
120
220
Left
Oil amount
[cm]
workshop book
KCE 207
KCE 207
KCE 202
KCE 207
KCE 207
KCE 207
KCE 207
KCE 207
KCE 202
KCE207
KCE207
KCE207
KCE207
Oil type
15
15
15 - 20
15 - 20
15 - 20
15 - 20
20 - 25
20 - 25
20 - 25
20 - 25
20 - 25
20 - 25
15 - 20
[%]
SAG
150
150
180
180
180
180
180
180
180
23
23
23
165
Air pressure
[psi]
Right
Left
min max min max
10,5
10,5
12,6
12,6
12,6
12,6
12,6
12,6
12,6
1,6
1,6
1,6
11,6
10,3
10,3
12,4
12,4
12,4
12,4
12,4
12,4
12,4
1,6
1,6
1,6
11,4
Air pressure
[bar]
Right
Left
min max min max
Air pressure
[kgf/cm]
Right
Left
min max min max
Air spring
Air spring
open oil bath
open oil bath
open oil bath
open oil bath
open oil bath
open oil bath
open oil bath
open oil bath
Coil spring
Coil Spring
Air spring
Air spring
Air spring
Air spring
Air spring
Air spring
Air spring
Air spring
air spring
Air spring
SF6AXON-E RL-
SF6RUX S-130
SF6RUX E-130
SF6-RUX triple
SF6RUX DJ-D-100
SF6XC PRO S TR-140
SF6XC PRO E TR-140
SF6XC PRO S TAD-140
SF6XC PRO E TAD-140
SF6DURO-E
SF6DURO-D
SF6NCX-FT-S-RL-
SF6NCX-FT-E-RL
SF6NCX-FT-E-LO
SF6NCX-E-RL
SF6NCX-E-LO
SF6NRX9100-RL
SF6NRX8200-RL
SF6NRX8100-LO
SF6-Condor TA 26
SF6CR990-LO
System
SF6AXON-S RL-
Models 2006
80
80
90
90
80
220
150
150
Right
220
120
120
Left
Oil amount
[cm]
workshop book
KCE202
KCE202
KCE 202
KCE 202
KCE202
KCE207
KCE207
KCE207
Oil type
15
20 - 25
15
15
15
15
15
15
15
15
20 - 25
20 - 25
20 - 25
20 - 25
20 - 25
20 - 25
20 - 25
20 - 25
15 - 20
15 - 20
[%]
SAG
150
150
150
150
150
150
150
150
150
150
180
180
180
180
23
23
23
120
120
Air pressure
[psi]
Right
Left
min max min max
10,5
10,5
10,5
10,5
10,5
10,5
10,5
10,5
10,5
10,5
12,6
12,6
12,6
12,6
1,6
1,6
1,6
8,4
8,4
10,3
10,3
10,3
10,3
10,3
10,3
10,3
10,3
10,3
10,3
12,4
12,4
12,4
12,4
1,6
1,6
1,6
8,3
8,3
Air pressure
[bar]
Right
Left
min max min max
Air pressure
[kgf/cm]
Right
Left
min max min max
air spring
air spring
RS8-EPICON-LOD 190mm
RS8-EPICON-DA 190mm
air spring
air spring
RS6-XC-PRO-S-LO 165mm
System
air spring
Models 2006
air spring
System
air spring
RS8-EPICON-DA 165mm
Models 2007
air spring
System
RS8-EPICON-LOD 165mm
Models 2008
[cm ]
Oil amount
[cm ]
Oil amount
Oil amount
[cm]
Rear Shock Air Pressure and Oil Level Chart
workshop book
Oil type
Oil type
Oil type
20-25
15-20
[%]
SAG
20-25
15-20
[%]
SAG
20-25
20-25
15-20
15-20
SAG
[%]
200
200
200
200
200
200
max
min
[psi]
200
200
max
Air pressure [psi]
min
[psi]
Air pressure [psi]
Air pressure [psi]

[psi]
min
max
[kgf/cm]
14,0
14,0
max
14,0
14,0
max
[bar]
13,8
13,8
max
[bar]
13,8
13,8
max
Air pressure
min
13,8
13,8
13,8
13,8
Air pressure
min
Air pressure
[bar]
min
max
[kgf/cm]
Air pressure
min
14,0
14,0
14,0
14,0
Air pressure
min
Air pressure
[kgf/cm]
min
max
2008/2007 models
Coil Spring Chart
SF8-DURO FR20
SF8-DURO FR20
SF8-DURO FR20
35
35
35
35
32
SF7-RUX E
32
SF7-RUX E
SF8-DURO FR20
32
SF7-RUX S
32
SF7-RUX S
100
100
160
160
130
150
130
150
150
[mm]
[mm]
32
Travel
Stanchion tube
diameter
SF7-RUX TRIPLE
Model
MTB Forks 26
workshop book
FEP200
on request
Soft
on request
Hard
Standard
FEP201
FEP201-20
Soft
FEP201-10
Standard
on request
Soft
Hard
FEP395
on request
Hard
Standard
FEP396
on request
on request
Soft
on request
Soft
Hard
Standard
FEP287
on request
Hard
Standard
FEP286
on request
Soft
on request
Standard
on request
Soft
Hard
FEP287
on request
Hard
Standard
FEP286
on request
Soft
on request
Standard
on request
Soft
FEP286
on request
Parts code Nomber
Hard
Standard
Hard
Type of
spring
200
235
232
230
296
332
280
281
280
281
2,8
3,4
3,8
3,8
3,2
3,2
3,2
3,2
3,2
[mm]
(C)
Wire diameter
21
20
19
17
35
31
23
26
23
26
26
(D)
Turn of
wire
3,9
4,7
7,4
10,5
3,1
4,5
4,1
3,6
4,1
3,6
3,6
[N/mm]
Spring
rate
16,6
20,6
20,6
20,6
16,4
20,6
19
19
19
19
281
[mm]
[mm]
19
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
35
35
SF7-DURO DJ D
SF7-DURO DJ D R
35
SF7-DURO DJ E
35
35
SF7-DURO DJ E
35
35
35
80
80
130
130
100
100
80
80
[mm]
[mm]
SF7-DURO DJ E
SF7-DURO DJ E
SF7-DURO DJ E
SF7-DURO DJ E
Model
Travel
Stanchion tube
diameter
MTB Forks 26 continued from previous page
workshop book
FEP275
on request
Soft
on request
Hard
Standard
FEP274
on request
Soft
FEP274-10
Standard
on request
Soft
Hard
FEP172
on request
Hard
Standard
FEP173
on request
Soft
FEP173-10
Standard
on request
Soft
Hard
FEP200
on request
Hard
Standard
FEP201
FEP201-20
Soft
FEP201-10
Standard
on request
Soft
Hard
FEP275
on request
Hard
Standard
FEP274
on request
Soft
FEP274-10
Parts code Nomber
Standard
Hard
Type of
spring
180
211
209
232
264
262
200
235
232
230
180
211
2,8
2,8
3,8
4,2
2,8
3,4
3,8
2,8
[mm]
(C)
Wire diameter
22
17
14
27
24
25
21
20
19
17
22
17
14
(D)
Turn of
wire
3,7
9,9
12
3,1
5,9
3,9
4,7
7,4
10,5
3,7
9,9
12
[N/mm]
Spring
rate
16,6
20,6
20,6
16,6
20,6
20,6
16,6
20,6
20,6
20,6
16,6
20,6
209
[mm]
[mm]
20,6
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
32
32
32
SF8-RAIDON-RLD
SF8-RAIDON-LOD
SF8-RAIDON-LOD
35
32
SF7-DURO DJ D
35
SF8-RAIDON-RLD
35
SF7-DURO DJ D R
SF7-DURO DJ D
35
120
100
120
100
130
130
100
100
[mm]
[mm]
SF7-DURO DJ D L
Model
Travel
Stanchion tube
diameter
workshop book
on request
FEP363
on request
Hard
Standard
Soft
FEP359
on request
Soft
on request
Standard
on request
Soft
FEP363
Hard
on request
Hard
Standard
FEP359
on request
Soft
on request
Standard
on request
Soft
FEP172
Hard
on request
Hard
Standard
FEP173
on request
Soft
FEP173-10
Standard
on request
Soft
FEP200
Hard
on request
Hard
Standard
FEP201
FEP201-20
Soft
FEP201-10
Parts code Nomber
Standard
Hard
Type of
spring
232
274
252
274
252
232
264
262
200
235
4,3
4,5
4,3
4,5
2,8
3,8
4,2
2,8
3,4
3,8
[mm]
(C)
Wire diameter
27
26
27
26
27
24
25
21
20
19
17
(D)
Turn of
wire
9,2
11,2
9,2
11,2
3,1
5,9
3,9
4,7
7,4
10,5
[N/mm]
Spring
rate
19,5
19,5
19,5
19,5
16,6
20,6
20,6
16,6
20,6
20,6
230
[mm]
[mm]
20,6
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
30
30
30
30
SF7-XCR-LO
SF7-XCR-LO
SF7-XCR-LO
30
SF7-XCR-RL
SF7-XCR-RL
30
32
SF8-RAIDON-LO
SF7-XCR-RL
32
120
100
80
120
100
80
120
100
[mm]
[mm]
SF8-RAIDON-LO
Model
Travel
Stanchion tube
diameter
workshop book
FEP251-90
Hard
FEP236-50
on request
Hard
FEP236-50
Soft
on request
Hard
FEP236-80
FEP251-30
Standard
FEP251-80
Soft
FEP251-90
Standard
19
FEP252-40
Soft
Hard
19
19
19
19
264
236
239
236
237
217
216
264
236
239
236
237
217
216
270
249
3,2
3,8
3,2
3,8
3,2
3,8
3,2
3,8
3,2
3,8
3,2
3,8
2,4
[mm]
(C)
Wire diameter
30
26
25
26
28
20
21
30
26
25
26
28
20
21
26
27
(D)
Turn of
wire
3,1
6,6
3,8
6,6
7,7
4,7
8,2
3,1
6,6
3,8
6,6
7,7
4,7
8,2
7,4
8,5
[N/mm]
Spring
rate
18,7
19
19
19
FEP252-70
Standard
FEP236-80
Soft
19
FEP251-30
on request
Soft
Hard
Standard
19
18,7
19
19
19,5
19,5
[mm]
[mm]
FEP251-80
Standard
FEP252-70
FEP252-40
Soft
on request
Standard
on request
Soft
Hard
FEP380
on request
Hard
Standard
FEP381
on request
Soft
on request
Parts code Nomber
Standard
Hard
Type of
spring
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
30
30
SF7-XCM-HLO
SF7-XCM-HLO
30
SF7-XCR
30
30
SF7-XCR
SF7-XCR
30
30
SF7-XCR-DA
SF7-XCR-DA
30
100
80
120
100
80
120
100
80
[mm]
[mm]
SF7-XCR-DA
Model
Travel
Stanchion tube
diameter
workshop book
18,7
19
19
FEP251-90
FEP251-80
FEP251-30
on request
Hard
Standard
Soft
Hard
19
FEP252-30
FEP252-40
FEP251-40
Soft
Hard
19
19
19
FEP236-40
FEP236-30
FEP236-50
FEP327-40
Hard
Standard
Soft
Hard
18,6
FEP319-40
FEP319-30
FEP319-50
Soft
Hard
Standard
Soft
249,5
249,5
247,5
229,5
237,5
225,5
264
260
257
239
238
236
217
217
215
264
236
239
236
237
217
216
3,2
3,5
3,6
3,2
3,5
3,6
3,2
3,5
3,8
3,2
3,5
3,8
3,2
3,5
3,8
3,2
3,8
3,2
3,8
3,2
3,8
[mm]
(C)
Wire diameter
26
26
23
20
21
18
30
30
29
25
25
25
20
20
20
30
26
25
26
28
20
21
(D)
Turn of
wire
3,8
5,2
6,5
6,5
8,4
3,1
4,3
3,8
5,2
6,9
4,7
6,5
8,6
3,1
6,6
3,8
6,6
7,7
4,7
8,2
[N/mm]
Spring
rate
18,6
18,6
18,6
FEP327-30
FEP327-50
Standard
18,6
18,6
19
19
FEP251-30
Soft
FEP251-20
19
FEP252-50
Hard
Standard
Standard
19
FEP236-50
Soft
19
19
FEP236-80
Standard
19
19
FEP252-70
FEP252-40
19
[mm]
[mm]
Soft
on request
Parts code Nomber
Standard
Hard
Type of
spring
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
28mm
28mm
SF8-XCT V2 MLO 26
SF8-XCT V2 26
30mm
SF7-XCM
30mm
30mm
SF7-XCM-MLO
SF7-XCM
30mm
30mm
SF7-XCM-DA
SF7-XCM-MLO
30mm
80mm
80mm
100mm
80mm
100mm
80mm
100mm
80mm
[mm]
[mm]
SF7-XCM-DA
Model
Travel
Stanchion tube
diameter
workshop book
FEP327-10
on request
FEP350-30
FEP350-50
Hard
Standard
Soft
FEP289-30
FEP289-50
19
FEP319-20
FEP289-40
Soft
Hard
Soft
19
FEP319
Standard
19
FEP319-10
Hard
Standard
15
15
16
16
16
19
19
FEP327-20
Soft
FEP327
FEP323-20
Soft
Hard
Standard
18
FEP323
19
18
FEP323-10
Hard
18
18
Standard
FEP326
279
279
284
282
282
249,5
249,5
247,5
228,5
227,5
226
285
285
282
283
249,5
249,5
247,5
229,5
237,5
225,5
4,5
3,6
3,2
3,5
3,8
3,2
3,5
3,8
3,7
4,2
3,2
3,5
3,6
3,2
3,5
3,6
[mm]
(C)
Wire diameter
35
36,5
29
31
27
25
25
25
18
20
21
34
31
28
25
26
26
23
20
21
18
(D)
Turn of
wire
10,5
14,8
7,5
10,1
11,6
3,8
5,2
6,9
5,2
6,5
8,2
5,3
7,6
10
9,4
3,8
5,2
6,5
6,5
8,4
[N/mm]
Spring
rate
18,6
FEP319-50
on request
Soft
Hard
on request
18,6
FEP319-30
Soft
18,6
FEP319-40
Hard
Standard
Standard
18,6
FEP236-30
FEP236-50
18,6
18,6
[mm]
[mm]
Soft
FEP236-40
Parts code Nomber
Standard
Hard
Type of
spring
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
30mm
28mm
28mm
28mm
25.4mm
SF7-NCX-FT-D-RL
SF7-NCX-FT-D-LO
SF7-NCX-D-RL
SF7-NCX-D-LO
30mm
SF8-NRX-E-LO 700C
SF8-NRX-LO 700c
30mm
63mm
63mm
63mm
63mm
63mm
63mm
63mm
[mm]
[mm]
SF8-NRX-E-RL 700C
Model
Travel
Stanchion tube
diameter
Trekking Bike Forks 700c
workshop book
FEP212-70
Hard
FEP258
on request
Soft
FEP291
Standard
17
FEP212-60
Soft
Hard
15
15
17
17
15
15
17
17
17
19
19
206
206
203
197
200
206
206
203
197
200
211
210
210
210
3,2
3,2
3,2
3,5
3,8
3,2
3,2
3,2
3,5
3,8
3,6
3,8
3,4
3,4
[mm]
(C)
Wire diameter
23
19
22
21
22
23
19
22
21
22
18
16,5
22
22
(D)
Turn of
wire
7,4
5,7
8,1
10,3
7,4
5,7
8,1
10,3
7,9
10,4
8,7
8,7
[N/mm]
Spring
rate
15,6
15,6
[mm]
[mm]
FEP212-10
Standard
on request
FEP291
Hard
Soft
FEP212-60
Soft
FEP258
FEP212-10
Standard
FEP212-70
Hard
Standard
on request
Soft
FEP335-10
Hard
FEP335
on request
Soft
Standard
FEP391
on request
Hard
Standard
FEP391
on request
Soft
on request
Parts code Nomber
Standard
Hard
Type of
spring
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
25.4mm
25.4mm
SF7-CT-SA 700c
25.4mm
SF8-NEX4600-HLO 26
SF8-NEX-4100 26
25.4mm
SF8-NEX-4110
25.4mm
25.4mm
SF8-NEX4610-MLO
SF8-NEX4600-MLO 26
25.4mm
25.4mm
63mm
63mm
63mm
63mm
63mm
63mm
63mm
63mm
[mm]
[mm]
SF8-NEX4610-HLO
SF7-NCX-D
Model
Travel
Stanchion tube
diameter
on request
Hard
on request
Soft
FEP181
Hard
FEP163
on request
Soft
Standard
FEP355
FEP335-10
Hard
Standard
FEP264
on request
Soft
on request
Hard
Standard
on request
Soft
FEP238
on request
Soft
Standard
FEP355
FEP335-10
Standard
on request
Soft
Hard
FEP264
on request
Hard
Standard
on request
Soft
on request
Hard
FEP264
on request
Soft
Standard
FEP291
FEP258
Hard
Parts code Nomber
Standard
Type of
spring
Trekking Bike Forks 700c continued from prevoius page
workshop book
15
15
192
189
208
206
211
209
208
206
211
211
206
2,9
3,4
3,8
3,4
3,2
3,8
3,4
3,4
3,2
3,2
[mm]
(C)
Wire diameter
27-19
26
29
26
30-19
34-21
29
26
30-19
30-19
23
19
(D)
Turn of
wire
4.5-6.4
8,1
11,7
15,7
7.0-11.1
5.0-8.1
11,7
15,7
7.0-11.1
7.0-11.1
7,4
[N/mm]
Spring
rate
14,4
14,3
15
15
14,4
14,3
15
15
15
206
[mm]
[mm]
15
(B)
Overall
length
(A)
Inner
diameter
Coil Spring Chart
23.8mm
25.4mm
SF7-CR-8V
SF8-CR880W 26
25.4mm
SF7-CR-8R-MLO
25.4mm
25.4mm
SF7-CR-8V-MLO
SF8-CR-8R
25.4mm
25.4mm
50mm
50mm
50mm
40mm
50mm
63mm
63mm
[mm]
[mm]
SF8-CR930
SF6-CR940-LO
Model
Travel
Stanchion tube
diameter
FEP273-10
Hard
FEP116-02
on request
Soft
FEP116-30
Hard
Standard
FEP273
on request
Soft
FEP273-10
Hard
Standard
on request
Soft
FEP273
on request
Soft
Standard
FEP264-10
on request
Standard
on request
Soft
Hard
FEP264
on request
Hard
Standard
on request
Soft
FEP181
Hard
FEP163
on request
Soft
Standard
FEP181
FEP163
Hard
Parts code Nomber
Standard
Type of
spring
Trekking Bike Forks 700c continued from prevoius page
workshop book
13
13
15
15
15
15
163
160
171
168
171
168
182
211
192
189
192
2,9
3,2
3,4
3,4
3,6
3,4
2,9
3,4
2,9
3,4
[mm]
(C)
Wire diameter
29-24
25
18
20
18
20
24-15
30-19
27-19
26
27-19
26
(D)
Turn of
wire
5.9-7.3
9,7
7,6
10,5
7,6
10,5
11.1-17.6
7.0-11.1
4.5-6.4
8,1
4.5-6.4
8,1
[N/mm]
Spring
rate
14,8
15
15
15
15
189
[mm]
[mm]
15
(B)
Overall
length
(A)
Inner
diameter
workshop book
Maximum possible rotor diameter
2008 MTB Forks
Duro Series
Durolux Series
Axon Series
Epicon Series
Raidon Series
XCR Series
XCM Series
XCT Series
XCU Series
M2000 Series
210mm
210mm
185mm
185mm
185mm
185mm
185mm
160mm
160mm
160mm
2008 Trekking Forks

NRX Series
NCX Series
NCX FT Series
NEX Series
185mm
185mm
180mm
180mm
2007 MTB Forks

Duro Series
Rux Series
XC-Pro Series
Axon Series
Epicon Series
Raidon Series
XCR Series
XCM Series
XCT Series
XCU Series
M2000 Series
NEX 26 Series
210mm
210mm
185mm
185mm
185mm
180mm
185mm
185mm
160mm
160mm
160mm
180mm
2007 Trekking Forks

NRX Series
NCX Series
NCX FT Series
NEX Series
M2000N Series
185mm
185mm
180mm
180mm
160mm
workshop book
Serial Number Explanation
country of
origin
year
production
line
month
day
07
06
21
07
05
15
C = China
T = Taiwan
workshop book
Tightening Torque Chart
1
2
3
4
5
6
7
8
Part to be tightened
Tightening torque [Nm]*
Fork top cap (alloy)

Fork top cap (plastic)
Lower fixing bolt/nut
V-brake pivot
Upper and Lower crown fixing bolts
Through axle fixing bolt (Durolux 20/Duro FR20)
axle nut (BB XCR FX, Hexagon 28mm)
BB XCR FX crank fixing bolt (BB XCR FX)
1/2
10
5
10
15
7
11
7-10
40-45
* Tolerance: 10%
schematic graphic showing nuts and

bolts for tightening torque chart
Pos.
3
5
schematic graphic showing nuts and

bolts for tightening torque chart
workshop book
bottom bracket crank

assembly BB-XRC FX
Oil Type Chart

Oil type
KCE202
KCE207
Oil type
Air chamber sealing oil
Viscosity (40deg.c)
11cSt
31cSt
wt
5
10
Viscosity
150 cSt
cc
6
chapter
Fork Maintenance
Manuals
VI
workshop book
Fork Maintenance
Check your fork before each ride! Contact your dealer immediately if you recognize any damages 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 figure out if there is any kind of play within the headset.
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 firmness 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 maintenance 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 differently as
normal please contact your dealer immediately to inspect your fork.
workshop book
We recommend servicing the fork after 50 and 100hours of riding. This service has to be performed
by a trained and qualified 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 fixing bolts for proper
torque (Nm)
oil the dust seal area with teflon 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 teflon 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 qualified bike mechanic. We strongly recommend this service 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!
workshop book
How to Replace Remote-Lock-Out + Damping (RLD) cartridge
Unscrew the fixing bolt half way using

an 8mm Allen key
c.
Hit the fixing bolt with plastic tip hammer slightly
d.
Unscrew the fixing bolt full way and

take it out
picture 2
b.
picture 3
Pull out the rebound adjuster knob

using a needle nose pliers
picture 4
a.
picture 1
Models:AXON / EPICON / NRX
Unfasten the remote lock unit fixing

bolt using a Phillips screwdriver No. 2
g.
Unfasten the remote lock cartridge using a 27mm socket wrench
h.
Take out the old cartridge
picture 6
f.
picture 7
Unscrew the fixing bolt of the remote

lock cover cap using a 2.5mm Allen
key
picture 8
e.
picture 5
workshop book
Pull out the support tube assy full way
k.
Tighten the new cartridge with 10Nm

using a 27mm socket wrench
l.
Fasten the damper fixing bolt with

6Nm using an 8mm Allen key
picture 10
j.
90 unlock
picture 11
Before assembling the new cartridge

make sure that it is set to the unlocked
position
picture 12
i.
picture 9
workshop book
Reinstall the remote lock out unit using a Phillips screwdriver No.2
o.
Reinstall the toothed wheel and

spring unit like shown on picture No.
15
p.
Assemble the remote lock unit cover

cap using a 2.5mm Allen key
picture 14
n.
open position
picture 15
Reassemble the rebound adjuster

knob
picture16
m.
picture 13
workshop book
workshop book
How to replace Remote-Lock-Out + Damping (RLD) cartridge
b.
Hit the fixing bolts with plastic tip

hammer slightly
c.
Unscrew the fixing bolts full way and

take them out
d.
Separate upper and bottom case
picture 2
Unscrew the two fixing bolts half way

using a 5mm Allen key
picture 3
a.
picture 1
RAIDON RL / XCR RL / NCX RL
picture 4
Models:
g.
Hit the fixing bolt slightly using a plastic tip hammer
h.
Take out the old cartridge and install

the new one
i.
Tighten the cartridge fixing bolt again

using a 10mm socket wrench / NCX
RL: 5mm Allen key
picture 6
Unscrew cartridge fixing bolt using a

10mm socket wrench / NCX RL: 5mm
Allen key
picture 7
f.
picture 8
Take off the remote look out unit using a 2.5mm Allen key
picture 9
e.
picture 5
workshop book
Reassemble the upper and bottom

case
l.
Before fastening the left fixing bolt

you have to pull up the fork
m.
Fasten the fixing bolts with 10Nm using a 5mm Allen key
picture 11
k.
picture 12
Reinstall the remote-lock-out unit using a 2.5mm Allen key
picture 13
j.
picture 10
workshop book
workshop book
How to replace Lock-Out (LO) cartridge
b.

hammer slightly
c.

take them out
d.
picture 2

picture 3
a.
picture 1
RAIDON LO / RAIDON LO air / XCR LO / XCM HLO

NCX D LO / NCX E LO / NCX FT D LO / NEX4610 HLO
picture 4
Models:
Take out the adjust core using a

needlenose pliers
g.
Unfasten the cartridge fixing bolt half

way using a 5mm Allen key
h.
picture 6
f.
picture 7
Take off the lock-out knob
picture 8
e.
picture 5
workshop book
Install the new cartridge and fasten

the fixing bolt with 10Nm
k.
Set the cartridge to the unlocked position before continuing. To do so use a

4mm Allen key
l.
Reassemble the adjust core
m.

case
picture 10
j.
picture 11
Unscrew the cartridge fixing bolt full

way and take out the cartridge
picture 12
i.
picture 9
workshop book

you have to pull up the fork.
o.
Tighten the fixing bolts with 10Nm

picture 14
n.
picture 13
workshop book
workshop book
How to replace the Travel-Adjust (TA) cartridge
Models:
DUROLUX SERIES / EPICON TAD / XC-PRO TAD / XC-PRO TA
Take off the travel adjust unit cover

c.
Take off the travel adjust core using a

Phillips screwdriver No.2
d.
Take out the circlip using a small

screwdriver
picture 2
b.
picture 3
Unscrew the fixing bolt using a 10mm

socket wrench
picture 4
a.
picture 1
Old travel adjust top cap unit
Unscrew the cartridge using a 27mm

socket wrench
g.
Hit the cartridge slightly using a plastic tip hammer and take it out
h.
Assemble the new cartridge and fasten it with 10Nm using a 27mm socket
wrench
picture 6
f.
picture 7
Take out the travel adjust core
picture 8
e.
picture 5
workshop book
Reassemble the circlip using a small

screwdriver
k.
Fasten then travel adjust core using a

Philips screwdriver No.2
l.
Reinstall the travel adjust unit cover

picture 10
j.
picture 11
Reinstall the travel adjust core
picture 12
i.
picture 9
workshop book
m.
Fasten the fixing bolt with 6Nm using

a 10mm socket wrench
picture 13
workshop book
New travel adjust top cap unit
a.

2mm Allen key
picture 1
The working steps which need to be carried out are very similar between the old and the new
travel adjust. The only big difference 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.
Take out the circlip using a small

screwdriver
c.
Take out the travel adjust core using a

circlip pliers
picture 3
b.
picture 2
workshop book
workshop book
How to solve air leaking problems
b.
Unscrew the air top cap using a

27mm/21mm Allen key
c.
Take out all remaining old oil
d.
Refill the fork with 6ml of 80W gear oil
picture 2
Release all air
picture 3
a.
picture 1
All air cartridge forks
picture 4
Models:
f.
Tighten the air top cap with 10Nm using a 27mm/21mm Allen key
g.
Inflate the fork according to the personal settings of the customer
picture 6
Grease the O-ring of the air top cap
picture 7
e.
picture 5
workshop book
We recommend inflating the fork over night with a test pressure of 150psi (10.3 bar) and to test it again
the next day.
workshop book
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
Take out the adjust core using a

needle nose pliers
c.
Test if the cartridge fixing bolt is

tightened properly with 10Nm using a
5mm Allen key
d.
Turn the core clockwise until the stopper using a 4mm Alllen key.
picture 2
b.
picture 3
Take off the lock-out knob
picture 4
a.
picture 1
The fork does not lock even after turning the lock out knob to the locked position
The fork should now be completely

locked!
Make sure the adjust core is installed

properly
f.
The lock-out knobs nose has to be

installed like shown in picture no.7
g.
To test if the fork unlocks, turn the

lock out knob counter-clockwise
picture 8
picture 7
picture 6
e.
picture 5
workshop book
workshop book
How to solve Mechanical-Lock-Out (MLO) issues
b.
Unscrew the lock out top cap using a

27mm/21mm socket wrench
c.
Take out the upper stopper using a

needle nose pliers
d.

10mm socket wrench
picture 2
Pull out the lock out knob using a

needle nose pliers
picture 3
a.
picture 1
XCM MLO / XCT V2 MLO / NEX MLO SERIES / CR8V MLO / CR 8R MLO
picture 4
Models:
Slide out the sup spring, lower index

and lower stopper
g.
Take out the fixing bolts using an extra long 5mm Allen key and a monkey
wrench
h.
Make sure the main fixing bolt is

a hexagon screw and not an Allen
screw. Otherwise the lock out mechanism can not work
picture 6
f.
picture 7
Separate the upper and the bottom

case
picture 8
e.
picture 5
workshop book
Picture No. 10 shows how upper stopper and lower index fit together
k.
Reinstall the main fixing bolt using a

extra long 5mm Allen key and a monkey wrench
l.
Slide the sup spring, lower index and

lower stopper back in
picture 10
j.
picture 11
The hexagon screw has to fit into the

lower spring stopper
picture 12
i.
picture 9
workshop book
Reinstall the lock out top cap with

10Nm using a 27mm/21mm socket
wrench
o.
Install the adjust stopper like shown

on picture No. 15
p.
Reinstall the lock out knob back again.

Make sure it is set to the unlocked
position (green)
picture 14
n.
picture 15
Slide in the upper stopper
picture 16
m.
picture 13
workshop book
q.
Reassemble upper and bottom case

with 10Nm using a 10mm socket
wrench
picture 17
workshop book
workshop book
Release all air
b.
Unscrew the fixing bolt using a 10mm

socket wrench
c.
Pull out the rebound adjust knob
picture AX02
a.
picture AX01
How to convert the travel of an Axon fork
e.
f.
picture AX04
Unscrew the fixing bolt half way
picture AX05
d.
picture AX03
workshop book
Slide out the support tube assy
i.
To convert the travel you have to remove the pin and reset the spacer
picture AX07
h.
picture AX09
Unscrew the fork nose using a monkey

wrench
100mm
80mm
picture AX08
g.
picture AX06
workshop book
k.
Grease the fork nose and fasten it
l.
Reassemble upper and bottom case
picture AX06
Reassamble the support tube assy

back into the upper
picture AX05
j.
picture AX07
workshop book
n.

a 5mm Allen key
o.
Reassemble the rebound adjuster

knob
picture AX03

a 10mm socket wrench
picture AX02
m.
picture AX01
workshop book
workshop book
b.
Unscrew the fixing bolt half way using a

5mm Allen key
c.
Hit the fixing bolts with plastic tip hammer slightly
picture EP2
Release all air
picture EP3
a.
picture EP1
How to convert the travel of an Epicon Suspension fork
Unscrew the air valve top cap using a

27mm socket wrench
f.
Pull out the air semi cartridge
g.
Take off the air valve top cap
picture EP5
e.
picture EP6
Unscrew the fixing bolts full way and take

them out
picture EP7
d.
picture EP4
workshop book
h.
Slide out the air piston, support tube,

rebound springs and spring guides
picture EP8
workshop book
1 Spacer = 120mm travel
picture EP10
picture EP11
Convert the travel:
picture EP12
i.
picture EP9
Make sure the air piston does not get dirty
k.
Seal the air piston with 6ml of a 80W gear

oil
l.
Seal the air valve top cap with

SR SUNTOUR Con Panna grease. Afterwards reassemble the air valve top cap
and the semi air cartridge
picture EP14
Reassemble the support tube, rebound

springs, spring guides and air piston back
into the air cylinders
picture EP15
j.
picture EP13
workshop book
workshop book
Reinstall the semi air cartridge to the fork
n.
Fasten the semi air cartridge with 10Nm

using a 27mm socket wrench
o.
Reinstall the fixing bolt and fasten it with

10Nm using a 5mm Allen key
p.
Inflate the fork
picture EP18
picture EP17
picture EP16
m.
workshop book
How to change slider sleeves (plugged dust seals)
b.
Take out the coil springs
c.
Unscrew the two main fixing bolts using a 5mm extra long Allen key
d.
picture 2
Unscrew the top cap using a preload

adjuster tool preload adjuster remover
picture 3
a.
picture 1
XCM SERIES / XCT V2 SERIES / NCX D / NCX D LO / NEW SERIES /

CR980 LW / CR920 / CR 8V SERIES / CR 8R SERIES
picture 4
Models:
Take out the old dust seals using a

pliers. Turn the sleeve approximately
90 degrees counter clock wise
g.
The clip of the slider sleeve has to

be clicked into the notch of the fork
lower
h.
After installing the sleeves, plug the

dust seals back onto the fork lower
picture 6
f.
picture 7
Take off the plugged dust seals using

a screwdriver
picture 8
e.
picture 5
workshop book
j.
Reinstall the coil springs
k.
Fasten the top cap using a preload

adjuster tool preload adjuster remover
tool
picture 10

case again and fasten with 10Nm using a 5mm extra long Allen key
picture 11
i.
picture 9
workshop book
workshop book
How to change slider sleeves (pressed-in dust seals)
b.

hammer slightly
c.

take them out
d.
picture 2

picture 3
a.
picture 1
XCR SERIES / XCP 75 DJ
picture 4
Models:
Take out the old dust seals
g.
The clip of the slider sleeve has to

be clicked into the notch of the fork
lower
picture 6
f.
picture 7
Take out the dust seals using a nail

lifter
picture 8
e.
picture 5
workshop book

case
j.

you have to pull up the fork
k.
Tighten the fixing bolts with 10Nm

picture 10
i.
picture 11
Reinstall the dust

seals using a dust seal
installer(28mm/30mm/32mm/35mm)
and plastic tip hammer
picture 12
h.
picture 9
workshop book
chapter
Exploded views
SR SUNTOUR
Suspension Forks
VII
OP/
2
2e
2f
2h
3
4
5
6
7
8
9
:
21
22
QBSUT!DPEF
GLF296.11
GLF161
GBB234
GTC352.27
GFF616
GLF1:7.13
GFQ197
GTX153
GTC222
GFF496.21
GFQ384
GFQ242.18
GFF2:7
GLF116.21
QBSUT!OBNF
RU
CPUUPN!!DBTF!BTTZ
2
TMJEFS!TMFFWFT!BTTZ
3
EVTU!TFBM
3
DBOUJ!CPTT
3
CPUUPN!TUPQQFS
3
VQQFS!BTTZ)UT-36601* 2
SFCPVOE!SVCCFS
3
3
XBTIFS
GJYJOH!CPMU
3
TQSJOH!HVJEF
3
NBJO!TQSJOH
3
EBNQFS
3
TQSJOH!HVJEF
3
BEKVTUFS!BTTZ
3
TDSFX
SFCPVOE!TQBDFS
SFCPVOE!TQBDFS
GJYJOH!OVU
NPVOU!DBQ
CPUUPN!DBTF
UBQQJOH!TDSFX
NPVOU!DBQ
DBOUJ!CPTT
CSBDF!DPWFS
EVTU!TFBM
OVU!QMBUF
CPUUPN!TUPQQFS
GJYJOH!CPMU
SFCPVOE!SVCCFS
XBTIFS
TQSJOH!HVJEF
NBJO!TQSJOH
EBNQFS
TQSJOH!HVJEF
TQSJOH!HVJEF!TQBDFS
18
19
13
20
14
SF7-NEX4510 MLO 700C

26 + 700c (50mm + 63mm)
21
22
15
23
4a
16
4b
10
17
FEE385-20
FEP131
13
14 damper
see Pos. 4
see Pos. 4
4a
4b slider sleeve
25
25a
25b
2
2
FKE046
FSB241-16
knob
see Pos. 25
see Pos. 25
FKE082-00
FEE490
1
1
1
FEP265-10
2
FEP272
1
1
FEE496-10
FEE263
1
FEE496
22
1
FEE504
20 lower stopper
21 bottom damper
2
FSB108
FEE492
19
1
1
FKE005-10
17
18 screw
1
FEP264-20
FEE450
16
15
1
1
FSB109
12
2
2
FEE491
11 bolt holder
FEP131-02
2
FEP086
10
FEP264
1
1
FKE086-00
FEE495
sleeve set
2
FKE087-00
9
24
brake boss
2
FEE451
23
2
FSN025
7
bottom stopper
2
FAA159
26
Part-No.
700c / 50mm
FAA068
Description
700c / 63mm
26
700c / 50mm
FPB099
700c / 63mm
FPB098
Qty.
FEP265
12
25b
Pos.
2
Part-No.
bottom case
FSN023
Description
11
25a
Pos.
24
25
SF6, english, 2006/01/21, V1.0
Qty.
11
16
23
12
17
18
model year 2007
SF7-XCM-MLO 26
19
13
20
21
14
22
16
10
4a
4b
mini boots
6
lock knob
canti boss
fixing nut
21
22
23
lower index
19
upper stopper
sub spring
18
20
bottom damper
17
spring guide-upper
14
lower stopper
main spring
13
16
damper
12
adjust knob
spring guide-lower
11
15
fixing bolt
10
bolt holder
FAA158-10
dust seal
FAA094-10
o-ring
4b
rebound rubber
FEE460-10
slider sleeve
4b
FKE049-10
sleeve set
4
upper case
FFF165
bottom stopper
3
FSN025
2
2
FSN023
FSB241-16
FKE078-10
FEE598
FEE591
FEP324
1
FEP263
1
FFF590
Qty.
FKE009
FEE592
FEP323
FEP322
FEE593
FSB109-20
FFF591
FFP086
FEP086
FAA216
FPB172
nut plate
Part-No.
2
Description
bottom case
Pos.
1
explosion drawing sr suntour XCM-LO, SF6, english, 2006/01/09, V1.0
19
18
11
20
12
16
SF7 XCM-DA 26"
13
4a
14
17
10
15
4b
20
19
18
FSB241-16
FSB070
FSN023
FUN006-04
Aduest unit-oil
16
FKE009
FEE434
FEP319
17
15
14
13
FEP320
12
Pivot
Fixing screw
Fixing nut
Rebound adjust
Oil damper unit
Adjust Konb
Spring guide -Upper
Main spring
Damper
Spring guide -Lower
FSB067-21
11
Washer
Fixing bolt
FSW042
FSB067-21
9
10
Rebond ruber
Upper assemble
FEP086
FKE0083-10
Mini boots
FAA158-10
Dust seal
FAA158-10
5
O-ring
Sleever sets
FAA216
FEE460-10
4a
Sleever assemble
4b
FKE049-10
Bottom stoper
FEE501
3
4
Nut plate
FSN025
Bottom Case
Description
FPB172
Part-Name
POS.
Q'ty
11
12
16
13
14
17
15
4a
10
4b
damper
main spring
spring guide-upper
adjust knob
fixing nut
pivot
12
13
14
15
16
17
rebound rubber
spring guide-lower
upper case
7
11
FKE083-10
mini boots
fixing bolt
FAA158-10
dust seal
10
FAA216
o-ring
4b
washer
FEE460-10
slider sleeve
4a
FKE049-10
sleeve assembly
4
2
1
FSB241-16
FSN023
FKE009
FEE434
FEP319
FEP320
FEE578
FSB067-21
FSW042
FEP086
FAA094-10
FEE501
FSN025
nut plate
2
bottom stoper
FPB172
bottom case
1
3
Part-No.
Description
Pos.
model year 2007
Qty.
SF7-XCM 26
explosion drawing sr suntour XCM-LO, SF6, english, 2006/01/09, V1.0
QBSUT!OBNF
GJYJOH!OVU
CPUUPN!DBTF!BTTZ
DBOUJ!CPTT
TMJEFS!TMFFWFT!BTTZ
EVTU!TFBM
explosion drawing SR Suntour RL REMOTE ASSEMBLY, SF7, english, 2007/02/12, V0.99b
RL REMOTE ASSEMBLY
modelyear 2007
1j
1i
1h
1f
1g
1e
2c
1d
1c
1b
Description
RL remote assembly
1a RL remote assembly part a see pos. 1

1b Snap ring
1a
Part-No.
FKE112
Qty.
2a
Pos.
2b
1
1
see pos. 1
1c RL remote assembly part c see pos. 1
1d RL remote assembly part d see pos. 1
1e RL remote assembly part e see pos. 1
RL remote assembly part f see pos. 1
1g RL remote assembly part g see pos. 1
1f
1h RL remote assembly part h see pos. 1
1i
RL remote assembly part i see pos. 1
1i
RL remote assembly part j see pos. 1
cable assembly
not part of the set
2a cable housing
see pos. 2
2b cable housing end cap
see pos. 2
2c cable (std. bicycle shifting cable)
see pos. 2

SRSuntour Workshop Book

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workshop book

SR SUNTOUR workshop book, version 2008/Mar/25 page 3

II. Owners manuals . ........................................ 13

Suspension Front Fork with Coil Spring or MCU............... 14

III. Service manuals .......................................... 27

Mounting the remote lock-out single lever........................ 28

Mounting the remote lock-out single lever........................ 31

Mounting and Operating the remote travel

Operating the hydraulic rebound damping....................... 39

Setting the SAG for SR Suntour Forks.................................... 41

Use and function of the Lock-Out system........................... 45

Overview of the fork systems................................................... 56

VI. Fork Maintenance Manuals ....................... 75

How to solve air leaking problems ....................................... 94

VII. Exploded views

IV. Instruction Sheet for Suspension

Before using the suspension seat post........................................................48

SF8 DURO FR20-160...............................................................................................127

Suspension Seat Post Instruction Sheet............................... 48

SR SUNTOUR workshop book, version 2008/Mar/25 page 5

SF8XCT V2................................................................................................................ 168

SF7 RL Remote Assembly......................................................................................170

SR SUNTOUR workshop book, version 2008/Mar/25, page 6

SR SUNTOUR workshop book, version 2008/Mar/25, page 8

CroMo STEERER TUBE

SR SUNTOUR workshop book, version 2008/Mar/25 page 9

SR SUNTOUR workshop book, version 2008/Mar/25, page 10

SR SUNTOUR workshop book, version 2008/Mar/25 page 11

IMPORTANT SAFETY INFORMATION

- Minimum insertion of handlebar stem (for threaded steerers)

Adjusting Preload (where it applies)

Notes on usage of the fork

Suspension Fork Warranty Card:

Fork model name

Term of limited warranty: Two years from the date of purchase

SR Suntour website: www.srsuntour-cycling.com

1st. service Date:___________________

Signature of the dealer: ______________________ Stamp: __________________

2nd. service Date:___________________ Signature of the dealer: ______________________ Stamp: __________________

SR SUNTOUR EUROPE GMBH

Specications are subject to change without notice.

IMPORTANT SAFETY INFORMATION

MOUNTING OF THE REMOTE TRAVEL ADJUSTER AND REMOTE LOCK-OUT CONTROL

Mounting of the lock-out control

Cable nipple. Shifting cable type.

Cable tension adjustment barrel.

Press the lever and then the

In this position, the

Cable tension adjustment barrel.

Here, the barell is screwed in

Fork performance tuning

Travel adjuster/ Air system/

In order to adjust the air pressure, please be sure to use the

For latest information please visit

The remote lock-out control

The remote travel adjuster

The I.C.E. type control DSM-XCR60-SC

The remote lock-out control

The remote lock-out control

Fork features and function

Clean the stanchion tubes and the dustseal area

Notes on usage of the fork

Suspension Fork Warranty Card:

Fork model name

Signature of the dealer: ____ Stamp:

2nd. service Date:_ Signature of the dealer: Stamp: __