Part ~ 1

SAFETY WARNING

The following instructions involve working with the complex internal parts of a suspension fork and it is recommended that only a skilled or trained mechanic should attempt these procedures to avoid any possibility of damage to the product or personal injury. Specialist tools may be required and in some cases special tools from RST are additionally required, the failure to use the correct tool could result in a premature failure of the produce leading to subsequent personal injury.

By reading this warning you accept the responsability to carry out the instructions under the understanding that you may void the warranty offered by RST and that any damage parts should be replaced before reassembly in order to maintain the fork correctly.

 

MAINTENANCE MANUAL

This manual is designed as an addition to the owner’s manual supplied with your RST fork.

Maintenance should be carried out as often as specified or when the performance of the fork has deteriorated.

SAFETY INSTRUCTIONS

RST recommends that if you are unsure about your ability to complete this maintenance work to consult an RST dealer before commencing any work. Improper installation of some parts can be extremely dangerous and can result in the failure of the fork resulting in possible personal injury.

ALWAYS Wear safety eye glasses when working on the internal parts of a fork.
and protective gloves when using shock oil.

REPAIR KITS

Before beginning any work on your fork it is recommended that you obtain the parts that will need replacement in order to avoid delays during the maintenance. The most common parts used are supplied in a REPAIR KIT that should be available from RST dealers.
The repair kit that you require for the models of fork covered by this manual is:-
 KIT A.

 

TOOLS REQUIRED:

4mm Hex wrench.
Phillips screwdriver #1.
RST 6mm hollow hex wrench.
RST Adjuster cap wrench (Large).

Non toxic cleaning solvent.
Cleaning rag, Cleaning brush.

Grease (Non-lithium based).
Replacement shock oil (5wt-SAE).
Oil disposal cup.

 

Use a 4mm hex wrench to loosen the axle pinch bolts (x4) and then remove the axle by turning counter-clockwise with a 12mm hex wrench.

Remove the front wheel.

 
First remove any pre load that might have been added and then use a 2.5mm hex wrench to remove the pre load and rebound adjuster knobs (x2) by turning counter-clockwise.

 

 
Use 90' snap ring pliers to remove the snap rings (x2) from the top of the stanchion tubes.  
Use a 17mm and a 14mm open ended spanner to remove the top caps (x2) from the compression rods.

NOTE: You may need to push the stanchions up in to the outer legs to be able to find the nut.

 
On the left hand stanchion tube (With disc mounts) push down on the compression rod and then release the snap ring.

CAUTION: The springs in this side of the fork is under load and could cause injury if they are removed with out first compressing them.

 

 
Remove the adjuster assembly (x1) and springs (x3) from the stanchion tube.  
Clean all parts using a non toxic cleaning solvent and a cleaning brush.

Allow parts to dry.

 

CHECK AND REPLACE ANY DAMAGED PARTS (Like the 'O' rings, boots or dust wipers)

If you do not have the RST repair kit then use the parts list in order to obtain the correct parts.

 

Advanced maintenance.

Wrong Manual?

Need some parts?

How to put back together.