Service - RockShox 1999 Jett XC Manual Del Propietário

2. Unscrew the top cap using 24mm wrench or socket wrench. Remove the spring stack assembly and
clean the stack with degreaser. Wipe dry.
3. Inspect the spring for compression set (see "Spring Specification" table, page 14) and o-ring on the
spring spacer. Replace as needed.
4. Pour the oil from the fork into an oil pan and compress the fork fully.
5. Remove the spring retainer located on the top of the plunger/damper rod assemblies by inserting a
6mm allen wrench in the fork leg and into the center of the spring retainer. Gently rock and turn the
spring retainer back and forth while pulling it up with the allen wrench.
6. Insert a long (6" minimum) 6mm hex 3/8" drive socket on 6" long extension in one leg through
plunger cap and engage hex completely in broach of plunger/damper bolt. Gently tap on extension
with mallet to ensure engagement. Install 3/8" drive ratchet in extension, stabilize one-piece lower tube
assembly between your feet and legs, push down while turning counterclockwise to break
plunger/damper bolt free. (We recommend putting the fork on the floor, resting the drop-outs on a
block of wood, and holding firmly between your feet and legs.)
I :
MPORTANT THE PLUNGER BOLTS ARE INSTALLED TO
T
HE FORCE REQUIRED TO LOOSEN THE BOLT IS SIGNIFICANT
6
HEAD WILL STRIP IF THE MM HEX SOCKET IS NOT FULLY ENGAGED
THE BOLT IS DEEP TO PREVENT STRIPPING WHEN THE HEX IS PROPERLY ENGAGED
6. Loosen plunger bolt completely and repeat procedure on other lower tube
I : T /
MPORTANT HE PLUNGER DAMPER BOLT IS PERMANENTLY FIXED TO THE
/
PLUNGER DAMPER ASSEMBLY AND WHEN YOU UNSCREW THE BOLT THE WHOLE
.
ASSEMBLY WILL SPIN
7. Slide off one-piece lower tube assembly (see Fig. 4). Remove fork boots.
8. Thoroughly clean upper tubes and inspect for wear and/or damage (nicks,
scratches, or dings).
9. Remove plunger assemblies and inspect for wear or damage(Note: more oil
will drain from the assemblies). Check compression set of top out spring by
referencing "Spring System Specification" on page 14.
10. Clean fork boots and slide onto uppers.
11. Then clean internals of lower tubes, bushings (two per leg), and Resi-wiper
seal. A long 3/8" drive socket extension wrapped in a lint-free rag works well.
I : C ,
MPORTANT LEAN LOWER BUSHINGS APPROXIMATELY
12. Apply a thin layer of New and Improved Judy Butter to the surface of the
upper bushings and fill the pocket between the lips of the Resi-wiper seal completely (Fig. 5).
I : F ,
MPORTANT OR BEST PERFORMANCE AVOID LITHIUM
,
STICKY TURN GRAY AND CAKE UP WHEN USED TO LUBRICATE THE BUSHINGS
LIMITED AND PERFORMANCE IS GREATLY REDUCED WHEN THIS HAPPENS
T
GREASE QUALITY AND CONDITION AT EACH
. T
PERFORMING PROPERLY RY USING ANOTHER TYPE OF LUBRICANT IF YOU EXPERIENCE PROBLEMS
13. Install one-piece lower tube assembly onto upper tubes, carefully engage upper Resi-wiper seal lip with
the upper tubes, and gently rock the one-piece lower assembly to engage the lower bushings with the
upper tubes.
14. Next, place medium strength locking compound (blue Loc-tite) on clean, dry threads of plunger bolt
P 12
AGE
80 -
IN LB WITH MEDIUM THREAD LOCKING COMPOUND
. T
HE PLUNGER BOLT
. T
HE BROACH ON
.
Fig. 4
6" (150 ) .
MM FROM TOP
Fig. 5
- . S
BASED GREASES OME LITHIUM GREASES CAN BECOME
. S
MOOTH FORK ACTION IS GREATLY
. I
F YOU USE LITHIUM GREASE
-
WENTY FIVE HOUR SERVICE INTERVAL TO ENSURE GREASE IS
PN 950-001827-00, R
and allow to dry.
15. The plunger/damper assemblies are
installed by dropping the assembly
down inside the upper tube from the
top. See figures 6 and 7 for orientation
of parts for both the plunger (right side)
and damper rod assembly (left side).
Thread plunger/damper bolt with a 6",
6mm hex wrench and 6" extension and
torque to 80in-lb (9Nm).
I
MPORTANT
PERMANENTLY FIXED TO THE ROD
16. Replace oil inside the lower tubes. Both
63 and 75mm travel Jett's come standard with 85cc's of RockShox Extra Light oil.
.
I
MPORTANT
PERFORMANCE AND TOO MUCH OIL WILL RESULT IN LESS TRAVEL AND A HARSH BOTTOM OUT
17. Refit fork boots into Resi-wiper seal groove using a small blade screwdriver. Engage boot with Resi-wiper
seal groove at the rear and rotate boot around the upper tube to fully engage its lower edge behind the
brace. Compressing the boot and twisting as well as applying a small amount of oil on the mating
surfaces helps.
18. Apply New and Improved Judy Butter to the entire spring stacks, completely cover the coil springs.
19. Install spring stack assemblies and top cap in upper tubes, starting top cap threads by hand.
20. Torque top cap to 30 to 40 in-lb (3.4 to 4.5 Nm). This should be between 30 and 60 degrees of
clockwise wrench movement after cap is flush with upper tube.
The following section contains detailed service procedures for all individual components of the Jett XC fork.
The spring system in Jett XC forks provide cutting edge performance with the lively action of a coil spring. However,
over time the springs can wear out, compromising performance. This is evident in compression set, when the coil
springs are shorter in a resting state than they were when new. Use the table listed below as a guide to know when
to replace the springs. Follow the directions found in the Maintenance procedures, "After Every Year or One
Hundred Hours of Riding," page12, for removal and installation.
,
CHECK
.
Travel
63mm
75mm
A
PN 950-001827-00, R
EV
: T
HE PLUNGER ROD BOLTS ARE
.
: D . T
O NOT EXCEED THESE VOLUMES OO LITTLE OIL WILL RESULT IN POOR DAMPING

Service

S R
PRING EPLACEMENT
S S S
PRING YSTEM PECIFICATION
Optimum Coil Replace Coil Optimum Top-out Spring
165mm 156mm 25mm
165mm 156mm 25mm
A
EV
Fig. 6
Fig. 7
.
Replace Top-out Spring
22mm
22mm
P 13
AGE