[Nosewheelie]

I have a 97 Rock Shox Judy that I'd like to rebuild, but I've lost the rebuild instructions.

It has the spring and MCU/elastimer (sp) damping combo that uses Judy Butter.

I know my best option is to can it and get a new fork, but I have 1 1/4" headset on an old Alpine Star and don't want to go through the hassle of sleeving the headset down, etc...

Can anyone give me some instructions on how this fork tears down and builds up?

Thx

 

[gtbike]

Try the Rock Shox trech support- get the number from thier website. Or try www.angryasian.com he may have some info. Also my Zinn and the Art of MTB Maintenance book (2nd Editiion) has a how to on the 95 Judy and others. On the elastomer side (righthand) pop out the bottom allen head, remove the preload topcap and remove the parts and lay them out neatly the way they came out. If they are gonna sit for a few days, take a picture of the layout, trust me on this. The left hand side has a bolt in the bottom for the damper, remove this and the top cap, clean it all in rubbing alcohol and reinstall. Good luck.

 

[Nosewheelie]

Thx - surfed the Rock Shox site - they have no info on anything older that 2002. Kids of sux.

I'll check out the other post.

Thx for the info - I'll give it a shot!

 

[Nosewheelie]

Angry Asian has the rebuild info - great link!

 

[BikeGeek]

I have the original manual. I've only got a paper copy though. I could mail a copy if you need it.

 

[Repack]

A very good cartridge tip:
The cart's are held together by snap rings and are very easy to rebuild.
When you are putting it all back together, slide a piece of metal wire betweent the plastic "plug" and the damper shaft. Fill up the shock body and new oil as much as possible before pushing the plug back down. Also coat the plug with oil. Push the plug down the shaft, keeping the wire in place betweet in and the shaft. As it goes into the oil, the extra oil will be able to escape around the wire. When the plug is pressed down all the way, slide out the wire. This insures that you have no air inside the cart. Air gets hot, expands and blows seals. Very bad.
This may sound complicated, but will start to make sense once you get it apart. I own a 97 Judy DH with aluminum carts held together by snap rings. Hopefully yours is the same. I think that some of the early Judy's had sealed plastic carts.