K2 Bike Chubby LT, Chubby User Manual

Noleen

Chubby / Chubby LT

Owner’s Manual

1998 CHUBBY / CHUBBY LT OWNER'S MANUAL - PDF

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Your Noleen Chubby and Chubby LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Read This Manual!
Precautions

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Frame Preparation
Fork Preparation / Installation

Suspension Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Tuning Variables
Tuning Adjustments

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Tools Needed
Lubrication
Seal and O-Ring Replacement
Bearing Replacement
Maintenance Schedule
Torque and Lubrication Table
Service Kits

INTRODUCTION

YOUR NOLEEN

CHUBBY AND

CHUBBY LT

Congratulations! You’ve just purchased the Noleen Chubby or Chubby LT Suspension Fork! With it’s unique dual triple clamp design,
and four inches of elastomer, spring, and air travel, the Chubby is designed to let you dive into the gnarliest terrain and come out
unrattled and unscathed.

So ride the Chubby and let it Rip!

GENERAL

INFORMATION

In this section:

• Read this Manual!

• Precautions

Note: The Noleen Chubby and Chubby LT come in a Standard size (for bicycles with 90mm to 125mm head tubes) and a Long size (for
bicycles with 126mm to 160mm head tubes). Make sure that you have the correct size Chubby. If you have further questions about
the correct size, see the Installation section. Also, for any other sizing questions, please contact your K2 Bike / Noleen Dealer.

NOTE : Read this manual carefully before attempting to install or service you Chubby Fork. It is important that you follow proper
procedure to ensure maximum performance.

CAUTION: K2 Bike strongly recommends that your Chubby Fork be installed by a K2 Bike dealer or other
qualified technician. These instructions are for a qualified installer who possesses proper training and tools.

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Improperly installed forks can be extremely dangerous, and can result in failure during use and severe injury.

CAUTION: The Noleen Chubby Fork is a competition off road fork, and as such does not come with reflectors

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or lights for road use. Adapt proper reflectors and lights if bicycle will be used in low light conditions.

CAUTION: Installation of an incorrect length steerer tube could result in fork failure and severe injury. See

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your authorized K2 Bike / Noleen dealer or other qualified technician to ensure proper installation.

CAUTION: In the event of a crash, there could be damage to your Chubby Fork that may not be visible.
Damaged forks can be extremely dangerous, and can result in failure during use and severe injuries. After a

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crash, take your fork to an authorized K2 Bike/Noleen dealer or qualified technician to verify its integrity.

2

INSTALLATION

Frame Preparation

In this section:

• Frame Preparation

• Fork Preparation /
Installation

Remove Upper

Triple Clamp

Proper frame preparation will make installing your new Noleen Chubby fork easier and allow your fork to function properly.

Notes : All Noleen suspension forks require the use of a threadless headset, such as a Dia-Compe Aheadset. If you do not have a
threadless headset, you will need to install one before you install your new Noleen fork.

1. Remove the old stem and fork from your bicycle. If you are installing the Noleen fork on a new frame that has never
had a fork installed, move on to the next step.

2. In order for the headset on your frame to function properly, the ends of the headtube should be perpendicular to the
sides of the headtube. Some headtubes need to be “faced” in order to hold the headset cups properly. If you believe
that your headtube needs to be faced, consult your local K2 Bike / Noleen dealer or other qualified bicycle dealer.

3. Lubricate the inside of the frame's headtube as well as the headset cups and press the upper and lower headset cups
into your frame. Make sure that the headtube and headset cups are free of dirt and grime.

NOTE: Headset cups should be installed using a headset press. Do not substitute this tool for anything else. See your local Noleen
dealer for assistance installing headset cups. Damage to the frame and/or headset can occur if not installed properly.

Fork Preparation / Installation - 6 Easy Steps!

Once you have a properly prepared frame, you can now install your Noleen fork. While your Noleen Chubby has been assembled with care at the
factory, partial disassembly and reassembly is required for mounting. Follow these steps:

Step #1 - Remove the Upper Triple Clamp from the fork.

1. Loosen the three bolts on the upper triple clamp.

2. Using the Chubby Wrench (preload adjuster removal tool), loosen and remove the preload adjusters and spring stack.

2. Slide the upper triple clamp off of the top of the fork.

Step #2 - Check the ”Critical Measurement“ for the Chubby / Chubby LT.

Dim A

”Critical Measurement“

Dim A

CAUTION: The lower triple clamp on the Chubby and Chubby LT must remain a certain distance above the
front tire. The Chubby needs this amount of room allow the suspension to compress fully without the tire

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striking the lower triple clamp. Improper fork installation could result in a loss of control and severe injury.

As stated in the caution above, the Chubby needs this amount of room allow the suspension to compress fully without the tire
striking the lower triple clamp. This measurement is different for the two Chubby forks. This measurement DOES NOT change for the different
sizes of each fork model. This measurement should be taken from the middle of the dropout (or the middle of the front hub axle) to the
bottom of the lower triple clamp. We call this measurement the “Critical Measurement.” See below for the Critical Measurement for
the Chubby and Chubby LT forks.

Dim A: Chubby (both Standard and Long sizes) = 442mm

Chubby LT (both Standard and Long sizes) = 467mm

Follow these instructions to set the ”Critical Measurement“ on your Chubby or Chubby LT:

1. Using a tape measure or ruler, measure the distance from the center of the fork dropout to the bottom of
the lower triple clamp.

2. Check this measurement against the ”Critical Measurement“ above.

3. Loosen the two bolts on the lower triple clamp and slide the triple clamp up or down so that both sides

are set to the ”Critical Measurement.“ Torque all of the lower triple clamp bolts to 85 in-lbs.

3