SUNTOUR SF7CR-8V-MLO, RS6-XC PRO-RL, SF7CR-8R-MLO, RS7-EPICON-DA, SF7CR-8V Workshop Handbook

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

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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 ausschließlich ausgebildeten Zweiradmechaniker erlaubt Reparatur- und Servicearbeiten an SR SUNTOUR Federgabeln vorzunehmen.

Français

French

Attention!

Uniquement les mécaniciens cycle certiés sont autorisés à réparer et entretenir les fourches SR SUNTOUR

Italiano

Italian

Attenzione:

Escluso persone istruiti e qualicati in meccanico di biciclette e permesso di aggiustare le SR SUNTOUR forcelle, non appena i lavori di servizi.

Česky Czech

*POZOR!

Opravy a servisní práce na vidlicích SR SUNTOUR jsou povoleny pouze proškoleným mechaniku*m

Polski

Polish

Uwaga!

Tylko przeszkolonym mechanikom rowerów wolno dokonywać napraw i serwisu widelców amortyzowanych rmy SR SUNTOUR

Español Spanish

ATENCION!

Sólo se permite llevar a cabo trabajos de reparación y servicio en las horquillas de suspension de SR SUNTOUR a mecánicos de bicicleta competentes.

Русский

Russian

Внимание!

Ремoнт и сервисные работы по вилкам SR SUNTOUR разрешается производить исключительно специализированным и обученным механикам.

中文

Chinese

注意 !

只有接受過訓練的技工才會被允許進行修補 SR SUNTOUR 的避震前叉及服務性質的工作.

日本語

Japanese

注意 !

SR SUNTOUR のサスペンションホークは訓練を受けたメカニックのみ修理およびサービスが許されています。

Български

език

Bulgarian

Внимание! Амортисьорните вилки SR SUNTOUR, могат да бъдат ремонтирани и поддръжани, само от оторизирани механици преминали курсовете за обучение!

Disclaimer

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

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Table Of Contents

Disclaimer ..........................................................................................3

I. Introduction ................................................... 7

Introduction .....................................................................................8

Abbreviations ...................................................................................9

Addresses ....................................................................................... 10

SR SUNTOUR corporate .................................................................................. 10

Worlwide Distributors .................................................................................... 10

II. Owner’s 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 spe ed ................................................................................. 39

Fork Model: Duro 200 6 ...................................................................................39

Fork Model: Duro DJ 2007 - 2008................................................................. 39

Fork Model: Axon / Epicon ............................................................................ 39

Decrease rebound sp eed ...............................................................................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 rea r susp ension ....................................................................44

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

Function of the Lock-O ut knob: ...................................................................45

IV. Instruction Sheet for Suspension

seat post SP-NCX-D3and SP-NEX-D4 ............. 47

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

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

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

SF 7AXO N -R LD .........................................................................................................120

SF7CR- 8R ..................................................................................................................121

SF7CR-8R-MLO .......................................................................................................122

SF7CR -8V-M LO........................................................................................................123

SF7CR- 8V ..................................................................................................................124

SF8DUROLUX20-TS ................................................................................................ 125

SF8DUROLUX 20-1.5 ..............................................................................................12 6

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

SF7DURO-DJ-D .......................................................................................................12 8

SF7DURO-DJ-E .......................................................................................................12 9

SF8EP ICON- RLD ......................................................................................................13 0

SF7EPI CON-R L ......................................................................................................... 131

SF8EP ICON- LOD .....................................................................................................132

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SF7EPI CON-LO ........................................................................................................133

SF7EPI CON-R LD ......................................................................................................13 4

SF7NEX4610-HLO-700-63 ....................................................................................135

SF8NEX4610-MLO-700-63 ...................................................................................136

SF8 NE X410 0-2 6- 63 ................................................................................................137

SF8NEX4110-700-63 ..............................................................................................138

SF8NEX4600-HLO-26-63 ......................................................................................13 9

SF8N EX4 600 -MLO -26 -63 .....................................................................................140

SF8NEX4510 -MLO 700c ........................................................................................141

SF7N CX- E-R L-700-75 .............................................................................................142

SF8NCX-E-LO-700 -63 ............................................................................................ 143

SF7NCX-D-RL-700-63 ........................................................................................... 14 4

SF7NCX-D-LO-700-63 ...........................................................................................145

SF7N CX- D-70 0- 63 ..................................................................................................14 6

SF8NRX S-RLD .........................................................................................................147

SF8NRX S-RL ............................................................................................................148

SF8NRX S-LOD- 63 ..................................................................................................149

SF8NRX S-LO............................................................................................................15 0

SF8NRX E-RL ............................................................................................................151

SF8NRX E-LO- 63 .....................................................................................................15 2

SF7NR X-LO- 63 ........................................................................................................153

SF8RAIDON-RL-air .................................................................................................15 4

SF8RAIDON-LO-air ................................................................................................ 155

SF8RAIDON-RLD ....................................................................................................156

SF8RAIDON-LOD ....................................................................................................157

SF8RAIDON-LO .......................................................................................................15 8

SF7 X1-LO ..................................................................................................................159

SF7XC M-HLO ...........................................................................................................160

SF7XCM-MLO 26” ...................................................................................................161

SF7XCM-DA 26” ......................................................................................................162

SF7XCM 26” .............................................................................................................. 163

SF7XCR-R L ............................................................................................................... 16 4

SF7XC R-LO ...............................................................................................................165

SF7XCR- DA ...............................................................................................................16 6

SF7XCR ......................................................................................................................167

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

SF8XCT V2-MLO ......................................................................................................16 9

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

chapter

Introduction

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

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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 it’s sometimes hard to understand what the working step really tries to explain. Moreover it’s 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 lm during workshops for local dealers. We have enclosed a DVD at the last page of the workshop book. On this DVD you will nd 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 nd in chapter V.

We would like to give you a short overview about what you will nd within this workshop book. In chapter II you will nd all fork and rear suspension instruction sheets. Chapter number III provides you with all necessary information about the assembling of our dierent 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 customer’s forks. In chapter number VI we have put together all necessary technically information about SR SUNTOUR forks. You will nd 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 nd all exploded views of our 2007-2008 suspension fork models.

A workshop book can never be nished 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

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

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Abbreviations

All Suspension Forks DA DAMPING ADJUST

ELD

ELECTRONICAL LOCK OUT + DAMPING

ADJUST HLO HYDRAULIC LOCK OUT LO LOCK OUT LOD LOCK OUT + DAMPING ADJUST MLO MECHANICAL LOCK OUT RL REMOTE LOCK OUT RLD REMOTE LOCK OUT + DAMPING ADJUST TAD TRAVEL ADJUST + DAMPING ADJUST TR TRAVEL ADJUST + REMOTE LOCK OUT

NRX MODELS S AIR E COIL SPRING

NCX MODELS S AIR E AIR D COIL SPRING

DURO DJ E CroMo STEERER TUBE DJ D STKM STEERER TUBE

AXON MODELS S AIR E AIR D COIL SPRING

RADOM CW CHAIN WHEEL CS CASSETTE SL SHIFT LEVER RD REAR DERAILLEUR FD FRONT DERAILLEUR DB DISC BRAKE SP SEAT POST FT FIRM TECH

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

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Worlwide Distributors

AUSTRIA

KTM FAHRRAD GMBH Harlochner Str. 13 5230 Mattighofen Austria Tel.: +43 7742 4091-34 Fax: +43 7742 4094-26 email: oce@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 Köln Germany tel.: +49 221 17959 - 20 fax: +49 221 17959 - 31

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

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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

I TALY

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

SLOVAKI A

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 Licheld, Stas. 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 Sinn lane Sinn lane industrial estate U.K. Tel.: +44 133 22 74 238 Fax: +44 133 22 74 201 email: sales@moorelarge.co.uk

chapter

Owner’s manuals

Owner‘s Manual

Suspension front fork w. coil spring or MCU

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 qualiﬁed 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.

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 ﬁrst 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

SR SUNTOUR recommends that your suspension fork be installed by a qualiﬁed 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 qualiﬁed 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 manufacturer‘s 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 fork‘s lowers. Please keep in mind that the narro-

west point at the lowers is usually at the height of the brake bosses - so you may have to deﬂate 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 retroﬁt 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.

INSTALLATION

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.

Handlebar

stem

Minimum insertion mark

Threaded length

More than 10mm

Steerer tube

Fig. 1

Headsets:

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.

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

)!!!

Notes on usage of the fork

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, re-

assembly, intentional breakage or damage, alterations or modiﬁcations 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 ﬁtness or merchatability of any kind, except as set forth above. SR SUNTOUR’s 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 speciﬁc 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.

Date of purchase: Fork model name Serial no.

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

Dealer Name: Phone#:

Address:

Purchaser Name: Phone#:

Address:

This warranty is void without proof of purchase.

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 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 INC.

Speciﬁcations are subject to change without notice.

Printed in TAIWAN.

Suspension Fork Warranty Card:

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 ﬁrst 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 ﬁrst fully counter-clockwise and then count the full turns you make clockwise. Please adjust always by the

same amount of turns on both sides.

SR Suntour website: www.srsuntour-cycling.com

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.

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!

After25hours

Afterevery ride

After50hours

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)

Teflon oil

bushings at the dealer

FOR MORE TUNING OPTIONS - HARDER/SOFTER SPRINGS AND MCU - PLEASE CONTACT YOUR LOCAL DEALER

Oil the dustseal area with

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

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 dealer‘s own business stationary in order to prove the date and frequency of the service intervals.

Function check of the fork and clean and grease service of

Instruction Sheet

Suspension front fork with <air/air> / <air/hydraulic> or < coil spring/hydraulic> system

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 qualiﬁed 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.

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 ﬁrst 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

SR SUNTOUR recommends that your suspension fork be installed by a qualiﬁed 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 qualiﬁed 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 manufacturer‘s 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.

INSTALLATION

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 ﬁnd 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 ﬁrmly 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 manufacturer‘s 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

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 manufacturer’s 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 28“or 26” wheel size. Also, you have to check the tire width and you have to allow a minimum of 5mm between tire and the fork‘s 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 deﬂate 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 retroﬁt 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 ﬁrst 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-clock-

wise 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 ﬁrmly in the outer casing stopper (see photo # 3).

e.)

Lead the cable around the guide pulley and thread it through the hole in the ﬁxing bolt. The ﬁxing 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 ﬁxing 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 ﬁxing nut and increase or decrease the cable tension at this point. After that, you can make the ﬁne 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 ﬁxing 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 ﬁrst 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 ﬁrmly in the outer casing stopper (#11).

e.)

Tension the cable lightly and tighten the ﬁxing 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 ﬁxing screw and increase or decrease the cable tension at this point (see #13). After that, you can make the ﬁne tuning again as described at a.) and b.). Don‘t forget to put an end cap on the cable for your protection (see #11).

Fixing bolt. Use a 3mm Allen key.

Cable tension adjustment barrel.

Cable nipple. Shifting cable type.

Cable

ﬁxing bolt

Cable guide

pulley

Cam lever

Press the lever and then the

handlebar to check the function.

For your protection, insert an end cap at

the cable end.

Decrease

tension.

Increase

tension.

Cam lever

released.

Travel adjust

push button.

„Schrader“

valve for air pressure adjust.

In this position, the

fork is now locked.

Lever bracket

ﬁxing bolt.

O u t e r casing stopper

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.

Cable clamping screw.

Pass the cable through this hole below the cable

clamping screw.

For your protection, insert an end cap at

the cable end.

5 6

- 2 -

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

Suspension 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 Intended use Sag

80 mm Racing 8-12 mm 80 mm XC 12-16 mm 100 mm Racing 10-14 mm 100 mm XC 14-18mm 130 mm Freeride 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 ﬂat ground and step off the bike. Measure the distance between the lower seal and the zip tie and you will ﬁnd 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

Check following points:

a) 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. b)

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. c) Brake pad adjustment on the rim and distance to the rim ( 1-2 mm is optimal) d) Brake lever travel - ideally the contact of the brake pad and rim should occur after 1/3 of lever travel range e) Firmness of the brake assembly - apply the brakes several times and check carefully for loose nuts, bolts, etc. f) Front wheel must be centred within the fork tubes. Check proper torque on wheel quick release mechanism.

Check the fork before each ride and contact your dealer if you have any questions.

Dropout

Fork

lowers

Fork

Crown

Steerer

Travel adjus-

ter/ Air system/

preload adj.

Lock-Out

system /

Hydraulic

system/

Air system

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

following steps (Right and left side from rider’s perspective

1.) unscrew by hand the cover cap on the left or right side of the fork crown.

In case of a travel adjustment fork, please follow the procedure

described on the previous page in order to access the air valve.

2.) attach the suspension fork air pump at the “Schrader” valve.

3.) pump up the fork to the desired hardness level -> see chart.

4.) remove the pump from the valve.

5.) replace the cover cap.

b) Setting Sag by spring preload

In order to adjust the Sag by spring preload, measure ﬁrst - 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 fork‘s springs, to harder or softer ones.

Rebound

adjuster

Stanchion

NOTE: Your fork‘s apperance

may vary from the images shown in

this instruction sheet.

For latest information please visit

our website:

WWW.SRSUNTOUR-CYCLING.COM

Air valve

cover cap

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

The remote lock-out control

The remote travel adjuster

The remote lock-out control

The remote lock-out control can be used separately, without the remote travel adjuster.

Rider weight Air pressure

lb. kg. psi

kgf/cm

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/cm

AIR PRESSURE CHART

Note:

This chart is just for your reference and the values

may vary depending on your riding style and terrain.

For your speciﬁc suspension fork, please visit our

website on: www.srsuntour-cycling.com, where you

can ﬁnd under your fork‘s model name a detailed air

pressure chart as downloadable pdf document.

- 3 -

Fork features and function

Travel adjustment

This feature allows you to adjust the travel of your fork depending on your preferences and the terrain you’re 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 inﬁnitely variable travel can be adjusted from 60-120mm (130mm - depending on the fork model) steplessly.

Remark

: The changement of the travel of the fork doesn’t 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 ﬂip 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 don’t forget to un-lock your system when you’re 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 ﬁrst 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:

- Teﬂon fortiﬁed oil

- SR SUNTOUR special grease (SRS No.9170-001) / high quality Teﬂon fortiﬁed 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.

If you ride in extreme weather or terrain conditions, we recommend a more frequent maintenance.

(

Remote

Travel

Adjuster

Remote

Lock-out

System

Air system

Lock-out

Air system

or coil spring

Coil

spring

Open oil + coil spring

Remote

Lock-out

System

Remote

Travel

Adjuster

AIR

System

We recommend the service after 50 and 100 hours of riding to be performed by a qualiﬁed bicycle mechanic.

He has all necessary tools for this servíce and the necessary know-how.

After25hours

Afterevery ride

After50hours

After100 hours

After200 hours

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

In any case, if you feel that your fork’s performance has changed or it handles differently as normal please contact immediately your local dealer to inspect your fork.

- 4 -

Notes on usage of the fork

LIMITED WARRANTY

assembly, intentional breakage or damage, alterations or modiﬁcations 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 ﬁtness or merchatability of any kind, except as set forth above. SR SUNTOUR’s 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 speciﬁc 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.

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

This warranty is void without proof of purchase.

SR SUNTOUR EUROPE S.A. Chaussee de Tervueren,43,1410 Waterloo. Belgium Tel: 0032-2-3544676 / Fax: 0032-2-354 7835 / E-mail: service@srsuntoureurope.com

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 INC.

Speciﬁcations are subject to change without notice.

Printed in TAIWAN.

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 ﬁnd on our website at - WWW.SRSUNTOUR-CYCLING.COM

- where you can download this instruction sheet as interactive pdf. ﬁle.

Date of purchase: Fork model name Serial number

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

Dealer Name: Phone#:

Address:

Purchaser Name: Phone#:

Address:

Suspension Fork Warranty Card:

SR Suntour website: www.srsuntour-cycling.com

- 5 -

Owners Manual

Rear Shock

Suntour RS6-XC PRO - LO

Suntour RS6-XC PRO - RL

Suntour RS7-EPICON-DA

Stand: October 2006

OWNER’S MANUAL

SR SUNTOUR RS6-XC PRO-LO/-RL and RS7-EPICON-DA

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.

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.

Even if you are a experienced bicycle rider and have been doing bicy-

cle service for years, it is important for EVERY person to read the man-

ual completely before you ride your bike which is equipped with a

SR SUNTOUR RS6-XC PRO and RS7-EPICON-DA rear shock.

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.

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.

This manual covers the following SR SUNTOUR rear shocks:

• 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

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 can’t handle it please contact us by using mail, phone or the internet

(adresses therefore are shown on the backside of the manual).

Important Safety Information

• 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!!

• Do not modify your bike, frame or shock. Modiﬁ cation, 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.

Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 1

rebound adjuster set (red)

RS6-XC PRO LO

lock out adjustment (blue)

rebound adjuster set (red)

RS7-EPICON-DA

dust cap

RS6-XC PRO RL

bend

cable

bushing

lock out controller

Main air chamber

Aluminium bushing

Main air chamber valve

RS6-XC PRO

-LO / -RL

RS7-EPICON-DA

Aluminium bushing

body

Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 2

Upgrade your bike with a new rear shock

To replace a rear shock on an existing bike where it has not been equipped origi-

nally it is important to follow several steps:

1. Make sure that the eye-to-eye length is the same as the original equipped

shock.

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.

WARNING! If a longer shock is installed the geometry of your bike is chang-

ing. 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

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.

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.

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 sufﬁ cient 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 differ-

ent shock mounting bores!

Establish which way you are going to position the shock take into consideration

access to the adjusters.

WARNING! Insufﬁ cient clearance between the shock, seatpost, swingarm,

frame or rocker can result in loss of control and serious injury or death

5. The tightening process requires only a medium amount of pressure, as the alu-

minium spacers are a tolerance ﬁ t.

7. Set-up the shock as described in the set-up instructions

Set-up Instructions

For maximum performance from your SR SUNTOUR shock, it is necessary to ad-

just 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.

Adjust the sag

The sag is adjusted by varying the air pressure and has to be determined by the

rider’s 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.

The air pressure is adjusted with a standard schrader valve shock pump on the main

air valve.

Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 3

The recommended amount of sag is as follows:

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 per-

centual difference between the uncompressed eye-to-eye length and the just mea-

sured one is called sag. We recommend getting assitance from another person dur-

ing that measurement.

Increase or decrease the air pressure and repeat the measurement to get the desired

amount of sag.

Information: The pressure range is 50-200psi. Never exceed an air pressure of 200psi in

the uncompressed shock.

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.

Adjust the rebound damping

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.

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 comfort-

able and safe without the suspension kicking you out of the saddle.

WARNING! Riding with improper rebound damping can result in loss of control and

result in serious injury or death.

Use the Lockout

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.

Be sure to open the lockout when riding in rough terrain. This ensures you the maxi-

mum comfort, riding control and prevents the oil pressure in the inside of the shock

to cause damages to the shock.

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.

Cross Country: 10-25% sag

Freeride: 25-30% sag

Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 4

Maintenance

SR SUNTOUR RS6-XC PRO and RS7-EPICON-DA rear shocks needs a minimum

of maintenance only:

• Never use a high pressure cleaner to clean the shock

• 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

WARNING! Opening the shock without having the knowledge how to do will

result in serious injury.

• 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 neces-

sary.

• Get the service done on the internal parts of the shock done more frequently

when it is used mainly under extreme conditions.

Maintenance Shedule

New installed shock / new bike:

• Check mounting hardware torque according to the bike or frame manual

• Check the air pressure

• Check the rebound damping

Before every ride:

• Check Air pressure

(it is normal that the shock is loosing air pressure over the time)

• Mounting hardware torque

Every 2500km:

• Bring the shock to an AUTHORIZED SR SUNTOUR SERVICE CENTER for

doing an extensive service on the internal parts

Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 5

Owners Manual RS6-XC PRO-LO / -RL + RS7-EPICON-DA, Page 6

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 modiﬁ cations 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.

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 makes no express or implied warranties of ﬁ tness or merchatability

of any kind, except as set forth above. SR SUNTOUR’s liability hereunder is ex-

pressly 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 dam-

ages, so the above exclusion may not apply to you. This warranty gives you speciﬁ c

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.

Contact and Service address

Check our web site http://www.srsuntour-cycling.com for local distrutors and service

centres.

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

SR SUNTOUR EUROPE GMBH

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

USA

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 DH-CT-600-Series Hub Dynamo Owner’s Manual

The DH-CT600-series hub dynamo is a compact light and efﬁcient bicycle dynamo hub. It is

developped to match the legal requirements, such as the german regulations StVZO §22a.

Some of the requirements are increased efﬁciancy, voltage limitation and a characteristic of the

voltage to speed relation which reduces ﬂickering 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 ﬁtted products which has been delicately designed and has passed severe ﬁeld and

lab tests to achieve the best performance.

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.

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 manual’s instructions carefully before installation and usage.

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.

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 covers the following SR SUNTOUR hub dynamos:

• SR SUNTOUR DH-CT624-32H (6V, 2.4W, 32 spokes)

• SR SUNTOUR DH-CT624-36H (6V, 2.4W, 36 spokes)

• SR SUNTOUR DH-CT630-32H (6V, 3.0W, 32 spokes)

• SR SUNTOUR DH-CT630-36H (6V, 3.0W, 36 spokes)

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 experi-

enced 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.

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.

If your dealer can’t handle it please contact us by using mail, phone or the internet (adresses are

shown on the backside of the manual).

Dynamo Hub Owner’s Manual DH-CT600-Series, page 1

fork

Installation of the front wheel

To install the front wheel follow the steps described below:

1. loose the nuts (FG9.5) and washer which are placed on the left and the right side of the axle

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.

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.

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.

WARNING: Never ride your bike with a off-center ﬁxed front wheel. A off-center ﬁxed 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.

dynamo hub

connection

terminal

fork

nut

washer

dynamo hub

nut

Dynamo Hub Owner’s Manual DH-CT600-Series, page 2

Installation of the electric cables and connectors

Information: Depending on the hub speciﬁcations 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 front-

and rear-lamp use. Depending on the legal requirements the type of hub must be choosen.

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

1mm

and a total diameter of 1.8 to 2mm including the insulation.

Warning: Do not touch unisolated lectric components (fx. unﬁxed cables, connector ter-

minals and more) during riding or rotation of the wheel. Touching electric parts can cause

electric shocks and burns.

front lamp

cable

(ground)

connector

plug

dynamo

hub

cable

To connect the lamps with the hub follow the shown instruction.

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.

Connect the upper end of the cable with the connectors of the

lamp.

Note: Do not switch over the two cables. If they are switched

over then the lamp will show no function.

If the lamp manufacturer

If a rear lamp is connected to the system, this is usually con-

nected directly to the front lamp. Check the manual of the front

lamp for further information. If there is any difﬁculty or malfunc-

tion please ask your dealer for assistance.

Dynamo Hub Owner’s Manual DH-CT600-Series, page 3

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 modiﬁcations 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.

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 war-

ranty 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 makes no express or implied warranties of ﬁtness or merchatability

of any kind, except as set forth above. SR SUNTOUR’s liability hereunder is ex-

pressly limited to repair or replacement of the product. Under no circumstances will

SR SUNTOUR be liable for incidental or consequential damages. Some jurisdic-

tions 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

speciﬁc rights and you may have other rights which vary from jurisdiction to jurisdic-

tion. In all places, the purchaser should contact the place of purchase for informa-

tion about warranty service.

Contact and Service address

check our web site http://www.srsuntour-cycling.com for local distrutors and service

centres.

SR SUNTOUR INC.

No.7 Hsing Yeh Road,

Fu Hsing Ind. Zone.

Changhua.50606

Taiwan, R.O.C.

Phone: +886 (4) 7695115

Fax: +886 (4) 769 4028

E-mail: orders@srsuntour.com.tw

SR SUNTOUR EUROPE GMBH

Am Marschallfeld 6a

83626 Valley

Germany

Phone: +49 / (0)8024 / 3 03 81 52

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

E-mail: service@srsuntoureurope.com

SR SUNTOUR USA

P.O. Box 61988

Vancouver WA 98666

Canada

Phone: +1 (360) 737 6450

Fax: +1 (360) 737 6452

E-mail: service@usulcorp.com

Dynamo Hub Owner’s Manual DH-CT600-Series, page 4

chapter

III

Service manuals

SR SUNTOUR workshop book, version 2008/Mar/25, page 28

workshop bookworkshop book

Mounting the remote lock-out single lever

Models: AXON / EPICON / NRX

a. 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

picture RL1.1

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

SR SUNTOUR workshop book, version 2008/Mar/25 page 29

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d. Take o the plastic cover using a Allen

key

picture RL1.2

e. Unscrew the cable xing 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.

picture RL1.4

f. Cut the cable to a proper length

picture RL1.5

SR SUNTOUR workshop book, version 2008/Mar/25, page 30

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g. Make sure the fork is set to the “Un-

locked position” and the little plastic toothed wheel sits like shown on picture no. 6

picture RL1.6

h. Reassemble the plastic cover again us-

ing a 2.5mm Allen key

picture RL1.2

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

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 it’s 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.

SR SUNTOUR workshop book, version 2008/Mar/25 page 31

workshop bookworkshop book

Mounting the remote lock-out single lever

Models: Raidon / XCR / NCX

a. 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

picture RL2.1

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 RL2.2

SR SUNTOUR workshop book, version 2008/Mar/25, page 32

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d. Take o the plastic cover

picture RL2.3

e. Unscrew the cable xing bolt with a

1.5mm Allen key.

picture RL2.4

Thread the cable through the outer casing stopper and through the cover unit hole. Tension the cable slightly and tighten it

picture RL2.5

f. Cut the cable to a proper

length(approx 12mm)

picture RL2.6

SR SUNTOUR workshop book, version 2008/Mar/25 page 33

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g. Reassemble the plastic cover again

picture RL2.7

h. Install a cable end cap at the end of

the cut cable using a needle nose pliers

picture RL2.8

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

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 it’s 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.

SR SUNTOUR workshop book, version 2008/Mar/25, page 34

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Mounting and Operating the remote travel adjust control – New TA Lever

Models: SF8 EPICON XC TAD

SF8 DUROLUX SERIES

Note: The travel adjust cartridge sits within the left stanchion tube

a. 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

picture TAL2.1

b. Choose the right length of the cable cas-

ing 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 rmly with the xing bolt using a

2.5mm Allen key

picture TAL 2.2

d. Cut the cable to a proper length (approx.

12m m)

picture TAL2.3

SR SUNTOUR workshop book, version 2008/Mar/25 page 35

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e. Install a cable end cap at the end of the

cut cable using needle nose pliers

picture TAL2.4

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

SR SUNTOUR workshop book, version 2008/Mar/25, page 36

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Mounting and Operating the remote travel adjust control – Old TA Lever

Note: The travel adjust cartridge sits within the left stanchion

a. 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

picture TAL1.1

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 travel adjustment function

picture TAL1.7

d. Remove the plastic cover cap, using a

2.5mm Allen key.

picture TAL1.2

SR SUNTOUR workshop book, version 2008/Mar/25 page 37

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e. Thread the cable through the outer

casing stopper and through the cable clamp. Tension the cable slightly and tighten the cable rmly with the xing bolt using a Phillips screwdriver

picture TAL1.3

f. Cut the cable to a proper length

(approx. 12mm)

picture TAL1.4

g. Reassemble the plastic cover cap

using a 2.5mm Allen key

picture TAL1.5

SR SUNTOUR workshop book, version 2008/Mar/25, page 38

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h. Install a cable end cap at the end of

the cut cable using a needle nose pliers

picture TAL1.6

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

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 ne tuning like described above.

SR SUNTOUR workshop book, version 2008/Mar/25 page 39

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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 stiness, 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 (7.5W). This fork tuning has to be carried out by an authorized and trained bike mechanic.

Fork Model: Axon / Epicon

Please note that the 7.5W oil can result into a failure of the lock out if it’s 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.

SR SUNTOUR workshop book, version 2008/Mar/25, page 40

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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 (7.5W). This fork tuning has to be carried out by an authorized and trained bike mechanic.

SR SUNTOUR workshop book, version 2008/Mar/25 page 41

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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 dierent 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 dierent weight and seating position which inuences the fork in a dierent 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 nd 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 inating 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 inate your fork. Inating the fork with a compressor will cause serious damage which is not covered by warranty! SR SUNTOUR forks have to be inated with special suspension fork air pumps.

63-100mm travel --> 15-20% sag

120-180mm travel --> 20-25% sag

a. Place your bike on a at 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

SR SUNTOUR workshop book, version 2008/Mar/25, page 42

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c. Get on your bike – try to avoid any

bouncing of the fork

Picture 2

d. According to your own weight and

seating position the fork will sag

Picture 3

e. Get o your bike again – try to avoid

compressing your fork while you’re getting o

f. Measure the distance between the

lower tube seal and the zip tie

Picture 4

140mm total travel

60mm sag = 45%

Too Much!

SR SUNTOUR workshop book, version 2008/Mar/25 page 43

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g. Inate the fork until you have reached

the proper pressure

Picture 5

h. Get on you bike once more try to

avoid any bouncing

Picture 6

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 7

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 nd 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.

SR SUNTOUR workshop book, version 2008/Mar/25, page 44

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Setting sag for rear suspension

How to Inate the fork:

Unscrew the cover of the Schraeder valve on the left side of your fork. Regarding travel adjust 1. forks, please note that the “Schraeder” valve is being located at the lower drop out.

Mount the suspension fork air pump at the “Schraeder” valve (please only use a special suspen-2. sion fork air pump, do not use any kind of compressor, normal bicycle pump or air pressure pumps at gas stations).

adjust the air pressure according to your own weight and seating position, so that you achieve the SAG 3. which is recommended for your fork.

Dismount the pump from the valve4. Reinstall the cover cap again5.

SR SUNTOUR workshop book, version 2008/Mar/25 page 45

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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-O-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.

Function of the Lock-Out knob:

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”

Picture LO1

Note: There are two dierent lock-out

cartridges available!

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 90°degree counter-clockwise until the stopper tab.

Picture LO2

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 180°degree counter-clockwise until the stopper tab.

Picture LO3

Note: If the fork doesn’t lock even if the LO knob is set to the “Lock-Out-Mode” or if the fork doesn’t

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

SR SUNTOUR workshop book, version 2008/Mar/25, page 48

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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 manufacturer’s specication 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 child’s hand.

SR SUNTOUR workshop book, version 2008/Mar/25 page 49

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Installation of the Suspension Seat Post

SR SUNTOUR recommends your NCX or NEX suspension seat post is being installed by a trained and qualied bicycle mechanic. Only a qualied 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

3. Grease the inside of the seat tube. If you are going to use a seat post shim, grease it inand outside

4. Install the seat post and insert it past the “minimum insertion mark” and appox. 10mm past the joint of top and seat tube

Installation of the saddle

a. Unscrew the two xing bolts using a

5mm Allen Key

picture 1

b. Take o the upper clamp plate

picture 2

SR SUNTOUR workshop book, version 2008/Mar/25, page 50

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c. 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 4

d. Tighten the two xing bolts until the

saddle is already xed but can still be adjusted.

picture 5

e. Adjust the saddle that it is centered

horizontal like shown in picture no. 6.

picture 6

f. Tighten the two xing bolts with a

torque value of 12Nm.

SR SUNTOUR workshop book, version 2008/Mar/25 page 51

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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 t 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 you’re 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.

How to increase the preload of the suspension seat post?

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

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.

SR SUNTOUR workshop book, version 2008/Mar/25, page 52

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How to change coil springs

1. Reinstall the suspension seat post of your frame

2. Unscrew the preload adjuster bolt

picture 1

3. Slide out the coil springs

picture 2

Please nd the dierent

coil spring setting combinations

here:

weight

[lbs]

weight

[kg]

Picture

Soft 99 – 165 45 – 75 SP3.1

Standard 144 – 220 65 - 100 SP3.2

Hard 176 – 265 80 - 120 SP3.3

picture SP 3.1 picture SP 3.2 picture SP 3.3

SR SUNTOUR workshop book, version 2008/Mar/25 page 53

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4. Reassemble the coil springs back into the seat post

picture 3

5. Tighten the preload adjuster bolt at least until 10mm of the whole thread is visible

picture 4

6. Install the suspension seat back to your bike again

chapter

Charts

SR SUNTOUR workshop book, version 2008/Mar/25, page 56

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Overview of the fork systems

Schematic explanation of positions of adjusters and valves on SR SUNTOUR suspension forks.

A B C D

AXON RL Remote-Lock-Out-Unit Air Pressure Adjust - -

AXON RLD Remote-Lock-Out-Unit Air Pressure Adjust Rebound-Damping Adjust -

DUROLUX 20 TS VVC Travel-Adjust-Unit Rebound-Damping Adjust Air Pressure Adjust

DUROLUX 20 TRIPLE VVC Travel-Adjust-Unit Rebound-Damping Adjust Air Pressure Adjust

DUROLUX 20 1.5 VVC Travel-Adjust-Unit Rebound-Damping Adjust Air Pressure Adjust

DURO DJ E Preload Adjust Preload Adjust Rebound-Damping Adjust -

DURO DJ D Preload Adjust Preload Adjust Rebound-Damping Adjust -

EPICON RLD Remote-Lock-Out-Unit Air Pressure Adjust Rebound-Damping Adjust -

EPICON LOD Hydraulical-Lock-Out Air Pressure Adjust Rebound-Damping Adjust -

EPICON RL Remote-Lock-Out-Unit Air Pressure Adjust - -

EPICON LO Hydraulical-Lock-Out Air Pressure Adjust - -

EPICON DA - Air Pressure Adjust Rebound-Damping Adjust -

EPICON XC TAD - Travel-Adjust-Unit Rebound-Damping Adjust Air Pressure Adjust

NCX S RL Remote-Lock-Out-Unit Air Pressure Adjust - -

NCX E RL Remote-Lock-Out-Unit Air Pressure Adjust - -

NCX E LO Hydraulical-Lock-Out Air Pressure Adjust - -

NCX D RL Remote-Lock-Out-Unit Preload Adjust - -

NCX D LO Hydraulical-Lock-Out Preload Adjust - -

NCX FT S RL Remote-Lock-Out-Unit Air Pressure Adjust - -

NCX FT E RL Remote-Lock-Out-Unit Air Pressure Adjust - -

NCX FT D RL Remote-Lock-Out-Unit Preload Adjust - -

NCX FT D LO Hydraulical-Lock-Out Preload Adjust - -

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SR SUNTOUR workshop book, version 2008/Mar/25, page 57

A B C D

NEX4610 HLO Hydraulical-Lock-Out Preload Adjust - -

NEX4600 HLO Hydraulical-Lock-Out Preload Adjust - -

NEX4610 MLO Mechnical-Lock-Out - - -

NEX4600 MLO Mechnical-Lock-Out - - -

NRX S RLD Remote-Lock-Out-Unit Air Pressure Adjust Rebound-Damping Adjust -

NRX S RL Remote-Lock-Out-Unit Air Pressure Adjust - -

NRX S LO Hydraulical-Lock-Out Air Pressure Adjust - -

NRX E RL Remote-Lock-Out-Unit Preload Adjust - -

NRX E RL Hydraulical-Lock-Out Preload Adjust - -

RAIDON RL air Remote-Lock-Out-Unit Air Pressure Adjust - -

RAIDON LO air Hydraulical-Lock-Out Air Pressure Adjust - -

RAIDON RLD Remote-Lock-Out-Unit Preload Adjust Rebound-Damping Adjust -

RAIDON LOD Hydraulical-Lock-Out Preload Adjust Rebound-Damping Adjust -

RAIDON LO Hydraulical-Lock-Out Preload Adjust - -

XCM HLO Hydraulical-Lock-Out Preload Adjust - -

XCM MLO Mechnical-Lock-Out - - -

XCR RL Remote-Lock-Out-Unit Preload Adjust - -

XCR LO Hydraulical-Lock-Out Preload Adjust - -

XCT V2 MLO Mechnical-Lock-Out - - -

SR SUNTOUR workshop book, version 2008/Mar/25, page 58

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Suspension Fork Air Pressure and Oil Level Chart

System

Oil amount

[cm³]

Oil type

SAG

Air pressure

[psi]

Air pressure

[kgf/cm²]

Air pressure

[bar]

Right Left [%]

Right Left Right Left Right Left

min max min max min max min max min max min max

SF 7-A XON -R LD air spring - - - 15 - 20 - - - 165 - - - 11,6 - - - 11,4

SF8-AXON-RL air spring - - - 15 - 20 - - - 165 - - - 11,6 - - - 11,4

SF8-Duro FR20 coil spring - - KCE 207 - - - - - - - - - - - - -

SF7-Duro DJ E coil spring 80 - KCE 207 - - - - - - - - - - - - -

SF7-Duro DJ D coil spring 80 - KCE 207 - - - - - - - - - - - - -

SF8-Durolux 20 triple air spring - - KCE 207 20 - 25 - 150 - 10,5 - 10,3

SF8-Durolux 20 1.5 air spring 80 - KCE 207 20 - 25 29 75 - 150 2,0 5,3 - 10,5 2,0 5,1 - 10,3

SF8-Durolux 20 TS air spring 80 - KCE 207 20 - 25 29 75 - 15 0 2,0 5,3 - 10,5 2,0 5,1 - 10,3

SF8-EPICON XC TAD air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-EPICON-RLD air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-EPICON-RL air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-EPICON-LOD air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-EPICON-LO air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-EPICON-DA air spring - - - 15 - 20 - - - 18 0 - - - 12,6 - - - 12,4

SF8-RAIDON-RL air air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-RAIDON-LO air air spring - - - 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF8-NRX S RLD 700C Ltd.

air spring 45 - KCE 207 15 - - - 150 - - - 10,5 - - - 10,3

SF8-NRX S RLD 700C air spring 45 - KCE 207 15 - - - 150 - - - 10,5 - - - 10,3

SF8-NRX S RL 700C air spring 45 - KCE 207 15 - - - 150 - - - 10,5 - - - 10,3

SF8-NRX S LOD 700C air spring 45 - KCE 207 15 - - - 15 0 - - - 10,5 - - - 10,3

SF8-NRX S LO 700C air spring 45 - not decided 15 - - - 150 - - - 10,5 - - - 10,3

SF7-NCX -E- RL 700C air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF7-NCX-E LO 700C air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF-CR990 LO 700C air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF-Condor TA 26’ air spring - - - 20 - 25 150 10,5 10,3

Models 2008

SR SUNTOUR workshop book, version 2008/Mar/25, page 59

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Suspension Fork Air Pressure and Oil Level Chart

System

Oil amount

[cm³]

Oil type

SAG

Air pressure

[psi]

Air pressure

[kgf/cm²]

Air pressure

[bar]

Right Left [%]

Right Left Right Left Right Left

min max min max min max min max min max min max

SF 7-A XON -R LD air spring 75 - KCE207 15 - 20 - - - 165 - - - 11, 6 - - - 11, 4

SF7-RUX triple open oil bath 220 220 KCE207 20 - 25 - - - 23 - - - 1,6 - - - 1,6

SF 7-R UX- S open oil bath 150 120 KCE207 20 - 25 - - - 23 - - - 1,6 - - - 1,6

SF 7-R UX- E open oil bath 150 120 KCE207 20 - 25 - - - 23 - - - 1,6 - - - 1,6

SF7 XC PRO TAD open oil bath 90 - KCE 202 20 - 25 - - - 180 - - - 12,6 - - - 12,4

SF7 XC PRO TA open oil bath - 20 - 25 - - - 180 - - - 12,6 - - - 12,4

SF7 XC PRO TR open oil bath - 20 - 25 - - - 180 - - - 12,6 - - - 12, 4

SF7 DURO DJ E coil spring 80 - KCE 207 - - - - - - - - - - - - -

SF7 DURO DJ D coil spring 80 - KCE 207 - - - - - - - - - - - - -

SF7 DURO DJ TRIPLE coil spring - - - - - - - - - - - - - - - -

SF7-EPICON-RLD air spring 85 - KCE 207 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF7-EPICON-RL air spring 85 - KCE 207 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF7-EPICON-LOD air spring 85 - KCE 207 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF7-EPICON-DA air spring 85 - KCE 202 15 - 20 - - - 180 - - - 12,6 - - - 12,4

SF7-NRX S RLD 700C Ltd. air spring 45 - KCE 207 15 - - - 150 - - - 10,5 - - - 10,3

SF7-NRX S RLD 700C air spring 45 - KCE 207 15 - - - 150 - - - 10,5 - - - 10,3

Models 2007

SR SUNTOUR workshop book, version 2008/Mar/25, page 60

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Suspension Fork Air Pressure and Oil Level Chart

System

Oil amount

[cm³]

Oil type

SAG

Air pressure

[psi]

Air pressure

[kgf/cm²]

Air pressure

[bar]

Right Left [%]

Right Left Right Left Right Left

min max min max min max min max min max min max

SF6AXON-S RL- Air spring - - - 15 - 20 - - - 120 - - - 8,4 - - - 8,3

SF6AXON-E RL- Air spring - - - 15 - 20 - - - 120 - - - 8,4 - - - 8,3

SF6RUX S-130 open oil bath 150 120 KCE207 20 - 25 - - - 23 - - - 1,6 - - - 1,6

SF6RUX E-130 open oil bath 150 120 KCE207 20 - 25 - - - 23 - - - 1,6 - - - 1,6

SF6-RUX triple open oil bath 220 220 KCE207 20 - 25 - - - 23 - - - 1,6 - - - 1,6

SF6RUX DJ-D-100 open oil bath 80 - KCE202 20 - 25 - - - - - - - - - - - -

SF6XC PRO S TR-140 open oil bath - - - 20 - 25 - - - 180 - - - 12,6 - - - 12 ,4

SF6XC PRO E TR-140 open oil bath - - - 20 - 25 - - - 180 - - - 12,6 - - - 12 ,4

SF6XC PRO S TAD-140 open oil bath 90 - KCE 202 20 - 25 - - - 180 - - - 12,6 - - - 12,4

SF6XC PRO E TAD-140 open oil bath 90 - KCE 202 20 - 25 - - - 180 - - - 12,6 - - - 12,4

SF6DURO-E Coil spring 80 - KCE202 - - - - - - - - - - - - -

SF6DURO-D Coil Spring 80 - KCE202 - - - - - - - - - - - - -

SF6NCX-FT- S- RL- Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6NCX-FT-E-RL Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6NCX-FT-E-LO Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6NCX-E-RL Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6NCX-E-LO Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6NRX9100-RL Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6NRX8200-RL Air spring - - - 15 - - - 15 0 - - - 10,5 - - - 10,3

SF6NRX8100 -LO Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

SF6-Condor TA 26” air spring - - - 20 - 25 - - - 150 - - - 10,5 - - - 10,3

SF6CR990-LO Air spring - - - 15 - - - 150 - - - 10,5 - - - 10,3

Models 2006

SR SUNTOUR workshop book, version 2008/Mar/25, page 61

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Rear Shock Air Pressure and Oil Level Chart

Models 2008 System

Oil amount

[cm]

Oil type

SAG

[%]

Air pressure [psi]

[psi]

Air pressure

[kgf/cm²]

Air pressure

[bar]

min max min max min max

RS8-EPICON-LOD 165mm air spring - - - 15 -20 - 200 - 14,0 - 13,8

RS8-EPICON-DA 165mm air spring - - - 15 -20 - 200 - 14,0 - 13,8

RS8-EPICON-LOD 190mm air spring - - - 20-25 - 200 - 14,0 - 13,8

RS8-EPICON-DA 190mm air spring - - - 20-25 - 200 - 14,0 - 13,8

RS7-XC-PRO-S -LO 165mm air spring - - - 15 -20 - 200 - 14,0 - 13,8

RS7-XC-PRO-S -LO 190mm air spring - - - 20 -25 - 200 - 14,0 - 13,8

RS6-XC-PRO-S-LO 165mm air spring - - - 15 -20 - 200 - 14,0 - 13,8

RS6-XC-PRO-S-LO 190mm air spring - - - 20-25 - 200 - 14,0 - 13, 8

Models 2007 System

Oil amount

[cm ]

Oil type

SAG

[%]

Air pressure [psi]

[psi]

Air pressure

[kgf/cm²]

Air pressure

[bar]

min

max

min max min

max

Models 2006 System

Oil amount

[cm ]

Oil type

SAG

[%]

Air pressure [psi]

[psi]

Air pressure

[kgf/cm²]

Air pressure

[bar]

min

max

min max min

max

SR SUNTOUR workshop book, version 2008/Mar/25, page 62

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF7-RUX TRIPLE 32 150

Hard on request

Standard FEP286 19 281 3,2 26 3,6

Soft on request

SF7-RUX S 32 150

Hard on request

Standard FEP286 19 281 3,2 26 3,6

Soft on request

SF7-RUX S 32 130

Hard on request

Standard FEP287 19 280 3,2 23 4 ,1

Soft on request

SF7-RUX E 32 150

Hard on request

Standard FEP286 19 281 3,2 26 3,6

Soft on request

SF7-RUX E 32 130

Hard on request

Standard FEP287 19 280 3,2 23 4 ,1

Soft on request

SF8-DURO FR20 L 35 16 0

Hard on request

Standard FEP396 20,6 332 3,8 31 4,5

Soft on request

SF8-DURO FR20 R 35 160

Hard on request

Standard FEP395 16 ,4 296 3 35 3 ,1

Soft on request

SF8-DURO FR20 L 35 10 0

Hard F EP2 01-10 20,6 230 4 17 10,5

Standard FEP2 01 20,6 2 32 3,8 19 7, 4

Soft FEP201-20 20,6 235 3,4 20 4,7

SF8-DURO FR20 R 35 100

Hard on request

Standard FEP20 0 16, 6 200 2,8 21 3,9

Soft on request

2008/2007 models

MTB Forks 26”

SR SUNTOUR workshop book, version 2008/Mar/25, page 63

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF7-DURO DJ E L 35 80

Hard F EP2 74-10 20,6 209 4 14 12

Standard FE P274 20,6 211 4 17 9,9

Soft on request

SF7-DURO DJ E R 35 80

Hard on request

Standard FEP275 16, 6 180 2,8 22 3,7

Soft on request

SF7-DURO DJ E L 35 100

Hard F EP2 01-10 20,6 230 4 17 10,5

Standard FEP2 01 20,6 2 32 3,8 19 7, 4

Soft FEP201-20 20,6 235 3,4 20 4,7

SF7-DURO DJ E R 35 10 0

Hard on request

Standard FEP20 0 16, 6 200 2,8 21 3,9

Soft on request

SF7-DURO DJ E L 35 130

Hard F EP 173 -10 20,6 262 4,2 25 8

Standard FE P17 3 20,6 264 3,8 24 5,9

Soft on request

SF7-DURO DJ E R 35 130

Hard on request

Standard FE P17 2 16 ,6 232 2,8 27 3,1

Soft on request

SF7-DURO DJ D L 35 80

Hard F EP2 74-10 20,6 209 4 14 12

Standard FE P274 20,6 211 4 17 9,9

Soft on request

SF7-DURO DJ D R 35 80

Hard on request

Standard FEP275 16, 6 180 2,8 22 3,7

Soft on request

MTB Forks 26” continued from previous page

SR SUNTOUR workshop book, version 2008/Mar/25, page 64

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF7-DURO DJ D L 35 100

Hard F EP2 01-10 20,6 230 4 17 10,5

Standard FEP2 01 20,6 2 32 3,8 19 7, 4

Soft FEP201-20 20,6 235 3,4 20 4,7

SF7-DURO DJ D R 35 100

Hard on request

Standard FEP20 0 16 ,6 200 2,8 21 3,9

Soft on request

SF7-DURO DJ D L 35 13 0

Hard F EP 173 -10 20,6 262 4,2 25 8

Standard FE P17 3 20,6 264 3,8 24 5,9

Soft on request

SF7-DURO DJ D R 35 13 0

Hard on request

Standard FE P17 2 16 ,6 232 2,8 27 3,1

Soft on request

SF8-RAIDON-RLD 32 100

Hard on request

Standard FEP359 19, 5 252 4,5 26 11 , 2

Soft on request

SF8-RAIDON-RLD 32 12 0

Hard on request

Standard FEP363 19 ,5 274 4,3 27 9,2

Soft on request

SF8-RAIDON-LOD 32 100

Hard on request

Standard FEP359 19, 5 252 4,5 26 11 , 2

Soft on request

SF8-RAIDON-LOD 32 12 0

Hard on request

Standard FEP363 19 ,5 274 4,3 27 9,2

Soft on request

MTB Forks 26” continued from previous page

SR SUNTOUR workshop book, version 2008/Mar/25, page 65

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF8-RAIDON-LO 32 100

Hard on request

Standard FEP3 81 19 ,5 249 2,4 27 8,5

Soft on request

SF8-RAIDON-LO 32 12 0

Hard on request

Standard FEP380 19 ,5 270 4 26 7, 4

Soft on request

SF7-XCR-RL 30 80

Hard on request

Standard FEP252-70 19 216 3,8 21 8,2

Soft FEP252-40 19 217 3,2 20 4,7

SF7-XCR-RL 30 100

Hard FEP 251-9 0 18,7 237 4 28 7, 7

Standard FE P251-8 0 19 236 3,8 26 6,6

Soft FEP251-30 19 239 3,2 25 3,8

SF7-XCR-RL 30 12 0

Hard on request

Standard FEP236- 80 19 236 3,8 26 6,6

Soft FEP236-50 19 26 4 3,2 30 3,1

SF7-XCR-LO 30 80

Hard on request

Standard FEP252-70 19 216 3,8 21 8,2

Soft FEP252-40 19 217 3,2 20 4,7

SF7-XCR-LO 30 100

Hard FEP 251-9 0 18,7 237 4 28 7, 7

Standard FE P251-8 0 19 236 3,8 26 6,6

Soft FEP251-30 19 239 3,2 25 3,8

SF7-XCR-LO 30 12 0

Hard on request

Standard FEP236- 80 19 236 3,8 26 6,6

Soft FEP236-50 19 26 4 3,2 30 3,1

MTB Forks 26” continued from previous page

SR SUNTOUR workshop book, version 2008/Mar/25, page 66

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF7-XCR-DA 30 80

Hard on request

Standard FEP252-70 19 216 3,8 21 8,2

Soft FEP252-40 19 217 3,2 20 4,7

SF7-XCR-DA 30 100

Hard FEP 251-9 0 18,7 237 4 28 7, 7

Standard FE P251-8 0 19 236 3,8 26 6,6

Soft FEP251-30 19 239 3,2 25 3,8

SF7-XCR-DA 30 12 0

Hard on request

Standard FEP236- 80 19 236 3,8 26 6,6

Soft FEP236-50 19 26 4 3,2 30 3,1

SF7-XCR 30 80

Hard FEP252-50 19 215 3,8 20 8,6

Standard FEP252-30 19 217 3,5 20 6,5

Soft FEP252-40 19 217 3,2 20 4,7

SF7-XCR 30 10 0

Hard FEP 251-4 0 19 236 3,8 25 6,9

Standard F EP251-2 0 19 238 3,5 25 5,2

Soft FEP251-30 19 239 3,2 25 3,8

SF7-XCR 30 12 0

Hard FEP236-40 19 257 3,8 29 6

Standard FEP236-30 19 260 3,5 30 4,3

Soft FEP236-50 19 26 4 3,2 30 3,1

SF7-XCM-HLO 30 80

Hard FEP32 7-40 18 ,6 225,5 3,6 18 8,4

Standard F EP327-30 18, 6 2 37, 5 3,5 21 6,5

Soft FE P327-50 18, 6 2 29,5 3,2 20 5

SF7-XCM-HLO 30 10 0

Hard FE P319- 40 18, 6 2 47, 5 3,6 23 6,5

Standard F EP319 -30 18 ,6 249,5 3,5 26 5,2

Soft FE P319 -50 18 ,6 249,5 3,2 26 3,8

MTB Forks 26” continued from previous page

SR SUNTOUR workshop book, version 2008/Mar/25, page 67

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF7-XCM-DA 30mm 80mm

Hard FEP236-40 18,6 225,5 3,6 18 8,4

Standard FEP236-30 18,6 2 37, 5 3,5 21 6,5

Soft FEP236-50 18, 6 229,5 3,2 20 5

SF7-XCM-DA 30mm 100mm

Hard FE P319- 40 18 ,6 2 47, 5 3,6 23 6,5

Standard F EP319 -30 18 ,6 249,5 3,5 26 5,2

Soft FE P319 -50 18 ,6 249,5 3,2 26 3,8

SF7-XCM-MLO 30mm 80mm

Hard on request

Standard FEP326 18 283 4 25 9, 4

Soft on request

SF7-XCM-MLO 30mm 100 mm

Hard F EP32 3-10 18 282 4,2 28 10

Standard FEP323 18 285 4 31 7, 6

Soft FE P323-2 0 18 285 3,7 34 5,3

SF7-XCM 30mm 80mm

Hard FEP 327-10 19 226 3,8 21 8,2

Standard FEP327 19 2 27, 5 3,5 20 6,5

Soft F EP327-20 19 228,5 3,2 18 5,2

SF7-XCM 30mm 10 0mm

Hard FEP 319-10 19 24 7, 5 3,8 25 6,9

Standard FE P319 19 249,5 3,5 25 5,2

Soft F EP319 -20 19 249,5 3,2 25 3,8

SF8-XCT V2 MLO 26” 28mm 80mm

Hard FEP289-40 16 282 4 27 11 ,6

Standard FEP289-30 16 282 4 31 10 ,1

Soft FEP289-50 16 284 3,6 29 7, 5

SF8-XCT V2 26” 28mm 80mm

Hard on request

Standard FEP350-30 15 279 4,5 36,5 14 ,8

Soft FEP350-50 15 279 4 35 10 ,5

MTB Forks 26” continued from previous page

SR SUNTOUR workshop book, version 2008/Mar/25, page 68

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

Trekking Bike Forks 700c

SF8-NRX-E-RL 700C 30mm 63mm

Hard on request

Standard FE P391 15, 6 210 3,4 22 8,7

Soft on request

SF8-NRX-E-LO 700C 30mm 63mm

Hard on request

Standard FE P391 15, 6 210 3,4 22 8,7

Soft on request

SF8-NRX-LO 700c 30mm 63mm

Hard FEP335-10 19 210 3,8 16 ,5 10,4

Standard FEP335 19 211 3,6 18 7, 9

Soft on request

SF7-NCX-FT-D-RL 28mm 63mm

Hard FEP212-70 17 200 3,8 22 10, 3

Standard FEP212-10 17 197 3,5 21 8 ,1

Soft FEP212-60 17 203 3,2 22 5,7

SF7-NCX-FT-D-LO 28mm 63mm

Hard FE P291 15 206 3,2 19 9

Standard FEP258 15 206 3,2 23 7, 4

Soft on request

SF7-NCX-D-RL 28mm 63mm

Hard FEP212-70 17 200 3,8 22 10, 3

Standard FEP212-10 17 197 3,5 21 8 ,1

Soft FEP212-60 17 203 3,2 22 5,7

SF7-NCX-D-LO 25.4mm 63mm

Hard FE P291 15 206 3,2 19 9

Standard FEP258 15 206 3,2 23 7, 4

Soft on request

SR SUNTOUR workshop book, version 2008/Mar/25, page 69

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF7-NCX-D 25.4mm 63mm

Hard FE P291 15 206 3,2 19 9

Standard FEP258 15 206 3,2 23 7, 4

Soft on request

SF8-NEX4610-HLO 25.4mm 63mm

Hard on request

Standard FEP264 15 211 3,4 30 -19 7.0 - 11.1

Soft on request

SF8-NEX4610-MLO 25.4mm 63mm

Hard on request

Standard FEP264 15 211 3,4 30 -19 7.0 - 11.1

Soft on request

S F8 - N E X - 4 110 25.4mm 63mm

Hard FEP335-10 14, 3 206 4 26 15 ,7

Standard FEP355 14, 4 208 3,8 29 11, 7

Soft on request

SF8-NEX4600-HLO 26” 25.4mm 63mm

Hard on request

Standard FEP238 15 209 3,2 34 -21 5. 0- 8.1

Soft on request

SF8-NEX4600-MLO 26” 25.4mm 63mm

Hard on request

Standard FEP264 15 211 3,4 30 -19 7.0 - 11.1

Soft on request

SF8-NEX-4100 26” 25.4mm 63mm

Hard FEP335-10 14, 3 206 4 26 15 ,7

Standard FEP355 14, 4 208 3,8 29 11, 7

Soft on request

SF7-CT-SA 700c 25.4mm 63mm

Hard F EP181 15 18 9 3,4 26 8 ,1

Standard F EP163 15 19 2 2,9 27-19 4.5-6.4

Soft on request

Trekking Bike Forks 700c continued from prevoius page

SR SUNTOUR workshop book, version 2008/Mar/25, page 70

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Coil Spring Chart

Model

Stanchion tube

diameter

Tra vel

Type of

spring

Parts code Nomber

(A)

Inner

diameter

(B)

Overall

length

(C)

Wire di-

ameter

(D)

Turn of

wire

Spring

rate

[mm] [mm] [mm] [N/mm]

[mm] [mm]

SF6-CR940-LO 25.4mm 63mm

Hard F EP181 15 18 9 3,4 26 8 ,1

Standard F EP163 15 19 2 2,9 27-19 4.5-6.4

Soft on request

SF8- CR930 25.4mm 63mm

Hard F EP181 15 18 9 3,4 26 8 ,1

Standard F EP163 15 19 2 2,9 27-19 4.5-6.4

Soft on request

SF7-CR-8V-MLO 25.4mm 50mm

Hard on request

Standard FEP264 15 211 3,4 30 -19 7.0 - 11.1

Soft on request

SF7-CR-8R-MLO 25.4mm 40mm

Hard on request

Standard FE P26 4-10 14 ,8 18 2 3,6 24 -15 11.1 -17. 6

Soft on request

SF7-CR-8V 25.4mm 50mm

Hard FE P273 -10 15 168 3,4 20 10 ,5

Standard FEP273 15 171 3 18 7, 6

Soft on request

SF8- CR-8R 25.4mm 50mm

Hard FE P273 -10 15 168 3,4 20 10 ,5

Standard FEP273 15 171 3 18 7, 6

Soft on request

SF8-CR880W 26” 23.8mm 50mm

Hard F EP 116 - 3 0 13 160 3,2 25 9,7

Standard F EP 116 - 0 2 13 163 2,9 29 -24 5 . 9 -7. 3

Soft on request

Trekking Bike Forks 700c continued from prevoius page

SR SUNTOUR workshop book, version 2008/Mar/25 page 71

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Maximum possible rotor diameter

2008 MTB Forks

Duro Series 210mm Durolux Series 210mm Axon Series 185mm Epicon Series 185mm Raidon Series 185mm XCR Series 185mm XCM Series 185mm XCT Series 160mm XCU Series 160mm M2000 Series 160mm

2008 Trekking Forks

NRX Series 185mm NCX Series 185mm NCX FT Series 180mm NEX Series 180mm

2007 MTB Forks

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

2007 Trekking Forks

NRX Series 185mm NCX Series 185mm NCX FT Series 180mm NEX Series 180mm M2000N Series 160mm

SR SUNTOUR workshop book, version 2008/Mar/25, page 72

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Serial Number Explanation

country of

origin

year

production

line

month day

T 07 D 06 21

C 07 E 05 15

C = China T = Taiwan

SR SUNTOUR workshop book, version 2008/Mar/25 page 73

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Tightening Torque Chart

Pos. Part to be tightened Tightening torque [Nm]*

1 Fork top cap (alloy) 10 2 Fork top cap (plastic) 5 3 Lower xing bolt/nut 10 4 V-brake pivot 15 5 Upper and Lower crown xing bolts 7 6 Through axle xing bolt (Durolux 20/Duro FR20) 11 7 axle nut (BB XCR FX, Hexagon 28mm) 7-10 8 BB XCR FX crank xing bolt (BB XCR FX) 40-45

* Tolerance: ±10%

1/2

schematic graphic showing nuts and

bolts for tightening torque chart

SR SUNTOUR workshop book, version 2008/Mar/25, page 74

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Oil Type Chart

Oil type Viscosity (40deg.c) wt KCE202 11 c S t 5 KCE207 31c St 10

Oil type Viscosity cc Air chamber sealing oil 150 cSt 6

schematic graphic showing nuts and

bolts for tightening torque chart

bottom bracket crank

assembly BB-XRC FX

chapter

Fork Maintenance

Manuals

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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 gure 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 rmness 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 fork’s performance has changed or it handles dierently as normal – please contact your dealer immediately to inspect your fork.

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We recommend servicing the fork after 50 and 100hours of riding. This service has to be performed by a trained and qualied 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 xing bolts for proper torque (Nm)

oil the dust seal area with teon 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 teon 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 qualied 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 isn’t 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 it’s warranty!

SR SUNTOUR workshop book, version 2008/Mar/25, page 78

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How to Replace Remote-Lock-Out + Damping (RLD) cartridge

Models:AXON / EPICON / NRX

a. Pull out the rebound adjuster knob

using a needle nose pliers

picture 1

b. Unscrew the xing bolt half way using

an 8mm Allen key

picture 2

c. Hit the xing bolt with plastic tip ham-

mer slightly

picture 3

d. Unscrew the xing bolt full way and

take it out

picture 4

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e. Unscrew the xing bolt of the remote

lock cover cap using a 2.5mm Allen key

picture 5

f. Unfasten the remote lock unit xing

bolt using a Phillips screwdriver No. 2

picture 6

g. Unfasten the remote lock cartridge us-

ing a 27mm socket wrench

picture 7

h. Take out the old cartridge

picture 8

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i. Before assembling the new cartridge

make sure that it is set to the unlocked position

picture 9

j. Pull out the support tube assy full way

picture 10

k. Tighten the new cartridge with 10Nm

using a 27mm socket wrench

picture 11

l. Fasten the damper xing bolt with

6Nm using an 8mm Allen key

picture 12

90° unlock

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m. Reassemble the rebound adjuster

knob

picture 13

n. Reinstall the remote lock out unit us-

ing a Phillips screwdriver No.2

picture 14

o. Reinstall the toothed wheel and

spring unit like shown on picture No. 15

picture 15

p. Assemble the remote lock unit cover

cap using a 2.5mm Allen key

picture16

open position

SR SUNTOUR workshop book, version 2008/Mar/25, page 82

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How to replace Remote-Lock-Out + Damping (RLD) cartridge

Models: RAIDON RL / XCR RL / NCX RL

a. Unscrew the two xing bolts half way

using a 5mm Allen key

picture 1

b. Hit the xing bolts with plastic tip

hammer slightly

picture 2

c. Unscrew the xing bolts full way and

take them out

picture 3

d. Separate upper and bottom case

picture 4

SR SUNTOUR workshop book, version 2008/Mar/25 page 83

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e. Take o the remote look out unit us-

ing a 2.5mm Allen key

picture 5

f. Unscrew cartridge xing bolt using a

10mm socket wrench / NCX RL: 5mm Allen key

picture 6

g. Hit the xing bolt slightly using a plas-

tic tip hammer

picture 7

h. Take out the old cartridge and install

the new one

picture 8

i. Tighten the cartridge xing bolt again

using a 10mm socket wrench / NCX RL: 5mm Allen key

picture 9

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j. Reinstall the remote-lock-out unit us-

ing a 2.5mm Allen key

picture 10

k. Reassemble the upper and bottom

case

picture 11

l. Before fastening the left xing bolt

you have to pull up the fork

picture 12

m. Fasten the xing bolts with 10Nm us-

ing a 5mm Allen key

picture 13

SR SUNTOUR workshop book, version 2008/Mar/25 page 85

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How to replace Lock-Out (LO) cartridge

Models: RAIDON LO / RAIDON LO air / XCR LO / XCM HLO

NCX D LO / NCX E LO / NCX FT D LO / NEX4610 HLO

a. Unscrew the two xing bolts half way

using a 5mm Allen key

picture 1

b. Hit the xing bolts with plastic tip

hammer slightly

picture 2

c. Unscrew the xing bolts full way and

take them out

picture 3

d. Separate upper and bottom case

picture 4

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e. Take o the lock-out knob

picture 5

f. Take out the adjust core using a

needlenose pliers

picture 6

g. Unfasten the cartridge xing bolt half

way using a 5mm Allen key

picture 7

h. Hit the xing bolt slightly using a plas-

tic tip hammer

picture 8

SR SUNTOUR workshop book, version 2008/Mar/25 page 87

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i. Unscrew the cartridge xing bolt full

way and take out the cartridge

picture 9

j. Install the new cartridge and fasten

the xing bolt with 10Nm

picture 10

k. Set the cartridge to the unlocked posi-

tion before continuing. To do so use a 4mm Allen key

picture 11

l. Reassemble the adjust core

picture 12

m. Reassemble the upper and bottom

case

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n. Before fastening the left xing bolt

you have to pull up the fork.

picture 13

o. Tighten the xing bolts with 10Nm

using a 5mm Allen key

picture 14

SR SUNTOUR workshop book, version 2008/Mar/25 page 89

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How to replace the Travel-Adjust (TA) cartridge

Models: DUROLUX SERIES / EPICON TAD / XC-PRO TAD / XC-PRO TA

Old travel adjust top cap unit

a. Unscrew the xing bolt using a 10mm

socket wrench

picture 1

b. Take o the travel adjust unit cover

cap using a 2.5mm Allen key

picture 2

c. Take o the travel adjust core using a

Phillips screwdriver No.2

picture 3

d. Take out the circlip using a small

screwdriver

picture 4

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e. Take out the travel adjust core

picture 5

f. Unscrew the cartridge using a 27mm

socket wrench

picture 6

g. Hit the cartridge slightly using a plas-

tic tip hammer and take it out

picture 7

h. Assemble the new cartridge and fas-

ten it with 10Nm using a 27mm socket wrench

picture 8

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i. Reinstall the travel adjust core

picture 9

j. Reassemble the circlip using a small

screwdriver

picture 10

k. Fasten then travel adjust core using a

Philips screwdriver No.2

picture 11

l. Reinstall the travel adjust unit cover

cap using a 2.5mm Allen key

picture 12

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m. Fasten the xing bolt with 6Nm using

a 10mm socket wrench

picture 13

New travel adjust top cap unit

The working steps which need to be carried out are very similar between the old and the new travel adjust. The only big dierence 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.

a. Unscrew the two xing bolts using a

2mm Allen key

picture 1

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b. Take out the circlip using a small

screwdriver

picture 2

c. Take out the travel adjust core using a

circlip pliers

picture 3

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How to solve air leaking problems

Models: All air cartridge forks

a. Release all air

picture 1

b. Unscrew the air top cap using a

27mm/21mm Allen key

picture 2

c. Take out all remaining old oil

picture 3

d. Rell the fork with 6ml of 80W gear oil

picture 4

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e. Grease the O-ring of the air top cap

picture 5

f. Tighten the air top cap with 10Nm us-

ing a 27mm/21mm Allen key

picture 6

g. Inate the fork according to the per-

sonal settings of the customer

picture 7

We recommend inating the fork over night with a test pressure of 150psi (10.3 bar) and to test it again the next day.

SR SUNTOUR workshop book, version 2008/Mar/25, page 96

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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

The fork does not lock even after turning the lock out knob to the locked position

a. Take o the lock-out knob

picture 1

b. Take out the adjust core using a

needle nose pliers

picture 2

c. Test if the cartridge xing bolt is

tightened properly with 10Nm using a 5mm Allen key

picture 3

d. Turn the core clockwise until the stop-

per using a 4mm Alllen key.

The fork should now be completely locked!

picture 4

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e. Make sure the adjust core is installed

properly

picture 5picture 6

f. The lock-out knob’s nose has to be

installed like shown in picture no.7

picture 7

g. To test if the fork unlocks, turn the

lock out knob counter-clockwise

picture 8

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How to solve Mechanical-Lock-Out (MLO) issues

Models: XCM MLO / XCT V2 MLO / NEX MLO SERIES / CR8V MLO / CR 8R MLO

a. Pull out the lock out knob using a

needle nose pliers

picture 1

b. Unscrew the lock out top cap using a

27mm/21mm socket wrench

picture 2

c. Take out the upper stopper using a

needle nose pliers

picture 3

d. Unscrew the two xing bolts using a

10mm socket wrench

picture 4

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e. Separate the upper and the bottom

case

picture 5

f. Slide out the sup spring, lower index

and lower stopper

picture 6

g. Take out the xing bolts using an ex-

tra long 5mm Allen key and a monkey wrench

picture 7

h. Make sure the main xing bolt is

a hexagon screw and not an Allen screw. Otherwise the lock out mechanism can not work

picture 8

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i. The hexagon screw has to t into the

lower spring stopper

picture 9

j. Picture No. 10 shows how upper stop-

per and lower index t together

picture 10

k. Reinstall the main xing bolt using a

extra long 5mm Allen key and a monkey wrench

picture 11

l. Slide the sup spring, lower index and

lower stopper back in

picture 12

SUNTOUR SF7CR-8V-MLO, RS6-XC PRO-RL, SF7CR-8R-MLO, RS7-EPICON-DA, SF7CR-8V Workshop Handbook

Specifications and Main Features

Frequently Asked Questions

User Manual