O W N E R S M A N U A L F O R
2004 AIR FORKS
580 N. Westgate Dr.
Grand Junction, CO 81505 USA
1.800.999.8277
www.whitebrotherscycling.com
A division of
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TABLE OF CONTENTS
SAFETY.......................................................PAGE 2
INTRODUCTION........................................PAGE 2
FORK INSTALLATION..............................PAGE 3
TUNING.......................................................PAGE 4
MAINTENANCE........................................PAGE 5
TROUBLE SHOOTING..... ........................PAGE 6
EXPLODED VIEWS.............................PAGE 7,8,9
WARRANTY..............................................PAGE 10
IMPORTANT
CONSUMER SAFETY INFORMATION
WARNING: RIDING A BIKE IS DANGEROUS. NOT PROPERLY MAINTAINING OR INSPECTING YOUR BIKE AND
IT’S COMPONENTS IS EVEN MORE DANGEROUS. IT IS ALSO DANGEROUS TO NOT READ AND FOLLOW
THESE INSTRUCTIONS.
1. NEVER REMOVE STEERER TUBE FROM CROWN. THIS IS A PRESSED IN PART. REMOVING IT WILL
RENDER BOTH THE CROWN AND STEERER TUBE INOPERABLE.* MAKE SURE THE FORK CAPS AND ALL
FORK HARDWARE (pinch bolts, etc.) ARE TIGHT BEFORE EACH RIDE.
2. DO NOT PERFORM ANY MODIFICATIONS OR ADJUSTMENTS THAT ARE NOT OUTLINED IN THIS
MANUAL. SEE THE TUNING SECTION FOR MORE DETAILS.
3. INSPECT YOUR FORK BEFORE EVERY RIDE. INSPECT THE CROWN, TUBES, AND AXLE SEAT AREAS FOR
ANY SIGNS OF FATIGUE, BENDING, CRACKING OR OTHER DAMAGE. IF YOU NOTICE ANY TYPE OF
DAMAGE, DO NOT RIDE IT. RETURN IT TO YOUR DEALER OR TO WHITE BROTHERS FOR A COMPLETE
INSPECTION AND NECESSARY REPAIR.
4. THIS WHITE BROTHERS FORK IS DESIGNED WITH A LOCKOUT THAT TURNS OFF THE FORK’S
SUSPENSION. THE LOCKOUT IS ONLY DESIGNED TO BE USED ON SMOOTH TERRAIN. USING THE
LOCKOUT ON ROUGH TERRAIN, BUMPS OR DROP-OFFS CAN CAUSE SERIOUS DAMAGE TO THE FORK
AND COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH.
5. PERFORM ALL RECOMMENDED MAINTENANCE ACCORDING TO THE MAINTENANCE SECTION OF THIS
MANUAL. FAILURE TO PERFORM MAINTENANCE COULD DRASTICALLY REDUCE THE FORK’S LIFE,
PERFORMANCE AND CAUSE YOUR FORK TO BE A SAFETY HAZARD.
6. WHITE BROTHERS RECOMMENDS THAT YOU WEAR PROPER SAFETY EQUIPMENT EVERY TIME YOU
RIDE, INCLUDING AN APPROVED BICYCLE HELMET. NEVER RIDE AT NIGHT WITHOUT LIGHTS.
7. ALWAYS USE GENUINE WHITE BROTHERS PARTS. USE OF AFTERMARKET REPLACEMENT PARTS AND
UPGRADES VOIDS THE WARRANTY AND COULD CAUSE STRUCTURAL FAILURE.
8.WHITE BROTHERS FORKS ARE DESIGNED FOR OFF ROAD USE ONLY. THEY ARE NOT EQUIPPED WITH
REFLECTORS FOR ROAD USE. IF YOU ARE GOING TO USE YOUR FORK ON THE ROAD, HAVE A DEALER
OR MECHANIC INSTALL REFLECTORS THAT MEET THE CONSUMER PRODUCT SAFETY COMMISSION’S
REQUIREMENTS.
*IF SERVICE BECOMES NECESSARY OR REMOVAL OCCURS, PLEASE CALL WHITE BROTHERS CUSTOMER SERVICE FOR PRODUCT
EVALUATION AND DIAGNOSIS.
INTRODUCTION
Thank you for purchasing your new White Brothers fork. Our forks are designed to help you perform at your absolute peak.
Your new White Brothers fork has oil damping and is air sprung for light weight performance. The air spring and damper is
set stock to satisfy a wide range of rider weights and riding styles. Fine tuning can be easily accomplished by changing air
pressure of the air spring. See the adjustment and maintenance section for rider weight verses air pressures settings. For very
heavy or very light riders the external damper can be adjusted to give a wide range of compression and rebound damping.
Steering accuracy is improved over conventional MTB forks by utilizing superior materials and design. These include
oversized 32mm fork tubes, a torsion box design steering crown with pressed in tubes, a one piece billet brake arch and extra
thick drop-outs. The WB forks bootless design allows a considerable amount more slider/stanchion overlap than competitor
forks which increases the fork steering accuracy. Fork travel has been chosen to offer the best performance possible for each
fork’s intended use. To ensure peak performance, proper installation and periodic maintenance is required. When riding on
public land, please respect the rights of others and stay on established paths and trails. By riding responsibly, you are helping
ensure the future of our sport.
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FORK INSTALLATION
White Brothers forks feature a 1-1/8” threadless steer tube. If you have a threaded type fork on your bicycle, consult
your dealer for the appropriate upgrade parts necessary to convert to a 1-1/8” threadless steer tube.
1. Remove your old fork from the bicycle. Measure the diameter and length of your old forks steerer tube to ensure
that the White Brothers steerer tube is the correct diameter and sufficient length for the installation.
2. Remove the crown race from your old fork.
3. Press the crown race onto your new White Brothers fork.(see Figure #1)
4. Preassemble the headset by sliding the fork steerer tube through the bearings. Then install the headset upper race,
headset spacer (optional), and stem onto the fork steerer tube. Adjust with optional spacers to your preferred height.
(See Figure #2) Refer to the head set owner’s manual if there are any questions about the pre-assembly.
5. Mark the steerer tube at the top of the stem. The steerer tube will now need to be cut to the correct length.
Disassemble and cut 3mm (1/8”) below the mark. Consult your dealer or mechanic if you don’t have the proper
tools to cut the steer tube.
6. The star fangled nut must now be installed into the steer tube. If you don’t have the set tool, we recommend dealer
installation of this part. (See Figure #3)
7. Clean and grease all headset bearings and races to prepare them for assembly. Note: Replace the bearings if there
is any sign of wear or corrosion.
8. Now loosely assemble the headset, stem and handle bars as done in step four.
9. Install the headset top cap into the star fangled nut. Tighten until there is no play in the steering. The fork should
rotate freely in the head tube. Straighten the stem in relation to the front tire and tighten the pinch bolts on the stem.
If there are any questions consult your dealer or mechanic.
10. Install your front brake and adjust according to the manufacture’s instructions.
11. Adjust the quick release on the hub to clear the secondary catches on the drop-outs. Tighten the quick release after
the axle is properly seated in the drop-out. Ensure that there is sufficient thread engagement (5 or more threads with
the quick release in the lock position) due to the thicker White Brothers drop-outs. Install the front wheel per
manufactures specifications.
12. Check to see that the brakes are adjusted and properly working. Make sure that the brake cable does not interfere
with any part of the bike when the fork is compressed and released.
Warning: When installing the wheel or a new tire, check for minimum clearance. Measure from the highest point on
the tire to the under side of the crown. There must be 1/8” or 3mm more clearance than the fork’s travel to ensure
adequate clearance in all riding conditions. Any less clearance can result in the tire hitting the crown resulting in
serious injury or death.
Optional Headset Spacer
Headset Upper Race
Headset Lower Race
Fork Crown
Star Fangled Nut
Steerer Tube
Figure #3
Figure #1
Steering Stem
Frame with
Headset Cups
Figure #2
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