04 AXEL SERVICE MANUAL Page 8 REV NC
Setting fork in longer travel:
1. Follow Disassembly steps above.
2. Using pliers, pull thicker clip from bottom of
rod and install it in slot just above flange.
3. Reassemble assembly and fork as
directed below
Thicker Clip in slot above flange
Assembly of Rebound Damping Assembly
WARNING All leg caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.
1. Install rebound damper into bottom of right leg and tighten per the Axel Schematic and
Torque Specification Table. Slide the black rubber bottomout up the shaft until it contacts
the damper cap. This will assist later during assembly of the outer leg casting to the
damper shaft.
Assembly of Compression Damping Assembly - Non-Adjustable FFD
WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.
1. Put a little bit of Prep M grease (Ref Answer Products PN 85-0031) on o-ring found on
the lower piston of the FFD assembly.
2. Install the FFD Assy into the top right hand of the crown/steer using a 27mm socket.
Tighten per the Axel Schematic and Torque Specification Table.
Assembly of Compression Damping Assembly - Adjustable Compression/Lockout
WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.
1. Fill right leg with damping oil using 5wt Motorex fork oil (Ref Answer Products PN 85-
0023) to the height noted in the Axel Schematic and Torque Specification Table. Cover
the opening at the top of the right leg of the crown/steer with a rag and cycle the fork six
times. Recheck oil level and add/drain to meet the level requirement.
2. Put a little bit of Prep M grease (Ref Answer Products PN 85-0031) on the urethane or
brown rubber o-ring found on the lower piston of the Lock out assembly.
3. Twist the Hex shaped aluminum shaft that sticks up from the top cap counter clockwise
until it stops (the system is completely open to oil flow at this point).
4. Using a motion like screwing in a screw. Twist the assy. and apply a little pressure to
insert the piston part of the mechanism past the threads at the top of the inner leg. Then
push the assy. into the leg until the threads on the cap intersect the threads inside the
inner leg, screw the cap. Tighten per the Axel Schematic and Torque Specification
Table.
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