04 AXEL SERVICE MANUAL Page 9 REV NC
5. Once the cap is tightened, twist the Hex shaped shaft clockwise until it stops (this is the
locked out position). Insert the springs into opposite holes in the top cap and then place
the ball bearings on top of the springs (place a little dab of grease on spring to hold ball
bearing in place).
6. Place the adjuster knob onto the hex shaped aluminum shaft and seat it onto the top cap
and ball bearing. Position the adjuster cap so that the lever part of the cap is at the
farthest point to the back of the crown.
7. Insert 2mm fixing screw and tighten to secure the knob. Twist the knob counter clockwise
to activate the fork suspension. Compress the fork several times to circulate the oil
through the system and then activate the Lock out system by moving the lever clockwise
to its stopping point at the back of the crown. The fork should have approximately 5 mm
of progressive travel before it locks out.
Note: This system is a combination of adjustable compression damping that becomes a lock
out. It is fully active when the lever is facing all the way forward (counter clockwise) and
locked out when the lever is facing all the way towards the back of the crown (clockwise).
Installation of Spring, Compression Rod Assembly, and Outer Leg Casting - Non
Wind Down Forks
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.
WARNING When installing the outer Leg Casting to the Crown Steer Assy, Compression
Rod bolts and Damper Shafts must be properly tightened prior to use. Failure to do so
could result in injury or possible death.
1. Screw the compression rod assembly into the crown/steer assy. Make sure that the comp
rod that accepts the 4mm screw is installed in the left leg. Tighten per the Axel Schematic
and Torque Specification Table.
2. Remove rubber fork boots from the casting and slide them onto the inner legs of the
crown/steer assy.
3. Lightly grease the bushings on the inside of the outer leg casting and on the lower portion
of the inner legs below the boots using a thick grease such as Motorex Bike Grease
2000.
4. Grease spring heavily with Motorex Bike Grease 2000. Install the spring preload and
spring assy into the crown/steer assy.
5. Tighten preload adjuster using 18mm socket and tighten per the Axel Schematic and
Torque Specification Table.
6. Insert 2mm hex screw into spring preload adjuster knob and install knob on the top left
side of the fork.
7. Press inner leg assembly into outer leg casting until comp rod contacts casting.
8. From the left leg dropout, use a 4mm hex wrench to install the compression rod screw
and tighten per the Axel Schematic and Torque Specification Table.
9. From the right leg dropout, use a 8mm hex wrench to turn the compression damper
counterclockwise until it screws into the casting and tighten per the Axel Schematic and
Torque Specification Table.
10. Slide fork boots down and snap over dust seal flange.
11. Lubricate the inner legs through the Microlube ports using Prep-M grease.
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