How to Adjust Epicon : Axon Fork Travel.pdf

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  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 1 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Miscellaneous ramblings of a guy who rides bikesHomeNews LinksPhotosMisc.AboutContact

    Type text to search here... Home > How To > How to Adjust Epicon / Axon Fork Travel

    How to Adjust Epicon / Axon Fork TravelAugust 12th, 2010 [print] Go to comments

    SR Suntour ships its SF9 Epicon RLD and Axon RLD forks with 100mm of travel, however, both can beadjusted to 80mm, 120mm, or 140mm if you need more or less travel. For this How-To, Im using my 2009Epicon RLD, but the Axons travel is adjusted the same way. The only difference between the two is howmuch torque you use when tightening the lower bolts during re-assembly, so pay attention to that part.First, youre going to need a few things:

    5mm and 8mm Allen wrenches (or 8mm & 10mm for the Axon) large adjustable wrench rubber mallet or dead-blow hammer grease fork air pump in-lb torque wrench with 5mm and 8mm bits (or 8mm & 10mm for the Axon) various shop towels hammer pin driver bench vise or something similar** Dont even bother with this if you dont have all the above tools already at hand, unless you want to endup with a (partially) disassembled fork, broken parts, and a bike that cant be ridden until you have it putback together again.

    As I mentioned, my Epicon came with 100mm of travel. It raised the front end of my bike about 1.5" overmy rigid fork, slowing cornering response. I ended up lowering it to 80mm, and Ive been riding it like thatfor the past few months. After my little flight over the handlebars last week, though, I thought Id raise it

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 2 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    again, giving me less of a forward-leaning stance, and perhaps lessening my chances of that happeningagain. Besides, Im close to giving this fork a full review, and I figured itd be better to try it at differenttravel lengths to see how it performs overall.

    Instead of going back to 100mm, I decided to go to 120mm, which is the most amount of fork travel Iveever had (as a long-time XC rider, I spent about a decade at 80mm, or on a rigid fork). My frame camestock with a 100mm fork, so going to 120mm adds some stress, but not so much that the frame cant take it. However, I think 140mm would be pushing it a bit much, and I dont want to take a chance with snappingmy head tube.

    Heres the fork before I took it apart, still set at 80mm of travel.

    First thing first, clean the fork as well as possible. I also took it off my bike to make the process easier, andId suggest the same for you. Cleaning it will keep dirt from finding its way into the fork lowers, whichcould result in scratched stanchions later. Make it shine before you even touch it with a wrench! Pay extraattention to the seals around the stanchions, since a lot of dirt and grime collects in that area. Removing dirtwill also make it easier for you to inspect every part, because it anything is excessively worn, now would bethe time to order some new parts.Next, we need to remove the air, so take off the top cap on the left side of the crown, and use a ball-endAllen wrench (or whatever you have) to depress the valve.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 3 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    With the air chamber empty, the stanchions will slide into the lowers.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 4 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Flip the fork upside-down, and pull out the rebound adjustment knob. You can use a pair of needle-nosedpliers, or just grab it with your fingers and pull. Its pressure-fit, so it should just pop out.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 5 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    If you look into where you just pulled the adjustment knob out of, youll see a recess for an 8mm Allenwrench. Youll need to back this bolt out just a few turns, but not all the way.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 6 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Next, grab your 5mm Allen wrench, and back the bolt on the other leg out about the same amount. Remember, the 5mm bolt has a washer on it, so dont lose it!

    Now, using a rubber mallet or soft dead-blow hammer, tap lightly but firmly, on both of the bolts you justloosened.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 7 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Tapping the bolts forces the internal seals to break loose, so you can now slide the stanchions out of thelowers. Set them on a surface where they wont get scratched.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 8 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Next, grab your large adjustable wrench and loosen the aluminum nut on the bottom of the left stanchion. Im making a point to tell you its aluminum so you dont destroy it with your steel wrench. Its prettytight, so keep yourself stable and make sure the wrench is adjusted as tight around it as possible. Roundingthe edges off would pretty much entirely suck, so use some common sense here.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 9 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    This is what it looks like with the aluminum nut removed:

    Keep in mind, this thing is full of grease (fortunately, not the drippy kind), and itll pretty much get all over

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

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    you, even if youre careful about handling it. Dont wipe any of it off, and you wont need to add any whenyou re-assemble it later.

    Take the damper assembly out of the stanchion and lay it somewhere it wont get damaged.

    Like I said, I have it on the 80mm setting. The next photo shows you your travel options. I know, it seemscounter intuitive that the further you get from the wide end, the shorter the travel is, but I guarantee this isright.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

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    Okay, now the shitty part begins and you thought this was all going to be a walk in the park. Youll haveto improvise in whatever manner you can, but I place the damper assembly in a bench vise, surrounded by arubbery, non-marking jacket that wont damage it. Ive always accomplished this one-handed, but if youhave someone around who will hold it while you hammer away at it, itll be a huge help.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 12 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Using your pin driver and a hammer, gently tap the pin all the way out. Its tiny, so itll probably fall intothe depths of hell under your workbench if youre not careful, so keep an eye on it. Tap straight down, anddont let the damper rotate on you. Having someone hold it steady will really help a lot at this point. Thatdamper rod is aluminum, so if you whack it with your steel hammer, theres a good chance youll dent orcrack it.

    Heres the pin that youre trying to knock out. Its a split design, which compresses when you tap it into thehole in the damper rod. Im sure theres a name for it, but I have no idea what it is. All I know is, its abitch to get out.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

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    With the pin out, you can slide the spring holder to whichever position you like (I chose 120mm).

    Make sure you line the spring holder up perfectly with the hole. Otherwise, when you go to hammer the pin

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 14 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    back in place, you might be off a little, and dent the (soft aluminum) damper rod with the (harder) steel pin. This time, feel free to skip the vise, and just place the assembly on some soft wood, like a workbench top. Using a normal hammer, gently tap the pin until its flush with the edge of the spring holder, and then finishhitting it in deeper using your pin driver.

    When youre all done, slide the spring assembly up to meet the holder, and its ready to go back inside thestanchion.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 15 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    Thread the aluminum nut back in by hand (lightly grease the threads first), then use your adjustable wrenchto tighten it down. SR Suntour doesnt give a torque spec for this, so just snug it down tight, but dont gooverboard.

  • 10/26/12 9:57 PMGearInches.com How to Adjust Epicon / Axon Fork Travel

    Page 16 of 28http://gearinches.com/blog/how-to/how-to-adjust-epicon-axon-fork-travel

    If you havent already, then now is a goo