HEADSHOKEXPERT
gallery of interesting problems
Damaged ridge of DLR compression valve
CAUSED BY: Insufficient tightness of assembly nut
SYMPTOMS: Lockout doesn’t work, lever rotates around
REMEDY: Clean debris from valve, retighten the assembly nut with a drop of Loctite
HOW TO PREVENT: Don’t let anyone but the expert near your fork
Broken o-ring seal on DLR lock lever
CAUSED BY: Inproper installation or maintenance. Water drained from the top down to the needle bearings.
SYMPTOMS: Harsh fork action
REMEDY: Corroded bearings and races should be replaced if beyond reparability.
HOW TO PREVENT: Regular maintenance intervals dicover the potential risk
Snapped air piston
CAUSED BY: Overtightening the air cilinder piston, threaded neck broken at piston connection point
SYMPTOMS: Impossible to keep any air in fork
REMEDY: Replace the plastic piston
HOW TO PREVENT: Don’t let anyone but the expert near your fork
Disintegrated elastomer
CAUSED BY: Age and/or improper maintenance (wrong grease!)
SYMPTOMS: No compression action at all
REMEDY: Replace the elastomer with coil spring or some combination
HOW TO PREVENT: Regular maintenance intervals
Worn out air inlet thread (Schrader)
CAUSED BY: Worn chuck on your air pump; too frequent air adding
SYMPTOMS: Can’t connect pump securely
REMEDY: Replace the lower fork cap that carries the air inlet or buy another honed air cylinder
HOW TO PREVENT: Put some fine oil on pump chuck and keep it clean and lubricated. Be gentle when mounting/dismounting the pump to your fork
Snapped shaft of lower damper rod (LockOut control shaft)
CAUSED BY: Excessive force during fork assembling
SYMPTOMS: Can’t control Lock Our function; Lower rod gets disconnected from lock out valve
REMEDY: Fix at HeadShokExpert
HOW TO PREVENT: Be gentle and sensible when working on the fork
Bent lock out shim and retainer plate
CAUSED BY: Too loose lock out shaft at the top nut (axial plane)
SYMPTOMS: Lock out lever is skipping; Can’t lock properly.
REMEDY: Fix at HeadShokExpert
HOW TO PREVENT: Don’t let anyone but the expert near your fork
Scratched damper rod
CAUSED BY: Attempt to manipulate the damper assembly without original tools
SYMPTOMS: Lockout step due to oil leakage
REMEDY: Fill and polish the damage, replace rod seals, or replace the whole damper unit (200€!)
HOW TO PREVENT: Don’t let anyone but the expert near your fork
Corroded linear bearings needles
CAUSED BY: Whashing the bike with pressurized water (hose from a tap) over the fork top
SYMPTOMS: Harsh fork action
REMEDY: Replace needle bearing set and set of races
HOW TO PREVENT: Take care of the way you maintain your fork (bike)
Corroded needle bearing races on Lefty
CAUSED BY: Broken rubber boot let water inside
SYMPTOMS: Harsh fork action
REMEDY: Remove the rust mechanically, then polish the surface and turn inside out
HOW TO PREVENT: Regular maintenance intervals should discover the potential risk
Broken top-out spring
CAUSED BY: too high air pressure (according to spring stiffness type) or general material fatigue
SYMPTOMS: harsh top-out; air leakage due to scratched air cylinder
REMEDY: Replace the spring; polish out the damage if possible; upgrade to honed air cylinder
HOW TO PREVENT: Regular maintenance intervals. Keep air pressure within the limits of your spring type
Cracked inner wall of the rubber boot
CAUSED BY: Age and/or improper maintenance
SYMPTOMS: No symptoms
REMEDY: Replace the rubber boot a.s.a.p.
HOW TO PREVENT: This happens… but regular maintenance intervals can detect such deformations on time
Crashed needle bearing cage
CAUSED BY: Irregular bearing reset
SYMPTOMS: Harsh fork action
REMEDY: Replace the bearing cage
HOW TO PREVENT: Regular maintenance intervals
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