No le e n
Ch u b b y / Ch u b b y LT
Ow n e r ’s Ma n u a l
1998 CHUBBY / CHUBBY LT OWNER'S MANUAL - PDF
Cong ra tula tions! You’ve just p urc ha se d the Nole e n Chub b y or Chub b y LT Susp e nsion Fork! With it’s uniq ue d ua l trip le c la m p d e sign,
a nd four inc he s of e la stom e r, sp ring , a nd a ir tra ve l, the Chub b y is d e sig ne d to le t you d ive into the g na rlie st te rra in a nd c om e out
unra ttle d a nd unsc a the d.
INTRODUCTION
So rid e the Chub b y a nd le t it Rip !
YOUR NOLEEN
CHUBBY AND
CHUBBY LT
GENERAL
INFORMATION
Note : The Nole e n Chubby a nd Chubby LT c om e in a Sta nda rd size (for bic yc le s with 90m m to 125m m he a d tube s) a nd a Long size (for
b ic yc le s with 126m m to 160m m he a d tub e s). Ma ke sure tha t you ha ve the c orre c t size Chub b y. If you ha ve furthe r q ue stions a b out
the c orre c t size , se e the Insta lla tion se c tion. Also, for a ny othe r sizing q ue stions, p le a se c onta c t your K2 Bike / Nole e n De a le r.
In this section:
NOTE : Re a d this m a nua l c a re fully b e fore a tte m p ting to insta ll or se rvic e you Chub b y Fork. It is im p orta nt tha t you follow p rop e r
proc e dure to e nsure ma ximum pe rforma nc e .
•
•
Read this Manual!
Precautions
CAUTION: K2 Bike strong ly re c om m e nd s tha t your Chub b y Fork b e insta lle d b y a K2 Bike d e a le r or othe r
q ua lifie d te c hnic ia n. The se instruc tions a re for a q ua lifie d insta lle r who p osse sse s p rop e r tra ining a nd tools.
Im prope rly insta lle d forks c a n be e xtre m e ly da nge rous, a nd c a n re sult in fa ilure during use a nd se ve re injury.
!
CAUTION: The Nole e n Chub b y Fork is a c om p e tition off roa d fork, a nd a s suc h d oe s not c om e with re fle c tors
or lig hts for roa d use . Ad a p t p rop e r re fle c tors a nd lig hts if b ic yc le will b e use d in low lig ht c ond itions.
!
!
CAUTION: Insta lla tion of a n inc orre c t le ng th ste e re r tub e c ould re sult in fork fa ilure a nd se ve re injury. Se e
your a uthorize d K2 Bike / Nole e n d e a le r or othe r q ua lifie d te c hnic ia n to e nsure p rop e r insta lla tion.
CAUTION: In the e ve nt of a c ra sh, the re c ould b e d a m a g e to your Chub b y Fork tha t m a y not b e visib le .
Da m a g e d forks c a n b e e xtre m e ly d a ng e rous, a nd c a n re sult in fa ilure d uring use a nd se ve re injurie s. Afte r a
c ra sh, ta ke your fork to a n a uthorize d K2 Bike / Nole e n d e a le r or q ua lifie d te c hnic ia n to ve rify its inte g rity.
!
2
INSTALLATION
Frame Preparation
Prope r fra me pre pa ra tion will ma ke insta lling your ne w Nole e n Chubby fork e a sie r a nd a llow your fork to func tion prope rly.
In this section:
Note s : All Nole e n susp e nsion forks re q uire the use of a thre a d le ss he a d se t, suc h a s a Dia -Com p e Ahe a d se t. If you d o not ha ve
thre a d le ss he a d se t, you will ne e d to insta ll one b e fore you insta ll your ne w Nole e n fork.
a
•
•
Frame Preparation
1.
2.
Re move the old ste m a nd fork from your bic yc le . If you a re insta lling the Nole e n fork on a ne w fra me tha t ha s ne ve r
ha d a fork insta lle d, move on to the ne xt ste p.
Fork Preparation /
Installation
In order for the hea dset on your fra me to function properly, the ends of the hea dtube should be perpendicula r to the
sidesofthe hea dtube. Some hea dtubesneed to be “fa ced”in orderto hold the hea dsetcupsproperly. Ifyou believe
tha t your he a dtube ne e ds to be fa c e d, c onsult your loc a l K2 Bike / Nole e n de a le r or othe r qua lifie d bic yc le de a le r.
3.
Lubrica te the inside ofthe fra me'shea dtube a swella sthe hea dsetcupsa nd pressthe uppera nd lowerhea dsetcups
into your fra me . Ma ke sure tha t the he a dtube a nd he a dse t c ups a re fre e of dirt a nd grime .
NOTE: He a d se t c up s should b e insta lle d using a he a d se t p re ss. Do not sub stitute this tool for a nything e lse . Se e your loc a l Nole e n
d e a le r for a ssista nc e insta lling he a d se t c up s. Da m a g e to the fra m e a nd / or he a d se t c a n oc c ur if not insta lle d p rop e rly.
Fork Preparation / Installation - 6 Easy Steps!
Once you ha ve a properly prepa red fra me, you ca n now insta ll your Noleen fork. While your Noleen Chubby ha s been a ssembled with c a re a t the
fa c tory, p a rtia l disa sse m bly a nd re a sse m bly is re quire d for m ounting. Follow the se ste ps:
Step #1 - Remove the Upper Triple Clamp from the fork.
1.
2.
2.
Loose n the thre e bolts on the uppe r triple c la mp.
Using the ChubbyWrench (preloa d a djusterremova ltool), loosen a nd remove the preloa d a djustersa nd spring sta ck.
Slid e the uppe r triple c la mp off of the top of the fork.
Re move Uppe r
Triple Cla mp
Step #2 - Check the ”Critical Measurement“ for the Chubby / Chubby LT.
CAUTION: The lowe r trip le c la m p on the Chub b y a nd Chub b y LT m ust re m a in a c e rta in d ista nc e a b ove the
front tire . The Chub b y ne e d s this a m ount of room a llow the susp e nsion to c om p re ss fully without the tire
striking the lowe r trip le c la m p . Im p rop e r fork insta lla tion c ould re sult in a loss of c ontrol a nd se ve re injury.
!
As sta te d in the c a ution a b ove , the Chub b y ne e d s this a m ount of room a llow the susp e nsion to c om p re ss fully without the tire
striking the lowe r triple c la mp. This me a sure me nt is d iffe re nt for the two Chub b y forks. This me a sure me nt DOES NOT c ha nge for the d iffe re nt
size s of e a c h fork mod e l. This m e a sure m e nt should be ta ke n from the m iddle of the dropout (or the m iddle of the front hub a xle ) to the
b ottom of the lowe r trip le c la m p . We c a ll this m e a sure m e nt the “Critic a l Me a sure m e nt.” Se e b e low for the Critic a l Me a sure m e nt for
the Chub b y a nd Chub b y LT forks.
Dim A:
Chubby (both Standard and Long sizes) =
Chubby LT (both Standard and Long sizes) =
442mm
467mm
Dim A
Follow the se instruc tions to se t the ”Critic a l Me a sure m e nt“ on your Chub b y or Chub b y LT:
1.
Using a ta p e m e a sure or rule r, m e a sure the d ista nc e from the c e nte r of the fork d rop out to the b ottom of
the lowe r trip le c la m p .
”Critic a l Me a sure me nt“
Dim A
2.
3.
Che c k this me a sure me nt a ga inst the ”Critic a l Me a sure me nt“ a bove .
Loose n the two b olts on the lowe r trip le c la m p a nd slid e the trip le c la m p up or d own so tha t b oth sid e s
a re se t to the ”Critic a l Me a sure m e nt.“ Torq ue a ll of the lowe r trip le c la m p b olts to 85 in-lb s.
3
NOTE: AFte r you se t the ”Critic a l Me a sure m e nt,“ you will b e le ft with a c e rta in a m ount of room b e twe e n the trip le c la m p s for your
bike 's he a dtube a nd the he a dse t. You will ne e d to know the he a dtube le ngth a nd the he a dse t sta c k he ight to find this m e a sure m e nt.
This is VERY IMPORTANT! The m a xim um a m ount of room b e twe e n the trip le c la m p s for our Chub b y a nd Chub b y LT forks a re :
Dim B:
Sta nd a rd Size
156mm
Long Size
191mm
Exa mple :
He a d tub e Le ng th
He a dse t Sta c k He ight
Tota l He ig ht
125mm
+
27m m
Dim B
Chubby / Chubby LT
152m m *
* In the e xa mp le a b ove , this c omb ina tion will fit a Chubby or Chubby LT Sta nda rd size fork.
Step #3 - Install the crown race seat and steerer tube.
1.
Ma ke sure tha t the c rown ra c e for your thre a dle ss he a dse t will fit onto the c rown ra c e se a t on the Chubby ste e re r
tube . The crown ra ce should ha ve a n inside dia me te r of 30.0mm (1 1/8“ Sta nda rd). The crown ra ce should be slightly
sma lle r tha n the c rown ra c e se a t so tha t a pre ss-fit is re quire d to se t the ra c e firmly onto the fork.
He a dtube / He a dse t
Me a sure m e nt - Dim B
2.
Ma ke sure tha t the lowe r trip le c la m p is sitting flush with the lip on the b ottom of the ste e re r tub e . If it is
not, loose n the ste e re r c la mp bolt a nd slide the ste e re r up until the bottom lip on the ste e re r is a ga inst the bottom
side of the lowe r triple c la mp. Re torque the ste e re r c la mp bolt to 85 in-lbs.
3.
4.
Slide the c rown ra c e onto the ste e re r tube a nd insta ll the ra c e using a slide ha mme r or othe r ra c e insta lla tion tool.
Inspe c t the ra c e a nd ma ke sure tha t the bottom of the ra c e sits flush with the c rown ra c e se a t on the lowe r triple
c la mp a nd tha t the ra c e is firmly in pla c e .
Prop e r Ste e re r Tub e
Insta lla tion
Step #4 - Install the fork.
1.
Slide the ste e re r tube into the he a dtube of the bike a nd, while supporting the bottom of the ste e re r tube a nd lowe r
triple c la mp with your ha nd, slide the uppe r c up or ra c e of the he a dse t onto the ste e re r.
2.
Route b oth d e ra ille ur a nd re a r b ra ke c a b le s b e twe e n the two trip le c la m p s a nd in b e twe e n sta nc hion
tube a nd he a d tube .
CAUTION: DO NOT route c a b le s outsid e of fork le g s. Loss of c ontrol a nd se rious injury m a y re sult. Alwa ys
route c a b le s b e twe e n fork le g a nd he a d tub e .
!
Crown Ra c e
Insta lla tion
3.
Slid e the up p e r trip le c la m p onto the ste e re r tub e a nd the sta nc hion tub e s a nd te m p ora rily tig hte n the
ste e re r c inc h b olt. Im p orta nt! Do not c ut the ste e re r tub e a t this p oint.
Insta ll ste e re r a nd fork
Prop e r Ca b le Routing
4
Step #5 - Decide where you want the upper triple clamp mounted.
The p osition of the up p e r trip le c la mp on the Chub b y forks is some wha t fle xib le . You c a n pla c e the uppe r triple c la mp dire c tly on top of the
he a d se t, or you c a n sp a c e it up so tha t it c la m p s up hig he r on the sta nc hions. Re m e m b e r: the p osition of the lowe r trip le c la m p is
FIXED, a nd should not be move d up or down. The ste p s b e low will show you how to mount the up p e r trip le c la mp p rop e rly in a ny loc a tion.
1.
2.
With the uppe r triple c la mp te mpora rily insta lle d, slide the ste m (with ha ndle ba r a tta c he d) onto the ste e re r a nd
p osition it whe re you would like it. Tig hte n the ste m c inc h b olts a nd sit on the b ike to c he c k the ha nd le b a r
he ig ht. Do not rid e the b ike like this. You a re only c he c king ha nd le b a r p osition now. Note : If you wa nt a
lowe r ste m p osition, the sta nc hion tub e s will p rob a b ly e xte nd a b ove the top of the up p e r trip le c la m p .
Ma ke sure this is wha t you wa nt b e fore m a king a ny a lte ra tions to the ste e re r tub e .
If you would pre fe r to ha ve the top of the sta nc hion tube s flush with the top of the uppe r triple c la mp, you will ne e d
to pla ce enough hea dsetspa cerson top ofthe hea dsetin orderto do so. Mea sure the a mountofexposed sta nchion
tube with the uppe r triple c la mp insta lle d dire c tly on top of the he a dse t. This is the a mount of he a dse t spa c e rs you
will ne e d.
Op tion 1
3.
4.
5.
6.
Insta ll the he a dse t spa ce rs a nd uppe r triple cla mp into the de sire d position a nd tighte n ste e re r cla mp bolt to 85 in-lbs.
Inse rt the two spring sta c ks a nd pre loa d a djuste rs into the sta nc hion tube s a nd tighte n with the Chubby Wre nc h.
Tighte n the re ma ining bolts on the uppe r c la mp to 85in-lbs.
Rota te the fork a nd c he c k for a ny binding or grinding in the he a dse t. If the fork rota te s smoothly, c ontinue on to the
ne xt ste p. If the fork binds or the he a dse t fe e ls rough, loose n the uppe r triple c la mp a nd re pe a t ste p 3.
Step #6 - Install the star-fangled nut, stem, handlebar and brakes. That's it!
1.
If you will wa nt to c ut the ste e re r tub e , m a ke sure tha t you ha ve e noug h room for your ste m . DO NOT c ut
the ste e re r tub e too short! Also, m a ke sure the sta r-fa ng le d nut is p rop e rly p la c e d in the ste e re r tub e
b e fore you d o a ny c utting .
Op tion 2
2.
3.
Insta ll the sta r-fa ngle d nut into top of ste e re r tube 10 - 12mm from the uppe r surfa c e with sta r fa ngle d nut insta lla -
tion tool, if it is not insta lle d a lre a d y. Do not a tte mpt to insta ll the sta r-fa ngle d nut without the prope r tool.
Whe n insta lling your ste m, the dista nc e be twe e n the top e dge of the ste m c la mp must e xte nd a bove the top of the
ste e re r tube 1-3mm. If the dista nc e is inc orre c t, re move the ste m a nd a dd or re move spa c e rs on top of the uppe r
triple cla mp to a chieve a 1-3mm dista nce.
10-12mm
CAUTION: Asse m b ly with the top of the ste m e xte nd ing m ore tha n 3m m a b ove the top of the top of the
ste e re r tub e c a n re sult in fork fa ilure d uring use a nd se ve re injury.
!
Prop e r Sta r-Fa ng le d
Nut Insta lla tion
4.
5.
Inse rt the Ahe a dse t c a p a nd sc re w through the top of the ste m a nd into the sta r-fa ngle d nut. Use the thre a dle ss
he a dse t c a p to a djust the he a dse t a s pe r the ma nufa c ture r's instruc tions. Re me mbe r: You will ne e d to loose n a ll of
the uppe r triple c la mp bolts a nd the ste m c la mp bolts to a djust the he a dse t.
1-3mm
Tighte n the two ste m bolts to 90-120 in-lbs or re fe r to the ste m ma nufa c ture r's torque spe c s for the ste m. Insta ll the
ha ndle ba r a nd bra ke / shifte r controls. Position a s de sire d a nd tighte n a ll bolts to ma nufa cture r's torque spe cifica tion.
Prop e r Ste m
Insta lla tion
CAUTION: If the two ste e re r p inc h b olts a re not se c ure ly tig hte ne d , the ste m m a y rota te or p ull off of the
ste e re r tub e , re sulting in loss of c ontrol a nd se ve re injury.
!
!
CAUTION: All Chub b y fork b olts should b e tig hte ne d to the p rop e r torq ue whe n insta lla tion is c om p le te d .
Fa ilure to torq ue a ll b olts p rop e rly c a n re sult in fa ilure d uring use a nd se ve re injury. Re fe r to Ma inte na nc e :
Se rvic e Ta b le for a ll torq ue , lub ric a tion, a nd Loc -tite sp e c ific a tions for a ll Chub b y b olts.
5
SUSPENSION
TUNING
Tuning Variables
All ride rs a re diffe re nt. The re fore , bic yc le suspe nsion ne e ds to be a ble to a djust to the diffe re nt ne e ds a nd de sire s of diffe re nt ride rs. The following
fa c tors should be c onside re d whe n a djusting the suspe nsion of a Nole e n fork:
In this section:
Rider Weight
•
•
Tuning Variables
Lighte r ride rs ne e d to ha ve softe r springs in orde r to ta ke full a dva nta ge of the tra ve l of the fork. He a vie r ride rs ne e d to use stiffe r MCU springs to
ke e p the fork from bottoming out. You ma y ne e d to a d just the stiffne ss of springs in your fork for your bod y we ight. Se e Suspe nsion Va ria ble s:
Spring Ra te for the c orre c t sp rings to use .
Tuning
Adjustments
Type of Riding
A suspe nsion fork use d for high-pe rforma nce off-roa d riding should ha ve stiffe r suspe nsion tha n one inte nde d for re cre a tiona l roa d use . The se ve re
imp a c ts a nd high sp e e d s of se rious off-roa d rid ing d e ma nd stiffe r sp rings, while more c a sua l rid ing is more c omforta b le with softe r sp rings. In
ge ne ra l, the fork should be se t up to ma ximize the use of suspe nsion tra ve l in the c onditions to be e nc ounte re d.
Personal Preference
Ne w suspe nsion ride rs ofte n pre fe r stiffe r suspe nsions tha t fe e l more like a rigid bike s. Howe ve r, suspe nsion forks work be st whe n a ride r a da pts
the ir style to use the suspe nsion fully. A spring tha t fe e ls soft a t first ma y be e xa c tly wha t you wa nt a fte r a we e k of rid ing.
Tuning Adjustments
Onc e you ha ve a n und e rsta nd ing of the va ria b le s a ffe c ting susp e nsion tuning , you c a n now m ove on to a c tua lly a d justing your
susp e nsion to fit your ne e d s. The Tuning Ad justm e nts of your Nole e n Chub b y susp e nsion a re :
Spring Rate
The Spring Ra te of a spring is the a mount of loa d re quire d to c ompre ss tha t spring one inc h. This de finition a pplie s ma inly to c oil springs a nd not
to MCU springs. Sinc e the Chubby a nd Chubby LT use a c ombina tion of MCU springs a nd a c oil spring, the spring c ha rt be low re fe rs to c ombina -
tions of MCU springs a nd not a c tua l spring ra te s. We sugge st diffe re nt spring ra te s for our bike s a nd forks be c a use diffe re nt ride rs pla c e diffe re nt
loa dson bicycles.
Spring se le c tion is a lso a ffe c te d gre a tly by ride r pre fe re nc e . More a ggre ssive ride rs ma y de sire the ir springs to be stiffe r, while a more re c re a tiona lly
orie nte d ride r ma y like a softe r ride with softe r springs. Expe rime nta tion with diffe re nt spring ra te s ma y be ne c e ssa ry to find the c orre c t se t up.
Spring Selection Tables
Consult the ta ble s be low to se le c t the spring se t tha t’s be st for you. Re me mbe r, the se a re re c omme nda tions. You
ma y wish to try stiffe r or softe r springs tha n re c omme nde d due to the te rra in you ride , your riding style , a nd pe rsona l pre fe renc e .
Rid e r We ig ht
Chubby (e a c h le g)
Chubby LT (e a c h le g)
up to 140
130-170
160-200
190-230
ove r 230
3 Blue , 3 Ta n
1 Blue , 5 Ta n
6 Ta n
5 Ta n, 1 Pink
4 Ta n, 2 Pink
4 Blue , 4 Ta n
2 Blue , 6 Ta n
8 Ta n
7 Ta n, 1 Pink
6 Ta n, 2 Pink
Replacing Springs on the Chubby and Chubby LT
The Chub b y c om e s e q uip p e d with six e la stom e rs a nd one c oil sp ring p e r le g , a nd the Chub b y LT ha s e ig ht MCU sp ring s a nd
one c oil sp ring .
NOTE: Afte rm a rke t forks a re sup p lie d with two a d d itiona l p ink Sp ring s for m od ific a tion of your Chub b y. Your Chub b y c a n b e
stiffe ne d b y re p la c ing a sta nd a rd ta n sp ring with a stiff p ink sp ring . To c ha ng e sp ring s, sim p ly follow the instruc tions b e low.
1.
2.
3.
Loose n uppe r triple c la mp sta nc hion bolts.
Unsc re w pre loa d a djuste rs with the Chubby Wre nc h a nd re move spring sta c k.
To c ha nge springs, pull sta c k a pa rt a nd re pla c e MCU springs with ha rde r springs towa rds the top of the sta c k.
Cha ng ing MCU Sp ring s
6
4.
5.
Re insta ll spring sta c k a nd pre loa d a djuste r into sta nc hion tube
Re torque a ll triple c la mp bolts to 85 in-lbs.
CAUTION: All Chub b y fork b olts should b e tig hte ne d to the p rop e r torq ue whe n se rvic ing your fork. Fa ilure
to torq ue a ll b olts p rop e rly c a n re sult in fa ilure d uring use a nd se ve re injury.
!
!
WARNING: Ma ke sure p re loa d a d juste r is insta lle d fully. Fa ilure to d o so c ould le a d to fork b ottom ing out a nd
se rious injury.
Preload
Pre loa d is the a m ount of loa d p la c e d on a sp ring to inc re a se the sp ring ra te in the initia l p a rt of the tra ve l. All of our Chubb y forks
fe a ture a d justa b le p re loa d . Pre loa d is use d to he lp a c hie ve the p rop e r a m ount of susp e nsion sa g for your b ike or fork.
Suspe nsion sa g is the a mount a shoc k c ompre sse s unde r the we ight of the ride r. All susp e nsion syste ms should e xhib it some a mount of
suspe nsion sa g. Nole e n forks should a ll be se t up prope rly with a c e rta in a mount of sa g. The optimum sa g a mount for a ll of our front suspe nsion
syste m s is 20% of the tota l whe e l tra ve l. For e xa m p le :
Our Chub b y LT ha s 125m m / 5 in. of tra ve l. To c a lc ula te the op tim um sa g for this fork, m ultip ly 125m m b y .2. The a nswe r
g ive s you a sug g e ste d sa g , whic h for the Chub b y is 25m m / 1 in.
Ad justing Pre loa d
Op tim um susp e nsion sa g :
Chubby 20mm
Chubby LT 25mm
To me a sure the a mount of sa g:
1.
Be fore you be gin me a suring, It he lps to c ompre ss the fork a fe w time s to ove rc ome a ny initia l fric tion the re ma y be
in the shoc k. This will he lp in obta ining a n a c c ura te me a sure me nt.
2.
Me a sure the d ista nc e b e twe e n a p oint on the lowe r le g of the fork (b ottom e d g e of the fork b oot, for
e xa m p le ) a nd a p oint on the up p e r p a rt of the fork (The b ottom of the lowe r trip le c rown) with no we ig ht
on the b ike .
Me a suring Op tim um
Susp e nsion Sa g
3.
4.
5.
The n m e a sure from the sa m e two p oints with a rid e r on the b ike . (Yo u will ne e d so m e he lp with this). The
d iffe re nc e b e twe e n the two m e a sure m e nts is the a m ount of susp e nsion sa g.
To inc re a se pre loa d on the Chubby, turn pre loa d a djuste r c a ps c loc kwise . To de c re a se the pre loa d on the
Chubby, turn pre loa d a djuste r c a ps c ounte rc loc kwise .
Ifyou ha ve increa sed the preloa d fullya nd a re stillgetting too much sa g, you ma yneed to cha nge the spring sta ckin
the fork. Re me mbe r: The corre ct a mount of pre loa d ca n only be a chie ve d with the prope r sugge ste d spring sta ck.
Damping
Da mping is the a c tion of c ontrolling the ra te a t whic h a shoc k c ompre sse s a nd e xte nds. The ra te a t whic h a spring c ompre sse s a nd e xte nd s
c a n b e c ontrolle d b y a numb e r of wa ys. The Chubby forks use a n a ir da mpe r in e a c h le g to c ontrol the ra te of re bound a nd c ompre ssion.
Air da mpe rs work ve ry we ll if tune d prope rly a nd a re a lso ve ry light. In the Chubby fork, the c ombina tion MCU / c oil spring sta c k works we ll with
the a irda mper.
The first typ e of d a mp ing is re bound da mping . Re bound da mping c ontrols the ra te a t whic h the spring e xte nds ba c k to its optimum sa g
le ngth. If the spring e xte nds too quic kly, the suspe nsion will e xhibit a "bounc y" or "live ly" fe e l. Too muc h re bound da mping will c a use the shoc k
to fe e l "d e a d " or "unre sp onsive ". The othe r typ e of d a mp ing is c ompre ssion da mping. Compre ssion da mping a ssists the spring to c ontrol
the ra te of shoc k c ompre ssion. A fork tha t ha s too muc h c ompre ssion d a mping will fe e l stiff or ina c tive ove r sma ll bumps, a nd a fork with too
little c ompre ssion da mping will fe e l too soft a nd te nd to bottom out quic kly.
The c om p re ssion a nd re b ound d a m p ing in our Chub b y forks a re nona d justa b le . The a ir d a m p e rs p rovid e a m p le re b ound a nd c om -
p re ssion d a m p ing for m a ny d iffe re nt rid e rs.
7
The Nole e n Chubby a nd Chubby LTa re de signe d to be ma inta ine d e a sily. Simple lubric a tion is usua lly a ll tha t is re quire d to ke e p the fork working
smoothly. The following ma inte na nce should be pe rforme d whe ne ve r you fe e l the pe rforma nce of your Chubby is de te riora ting.
MAINTENANCE
In this section:
CAUTION: K2 Bike strong ly re c om m e nd s tha t your Nole e n susp e nsion c om p one nts b e d isa sse m b le d a nd
a djuste d by your a uthorize d Nole e n de a le r. Your a uthorize d Nole e n de a le r posse sse s the prope r tra ining a nd
tools to se rvic e your bic yc le . Imprope rly a sse mble d or a djuste d bic yc le s c a n be e xtre me ly da nge rous, a nd c a n
re sult in fa ilure d uring use a nd se ve re injurie s. The se instruc tions a re p rovid e d for owne rs ha ving suffic ie nt
knowle d g e a nd the p rop e r tools to d o the job .
•
•
•
Tools Needed
Lubrication
!
Seal and O-Ring
Replacement
WARNING: Following a ny m a inte na nc e on your fork, b e sure a ll b olts a re c he c ke d a nd torq ue d to p rop e r
sp e c e c fic a tion. Fa ilure to d o so c ould re sult in fork fa ilure a nd se rious injury.
•
•
•
•
Bearing
Replacement
Maintenance
Schedule
Tools Needed:
•
•
•
4, 5 a nd 6mm He x Wre nc h
K2 Goo (or othe r Te flon-fortifie d gre a se )
8mm He x Wre nc h with long e xte nsion
•
•
•
In-lb Torq ue Wre nc h with 4, 5 a nd 6mm he x bits
Thre a d-loc king c ompound - Loc tite Blue #242
Inte rna l sna p-ring plie rs
Torque and
Lubrication Table
Service Kits
Lubrication
Sliders and Stanchions
Lubric a tion of the slide rs a nd sta nc hion tube s is a simple proc e dure tha t should be done e ve ry month during norma l riding c onditions. This will
a llow the two fork tube s to move smoothly, a nd will re duc e fric tion be twe e n the sta nc hion a nd slide rs.
1.
2.
3.
Cle a n off a ll dirt a nd grime from fork a nd re move front whe e l.
Disc onne c t front bra ke c a ble from bra ke le ve r. This will a llow you to le a ve the bra ke s on while re moving slide rs.
Re move 4 mm he x bolts loc a te d on bottom of fork le gs. You ma y e xpe rie nc e diffic ulty whe n doing this.
Re m oving Slid e rs
Note : If you ha ve troub le re m oving the b ottom slid e r b olts, inc re a se the p re loa d on the sp ring sta c k a nd try a g a in. If this d oe sn't
work, re m ove the sp ring sta c k a nd the x-sha p e d sp a c e r a nd inse rt a n 8 m m wre nc h with a long e xte nsion into the sp ring se a t to
p re ve nt the sp ring se a t from rota ting . Se e Chub b y d ia g ra m on p a g e _____ for p a rt e xp la na tions.
4.
5.
6.
7.
8.
Push rub b e r fork b ootie s up off of slid e rs.
Se pa ra te slide rs from sta nc hion tube s with a downwa rd tug.
Cle a n the outside of the sta nc hion tube s a nd the inside of the slide rs with c le a n ra g.
Apply thin la ye r of gre a se to sta nc hion tube s a nd a lso to the inside of the wipe r se a l on the slide rs.
Push slid e r up onto sta nc hions a nd re insta ll lowe r slid e r b olts. Torq ue to 80 in-lb s.
Re g re a sing Fork Le g s
Elastomer Stack and inner Stanchion Tubes
Re gula r c le a ning a nd regre a sing of the spring sta c k will e nsure smooth spring move me nt a nd c onsiste nt pe rforma nc e .
1.
2.
Loose n uppe r triple c la mp sta nc hion bolts a nd re move pre loa d a djuste rs with spring sta c k.
Cle a n the inside of the sta nc hion tube s with a c le a n ra g. You ma y ne e d a long, thin rod to he lp push the ra g into the
sta nchion tubes.
3.
4.
Wipe a wa y old gre a se from spring sta c k with c le a n ra g a nd a pply a ne w la ye r of gre a se to a ll springs.
Re m oving Sp ring Sta c k
Re inse rt spring sta c k into sta nc hion tube . Re tighte n pre loa d a djuste r a nd torque uppe r triple c la mp bolts to 85 in-lbs.
8
Air Damper
If you a re e xpe rie nc ing inc onsiste nt re bound da mping with your Chubby fork, you should c he c k the a ir da mpe r for prope r func tion.
1.
2.
3.
Re move slid e rs a nd sp ring sta c k. For instruc tions on this, se e Lubric a tion: Slide rs a nd Spring Sta c k.
Re move inte rna l sna p ring loc a te d a t the bottom of the e xpose d sta nc hion tube s with inte rna l sna p ring plie rs.
Now pull downwa rd on a ir the da mpe r with a firm tug to se pa ra te a ir da mpe r from sta nc hion tube s.
Re m oving Air Da m p e r
NOTE: The o-ring s a round the a ir d a m p e r a nd the a lum inium stop p e r m a y b e worn a nd ne e d to b e re p la c e d . Se e Ma inte na nc e : Se a l
a nd O-ring Re p la c e m e nt for full instruc tions.
4.
5.
Re m ove a ll g re a se a nd d irt from a ir d a m p e r unit with c le a n ra g . It is ve ry im p orta nt to c le a n the a ir
d a m p e r a nd surround ing p a rts thoroug hly to a llow the p rop e r flow of a ir throug h the d a m p e r hole s.
Now a pply a thin la ye r of ne w gre a se to O-rings only. Do not put a ny gre a se ove r da mpe r hole s. This c ould c log
the d a m p e r a nd p re ve nt it from op e ra ting p rop e rly.
6.
7.
8.
Cle a n the re st of the fork thoroughly a nd lightly gre a se slide rs a nd sta nc hions.
Re insta ll a ir d a mpe r into bottom of sta nc hion. Insta ll a luminium stoppe r into le g until it stops.
Using inte rna l ring plie rs, re pla c e inte rna l ring onto bottom of a ir da mpe r. Lightly gre a se the e nd of the sta nc hion
tube a round the extended rod spa cer.
Re insta ll Air Da m p e r
9.
Insta ll slid e rs (torque lowe r bolts to 60 in-lbs) a nd spring sta c k a nd torque uppe r triple c la mp bolts to 85 in-lbs.
Seal and O-Ring Replacement
You ma y find it ne c e ssa ry to re pla c e the top wipe r se a ls a nd o-rings in the Chubby a nd Chubby LT a fte r some time . The o-rings will be gin to we a r
a nd lose the ir e ffe c tive ne ss. You ma y notic e inc onsiste nt da mping suc h a s a quic k re bound, a nd re pla c ing the o-rings will he lp fix this. The re a re a
tota l of four o-rings in e a c h le g: two a round the a ir da mpe r, one on the outside of the a luminium stoppe r, a nd one of the inside of the a luminium
stoppe r. The y should a ll be re pla c e d a t the sa me time .
1.
2.
3.
Follow the ste p s in Lubric a tion: Air Da mpe r to d isa sse mb le the fork a nd the a ir d a mp e r.
Re pla c ing Air Da mpe r
O-Ring s
Remove the a luminium stopper from the da mper rod a nd clea n thoroughly.
Re move the o-rings from the da mpe r a nd the oute r a nd innne r a luminium stoppe r o-rings using a sma ll sc re wdrive r
or pa pe r c lip. Be ve ry c a re ful not to sc ra tc h or othe rwise da ma ge the surfa c e tha t holds the o-rings.
4.
5.
6.
7.
Re pla c e the old o-rings with ne w one s, be ing c a re ful to put the ne w o-rings into the ir prope r position. Lightly gre a se
the ne w o-rings.
Re insta ll the a lum inium stop p e r with the fla t sid e d own a nd follow the ste p s in Lub ric a tion: Air Da m p e r for
re insta lla tion of the a ir da mpe r.
To re pla c e the wipe r se a ls on the slide rs, pry off the old wipe rs with a sma ll sc re wdrive r, be ing c a re ful not to da ma ge
the tops of the ma gne sium slide rs.
Insta ll the ne w wipe r se a ls a nd gre a se the insid e e d ge . Se e Lubric a tion: Slide rs for instruc tions on re insta lla tion.
Bearing Replacement
The be a rings in the Chubby a nd Chubby LT a re pre ss-fit me ta l be a rings tha t a re insta lle d in e a c h slide r. Se rvic ing the se be a rings c a n only be done
by your Nole e n / K2 Bike De a le r or othe r qua lifie d me c ha nic with the prope r tra ining a nd the prope r tools.
CAUTION: Do not a tte m p t to se rvic e the b e a ring s tha t a re insta lle d in the slid e rs of your Chub b y or Chub b y
LT fork. Im p rop e rly se rvic e d Nole e n forks c a n b e e xtre m e ly d a ng e rous, a nd c a n re sult in fa ilure d uring use
a nd se ve re injurie s.
9
Maintenance Schedule
The following ta ble is a guide line for se rvic ing your Nole e n fork. More fre que nt riding a nd we tte r, muddie r c onditions will inc re a se the fre que nc y
of re quire d se rvic e . Ple a se ta ke your riding ha bits a nd c onditions into a c c ount whe n se rvic ing your Nole e n suspe nsion fork.
Re quire d Inspe c tion/ Se rvic e
Eve ry Rid e
Monthly
Ye a rly
Che c k torque on a ll bolts
Checkhea dseta djustment
Checkshockfunction
4
4
4
Grea se sea lsa nd bea rings
Check/ grea se bra ke pivotposts
Check / a djust Suspension Sa g
Inspe c t / se rvic e a ll se a l a nd o-rings
4
4
4
4
Torque / Lubrication
Product
Pa rtNa me / Loca tion
Size / De sc ription
Torque (in-lbs)
Lubrica tion
Loctite
Chubby fork
Triple Crown
Bra ke Bridge
Bra ke pivot
M6 x 1 x 18 SHCS
M6 x 1 x 14 FHCS
M8 Bra ke Pivot Post
M5 x .8 x 15 SHCS
85
60
60
60
Yes
Yes
No
Blue
Blue
Red
Slide r bottom
Yes
None
Service Kits
The following Re pla c e me nt / Se rvic e Kit is a va ila ble from your K2 Bike / Nole e n Authorize d De a le r. It is inte nde d to be use d byyour K2 Bike / Nole e n
de a le r or othe r qua lifie d me c ha nic posse ssing the prope r tra ining a nd tools.
Nole e n Chubby Se a l Kit
Conta ins wipe r se a ls a nd o-rings ne e de d for se rvic ing fork
RK007
10
Ite m # Pa rt #
Qty
De sc rip tion
Ite m #
Pa rt #
Qty
De sc rip tion
Nut
M5 x .8 x 15 SHCS (slid e r b ottom)
Foa m Spring Conne c tors (10 in Chubby)
Bea ring (upper)
Bea ring (lower)
Spring Se a t Support
Aluminum Stoppe r
AirVa lve Da mper
Foa m Spring, Ta n (Me d) 40mm (12 in Chubby)
Foa m Spring, Blue (Soft) 40mm
Foa m Spring, Pink (Ha rd) 40mm
Coil Spring
Sea l(wiper)
Top Spring Re ta ine r
1
2
3
15150-x
15151-x
15244-x
1
1
2
2
2
2
2
2
2
2
4
2
2
2
2
2
Slid e r Assy, Right
Slid e r Assy, Le ft
15
16
17
18
19
20
21
22
23
M5FKQ-2Y40-000
M5FKU-2Y10-000
M5FR5-2141-000
M5FK5-2142-000
M5FR5-2143-000
M5FR5-2144-000
M5FR5-2163-000
M5FR5-2168-000
M5FR5-2312-000
M5FR5-2315-000
M5FR5-2317-000
M5FR5-2350-000
M5FR5-2610-000
M5FR7-2166-000
M5FRY-2167-000
M5FR5-2143-000
2
2
14
2
2
2
2
2
16
-
Sta nchion Tube, Chubby
Sta nchion, Tube Chubby LT
End Spa cer,Chubby
End Spa cer, ChubbyLT
Middle Spa cer
Rod Spacer
Re ta ining Ring
O-Ring (Aluminium Stoppe r - inne r)
O-Ring (Air Da mper)
O-Ring (Aluminium Stoppe r - oute r)
Preloa d Adjuster
15735-x
4
15245
15734
5
15246-x
6
15249
7
8
9
10
11
12
13
14
3952B-25000
8064A-01100
8064A-02000
8064A-02500
H5FRT-2161-000
M5FK5-2310-000
M5FKD-2310-000
M5FKP-2360-000
-
24
25
26
27
28
2
2
2
2
2
Bumper
RubberCylinder
Rebound Spring
Bottom Spring Re ta ine r
Rebound Bumper
11
Ite m # Pa rt #
Qty
De sc rip tion
1
2
3
4
5
6
7
8
15083-1
15083-2
15181
15247-x
1
1
1
1
2
2
2
4
2
1
2
6
Forged Triple Cla mp (upper)
Forge d Triple Cla mp (lowe r)
Sta r Fa ngle d Nut
SteererTube
Sta nchion Bumper
Wire Tie
Bra ke Pivot Post Wa she r
M6 x 1 x 14 FHCS (Bra ke Brid g e )
M8 Bra ke Pivot Post
Bra ke Bridge
4 inc h boot
M6 x 1 x 18 SHCS (trip le c la mp s)
15344
M5FKF-2340-000
M5FKH-2Y20-000
M5FKP-2Y10-000
M5FKZ-2720-000
15650-x
9
10
11
12
M5FRA-2310-000
MTFK1-2Y14-100
12
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