A Division Of
Mountain Racing Products, Inc
580 N. Westgate Dr.
Grand Junction, CO 81505 USA
1.970.241.3518
Download from Www.Somanuals.com. All Manuals Search And Download.
FORK INSTALLATION
White Brothers forks feature a 1-1/8” threadless steer tube. If you have a threaded type fork on your bicycle, consult
your dealer for the appropriate upgrade parts necessary to convert to a 1-1/8” threadless steerer tube.
1. Remove your old fork from the bicycle. Measure the diameter and length of your old forks steerer tube to ensure
that the White Brothers steerer tube is the correct diameter and sufficient length for the installation.
2. Remove the crown race from your old fork.
3. Press the crown race onto your new White Brothers fork.(see Figure #1)
4. Preassemble the headset by sliding the fork steerer tube through the bearings. Then install the headset upper race,
headset spacer (optional), and stem onto the fork steerer tube. Adjust with optional spacers to your preferred height.
(See Figure #2) Refer to the headset owners manual if there is any questions about the pre-assembly.
5. Mark the steerer tube at the top of the stem. The steerer tube will now need to be cut to the correct length.
Disassemble and cut 3mm (1/8”) below the mark. Consult your dealer or mechanic if you don’t have the proper
tools to cut the steerer tube.
6. The star fangled nut must now be installed into the steerer tube. If you don’t have the set tool, we recommend
dealer installation of this part. (See Figure #3)
7. Clean and grease all headset bearings and races to prepare them for assembly. Note: Replace the bearings if there is
any sign of wear or corrosion.
8. Now loosely assemble the headset, stem and handle bars as done in step four.
9. Install the headset top cap into the star fangled nut. Tighten until there is no play in the steering. The fork should
rotate freely in the head tube. Straighten the stem in relation to the front tire and tighten the pinch bolts on the stem.
If there are any questions consult your dealer or mechanic.
10. Install your front brake and adjust according to the manufacture instructions.
11. Install and tighten the wheel in the front fork. Tighten the 20 mm thru axle nut and the pinch bolts.
12. Check to see that the brakes are adjusted and properly working. Make sure that the brake cable does not interfere
with any part of the bike when the fork is compressed and released.
Warning: When installing the wheel or a new tire, check for minimum clearance. Measure from the highest point on
the tire to the under side of the crown. There must be 1/8” or 3mm more clearance than the fork travel to ensure
adequate clearance in all riding conditions. Any less clearance can result in the tire hitting the crown resulting in
serious injury or death.
Optional Headset Spacer
Steering Stem
Star Fangled Nut
Headset Upper Race
Steerer Tube
Frame with
Headset Cups
Headset Lower Race
Fork Crown
Figure #1
Figure #2
Figure #3
PAGE 3
Download from Www.Somanuals.com. All Manuals Search And Download.
TUNING
To get the most out of your White Brothers fork, it is important that you tune the fork to fit your
weight, riding style and the terrain you ride.
INITIAL BREAK-IN PERIOD:
Your new fork is designed to break-in over a period of 10 hours or more of riding. As all the parts
bed into each other, the stiction (friction) of the fork decreases and the sensitivity increases. After
the initial brake-in period, fine tuning the air pressure and damping adjustments may be
beneficial to achieve the best possible performance.
TOOLS NEEDED:
24MM.socket with ratchet.
4mm Allen wrench
6mm Allen wrench
AIR SPRING / OIL DAMPER
Air Pressure Adjustment
Compression Adjustment
Your new White Brothers fork is designed with a air spring and oil damping. The
following guidelines for adjusting and maintaining your fork will enable you to enjoy
maximum performance and longevity from your fork.
1. First, test ride the fork over easy terrain. If after riding the fork over varied terrain you
decide that more tuning is necessary, continue to the next step.
2. The compression or spring of the fork can be changed two ways: 1) by adjusting the
spring air pressure 2)by adjusting the rebound setting or adding air to the damper.
3. To adjust the air pressure remove the dust cap from the left leg to expose the air valve.
Add or remove pressure using a high pressure air pump to achieve your desired spring
support. 50-100psi. is the user range. The fork is delivered with 80 psi.
4. Compression adjustment is done by adding or removing air at the top of the right leg.
Pressures can range from 50 to 150 lbs. Higher air pressure will provide more
compression damping while lower air pressure will provide less compression damping.
Less compression damping will increase the fork dive but will feel smoother over small
bumps. More compression damping will feel stiffer over small bumps but will be more
resistant to bottoming. DO NOT COMPRESS FORK WITHOUTAIR IN DAMPER!
5. Rebound adjustment is done by turning the knob on the bottom of the right leg. Turn
the knob clockwise for slower rebound. To speed up rebound, turn the knob counter-
clockwise. Start with a middle setting and fine tune the rebound from there. Proper
rebound will allow the tire to track the ground over consecutive bumps. Too slow of
rebound will pack-up (feel stiff over consecutive bumps) while rebound set too fast will
cause the fork to top out harshly. Usable adjustment range is 1.5 to 6 turns out from
bottom.
Rebound Adjustment
Figure #4
PAGE 4
Download from Www.Somanuals.com. All Manuals Search And Download.
MAINTENANCE
Your White Brothers fork requires periodic maintenance to ensure peak performance and long life. Neglecting proper
maintenance will reduce the fork’s life. Internal build up of water and dirt or a lack of lubrication will cause excessive wear
and void the warranty.
BEFORE EVERY RIDE: Visually inspect your fork for bent or broken parts, loss of oil, abnormal sounds or other
indications of possible fork failure. Compress you fork to verify proper function. Check all other bicycle components to
ensure proper working order.
AFTER EVERY RIDE: Clean and dry the exterior of your fork. When cleaning the fork, do not direct the water spray at the
seals. Visually inspect your fork for damage.
*EVERY 30 HOURS OFRIDING: Your fork should be disassembled, inspect, cleaned and re-grease. If the fork appears to
be relatively clean, you can go 40 hours between servicing. If the fork appears excessively dirty you should service it every
20 hours. The three things that will effect the service interval and performance of your fork are water, mud and dust. How
much you use your fork in those conditions will determine how much service it requires.
*EVERY 100 HOURS OFRIDING: Complete service should include removing the lower fork legs cleaning and re-
greasing all shafts, bushings and seals. Check top cap assembly’s, damper cartridge, stanchion plug, brake bolts and shaft
bolts for proper torque. At this time, the fork should be carefully inspected for wear and damage before reassembly. Contact
White Brothers for replacement parts and service. We recommend that this service be performed by a certifiedWhite
Brothers service center or by the factory.
*White Brothers recommends that you consult with a qualified technician before performing:
Basic Fork Disassembly and Inspection
1. Disconnect the front brake and remove the wheel as outlined in you bicycle owners
manual.
2. Remove the rebound knob from the bottom of the right dropout. Loosen the allen
bolts at the bottom of the fork legs(See figure #5). Back out the compression
screws 1\4” and using a dead blow hammer knock the bolts back into the lower
legs. Finish removing the compression screws.
3. Simply slide the fork legs off the end of the inner stanchion tubes.
4. Check the air pressure in the damper. It should be between 50 and 150 psi. Inspect
the damper leg for visible leakage. Push in the damper rod to full compression. The
damper rod should return on it’s own. If the damper has visible leakage and/or the
damping feels inconsistent as it is stroked, return the fork to White Brothers or a
dealer familiar with rebuilding the damper for service. The damper is a sealed unit
and should not be opened unless service is required. Damper service should be
performed by White Brothers.
5. Remove the air pressure from the spring side air cap. Remove the top cap and check
oil on the piston. It should have 10cc’s of fork oil on the top of the piston. Install air
cap and inflate to desired pressure.
6. Clean all parts with a clean, non-abrasive rag. Amild grease cutting cleaner or
solvent might make this an easier task. Once clean, inspect the seals for tears or
cracks. If in good condition, re-grease them with Slick Honey or other suitable non-
lithium grease. If your seals show signs of wear have them replaced.
7.Check the DU bushings carefully for wear. This is done by looking at the color of the
bushings. If the bushings are dark gray, they are in good condition. If they are
bronze/gold in areas, they are worn and can cause fork stanchion damage. If there is
Figure #5
noticeable movement back and forth when the legs are fully engaged on the fork
stanchions, the DU bushings may need to be replaced. Please note that special tools
are required to remove and replace these bushings. This service can be performed by
White Brothers.
8. Next, inspect the fork stanchion tubes for wear, nicks or scrapes. These will cause
premature wear on the seals and DU bushings. Check again for noticeable play
between the stanchion tubes and the fork lower.
9.If everything is free of problems, coat all parts with a liberal coat of Slick Honey or
other non-lithium grease. Be sure to lube the DU bushings located inside the lower
leg.
PAGE 5
Download from Www.Somanuals.com. All Manuals Search And Download.
Basic Fork Reassembly
1. Make sure all the spacers and bottoming bumpers are installed on the control rods (see exploded views for proper
installation). With all parts cleaned and reinstalled with new grease, fit the lower assembly over the stanchion tubes and gently
rock and slide together until the control rods are touching the bottom of the lower assembly. Thread the compression screws
into the control rods starting with the damper side and firmly tighten.. Downward pressure on the fork will help hold the
control rods from rotating until the compression screws become tight. Note: Ensure the compression screws are fully tight
before riding.
2. Check the spring air pressure 50-150 psi. Damper pressure should be between 50 and 150 psi.
3. Make sure the fork caps are fully tightened into the top of the stanchion tubes. Connect the front brake and wheel as outlined
in you bicycle owners manual. Ensure that the 20mm axle nut and pinch clamps are tight before riding.
4. Compress the fork to make sure it works smoothly and the brake cable does not interfere with the operation of the fork.
TROUBLE SHOOTING
Fork Feels Sticky
This is usually caused by:
1. A lack of lubrication. Clean and lubricate the fork as outlined in the maintenance section.
2. Contamination inside the fork. Clean and lubricate the fork as outlined in the maintenance section.
3. Fork is not sufficiently broken in. Contact White Brothers for further technical information.
The Fork Bottoms Too Easily
1. Incorrect spring air pressure. Add air pressure as outlined in #3 of the tuning section.
2. Insufficient compression damping. Add compression damping by adding air (50-150 lb range) to the top of the right leg.
The Fork Doesn’t Use Full Travel
1. Incorrect spring air pressure. Remove air pressure as outlined in #3 of the tuning section.
2. Excessive compression damping. Reduce the compression damping by removing air (50-150 lb range) from the top of the right
leg.
Damping Adjustment is Not Working
1. Damper may need servicing. Contact White Brothers for technical information.
PAGE 6
Download from Www.Somanuals.com. All Manuals Search And Download.
Exploded Views
The following is an illustration and parts table
which gives you the exploded view of your White
Brothers fork. The parts table indicates the part
numbers for each individual part in the fork.
Reference these numbers when ordering
replacement parts. See your local dealer or contact
White Brothers to order the parts you require.
20
3
42
41
ITEM NO.QTY.PART NO.
DESCRIPTION
Lower Assembly
Brace disk only
BW Outer Leg
20mm Dropout Damper Side
20mm Dropout Disk Side
XC Negative Spring
Upper Assembly
Steer Stem Single Crown
Crown
40
39
1
1 100225-20
19
18
1
2
1
1
P1610-2
100225
100532
100533
15
38
35
37
17
16
2
3
8 100016
1 P1139-1
13
34
36
36
1
1
2
P1252
97-3706-1
97-3204
14
15
Inner Leg
Control Rod
4
5
6
1 Control Rod
1 97-3342
1 100576
1 P4600
Topout Bumper
Topout Bumper Guide
Compression Rod Top
Nylon Rod Bushing
O-Ring 313
33
7
8
7
5
6
8
1 P2504
9
2 F-2402
1 100577
1 Stan Plug
1 P3290
1 100572
1 100262
2 P3000
3 P3028
2 100060
2 100054
10
11
12
13
14
15
16
17
18
Topout Spacer
24
Stanchion Plug
Orange Compression Bumper
Air Piston
O-Ring 211
Piston Band
O-Ring 021
Air Cap
Schrader Valve Assm.
Schrader Valve
O-Ring 010
4
32
1
1
100053
100033
16
43
44
44
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
2 P4650
Dust Cap
Star Nut
20mm Axle
20mm Axle Nut
Bolt M6
FR Damper Shaft
Rebound Adj Extension
Rebound Adj Needle
Hex Rebound Adj
1 97-9301
1 100285
1 100531
2 97-852
1 100049
1 100065
1 100050
1 100064
9
31
26
10
25
9
1 ZTA-ORING-006O-Ring 006
28
2 100063S
2 100055
1 P2201-1
1 97-1409
1 P2014
1 P2015
1 P2012
2 P3315-1
1 P2004
1 P2006
1 P2005
1 P4010
1 P2010
1 P3021
2 97-1351
Compression Screw Solid
Washer .3125 x .4375
Seal Head
2
27
Shaft Seal
Check Valve Guide
Check Valve Spring
DH Piston
Pre-Load Spacer
Shim 23 x 12 x .25
Low Speed Shim 22 x 8 x .02
Belleville Washer
Damper Bolt
23
11
12
21
23
Floating Piston
O-Ring 118
Wiper Seal
30
1
97-1351
Wiper Seal
29
44
45
4 97-986
1 100200
DU Bushing
22
30
29
Damper Adjuster
Adjuster Knob
O-Ring 003
1
1
100052
100032
45
PAGE 7
Download from Www.Somanuals.com. All Manuals Search And Download.
Owners Name:___________________________________________________________________________
Address:_________________________________________________________________________________________________
______________________________________________________________________
Phone:_________________________________________________________________________________
Purchase Date:___________________________________________________________________________
Purchase Location:________________________________________________________________________
Serial #: Located on lower back side of right axle clamp.__________________________________________
MAINTENANCE LOG
Date
Service Performed
Date
Service Performed
.
WARRANTY CLAIMS
White Brothers forks are designed to enhance riding pleasure and as such are warranted to be free from defects in materials and
workmanship for a period of one year from the date of purchase. On receipt if it is found to be defective, White Brothers will
determine replacement or repair of the fork. This warranty is the sole and exclusive remedy. White Brothers shall not be liable for
any indirect, special or consequential damages. Warranty does not apply to any product that has been installed improperly or
adjusted using methods not outlined in this manual. Warranty also does not cover forks that have been misused, or forks that have
altered/missing serial numbers (located on the back of the right fork stanchion). The fork is not warrantied against damage in the
appearance of the fork or for modifications not outlined in this manual. This warranty does not cover breakage, bending, or
damage that may result from crashes, falls or abuse. Normal wear (i.e. seals, bushings, sliders finish, etc) and tear and damage
caused by lack of proper maintenance is not included. *The warranty registration card must be filled out and returned within
30 days of purchase to activate and validate this warranty. A copy of the proof of purchase must be included with all
warranties. Customers in the US please contact White Brothers or your dealer for a Return Authorization Number (RA#) before
returning the forks. All forks returned for inspection must be sent freight paid to:
A Division Of
Mountain Racing Products, Inc
580 N. Westgate Dr.
Grand Junction, CO 81505 USA
1.970.241.3518
*Consumers outside the US please contact the dealer or distributor in your area.
PAGE 8
Download from Www.Somanuals.com. All Manuals Search And Download.
|