K2 Bike Chubby - Manual (Page 9)

The Noleen Chubby and Chubby LT are designed to be maintained easily. Simple lubrication is usually all that is required to keep the fork working
smoothly. The following maintenance should be performed whenever you feel the performance of your Chubby is deteriorating.
CAUTION: K2 Bike strongly recommends that your Noleen suspension components be disassembled and
adjusted by your authorized Noleen dealer. Your authorized Noleen dealer possesses the proper training and
tools to service your bicycle. Improperly assembled or adjusted bicycles can be extremely dangerous, and can
result in failure during use and severe injuries. These instructions are provided for owners having sufficient
knowledge and the proper tools to do the job.
WARNING: Following any maintenance on your fork, be sure all bolts are checked and torqued to proper
spececfication. Failure to do so could result in fork failure and serious injury.
Tools Needed:
• 4, 5 and 6mm Hex Wrench • In-lb Torque Wrench with 4, 5 and 6mm hex bits
• K2 Goo (or other Teflon-fortified grease) • Thread-locking compound - Loctite Blue #242
• 8mm Hex Wrench with long extension • Internal snap-ring pliers
Lubrication
Sliders and Stanchions
Lubrication of the sliders and stanchion tubes is a simple procedure that should be done every month during normal riding conditions. This will
allow the two fork tubes to move smoothly, and will reduce friction between the stanchion and sliders.
1. Clean off all dirt and grime from fork and remove front wheel.
2. Disconnect front brake cable from brake lever. This will allow you to leave the brakes on while removing sliders.
3. Remove 4 mm hex bolts located on bottom of fork legs. You may experience difficulty when doing this.
Note: If you have trouble removing the bottom slider bolts, increase the preload on the spring stack and try again. If this doesn't
work, remove the spring stack and the x-shaped spacer and insert an 8 mm wrench with a long extension into the spring seat to
prevent the spring seat from rotating. See Chubby diagram on page_____ for part explanations.
4. Push rubber fork booties up off of sliders.
5. Separate sliders from stanchion tubes with a downward tug.
6. Clean the outside of the stanchion tubes and the inside of the sliders with clean rag.
7. Apply thin layer of grease to stanchion tubes and also to the inside of the wiper seal on the sliders.
8. Push slider up onto stanchions and reinstall lower slider bolts. Torque to 80 in-lbs.
Elastomer Stack and inner Stanchion Tubes
Regular cleaning and regreasing of the spring stack will ensure smooth spring movement and consistent performance.
1. Loosen upper triple clamp stanchion bolts and remove preload adjusters with spring stack.
2. Clean the inside of the stanchion tubes with a clean rag. You may need a long, thin rod to help push the rag into the
stanchion tubes.
3. Wipe away old grease from spring stack with clean rag and apply a new layer of grease to all springs.
4. Reinsert spring stack into stanchion tube. Retighten preload adjuster and torque upper triple clamp bolts to 85 in-lbs.
MAINTENANCE
In this section:
• Tools Needed
• Lubrication
• Seal and O-Ring
Replacement
• Bearing
Replacement
• Maintenance
Schedule
• Torque and
Lubrication Table
• Service Kits
!
Removing Sliders
Regreasing Fork Legs
Removing Spring Stack
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