K2 Bike Chubby - Manual (Page 10)

Air Damper
If you are experiencing inconsistent rebound damping with your Chubby fork, you should check the air damper for proper function.
1. Remove sliders and spring stack. For instructions on this, see Lubrication: Sliders and Spring Stack.
2. Remove internal snap ring located at the bottom of the exposed stanchion tubes with internal snap ring pliers.
3. Now pull downward on air the damper with a firm tug to separate air damper from stanchion tubes.
NOTE: The o-rings around the air damper and the aluminium stopper may be worn and need to be replaced. See Maintenance: Seal
and O-ring Replacement for full instructions.
4. Remove all grease and dirt from air damper unit with clean rag. It is very important to clean the air
damper and surrounding parts thoroughly to allow the proper flow of air through the damper holes.
5. Now apply a thin layer of new grease to O-rings only. Do not put any grease over damper holes. This could clog
the damper and prevent it from operating properly.
6. Clean the rest of the fork thoroughly and lightly grease sliders and stanchions.
7. Reinstall air damper into bottom of stanchion. Install aluminium stopper into leg until it stops.
8. Using internal ring pliers, replace internal ring onto bottom of air damper. Lightly grease the end of the stanchion
tube around the extended rod spacer.
9. Install sliders (torque lower bolts to 60 in-lbs) and spring stack and torque upper triple clamp bolts to 85 in-lbs.
Seal and O-Ring Replacement
You may find it necessary to replace the top wiper seals and o-rings in the Chubby and Chubby LT after some time. The o-rings will begin to wear
and lose their effectiveness. You may notice inconsistent damping such as a quick rebound, and replacing the o-rings will help fix this. There are a
total of four o-rings in each leg: two around the air damper, one on the outside of the aluminium stopper, and one of the inside of the aluminium
stopper. They should all be replaced at the same time.
1. Follow the steps in Lubrication: Air Damper to disassemble the fork and the air damper.
2. Remove the aluminium stopper from the damper rod and clean thoroughly.
3. Remove the o-rings from the damper and the outer and innner aluminium stopper o-rings using a small screwdriver
or paper clip. Be very careful not to scratch or otherwise damage the surface that holds the o-rings.
4. Replace the old o-rings with new ones, being careful to put the new o-rings into their proper position. Lightly grease
the new o-rings.
5. Reinstall the aluminium stopper with the flat side down and follow the steps in Lubrication: Air Damper for
reinstallation of the air damper.
6. To replace the wiper seals on the sliders, pry off the old wipers with a small screwdriver, being careful not to damage
the tops of the magnesium sliders.
7. Install the new wiper seals and grease the inside edge. See Lubrication: Sliders for instructions on reinstallation.
Bearing Replacement
The bearings in the Chubby and Chubby LT are press-fit metal bearings that are installed in each slider. Servicing these bearings can only be done
by your Noleen / K2 Bike Dealer or other qualified mechanic with the proper training and the proper tools.
CAUTION: Do not attempt to service the bearings that are installed in the sliders of your Chubby or Chubby
LT fork. Improperly serviced Noleen forks can be extremely dangerous, and can result in failure during use
and severe injuries.
Reinstall Air Damper
Replacing Air Damper
O-Rings
Removing Air Damper
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