Untitled Document

Installing your GEM cartridges

The following instructions will help you install the GEM Cartridge kit in your Rock Shox JUDY Fork*. The installation process requires the following tools:

5mm Allen wrench
Snap Ring Pliers
Small mallet
Bike stand (if available)

To simplify this process Risse Racing Technology recommends using a bike stand. If you do not have a bike stand have a friend, or significant other, assist you.

Instructions

Remove front wheel from bike

Disconnect front brake cables

Loosen and remove the two 6mm bolts on the bottom of the lower legs.

Slide the lower legs down and free from the upper tubes
Note: If the lower legs are stuck, reinstall the 6mm bolts do 3 turns and tap lightly on the bolts to help free the lower legs

Remove snap rings from the bottom of the upper tubes.

Pull the compression and rebound cartridges out of the tubes.

Remove the shaft end plates and install on the GEM cartridge, and the dummy leg

Install the GEM cartridge into the upper tube (non drive-train side).
Note: The adjuster screw must be tuned in (clockwise) all of the way

Place the wave spring washer (in place of the plastic washer, which is no longer required) on top of the cartridge

Install the snap ring (sharp edge out away from the cartridge) in the groove

Install the dummy leg into the upper tube (drive train side).

Install the snap ring (sharp edge out away from the cartridge) in the groove

Lubricate the upper tubes, use either Teflon Grease (Pedro's or Finish Line) or Elasto Lube

Install the lower tubes onto the upper tubes.

Reinstall the 6mm bolts (the hollow bolts on the cartridge side)

Tighten the 6mm bolts 5ft/lbs (6.8N/m) use blue Loc-tite 242).

Reattach the brake cable and install the front wheel

Adjustments

The GEM cartridge is rebound adjustable. To adjust the cartridge, use a 2mm allen wrench. Clockwise increases the rebound damping force. Counterclockwise decreases the rebound damping.

The adjuster turns 2-3 revolutions, with positive stops at the each end of the range. The bolt which attaches to the lower leg acts as the positive stop for loosening the adjuster.