Mount the RX1 Suspension Fork

Dismount the fork to mount the RX1 suspension fork.

  1. Secure the bike in a stable position so that the front wheel and fork are unloaded and the bike cannot fall over.
  2. Remove the front wheel using a 15/16 open-end/ring wrench key.
  3. Remove the front brake caliper using a 5 mm Allen key. Do NOT operate the brake when removed, otherwise the brake cylinders and pads will jam together!
  4. Disconnect light cable from lamp (2x Japan round plug / Higo 2-pin round plug) and disassemble lamp with holders (5 mm Allen key).
  5. Disconnect display (Higo 5-pin round connector), brakes (Higo 2 or 3-pin round connector) and, if necessary, thumb throttle (Higo 3-pin round connector / JST 3-pin connector).
  6. Dismantle grips (3 mm Allen key) and fittings (if necessary, thumb throttle (3 mm Allen key), right brake lever (5 mm Allen key), gear shift / switch unit (2.5 mm Allen key), left brake lever (5 mm Allen key), bell (Phillips screwdriver) and display (3 mm Allen key) one after the other.
  7. Remove all eight handlebar bolts, four from the handlebar rails and four from the display strut.
  8. When carefully pushing both handlebars apart to the sides, carefully push the screen holder upwards without scratching the frame (for this step may need help from a second person). Mark the height of the display holder strut beforehand with e.g. tape on the handlebars for later.
  9. Remove the plastic cap from the steering head/steering head bearing and loosen the steering head bolt (8mm Allen key). Hold the head bearing bolt from below with a 32mm open-end wrench.
  10. Remove the steering head bolt from below. To do this, center the fork so that the fork bridge holes are exactly centered so that the bolt does not jam. First push from above and then pull from below. Caution: The fork is now exposed and can fall over if it is not held firmly.
  11. Remove the fork from the main frame, thread the fittings through the fork and look for any parts of the head bearing that fall out, such as a spacer/clamping ring or similar. If necessary, clean them with a cloth before you install them again.
  12. Pull the marked handlebars out of the fork and insert them into the suspension fork. If necessary, apply assembly grease to the lower part of the bars.
  13. Slide the suspension fork onto the head bearing of the main frame and make sure that all components of the head bearing are in place (spacer/clamping ring etc.).
  14. Insert the headstock pin from below, using assembly grease if necessary, and push it through to the top, centering the fork properly until the pin also passes through the upper triple clamp. Then tighten it so that the bolt flange lies smoothly on the lower fork crown. If necessary, loosen the bolt slightly so that the handlebar is free to move.
  15. Carefully insert the display mounting brace between the fork spars, gently pulling the fork spars apart.
  16. Position the handlebars in a comfortable position and retighten the eight screws.
  17. Mount all the fittings on the handlebars one by one and tighten them once they are in their correct position.
  18. Mount the lamp, connect the armature connectors to the wiring harness and close the cable protection cover.
  19. Mount the front wheel and tighten it. Make sure that both lower fork tubes are properly centered by mounting the mudguard bar. You may need fewer spacers on the axle, because the fork legs of the suspension fork are wider than those of the normal fork.
  20. Mount the brake caliper and center it so that the front wheel can rotate freely and without noise.

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