FORK COIL SPRING CONVERSION INSTALLATION

FSCS SERIES - WP 2016 AER48

Thank you for purchasing a Spring Conversion Kit. This kit converts the stock air spring forks to a coil spring. You will notice improvement in ride quality as well as eliminating both the possibility of a blowout and the constant maintainence of the air pressure.

These instructions cover 2016- WP Air Forks. 

These are SFF (Single Function Forks) which means the damping is in one leg while the other leg has the air spring force. Only the air spring leg needs to be worked on to install this kit.

Springs - Sold separately. In general 48mm forks require FRSP 4466 Series Springs.

To get the ultimate performance we, of course, recommend Compression and Rebound Gold Valves and Ultra Slick Oil.

If you have Gold Valves:

DVS Setup Sheet - If you haven't already, go to DVS Valving Search, insert your Access Code, and rider data and print your DVS Setup Sheet.

Installing this kit does not require splitting the Fork Tubes. If you need to replace Seals or Bushings click here for general Fork rebuild procedures. 

Supplies 
 
USF-05 Fork Oil - extremely slippery
Contact Cleaner - or other good, clean solvent
Fork Springs (check the Product Search for rate recommendations)

 Tools Required
 
- TFCW 4650 - Fork Cap Wrench for the new cap (sorry)
TFCW 50H - Fork Cap Wrench for the stock cap
TMVJ 065 Vise Jaws mounted on a Vise - suggested
- TFGC 500 - Graduated Cylider
 

 

1- Hold the Outer Fork Tube in the "V" of the TMVJ 065 Vise Jaws at the point where the Lower Triple Clamp contacts the Tube.

2- Depressurize all air chambers.
 
Use a TFCW 50H Fork Cap Wrench to remove the Cap.
 
Pour out the old oil and dispose of it properly.

 

3- Use a 19mm socket to remove the Bottom Bolt. Do not use an impact!

 

4- Slide out the stock Cartridge from the top.
 
Clean everything or, at minimum, drain the oil.
 
Note - When switching to Ultra Slick Oil the more old oil you remove, the less contaminated the new oil will be and the slipperier it will be.

 

5- ASSEMBLY
 
Use the stock Jam Nut and Adapter.
 
Notice the plastic spacer on the Damping Rod. This spacer creates the correct bottom-out point and limits the travel to match stock. Make sure it is on the rod before the Nut and Adapter are installed.
 
Put the Nut on the rod far enough so the Adapter can be installed all the way and the Rod bottoms out in it. Tighten the Jam Nut.

 

6- Insert a Spring Preload Washer into the bottom of the Fork Tube.
 
Do not put the Spring directly on the Fork Bottom or it will chip off pieces of aluminum into the oil and damage the forks.
 
(What happened to that index finger? Let me just say that playing with explosives is not always fun.)

 

7- Visually inspect to see that the Washer is lying flat. Use a flashlight if you can't see it clearly. If it is not located properly reach in from the bottom and move it into place.
 
Take a closer look Paul.

 

8- Insert the Fork Spring.

 

9- Install the Spring Conversion Cartridge. The hex on the Adapter must align with the internal hex in the bottom of the fork leg.

 

10- Install the Bottom Bolt and tighten it by hand.

 

11- SETTING FORK SPRING PRELOAD
 
THE PRELOAD DESIGN HAS BEEN CHANGED TO A SPACER AND THREADED JAM NUTS BUT THE IDEA OF PRELOAD IS THE SAME. WE WILL UPDATE THESE INSTRUCTIONS SOON.
 
With the:
 
Outer Fork Tube fully collapsed,
Spring all the way in, and the
Cartridge extended
 
measure the reference distance from the top of the Outer Fork Tube to the end of the Spring Retainer.
 
This is L1. As you can see this one is about 56mm.

 

12- While holding the Cartridge extended, push down on the collar and put the Clip into the next lower groove.
 
Make sure the wire Clip is FULLY IN THE GROOVE and it is SEATED in the Spring Retainer. THIS IS CRITICAL!

 

13- Measure the reference distance again. This is L2. In this case it is 53mm.
 
The difference between L1 and L2 is the Preload.
 
         56  L1
        -53  L2
           3 mm Preload
 
Reposition the Clip or add Spring Preload Washers on the bottom to achieve 3 to 5mm of Preload.

 

14- Use the Graduated Cylinder and install the proper amount of Fork Fluid. No bleeding necessary.
 
USF-05 is preferred as it is impressively slippery (if I do say so myself).
 
Use USF-05:
525cc for motocross
575cc for SX
500cc for off road
in this leg only.
 
See DVS or Product Search for Damping Rod leg level.

 

15- Tighten the Fork Cap.
 
 
Improper fork installation is, perhaps, the most common error that is made. This has a huge effect on harshness!
 
Have fun!
 
Very important - Once again, make sure the clip under the Spring Retainer is fully seated in the groove.