Groove HD User Manual

Groove HD User Manual
USER MANUAL
Congratulations on your purchase of another cutting-edge suspension
product fromWhite Brothers! Please read this manual completely before
you ride. It will help you to set your fork for optimum performance.
IMPORTANT CONSUMER SAFETY INFORMATION
WARNING: RIDING A BIKE IS DANGEROUS. NOT PROPERLY MAINTAINING OR INSPECTING YOUR BIKE AND ITS COMPONENTS IS EVEN MORE
DANGEROUS. IT IS ALSO DANGEROUS TO NOT READ AND FOLLOW THESE
INSTRUCTIONS.
1. Never remove steerer tube from lower crown, this is a pressed in part. Removing it will render both the crown and steerer tube inoperable. Make sure
the fork caps and all fork hardware (pinch bolts, etc.) are tight before each ride.
2. Do not perform any modifications or adjustments that are not outlined in
this manual. See the tuning section for more details.
3. Inspect your fork before every ride. Inspect the crown, tubes, and axle seat
areas for any signs of fatigue, bending, cracking or other damage.If you notice
any type of damage, do not ride it. Return it to your dealer or to White Brothers for a complete inspection and necessary repair.
4. Perform all recommended maintenance according to the maintenance section of this manual. Failure to perform maintenance could drastically reduce
the fork’s life, performance and cause your fork to be a safety hazard.
5. White Brothers recommends that you wear proper safety equipment every
time you ride, including an approved bicycle helmet. Never ride at night without lights or relflectors.
6. Always use genuine White Brothers parts. Use of aftermarket replacement
parts and upgrades voids the warranty and could cause structural failure.
7.White Brothers forks are designed for off road use only. They are not
equipped with reflectors for road use. If you are going to use your fork on the
road, have a dealer or mechanic install reflectors that meet the consumer product safety commission’s requirements.
*If service becomes necessary or removal occurs, please call White Brothers customer service for product evaluation and diagnosis.
Your new White Brothers fork has oil damping and is air and coil sprung for light
weight performance. The springs and damper are set stock to satisfy a wide range of
rider weights and riding styles. Fine tuning can be easily accomplished by changing
air pressure and external damper settings. See the tuning section for details. Steering
accuracy is improved over conventional MTB forks by utilizing superior materials
and design. Every effort has been made to make White Brothers forks very light and
perform at a level superior to other forks on the market. To ensure peak performance,
proper installation and periodic maintenance is required. When riding on public land,
please respect the rights of others and stay on established paths and trails. By riding
responsibly, you are helping ensure the future of our sport.
FORK INSTALLATION
White Brothers forks feature a 1-1/8” threadless steerer tube. If you have
a threaded type fork on your bicycle, consult your dealer for the appropriate upgrade parts necessary to convert to a 1-1/8” threadless steerer tube.
Check with your frame manufacturer to ensure your bike is designed for a
triple clamp fork. If not, you may void your warranty.
WARNING: REFER TO THE HEADSET OWNERS MANUAL IF THERE ARE ANY
QUESTIONS ABOUT THE HEADSET INSTALLATION.
1. Remove your old fork from the bicycle. Measure the diameter and length of
your old fork’s steerer tube to ensure that the White Brothers steerer tube is the
correct diameter and sufficient length for the installation.
2. Remove the crown race from your old fork.
3. Press the crown race onto your new White Brothers fork.(see Figure #1)
4. Preassemble the headset by sliding the fork steerer tube through the bearings. Then install the headset’s upper race, upper triple clamp, headset spacer
(optional), and stem onto the fork steerer tube. Adjust with optional spacers to
your preferred height. (see Figure #2)
5. Mark the steerer tube at the top of the stem. The steerer tube will now need
to be cut to the correct length. Disassemble and cut 3mm (1/8”) below the
mark. Consult your dealer or mechanic if you don’t have the proper tools to cut
the steerer tube.
6. The star nut must now be installed into the steerer tube. If you don’t
have the set tool we recommend dealer installation of this part. (see Figure #3)
7. Clean and grease all headset bearings and races to prepare them for assembly.
Note: Replace the bearings if there is any sign of wear or corrosion.
8. Now loosely assemble the headset, stem and handle bars as done in step four.
(see Figure #2)
9. Install the headset top cap into the star nut. Tighten until there is no play
in the steering. The fork should rotate freely in the head tube. Straighten the
stem in relation to the front tire and tighten the pinch bolts on the stem. Tight-
en the pinch bolts on the upper clamp and double check that the lower clamp
bolts are tight. These can easily be over tightened. We recommend tightening to
8 foot pounds. If there are any questions consult your dealer or mechanic.
10. Slide the wheel in and line up the brake rotor with the brake caliper then
line up the hub with the axle feet. Slide the 20mm axle from either direction
and tighten the axle nut. Tighten the pinch clamps after the axle is properly
seated and tight.
11. Adjust your front brake according to the manufacture’s instructions.
12. Check to see that the brakes are adjusted and properly working. Make sure
the brake line doesn’t interfere with any part of the bike when the fork is compressed and released.
STEM
OPTIONAL HEADSET SPACER
STAR NUT
UPPER CLAMP
STEERER TUBE
HEADTUBE (FRAME)
HEADSET RACE
OUTER FORK TUBE
LOWER CLAMP
FIGURE 1
FIGURE 2
FIGURE 3
WARNING:
WHEN INSTALLING THE WHEEL OR A NEW TIRE, CHECK FOR MINIMUM
CLEARANCE. MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE
UNDER SIDE OF THE CROWN. THERE MUST BE 1/8” OR 3MM MORE CLEARANCE THAN THE FORK’S TRAVEL TO ENSURE ADEQUATE CLEARANCE IN
ALL RIDING CONDITIONS. ANY LESS CLEARANCE CAN CAUSE THE TIRE TO
HIT THE CROWN RESULTING IN SERIOUS INJURY OR DEATH.
THE GROOVE WILL NOT WORK ON FRAMES WITH HEAD TUBES
LONGER THAN 5-1/2”.
INITIAL BREAK-IN PERIOD
Your new fork is designed to break-in over a period of 10 hours or more of riding. As
all the parts bed into each other, the stiction (friction) of the fork will diminish and the fork will absorb the bumps better. After this initial break-in, fine
tuning the hydraulic damper may be beneficial to achieve the best possible fork
performance for your weight and riding style.
TUNING YOUR DAMPER
1. Rebound damping is adjusted by turning the slotted brass adjuster on the top
cap of the right leg. The adjuster has 8 turns of adjustment. Turn the adjuster
clockwise for slower rebound. To speed up rebound, turn the adjuster counterclockwise. Start with a middle setting and fine tune the rebound from there.
Proper rebound will allow the tire to track the ground over consecutive bumps.
Rebound that is set too slow will pack-up (feel harsh over consecutive bumps)
while rebound set too fast will cause the fork to top out harshly. If the fork is
topping out and you have the correct spring for your weight, turn the adjuster
one turn at a time until the top-out stops.
2. Compression damping can be changed two ways: (1) by adjusting the compression damping screw on the back of the canister on the bottom of the right
fork leg. Threading it in slows compression and threading it out speeds up
compression; and (2) by adding or removing air pressure (or nitrogen)from the
canister at the bottom of the right leg. Pop off the dust cap and adjust between
50 psi min. and 175 psi. max. Adding air will increase the compression damping (slow it down) and removing air will decrease compression damping (faster
compression). Less compression damping will increase the fork dive but will
feel smoother over small bumps. More compression damping will feel stiff over
small bumps but will be more resistant to bottoming. Never run less than 50
psi in the canister.
WARNING:
EXCEEDING THE MAXIMUM RECOMMENDED DAMPER PRESSURE CAN RESULT IN CATASTROPHIC RUPTURE OF THE RESERVOIR CANISTER, CAUSING SERIOUS INJURY OR DEATH.
Your White Brothers fork requires periodic maintenance to ensure peak performance and long life. Neglecting proper maintenance will reduce the fork’s life.
Internal build up of water and dirt or a lack of lubrication will cause excessive
wear and void the warranty.
Before every ride: Visually inspect your fork for bent or broken parts, loss of oil,
abnormal sounds or other indications of possible fork failure. Compress you
fork to verify proper function. Check all other bicycle components to ensure
proper working order.
After every ride: Clean and dry the exterior of your fork. When cleaning the
fork, do not direct the water spray at the seals. Visually inspect your fork for
damage.
Every 50 hours of riding: Complete service should include removing the upper
fork legs cleaning and re-greasing all shafts, bushings and seals. Check damper
leg for proper function(see disassembly of the damper leg).
Note: disassembly of the hydraulic damper should be left for the White Brothers
factory.
WARNING: IMPROPER SERVICING OF THE DAMPER LEG CAN RESULT IN
HYDRAULIC LOCK AND CATASTROPHIC FAILURE OF PRESSURIZED PARTS,
CAUSING SERIOUS INJURY OR DEATH. SERVICING OF THE DAMPER MUST
BE REFERRED TO THE WHITE BROTHERS FACTORY OR A FACTORY AUTHORIZED SERVICE CENTER.
*WHITE BROTHERS RECOMMENDS THAT YOU CONSULT A TECH BEFORE PERFORMING THE FOLLOWING:
BASIC FORK DISASSEMBLY
REMOVAL OF THE LEG ASSEMBLIES
1. Disconnect the front brake and loosen the pinch clamp bolts at the bottom
of each leg. Unthread the axle with a 17mm wrench and remove the wheel.
2. Loosen the four M6 upper clamp bolts. Before loosening the lower clamp
bolts,
start to loosen the top caps using a 25mm socket. Then loosen the lower clamp
bolts and slide the legs out of the clamps.
DISASSEMBLY OF THE SPRING LEG ASSEMBLY (LEFT HAND)
1. Unscrew the top cap from the outer leg. Check for noticeable play between
the stanchion tube and the outer fork tube. If there is play, contact White
Brothers or a qualified dealer for service.
2. Lower the outer leg until the seal touches the drop out. Place in vise with soft
jaws.
3. Remove air from cap. Use a 25mm socket to loosen the rod from the air cap.
Hold the shaft on the flats with a 9mm open end wrench and unscrew the air
cap from the shaft.
4. Remove the inner leg from the outer leg. Remove the stanchion plug using a
25mm wrench or socket.
5. Clean and inspect all the parts. Check the DU bushings inside the outer leg
carefully for wear. This is done by looking at the color of the clean bushings. If
the bushings are dark gray, they are in good condition. If they are bronze/gold
in areas, they are worn and can cause fork stanchion damage. Please note that
special tools are required to remove and replace these bushings. This service
can be performed directly through White Brothers or a qualified dealer.
6. Next, inspect the fork stanchion tubes for wear, nicks or scrapes. These will
cause premature wear on the seals and DU bushings. If there is any damage to
the stanchion tubes, have them replaced.
7. Inspect the o-rings for damage. There is a o-ring on each end of the control rod and on both spring guides. If there’s any question about them sealing,
replace the o- rings.
DISASSEMBLY OF THE DAMPER LEG ASSEMBLY (RIGHT HAND)
*Service of the damper is best performed by the WB factory. Contact White
Brothers for the details.
1. Unscrew the top cap from the outer leg. Check for noticeable play between
the stanchion tube and the outer fork tube. If there is play, contact White
Brothers or a qualified dealer for service. Slide the outer leg down to the axle
clamp. 2. Unscrew the top cap counterclockwise from the shaft by holding the
flats on the shaft with an open end wrench.
3. Remove plastic washer, bumper and spring, then pull the inner leg out of the
outer leg.
BASIC FORK REASSEMBLY
REBUILDING THE OUTER LEGS
1. Throughly clean all the parts.
2. Check the condition of the wiper seals and the inner oil seal for cracks, abrasions or obvious signs of wear. They help to keep the dirt out, especially when
riding in harsh conditions.
Note: If the wiper seals are in question, replacement is always recommended.
3. The wiper seals can be removed with a spoon style tire iron or something
similar and can be re-installed using a large socket as a driver to install squarely
into the leg.
Note: Jamming the seals in at an angle can crush the steel casing and the seal will
no longer seal correctly and/or stay in place.
4. Apply grease to the DU bushings down inside the leg. Verify the bushings
are in good working order. Bushings are replaceable but require a number of
special tools to remove and install. Return to White Brothers to have the bushings changed if required.
REBUILDING THE SPRING LEG SUBASSEMBLY
1. Throughly clean all the parts.
2. Check the condition of the o-rings and replace if necessary.
3. Install the parts as shown in the exploded view, using heavy grease on all
internal parts. Thread the assembly into the inner leg. Use a 25 mm socket to
get the stanchion plug started, being carful not to cross thread it into the stanchion.
REBUILDING THE DAMPER LEG ASSEMBLY
1. Throughly clean all the parts.
2. Inspect for obvious signs of damage. Pressurize the damper canister to at
least 50psi. Test the damper by pushing the shaft down. It should compress and
return in a controlled manner. Screw the compression adjuster in to insure the
damper slows when adjusted. At the top of the stroke, if the damper shaft does
not return to 8” above the seal head this indicates the need for damper service.
Reinstall the greased spring. Reinstall the washer and bumper after the outer
leg is installed.
REINSTALLING THE OUTER LEGS
1. Apply Slick Honey or other non-lithium based suspension lube to the DU
bushings inside the outer leg. Make sure to lube the lower DU bushing which is
deep in the outer leg.
2. With all parts cleaned and reinstalled with new grease, fit the outer leg over
the stanchion tube and gently rock and slide the legs until the inner leg slides
into the bushings. Slide the outer leg all the way down to the drop out. Check
for noticeable play between the stanchion tubes and the fork lower. If there is
play, contact White Brothers for service.
REINSTALLING THE SPRINGS AND LH TOP CAP
1. A 10mm wrench will hold the flats on the shaft as you thread the top cap
down until it stops. Hold the top cap with a 25 mm socket and tighten.
2. Thread the top cap into the outer leg and tighten. Note: A little more than
hand tight is all that is necessary, as the upper clamp will hold the top caps
tight.
REINSTALLING THE RH TOP CAP
1. Screw the rebound needle in clockwise until it stops then back it out 3 to 4
turns.
2. On the damper shaft, install the chrome bottom out spring onto the seal
head,
spring spacer and then the yellow bumper with heavy grease on all parts. The
parts will be seated the first time the fork bottoms out.
3. Install the top cap onto the damper shaft and tighten. Remove the assembly
from the vise and thread the top cap into the outer leg and tighten. Note: A
little more than hand tight is all that is necessary, as the upper clamp will hold
the top caps tight.
TECHNICAL DRAWING
PARTS TABLE ON FOLLOWING PAGE
10
48
17
49
18
48
3
19
1
15
56
8
43
61
14
16
21
13
9
39
62
62
62 62
48
22
23
24
52
52
26
52
41
28
53
32
39
20
30
50
1
42
29
51
11
14
27 25
52
2
43
12
40
38
37
34
7
5
4
36
35
58
34
33
31
6
52
52
55
56
57
44
47
52
51
54
57
47
60
45
46
46
59
50
7
52
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
QTY. PART NO.
2 100021-100022
1 P1159-1
1 P1157-110
1 100609
1 100610
1 97-3677
2 97-1351
1 101468
1 100600
1 P2348
1 100668
1 100669
1 97-3342
2 100054
1 P3220
1 100615
1 100616
1 P3290
1 97-3914
1 P2028
1 P2035
1 97-1409
1 P2014
1 P2015
1 P2004
1 P2012
1 P3000
1 P2006
1 P2005
1 P4010
1 P3026
1 P1515-1
1 P2001B
2 29-136
1 P2016
1 P3028
1 29-127
1 P4011
2 P3021
1 P2010
1 100162
1 100627
2 P4650
1 98-406-1
1 98-406-2
6 P4005
4 97-9200
11 97-852
1 97-9300
2 P4301
2 P3060
8 97-986
2 101288
1 P4015
1 P4004
2 97-1418
2 P4051
1 101887
1 100262
1 100531
1 100016
4 P3310-1
DESCRIPTION
DH Outer Leg
Crown/Steerer Assembly
Upper Crown
Spring Leg Assm.
Damper Leg Assm.
Axle
Wiper Seal
Seal Head
DH Air Cap
DH Damping Cap
Compression Rod
Spring Guide/Air Piston
Bumper Soft
Schreader Valve Assembly
Spring Progression
Seal Head
Top Cap Plug
Compression Bumper Medium
Spring Spacer 5mm
DH Damper Shaft
Needle Assm.
Shaft Seal
Check Valve Guide
Check Valve Spring
Check Valve 22x12x0.02
Piston
Piston Band
Low Spd Shim 22x8x0.02
Belvil Washer
Shim Stack Bolt
O-Ring 024
Reservoir Can
Shim
Shim
Compression Piston
O-Ring 021
Shim
Piston Bolt
O-Ring 118
Floating Piston Assm.
O-Ring 2x22.5
Air Cap Triple Clamp Series
Dust Cap
LH Stone Guard
RH Stone Guard
Screw Nylon Guard
M5x16mm Screw
Bolt M6
Star Nut
C Clip
Oil Seal
DU Bushing
O-Ring 008
Retaining Pin
Compression Adjuster Screw
O-Ring 006
Set Screw 6mm x 6
Compression Spring
O-Ring 211
Axle End Bolt
Negative Spring
Negative Spring Shim
SERVICE LOG
SERVICE
DATE
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LIMITED WARRANTY
Who is covered:
This warranty is extended only to the original end-use purchaser, or the person
receiving the product as a gift, and shall not be extended to any other person or
transferee. Original proof of purchase is required.
What is covered/For how long:
Your White Brothers fork is warrantied for a period of 1 year from the date of
retail purchase (two years in Europe). White Brothers warrants that this product,
when delivered to you in new condition, in original packaging, from a White
Brothers authorized reseller and used in normal conditions, is free from any
defects in manufacturing, materials, and workmanship.
What is not covered:
This warranty does not cover defects resulting from improper or unreasonable use
or maintenance; improper installation, failure to follow operating instructions;
accident; unauthorized alterations of modification of original condition; damages
caused by inadequate packing or shipping procedures; wear items including seals,
bushings, o-rings, piston bands, foam rings, stanchions, bottom out bumpers,
stripped fastener threads and heads; and products purchased from unauthorized
dealers.
What we will do:
During the warranty period, we will, at our sole option, repair or replace any
defective parts within a reasonable period of time and free of charge.
What we will not do:
Pay shipping, insurance, or transportation charges from you to us, or any import
fees, duties and taxes.
What you must do to obtain Limited Warranty Service:
Return product, with proof of purchase from an authorized White Brothers
dealer, using the following procedures:
1. Contact White Brothers for specific return and shipping instructions.
2. Label and ship the product, freight prepaid, to the address provided
by White Brothers; and
3. Place any necessary return authorization number prominently on the
outside of the carton.
OTHER CONDITIONS
THE PROVISIONS OF THIS LIMITED WARRANTY ARE IN LIEU
OF ANY OTHER WARRANTY, WHETHER EXPRESSED OR IMPLIED, WRITTEN OR ORAL, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
WHITE BROTHERS MAXIMUM LIABILITY SHALL NOT EXCEED
THE ACTUAL PURCHASE PRICE PAID BY YOU FOR THE PRODUCT.
IN NO EVENT SHALL WHITE BROTHERS BE LIABLE FOR SPECIAL,
INCIDENTAL, CONSEQUENTIAL, OR INDIRECT DAMAGES HOWSOEVER CAUSED INCLUDING WITHOUT LIMITATION THE REPLACEMENT OF EQUIPMENT AND PROPERTY. THIS WARRANTY
IS VOID IF THE LABEL BEARING THE SERIAL NUMBER HAS BEEN
REMOVED OR DEFACED.
OTHER LEGAL RIGHTS
This limited warranty gives you specific legal rights, and you also may
have other rights that vary from state to state or country to country. Some
places do not allow limitations on implied warranties or the exclusion or
limitation of incidental or consequential damages, so the above limitations
or exclusions may not apply to you.
* Failure to register this product will not affect your limited warranty rights,
however, proof of purchase is required.
WHITE BROTHERS CYCLING IS A DIVISON OF:
MOUNTAIN RACING PRODUCTS
580 N WESTGATE DR
GRAND JUNCTION, CO 81505
970.241.3518
FOR MORE INFORMATION VISIT US ON THE WEB:
WHITEBROTHERSCYCLING.COM
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