vorsprung Secus Fork Air Spring Upgrade Kit Instruction Manual

vorsprung Secus Fork Air Spring Upgrade Kit

TOOLS REQUIRED

NOTE: Do not proceed unless you have the following tools and supplies on hand.

• 10mm shaft clamps
• Torque wrench (+4mm hex attachment)
• 14mm spanner
• 11mm socket
• Slickoleum (Slick Honey) grease
• Red Loctite
• Secus Body
• Secus Footstud
  • Installation spacer
  • F ootnut
  •  3x additional foodstud o-rings (as spares, in case of damage during assembly)
  • 2x 0.50mm spacer shims

Note: three of the o-rings may not be installed when you receive the footstud. This is ok, leave them off until directed to install them. If they are installed, leave them in place.

ASSEMBLY

There are 3 main sections to installing the SECUS on your Fox 40:

• PART 1 – Replacing the stock footstud from your fork
• PART 2 – Installing and positioning the Secus on your fork
• PART 3 – Inflation & equalization process

REPLACING THE STOCK FOOTSTUD FROM YOUR FORK

• See manufacturer’s service instructions for disassembling the stock air spring and removing it completely from your fork. Refer to the relevant factory service instructions up until you have removed the air spring from the stanchion. ROCKSHOX: https://www.sram.com/service/rockshox/7,434 Refer to the Factory service instructions for torque specifications, lubrication specifications and general disassembly/reassembly.
• Secure shaft firmly using 10mm Shaft Clamps. Ensure you are not clamping too close to the footstud and potentially onto the threads internally, allow approx 1 inch/25mm.
• Heat area with heat gun. Remove foot stud from shaft using 14mm wrench or knipex, do not use multigrips.
• Clean Loctite residue from shaft thoroughly.

ADDITIONAL STEP FOR PIKE & LYRIK C1 AIR SHAFTS (ZEB NOT INCLUDED):

• Remove original sealhead from shaf

• Replace with BIP (B1/B2) Sealhead, ensuring that the flat side of the sealhead is facing out of stanchion / stepped edge facing in.

• Place a drop of Red Loctite onto airshaft thread. Thread the Footstud down onto the shaft by hand

• USE A TORQUE WRENCH. Torque using 4mm hex attachment. Torque to 30in.lbs or 3.3Nm.

• See manufacturers service instructions for re-assembling the air spring & your lowers. ROCKSHOX: https://www.sram.com/service/rockshox/7,434
  Refer to the Factory service instructions for torque specifications, lubrication specifications and general disassembly/reassembly. Refer to the relevant factory service instructions up until you have torqued the damper side and you are ready to torque the spring side.
  Note: Place an additional 5ml of oil in the spring side.

• When spring side is filled with oil & ready to torque, note the protrusion of foot stud. The third o-ring groove should be barely stick-ing out from the lowers. Use installation tool (plastic cylindrical spacer) to pull the shaft through into the lowers & engage the press-fit.

• Place installation tool over footstud & wind down nut. Use an 11mm socket to pull the shaft through until you feel minor resistance. Don’t do it up tight. Remove installation tool.

INSTALLING THE SECUS BODY

• If the three smaller o-rings are already installed on the footstud when you receive it, ensure o-rings are lubricated with Slickoleum (also sold as Slick Honey, SRAM Butter etc). If these o-rings are not installed on the footstud yet, leave them off and go to step If they’re already on there, just lubricate them – no need to remove them.

• Slide Secus body over foot stud. Place footnut on by hand.

• Use a torque wrench to torque the footnut to 50in.lbs (5.6Nm) in order to fully seat the assembly. Do not exceed 50in.lbs or you will break things. DO NOT tighten without a torque wrench or you will break things.

• Now that the footstud is fully seated in the lowers, remove footnut & Secus body from footstud. Sit Secus body next to footstud and check alignment of centre ridge on Secus body with centre o-ring groove on footstud. The centre o-ring groove on the footstud needs to align with the centre ridge on the Secus body to ensure that the o-rings all seal properly.

• Being careful not to damage the o-rings if they are already on the footstud (as pictured), install as many 0.50mm shims as necessary (min: 0, max: 2) on footstud between fork lower and Secus body, in order to visually align centre ridge on Secus body with centre o-ring groove on footstud. Most forks will re-quire zero spacers, but some (notably Boxxer and 2021+ Pikes) will require 1 or 2 for correct alignment due to different thicknesses of the lower leg.

• Install o-rings onto the footstud in the 3 o-ring grooves if not already installed. Inspect carefully for any cuts/damage. Install Secus once more onto the footstud. Install the footnut back onto the footstud and use a torque wrench to torque to 50in.lbs (5.6Nm) once again.

• Install the fork back onto your bike at this stage. Also install your front wheel & ensure brake caliper is aligned as per normal.

• Slightly loosen the footnut so Secus body can rotate. Position the Secus close to the brake mount, ideally with a 2mm gap.
  Note – if you leave less than 1mm gap, the flex in the system may mean that the Secus can rattle against the caliper.

• Using the torque wrench, torque to 50in/lbs (5.6Nm) whilst holding the Secus in place. You can loosen the footnut at any time to relocate it – the rotational position does not matter for function, only for clearance and minimising protrusion of the Secus.

INFLATION & EQUALIZATION PROCESS

It is recommended that you inflate to 20% higher pressure than what you previously ran, as a starting point. You may wish to run more or less pressure than this – it is only a starting point. At this point, the fork will be extremely stiff and it will be topping out hard – this is normal.

Push down slowly onto fork to equalize (this will be difficult – you can do it at a lower pressure initially). You will hear a hissing sound as the air from the positive chamber passes through the ports into the negative chamber. As this occurs, the pressure in the positive chamber will drop.

Continue the process of adding more air & pushing down again to equalize the fork pressure to your desired pressure.

Push the GOLD button on the bottom of the Secus. This charges the Midstroke Support Valve with the correct amount of pressure. It only needs to be pushed once, but pressing more times won’t alter anything. If you are changing pressures (up or down), be sure to push it.

Tuning your fork with air volume tokens

See below for recommended starting points for setting up your Secus with air volume tokens. Add one volume spacer for e-bike fitments.

THINGS TO NOTE:

Deflation/ depressurization
If you are fully deflating the fork, ensure the gold button is held down while releasing air slowly from top cap. This will ensure the negative chamber is fully discharged while depressurising. If the fork sucks down more than 20mm while depressurising, that means the air piston has come past the equalization ports too fast and air is still trapped in the negative chamber, unable to equalize and escape via the positive chamber. In this case, re-inflate the fork (or forcibly ex-tend it by placing your foot on the wheel and pulling on the bars), re-equalize it, then let air out more slowly.

NOTE: You must depressurize the fork fully if you wish to take the lowers off. Do not remove the lowers without depressurizing the air spring.

Flying with your Secus
Pay special attention when boxing/bagging your bike – ensure the fork is supported by the axle and not resting on the Secus when flying.
Be aware – there is now an additional part on your fork.
Please do not lean the Secus on the floor (especially while the front wheel is off, or if you are packing your bike into a box), or against anything. Likewise, be careful when carrying the bike on a truck tailgate – ensure the Secus is not contacting the bumper or other bikes.
12 Month Crash Replacement Guarantee
We will replace any damaged parts of your Secus in the event of a crash or accident for the first 12 months of ownership, free of charge. Just send through pictures to the email below so we can help you ascertain which parts require replacement.
Questions?
Email steve@vorsprungsuspension.com
www.vorsprungsuspension.com

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