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Duke XC rebuild or replace

12K views 38 replies 7 participants last post by  phantoj  
#1 · (Edited)
Duke XC rebuild

Picked up an old Stumpy with one of these, and it needs a rebuild or replacement. Its only holding about 110 psi and the rebound adjustment doesn't seem to do anything (I've never even had a rebound adjustment, but its supposed to be very noticeable when it works). Money is the paramount consideration here.

Seems like some people hated these forks from the start, while others still use them and like them. I have tools but no bike stand. I've never serviced sus forks before, but don't mind learning how, but also don't want to waste my time if it makes more sense to replace it. However with money being an issue I'd probably just end up with another used fork that needs servicing, right? My riding will be mostly 4wd mountain roads and some single track, but I'm not hardcore.
 
#36 ·
I found a part at my local Ace Hardware...

Danco #40 Cap Thread Gasket Part No 35575B.

Nylon, 1-1/8" OD, 15/16" ID x 1/16" H

The OD is 28.6mm, but I needed closer to 27.2, so I sanded down the OD just a little bit to get it to fit. Then I assembled the damper into the fork leg, first the damper shaft, then the original metal ring, then the Danco 1/16" nylon gasket, then the damper seal head, then finally the snap ring. Sorry no pics.

On the spring side, I have the nylon spring "seal head", then the wavy washer, then the snap ring. Ideally, I'd set it up:

metal ring
wavy washer
nylon seal head
snap ring

But I only have one metal ring and I need it for the damper side. I don't believe there are ever significant forces driving the "seal head" INTO the fork leg on the spring side, so I think I'm OK with this and the wavy washer is doing an OK job of controlling the slop on the spring side.

The 1/16" nylon gasket seems to be taking up the extra space perfectly, so I think I got rid of the clunking. Next step is install it in a bike and see how it rides. Intended recipient is a size Small hardtail my 10 y/o rides.
 
#38 ·
Sorry I'm in travel mode and haven't replied to your pm. I've got the remnants of the kit which has at least one ring/washer and wavy washer (although they may be the used ones I removed). I will send them to you but it'll be a little bit, maybe later next week