Upgrade your Rockshox and Manitou Forks

by Mitch Trujillo, PCI #244T
Boulder PD (CO)
IPMBA Industry Relations Committee

So, do you have an old RockShox or Manitou fork on that patrol bike that just doesn't work like it used to? Chances are, if you have a single-crown RockShox fork dating back to 1995, a Manitou SX model, or even White Brothers model, an EKO Sport Total Air Cartridge Kit might be the way to rejuvenate that tired fork.

Last year, while going through the garage, I came upon my used 1998 Manitou SX-Ti fork. The internals were good, but the feel of the springs never did suit me. Long ago, I heard that the old Englund Total Air systems had a great reputation as replacements for the stock internals for many forks, so I decided to rebuild my Manitou. Luckily, I found out that Colorado-based EKO Sport had purchased the rights from Englund, and were still producing the service kits. Even better, EKO Sport provides IPMBA members with 20% off the retail cost of the kit.

EKO offers twenty-one fork-specific kits. They retail from about $100 to $135. My kit was ordered and received in a timely fashion. Good thing there is a detailed set of step-by-step instructions! I'd never taken a fork apart before. After reading the instructions twice, which is highly recommended, I disassembled the fork and installed the cartridges. It was a breeze.

First, the cartridges have to be set up for your individual taste. I left the #2 damping adjuster (suitable for most riders and comes pre-installed) on the fork. If you like slower rebound damping, the #1 would be used. If you want faster rebound, use the #3. Each has a different size valve hole to control the correct amount of air flow. The small, plastic adjusters are installed using a 4mm Allen key. They sit inside the cartridge and are easily accessible. The compression damping is set by turning the adjuster in (for stiffness) or out (for plushness).

After that, you remove the fork's sliders, springs, and control rods, then wipe clean the outer stanchions and bushings inside the fork legs. The instructions vary according to fork model. If you have never rebuilt a fork before, you may have to disassemble and reassemble the fork a couple of times before everything is correct. Total time for the upgrade installation: two hours.

EKO recommends yearly maintenance by removing the cartridge with the handy tool (included) and lubricating it with Slick Honey or RockShox Judy Butter. I prefer the Slick Honey, which can be found in your LBS (local bike shop). EKO also throws in a section of PCV for emergencies. The section is strategically placed inside the fork leg should a cartridge seal blow and the fork has to be converted to a rigid fork for the ride home. Anyone who has experienced a blown fork seal will appreciate this.

I used a shock pump to amp up the cartridge to about 150psi. After putting half-boots on the sliders, I weighed the fork at three pounds light! The 72mm of travel is smooth and responsive. I noticed a little bit of "top out" (rebounding to full extension with authority is the best way to describe it), which is the way I like my forks. The fork feels very stiff laterally, and the EKO Sport cartridge hold its air very well. Weeks passed before I checked the air pressure, and to my surprise, no leaks.

After a full year of riding on urban patrol and on trails, I've found that my Manitou SX forks, with the installed EKO Sport Total Air Cartridge upgrade kit, need very little maintenance and are user friendly. I've also given a new lease on life to a set of forks that were gathering dust. On the whole, I'd recommend the product kit to anyone wanting to upgrade as opposed to springing for a comparable new fork.

Regular Cost: Contact for Product List

Cost to Members: 20% off Retail

Form of Payment: CK, MC, V, D

Ordering Options: Phone, Fax, Email, Web

Contact Name: Jason Tillinghast

Contact: EKO Sport Inc., 580 N. Westgate Dr., Grand Junction, CO 81505, (970) 241-3518, (800) 999-827, fax (970) 241-3529, Email: jtillinghast@ekosport.com

Website: www.ekosport.com

EKO Sport is listed in the IPMBA Product Purchase Program

Mitch is an IPMBA Instructor Trainer, an IMBA National Mountain Bike Patroller, and has a penchant for singlespeeds. He can be reached at trujillom@ci.boulder.co.us.

© 2003. This review first appeared in the Fall 2003 issue of IPMBA News.