Step-by-Step: Rebuilding Your Mattoc Pro Suspension Fork

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Rebuilding your Mattoc Pro [paid link] suspension fork is a crucial maintenance task to keep your bike’s suspension system functioning at peak [paid link] performance. Whether you’re experiencing poor suspension performance, unwanted noises, or just conducting routine maintenance, this guide will take you through each step of the process.

Tools Required

  • 10mm and 15mm open-end wrenches
  • Torque wrench [paid link]
  • Allen wrenches [paid link] (specific sizes depend on your fork)
  • Suspension oil (refer to manufacturer specifications)
  • Syringe (for suspension oil)
  • Cleaning rags
  • Fork seal driver tool
  • Soft mallet or hammer (to use with fork seal driver)
  • 5mm and 8mm socket wrenches
  • Compression and rebound adjustment tool (if required)
  • Fork oil bath tray
  • Brake cleaner
  • Silicone grease
  • Replacement seals and O-rings (if needed)

Disassembling the Mattoc Pro Suspension Fork

Step 1: Remove the Fork from the Bike

Start by removing the fork from the bike. Use the 15mm open-end wrench to loosen the quick release or through-axle, depending on your setup. Once the axle is removed, you can lift the fork out of the bike frame.

Step 2: Remove the Front Wheel and Brake Components

If you haven’t already, remove the front wheel to give yourself enough room to work. Depending on your bike, you may need to disconnect the brake hose or remove the brake caliper. Secure the brake components so they do not get damaged during the rebuild.

Step 3: Drain the Suspension Fluid

Place the fork in an upright position, and remove the air valve cap to release any pressure in the fork. Use a drain pan to catch any remaining suspension fluid as you proceed to drain it. You can gently compress the fork to help remove the oil from the damper and air spring.

Step 4: Remove the Top Cap and Stem

Using a 5mm Allen wrench [paid link], remove the top cap of the fork. This allows you to access the damper and air spring components inside the fork. Keep the cap and other small components in a safe place for reassembly.

Step 5: Remove the Damper Cartridge

After removing the top cap, you can access the damper cartridge. Use the appropriate wrench or tool to carefully extract the cartridge from the fork legs. Make sure to place the damper in a clean container as you remove it to prevent contamination.

Step 6: Remove the Air Spring Assembly

Once the damper is removed, you can proceed to remove the air spring assembly. Use the correct tools to carefully disassemble the air spring from the fork. Clean the parts thoroughly and inspect the seals and O-rings for damage.

Cleaning and Inspecting Components

Step 7: Clean the Fork Components

Clean each part of the fork with brake cleaner or suspension-specific cleaner. Pay close attention to any dust seals, oil seals, and the stanchions. Use a soft rag to remove any debris that may have built up on the fork.

Step 8: Inspect Seals and O-rings

Carefully inspect the seals and O-rings for signs of wear. If you find any damage or wear, it’s essential to replace them. Leaking seals can result in poor performance, so replacing them during the rebuild is critical to ensure the longevity of your fork.

Step 9: Inspect the Damper and Air Spring

Check the damper and air spring for any signs of damage. Ensure the piston rods move freely, and there is no oil leakage from the damper. If there are issues with the damper, consider replacing it or servicing it according to the manufacturer’s guidelines.

Rebuilding the Mattoc Pro Suspension Fork

Step 10: Lubricate and Reassemble the Fork

Apply suspension grease or silicone grease to all moving parts, including the stanchions, seals, and the damper. This will help reduce friction and prolong the life of the fork. Reassemble the air spring and damper components in reverse order of removal, making sure each part is securely tightened to the manufacturer’s torque specifications.

Step 11: Reinstall the Damper Cartridge

Carefully reinstall the damper cartridge into the fork, ensuring it is properly aligned. Torque the damper cartridge to the manufacturer’s specifications to avoid any leaks or performance issues.

Step 12: Install the Air Spring

After the damper is securely in place, reinstall the air spring assembly. Ensure it is seated correctly and lubricated. Use a torque wrench [paid link] to tighten any necessary bolts to the correct specification.

Step 13: Install New Seals

Install the new seals and O-rings if they were replaced. Make sure they are properly seated and that there is no debris under the seals that might prevent them from functioning correctly. Use a fork seal driver tool to press the seals into place evenly.

Adding Suspension Fluid

Step 14: Add Suspension Oil

Now that the fork is reassembled, it’s time to refill it with the proper suspension oil. Use the recommended type and amount of oil for your Mattoc Pro [paid link] fork. Using a syringe, carefully pour the oil into the damper and air spring. Pay attention to the oil levels as specified by the manufacturer to ensure optimal performance.

Step 15: Bleed the Fork

Some models may require a bleed after the oil is added to ensure there are no air bubbles in the suspension. Follow the manufacturer’s procedure for bleeding the fork to remove any trapped air.

Testing and Final Adjustments

Step 16: Reinstall the Fork and Test

Once the rebuild is complete, reinstall the fork back onto the bike. Reconnect the brake components, if necessary, and tighten everything according to the manufacturer’s torque specifications. Test the fork’s compression and rebound settings to ensure proper functionality.

Step 17: Fine-Tune Compression and Rebound Settings

Make sure to adjust the compression and rebound settings to match your riding style and preferences. Refer to the owner’s manual for the recommended settings based on your weight and riding conditions.

Troubleshooting Common Issues

1. Fork Not Compressing Properly

If the fork feels too stiff or doesn’t compress as expected, check for the correct amount of oil in the air spring. Low oil levels can cause stiffness, and improper air pressure can affect compression. Ensure that all seals are intact and that the damper is functioning correctly.

2. Excessive Noises During Suspension Travel

Noises can often be caused by dirt or damaged seals. Inspect the fork for dirt buildup or worn seals that could allow debris inside. Replace any damaged seals to prevent further issues.

3. Fork Not Returning to Full Extension

If your fork is not extending properly, it may be caused by a hydraulic lockout issue or air pressure imbalance. Ensure the lockout is functioning as intended and that the air spring is correctly inflated.

Customizing and Optimizing Your Mattoc Pro Suspension Fork

To optimize your Mattoc Pro suspension fork, consider the following adjustments:

  • Tune the Compression and Rebound Damping: Adjust the settings based on your weight, riding style, and trail conditions. For smoother trails, you might prefer a faster rebound, while more aggressive riding could benefit from slower rebound and firmer compression.
  • Adjust the Air Spring Pressure: Adjust the air pressure according to your weight and riding preferences. A stiffer air spring is ideal for aggressive riding, while a softer air spring offers more comfort for trail riding.
  • Upgrade Seals and Oil: Using higher-quality seals and suspension oil can improve the performance and lifespan of your fork.

Compatibility with Other Drivetrain Components

The Mattoc Pro suspension fork is compatible with most modern drivetrain components, but it is essential to ensure the correct axle type and dropout dimensions match your bike’s frame. Additionally, check that your brake caliper mounts are compatible with the fork’s post mount or IS mount brake system.