Step-by-Step: Rebuilding Your Revel RoughCut RCP35 Suspension Fork

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The Revel RoughCut RCP35 [paid link] suspension fork by X-Fusion is a high-performance component designed for aggressive riding styles. Over time, the fork can experience wear and tear, reducing its performance. Rebuilding the suspension fork will restore its full functionality, ensuring you continue to ride smoothly and efficiently. This step-by-step guide will walk you through the necessary processes to rebuild the Revel RoughCut RCP35 [paid link], including the tools required, installation, adjustment, troubleshooting, and optimization.

Tools Required

To perform a complete rebuild on the Revel RoughCut RCP35 suspension fork, you will need the following tools:

  • Suspension fork service tool kit
  • 8mm and 10mm wrenches
  • Torque wrench [paid link]
  • Hex keys [paid link] (5mm, 6mm)
  • T25 Torx driver
  • Flathead screwdriver
  • Soft mallet
  • Small brush for cleaning
  • Fork oil (specific to the RCP35 model)
  • Hydraulic fluid (if needed for damping system)
  • Replacement seals and O-rings
  • Grease (for stanchions)
  • Rag or cloth for wiping parts clean

Disassembly of the Revel RoughCut RCP35

The first step in rebuilding your Revel RoughCut RCP35 suspension fork is disassembly. This process will give you access to the internal components that need to be serviced.

  1. Remove the Fork from the Bike: Using a 5mm or 6mm hex key, remove the fork from the bike’s head tube. Place the fork on a clean work surface to begin the disassembly.
  2. Remove the Front Wheel: Using your 8mm wrench or quick-release, remove the front wheel of the bike.
  3. Remove the Brake Caliper (if applicable): If your bike uses disc brakes, you will need to detach the brake caliper by removing the mounting bolts with a 5mm hex key [paid link]. It’s advisable to use a cloth to protect the brake pads from contamination.
  4. Detach the Lower Leg Assembly: Use your 10mm wrench to loosen and remove the bolts securing the lower leg assembly. A soft mallet can help loosen any stubborn parts. Set the lower legs aside carefully.
  5. Remove the Air Cap and Drain Oil: Unscrew the air valve cap and depressurize the air chamber. Once the fork is deflated, remove any remaining fork oil by inverting the fork and allowing the fluid to drain completely.

Inspection of Internal Components

After disassembling the fork, it’s important to inspect the internal components for any signs of wear or damage.

  1. Inspect Seals and Bushings: Examine the seals and bushings for wear or cracking. Replace them if they show any signs of damage to prevent oil leaks or air pressure loss.
  2. Check the Stanchions: Look for scratches or dents on the stanchions, as these can affect the performance and longevity of the fork. If damaged, consider replacing the stanchions.
  3. Examine the Damping Cartridge: The damping system should be free of leaks and properly lubricated. If you notice any fluid leakage, the damping cartridge may need to be replaced or serviced.
  4. Clean All Parts: Use a small brush and a rag to clean all the components. Avoid using harsh chemicals, as they can damage the fork’s internals.

Rebuilding the Revel RoughCut RCP35 Suspension Fork

Rebuilding the fork involves reassembling the internal components with new fluids, seals, and other parts that need replacement.

  1. Lubricate the Stanchions: Apply a thin layer of suspension-specific grease to the stanchions before reassembling the lower leg. This will help prevent friction and wear.
  2. Install New Seals and O-Rings: Carefully install the new seals and O-rings into the appropriate places. Make sure the seals are properly seated to prevent any oil leaks.
  3. Install the Damping Cartridge: If the damping cartridge needs replacement or servicing, install the new or repaired damping system. Make sure it’s properly aligned and secure before tightening the bolts.
  4. Add Suspension Fluid: Refer to the fork’s service manual for the recommended type and amount of fork oil. Pour the oil into the lower leg and compress the fork slightly to allow the oil to settle.
  5. Reassemble the Lower Leg: Carefully reassemble the lower leg, ensuring that the seals and components align correctly. Tighten the bolts securely, but avoid over-tightening to prevent damage to the fork.
  6. Reattach the Air Spring and Cap: Install the air spring and screw the air valve cap back on. Ensure the cap is tightly secured to maintain proper air pressure.
  7. Install the Fork Back on the Bike: Once the fork is fully reassembled, reinstall the fork onto the bike’s head tube. Tighten the headset and stem bolts to the recommended torque settings.

Adjusting and Fine-Tuning the Fork

Once your fork is rebuilt, the next step is adjusting the settings to your riding style.

  1. Set the Air Pressure: Use a shock pump to set the air pressure according to the manufacturer’s recommended settings. Air pressure affects the fork’s responsiveness and comfort, so adjusting it correctly is crucial.
  2. Adjust the Compression Damping: The compression damping controls how fast the fork compresses under load. Adjust the dial to your preferred setting, taking care not to over-compress the fork for smooth travel.
  3. Set the Rebound Damping: Rebound damping affects how quickly the fork extends after compression. Experiment with different settings to find the rebound speed that suits your riding style.
  4. Test Ride: After making the necessary adjustments, take your bike for a test ride. Monitor how the fork feels on various terrain types, making adjustments as needed.

Troubleshooting Common Issues

Even after a full rebuild, you may encounter some issues with the Revel RoughCut RCP35. Here are a few common problems and their solutions:

  1. Fork is Too Soft: If the fork feels too soft, you may need to increase the air pressure or adjust the compression damping to provide more support.
  2. Fork Sinks Too Low During Use: This can indicate a problem with the air spring or compression damping. Check for leaks in the air chamber and adjust the compression settings.
  3. Rebound is Too Fast or Slow: If the fork is bouncing too fast or too slow, adjust the rebound damping. A too-fast rebound can make the fork feel unstable, while a too-slow rebound can create excessive resistance.
  4. Oil Leaks: If you notice oil leaking from the seals, it’s a sign that the seals need replacement. Ensure that the seals are properly seated during the rebuild.

Customization and Performance Optimization

The Revel RoughCut RCP35 suspension fork can be customized to suit various riding styles and preferences.

  1. Upgrade to a High-Flow Damping Cartridge: If you prefer a more responsive fork, consider upgrading to a high-flow damping cartridge for increased performance in technical terrain.
  2. Install a Volume Spacer: For riders looking for a more progressive feel, adding a volume spacer to the air spring will increase the ramp-up rate during compression, preventing bottom-out on aggressive rides.
  3. Use Different Fork Oils: Experiment with different fork oils to fine-tune the fork’s performance. Thicker oils provide more control, while thinner oils offer a more responsive, softer feel.

Comparison with Other Forks

When comparing the Revel RoughCut RCP35 with other models in the market, it stands out for its durability, stiffness, and adjustable features. The RockShox Pike, for example, also offers an excellent performance but comes with a higher price point for comparable features. The X-Fusion Revel RoughCut RCP35 provides an exceptional balance between performance and cost, making it a top choice for riders who demand high performance without breaking the bank.

Compatibility with Other Drivetrain Components

The Revel RoughCut RCP35 suspension fork is compatible with a wide range of drivetrain components. However, ensure that your bike’s frame, wheel size, and headset are compatible with the fork’s specifications. It is recommended to check the fork’s axle standards and clearance to ensure smooth integration with your other components.