The Revel RoughCut RCP35 [paid link] from X-Fusion is a standout in the world of high-performance mountain bike suspension. Designed for serious riders looking for advanced suspension technology, it promises improved control, comfort, and durability in challenging terrains. In this guide, we’ll break down everything you need to know about the Revel RoughCut RCP35 [paid link], from installation to optimization, and help you decide if it’s the right upgrade for your bike.

Tools Required

Before starting the installation and maintenance of your Revel RoughCut RCP35 fork, gather the following tools:

• 5mm Allen wrench [paid link]
• 6mm Allen wrench [paid link]
• Torque wrench [paid link] (for precise tightening)
• Suspension fluid (recommended by X-Fusion)
• Grease (for headset and fork crown)
• Flathead screwdriver
• Isopropyl alcohol (for cleaning parts)
• Bike stand [paid link] (optional, but highly recommended)
• Soft rags or towels (to protect parts from damage)

Installation of the Revel RoughCut RCP35

Installing the Revel RoughCut RCP35 fork is straightforward if you follow these steps carefully. This process assumes that your bike is already equipped with a compatible headset, brake system, and front wheel. If not, you’ll need to install these parts before beginning.

1. Prepare the Fork and Headset
   • Begin by removing the old fork from your bike if one is already installed.
   • Clean the headset and fork crown area thoroughly with isopropyl alcohol to ensure no debris or grease remains.
2. Install the Headset
   • If the headset is not yet installed, place the lower headset bearing into the frame’s head tube. Grease the bearings lightly to avoid any creaking and ensure smooth operation.
   • Install the upper headset bearing and press it into place.
3. Install the Fork
   • Carefully slide the Revel RoughCut RCP35 fork into the head tube of the frame.
   • Secure the fork in place by installing the headset spacers and top cap, followed by tightening the stem clamp bolts.
4. Attach the Brake Mounts and Front Wheel
   • If your fork is equipped with a post-mount brake system, attach the caliper to the fork’s post-mount brackets.
   • Install the front wheel into the dropouts, making sure it is properly aligned before tightening the quick release or thru-axle (depending on your fork type).
5. Set the Suspension Travel
   • The Revel RoughCut RCP35 features adjustable travel. Set the fork to the preferred travel setting based on your riding style and terrain preferences. Consult the user manual for specific instructions on travel adjustment.
6. Check Alignment and Torque
   • After securing the fork and brake components, use a torque wrench [paid link] to ensure all bolts are tightened to the manufacturer’s recommended torque specifications. This is crucial for safety and performance.

Adjustment and Tuning for Optimal Performance

The Revel RoughCut RCP35 fork offers various adjustments to fine-tune the ride based on your personal preferences and the demands of your riding environment. Here’s a breakdown of the key adjustments:

Rebound Damping

Rebound damping controls the rate at which the suspension returns to its fully extended position after compression. If the rebound is too fast, it can result in a bouncy ride; too slow, and you’ll experience a sluggish response.

• To adjust: Turn the rebound knob located at the bottom of the right fork leg. Rotate it clockwise to slow the rebound and counterclockwise to speed it up. Start with a middle setting and fine-tune from there.

Compression Damping

Compression damping affects how the fork handles impacts. It helps control how much the suspension compresses under force, such as when hitting a bump or rock. The Revel RoughCut RCP35 has separate high and low-speed compression adjustments for fine-tuning.

• Low-Speed Compression: This adjustment controls small, gradual impacts (e.g., pedal bob). Turn the dial to increase or decrease the compression to suit your riding style.
• High-Speed Compression: This controls the fork’s response to sudden, large impacts. Adjust this setting to reduce harshness during aggressive downhill riding.

Air Spring Pressure

The air spring pressure setting affects the overall firmness or softness of the fork. Adjusting the air pressure allows you to tailor the fork’s ride to your weight and riding conditions.

• To adjust: Use a high-quality shock pump to increase or decrease the pressure according to your weight and riding style. The recommended air pressure range is typically listed in the fork’s user manual.

Travel Adjustment

The Revel RoughCut RCP35 features adjustable travel, typically between 130mm and 160mm. This allows you to adapt the fork to different terrain or riding preferences.

• To adjust: Follow the instructions in the manual for adjusting the travel using the internal air spring adjustments.

Maintenance of the Revel RoughCut RCP35

Maintaining your Revel RoughCut RCP35 fork is essential for long-term performance and reliability. Regular maintenance ensures smooth operation, prevents damage, and extends the lifespan of your fork. Follow these steps to keep it in top shape.

Regular Cleaning

• After each ride, clean the fork with a damp cloth to remove dirt, mud, and debris. Make sure to clean the fork stanchions to prevent dirt from entering the seals.
• Avoid using high-pressure water, as it can force dirt into the fork seals.

Suspension Oil Change

• Every 50-100 hours of riding, change the suspension fluid to maintain optimal performance. Use the recommended suspension oil for the Revel RoughCut RCP35.
• Remove the lower legs and carefully drain the old oil. Refill with the appropriate amount of new oil, making sure to follow the manufacturer’s guidelines for the correct oil type and volume.

Seal Maintenance

• Check the seals on the fork regularly. If you notice any oil leakage around the seals, it may be time to replace them. Worn-out seals can cause loss of suspension performance and increase the risk of dirt entering the internals of the fork.

Troubleshooting Common Set-Up Issues

Even with high-quality components like the Revel RoughCut RCP35, you may encounter a few issues during installation or use. Here are some common problems and how to troubleshoot them.

Unusual Noise or Creaking

If you hear creaking or unusual noises coming from the fork, check for loose bolts or parts. Make sure the headset, stem, and fork bolts are properly tightened. Apply grease to any contact points to prevent squeaks.

Fork Bottoming Out

If your fork bottoms out (compresses all the way under heavy impact), it may be due to insufficient air pressure or excessive rebound damping. Check the air pressure and adjust the rebound settings for smoother compression.

Insufficient Travel or Soft Feel

If the fork feels too soft or doesn’t provide enough travel, it may be a sign that the air pressure is too low. Use a shock pump to increase the air pressure in the fork to match your weight and riding style.

Customization and Optimization for Better Performance

For riders looking to enhance the performance of the Revel RoughCut RCP35, there are several customization options to explore. These adjustments can help you tailor the fork’s performance to your specific needs.

Upgrade the Air Spring

Consider upgrading the air spring to one with a different curve if you require a firmer or softer feel. This can help improve performance on different types of trails.

Fine-Tune Compression Settings

Optimizing both low and high-speed compression settings can drastically improve ride quality. Experiment with different settings to strike the perfect balance between comfort and control.

Install Custom Decals or Paint

While it doesn’t affect performance, customizing the aesthetics of your fork with custom decals or paint can make your bike stand [paid link] out and match your personal style.

Comparison with Similar Models

The Revel RoughCut RCP35 is an excellent choice for riders seeking a versatile [paid link] fork with adjustable features, but it’s important to compare it with similar models to ensure you’re making the right choice.

X-Fusion Trace 36

The X-Fusion Trace 36 offers similar performance to the Revel RoughCut RCP35, but it has a slightly different focus. The Trace 36 is a great choice for aggressive downhill riders due to its robust build and slightly stiffer feel. However, the RoughCut RCP35 offers more fine-tuning capabilities, making it a better choice for riders who want more flexibility in setting up their suspension.

RockShox Pike Ultimate

The RockShox Pike Ultimate is another competitor in this category, known for its smooth performance and ease of adjustment. It is slightly more expensive than the Revel RoughCut RCP35, but its reputation for reliability and ease of setup makes it a solid choice for all-around trail riders.

Understanding Compatibility with Other Drivetrain Components

The Revel RoughCut RCP35 is compatible with a wide range of drivetrains and components, but it’s important to ensure it aligns with your bike’s setup. Always double-check the steerer tube size, axle type, and brake mount compatibility before purchasing.

• Axle Type: Ensure the axle type (quick release or thru-axle) matches your frame and wheels.
• Brake Mount: The RCP35 is designed with post-mount brake compatibility, so make sure your brake system aligns with this mounting style.