DIY Suspension Fork Maintenance: Care Tips for Your Revel RoughCut RCP35

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The Revel RoughCut RCP35 [paid link] from X-Fusion is a high-performance suspension fork designed to handle a variety of terrains with precision and reliability. Proper maintenance is essential to keep it functioning smoothly, ensuring both longevity and optimal performance. This guide provides step-by-step instructions on how to install, adjust, maintain, troubleshoot, and customize your Revel RoughCut RCP35 [paid link]. By following these tips, you’ll be able to ensure that your fork remains in peak [paid link] condition for years to come.

Tools Required

  • 5mm and 6mm Allen wrenches [paid link]
  • Torque wrench [paid link]
  • Suspension oil
  • Oil drain pan
  • T20 Torx wrench [paid link]
  • Grease
  • Clean rags
  • Soft brush or toothbrush
  • Fork seal cleaning tool
  • Stanchion cleaning tool (optional)
  • Replacement seals and bushings (if needed)

Installation of the Revel RoughCut RCP35

Proper installation of your Revel RoughCut RCP35 is crucial for achieving the best performance. Follow these steps for a correct and secure installation:

  1. Prepare Your Bike: Start by securing your bike in a repair stand. This will make the installation process much easier.
  2. Remove the Old Fork: Use the appropriate Allen wrenches [paid link] to remove your old suspension fork. Loosen the headset and stem bolts, and gently slide the fork out of the head tube.
  3. Install the Revel RoughCut RCP35: Place the fork into the head tube and tighten the headset and stem bolts to the recommended torque settings. Ensure the fork is properly aligned and secure.
  4. Check the Suspension Settings: Before riding, check the suspension settings. The Revel RoughCut RCP35 features adjustable compression and rebound damping, so set these to your preferred ride characteristics.

Adjustment and Tuning for Optimal Performance

The Revel RoughCut RCP35 comes with multiple tuning options that allow you to tailor its performance. Here’s how you can adjust its settings:

Adjusting Compression Damping

  1. Locate the Compression Damping Knob: This is typically found on the top of the fork.
  2. Turn the Knob: Turning it clockwise increases compression damping, while turning it counterclockwise decreases it.
  3. Test the Fork: Ride your bike and adjust the compression damping based on your terrain. More damping is suitable for rough trails, while less is better for smoother surfaces.

Adjusting Rebound Damping

  1. Find the Rebound Knob: This knob is typically located at the bottom of the fork.
  2. Set the Rebound Speed: Turn the knob clockwise for slower rebound (suitable for steep, rocky terrain) and counterclockwise for faster rebound (ideal for smoother trails).
  3. Test and Fine-tune: Make minor adjustments during rides to find the most comfortable setting based on the conditions.

Air Pressure

The Revel RoughCut RCP35 features an air spring system. To adjust the air pressure:

  1. Locate the Schrader Valve: This is typically located on the fork’s lower leg.
  2. Use a Shock Pump: Attach the shock pump to the valve and add or release air to achieve the recommended pressure.
  3. Set According to Your Weight: Refer to the manufacturer’s guidelines for recommended air pressure based on your weight and riding style.

Maintenance: Keeping Your Fork in Top Condition

Regular maintenance of the Revel RoughCut RCP35 ensures that it continues to perform at its best. Here’s how to keep it running smoothly:

Cleaning the Fork

  1. Wipe Down After Each Ride: After every ride, use a clean rag to wipe down the fork, particularly the stanchions, to remove dirt and debris.
  2. Use a Soft Brush: Gently brush the fork seals and stanchions with a soft brush or toothbrush to remove any built-up grime.
  3. Inspect the Seals: Check for any tears or damage to the seals. If damaged, replace them immediately to prevent contaminants from entering the fork.

Servicing the Fork Internals

  1. Drain the Suspension Oil: Place the fork over an oil drain pan, remove the air valve, and unscrew the lower leg bolts. Allow the oil to drain out completely.
  2. Clean the Fork Internals: Use a clean rag to wipe down the internals of the fork. You can also use a stanchion cleaning tool to remove excess oil or debris.
  3. Replace the Oil: Refill the fork with the recommended suspension oil, ensuring you follow the correct oil volume for your specific fork model.
  4. Reassemble the Fork: Once the oil has been replaced, reassemble the fork and tighten the bolts to the recommended torque settings.

Replacing Fork Seals and Bushings

  1. Disassemble the Fork: To replace the seals, you’ll need to disassemble the fork. This may involve removing the lowers and taking out the internals.
  2. Clean the Fork: Before installing new seals, ensure the fork is clean and free from any dirt or old oil.
  3. Install New Seals: Carefully install the new seals, ensuring they are seated correctly to avoid leaks.
  4. Reassemble: Reassemble the fork, making sure to grease all the necessary contact points and bolts before tightening them to the correct torque.

Troubleshooting Common Issues

While the Revel RoughCut RCP35 is a high-quality fork, issues may occasionally arise. Here are some common problems and how to fix them:

1. Fork Not Holding Air Pressure

  • Cause: Leaking seals or damaged Schrader valve.
  • Solution: Inspect the seals and replace any that are damaged. If the Schrader valve is damaged, it may need to be replaced or reinstalled.

2. Fork Feels Too Soft or Too Hard

  • Cause: Incorrect air pressure or compression settings.
  • Solution: Adjust the air pressure according to your weight and riding style. Also, check the compression settings and adjust them as needed.

3. Fork Sticking or Not Moving Smoothly

  • Cause: Dirt or debris in the fork or damaged seals.
  • Solution: Clean the fork and seals thoroughly. If the issue persists, inspect and replace the seals or internals if necessary.

4. Rebound Not Functioning Properly

  • Cause: Incorrect rebound setting or internal issues.
  • Solution: Ensure the rebound knob is set correctly. If the rebound is still not functioning, the fork may require internal servicing or oil replacement.

Customization and Optimization for Better Performance

While the Revel RoughCut RCP35 is already a high-performance fork, some customization can enhance its performance for your specific riding style. Here are a few options:

Upgrade the Air Spring

If you prefer a more progressive spring feel, consider upgrading the air spring. A different air spring can provide a more tailored response for aggressive riding, especially on steep descents.

Swap Out the Fork Seals

Higher-quality seals can help keep dirt and moisture out, improving fork longevity and performance. Consider upgrading to premium seals if you regularly ride in muddy or wet conditions.

Adjust Suspension Settings Based on Terrain

If you ride in varying conditions, keep a shock pump and tool kit handy to fine-tune your settings between rides. Adjusting the compression and rebound damping based on the trail or racecourse conditions will significantly improve your ride quality.

Compatibility with Other Drivetrain Components

The Revel RoughCut RCP35 is compatible with a wide range of drivetrain components. However, it’s essential to ensure the fork’s specifications match your bike’s geometry and intended use. For example, confirm the fork’s steerer tube diameter and axle type match your frame’s requirements. Additionally, some bikes with certain geometries may benefit from different travel lengths or headsets, so consider these factors when integrating the fork with your overall setup.