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The Suntour Durolux

Suntour Durolux RCA damper overhaul. I tired to talk as slow as possible. I hope this helps all who mailed me asking for instructions on how to change the oil. I alos plan on doing a travel adjust video too when my broken coracoid process heals. RideOn!

107 Comments

  • + 4
 Nice vid. Very Thorough. The Audio quality needs improvement. It changed with each shoot. Also, its worth mentioning that you should be careful when you are checking all the adjustments while the damper is still out of the fork. Don't want to bend that rods cuz you are manhandling it when its fully compression damped.
  • + 2
 Yes, I was using my gopro and next time will change the back cover to the open case.
The sound too Im very sad that it came out so quite.

As for the damper its not gas charged or air charged to there is not pressure restricting movement. If it were then I would need to be more careful, also my face expressions were a little embellished!

The damper moves nicely but changing the rebound and compression gives you a first hand feel of how well the damper is actually working. The rod or damper's shaft has a long rebound rod inside as well so,
its really strong.
The 6 adjustments I showed in the video on the compression is only half of what it would be fully compressed.
It has 15 clicks of compression but, what I wanted to show was just 6 goes a long way, hahahha
A lot of my buddies have their air pressure to low or spring rate too low and use too much compression or visa versa!

Thank you, I plan on doing some more videos as I love working on my bike.
Also Im out with a dislocated shoulder which might need surgery so, in recovery I will have some spare time, hahahha
Actually after I finished this overhaul it was 3:30 and cooling off so I went for a short xc ride and that when I crashed, ahahhahah

This was my first explaining procedure so, it was kinda of weird talking to the camera, ahhahahhahha
Next time the audio will be much better as I know what to do now.

RideOn!
  • + 1
 Great video! Easy to follow and understand! tup Pretty cool that you can do a quick check of the damper without having to bolt it back into the fork! Very cool!


Two questions, Sensei: (1) the oil that drained out in the very beginning of the overhaul, is that oil that leaked out of the damper? And if so is that normal? (2) The selection of oil weights - you used a heavier weight oil due to a heavier rider weight, any risk of the heavier weight adding more pressure to the seals in the damper?

Thanks for posting it! Very interesting stuff! tup
  • + 2
 Thank you!
I will look into doing more overhaul videos in the future!*
1- the damper is sealed and locked together or screwed together.
So, if the damper came unscrewed while riding then yes, there would be extra oil to pour out.
And yes, that would not be normal.*
On my damper I had oil in there as extra lube for the seals.
The second time around I opted to use just the slick honey!
2- No, there is no pressure in the system.
Its an open oil bath closed damper if that makes sense.
*The rebound piston pushes oil up and through the compression's shim stack and there is air in the upper half of the damper. ( In the video I put oil in both halves but the oil all drains into the lower half once assembled ). So, there is no pressurized air in the system.
*The heavier oil just allows lighter adjustments for heavier people.
For example= if Im 200lbs and use the 5wt oil, with my air pressure I will use 4 clicks of compression and 4 on the rebound.
If the rider is lighter and uses the 2.5 wt oil with his decided air pressure he will use the same adjustments of four clicks of compression and rebound to have the same ride.
*So, in a way the heavier oil is actually easier on the system because if I at 200lbs had 2.5 wt oil I would need 8 clicks of compression and rebound putting more pressure through the shims, but the seals would be all good as its not pressurized.
*I also overhaul a lot of rear shocks which are pressurized.
My Roco air for example, I have a mix between 10wt and 15wt, for the last 4 years and never had any problems, just a smooth ride with light adjustments.
With the heavier oil Im able to use less air pressure to prevent bottoming as the system is more stable to my weight.
*For most of my friends shocks I overhaul I use 2.5 to 5wt oil( expect MOMO who has 15wt) because they are lighter and also ride very lightly!
*Thank you for liking this video and Im looking forward to doing more.
RidEOn!
  • + 1
 yes that was a very well done video. great job!
  • + 1
 Thank you man!
  • + 1
 hahahaha you scared my kids again hahahahaha.....very well layed out mate.so easy to follow.Since i have known you i just email you on how to fix it and you tell me..you have saved me heaps of time and money.....love your work... and yes,you are a bike geek hahahaha.
  • + 1
 hhhahahhahahahah Thank you very much for the respect mate! Im just glad I can help where I feel help is needed! I will continue to do my best! hahahahhah I think you might be a geek too! hahahhahha RidEOn mate!
  • + 1
 I think that is why we are like brothers,our passion for bikes is 100%.
Since i have known you i have changed oil and springs in forks,fixed problems with chains,done a service on a headset and i have even bled my brakes.This may sound like a easy list of jobs but for some one who has no mechanical mind this is huge.

Long live the Geek.......hows the wing mate? (shoulder)
  • + 1
 hahhahaahahhha
Your Awesome mate!
What ever can be helped Im there to help, hahahha
I really enjoy helping and I guess Its my Job!
Your positive outlook gives me the strength to continue doing what I am!

As for my wing Im still out!
Its been over a month now and Im still far from riding.
I cant do a push up yet and Im still at about 40 full range movement.
I dont know how but Im out for a long time mate!
Good news I have been on some one handed rides with the kids and wife.
I love just being on the bike and if my entire life is all one handed from here on Im fully happy!


I want to do more videos of this kind and of course improve the audio quality.
do you have any request?
RideOn Brother!
  • + 1
 Mate please just hang in there...The real good times are ahead.I would love to see you do a tech video on greasing a BB or maybe a rear shock service...I loved this video as it made sense and was way funny...take care bro ride on
  • + 1
 Cool mate! I too want to do a rear shock video that would be cool! As for the BB its been done in my build videos of the Rune and Bottlerocket but with no commentary! Good idea mate! RidEOn!
  • + 1
 Hahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahahah.............. What was that! Hahahahahahahahahahaha................
Brilliant, good mechanical skills with a dose of fun..... top notch hahahahahehehehehe! Smile I was impressed with the sealed rebound damper / compression, preload system its simalar to my boxxer fork and just as smooth. Great vid and cant wait to show the lads their gona love it to hahah! Smile
  • + 1
 hhhhahhhhhhhahha Thank you Chris! I made this about a year ago now. I went for an afternoon ride before work on this fork and its still super smooth! I love the durolux for its top quality ride and inexpensive price! Im not familiar with the current boxxers but if it has a close system in proximity then it must be super smooth! RideOn!
  • + 1
 do you have the travel adjust tutorial yet? I couldn't find it in your videos. This video was pretty awesome and I'm hoping the travel adjust is awesome too.

I'm thinking about this fork for my Bottlerocket and ditching my totem. The totem is sexy, but overkill for my riding. I'd probably keep this at 160 and bump it up to 180 for shuttle days. Assuming its a quick fix though. Heck, maybe I just keep my Totem for shuttle days.

-joel
  • + 1
 Thank you joel, this fork would be perfect for just that. I do have a travel adjust video as well, I will mail it to you! RideOn!
  • + 1
 hi
I have my Epicon (only lockout, no compression damper adjustment)lowered to 65mm, works really great and smooth.
My only problem with it is that it tend to blow through mid section of the travel very easily even though I pump the air pressure very high.
It feels very stiff when you stand on the bike and press it. But once you hit large bump or land a 60cm drop, it almost bottom out. Do you have any solution for it?
Also I've heard that all suntour Air forks are showing this kind of tendency( my friend's durolux do too)
Will change to a higher weight damping oil help?
  • + 1
 Do you have the Epicon with the Travel Adjust or set travel. If you have the set travel version, you can add some more oil or grease in the air spring to create a smaller air chamber, improving fork dive. It will make the fork feel more progressive and wont bottom out. The same would be for your friends Durolux. But if you both have the TA travel adjust versions, I don't know how to help you as I have never rode one! RideOn!
  • + 1
 Hay Mine is a set travel version, I'll give it a try! Thanks for the heads up.
  • + 1
 Oh cool! Then you can create a small air chamber by adding some heavy weight oil or some suspension grease. Or you can also add a little rubber or sponge tube about 30-40mm long with a hole in the middle. This will create more pressure in the air chamber with the same amount of air, your mid stroke should increase considerably! RideOn!
  • + 1
 Superb work! I'm liking your new direction, too! I think my 36rc2 could benefit from some attention, as I can never get full travel, and my RS Pike is only getting about 50% Any advice?

Keep up the excellent work, mate!
  • + 1
 Thank you mate!
I too have the 36 and its just like this fork the Durolux
The ride pretty close too.

If you want a less progressive stroke for the 36 try taking out 10psi.
So, if you have her set at 90psi then try 80psi and compensate with more low speed compression.
Also the high speed compression you should try running it full open.

For me, I dont want full travel on my 36 and like all my forks stiff.
I rune the 36 with 90psi and about 15-20mm of sag but the fork is very supple.
I dont get full stroke but I like the bottomless feeling.
I think on big jumps or drops it will move about 160-165mm, I have it set at 170mm.

But try less air and if it feels soft turn up the low speed compression.


As for the Pike I dont know mate!
I need to know what year and model it is?
Is it a coil or air Pike?
Does it feel smooth but you only get 50% or do you feel it stop.

I think your pike might have too much oil in the damper side not allowing full stroke.
Its a small chamber and if the oil level was too high it will just stop where the chamber runs out of room to move.
If you feel a thump and it wont go past 50% then you might have too much oil.

But its really had to make any suggestions unless I can feel it!

RideOn mate and let me know what you think!
  • + 1
 Holy crap! Your running 90psi in your 36? How much do you weigh? I run between 45 and 50psi, depending on what trail I'm riding. I usually run only a couple of clicks of high speed damping and about 5 clicks of low speed. But I still only get about 70% of travel.

Where we live, the trails are very rocky and loose. It's often difficult to get the front wheel to track accurately, as it feels very 'nervous', especially in corners.

My DHX Air is really plush, and I'm really pleased with it. But I can't seem to get the 36 dialed in to balance out the front and rear of the bike.

Thanks for getting back to me. Cheers mate!
  • + 1
 But where as the 36 still feels bottomless, the Pike 454 (coil) feels really plush for the first half of the stroke, but then it ramps up really harshly. I never noticed it before as I used it on my training bike. But when I took it down the local rock garden trails, it felt really sketchy and unsafe. When I checked the travel, I was only getting about 50%, and that was with every thing wide open.
  • + 1
 hhhahahahhahhahahha
I weigh 90kg , hahahahaha

It sounds like you could maybe run your rear shock a little stiffer putting more balance on the front.
Also lowing the front to try and see if a little more sag could help your front stay planted.


I love my 36 and this Durolux, both ride awesome.
They track great and are very plush while staying active as well.

I think the 70% is good.
The rest is left for when your in trouble off a drop or G-out!
I G-outed on one section after a drop a while back and it actually bottomed out the 36.
If you take out the air does it get full travel?


I think your pike has too much oil in the damper.
The coil spring is just a coil and the damper side has oil and the damper.
One way to check is to unscrew the top cap on the coil side.
Then compress the fork and see if you get full travel.
If not its in the damper side and there is either too much oil or your oil is old and as you ride it foams up only giving you half of your travel.

Give it try!
Thank you mate!
  • + 1
 I'm impressed by your knowledge Niko! What you say about the Pike makes a lot of sense. I've had it about two years and only recently changed the oil in the lowers for the first time, so now the beginning stroke feels really plush. I haven't had any problems with oil leakage, and haven't gone anywhere near the damper side, so maybe the oil, as you say, is old. I'll give it a look over tomorrow morning and let you know how it goes. Cheers mate!
  • + 1
 Awesome Mark! I know its hard to do this over the net and a in person evaluation would be easy but, little by little we can get you pike in peaking order, hahahhahahha As oil gets dirty it starts foaming in systems that have air mixed in with the oil like on the pike. If its foaming really bad your lose of travel is one ailment or it just has too much oil. No leakage is a good sign. The rock oil I used in this video does a beautiful job of not foaming on me! RideOn!
  • + 1
 Good news! Did a full overhall of my Pike. Lower lube, and motion control damper service, new oil throughout and it's buttery smooth!!! Only a slight issue, but now I have no Lockout or 'gate' on the compression damping. Feels GREAT though!!!
  • + 1
 Awesome!
Sounds like you did great but if you have now lock out or floodgate that means there might not be enough oil, hahahhahahhahah
The compression on the pike is up top and if not enough oil you will have nice rebound but no compression or lockout.

However do you have full travel or at least more than 50%?
If so try adding just enough oil to get your compression and lock out on par!
You can just add little by little from the top so it should be easy.

Good job matey!

RidEOn!
  • + 1
 niko SR Suntour is going to love this one. You're vids are so well liked with all the SR Suntour peeps and even management loves watching them. Keep em coming, keep it fun. Ride On brutha!
  • + 1
 WOW really! Im super stoked Sprockets! I hope this does a good job representing the fork and its internal workings. I had tons of mails asking to do this so I did! Next they want to know how to change the travel. RideOn!
  • + 1
 this is the best video EVAR!!!! Made me laugh and very well done. the way you speak is like how some of my teachers speak from like elementary. didnt you say you work at a english teaching school?
  • + 1
 hahhaha Yes, I run an English school! Im the teacher as well, so my teaching personality comes out! I was trying to consider not everyone speaks English and know that first hand living in Japan so, was talking slow in respect to all of those who might use this to overhaul their fork! Im glad you like it! RidEOn!
  • + 1
 oh right on!
  • + 1
 You are a genius, man!!! Very easy to understand, thank you!!! I`m going to buy a Durolux! Is there any other helpfull video about this fork???
  • + 1
 Thank you brother!
The fork is awesome!

Here is one more video I did on the fork on how to change the travel.

www.pinkbike.com/video/215831


My Durolux is now over a year old and she is still in great condition.

rideOn!
  • + 1
 www.facebook.com/pages/SR-Suntour-Inc/104197452960119

your video circulating around facebook keep it man
  • + 1
 thank you buddy! I just gave it a look and thank you for the link! I had no idea but that explains how it has so many views than my other usual videos! RideOn mate!
  • + 1
 ZiggyZuggy your awesome buddy! RideOn!
  • + 1
 this 5 stars pro introduction nikosan tup I don't know what you doing tho lol but nice aria
  • + 1
 hhhahahhahah Thank you my friend! I was overhauling the damper! RideOn!
  • + 2
 This Gentleman for Tech Tuesday!
  • + 1
 Tech Tuesday's would be so much more fun with Niko on it!
  • + 1
 hhahahahahhaha Thank you mates! Im pleased you liked it! Next Tech nikoniko will have better audio for sure! RidEOn!
  • + 1
 sugoku wakari yasui setumei ! but i dont understand english!hahahaha i am foooool!hahaha
  • + 1
 hhhhahahahahha Your not a fool your just unable to understand my English! RideOn!
  • + 1
 i study english man!hahaha
  • + 1
 funny joke is need it..hehehe im always use in my class! hehheh im PE teacher
  • + 1
 Awesome brother! PE is a favorite of most students! RidEOn!
  • + 1
 hahahahah!! ur vid make me laugh a lot!! anyway ur teacher!!!??? hahhah me tooooooo hhhahaa
  • + 1
 Thank you dude!
Im funny man sometimes, ahhahahahhahhah
What kind of teacher are you?
  • + 1
 Fucking awesome tutorial! Great Job Niko! I think now I'm gonna buy this fork to use your tutorial hahahahaha.
  • + 1
 RidEOn Method man! This is a nice FR fork and can be set up to your liking! RidEOn!
  • + 1
 I'm not saying that is not a nice fork but I dont like single crownWink
  • + 1
 Single crowns are great man! But stick with what you like for sure! rideOn!
  • + 1
 Nice vid man.
Look, I have a Sr Suntour Duro, it's not the dj version. It's the 120mm one.
I really need to low the travel to 100mm at least.
Do you know if it's possible to do that, low the travel of this suspension?

Thanks Salute
  • + 1
 I would have to look it up!
I dont have the duro and mine is the Durolux and if the Duro is the same then yes.
I have mine lowered from 180mm to 135 right now.

My next video Im thinking of doing a travel change video!

What model Duro do you have?
  • + 1
 I really don't know man.
I think the working of this one:

www.all-about-the-bike.co.uk/sr-suntour-duro-dj-e-suspension-forks---free-delivery-2945-p.asp

is the same of mine because this one is to Dirt Jump and have 100mm, mine has 120mm.
It's the same model I think...
  • + 1
 No no no no, mine is 130mm not 120mm sorry.
  • + 1
 If your duro is a coil spring then it might not be able to lower it! You need to open it up and see if there are any spacers in with the spring. for example, if you open up and take out the spring and it has a 20mm or 40mm plastic or metal spacer then you can most likely lower the fork the amount of the spacer. If there is no spacer it might be impossible unless you dont mind excessive amounts of preload! RidEOn!
  • + 1
 Yes it has a spring on the left side, but any spacers.

Thanks a lot anyway man Big Grin
  • + 1
 Oh too bad, that means it might not be able to lower it! RidEOn!
  • + 1
 Thanks man, for your time Smile

RideOn Smile
  • + 1
 Wow what nice video.you are a funny guy amigo. today i learnt how to change the fork old. RideOn amigo!!
  • + 1
 RideOn Amigo! ahhahaha Im glad you liked it!
  • + 2
 Good stuff, liking the evil laugh at the start lol
  • + 1
 hhahahahha I have to add comedy to everything!
  • + 2
 Very nice work niko Pimp
  • + 1
 Thank you dude! Im glad you liked it! RidEOn!
  • + 1
 Wow brotha!! Awesome video! Is the Durolux still going strong? Excelent job on the tutorial man!

TeachOn!
  • + 2
 The Durolux is magical brother! I rode all the top forks from Marzocchi, you like your 66 well I was on a higher quality model but the durolux is just as strong and oh so smooth! Im loving this fork and expect to lots of my parts take the same evolution! Low price high quality is my new motto! RidEOn and thank you brother!
  • + 1
 So glad she's working alright brother! I was laughin' my ass off with your evil laughs, lol
  • + 1
 hhhahahhahahah I will add more evil laughs in the future brother! hahahaha Im still unable to move my shoulder and hope to start improving soon! RidEOn!
  • + 1
 Soo Nice Niko ! I Laught All The Time Haha , Thanks For The Information ! Wink
  • + 2
 hhhahahh Thank you dude! Im glad this somewhat boring video of a forks over haul made your day! ridEOn!
  • + 1
 It Was Not Boring At All Haha !
  • + 1
 Thank you man! If you ever have any questions with some work on your bike just let me know! RiseOn!
  • + 1
 Thats Good Thanks You Niko !
  • + 1
 Very informative and funny!

Good wirk bro!
  • + 1
 RidEOn mate! I like things to be a little funny!
  • + 1
 would the dirty oil make your fork stick?
  • + 1
 No! The oil is actually very protected in the oil chamber. It would get dirty after maybe 2 years of normal riding and a year of hard riding, but it would not make it stick. I actually overhauled it to add more oil to make the whole fork more progressive taking bigger hits a litter better. Also the stock oil is not as good as the rockoil which is like a butter cream for suspension, hahahahhahha The fork is superiorly smooth out of the box and still is impressing my with every ride!
  • + 1
 I have to get my fork checked . It sticks a little bit after i have it in lock-out. Its an marz 44 rlo with air .
  • + 1
 I good over haul of the tst on your 44 might help things out!
actually the tst damper on your 44 is 85% the same as this damper and the same method as I have explained here would get you through the over haul.

But, what I dont understand is your fork is running smooth, you lock her up ride it and then open the damper again experiencing some form of stiction.
After riding her a bit she then becomes smooth again?

I wonder and would not know unless it was in my hands but, if you want to over haul it I could walk you through the procedure.

RideOn!
  • + 1
 It just sticks a little bit after it has been in lockout. I have to take it to the LBS to get the sasquatch checked out . It works good but needs to be checked after a year of use.( 2010 model year) It is alot more squishy then my old Marz Z1-wedge (2002) was.
  • + 1
 sounds good! Just a little stiction isnt bad unless its really hindering your ride! Get her check out and they might be able to help you! 2002 they had some killer forks! But Im sure the new 44 is much more advanced! RidEOn!
  • + 1
 The Fork is Sweet now ...............Just needed Air.
  • + 1
 hhhhhahhaahahahhaha your killing me buddy!
  • + 1
 Your work is bicycle mechanic? How much bicycle overhaul ?
  • + 2
 hhahahhahahahhahah I will overhaul you bike for free!
  • + 2
 Once you overhaul my bike, I would give you a donut two donut, three donut!
  • + 1
 OK!!!!! Im Happy!
  • + 1
 niko you know your stuff man! great tutorial =)
  • + 1
 Thank you mate! Im going to have to more as I do all my work at home!
  • + 1
 Wow you no alot about bikes!
  • + 1
 ahahhahhaha Im a bike geek!!! RidEOn Shane!
  • + 1
 That is a great Video where did you get your knowledge on forks from?
  • + 1
 from years of being a geek! hahahahaha I worked on electronics through high school and collage. I use to work in a shop that would repair anything. We never had manual or instructions on how to fix a product. So, with logical thinking on what the aliment was for each electronic we were able to fix anything. My father was also a mechanic and was always repairing anything under the sun. With this background I have been able to grasp the knowledge of how suspension works. For the last 8-9 years I have been rebuilding my forks and rear shocks as my style and weight does not really work for the norm here in Japan. I have been able to configure new settings that work for me and get out on the trails in style! Thank you Brett and I hope to get to know you better! RideOn, Niko
  • + 1
 Really good info, nicely done. Thank you!
  • + 1
 Thank you mate! I hope it helps you when the time is needed! RidEOn!
  • + 1
 Hahaha, you're going to put the bike shops out of work! DIY rules!
  • + 1
 Hahahah Thats not my intention! I have self trained myself through my education growing up. I have somehow grasped the understanding of how suspension works and put it through a simple process that works. Every fork or rear shock I have overhauled for riders in my realm has said its perfect. Im blown away at this, ahhahahahhaha Because I randomly choose all the settings for their bike's ratio, body weight and riding style. As for me Im very stable working on my products but never would like to take work from the professionals. RideOn mate!
  • + 1
 hahaha loving the new vid mate i need to do mine soon
  • + 1
 Thank you mate! Sorry for the boring video but I got some messages on how to change the oil on the durolux so I made a video! RidEOn!
  • + 1
 Not only does it use shims but there are two shim stacks one for the compression and the other for the rebound. Very nice dampening and nothing close to the VF which I have worked on many times. You saw in the video I pulled out the compression shims before draining the oil! Plus the shims are in a stack and I have no need to open them up, hahahahhah The Honey grease is very soluble and acts like oil in the lowers. I dont like opening a fork and dealing with dirty oil so the Honey grease is awesome. Everything stays very lubed and there have never been any problems for me anyway. Also there is oil in the damper which lubes the rod every time its compressed, just like a rear shock! The fork is awesome buddy! Its no different than my 36 and rides just as smooth! The system is also the same as the 55 tst, the damper disassembly is also the same, ahhahhahah Suntour is just unknown for their aftermarket products and once enough info gets out that might change. Im confident enough to replace my 36 with these when the time comes, And my double takes just as much of a beating as well, ahhahaha RidEOn bro!
  • + 1
 Hey, great video, very funny and nice presentation but I have to share this... When you opened the fork, you drained some oil out of the lowers, but when reassembling you didnt put any oil in it, just lubricated the rebound shaft with grease. In my opinion that is not very smart, while you need some bath oil in the lowers also to lubricate the stanchion sliders. The rebound damper shaft doesnt need to be lubricated from outside, because it is taken care of from the inside but you need to take care of your bushings. Unless you open your fork every month and grease up foam ring under the dust wipers your fork would seize up destroying bushings and stanchion sliders and create play. Monkey Control
  • + 1
 The slick honey does a good job keeping the stanchions slick and smooth. I dont put oil in the lowers as it just to lube the inner legs and seals. So, if your fork feels sticky you just add some external grease or oil to the seals and stanchions then cycle the fork. Wipe off the excess and your ready to go! Before assembling the fork I put lots of grease on the seals which stays on there great. The slick honey is amazing and other grease might not work as well. Im really sad I cant find it anymore. So, if you dont have slickhoney then yes, a good amount of oil 30-50 ml will ensure a smooth ride. Thank you for the impute! RideOn!

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