Step 1

Remove the Saddle Clamps and hardware. Turn the 4mm hex bolts counter-clockwise to remove them from the Saddle Clamp Nuts. Set all clamps and hardware aside.

Step 2

Clean your bike work stand clamps and the exterior of the seatpost to prevent damage during clamping. Clamp the seatpost in your workstand, then unthread the Lower Post Collar by turning it counter-clockwise by hand. If too tight to unthread by hand, you may use channel lock type pliers with a shop rag to protect the collar from damage. Remove the o-ring under the collar.

Step 3

Unthread the Bottom Cap counter clockwise to remove it from the lower post.

Step 4

Separate the Upper Post Assembly from the Lower Post. Take note of the position of the ball bearing in the base lug and mark the anti-rotation hole that the ball bearing was found in. This is in case the ball falls out during service.

If you use a Sharpie or other marker to make this mark, take care not to remove the mark as you clean parts throughout the rebuild. A scribed line is also an option for marking the position of the ball bearing.

Remove the keys and index pins.

Step 5

Clamp the Upper Post Assembly in your bike stand. Remove the Pushrod from the bottom of the Shaft. Using a T25 torx to hold the Shaft in place, unthread the Base Lug counter-clockwise from the Shaft using a 10mm wrench.

Step 6

Remove the Lower Bushing followed by the Lower Bushing energizer o-ring, Top Out Washer, and Collar assy.

Step 7

To replace the Dust Wiper use a flat screwdriver with a twisting motion to lift up on the Wiper.

Step 8

Setting the Collar Assembly against a table, use a pick to remove the retaining ring that sits between the Bushing Carrier and Collar.

Step 1

Install Upper Bushing Carrier Assembly from kit into your Post Collar. Hold Collar against a flat surface and reinstall your reatining ring.

Step 2

Install new wiper seal/anti-rattle ring assembly from the kit. Bend old Lower Bushing so it fits around Wiper and use a soft jaw vise to press Wiper Seal into Collar Assembly. The top of the wiper flange must sit flush with the top of the collar.

Step 3

Pack the new wiper with Slick Honey, then reinstall Collar Assembly onto Upper Post, followed by Top Out Washer

Step 4

Install new greased Lower Bushing Energizer O-Ring and new Lower Bushing from kit. Orient Bushing split to side of the post.

Step 5

Remove the black air cap at the top of the post by turning it counter-clockwise with a 10mm socket. Charge the post to 275-325psi. Reinstall the Air Valve Cap finger tight with a 10mm socket.

Step 6

Reinstall the Base Lug, threading it clockwise onto the shaft. Hold the Base Lug in place with your 10mm wrench while you tighten the shaft COUNTER-CLOCKWISE into the Base Lug, tightening (counter-clockwise) to 30in-lb (3.4Nm) torque. Reinstall the Push rod after torque.

Step 7

Coat the entire upper post below the collar and the top 2.5" of the inside of the lower post with a thick (clump-level) film of Slick Honey. Install the Index Pins and Travel Adjust Keys.

Step 8

Rotate the base lug so that the ball aligns with the back index pin.

Align the ball bearing with the groove in the inside of the Lower Post that is closest to the laser etching on the back of the Lower Post. Align the back of the upper post (higher of the two saddle mounting tabs) with the laser-etching on the back of the lower post. Slowly feed the Upper Post Assembly into the Lower Post. 

Note: Increased force may be required to install the upper post into the lower post as the lower bushing is energized by the o-ring.

Step 9

Thread the Actuator into the end of the Lower Post. Tighten the Bottom Cap clockwise using its thickest part to 40 in-lb (4.5 Nm) torque.

Step 10

Install the Lower Post Collar tightening clockwise until hand tight. Reinstall the Lower Post Collar O-ring.

Step 11

Reinstall the Saddle Clamps making sure all arrows face the front of the post. Clean the exterior of your post with Isopropyl alcohol.