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Hi, I have rebuilt an Ultra Headshok from a 2002 F600 and it's working ok but not great because the lockout/pre-load washers had been mangled at some point and don't work 100%, even after my attempts at repair. See attached pictures This might be a long shot but does someone have any washers...

I'll have a look. Need to take the forks from the frame first.

I have one. I had to decommission my old Jeykll as the frame developed a crack between the top tube and seat tube but the rear forks are fine. The only trouble is that I am in the UK and I think you are in the US so I am not sure of the practicality of getting it to you. PM if you think its...

Mike A, thanks for the reply. Pics attached showing some evidence of damage to the lockout shims - hopefully recoverable if I can dismantle it. Otherwise shaft and pistons (air & oil damper) look ok. What I am stuck on is this step in the MTBR instructions: "Disassembly: Sorry to say, you...

Update: forks now back in the (replacement) frame, oiled up and pressurised. All good so far but still getting the transmission sorted so haven't actually ridden it to proof test it. But very optimistic. I have turned my attention to the other bike & forks - F600 with Ultra forks from about...

Victor, Mike, Thanks very much. That's clear now. I haven't taken the piston assembly apart to get access to the top cup and it doesn't sound as if I really need to, so I'll replace the outer lower cup seal with a blue one and keep the other as spare. I'll use the larger o-ring in place of #8...

I understand that is the only seal kit available at the moment so it is a matter of making do and finding workarounds. Certainly I haven't been able to find the HD166 in stock anywhere closer than Salt Lake City (eBay) and Australia (Cycleclinic)! Just to clarify, I have found the correct air...

Hi everyone, I am in the process of servicing a couple of Headshocks. Working on the Super model first - this is off a 2001 Jekyll and the guide from Victor at the beginning of this thread has been super useful. However, I have a couple of queries for things I can't work out at the moment...

An update: I now have the tool from Bitul via Ebay. It was dispatched very quickly but got held up in UK Customs (Brexit problem?) until now, so it took a total of about 3 weeks. I also have the seal kit from Race Ready Ltd (Bits4bikes on Ebay) so I will have a go over the next couple of days...

OK, Michal has confirmed that the only difference between FK071 and FK072 is the tool height and the FK072 shortness can avoid fouling on some forks. As my air cartridge is about 22mm below the edge of the steerer tube, I've ordered the FK072 as the 29mm tool height should be sufficient. I'll...

Thanks MikeA, that's really useful. I'm just trying to confirm similarities & differences with Mikael at Fitul before going for one or the other but I think he must be away for the Easter weekend. His initial recommendation was the FK071 but with the plea to check dimensions which is hard when...

Many thanks both, I'll follow up as you suggest. I've also been in contact with Michal from Bitul in Poland and he has asked for some more dimensions of the fork which I will do later today. I'll report back when I've come to some sort of conclusion.

Hi, I've been doing some more research and reading the small print about the Bitul castle tools. For the 2001 vintage headshocks I think I am after the FK072 model. https://www.ebay.co.uk/itm/284559081430?hash=item42410affd6:g:JS8AAOSwh3Bhr28i and...

Hi everyone, This is my first post; glad to be here. I am trying to revive a couple of Headshocks I have from bikes that I bought in about 2001 (a Jekyll and an F600 Furio hardtail) One Headshock is a Super (disk brake only), the other an Ultra (disk and v brakes). Both have the air valve...