ASSEMBLY INSTRUCTIONS

Assembly Instructions for the PUSH HC-97 Kit

PUSH Industries 1
Safety Warnings
Warning!
The front forks are an important part of your bike. Before installing and using your new HC97 Compression System, please visit
https://www.pushindustries.com/pages/hc97-support to learn the correct installation and adjustment procedures of the forks. Improperly
installed and/or adjusted forks can cause serious harm or death and may severely damage your bicycle. Broken or malfunctioning forks may
cause loss of bicycle control and result in SERIOUS INJURY OR DEATH. If the fork ever loses oil, air or makes unusual noises, stop riding and have
the fork inspected by PUSH or a PUSH Authorized Tuning Center. Modification, improper service or use of aftermarket replacement parts voids
the warranty and may cause the fork to malfunction, resulting in loss of bicycle control and SERIOUS INJURY OR DEATH. Do not modify your bike
frame or fork. Use only genuine PUSH HC97 parts. Follow service maintenance recommendations. Fork service should be performed by PUSH or
a PUSH Authorized Tuning Center. Visit pushindustries.com or contact us at (970)-278-1110 to locate a PUSH Authorized Tuning Center. Never
apply heat to any part of the fork. The PUSH HC97 is manufactured exclusively for the fork model for which it is ordered. Switching the fork
between different bicycles may not only decrease the fork performance but might also cause damage to the bike and can result in SERIOUS
INJURY OR DEATH. Always contact PUSH or a PUSH Authorized Tuning Center to verify compatibility before switching a fork
from one bike to another.
Warranty
PUSH Suspension Warranty
PUSH Industries Incorporated, hereafter referred to as PUSH, a Colorado corporation having offices at 1520 Taurus Ct., Loveland, CO 80537.
PUSH makes the following LIMITED WARRANTY with respect to its suspension products.
PUSH LIMITED WARRANTY LIMITED ONE (1) YEAR WARRANTY ON SUSPENSION PRODUCTS.
Subject to the limitations, terms and conditions hereof, PUSH warrants, to the original retail owner of each new PUSH suspension product, that
the PUSH suspension product, when new, is free from defects in materials and workmanship. This warranty expires one (1) year from the date of
the original PUSH suspension product retail purchase from PUSH Industries, any PUSH Authorized Dealer, PUSH Authorized Factory Tuning
Center, or PUSH Authorized Distributor unless otherwise dictated by requirement of law.
TERMS OF WARRANTY
This warranty is conditioned on the PUSH suspension product being operated under normal conditions and properly maintained as specified by
PUSH. This warranty is only applicable to PUSH suspension products purchased new from an authorized PUSH source and is made only to the
original retail owner of the new PUSH suspension product and is not transferable to subsequent owners. This warranty is void if the PUSH
suspension product is subjected to abuse, neglect, improper installation, improper or unauthorized repair, improper or unauthorized service,
maintenance, alteration, or modification (to include, but not limited to, using any spring that is not PUSH authorized), accident or other
abnormal excessive, or improper use. Should it be determined, by PUSH in its sole and final discretion, that a PUSH suspension product is
covered by this warranty, it will be repaired or replaced, by a comparable model, at PUSH’s sole option, which will be conclusive and binding.
THIS IS THE EXCLUSIVE REMEDY UNDER THIS WARRANTY. ANY AND ALL OTHER REMEDIES AND DAMAGES THAT MAY OTHERWISE BE APPLICABLE
ARE EXCLUDED, INCLUDING, BUT NOT LIMITED
TO, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR PUNITIVE DAMAGES.
This limited warranty gives the consumer specific legal rights. The consumer may also have other legal rights which vary from state to state or
country to country. Some states and countries do not allow the exclusion or limitation of incidental or consequential damages or warranties, so
the above limitations or exclusions may not apply to you. If it is determined by a court of competent jurisdiction that a certain provision of this
limited warranty does not apply, such determination shall not affect any other provision of this limited warranty and all other provisions shall
remain in effect.
THIS IS THE ONLY WARRANTY MADE BY PUSH ON ITS SUSPENSION PRODUCTS AND COMPONENTS, AND THERE ARE NO WARRANTIES THAT
EXTEND BEYOND THE DESCRIPTION HEREIN. ANY WARRANTIES THAT MAY OTHERWISE BE IMPLIED BY LAW INCLUDING, BUT NOT LIMITED TO,
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED

Safety First!
Proper safety gear should always be used when servicing or installing
suspension components.

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 Tools Required Safety Equipment

- Bench Vise - Safety Glasses

- Soft Jaw Tube Clamps - Nitrile Gloves
- RockShox Bleed Adapter - Oil Pan
- T10 Torx Driver - Lint-Free Rags
- 10mm Wrench
- 15mm Cone Wrench
- Adjustable Wrench Greases & Fluids
- 5mm Hex
- 2mm Hex
- 5wt Suspension Oil
- 1.5mm Hex
- PUSH SOS Lube
- 10mm Socket
- Blue Loctite 243
- 32mm Chamferless Socket
- Torque Wrench
- Socket Wrench
- 10” Socket Extension

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 VISUAL INSTRUCTIONS

STEP 1:

a. Your new HC-97 Compression

assembly comes out of the box
partially assembled. Some stock
components of your Damper are
reused. Refer to the “Charger II
Disassembly” procedure for more
information.

STEP 2:

a. Use a 2mm Hex to remove the M3

screw retaining the Blue Low Speed
Knob.

b. Remove and set aside the Low Speed

Knob and screw.

STEP 3:

a. Use a 1.5mm Hex to loosen and

remove the two M3 set screws in the
Black High Speed Knob.

b. Remove and set aside the High Speed

Knob and screws.

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 STEP 4:

a. Unthread the black Top Cap counter-

clockwise from the silver Compression
Tube.

STEP 5:

a. Align the stock Bladder with the

Compression Tube.

b. Apply a light film of SOS Lube to the

inside of the Bladder.

STEP 6:

a. Starting at the small diameter end of

the Compression Tube, slide the
Bladder upwards.

b. Slide the bladder up until it locks into

the gland below the threads on the
Compression Tube.

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 STEP 7:

a. Prepare the stock Compression Bolt,

Check Shim and Spring for re-
assembly.

b. Ensure the larger diameter of the

conical Check Spring is against the
Check Shim as shown in the visual.

STEP 8:

a. Mount a 10” socket extension with a

10mm socket into a vise.

b. Place the complete Compression Bolt

assembly from STEP 7 into the socket.

c. Slide the Compression Tube over the

Bolt and extension.

STEP 9:

a. Pinch the threaded end of the

Compression Bolt with your hand and
lift the assembly upwards a few
inches.

b. Rotate the Cartridge Tube to ensure

the Bolt is still fully seated in the
Valve.

c. Use a dental pick to lightly press the

shim downward to ensure the Check
Shim can open and is not pinched in
the assembly.

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 STEP 10:

a. Slide the Compression Bolt back into

the socket.

b. Add a small drop of Blue Loctite 243 to

the Compression Bolt

c. Thread the HC-97 Compression

assembly from STEP 6 onto the
Compression Bolt. Use care in order to
avoid cross-threading the bolt.

STEP 11:

a. Gently pull up the Bladder to expose

the wrench flats on the silver HC-97
Compression Tube

b. Use a 15mm cone wrench to tighten

the Compression Tube until it is snug.

STEP 12:

a. Apply a light film of SOS Lube to the

Outer Diameter of the Bladder near
the top edge.

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 STEP 13:

a. Push the HC-97 Top Cap onto the

assembly and thread the Cap
clockwise.

b. Thread the Top Cap until it has a firm

stop.

c. Use a 32mm chamferless socket to

torque the Top Cap to 5.1Nm (45in-lb)

STEP 14:

a. Ensure the bottom of the Bladder is

engaged into the gland of the
Cartridge Tube.

b. Apply a light film of SOS Lube to the

outside of the Bladder near the
bottom edge.

STEP 15:

a. Hold the Bladder in your hand and

thread the Red Lock Ring onto the
Cartridge Tube.

b. Thread the Lock Ring on until there is

one thread of the Cartridge Tube
showing.

*Note: there is no hard stop for the Lock

Ring, and threading past three visible
threads can damage the Bladder.

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 STEP 16:

a. Clamp the Rebound Assembly into a

10mm soft jaw vise.

b. Use a 10mm wrench or socket to

remove the Piston Nut.

c. Remove the stock shim stack from the

top of the Piston.

STEP 17:

a. Select the Rebound code that best

matches your rider weight from the
Tuning Guide on the PUSH website.

b. Use a caliper or ruler to identify the

shims by the outer diameter.

c. Align the Shim Stack according to the

Tuning Guide.

STEP 18:

a. Install the Shim stack onto the piston.

Ensure the largest diameter shim is
against the face of the piston.

b. Replace the Piston Nut and torque the

Nut to 3.7Nm (33in-lb).

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 STEP 19:

a. Ensure that the Check Shim on the

opposite side of the Piston is not
pinched.

b. Use a finger nail to lightly bend open

the shim. The opening pressure should
be consistent around the whole
diameter.

STEP 20:

a. Lightly clamp the Cartridge Tube

assembly into the vise using the
wrench flats.

b. Fill the Tube with 5wt suspension oil

until it is full.

STEP 21:

a. Thread the Rebound assembly into the

Cartridge Tube.

b. Torque the Seal Head to 5.1Nm (45in-

lb)

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 STEP 22:

a. Insert the stock Rebound knob into

the end of the Rebound Shaft.

b. Turn the Knob counter-clockwise until

it stops to fully open the low-speed
rebound.

c. Remove the Knob

STEP 23:

a. Draw 5wt Suspension Oil into the

RockShox Bleed syringe until it is half
full.

Note: Do not use bleed syringes that

have also been used with DOT brake
fluid. The brake fluid can break down
the internal seals causing the damper
to fail.

STEP 24:

a. Use a T10 torx driver to remove the

Bleed screw in the Seal Head.

b. Screw the Bleed Syringe adapter into

the bleed port.

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 STEP 25:

a. Pressurize the system by depressing

the syringe.

b. Continue to apply pressure with the

syringe.

c. Cycle the Rebound Shaft up and down

until all the air bubbles have escaped
the Cartridge Tube.

STEP 26:

a. Fully extend the Rebound Shaft.

b. Release the pressure of the syringe

and allow the bladder to equalize and
reach a resting position.

STEP 27:

a. Unthread the Bleed Adapter. Caution

some oil will escape when the Adapter
is removed.

b. Insert the Bleed Screw and tighten it

to 1.1-2.3Nm (10-20 in-lb)

c. Wipe the excess oil with a clean rag.

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 STEP 28:

a. Remove the Damper from the vise and

cycle the Rebound Shaft by hand.

b. The damping should feel consistent

with no gaps in force.

c. If the Damper feels inconsistent, the

bleed process may need to be
repeated until all the air is removed.

STEP 29:

a. Thread the Damper into the crown of

the fork.

b. Tighten the Damper with a 32mm

chamferless socket.

STEP 30:

a. Re-install the High Speed Knob.

b. Apply Blue Loctite 243 to the set

screws.

c. Ensure the set screw holes are aligned

with the flats on the silver Barrel.

d. Use a 1.5mm Hex to tighten the set

screws with even pressure on both
sides.

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 STEP 31:

a. Re-install the Blue Low Speed Knob.

b. Apply Blue Loctite 243 to the counter-

sunk screw

c. Use a 10mm wrench to hold the knob

in place, then tighten the screw with a
2mm hex.

STEP 32:

a. Complete the Lower Fork Service

procedure. Refer to the ACS-3
instructional video for details.

b. To learn more visit:

https://www.pushindustries.com/pages/a
cs3-support

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