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DT Swiss Forks.
NB: Originally posted elsewhere on the Global Riders Network and appears via syndication.
I just finished fixing my XRC 100 forks. There's not much info on the internet about them so if you need some tips I might be able to help you out.
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Why don't you just tell the story now? Include some pics? That way there will be some info on the Internet to help everyone?
I've already put the forks back together. There's some tricks involved in pulling the damper out and putting it back in again.
I have the same forks. I got to the part where they tell you to unscrew the lowers with a 4mm Allen key.
Only mine didn't have a 4mm allen key but a nut holding a threaded bolt which I could undo with a small Allen key. And that's as far as I got. Even with all the bolts undone the lowers wouldn't come off.
I decided then that it wasn't for me and brought them to my favourite LBS to send to DT to do a service.
Heard back from them a couple weeks later, saying that there was something wrong with them and they've sent them to Taiwan. They've had them now for over a month and can't seem to figure out what's wrong with them but apparently they're not holding oil.
Ironically they were riding beautifully before I sent them away.
To be fair to DT, they sent me some XRM100s as loan forks in the meantime. Nice piece of kit by the way but still looking forward to getting the XRCs back as they're much lighter. (plus the white XRMs look really crap on my black Blur).
anyway, if I ever get them back I would really like to know how to take them apart for the next service. Have got motorex oil and seals ready to go.
On mine, you use a 4mm allen key and you turn it clock-wise, (they screw inwards). You do both sides about 10 turns. Then the lowers just slide off. If you want to remove the damper, unscrew cap the top of the fork, you need a special tool but I did it with some internal circlip pliers. The blow-off part is at the top and has a thread about 5cm from the top, which unthreads as you screw off the top, so to do it up you have to have the lowers off the forks. The tricky part is getting the oil in the top and bottom. I used about 60ml in the damping part. You have to put it nearly all back together but leave the damping unit about 25mm out the top. Add the oil, whilst pumping it a bit to get out the bubbles, then slide the rest of the damper in and screw it up.