Lockout knob for Zoom suspension fork

Motivation

• lost the original knob before taking measurements

• designed for Zoom 188DS AMS, may work with others

Design

• stumbled upon this repair video: Suntour Fork Lockout Repair

• turns out there's a tiered & splined plastic piece that features a press fit 4 mm hex rod

• hex rod actuates the lockout

• it feels like the hex rod is grabbed by some internal mechanism lightly to retain it axially

  • as of rev 4, there is no designed feature to further retain the knob axially – use at your own risk

• as of 2023-09-11, still under development

  • design recycles the hex rod which is about 30 mm long

  • I used an arbor press to liberate it from the OEM plastic part & to install it into my PLA part

Rev 4

• added 2023-09-16

• seems to work well

• rode 100 miles or so without it falling out, hitting some rougher bumps

Prior art

• similar part on Thingiverse

• Suntour lock lever overview with views of different actuation possibilities