Step 1

Need to note location and orientation of rebound knobs/shaft end eyelet as well as air valve.  Confirm orientation of the two decals with dots are aligned before any disassembly.

Step 2

Note: Turning Firm Mode lever (if equipped) to clockwise closed position helps keep the shock extended to avoid compressing beyond transfer port to avoid stuck down. Remove the black air cap and thread on your FOX shock pump. Slowly release all air from the main air chamber with your pump making sure the shock does not compress beyond the transfer port to avoid it being stuck down, then remove the pump. Verify that all air has been released by depressing the Schrader valve.

Step 3

Push XV sleeve down away from retaining ring. Rotate the wire retaining ring to align the opening in the ring with the tab on eyelet. Use a pick to remove the ring.

Step 4

Notice: Remove the rebound knob or apply a strip of tape over it to prevent the inside of the XV sleeve from getting scratched, which can cause air leaks.

Slide the outer air sleeve away from the negative air sealhead to remove. 

Step 5

Use the X2 air sleeve clamps (PN: 803-04-354) to hold the inner air sleeve while you remove the negative air sealhead with the sealhead tool (PN: 398-00-419) and then the shaft eyelet with Knipex pliers or the eyelet torque tool (PN: 398-00-280).

Step 6

Unthread the Rezi Fill Air Cap counter-clockwise with a Schrader Valve Stem tool then set aside. Release the IFP pressure by depressing the valve stem inside the Reservoir End Cap.

Step 7

Push the Reservoir End Cap into the Reservoir to gain access to the wire retaining ring. Remove the wire retaining ring with a thin shim then set aside. Use a small hex wrench to lift the Reservoir End Cap out from the Reservoir.

Step 8

Unthread the Bleed Screw counter-clockwise with a T8 Torx. Drain the damper oil out over a waste oil basin by cycling the shock with the bleed port facing down into the waste oil basin. You can use the Shaft Eyelet to help you cycle the shock if needed.

Step 9

Clamp the Body Eyelet in your soft-jawed vise then remove the Bearing Housing Cap and any Travel Spacers (if present) by unthreading counter-clockwise and removing the two screws with a 2mm hex wrench. 

Step 10

Use the Bearing Housing Driver (PN: 398-01-191) to unthread the Bearing Housing Counter-Clockwise. Lift the Shaft Assembly out of the Body then remove the Sleeve Assembly. Pour any oil out from shock body.

Step 11

Use the IFP depth setting tool to remove the IFP by engaging the protrusion of the IFP with the tool then turning the tool 90 degrees. Lift up on the tool to remove the IFP from the reservoir.

Step 12

Unthread the set screw in the 2Pos lever by turning it counter-clockwise with a T10 torx. Remove the 2Pos from the eyelet. Note: turn HSC adjuster at least 1 click clockwise before unthreading DSC Endcap.

Step 13

Clamp shock using Damper Body Clamps 803-04-355. Use a flat drive to carefully lift up the DSC Housing Cover and remove O-ring. Use the 12 Pin Spanner Socket (PN: 398-01-194) to unthread the DSC Endcap counter-clockwise from the eyelet then set it aside.

Step 14

Using a 6mm L Hex to slightly angle and then pull out the DSC Cartridge from within rezi.

Step 15

Remove the Firm Mode Piston using your Firm Mode Piston tool (PN:398-01-190) by unthreading it counter-clockwise. Be careful not to lose the Firm Mode Butterfly Valve and Spring Washer.

Step 16

Remove Firm Mode Adjust Shaft being careful not to lose ball bearing and spring detents.

Step 17

Clean the Damper Body and Clamps with Isopropyl alcohol. Clamp the Body in your Damper Body Clamps (PN:803-04-355) then heat the body area of the eyelet to break down the Loctite. Unthread the Body counter-clockwise from the Eyelet. Take care as the eyelet may be hot!

Step 18

For P-Se an F-S only.

Clamp the eyelet assembly then loosen up the HSR Adjust Clamp set screw with a T10 torx. Use a 1.5mm hex key to turn the HSR adjuster shaft clockwise (causing the HSR knob to also turn), which will unthread the HSR Adjust Clamp. Remove HSR clamp, Leaf Springs and VVC Plate.

Step 19

Unthread Piston bolt using a 16mm socket for F-S/P-Se or a 15mnm socket for P-S.

Step 20

Pull the Rebound Rod out from the Shaft. Remove the Bearing Assembly by pulling it up off of the shaft, followed by Bearing Housing Cap, MCU Bumper and Bottom Out O-ring. 

Step 21

Clean the exposed shaft and clamps with Isopropyl alcohol then dry it with a lint-free paper towel. Invert the shock, then carefully clamp the shaft in your clamps (PN: 803-00-805).  Heat the shaft/eyelet junction with a torch to loosen the Loctite. Unthread the eyelet counter-clockwise to remove. 

Step 22

Remove Compression Valving, Main Piston, and Rebound Valving from Piston Bolt

Step 23

Note: The next two steps only need to be performed if changing the bleed shim.

Use a T25 to hold the HSR Adjuster Shaft to unthread the HSR Adjuster Nut counterclockwise using a 8mm 12point deep socket.

Step 24

Remove HSR adjuster nut, spring washer, valve and bleed shim.

Step 1

Use a plastic pick to replace the all seals on the Bearing Assembly,  with new greased ones from the kit. Verify that the o-rings within the Bearing Assembly have been seated properly. Also replace the Topout Bumper and Back up rings.

Step 2

Use a plastic pick to replace the seals and back up rings on the Neg Air Sealhead with new greased ones from the kit.

Step 3

Use a plastic pick to replace IFP o-ring with a new greased one from the kit. Replace the o-rings on the Reservoir End Cap, Air Fill Cap and Bleed screw with new greased ones from the kit.

Step 4

Clean shaft threads and apply Loctite activator 7649 and red Loctite 277 to 2-3 threads of the Outer Shaft making sure not to get Loctite on the Inner Shaft.

Step 5

Carefully thread on the eyelet to shaft observing any binding.  If there is any binding, turning the HSR knob slightly might be necessary to avoid damaging the gear parts.  When the shaft and eyelet are snug turn the HSR knob by hand to ensure it turns freely before torquing the eyelet. Clean the shaft with Isopropyl alcohol and a lint-free paper towel then clamp in your 1/2" shaft clamps. Tighten the Shaft Eyelet clockwise to 245 in-lb (27.68 Nm) torque with your Eyelet Torque Tool.

Step 6

Install a new bottom out bumpers and Bearing Housing Cap (Important: Note orientation of countersink holes). Coat the seals of the Bearing Assembly with a thin film of Slick Honey, then reinstall the Bearing Assembly onto the shaft using 1/2" Shaft Bullet (PN:398-01-253) as shown. Reinstall Rebound Rod into shaft after replacing O-ring with new greased one from the kit.

Step 7

Ensure Rebound Rod is fully seated in the Cam Slot by turning HSR knob to make sure the rod turns and turning the LSR knob counter-clockwise while pushing in on the rebound rod and the knob stops.

Step 8

Reinstall bleed shim, valve, spring washer onto Piston Bolt.

Step 9

Install HSR Adjuster Shaft and thread on HSR Adjuster Nut. Torque to 15in-lb (1.7Nm) using a xx socket and a T25 to hold the HSR Adjuster Shaft.

Step 10

Thread on Piston Bolt and torque with 16mm hex(F-S/P-Se) or 15mm(P-S) to 80in-lbs(9.0Nm) without the VVC Plate in place.

Step 11

Only for P-Se and F-S 

1. install VVC Plate
2. Run down HSR clamp and leaf springs using a 1.5mm hex.
3. Obtain qty 2 .0031" thick valves (example 044-03-080).
4. Locate holes on VVC plate in middle of VVC range.
5. Place 1 valve on either side between VVC plate and .900 valve and aligned with holes from step 4
6. Adjust HSR adjuster shaft so the VVC adjuster nut turns freely and and there is no preload on the leaf valves.
7. Adjust the HSR knob clockwise 1 click at a time until the leaf springs are aligned to the holes in step 4 when torqued to the specification on the leaf valve stack. Note: Each VVC leaf valving assembly has its own torque specification.
8. Torque m3 fastener in HSR adjust clamp to 15in/lbs.
9. Remove .0031" shims

Note: HSR VVC Leaf Valves orientation is critical and can be found here»

Note: Turn HSR knob and ensure the VVC clamp nut rotates freely through the range of travel in the VVC plate

Step 12

Replace the eyelet o-ring with one greased one from the kit. Clean threads of body with alcohol. Apply Loctite activator 7649 and red Loctite 277 to 2-3 threads for a full 360 degrees on the body. Reinstall the Body on the eyelet assy tightening clockwise by hand. Clamp the Outer Body in your shaft clamps, then use the Eyelet Torque Tool to tighten clockwise to 35ft-lb (47.5 Nm) torque.

Step 13

Reinstall your Firm Mode Assembly and torque to 160in-lb (18.1Nm) ( using your Firm Mode Piston tool (PN:398-01-190). Tip: Using an 8mm fork damper shaft helps center and drive in the lock out piston. Install Firm mode lever and verify detents function properly.

Step 14

Replace the O-rings on the HSC Adjust Shaft and DSC housing Cap. Reinstall your Base Valve Assembly and torque to 20Ft-lbs (27Nm) using your 12 Pin Spanner Socket (PN: 398-01-194). Reinstall Housing Cap Cover. Note: HSC needs to be not at minimum setting.  Suggest middle of range or closed.

Step 15

Install a new Sag Indicator O-ring from the kit onto the body.  Coat the seals with a thin film of 20 wt. Gold oil then reinstall the Neg Air Sealhead onto the Body using damper body Bullet (PN:398-01-252) as shown. Reinstall any Negative Air Volume Spacers if present. Reinstall Inner Air Sleeve. 

Step 16

Reinstall the rebuild Shaft Assembly into the Body. tighten clockwise torque with the Bearing Housing Driver (PN: 398-01-191) to 30Ft-LB(40.7Nm).

Step 17

Coat the IFP with a thin film of Slick Honey then reinstall into the Reservoir with the Bleed Screw facing up. Reinstall the wire retaining ring.

Step 18

Thread the Fill-Machine adapter clockwise into the bleed port. Vacuum the shock, then fill with FOX 4wt. oil. Using your IFP depth setting tool (803-00-566), set the IFP depth as follows:

• Transverse Reservoir (all sizes): 39 +/-1.25mm (1.535 +/- 0.05 in)
• Parallel Reservoir (250mm Eye to Eye): 45 +/- 1.25 mm (1.772 +/- 0.05 in)

Reinstall the set screw with a new greased o-ring from the kit and tighten to 10 in-lb (1.1 Nm).

Step 19

Remove the wire retaining ring from the Reservoir. Coat the o-ring of the Reservoir End Cap with a thin film of Slick Honey then reinstall into the Reservoir. Push the End Cap down then reinstall the wire retaining ring.

Step 20

Use a small hex wrench to align Reservoir End Cap ( port pointed towards rebound end of shock for transverse rezi and parallel to shock axis for parallel rezi). Install the Rezi Fill Adaptor (PN:803-04-357) by threading it in clockwise. Set the IFP pressure to 150 psi. Remove the Fill Adaptor and reinstall the Rezi Fill Air Cap with a Schrader Valve tool, tightening clockwise to 3 in-lb (0.3 Nm) torque. 

Step 21

Apply 2cc of FOX 20wt. Gold oil onto the Bearing Assembly then reinstall the Inner Air Sleeve as shown. Thread the Shaft Eyelet clockwise onto the Inner Air Sleeve then clamp the Shaft Eyelet in your soft-jawed vise. Tighten the Neg Air Sealhead clockwise to 22ft-lbf (29.8 Nm) torque. 

Step 22

Reinstall any Positive Volume Spacers. Coat the air seals in a thin film of Slick Honey then reinstall the outer air sleeve with the air valve side first. Remove the rebound knob or apply a strip of tape over it to prevent the inside of the XV sleeve from getting scratched, which can cause air leaks. Slide the outer air sleeve all the way to the negative air sealhead to engage the air seals. Reinstall the wire retaining ring making sure that it is fully seated in its groove.

Step 23

Attach your shock pump then add air while you slowly cycle your shock through 25% of its travel 10 times as you reach your desired pressure. Reinstall the black air cap.

Step 1

The shock has a pair of decals installed that show the factory alignment of the air valve/XV sleeve. When changing volume spacers or performing any shock service, you must ensure the shock is reassembled with the dots aligned. Failure to do so may result in shock or frame damage. If you are re-aligning the air valve/XV sleeve, you must remove the lower decal and affix a replacement (included with aftermarket product) so they are aligned as shown.

Step 2

Remove the air cap, attach a shock pump, then SLOWLY release all air out of the main air chamber.

Step 3

Push XV sleeve down away from retaining ring. Rotate the wire retaining ring to align the opening in the ring with the tab on eyelet. Use a pick to remove the ring.

Step 4

Note: Remove the rebound knob or apply a strip of tape over it to prevent the inside of the XV sleeve from getting scratched, which can cause air leaks.

Slide the outer air sleeve away from the negative air sealhead. 

Step 5

Your shock should come positioned correctly on your bicycle from the factory. However, if the XV air sleeve is rotated for any reason, it must not interfere with any part of the shock or frame. In the examples below, the XV air sleeve/air valve is rotated separately from the rebound eyelet. Images show a few examples of air valve positions to achieve proper clearance between the air valve and shock reservoir, but the shock would still need to be tested for frame clearance throughout the entire stroke.

Step 6

In strut mount applications, the rebound eyelet is typically rotated 90 degrees. The air valve/XV sleeve must be repositioned (rotated separately from the rebound eyelet) into one of the proper clearance locations. Images show a few examples of air valve positions to achieve proper clearance between the air valve and shock reservoir, but the shock would still need to be tested for frame clearance throughout the entire stroke. Make sure the air valve is not positioned toward the shock reservoir.

Step 7

Install the shock onto your frame according to your frame manufacturer’s instructions. Slowly compress the suspension through its entire travel. Check that the shock does NOT contact any portion of your frame or linkage as it cycles through its travel.

Step 8

These images show the range of positions you can Not use because the air valve will interfere with the reservoir and will result in shock damage. NOTE: On parallel reservoir models (250 mm x 75 mm with no lever), the air valve will clear the shock reservoir in any of the available positions. It will still need the same test for frame clearance as mentioned above.

Step 9

Slide the XV sleeve down to the negative air sealhead to engage the air seals. Reinstall the wire retaining ring, and make sure that it is fully seated in its groove.