Make sure that your fork is ready to ride

1. Check that quick-release levers and axle pinch bolts of the bike are properly adjusted and tightened.
2. Inspect the entire exterior of your fork. The fork should not be used if any of the exterior parts appear to be damaged. Contact your local dealer or FOX for further inspection and repair.
3. Check your headset adjustment. If loose, adjust it accordingly to your bicycle manufacturer's recommendations.
4. Check that all brake cables or hoses are properly fastened. 
5. Test the proper operation of your front and rear brakes on level ground.
6. Before every race or ride, clean the outside of your fork with only mild soap and water, and wipe dry with a soft dry rag. Do not spray water directly into the seal/upper tube junction. Do not use a high pressure washer on your fork.

Prepare your PODIUM fork by determining whether to run the factory-installed fork guards (recommended) or the mast. The mast will provide a more sleek look but will not protect the finish on the fork tubes from airborne rock or debris during riding.

Fork Guard Installation

1. Install each fork guard as shown.

2. Use a 2.5 mm hex bit and a torque wrench to tighten the three bolts on each fork guard to 3.4 N.m (30 in-lb).

3. Follow the instructions for the Fork Installation section below, then go to the Brake Routing with Fork Guard section.

Mast Installation

1. Use a 2.5 mm hex wrench to remove the three bolts on each fork guard. Remove the fork guards. Set the bolts aside for the next step.

2. Install the cover plate and mast as shown. Use a 2.5 mm hex bit and a torque wrench to reinstall two bolts on each side, and  tighten to 3.4 N.m (30 in-lb).

3. Follow the instructions for the Fork Installation below, then go to the Brake Routing with Mast section.

1. Remove the existing fork from the bicycle. Remove the crown race from the old fork. Measure the steerer tube length of the old fork and transfer this measurement to your new FOX fork’s steerer tube. If you don’t have an existing fork, measure the headset stack height (headset parts and frame head tube) and refer to your stem manufacturer’s instructions to be sure there will be enough clamping surface for the stem.

2. Mark the steerer tube and cut it to the proper length.

3. Install the headset. Always use a new threadless headset and follow the headset manufacturer’s instructions.

4. Install a 39.8 mm crown race for 1 1/2 in. steerer tubes. Use a crown race setter to install the crown race firmly against the top of the crown.

5. Use a star-fangled nut installation tool to install the star nut 4-10 mm below the top of the steer tube.

6. Install the fork onto the bicycle. Install the headset bearing parts and stem in accordance with the headset manufacturer’s  instructions, and adjust the headset preload accordingly until you feel no excessive play or bearing drag. Tighten the stem clamping bolts to the stem manufacturer’s torque specifications.

7. The PODIUM fork has post mounts for a 200 mm rotor size. Any rotor size greater than 200 mm will need adapters between the caliper and fork post mounts for rotor sizes 203 mm through 230 mm. Install the brakes according to the brake manufacturer’s instructions. Maximum rotor size is 230 mm.

8. Next, go to the brake routing section for your setup, whether you are using a Fork Guard or a Mast.

Follow this section if you are using the fork guards. If you are using the mast, go to the next section: Brake Hose Routing with Mast.

1. Install the brake hose clamp onto the slotted opening of the lower fork guard. Verify that the protrusion on the clamp is fully installed in the slot of the guard.
   
   

2. Route the front disc brake hose or cable housing along the inside of the left lower tube. Then, carefully open the brake hose clamp enough to slide the brake hose into the clamp. Verify the brake hose has ample length on the inside routing so the upper tube does not contact the brake hose during compression of the fork. Use a 2.5 mm hex wrench to loosely install the two brake hose clamp screws, as further adjustments will be needed in a later step.
   
   

3. Remove the two screws from the middle and upper brake hose guides. The middle brake hose guide is marked with an “M” and has a slightly smaller diameter than the upper brake hose guide (marked with a “U”). Install the brake hose through the opening in each of the guides and install them on the left fork leg. Loosely reinstall the screws.
   
   

4. Position the middle and upper hose guides so that the bottom slit is aligned with each of the arrow graphics that are laser etched on the fork (represented by the white arrowheads). Use a 2.5 mm hex bit and a torque wrench to tighten the screw to 0.9 N.m (8 in-lb).
   
   

5. Verify the front brake hose length is sufficient above the upper brake hose guide to the brake lever. Verify there is a smooth arc in the brake hose between the brake hose clamp to the brake caliper (A). All sections of brake hose must have an unrestricted path during the compression of the fork. NOTE: Some disc brake calipers allow for adjustment of the hose angle via banjo bolts. Follow the brake manufacturer’s instructions for repositioning the hose angle to allow for a smooth arch of the brake hose to clear the largest diameter portion of the upper tube at the seal area during compression (B).
   
   

6. Finally, check that the brake hose and clamp are now in a position that allows an even gap all the way around the inside of the fork guard to prevent any rubbing or friction. Use a 2.5 mm hex bit and a torque wrench to tighten the two brake hose clamp screws to 0.9 N.m (8 in-lb). 
   
   

1. Install the brake hose clamp onto the slotted opening of the mast. Verify that the protrusion on the clamp is fully installed in the slot of the guard.
   
   

2. Route the front disc brake hose or cable housing along the inside of the left lower tube. Then, carefully open the brake hose clamp enough to slide the brake hose into the clamp. Verify the brake hose has ample length on the inside so that the upper tube does not contact the brake hose during compression of the fork. Use a 2.5 mm hex wrench to loosely install the two brake hose clamp screws, as further adjustments will be needed in a later step.
   
   

3. Remove the two screws from the middle and upper brake hose guides. The middle brake hose guide is marked with an “M” and has a slightly smaller diameter than the upper brake hose guide (marked with a “U”). Install the brake hose through the opening in each of the guides. Loosely reinstall the screws.
   
   

4. Position the middle and upper hose guides so that the bottom slit is aligned to the top peak of each arrow graphics that are laser etched on the fork (represented by the white arrowheads). Use a 2.5 mm hex bit and a torque wrench to tighten the screw to 0.9 N.m (8 in-lb).

5. Verify the front brake hose length is sufficient above the upper brake hose guide to the brake lever. Verify there is a smooth arc in the brake hose between the brake hose clamp to the brake caliper (A). All sections of brake hose must have an unrestricted path during the compression of the fork. NOTE: Some disc brake calipers allow for adjustment of the hose angle via banjo bolts. Follow the brake manufacturer’s instructions for repositioning the hose angle to allow for a smooth arch of the brake hose to clear the largest diameter portion of the upper tube at the seal area during compression (B).
   
   

6. Finally, check that the brake hose and clamp are now in a position that allows an even gap all the way around the inside of the mast to prevent any rubbing or friction. Use a 2.5 mm hex bit and a torque wrench to tighten the two brake hose clamp screws to 0.9 N.m (8 in-lb). 
   
   

1. Install the front wheel into the dropouts and slide the axle through the dropouts and hub.
2. Use a 5 mm hex wrench to torque the axle bolt to 13.6 N•m (120 in-lb).
3. Use a 5 mm hex wrench to torque the two pinch bolts on the non-drive side dropout to 6.2 N•m (55 in-lb).
4. Compress the fork a couple of times to ensure that the lower leg has settled into its low-friction point.
5. Use a 5 mm hex wrench to torque the two pinch bolts on the drive side dropout to 6.2 N•m (55 in-lb).
   
   

1. IMPORTANT: the PODIUM fork has 12cc of 20wt. Gold Oil for air chamber lubrication. Turn the fork upside down whenever adding or removing air pressure. Also, make sure to cover the rotor to prevent oil from contaminating braking surfaces.

2. Release all air pressure from the fork. First, remove the lower left side air knob. Then, slowly depress the Schrader valve.

3. Compress the fork completely.

4. Measure the distance from the edges of the inflated tire to the lower fork guards, crown, upper tubes, and steerer. There must be AT LEAST 8.5 mm of clearance around the entire tire.

5. Add air pressure to your desired setting using a FOX high-pressure pump. 

6. You must repeat this test EVERY time you change tires or rims.
   
   

Changing volume spacers in FOX PODIUM forks is an easy internal adjustment that allows you to change the amount of mid stroke and bottom out resistance. If you have set your sag correctly and are using full travel (bottoming out) too easily, then you could install one or more spacers to increase bottom out resistance. If you are not using full travel, then you could remove one or more spacers to decrease bottom out resistance.

1. IMPORTANT: the PODIUM fork has 12cc of 20wt. Gold Oil for air chamber lubrication. Turn the fork upside down whenever adding or removing air pressure, and/or removing the bottom cap. Also, make sure to cover the rotor to prevent oil from contaminating braking surfaces (having the wheel installed helps to remove the bottom cap). Remove the lower left air knob.

2. Release all air pressure from the fork by slowly depressing the Schrader valve.

3. Carefully unthread the left side bottom cap from the fork with a Park Tool FR-5 or FR-5.2 cassette tool.

4. Pull up to remove the left side bottom cap assembly from the left side lower lug.
5. Pull off the air volume spacer or spacers to install or remove them from the left side bottom cap.
6. Reinstall the left side bottom cap assembly into the left side lower lug and tighten to 24.8 N.m (220 in-lb) with a Park Tool FR-5 or FR-5.2 cassette tool.
7. Add air pressure to your desired setting using a FOX high-pressure pump. Set the sag according to instructions online at www.ridefox.com.
   
   

To achieve the best performance from your FOX suspension, adjust the air pressure to attain your proper sag setting. Sag is the amount your suspension compresses under your weight and riding gear. Sag range should be set to 15–20% of total fork travel.

Turn your compression adjusters to the closed position (full clockwise) until they stop. Then back them out (counterclockwise) 6 clicks for High-Speed Compression and 8 clicks for Low-Speed Compression as a starting point. 

High-speed compression adjustment is useful to control fork performance during bigger hits, landings, and square-edged bumps.

Low-speed compression adjustment is useful to control fork performance during rider weight shifts, G-outs, and other slow inputs.

Rebound controls the rate of speed at which the fork extends after compressing. The rebound adjustment is dependent on the air pressure setting. For example, higher air pressures require slower rebound settings. Use your air pressure to find your rebound setting. The rebound adjuster is located underneath the damper-side fork leg.

To adjust the rebound, unscrew and remove the protective cap located at the right-side bottom of the PODIUM fork. Turn your rebound knob to the closed position, clockwise until it stops. Then turn it counter-clockwise to the number of clicks shown in the table.

High-speed rebound adjustment is useful to control fork performance during bigger hits, landings, and square-edged bumps.

Low-speed rebound adjustment is useful to control fork performance during rider weight shifts, G-outs, and other slow inputs.

Properly cleaning your FOX product between rides, in addition to maintenance service scheduled at regular intervals, will help to reduce repair costs and extend product life. For further service procedures information, visit www.ridefox.com/OwnersManuals, or contact FOX for
complete maintenance service (1.800.369.7469 or [email protected]).

*For those who ride lift-accessed DH, Park, or Extreme Freeride or in extremely wet/muddy or dry/dusty environmental conditions where trail debris is sprayed onto the fork while on the trail, FOX encourages riders to perform maintenance earlier than recommended above as needed. If you hear, see, or feel something unusual, stop riding immediately and contact a FOX Authorized Service Center for proper servicing.