SERVICE PROCEDURES
2021-2025 FLOAT X2 Rebuild
Required Parts
- 025-03-063 Oil: Suspension Fluid, 4 WT, 1.0 Liter Bottle
- 803-01-921 Seal Kit: 2023 FLOAT X2 Spring and Damper Rebuild
Required Tools
- 398-00-280 Tooling: Eyelet Torque Tool
- 398-00-419 Tooling: 2016 Float X2, Negative Air Seal
- 398-00-881 Tooling: Custom Spanner Socket, 4-Pin, 2021 DHX2 / FX2, Comp Base Valve
- 398-00-882 Tooling: Custom Spanner Socket, 4-Pin, 2021 DHX2 / FX2, Reb Base Valve
- 398-00-887 Tooling: 2021 Float X2, Bearing Housing Driver
- 398-00-951 Tooling: Torque Fixture, 54mm Trunnion Eyelet, Tall
- 803-00-463 Kit: Fill Machine Adapter, 04-07 Epic IV, DHX Air, RC2_RC4 Shocks
- 803-00-566 Kit:Bike IFP Depth Setting Tool Set
- 803-00-805 Kit: Shaft Clamps, Shocks, CTD 9mm, 3/8in, 1/2in, 5/8in
- 803-00-969 Kit: Tooling: Clamps, FLOAT X2, Body
- 803-01-545 Kit: Tooling: Clamps, 2021 DHX2 / Float X2, Rezi Body
- 803-01-578 Kit: Service Tool, 2021 DHX2 / Float X2, VVC Set, Assembly
- 803-01-690 Kit: Tooling: Clamps, ALL FLOAT X2's, Inner Air Sleeve
- 803-01-826 Kit: Tooling: Rear Shock, Rezi End, Air Fill Adaptor, MY 2021
WARNING: Always wear safety glasses and protective gloves during service to prevent potential injury. Failure to wear protective equipment during service may lead to SERIOUS INJURY OR DEATH.
WARNING: FOX products should be serviced by a trained bicycle service technician, in accordance with FOX specifications. If you have any doubt whether or not you can properly service your FOX product, then DO NOT attempt it. Improperly serviced products can fail, causing the rider to lose control resulting in SERIOUS INJURY OR DEATH.
WARNING: FOX suspension products contain pressurized nitrogen, air, oil, or all 3. Suspension misuse can cause property damage, SERIOUS INJURY OR DEATH. DO NOT puncture, incinerate or crush any portion of a FOX suspension product. DO NOT attempt to disassemble any portion of a FOX suspension product, unless expressly instructed to do so by the applicable FOX technical documentation, and then ONLY while strictly adhering to all FOX instructions and warnings in that instance.
WARNING: Modification, improper service, or use of aftermarket replacement parts with FOX forks and shocks may cause the product to malfunction, resulting in SERIOUS INJURY OR DEATH. DO NOT modify any part of a fork or shock, including the fork brace (lower leg cross brace), crown, steerer, upper and lower leg tubes, or internal parts, except as instructed herein. Any unauthorized modification may void the warranty, and may cause failure or the fork or shock, resulting in SERIOUS INJURY OR DEATH.
Note: The Damping Adjuster Cartridge Assemblies should be considered non-rebuildable as they are difficult to dissassemble and reassemble. The Damping Adjuster Cartridge Assemblies do not need to be removed from the shock to perform a full rebuild. Removal and reinstallation of the Damping Adjuster Cartridges is shown below for reference.
NOTE: The Main Piston VVC system only needs to be disassembled and rebuilt if changing Main Piston Valving.
NOTE: The anodization color of the main piston may vary between clear, black, and orange. There are no functional or performance differences between different colored pistons.
Disassembly
WARNING: Please verify that all air has been released from the air chamber by pushing down on the Schrader valve core. Failure to release all air pressure before further disassembly may cause parts to eject causing SEVERE INJURY OR DEATH.
Step 4
With the non-adjuster eyelet clamped in your soft-jawed vise, carefully engage the prongs of the negative air sealhead tool (PN: 398-00-419) with the notches of the negative air sealhead. Do not scratch the outer body with your tool. Maintain downward pressure on the negative air sealhead tool to keep it engaged while you turn it counter-clockwise to unthread.
DO NOT clamp the FLOAT X2 Inner Air Sleeve below the externally threaded area. Only use the FLOAT X2 Air Sleeve Clamps (PN: 803-01-690 REV A) to clamp the FLOAT X2 Inner Air Sleeve between the ribs.
WARNING: Using the 2019 FLOAT X2 Air Sleeve Clamps (803-01-318 REV A) can cause damage to the inner air sleeve on certain size 2021 and later FLOAT X2 shocks. Please use only the 803-01-690 REV A Air Sleeve Clamps as they've been modified to fit all sizes of all FLOAT X2 shocks for all model years. Failure to use the correct clamp may cause the product to malfunction, resulting in SEVERE INJURY OR DEATH.
Step 5
You will need to separate either the negative air sealhead from the inner air sleeve or separate the inner air sleeve from the shaft eyelet. Clean the inner air sleeve with Isopropyl alcohol and lint-free paper towels. Use the X2 air sleeve clamps (PN: 803-01-690) to hold the inner air sleeve while you remove either the negative air sealhead with the sealhead tool (PN: 398-00-419) or the shaft eyelet with Knipex pliers or the eyelet torque tool (PN: 398-00-280).
Step 18
Clamp the Reservoir in the 2021 X2 Resi shaft clamps (PN: 803-01-545) then heat the reservoir area to break down the Loctite. Unthread the Reservoir counter-clockwise from the Eyelet. (Note: While a DHX2 is shown in images for this step, the procedure is identical for FLOAT X2 shock Resi removal).
Step 25
Clamp the 3/8" shaft in your shaft clamps (PN: 803-00-805) then unthread the Main Piston Assembly from the shaft by turning the HSR VVC Plate counter-clockwise with a 19mm wrench. Set aside the VVC Assembly. Remove the Bearing Assembly by pulling it up off of the shaft. (Note: Orange Prototype Piston shown, production versions will be black or clear anodized).
NOTE: The Main Piston VVC system only needs to be disassembled and rebuilt if changing Main Piston Valving. You may skip to Reassembly if you are not changing Main Piston Valving.
Main Piston VVC Rebuild
Step 5
Install the Shaft Simulator provided with the 803-01-578 VVC Assembly Tool by threading it onto the Piston Bolt clockwise by hand. Clamp the Shaft Simulator in your soft jawed vise. Reinstall the HSR plate onto the Piston Bolt making sure to engage the hex feature. Use a 19mm socket to tighten the Piston Bolt to the Shaft Simulator, turning clockwise to 80 in-lb (9.0 Nm) torque.
Step 6
Reinstall the HSR Adjuster with Leaf Springs into the Piston Bolt through the HSR Plate as shown. Make sure that the hex of the HSR Adjuster is mated with the hex feature on both Leaf Springs. Make sure that the thicker of the two Leaf Springs is positioned closest to the HSR Plate. Thread the two 5mm nuts onto the HSR Adjuster leaving space between each nut as well as between the first nut and the end of the Piston Bolt as highlighted by the red arrows.
Step 9
Set your torque driver to 14cNm (This is 14cNm, not 14 in-lb or 14 Nm, a special torque wrench may be needed. FOX recommends the Tohnichi Torque Screwdriver RTD30CN 4~30 cNm model). Tighten the lower 5mm nut clockwise to 14 cNm (you can have both nuts within the socket during tightening as long as there is space left between the nuts).
Step 12
Slide the clamp over the rim of the knurled fixture then tighten the QR clamp just enough to hold the knurled fixture in place (use similar tension to a standard fork QR. You may adjust the QR as needed to achieve proper tension). The base of the knurled fixture must not turn during the next steps. If it does, the procedure must be repeated without allowing the knurled fixture base to rotate.
Step 17
Clamp the Shaft Simulator in your soft-jawed vise, then turn the HSR plate counter-clockwise with your 19mm socket to remove it. Keep the Shaft Simulator with your VVC Assembly tool. It is normal to have a small gap between the 5mm nuts and the Piston Bolt once the Shaft Simulator has been removed.
Reassembly
Step 5
Clean the retained Rebound detent ball and surrounding area with Isopropyl alcohol and compressed air. Reinstall the red Rebound knob into the Shaft Eyelet with the serrated side facing away from the eyelet. Reinstall the Bottom Out Bumper onto the Shaft Eyelet with it's small end facing the eyelet as shown. Press it down to fully seat it in place.
Step 7
Reinstall the VVC Main Piston Assembly onto the Shaft making sure not to pinch any shims and taking care to align the HSR Adjuster with the HSR Inner Shaft. Tighten by turning the HSR Plate clockwise with a 19mm socket or crowsfoot to 80 in-lb (9.0 Nm) torque. (Note: Orange Prototype Piston shown, production versions will be black or clear anodized).
Step 12
Apply 1-2 drops of blue Loctite 243 to the threads of the Reservoir. Make sure to orient the 2Pos adjuster so the lever is in-line with the shock centerline axis in Firm mode and 90 degrees to the shock in Open Mode before torqueing the Rezi to the Eyelet. Reinstall the Reservoir, tightening clockwise by hand. Clamp the Reservoir in your shaft clamps, then use the Eyelet Torque Tool (PN: 398-00-280) to tighten clockwise to 120 in-lb (13.6 Nm) torque.
Step 13
Reinstall the Inner Body into eyelet, pushing down to seat it within the o-ring. Apply 2-3 drops of red Loctite 263 to the first 3 threads for a full 360 degrees. Reinstall the Outer Body over the Inner Body tightening clockwise by hand. Clamp the Outer Body in your shaft clamps, then use the Eyelet Torque Tool to tighten clockwise to 144 in-lb (16.3 Nm) torque.
Step 19
Remove the Bleed Screw by turning it counter-clockwise with a 2mm hex. Thread the Fill-Machine adapter clockwise into the bleed port. Vacuum the shock, then fill with FOX 4wt. oil. Set the IFP to 1.140in +/- 0.05in using your IFP depth setting tool (803-00-566). Reinstall the set screw with a new greased o-ring from the kit and tighten to 10 in-lb (1.1 Nm). Remove the Shaft Eyelet by unthreading it counter-clockwise.
Step 21
Use a small hex wrench to hold the Reservoir End Cap in place while you install the Rezi Fill Adaptor (PN: 803-01-826) by threading it in clockwise. Set the IFP pressure to 100 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. Tighten the 2Pos lever set screw clockwise to 7 in-lb (0.8 Nm) torque with a 2mm hex wrench.
Step 23
Add 1cc of 20 wt. Gold oil to the Negative Air Chamber before threading the Neg Air Sealhead to the Inner Air Sleeve as shown. Clean the Inner Air Sleeve with Isopropyl alcohol and a lint-free paper towel. Clamp the Inner Air Sleeve in your shaft clamps then tighten the Neg Air Sealhead clockwise to 180 in-lb (20.3 Nm) torque with the Neg Air Sealhead Tool.
Step 24
Add 2cc of 20 wt. Gold oil to the positive air chamber. Apply red Loctite 263 to the first 1-2 threads of the Outer Shaft making sure not to get Loctite on the Inner Shaft. Thread the Shaft Eyelet onto the Shaft making sure to engage the hex of the HSR Inner Shaft with the red Rebound Knob. Clean the shaft with Isopropyl alcohol and a lint-free paper towel then clamp in your 3/8" shaft clamps. Tighten the Shaft Eyelet clockwise to 80 in-lb (9.0 Nm) torque with your Eyelet Torque Tool.
Step 26
Coat the air seals in a thin film of Slick Honey then reinstall the outer air sleeve with the air valve side first. Rotate the outer air sleeve until the tab on the eyelet aligns with the notch in the outer sleeve. 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.