Step 1

Use a 2 mm hex to remove the rebound knob after turning it all the way counter-clockwise. Free the cartridge from the lower assembly with a 10mm socket wrench and the Fox 32mm damper removal tool (PN 398-00-601). Drain the oil into a waste oil basin.

Step 2

Carefully use a thin flat blade screwdriver to remove the iCD actuator cover.

Step 3

Remove the hoopster style retaining ring for the iCD fork actuator. Use a 17mm cone wrench to pull up on the iCD fork actuator. Do not lever the actuator out with the cone wrench, only use the wrench to pull straight up.

Step 4

Use a 28mm 6-point chamfer-less socket to remove the cartridge from the fork.

Step 5

Clamp the cartridge and use the FOX iCD Damper Clocking Tool PN 398-00-576, to set the cartridge into descend mode by turning the lockout shaft located next to the bleed screw. Descend mode is attained when the lockout shaft flat is oriented perpendicular to the red bleed set screw, as shown.

Step 6

Invert and clamp the cartridge assembly in your shaft clamps (PN 803-00-147). Use a 13mm cone wrench to loosen the seal head. Remove the assembly from the clamps and separate the shaft assembly and body, over a waste oil basin to drain the oil.

Step 7

To remove the bladder retainer and retaining ring, place the bladder and cartridge body assembly into the second largest hole in the #2 clamps. Loosely rest the bladder ring on the clamps, as shown below; no clamping pressure is applied to the bladder ring. Be careful not to scratch the cartridge body as you remove the retainer and retaining ring.

Step 8

Insert a 5mm hex wrench up through the cartridge body to engage and stop the internal coupler from rotating as you unthread the topcap with a 28mm 6-point chamfer-less socket. 

Step 9

Remove the bladder from the cartridge body and separate the bladder and bladder ring.

Step 10

Use a square drive extension or socket to push the iCD bulkhead assembly out through the bottom of the topcap. Do not press against the flat-sided lockout shaft in the center of the bulkhead assembly.

Step 11

Clean the bulkhead assembly and replace its o-rings. Remove the red bleed screw with a 1.5mm hex wrench.

Step 12

Replace the internal and external topcap o-rings.

Step 1

Clean the shaft clamps and shaft with isopropyl alcohol. Clamp the damper shaft assembly just tightly enough to let you unthread the rebound adjuster from the shaft. Remove the rebound adjuster with a 1/2" wrench, followed by the original seal head.

Step 2

Drop the rebound tube from the shaft.

Step 3

Invert the damper shaft assembly in the clamps. Remove the main piston assembly with a six-point 8mm box-end wrench or socket and set all parts aside in order.

Step 4

Use the rebound tube to carefully dislodge and remove the rebound needle and spring from inside the shaft. Push the rebound needle out through the rebound adjuster end of the damper shaft.

Step 5

Thoroughly clean all parts and remove and discard the rebound needle o-ring if present. FIT iCD forks no longer utilize an o-ring on the rebound needle. 

Step 6

Clamp the shaft carefully so the rebound adjuster end (the end with no retaining ring) is facing up. Install the 8mm Shaft Bullet Tool (398-00-320) and grease with a thin film of Slick Honey.

Step 7

Install the new Seal Head Assembly from the rebiuld kit with as shown, then remove the bullet tool.

Step 8

Reinstall the Rebound Adjuster Assembly as shown and torque to 55 in-lb (6.2 Nm) with a 1/2in. crows foot. 

Step 9

Invert the damper shaft and clamp so the end with the retaining ring is facing up. Slowly fill the damper shaft with 10wt. Red until full. Slowly insert the rebound tube into the full damper shaft. This will displace oil.

Step 10

Install the rebound needle and spring as shown followed by the check limiter/spring perch, spring, main piston assembly and piston bolt. Start threading the piston bolt to keep the parts together but do not tighten.

Step 11

Make sure that the check shim (the shim under the piston assembly) can move freely as isn't pinched between the piston and the end of the damper shaft. Once sure that the check shim is not pinched, torque the piston bolt to 55 in-lb (6.2 Nm).

Step 12

Replace the piston glide ring.

Step 1

Lubricate the new bladder with slick honey and install the lower bladder ring as shown. Slide the bladder over the body, snapping the bladder lip over the lip of the coupler.

Step 2

Carefully install the bulkhead assembly in through the bottom of the topcap.

Step 3

Clamp the cartridge in the shaft clamps, and lubricate the larger end of the bladder with slick honey.

Step 4

Thread the topcap down into the bladder as you push the lower bladder ring upward. If necesarry, the bladder installation tool (PN: 398-00-321) can be used to help tuck the bladder into the topcap. Torque the topcap to 75 in-lb (8.5 Nm).

Step 5

Set the bladder and cartridge body assembly into the second largest hole in the shaft clamps PN 803-00-147, loosely resting the bladder ring on the clamps. As you gently pull the assembly down by the topcap, install the bladder retainer and retaining ring.

Step 6

Install the rebuilt shaft assembly into the cartridge body. Tighten the seal head to 75 in-lb (8.5 Nm) torque.

Step 7

The iCD topcap has enough oil capacity for the hand bleeding process; the FOX FIT bleeder tool (PN 803-00-276) is not needed. Compress the cartridge completely and then fill the topcap with FOX 10wt. red oil.

Repeatedly squeeze and release the bladder to force out any air. Next, cycle the shaft slowly down to full extension, drawing oil into the cartridge. If bubbles are present in the topcap oil, wait until the bubbles have risen to the top before drawing clear oil down into the cartridge.

Repeat the squeeze, cycle, and wait process described above, until air bubbles stop appearing in the topcap as you squeeze and cycle the cartridge. 

Do not let the oil level in your topcap drop to the point where you can ingest air into the cartridge. Add oil to the syring as necesarry.

Step 8

When no new air bubbles can be seen in the topcap oil, install the bleed set screw (with new o-ring) to 5 in-lb (0.6 Nm) torque. Drain the excess oil from the topcap and clean out any residue with isopropyl alcohol.

Step 9

Test for a good bleed by cycling the cartridge. You are looking for smooth damping, with no bubbling or gurgling sounds. Next, use the FOX iCD tool PN 398-00-576 to reset the lockout shaft to climb mode by turning it 90 degrees (lockout shaft flats are in line with the red bleed screw in Climb mode). Finally, test for a firm lockout.

Step 10

Install the cartridge into the fork, tightening the topcap to 220 in-lb (24.8 Nm) torque.

Step 11

Use the crescent shaped end of the FOX iCD tool PN 398-00-576 to set proper bulkhead assembly orientation, relative to the center of the fork steerer tube. 

Step 12

Carefully insert the actuator unit, gently rotating it until it aligns with the central lockout shaft. Continue rotating the actuator unit until it aligns and mates with the crescent shaped feature in the bulkhead assembly. Continue pressing the actuator unit in until it engages with the o-ring inside the topcap.

Step 13

Install the hoopster style retaining ring to secure the iCD fork actuator in the topcap.

Step 14

Peel the protective film from the adhesive foam tape on the fork actuator cover before installing it over the installed fork actuator unit.

Step 15

Invert the fork and fill with 30cc FOX 20 wt. Gold oil in each leg. Gold oil should only be used with compatible 32mm dust wipers found in kit: 803-00-878.

Install the bottom nuts with new crush washers, tightening to 50 in-lb (5.7 Nm) torque. Install the rebound knob with a 2 mm hex, making sure the set screw correctly settles into its indentation on the rebound adjuster; tighten to 11 in-lb (1.2 Nm) torque.