SERVICE PROCEDURES
2014-2017 TALAS 5 Air Seal Replacement
Required Parts
- 036-01-071 Seals: U-Cup, Scraper, TALAS 5
- 036-01-080 Seal, Air Piston, TALAS 5
- 241-01-002-C Fastener, Custom: Crush Washer, Plastic
Required Tools
- 398-00-681 2002-017 32 Damper-side and ALL 32-34-36-40 Spring-side Removal Tool
- 398-00-702 Tooling: Fork Topcap Socket, 26mm, 3/8 Drive
- 398-00-706 Tooling: Fork Topcap Socket, 32mm V2, 3/8 Drive
- 398-00-707 Tooling: Fork Topcap Socket, 28mm V2, 3/8 Drive
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 qualified 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.
This procedure guides you through the replacement of air seals in any TALAS 5 system. For additional information and assembly drawings specific to your model please go to the appropriate page below:
PARTLIST - FORK- 2014 32mm TALAS 5 26/27.5 »
PARTLIST - FORK- 2014 32mm TALAS 5 29 »
PARTLIST - FORK- 2014 34mm TALAS 5 26/27.5 »
PARTLIST - FORK- 2014 34mm TALAS 5 29 »
Cartridge Removal and Disassembly
Step 1
Remove the blue air cap. While holding the lever away from the counter-clockwise hard stop, remove the nut with a 7/16" socket. Remove the lever.
Step 2
Use a 10mm socket to remove the bottom nut. Remove the crush washer and use Damper Removal Tool 398-00-601 to free the cartridge from the lowers. Drain the oil into your waste oil basin.
Step 3
Use a 6-point Chamfer-less socket to remove the cartridge from the fork crown.
32mm Forks: 26mm socket
34mm Forks: 28mm socket
36mm Forks: 32mm socket
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
Release the air pressure from the cartridge, then remove the wire retaining ring with a shim or pick tool without damaging the inside surface of the cartridge tube.
Step 5
Hold the air valve core down with a small tool while you remove the air shaft assembly and negative plate from the cartridge tube by pulling down.
Step 6
Remove the scraper seal followed by the U-cup seal. Coat a new U-cup seal with a thin film of Slick Honey and install in the upper piston groove so its lip is facing up. Coat a new scraper seal with a thin film of Slick Honey and install into the lower piston groove so its lip is facing down. Invert the air shaft assembly and set it aside to allow any trapped Float Fluid to drain out through the hollow piston bolt.
Step 7
Remove the wire retaining ring that secures the XV (Extra-Volume) sleeve to the cartridge tube. Remove the XV sleeve by sliding it down and off the cartridge tube. Clean the XV sleeve and cartridge tube of any Float Fluid and replace the two o-rings with new ones coated with a thin film of Slick Honey. Reinstall the XV sleeve followed by the wire retaining ring.
Cartridge Reassembly and Installation
Do not use more than the specified amount of FLOAT Fluid for your specific model of TALAS 5 cartridge.
TALAS 5 cartridges have shipped both with and without XV sleeves. Pay careful attention to the Float Fluid volume chart.
Step 1
Inject the appropriate amount of Float Fluid for your fork into the Cartridge Tube while rotating the tube to coat the entire inner surface.
| Fork Family | Wheel Size | Float Fluid Volume (With XV Sleeve) | Float Fluid Volume (No XV Sleeve) |
| 32mm | 26/27.5 | 15cc | 5cc |
| 32mm | 29 | 17cc | 7cc |
| 34mm | 26/27.5/29 | 15cc | 5cc |
| 36mm 160 | 26 | 15cc | 5cc |
| 36mm 180 | 26 | 5cc | N/A |
Step 2
Coat the air piston seals and topout/negative springs with Float Fluid then install the Air Shaft assembly into the Cartridge Tube. Holding the air valve open during this step can assist in Air Shaft Assembly installation. Install the negative plate and wire retaining ring. Pull on the air shaft to verify that the wire retaining ring is properly seated.
Step 3
Add 135psi to the TALAS 5 cartridge, then install into the fork crown and torque to 220 in-lb (24.8 Nm) with your 6-point Chamfer-less topcap socket.
Step 4
With the TALAS set to the Long-Travel position (fully clockwise) install the lever so it is oriented toward the riders 10 o'clock. Install the tank valve nut with a 7/16" socket to 25 in-lb (2.8 Nm) torque while holding the lever away from the full clockwise hard stop.
Step 5
Invert the fork and pour in the appropriate amount of FOX 20wt. Gold bath oil.
| Fork | TALAS-side Bath Oil Volume |
| All 32mm/34mm | 30cc |
| All 36mm | 40cc |
Step 6
Install a new crush washer followed by the bottom nut. Torque to 50 in-lb (5.7 Nm) with your 10mm socket.
Step 7
Replace the blue air cap and thouroughly clean the exterior of your fork.