SERVICE PROCEDURES

Step 1

Carefully clamp the wrench flats of the lower pressure tube in your soft-jawed vise. Unthread the topcap from the pressure tube counter-clockwise with your 6-point chamfer-less 26mm socket,Lift the topcap assembly up and out of the pressure tube.

Step 2

Remove the cartridge from the vice and invert over your waste oil basin. Drain all oil from the cartridge  then carefully clamp the pressure tube with the base stud facing up. Unthread the sealhead counter-clockwise from the cartridge body with a 20mm wrench. 

Step 3

Hold on to Top Cap and unthread the Piston Nut counter-clockwise with an 8mm wrench/socket. Remove the Piston, Check Spring, Check Shim followed by the Compression Piston and Compression Valving.

Step 4

Unthread the Compression Needle counter-clockwise, then pull up to remove.

Step 5

Replace the o-rings on the Topcap and Compression Needle with new greased ones from the kit. A plastic seal pick is recommended to prevent damage to the seal glands.

Step 6

Apply clump level of Blue Utraplex LT2 grease(025-01-027) to threads of Compression Needle. Reinstall the Compression Needle into the Compression Shaft.

Step 7

Clean and inspect the Compression Valving shims for any damage. Replace if necesarry. Orient the Compression Valving in its original order then reinstall onto the Compression Needle.

Step 8

Reinstall the Compression Piston onto Compression Needle( Important orientation of Piston is critical, one reaide ring towards top cap. Reinstall the Check Shim on top of the Compression Piston.

Step 9

Reinstall the Check Spring, then apply 1-2 drops of Red Loctite 263 to the Piston Nut threads. Reinstall the Piston Nut tightening clockwise to 16 in-lb (1.8 Nm) torque with an 8mm socket. Verify that the Check Shim is not pinched and can spin freely after Piston Nut tightening. Clean off any excess Locitite.

Step 10

Carefully clamp the Pressure Tube and unthread the Sealhead counter-clockwise from the cartridge body with a 20mm wrench. Lift the damper shaft assembly up to remove it from the cartridge body.

Step 11

Clean the Damper Shaft Assembly with Isopropyl alcohol and a lint-free paper towel then carefully clamp the damper shaft with the sealhead above the shaft clamps. Unthread the Base Stud counter-clockwise using a 9mm wrench.

Step 12

Turn the Rebound Needle with the Base Stud, keeping them together as you remove them. Replace the O-Ring on the Needle with a new greased one from the kit

Step 13

Remove the Sealhead. Insert the 10mm Shaft Bullet(398-00-371) into the Shaft then coat it with slick honey and install the new Sealhead from the kit then remove the tool. 

Step 14

Apply 2-3 drops LOCTITE 263 to the Base Stud threads. Insert the Rebound Needle with Base Stud and turn the Base Stud and Needle together as you thread them in clockwise. Tiorque to 40in-lb(4.5Nm)

Step 15

Apply 1-2 drops of blue Loctite 243 to the threads of the Pressure Tube. Take care not to get Loctite on the o-ring within the Sealhead Assembly. Reinstall the Damper Shaft Assembly tightening the Sealhead clockwise

Step 16

Carefully clamp the wrench flats of the lower pressure tube in your soft-jawed vise. Fill the Pressure Tube to required oil level with FOX 5wt. Teflon infused oil*. Stroke the Damper Shaft ~5 times then fully extend the Damper Shaft.

 *Originally shipped with 5 WT Teflon, now approved for 4WT. Please consume 5WT while supplies last.

Step 17

Apply blue Loctite 243 to the Cartridge body threads. Then slowly push the Top Cap assembly into the body. Thread the Topcap clockwise onto the body and torque to 150in-lb(16.9Nm).