SERVICE PROCEDURES

Step 1

Hold the Rail Compression Knob from turning while you unthread its screw counter-clockwise with a 2mm hex wrench. Set the knob and screw aside in a clean area.

Step 2

Unthread the damper-side topcap assembly counter-clockwise with a 6-point chamfer-less 26mm socket. Lift the Topcap Assembly out of the upper tube. Pour out any damper oil from the upper tube.

Step 3

Remove the retaining ring from the bottom of the damper-side upper tube. 

Never remove the retaining ring from the middle of the shaft as the edges of the ring may scratch the shaft. Always remove the retaining ring from the shaft by pulling it past the end of the shaft.

Step 4

Pull the Damper Shaft Assembly out from the end of the upper tube. Set the Damper Shaft Assembly aside in a clean area.

Step 5

Invert the Rail Topcap Assembly and carefully clamp it in your shaft clamps (PN: 803-00-830 shown but other 10mm shaft clamps will work). Unthread the Piston Nut counter-clockwise with an 8mm socket. Remove the Piston Nut and Check Spring.

Step 6

Remove the Check Shim followed by the Compression Piston and Compression Valving.

Step 7

Remove the Preload Hat then remove the Pin through the shaft.

Step 8

Remove the Topcap Assembly from your shaft clamps. Unthread the Compression Needle counter-clockwise, then pull up to remove.

Step 9

Replace the o-rings on the Topcap and Compression Needle with new greased ones from the kit. While a metal seal pick is shown pointing at the seals to be replaced, a plastic seal pick is recommended to prevent damage to the seal glands.

Step 10

Dip the Compression Needle up to the threads in FOX 5wt. Teflon infused oil. Reinstall the Compression Needle into the Topcap by threading it in clockwise. 

Step 11

Invert the Rail Topcap Assembly and carefully clamp it in your shaft clamps (PN: 803-00-830 shown but other 10mm shaft clamps will work). Reinsert the Pin through the Shaft. Replace the o-ring inside the Preload Hat with a new greased one from the kit. Reinstall the Preload Hat onto the Shaft.

Step 12

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 Piston Stud.

Step 13

Replace the U-cup seal on the Compression Piston with a new greased one from the kit. Make sure that the U-cup seal lip is oriented as shown.

Step 14

Reinstall the Compression Piston onto the Piston Stud as shown. Reinstall the Check Shim on top of the Compression Piston.

Step 15

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 16

Replace the glide ring on the Rebound Piston with a new one from the kit.

Step 17

Replace the o-ring on the outside of the Sealhead as well as the Base Stud with new greased ones from the kit.

Step 18

Clean the inside of the upper tubes with Isopropyl Alcohol then dry with a lint-free paper-towel.

Step 19

Coat the Sealhead of the Damper Shaft Assembly with a thin film of Slick Honey then reinstall into the bottom of the Damper-Side upper tube. Seat the Sealhead fully into the upper tube, then reinstall the Hoopster style retaining ring (make sure to install the retaining ring from the end of the Damper Shaft assembly to prevent scratching the shaft. Verify the retaining ring is fully seated by pully on the Damper Shaft Assembly.

Step 20

With the fork upright, pour 135cc of FOX 4wt. oil into the Damper-Side upper tube.

Step 21

Coat the Topcap Assembly u-cup seal with a thin film of Slick Honey then reinstall the Topcap Assembly into the Damper-Side upper tube. Tighten clockwise to 220 in-lb (24.8 Nm) torque with a 26mm 6-point chamfer-less socket.

Step 22

Use the Compression Lever as a wrench to turn the Compression Needle fully clockwise until it comes to a gentle stop. Remove the Compression Lever, then reinstall it as close to the back of the crown as possible (in the fully locked out position). Hold the Compression Lever from turning while you reinstall the screw, tightening clockwise to 11 in-lb (1.2 Nm) torque with a 2mm hex wrench.