SERVICE PROCEDURES
Podium Bushing Removal and Installation Procedure
Required Parts
- 803-04-377 Kit: 2026, Podium, CSU Bushings
Required Tools
- 8mm Allen
- 19mm socket
- 398-01-216 Tooling: Fork, Bushing Install, Guide, Podium, 10.75mm Flange
- 803-01-911 Kit: Tooling: 36mm Fork Bushing Extractor Assembly
- 803-04-336 Tooling: Complete Fork Bushing Install Tool Set
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.
Bleeder valves must be removed prior to extracting the old bushings, and put back in after installing the new bushings. If the bleeder valves are left in during the bushing extraction/install process, the bleeder valves can be damaged and metal shavings can get into the bath oil.
Removal
Step 1
Thread both 5/8" nuts onto the threaded rod. Once they’re far enough down to clear the lower bushing, tighten the two nuts together. Install the washer and sleeve, followed by the extractor.
Step 2
Clamp the CSU assembly. Insert Bushing Extractor Assembly past the upper and lower bushing until Sleeve sits flush with lower leg.
Step 3
With your 24 mm wrench, turn the head of the extractor rod clockwise until the bushings are pulled out.
Step 4
Unthread Extractor, and sleeve. Extracted bushing will be inside of the sleeve.
Repeat steps 1-4 for the other side of the lower leg.
Install Upper Bushing (Spiral Grooves)
Step 1
Install the correct Installation Tip and Guide Ring based on the Fork family. The Installation Tip and Guide Ring are engraved with fork family. Install Guide Ring first (with the small diameter end closest to the installation Tip), then the Installation Tip. Use a 8mm allen to tighten the M10 screw until the Installation Tip is sercured into the shank.
Step 2
For Podium forks, the approriate bushing depth is 171.75mm. Use the 50mm, 25mm, 20mm, and 2.5mm spacers to acheive this depth. Slide Spacers over the M12 bolt in the handle.
Step 3
Use a 19mm Socket to screw the M12 bolt into the shank portion of the tool. Once the Spacers are installed, the depth can be verified by measuring from lip on the Installation Tip to the lip of the Guide Ring. Insert the Hammer Cap onto the Handle. The tool is now assembled.
Step 4
Place the upper bushing on the Installation Tip and insert the bushing into the CSU. Note: Slits oriented outward.
Step 5
Slide the Guide Ring into the wiper bore at the top of the fork lower until the Guide RIng bottoms out on the top of the fork lower. Using a mallet, drive the bushing into the fork lower. The bushing will be at its depth once the handle of the tool makes contact with the top of the Guide Ring.
Repeat steps 1-4 for the other side of the CSU.
Install Lower Bushing (No Grooves)
Step 1
Install the correct Installation Tip and Guide Ring (with the small diameter oriented toward the installation Tip) based on fork family. Install Guide Ring first, then the Istallation Tip. Use a 8mm allen to tighten the M10 screw until the Installation Tip is secured into the handle.
Step 2
Once the Installation Tip and Guide Ring is installed, the depth can be verified by measuring from the tip of the Installation Tip to the lip of the Guide Ring. Note: All lower bushings require a depth of 15.25mm. NO SPACERS REQUIRED. Insert the Hammer Cap into the Handle. The tool is now assembled.
Step 3
Place the lower bushing on the Installation Tip and insert the bushing into the CSU. Note: Bushing slits oriented outward.
Step 4
Using a mallet, drive the bushing into the fork lower. The bushing will be at its depth once the handle of the tool makes contact with the top of the Guide Ring.
Thoroughly clean and inspect the fork chassis for any debris that could potentially compromise the new dust wiper seals.
Repeat steps 1-4 for the other side of the CSU.