Step 1

Remove the Air Cap by turning it counter-clockwise. Release the air pressure by depressing the Schrader Valve core.

Step 2

Unthread the black Rebound Knob Cover by turning it counter-clockwise. Remove the red Rebound Knob by turning the 2mm hex screw counter-clockwise with a 2mm hex wrench. You do not need to fully remove the screw from the knob to remove the knob from the fork.

Step 3

Unthread the damper-side Bottom Nut by turning it counter-clockwise with a 15mm socket. Unthread the spring-side Bottom Nut by turning it counter-clockwise with a 10mm socket. Remove both crush washers. 

Step 4

Use Damper Removal Tools 398-00-681 and 398-00-682 to dislodge the shafts from the lowers. Make sure that you have approximately half of the available threads engaged with your tool before striking with your mallet. Remove the damper removal tools, then bring the fork upright over an oil basin to drain. After oil stops draining from the lowers, pull the lowers off of the upper tubes and set them aside.

Step 5

With a chamfer-less 6-point 32mm socket (PN: 398-00-705), unthread the air-side topcap assembly completely by turning it counter-clockwise. Pull straight up to remove the entire topcap assembly from the air-side stanchion tube. Some upward force might be needed to overcome the friction of the stock air volume spacers.

Step 6

Remove the Retaining Ring from the bottom of the air-side Upper Tube. Take care not to scratch the Air Shaft with the Retaining Ring or Pick tool. Remove the Air Shaft Assembly by pulling it out of the bottom of the air-side Upper Tube.

Step 1

Use a lint-free paper towel to remove the q-ring from the air piston. DO NOT use any tools to remove the q-ring as you can damage the sealing surfaces of the piston. Install a new greased q-ring from the kit making sure it is fully seated and not twisted.

Step 2

Clean the shaft with Isopropyl alcohol then clamp it in your 10mm shaft clamps (PN: 803-01-324). Remove and discard the o-ring from the base stud then carefully apply heat to the shaft at the base stud with a propane torch for 5-10 seconds to break down the Loctite.  

Step 3

Unthread the base stud counter-clockwise with a 12mm wrench, then lift up to remove. For forks 130mm and longer, remove the remaining o-ring on the base stud and replace with a new greased one from the kit. Forks 120mm and shorter do not have this seconday o-ring on the base stud.

Step 4

Lift up on the neg plate to remove it from the shaft. Remove the external o-ring and replace it with a new greased one from the kit. Remove the seal from the inside of the neg plate.

Step 5

Install a new greased Q-ring from the kit into the seal groove. Insert the seal through the bushing and guide it into position with a blunt tool like a 2mm hex wrench or similar. Make sure the Q-ring is fully seated in it's groove and not twisted.

Step 6

Insert the FLOAT NA2 bullet tool (PN: 398-00-657) into the shaft, then coat it with a thin film of Slick Honey. Reinstall the neg plate. Remove the bullet tool.

Step 7

Apply 1-2 drops of red Loctite 262 to the threads inside the shaft, taking caution not to get Loctite in the area of the shaft where the base stud o-ring will seat. Insert the base stud and thread it in clockwise, tightening to 50 in-lb (5.7 Nm) torque with a 12mm crow's foot.

Step 8

Install a new greased o-ring from the kit onto the base stud.

Step 9

Apply a thin film of Slick Honey to the inside of the upper tube. Apply a thick film of Slick Honey to the air shaft assembly in the areas of the piston, neg plate, and shaft above the neg plate. 

Step 10

Insert the air shaft assembly into the end of the upper tube. Push the air shaft assembly into the upper tube far enough to allow you to start the neg plate into the upper tube. Push the shaft into the upper tube to pull the neg plate into its installed position.

Step 11

Replace the retaining ring making sure it is fully seated in its groove by pulling on the air shaft.

Step 12

Inject 3cc of FOX 20wt. Gold oil into the main air chamber through the top of the upper tube. Reinstall the topcap into the fork crown and tighten clockwise to 220 in-lb (24.8 Nm) torque with your 6-point chamfer-less 32mm socket.

Step 13

Add air pressure to your desired setting using a FOX high pressure pump. Reinstall the air cap.

Step 1

Soak the new foam rings from the Dust Wiper kit in a small cup of FOX 20wt. Gold bath oil.

Step 2

Using a wooden or plastic dowel is the recommended method for removing the dust wipers and foam rings. If you choose to use a wrench or other metallic tool, use extra caution not to scratch the inner wall of the magnesium lower leg, as you lever out the dust wiper. Do this by making sure the tip of your metallic tool is cushioned from the magnesium lower leg by the foam ring, just below the dust wiper.

Repeat the process on the other side. Discard the original foam rings and dust wipers as they are not reusable once removed due to potential distortion.

Step 3

Thoroughly clean the seal bore and the inside of the lower legs with warm soapy water or Isopropyl alcohol. Blow the lowers dry with clean compressed air. Install new foam rings soaked in FOX 20wt. Gold Oil.

Step 4

Use a small amount of FOX 20wt. Gold oil to coat the outside ribs and exposed metal base of the new dust wiper. Rest the oiled wiper onto the seal driver.

Step 5

While holding the lower leg driver straight in relation to the fork, tap the driver with a plastic faced mallet until the wiper is flush with the edges of the seal bore. Repeat on other side.

Step 1

Reinstall the Lower Leg Assembly onto the Upper Tubes then invert the fork so the dropouts are higher then the rest of the fork. Inject 10cc of FOX 20wt. Gold oil into the spring-side Lower leg. Inject 20cc of FOX 4wt. oil into the damper-side Lower Leg.

Step 2

Push the Lower Leg Assembly fully onto the Upper Tubes to fully seat the Lower Leg Assembly. Clean the threads of the Plunger Shaft and Damper Assemblies with Isopropyl Alcohol and a lint-free paper towel.

Step 3

Install a new Crush Washer onto each threaded shaft followed by the appropriate Bottom Nut. Tighten the spring-side Bottom Nut clockwise to 50 in-lb (5.7 Nm) torque with a 10mm socket. Tighten the damper-side Bottom Nut clockwise to 150 in-lb (16.9 Nm) torque with a 15mm socket.

Step 4

Use a 2mm hex wrench to install the red rebound knob. Make sure that the set screw lines up with the depression in the rebound adjuster shaft. Reinstall the black rebound knob cover. Clean the exterior of your fork.