SERVICE PROCEDURES
2016-2018 FLOAT X2 and DHX2 2-Position Lever Upgrade
Required Parts
- 803-01-131 Kit: Upgrade, X2 F-S 2-Position Lever CD Cartridge Assembly, and Valve Seat
- 803-01-252 Kit: Upgrade, 2018 X2 F-S 2-Position Lever CD Cartridge Assembly, and Valve Seat
Required Tools
- 027-00-013 Pump: Fox Digital HP w/ Bleed, Foldable, Replaceable Battery, 300 psi
- 398-00-417 Tooling: 2016 Float X2, Cartridge Adjuster
- 398-00-662 Service Tool, Check Plate Socket, DHX2/Float X2, 2pos-Adj
- 398-00-680 Tooling: Custom Spanner Socket, X2, Rebound Base Piston
- 398-00-686 Tooling: 2016 Float X2, Check Plate Driver, 14mm Hex with Relief
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.
The Damping Adjuster Cartridge Assemblies should be considered non-rebuildable as they are difficult to dissassemble and reassemble. The Damping Adjuster Cartridge Assemblies do not need to be removed from the shock to perform a full rebuild. If damaged, please replace as complete assemblies.
X2 Damping Adjuster Cartridge Assemblies should be removed and replaced one at a time on complete shocks to prevent needing a vacuum bleed. The procedure below shows the removal and installation of one Damping Adjuster Cartridge Assembly. If needing to access both rebound and compression assemblies, do not have both adjusters out at the same time. Remove and replace one, then repeat for the other assembly.
The following procedure guides you through the removal of the stock Compression Adjuster Assembly and installation of the X2 2-Position Compression Adjuster Assembly into a new FLOAT X2 or DHX2 shock. If doing this upgrade to a used FLOAT X2 or DHX2, a full bleed is recommended as shown in the rebuild procedure.
Complete and bled FLOAT X2 and DHX2 shocks can have their Damping Adjuster Cartridge Assemblies removed and installed without performing a full rebuild or vacuum bleed.
X2 Damping Adjuster Cartridge Assemblies can also be removed and replaced during a full rebuild if desired. For full rebuild instructions please go to:
Additional information and details about Damping Adjuster Cartrige Assembly removal and installation in X2 shocks can be found by clicking: X2 Damping Adjuster Cartridge Assembly Removal/Installation »
Step 1
Start by preparing the X2 2-Position Compression Damping Assembly by removing the Valve Seat Assembly. Remove the blue lever with a 1.5mm hex, then remove the black cartridge cap and set aside.
Step 2
For best results, FOX recommends vacuuming X2 Damping Adjuster Cartridge Assemblies in an oil bath to purge any trapped air from within the cartridge. A clear syringe with a removable plunger is needed for these steps.
If the syringe is unavailable to you, X2 Damping Adjuster Cartridge Assemblies may be installed without first being vacuumed. Assemblies should be completely submerged in FOX 10wt. red oil for at least 10 minutes with some slight aggitation throughout that 10 minute period to dislodge most trappped air. Results may vary and your shock may need a full bleed as described in the full rebuild procedure:
If not using the syringe to pre-bleed the Damping Adjuster Cartridge Assembly, please skip to step 5.
Step 3
Drop the Adjuster Cartridge Assembly into the empty syringe, then insert the plunger and seal the syringe. Draw 10wt. red oil into the syringe and purge out any excess air until the Damping Adjuster Cartridge Assembly is completely submerged.
Cover the open tip of the syringe with a gloved finger, then pull the plunger to create a vacuum within the syringe. Make sure the Damping Adjuster Cartridge Assembly remains submerged in oil as you see bubbles escaping from the assembly.
Step 4
When bubbles have stopped escaping from the assembly, release the plunger. Remove the syringe plunger while keeping the assembly submerged. Pour the assembly out into a container of oil.
Step 5
Make sure FLOAT X2 and DHX2 shocks are fully extended. Do not release air pressure from the main air chamber of the FLOAT X2 shock.
Step 6
Clamp the FLOAT X2 or DHX2 shock in your soft-jawed vice and unthread (counter-clockwise) the reservoir end cap assembly from the reservoir with a 6mm hex wrench. Release the nitrogen charge by depressing the Schrader valve within the reservoir.
Step 7
Clamp the non-adjuster eyelet in your soft-jawed vice so the shock sits horizontal and the Damping Adjuster Cartridge Assemblies are facing up and level.
Step 8
Use the Adjuster Cartridge tool (PN: 398-00-417) to unthread the compression adjuster counter-clockwise. Remove the Adjuster Cartridge Assembly, High Speed Spring, and Poppet assembly.
WARNING: X2 Valve Seat Assemblies are left-hand threaded. Remove by turning clockwise. Install by turning counter-clockwise. Improper removal or installation can cause part failure, causing the rider to lose control resulting in SERIOUS INJURY OR DEATH.
Step 9
Remove the original Compression Valve Seat Assembly by unthreading it clockwise with the 14mm hex wrench PN: 398-00-686 (shown) or Custom Spanner Socket, X2 PN: 398-00-680.
Step 10
Add FOX 10wt. red oil to the eyelet, then install the X2 2-Position Compression Valve Seat by threading it counter-clockwise to 80 in-lb (9.0 Nm) with the Check Plate Socket, DHX2/Float X2, 2pos-Adj (PN: 398-00-662).
Step 11
Top off the eyelet opening with FOX 10wt. red oil. Make sure the High Speed Spring and Poppet Assemblies are assembled onto the Damping Adjuster Cartridge Assembly, then drop them into the eyelet and press down to fully seat the assembly.
Step 12
Install the black Cartridge Cap and thread clockwise to 80 in-lb (9.0 Nm) torque.
Step 13
Use the blue 2-position lever to rotate the adjuster counter-clockwise until it comes to a gentle stop. Remove the blue lever and reposition it on the aduster so that the lever can rotate through it's entire range without contacting the shock eyelet or any part of the bike frame. Tighten the set screw with a 1.5mm hex wrench clockwise to 3.5 in-lb (0.4 Nm).
Step 14
For DHX2 shocks fill the IFP chamber to 150 psi (10.3 bar) with your shock pump.
For FLOAT X2 shocks fill the IFP chamber to 125 psi (8.6 bar) with your shock pump.
Install the reservoir end cap, tightening to 30 in-lb (3.4 Nm) with your 6mm hex wrench.
Dyno test all functions of the shock to verify proper performance. Perform a full bleed if necessary by following the steps in the rebuild procedure available here:
Clean the exterior of your shock.