Podium X Rebuild
Contents
1. RACING SHOX Shock Absorber Rebuild Manual Model PODIUM X FOX RACING SHOX 130 Hangar Way Watsonville CA 95076 PHONE 800 369 7469 ext 7647 FAX 831 768 7026 Email info foxracingshox com Website www foxracingshox com 605 01 017 Rev B TABLE OF CONTENTS DISClATINGD na a O ened 3 Consumer Dalol yersan E N a 3 Removal g INS CAN Oiio ienn R E EEA 3 Recommended Service Intervals ccccesccescceeeceeeeees seaeeeues 3 Tools amp Materials Required for Rebuild c ccc ccc e eee eee ees 4 IRC DUIIG IMS tr UCONN Sig aiA nox herent EE nen AE E EEEE 5 18 Contact Morna Oresi ri E T A 19 D o E E IE EI EE E N E AET E 19 Warrant PONO eeina a T A 19 Methodsof Payment ecssisanssscnunsesamneasanenesonen OTTE OERIEN NIA 19 Methods OF SID PINS reccbre ene odes a E 19 605 01 017 Rev C Disclaimer FOX Racing Shox is not responsible for any damages to you or others arising from riding transporting or other use of your FOX equipped vehicle In the event that your shock breaks or malfunctions FOX Racing Shox shall have no hability or obligation beyond the repair or replacement of your shock pursuant to the terms outlined in the Service and Warranty provisions of this manual Consumer Safety RIDING A MOTOR VEHICLE IS DANGEROUS AND CAN RESULT IN SERIOUS INJURY OR DEATH RIDE RESPONISBLITY AT ALL TIMES e Maintain your vehicle and your suspension e Always wear a helmet protective clothing and eye protection2. an y ee Di wees en lt ig 25 e a PEAR x 7 ee bon Figure 20 gt eae lt 4 4 ee Si i Dt Install the new well lubricated o ring into the bearing housing Correct o ring placement is in the groove next to the DU bushing Check to make sure the seal is properly seated and is not twisted If a tool is required to aid in proper seating of o ring use the non writing end of a pen or a similar soft blunt object to push it in Install the new U cup seal into bearing U cup should be installed so the cupped end is facing the DU bushing inside of bearing Check to make sure seal is properly seated If a tool is required to aid in proper seating of U cup seal use the non writing end of a pen or a similar soft blunt object to push it in Figure 21 11 605 01 017 Rev B P ANA Pe Al We et Ae n y Se Ke T aS Tr T RE TR T Pe 4s lt ee ie SAS Se ss oe my a Set ae FO Figure21 E Se 35 Clamp shaft eyelet securely in vice and place seal bullet tool on end of shaft 36 Slide bottom out bumper onto shaft The tapered side of the bottom out bumper should be facing away from the shaft eyelet 37 Lubricate the seal bullet tool with assembly lube Slide the bearing cap onto shaft with the threaded side facing away from the shaft eyelet Figure 22 This should be done in a single smooth motion to avoid damaging the seal If seal hangs up on the edge of the shaft DO NOT FORCE IT ON Re
3. e Ride within your limits e Tread lightly Removal amp Installation The method for removing and installing your FOX Racing Shox is different for every vehicle Refer to your vehicle s service manual for complete instructions Recommended Service Intervals Your FOX Racing Shox will perform the best if serviced at regular intervals Every Ride Wash and dry your vehicle and suspension Every 100 hours Visually inspect shock seals Every 500 hours or Annually Charge shock oil and seals Tools amp Materials Required for Rebuild 605 01 017 Rev C Damp Piston Bearing Damp Piston O ring IFP Bearing IFP O ring Resi end cap amp Bearing O ring Seal head shaft O ring Seal head shaft U cup seal Seal head shaft wiper 1 Fox dwt Shock Fluid 1 Qt Fox P N 803 11 005 2 Fox IFP Depth Setting Tool Fox P N 803 00 255 3 Fox Seal Installation Bullet 5 8 Fox P N 398 00 094 A 4 Pin Spanner Wrench 3 16 Pins 5 3 32 Hex Key Allen Wrench P 6 5 32 Hex Key Allen Wrench Rebuild Kit 803 00 230 7 T15 Torx Wremch 8 Scribe or Dental Pick A DE eee 9 W Flat Blade Screwdriver Qty 1 029 00 029 A 10 2 Phillips Screwdriver Qty 1 002 00 000 A 11 Standard Pliers Qty 1 029 00 324 A ne n Nose Pliers Qty 2 029 03 222 A 34 Socke 14 Torque Wrench ee eerie 15 Soft Faced Rubber Mallet se eee 16 Nitrogen Tank w Regulator Qty 1 036 02 002 A 17 Cleaning Solvent Qty 1 029 02 019 18 Vice
4. 46 47 on the IFP Figure 29 Be careful not to pull the IFP out completely Stroke the IFP back and forth a few times You should see bubbles rising to the surface inside the body tube Repeat this process until you don t see any new bubbles inside the body tube Figure 29 Set compression adjuster halfway in Firmly grip the reservoir housing With your other hand pull back forcefully on the IFP Depth Setting Tool until the edge of the IFP is close to being flush with the edge of the reservoir Stop the IFP in this position As you pull forcefully on the IFP you should feel tension as the IFP pulls back This step is done to open the damp plate circuit and bleed the system Let the reservoir hang in this position for a minimum of 5 minutes Hold the reservoir under the body tube with the compression adjuster facing up Slowly push the IFP into the reservoir until it bottoms out Set compression adjuster full in Fill the body tube with oil approximately 2 below the retaining ring groove Wrap the new piston band around the piston Insert the shaft assembly into the body tube allowing oil to overflow Figure 30 Slowly push shaft into body until piston assembly is approximately 1 below oil surface Slowly pull shaft assembly out of the body until the rebound ports of the shaft are just below the oil surface If you pull the shaft out too far you will hear a sucking noise when air is pulled in and will have to start the bleed
5. 1 017 Rev B Figure 15 27 Slide bearing assembly off of shaft Use extreme caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft Figure 16 28 Slide the bearing cap and bottom out bumper off of the shaft 29 Using a small pair of needle nose pliers grab the lip of the bearing cap dust seal Use an inward prying motion to remove the seal Figure 17 Figure 17 30 Using a small pair of needle nose pliers grab the lip of the U cup seal in the bearing assembly Use an inward prying motion to remove the seal Figure 18 Use a scribe or a dental pick to remove the o ring seal from center of the bearing assembly Figure 19 Use extreme caution when removing seals from bearing assembly Do not scratch the o ring groove or DU bushing Doing so will compromise the performance of your shock 10 31 32 33 34 605 01 017 Rev B Figure 18 Thoroughly clean the bearing bearing cap and piston assembly with solvent Dry with compressed air in a well ventilated area If compressed air is not available dry parts usine clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate Install new dust seal into bearing cap Seal should be installed with lip protruding from the flat side of the bearing cap Check to make sure seal is properly seated If a tool is required to aid in proper seating of seal oe
6. ELY DANGEROUS 16 605 01 017 Rev B 54 Remove the shock from the vice 55 Clean all oil residue from the shock and reservoir with solvent and dry with compressed air in a well ventilated area If compressed air is not available dry the shock and reservoir using clean lint free paper towels and let sit in a well ventilated area to allow the solvents to evaporate 56 Clamp the body cap of shock securely in vice with shaft end up Use pin spanner tool to secure the bearing cap to bearing Using a 3 32 hex key tighten the setscrew to lock the bearing cap into place Figure 38 Figure 38 57 Compress shock completely Roughly 60 pounds of force is required to initiate movement of shaft If you do not feel resistance to compressing the shock the reservoir pressure was not set correctly Once shock is fully compressed turn rebound adjustment knob clockwise until it stops Let go of the shaft The shaft should extend very slowly or not at all Turn rebound adjustment knob counter clockwise and set to the position recorded previously The shaft should speed up as adjuster is opened 17 605 01 017 Rev B NOTE Time permitting we recommend allowing the shock to sit for 24 hours and repeating step 59 This hold 58 59 60 61 62 period allows you to re inspect the shock and identify any possible oil leaks or nitrogen loss before the shock is re installed Reinstall the stainless steel thrust washers
7. ean the entire shock assembly with soapy water Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush Never pressure wash your shock as this can force water and debris inside which will damage the seals Dry the shock assembly with compressed air if available or use clean towels 6 Back the rebound adjustment screw all the way out full soft Back the compression adjustment knob all the way out full soft 7 Clamp the shock body securely in a vice with the shaft side up Be sure to use SOFT JAWS to prevent damage to the shock alternately a clean towel can be used in the vice jaws to protect the shock 8 Using a 3 32 Hex Key loosen the bearing cap set screw Use pin spanner tool to unscrew the bearing cap and slide the bearing cap up to the bottom out bumper Figure 3 605 01 017 Rev B A 11 Depress the reservoir end cap to expose the wire retaining ring Use a scribe or dental pick to remove wire ring Use extreme caution not to scratch the bore of the reservoir tube A thin valve shim can also be used to remove the ring Figure 6 605 01 017 Rev B 12 Thread reservoir cap extraction tool into reservoir end cap and remove using a twisting motion Set reservoir cap aside on a clean lint free paper towel Figure 7 13 Using your fingertips depress the bearing into the body tube to expose the wire retaining ring Locate the end of the ring and push inward with your
8. f the body facing up Turn E gt ee ba 4 gt compression adjustment knob all the way in or full clockwise full firm Lubricate the new IFP o ring with an ample amount of assembly lube and install it onto the IFP Hold the reservoir tube at a level that is below the shock body tube with the open end facing up Fill the reservoir to retaining ring groove with Fox 5wt shock oil 803 11 000 A You should see bubbles rising to oil surface Wait until bubbling slows or stops completely If oil level has fallen add more oil until level is at retaining ring groove Insert IFP into reservoir with the bleed screw removed Use a smooth motion and push straight in until o ring seats into the retaining ring groove allowing oil to overflow Install the IFP bleed screw Back the compression adjustment knob all the way out Use your free hand to wrap new piston band around IFP with the rounded edge out and push the IFP into the reservoir until the edge is flush with the end of the reservoir Figure 27 Be careful not to pinch the piston band Now holding the reservoir below the body tube with the compression adjuster side up push IFP into reservoir tube until it bottoms out inside Figure 28 You should see large air bubbles rise to the surface of the oil in the body tube 13 605 01 017 Rev B Figure 28 44 Fill shock body half way with oil While still holding the reservoir below the body tube very slowly pull back 45
9. fingertip Remove retaining ring A scribe or dental pick can also 14 Align the slot of the IFP Depth Setting Tool with the end of the IFP Internal Floating Piston Insert the IFP Depth Setting tool into reservoir and rotate 90 degrees to engage the IFP Push the IFP Depth Setting Tool until the IFP bottoms out inside of reservoir This will cause shaft assembly to be pushed out of the body tube Figure 9 If this does not happen easily you will need to pull up on the shaft assembly to remove it from the shock body Remove the shaft assembly from the body tube and place on a clean lint free paper towel 605 01 017 Rev B 15 Gently pull the IFP out of the reservoir tube using the IFP Depth Setting Tool Figure 10 and place it ona clean lint free towel Remove the shock from the vice and pour shock oil from body and reservoir tubes into a proper disposal container DO NOT RE USE OLD SHOCK OIL Take several sheets of clean lint free paper towels and stuff them into the body and reservoir tubes This is done to prevent residual oil from dripping out of body and reservoir tubes st 16 Inspect IFP o ring If it is worn or damaged remove using a scribe or dental pick Use extreme caution not to scratch the o ring groove Place the IFP on clean lint free paper towel 17 Next inspect the CD adjuster Using a T15 torx wrench remove blue CD knob Figure 11 SS Figure 11 18 Using 5 8 socket remove CD adjuster f
10. ing process over Add oil as necessary Repeat the previous steps until there are no more bubbles rising to the oil surface 14 48 49 605 01 017 Rev B Hold the shaft assembly as straight as possible and hit the shaft eyelet a couple of times squarely from above with a rubber mallet Figure 31 This is done to momentarily open the shim stack and allow any trapped air to escape You should see small bubbles rise to the surface Fill body tube with oil until oil level is flush with edge of body tube Slowly pull the shaft out until rebound ports are just below the oil surface If you pull the shaft out too far you will hear a sucking noise when air is pulled in If this happens you will have to start the bleeding process over Add oil as necessary Hold the shaft eyelet with one hand With other hand slide the bearing assembly down the shaft until contact with oil is made Find the bleed port in bearing assembly and position it away from your face and body With one hand very slowly push the bearing assembly into body tube Be sure to have a small container in your other hand to catch the excess oil as it flows out of the bleed port in the bearing Do not allow the shaft to move as you push the bearing in until the bearing makes contact with the piston assembly Then push bearing and shaft assembly into body tube until it stops at the external o ring of the bearing assembly Figure 32 With one hand continue applying pressure to
11. move the bullet tool with the bearing cap still attached from the shaft end Remove the bearing cap from the bullet tool and repeat this step Figure 22 38 Lubricate the bearing assembly seals with an ample amount of assembly lube Slide the bearing assembly onto shaft with the threaded side facing the bearing cap Figure 23 This should be done in a single smooth motion to avoid damaging the seals If a seal hangs up on the edge of the shaft DO NOT FORCE IT ON Remove the bullet tool with the bearing assembly still attached from the shaft end Figure 24 Remove the bearing assembly from the bullet tool and repeat this step 12 39 40 41 42 43 605 01 017 Rev B Insert the shaft of a phillips head screwdriver through the center of the piston assembly The pointed end of the screwdriver should be on the same side as the top out plate large black plate Cut and remove the tie wrap that was holding the piston assembly together Hold the piston assembly from underneath the top out plate and insert the end of the screwdriver into the shock shaft Figure 25 Slide the piston assembly onto the shaft end Check to make sure ensure the piston assembly is properly seated and install the piston lock nut Torque the nut to 25ft lbs Figure 26 l p ISR i e j F Pme _ al _ J Ya P 4 F K Figure 25 D p Figure 26 E Clamp the body cap of the shock securely in the vice with the open end o
12. r 4 Include a description of the problem vehicle information manufacture year amp model type of FOX product spring rate type of riding and a return address with daytime phone number Warranty Policy FOX Racing Shox products are covered by a 1 Year Limited Warranty against defects in materials and or workmanship Any modifications to the product will void all warranty This Warranty will be extended to the original retail consumer of an OEM Customer s FOX Racing Shox equipped vehicle and is valid for one year from the original date of purchase from an OEM Customer s authorized dealer Warranty is limited to the repair or replacement of the FOX Racing Shox product FOX Racing Shox reserves the right of final decision with regards to all warranty related issues Warranty is void when damage to the shock has occurred from the following Abuse Seal damage due to power washing Damage to the exterior finish caused by debris rocks or crashes Any attempts to disassemble shock absorber Modifications Non factory oil use or improper service Shipping damage or loss purchase of full insurance is recommended Methods of Payment VISA MasterCard and or Cashier s Check Methods of Shipping FOX Racing Shox uses UPS Ground Service within the USA Customer may request UPS Air Service at an extra cost All non warranty shipping charges are the customer s responsibility 19
13. rom reservoir assembly Figure 12 19 20 21 22 23 24 29 26 605 01 017 Rev B Inspect inboard and outboard o rings for wear If worn replace Be careful not to scratch CD housing when removing o rings Figure 13 C Reflow check valve Fi gure 13 Inspect the reflow check valve to ensure that it operates smoothly and that the valve is not bent or deformed When the components in CD adjuster cartridge are inspected and or replaced reinstall into reservoir assembly Torque to 12 ft lb Install blue knob back on CD adjuster cartridge Torque to 22 in lb Set body assembly aside on a clean lint free paper towel Clamp the shaft eyelet securely in vice with the piston end up Using a 34 wrench remove piston lock nut from end of shaft Slide only the tip of Phillips Head Screwdriver into hole at end of shaft Hold the piston assembly under the top out plate and lift upwards Slide the piston assembly onto the shaft of the Screwdriver Remove the Screwdriver from shock shaft while supporting the piston assembly Figure 14 Slide a 12 inch tie wrap through the entire piston assembly Secure the two ends of the zip tie together and remove the screwdriver Figure 15 There are many pieces to the piston assembly and the assembly order of these pieces is critical to the proper performance of your shock This step ensures that the proper order is kept Place piston assembly on a clean lint free paper towel 605 0
14. tender spring spring coupler main spring and spring retainer on shock body Thread the spring preload ring down against the spring and set the preload to the measurement you took when you removed the spring Figure 1 Tighten pinch bolt to lock preload ring in place Torque to approximately 5 ft lb Set the compression and rebound adjusters to the position recorded previously Remove the shock from the vice Reinstall spherical bearing o rings and reducers Congratulations You ve completed the servicing of your FOX Racing Shox Carefully reinstall the shock on your vehicle Be sure to RIDE SLOWLY in the beginning to ensure the shock and your vehicle s suspension is performing correctly Thanks again for choosing FOX Racing Shox 18 605 01 017 Rev B Contact Information FOX Racing Shox Phone 800 369 7469 ext 7647 130 Hangar Way North America 800 369 7469 Watsonville CA 95076 Fax 831 768 7026 E mail info foxracingshox com ebsite www foxracingshox com Business Hours Monday Friday 8 O0AM 5 00PM Pacific Time Service Warranty 1 Contact FOX Racing Shox at 800 FOX SHOX 800 369 7469 to obtain a Return Authorization Number RAN and shipping instructions 2 Satisfactory proof of purchase receipt is required for warranty consideration 3 Mark the Return Authorization Number RAN and the Return Address on the outside of the box Send the shock to FOX Racing Shox with the shipping pre paid by sende
15. the bearing assembly With other hand set the compression adjustment knob full out As you do this the bearing and shaft assembly should push further into the body tube Push the bearing and shaft assembly into the body tube until the retaining ring groove is exposed Figure 33 Install the wire retaining ring and check to make sure retaining ring is properly seated 15 605 01 017 Rev B 50 Push the IFP further into the reservoir As you do this the shaft and bearing assembly should rise until the S1 I bearing assembly engages with the wire retaining ring inside the body tube Remove the IFP depth setting tool by rotating it 90 degrees Install the reservoir end cap with the Schrader valve facing the outside of the reservoir tube Figure 34 Push down on the reservoir end cap using even pressure until it bottoms Figure 35 Install the wire retaining ring and check to make sure retaining ring is seated properly Push the shaft assembly completely into the body tube If reservoir cap is not properly seated against the retaining clip tap it gently with a rubber mallet until it snaps into place Remove shock assembly from vice gt Dee a Figure 35 Using a Nitrogen regulator system charge the shock through the reservoir Schrader valve to 200 PSI Figure 36 CHARGE THE SHOCK USING NITROGEN GAS ONLY DO NOT FILL WITH ANY OTHER GASSES Doing so will compromise the performance of your shock and may be EXTREM
16. w Soft Jaws Qty 1 029 03 022 A 19 Tape Measure 20 Reservoir End Cap Extraction Tool CD adjuster housing O ring CD adjuster housing O ring 605 01 017 Rev B REBUILD INSTRUCTIONS Important notes e SAFETY FIRST Always wear safety glasses and read directions completely BEFORE disassembling the shock e Cleanliness is critical make sure your work area is clean and un cluttered prior to starting work Contamination of the shock will lead to premature wear and poor function of your shocks e IMPORTANT When replacing a seal during a service make sure that the new seal is the same size shape and material as the one you are replacing In some cases there may be two seals in the rebuild kit that look similar 1 Measure the location of the preload ring and cross over ring note some shocks with single spring will not have a cross over ring relative to the body cap Figure 1 Figure 2 Record these measurements as well as the rebound and compression adjustment settings 14 1 lt Fz Figure Figure 2 A R pe yo x pa t aii 2 Using a 5mm allen wrench loosen pinch bolt on preload ring and back it off until spring is loose on the body Remove the lower spring retainer 3 Remove the springs spring coupler and stainless steel thrust washers note some shocks with single spring will not have tender spring or spring coupler 4 Remove the eyelet reducers and o rings from both ends of the shock 5 Cl
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