Shock Absorber Rebuild Manual
Contents
1. Generation II Shaft Generation Shaft To be replaced 4 Generation Il Metering Rod Part number series are 210 58 XXX 5 Generation Il Shaft part number series are 229 49 XXX b 605 01 016 Rev E 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 1 With your vehicle safely placed on a stand carefully remove the shocks Set the mounting hardware aside 2 Remove the eyelet reducers and o rings clean and set aside keeping careful note of top and bottom reducers Carefully wash and wipe the exterior of the shock to remove any dirt that may cause contamination Check the position of the compression and rebound clickers Do this by turning the knobs full clockwise and counting clicks Rebound and compression clicker settings are counted as clicks out from full in clockwise closed The compression clicker should have between 18 and 20 clicks The rebound clicker should have between 18 and 23 clicks After you2. ee Me ss B th 50 Using a small amount of assembly lube install the new samurai wiper ensuring the seal lip is orientated outwards 605 01 016 Rev E 51 Heavily lubricate the seal and bearing surfaces of the FLOAT X EVOL air sleeve Completely fill the seal and bearing glands with assembly lube 52 Use the air sleeve bullet tool and lube to slide the air sleeve back onto the body 53 Set the slow speed DSC adjuster to fully open 54 Fill the piggyback reservoir with clean oil almost to the rim it is normal for oil to seep through the CD into the shock body just keep topping off the reservoir until close to over flowing 55 Set the slow speed DSC adjuster to fully closed remove the IFP bleed screw and insert the IFP into the reservoir 56 Slowly push the IFP down into the oil ensuring that the trapped air bleeds out of the hole DO NOT push the IFP to the bottom of the reservoir yet 57 Install the IFP bleed screw It is ok to leave some oil trapped in the reservoir above the piston 58 To bleed the DSC mechanism open the slow speed DSC adjuster and push the IFP to the bottom of the reservoir Next pull the IFP back to 2 from the top of the reservoir Repeat this step several times to ensure a full bleed 605 01 016 Rev E 59 Fill the shock body with oil to about 1 5 from the top of the shock body and close the slow speed DSC adjuster 60 Back out the rebound adjuster on the shaft
3. RACING SHOX Shock Absorber Rebuild Manual Model FLOAT X EVOL 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 01 016 Rev E TABLE OF CONTENTS SS UN VST A A E E E E 3 OS UMT eS y cecetcc ec vette erecta acta eee ce eadansnedsneaias 3 kamovale IAS RAN Sl Oli teaserarsaricmrereenan tases vanveeaiescnanmmrmanancaen 3 Recommended Service INCErVAIS ccccceeseeseesseesssessteessesseesenees 3 Service Tools CONSUMADIES cccccccscseessssescsssesseeesseessteesieeeseneas 4 FOX SOSCIA TOO eieaa Eeoa 4 Fox FLOAT X EVOL Service Parts Kit ssssssssesrseerserrerrsrrernn 5 Rebuild INStrUCtIONS s ssnnssnssnsneenrsrrsrnsrrsrrnrrrsrrnsrrsrrsnrnsrnsrrnnrnnn 6 20 COMEACE ATOM IIA GION esisi ernen n ee E 21 OC O E 21 Warranty POLICY cccccccssssscssceeescecscsssreeeeeeeeeeseseeeesesteeeeeeeeeeesens 21 Methods of EZ hs 9 92 9 Gener nee nee eer nnn nE EEEN 21 Methods Of SHIP DIN QL ccceccccccesssseseeeeeeeseseeessseeeeveeeeeseeserssees 21 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 liability or obligation beyond the repair or replacement of your shock pursuant to the terms outlined in the Service
4. Air sleeve bullet tool FOX P N 398 000 244 Shaft bullet tool FOX P N 398 00 026 B Reservoir end cap extraction tool IFP setting tool FOX P N 803 00 294 Bearing Holder O Ring Install Tool FOX P N 398 00 279 Continuous Piston Band Installation Tool FOX P N 803 00 288 Shaft and Body Clamp 1 459 Bore 0 50 Shaft FOX P N 398 00 283 DSC Valve 29mm Hex Install Tool FOX P N 398 00 267 FOX Oil High VI Race Oil light Swt 1 0 Quart FOX P N 803 11 005 FOX Oil High VI Race Oil Clight 5wt 1 0 Gallon FOX P N 803 111 004 605 01 016 Rev E FOX FLOAT X EVOL Service Parts Kit 1 pair of shocks 803 000 229 EVOL IFP O RING CD HOUSING O RING INNER CD HOUSING OUTER END CAP O RING FOX Float Fluid 5cc pillow pack Fox P N 029 00 211 A Fox P N 029 02 019 A Fox P N 029 03 022 A Fox P N 025 03 002 A Description Qty Part Number BODY CAP O RING 2 Fox P N 029 01 135 A EXTERNAL O RING 2 Fox P N 029 03 033 A SAMURAI WIPER Blue 2 Fox P N 036 02 016 A SAMURAI BACK UP SEAL Black 2 Fox P N 036 02 017 A AIR SLEEVE SEAL 2 Fox P N 036 01 014 A AIR SLEEVE SLYD RING 4 Fox P N 002 00 013 CONTINUOUS PISTON BAND 2 Fox P N 002 002 015 PISTON O RING 2 Fox P N 029 08 066 SHAFT SEAL 2 Fox P N 036 01 013 A SHAFT O RING 2 Fox P N 029 06 112 A BEARING TO BODY O RING 2 Fox P N 029 03 125 A IFP O RING 2 Fox P N 029 00 324 A IFP BEARING 2 Fox P N 002 00 000 A 2 2 4 2 Correct o ring placement is CRITICAL to ensure correct shock perform
5. air piston seal in the center groove and pry it outward away from the bearing assembly Insert the barrel of a pen or similar plastic part that will not scratch the aluminum behind the air piston seal and pry it all the way out of its groove and off of the bearing assembly 35 Using a little assembly lube carefully work the replacement seal into the seal groove of the bearing The grooved side of the seal concave should point towards the non threaded end of the bearing The orientation of this seal is critical Be sure it is oriented correctly 605 01 016 Rev E 36 Using a pick tool while taking care not to score the aluminum remove the SHAFT SEAL 46 and SHAFT O RING 47 Again using a little assembly lube carefully work the replacement o ring and seal into the bearing You may need to use a small blunt tool to helo work these parts into place 38 If you would like to inspect the condition of the EVOL IFP 21 and EVOL IFP O Ring 22 apply a loosening torque to the EVOL RESERVOIR END CAP 17 and to the EVOL RESERVOIR 20 using a 1 wrench and a rubber strap wrench respectively In this manner remove the end cap and reservoir from the EVOL OFFSET ADAPTOR 23 as a single unit To bypass the EVOL chamber overhaul skip to step 43 605 01 016 Rev E 39 To remove the EVOL IFP 21 from the EVOL RESERVOIR 20 cover the end of the reservoir with a rag and charge the SCHRADER VALVE 16 with a jet of
6. completely by pressing the center pin of the Schrader Push the RESERVOIR END CAP 51 down and use a pick tool to remove the RESERVOIR SNAP RING 52 Pull the reservoir end cap out of the reservoir Use FOX Reservoir End Cap Extraction tool With End cap removed measure the depth of the IFP in the reservoir for reference during reassembly Note your IFP Depth a 605 01 016 Rev E 14 Using a 5 64 Allen wrench carefully loosen the BLEED SET SCREW 41 and remove the BALL BEARING 29 set aside tip use a small magnet to remove the ball from the hole ty 15 Using IFP setting tool raise the IFP approximately 1 such that the oil height in the shock body is lowered 16 Using the FOX bearing head removal tool unscrew the BEARING HEAD ASSEMBLY 42 from the shock EVOL end of the shock free from the reservoir half of the shock You may need to gently wiggle rock the shaft to help ae 19 605 01 016 Rev E Remove the air sleeve from the reservoir end of the shock During normal operation the exterior of the air sleeve may get minor chips in the anodizing from roost If the shock has sustained significant damage from large rocks or flying debris the air sleeve will need to be replaced 20 Inspect the air sleeve EXTERNAL O RING 35 replace if necessary 21 Examine the condition of the AIR SLEEVE BEARING 14 SAMURAI BACK UP SEAL 13 and SAMURAI WIPER 12 If the two seals show sig
7. the desired setting is reached If the previous settings are not known use the following table as a starting point pe 14 clicks 14 clicks 14 clicks 140 Ib out out out Pi al 180 Ib out out out pr ala aa 200 Ib out out out Time permitting we recommend allowing the shock to sit for 24 hours This hold period allows you to re inspect the shock and identify any possible oil air or nitrogen leaks Congratulations you have completed the servicing of your FOX Racing Shox Re fit the eyelet reducers and new o rings and re fit the shocks to the vehicle using the manufacturers recommended torque settings After conducting a complete suspension tear down be sure to RIDE SLOWLY in the beginning to make sure the shock and your vehicle suspension are performing correctly Contact Information FOX Racing Shox Phone 800 369 7469 ext 7647 150 Hangar Way North America 800 369 7469 605 01 016 Rev E Watsonville CA 95076 Fax 831 768 7026 E mail info foxracingshox com Website www foxracingshox com Business Hours Monday Friday 8 00AM 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
8. the shipping pre paid by sender 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 e 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
9. ve checked the setting and for smooth operation of the clickers back both adjusters fully out or full open counter clock wise Securely mount the shock in a soft jaw vice by the EVOL chamber end BOTTOM Remove the gold Schrader valve caps set aside Using the 1I50PSI FOX high pressure pump take note of the main chamber pressure Write it down Using the 300PSI FOX high pressure pump take note of the EVOL chamber pressure Write it down Using the pump or a suitable blunt tool deoressurize the MAIN chamber first and the EVOL chamber second Both should hiss as air is released and the shock should contract slightly due to the internal negative spring oe 10 11 12 13 605 01 016 Rev E Loosen the AIR SLEEVE 38 use a strap wrench positioned over the very end of the sleeve to orevent distortion Un tighten but do not fully remove the air sleeve yet Flip the orientation of the shock and securely fasten it in the vice by reservoir end TOP Completely un thread the air sleeve from the EVOL body cap by hand and slide it down the body Look for oil in the air chamber sitting on top of the bearing head assembly This indicates worn shaft seals There should be a small amount of assembly lube present but no shock oil in the air chamber NO OIL IN HERE Using a pin spanner wrench remove the RESERVOIR SCHRAEDER CAP 49 set aside Using a suitable sharp pointed object depressurize the nitrogen charge
10. ance and to avoid leaks When replacing an o ring check the old o ring internal diameter and cross sectional diameter to ensure that you have the correct new o ring out of the kit to replace it lt 605 01 016 Rev E This following instruction will explain the differences between the Generation vs Generation II Shaft and Metering Rod design There is a chance that if you are servicing an older set of Float X Evol shocks that it could contain Generation parts that needs to be replaced Generation parts are no longer available and has been completely replaced by Generation Il parts If you service shocks with Generation Shaft Rod design we recommend getting the parts replaced by Generation II Shaft Rod Keep in mind to always replace these parts if the shocks come as a pair Generation and II parts are NOT interchangeable and WILL NOT work together 1 To determine if the Rod Shaft is of Generation or Il disassemble the shock and inspect the parts per below always update to Generation II parts 2 Generation Metering Rod vs Generation II Metering Rod shown below Always replace Shaft and Rod at the same time Generation II has an o ring gland Generation Metering Rod To be e replaced lt 7 Generation II Metering Rod 605 01 016 Rev E 3 Generation Shaft vs Generation Il Shaft shown below It Is critical to always replace the Shaft and Metering Rod at the same time
11. and Warranty provisions of this manual 605 01 016 Rev E Consumer Safety RIDING A MOTOR VEHICLE IS DANGEROUS AND CAN RESULT IN SERIOUS INJURY OR DEATH RIDE RESPONISBLY AT ALL TIMES Maintain your vehicle and your suspension Always wear a helmet protective clothing and eye protection Ride within your limits 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 Change shock oil and seals Service Tools consumables 605 01 016 Rev E Safety Glasses Latex Gloves Vice w soft grip jaws Clean lint free workshop cloth Air compressor w snub nose adaptor Regulated Nitrogen pre charge rig with Schrader adaptor Pin soanner wrench Torque wrench Assorted sockets Glass beaker or suitable container for used oil Light viscosity Lithium based grease assembly lube Scribe Dental Pick tool 5 64 Hex key Allen wrench T15 Torx wrench Small magnet Rubber Mallet Air sleeve rubber strap wrench FOX Special Tools Service Rebuild Kit FOX P N 803 000 229 Bearing Head removal install tool Torque wrench extension FOX P N 398 00 249
12. assembly Using a small Allen wrench depress the METERING ROD 39 by inserting the long end of the Allen wrench into the SHAFT POST 4 and lightly pressing until the metering rod moves away from the jet 61 While holding the negative spring and spacer at the top of the shaft with one hand insert the shaft and bearing assembly into the shock lower taking care not to spill oil into the air sleeve 62 Very slowly push the shaft down into the oil while rotating and wiggling the shaft until there are no bubbles rising in the oil 63 Using a rubber mallet gently tap the shaft to allow air trapped between the piston and valve shims to escape 64 Gently lower the negative spring and spacer into the oil taking care not to let the oil overflow into the air sleeve 605 01 016 Rev E 65 Make sure the piston assembly and the rebound hole in the shaft DO NOT come out of the oil bath If the rebound adjust hole in the shaft comes out of the oil bath air can transfer to the underside of the piston aerating the shock Add oil to the shock as required to keep the hole covered Pull the shaft assembly out of the oil until the top of the negative spring is even with the end of the body 66 Add 1 2cc s of Float fluid to the gap between the air sleeve and the damper body underneath the bearing The Float fluid lubricates the external sliding air sleeve seals Do this before installing the bearing head assembly This Float fluid lubricate
13. compressed air to shoot the IFP out of the chamber 40 Inspect the condition of the IFP and o ring and replace if necessary 41 Run a grease covered finger around the inside of the EVOL reservoir to lubricate the surface taking care NOT to introduce large amounts of grease to the EVOL reservoir 42 Add 1 2cc s of float fluid to the Evol reservoir by dribbling it down the inside wall of the EVOL chamber This helps to lubricate the IFP and Is the only lubrication this part receives during normal operation 43 Make sure the EVOL IFP and o ring are heavily lubricated with grease prior to re assembly Re install the IFP 44 Inspect the EVOL RESERVOIR O RING 18 for damage or wear replace 45 Torque the EVOL RESERVOIR END CAP 17 to 12FT LBS 46 Place the bullet tool on the shaft 47 Lubricate the bearing with some assembly grease install on the shaft Install the negative spring Spacer negative spring and damping piston valving assemblies LAG S 605 01 016 Rev E 48 Torque the piston nut to 18ft los Remove the piston assembly from the vice and set on a clean lint free rag 49 Take the FOX air sleeve and cover the new samurai backup seal with a little assembly lube work the seal into the groove ensuring the orientation of the seal is correct The seal lip should face outwards Install black seal 1t and blue seal 2 sa ET i a ee hal m a 4 f E yee u r pee sa tie st a
14. he shims as required Remove the BEARING HEAD ASSEMBLY 42 from the shaft taking care to note the order of the NEGATIVE SPRING 9 THRUST WASHER 9a SPACER 10 etc Set these pieces aside Inspect the BODY CAP O RING 34 Replace this part if necessary making sure to install the new o ring in the o ring gland and not in the thread relief Inspect the condition of the internal SHAFT SEAL 46 and SHAFT O RING 47 in the bearing head assembly If they are worn or if there were signs of oil present in the air sleeve replace these parts as outlined below Inspect the SHAFT BEARING 48 if it is worn return the bearing head assembly to FOX for replacement Clamp the Bearing Holder O Ring Install Tool into the vice and place the SHAFT BEARING 48 onto the tool 605 01 016 Rev E 33 Check the condition of AIR SLEEVE SEAL 44 and AIR SLEEVE SLYDE RINGS 43 These components should be replaced if they show signs of wear There should be no signs of damage or wear to the aluminum bearing head If the air seal needs to be replaced use a pick tool to remove the old seal from the shaft Use extreme caution when using a scribe to remove seals Always spear the seal with the point of the scribe Do not wedge the point of the scribe in behind the seal This can scratch the surface of the seal groove which will compromise the performance and reliability of the shock absorber 34 Pointing the scribe downward spear the
15. ns of wear these components should be replaced as outlined in the following steps If the air sleeve bearing is badly worn or scored you will need a new air sleeve or the sleeve will need to be returned to Fox Racing Shox for the bearing to be replaced 22 Carefully use a pick tool to remove the samurai seal and back up seal from the air sleeve Take care not to score any of the aluminum seal seating surfaces TERDA 23 Take the bottom end of the shock out of the vice and tip the oil into a clean glass beaker or suitable clean container to examine the condition of the shock oil There should be no large wear particles in the oil Very old oil may show signs of break down and be darker in color The oil should not be emulsified creamy or aerated Remove the Internal Floating Piston I F P 59 from the reservoir to ensure that all the oil is completely discharged from the shock Set the damper body aside A A 24 25 26 27 28 29 SO Si 2 605 01 016 Rev E Make sure to dispose of used shock oil correctly Do NOT re use old shock oil this may lead to contamination and premature wear Clamp the EVOL chamber BOTTOM end of the shock in a soft jaw vice Examine the CONTINUOUS PISTON BAND 7 for signs of wear replace if necessary as outlined below Undo the SHAFT NUT 5 and remove the PISTON 6 and valving assembly Set on a clean dry lint free cloth If making a valving change adjust t
16. s the back side of the Float air seal and is the only lubrication other than the assembly lube that the seal has during normal operation 68 Heavily lubricate the seal and slide rings Make sure the glands are filled with assembly lube 69 Carefully lower the bearing assembly onto the damping body and thread into the shock Use the FOX Bearing head tool to torque the bearing assembly to 50FT LBS Some shocks may require the air sleeve to be slid partially onto the bearing prior to threading the bearing into the body depending on length 50 ft lbs 605 01 016 Rev E 70 Pull the shaft to make sure the shock is extended to the point where the negative spring just contacts the bearing 71 Pull the air sleeve up onto the bearing to stop excess oil from running into the underside of the bearing 72 Using the FOX reservoir end cap and IFP tool slowly push the IFP down to the correct setting per the diagram below This forces fluid through the shock and out of the hole in the bearing You should see fluid flowing out into the air sleeve and bubbles of air As you get close to the correct IFP setting there should be no more bubbles of air coming out of the bleed hole 5 0 long reservoir 2 875 4 0 long reservoir 1 875 73 Drop the ball bearing into the hole and install the bleed set screw to seal the shock lightly torque to 48 in lbs 605 01 016 Rev E 74 Tip out excess fluid out and mop up
17. the top of the bearing with a rag This portion of the shock should not have any oil present as it may block the air transfer port to the EVOL chamber Oil in this part of the shock is also a useful indication of shaft seal wear The shock should be dried thoroughly so as to not block the EVOL transfer port and to enable the next shock service technician to accurately diagnose correct shock seal performance 74 Clean the excess fluid out of the reservoir from above the IFP 75 Install the reservoir end cap and reservoir snap ring 76 Charge the reservoir with Nitrogen to 225PSI The shock should extend due to the compression of the negative spring 77 Refit the reservoir SCHRADER CAP 49 and torque to 35IN LBS 605 01 016 Rev E 78 Lightly run a finger around the air sleeve o ring in the EVOL cap to ensure it is correctly seated in the gland with a little lube Slide the air sleeve up the body and thread into the cap Tighten using a strap wrench to ensure the sleeve is tight 80 Use the 15OPSI Fox High pressure pump to set the pressure in the MAIN chamber It is normal for the shock to extend slightly 81 82 83 84 605 01 016 Rev E Set the low speed compression LSC high speed compression HSC and rebound clicker positions Turn the adjuster clockwise until it stops this is the fully closed firm position Now turn the adjuster counter clockwise while counting the number of clicks until
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