Shock Absorber Rebuild Manual
Contents
1. 16 Figure 20 47 Slide the bearing cap and bottom out bumper off of the shaft 48 Using proper shaft clamps mount shaft securely in vice Fig 21 A very high level 49 50 of clamping force 15 required to prevent shaft from spinning in clamps Allowing the shaft to spin in clamps can cause permanent damage to the shaft and may cause the shock to leak Figure 21 Heat eyelet flange with a torch to loosen the thread locking compound that secures the eyelet to the shaft Fig 21 Extreme caution 1s to be used when operating a torch Refer to the torch manufacturers owner s manual for proper operation instructions Follow all safety guidelines Use an adjustable wrench to loosen the eyelet from shaft Fig 22 If shaft begins to spin increase clamping force of vice and repeat previous step Do NOT remove eyelet completely Once eyelet is loose allow it to cool before further handling 17 51 Once the eyelet has been given sufficient time to cool use an adjustable wrench to remove it from the shaft Clean the thread locking compound from eyelet and shaft threads and set it aside 52 Using a scribe or dental pick push the exposed end of the rebound metering rod into the shock shaft until 1t comes out of the piston assembly end Wipe off any residual oil that coats the rebound metering rod and set it aside on a clean lint free paper towel Be very careful to avoid damaging the needle that is attached to the end o2. E mm 5 r s K E G LN 3 x K e r v D A roca et MS 7 Ke Le 4 a S n w E Be D 5 E OW E gt Kai E ET E 3 Vd gt P a dee AAF ed Peine pet ou A 63 Clamp shaft eyelet securely in vice and place seal bullet tool on end of shaft 64 Slide bottom out bumper onto shaft The tapered side of the bottom out bumper should be facing away from the shaft eyelet 65 Lubricate the seal bullet tool with assembly lube Slide the bearing cap onto shaft with the threaded side facing away from the shaft eyelet Fig 30 This should be done in a single smooth motion to avoid damaging the seal If seal hangs up on the 20 66 67 68 edge of the shaft DO NOT FORCE IT ON Remove the bullet tool with the bearing cap still attached from the shaft end Fig 32 Remove the bearing cap from the bullet tool and repeat this step Figure 30 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 Fig 31 This should be done in a single smooth motion to avoid damaging the seals Ifa 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 Fig 32 Remove the bearing assembly from the bullet tool and repeat this step
3. 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 1s at retaining ring groove Insert into reservoir Use a smooth motion and push straight in until o ring seats into the retaining ring groove allowing oil to overflow Set the compression adjustment knob to the 1 position 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 Fig 36 Be careful not to pinch the piston band Set the compression adjustment knob to position 1 Now holding 22 the reservoir below the body tube with the compression adjuster side up push into reservoir tube until it bottoms out inside Fig 37 You should see large air bubbles rise to the surface of the oil in the body tube Figure 36 73 Fill shock body half way with oil While still holding the reservoir below the body tube very slowly pull back on the IFP Fig 38 Be careful not to pull the IFP out completely Wait one minute then push the IFP back to the bottom You should see bubbles rising to the surface inside the body tube Repeat this process several times until you don t see any new bubbles inside the body tube Figure 38 74 Set compression adjuster to the 3 position Firmly grip the reservoir hose at CD housing With your other hand pull ba
4. RACING SHOK Shock Absorber Rebuild Manual Models PODIUM COMP 03 PODIUM PRO 03 PODIUM X 03 FOX RACING SHOX 130 Hangar Way Watsonville CA 95076 831 768 1100 FAX 831 768 9342 Email service foxracingshox com Website www foxracingshox com TABLE OF CONTENTS Introduction Contact Information EE Warranty Policy Methods of Payment ee ie Methods of 5 DISC ATE Cl aio is se ee Ss ance ees sunu Se a Consumer Safety Removal amp Installation Recommended Service Intervals Tools amp Materials Required for Rebuild Rebuild Instructions Introduction Congratulations on choosing FOX Racing Shox In doing so you have chosen the best suspension in the industry All FOX Racing Shox products are designed manufactured and assembled by the finest professionals in the industry Contact Information FOX Racing Shox Phone 831 768 1100 130 Hangar Way North America 800 369 7469 Watsonville CA 95076 Fax 831 738 9342 E mail service 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 1s required for warran
5. Figure 32 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 Fig 33 Slide the piston assembly onto the shaft end Check to make sure the piston assembly is seated properly and install the piston lock nut Torque the nut to 25ft Ibs Fig 34 21 69 70 71 12 Figure 33 E P Lubricate the flat end of the metering rod with a small amount of assembly lube Insert metering rod flat end first into the shaft Fig 35 Push needle down into the shaft with a blunt object until you feel the metering rod push past the o ring seal Install the shaft jet using a torque driver Torque jet to 40in lbs Remove shaft assembly from vice and set it aside on a clean lint free paper towel Clamp the body cap of the shock securely in the vice with the open end of the body facing up Set compression adjustment knob to position 8 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
6. Customer may request UPS Air Service at an extra cost All non warranty shipping charges are the customer s responsibility 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 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 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 Charge shock oil and seals Tools amp Materials Required for Rebuild Safety Glasses Latex Gloves Lint Free Towels Assembly Lube lithium based grease Loctite 271 12 Tie Wrap Zip Tie MAPP Gas or Propane T
7. shock is fully discharged pull reservoir away from the Fox Safety Needle in a Straight smooth motion Clamp the body cap of the shock securely in vice with shaft side up Gently tap the reservoir end cap with a rubber mallet to expose the wire retaining ring Locate the end of the ring and push inward with fingertip Remove the retaining ring A scribe or dental pick can also be used for this step but use extreme caution not to scratch the bore of the reservoir tube Fig 4 I 18 Use pliers to grab flats of the gas valve of reservoir cap Extract cap from reservoir tube using a twisting motion Set reservoir cap aside on a clean lint free paper towel 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 fingertip Remove retaining ring A scribe or dental pick can also be used for this step but use extreme caution not to scratch the bore of the body tube Fig 5 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 Fig 6 Remove the shaft assembly from the body tube and place on a clean lint free paper towel Remove the shock from the vice and p
8. side of the CD housing to unseat the wire retaining ring that secures the damp plate assembly Use pointed tool such as a scribe or dental pick to remove the retaining ring Use extreme caution not to scratch the bore of the CD housing Fig 9 26 Insert a 5 32 Hex Key into the screw head of the damp plate Remove damp plate by twisting clockwise Fig 10 Place the damp plate assembly on a clean lint free paper towel 11 27 Remove damp plate sealing o ring using a scribe or dental pick Use extreme caution not to scratch the o ring groove Scratching the o ring groove will compromise the performance of your shock 28 Check to make sure the compression adjustment knob 15 set to the 1 position Insert a 5 32 Hex Key into the largest hole in the side of the CD housing to keep the knob from turning Use a 3 32 Hex Key to remove the screw that secures the compression adjuster knob Fig 11 29 Remove the compression adjustment knob o ring clicker balls 2 and springs 2 30 Remove 5 32 Hex Key from CD housing 31 Push on the protruding adjuster drum stem to remove it from CD housing Fig 12 12 32 Remove the adjuster drum sealing o ring using a scribe or dental pick Use extreme caution not to scratch o ring groove Clean the adjuster drum with cleaning solvent 33 Remove the paper towels from the body tube and reservoir Clean the body tube reservoir tube IFP and CD housing thoroughly with solvent
9. 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 r M TY E W j H A57 V RE e vs 24 78 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 Fig 41 With one hand continue applying pressure to the bearing assembly With other hand set the compression adjustment knob to the 1 position 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 e
10. Dry with compressed air in a well ventilated area If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the solvents to evaporate 34 Lubricate the new adjuster drum o ring with assembly lube and carefully install it onto the drum Check to make sure the o ring 15 not twisted and 1s installed correctly 35 Insert the adjuster drum into CD housing using even pressure to avoid damaging the o ring When the adjuster drum 15 seated properly the adjuster drum should be flush with the inside surface of the CD housing Fig 13 Check to make sure the drum rotates freely in the bore and orient the largest cavity of the adjuster drum with the bleed hole large hole in the CD housing Figure 13 36 Lubricate and carefully install the damp plate sealing o ring inside the CD housing Make sure o ring 1s properly seated 13 37 Insert the damp plate assembly into CD housing with the 5 32 hex head facing out Align the slot at top of damp plate with the bleed hole in the CD housing Fig 14 Seat the damp plate into CD housing using even pressure in order to not damage the o ring Continue applying pressure to damp plate until it bottoms in CD housing Insert the wire retaining ring The end of the retaining ring should be aligned with the access hole in the side of CD housing This is done to ensure ease of future service on your shock Check to make sure the retaining
11. ck 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 75 Hold the reservoir under the body tube with the compression adjuster facing up Slowly push the into the reservoir until it bottoms out Set compression adjuster to the 8 position 29 76 the body tube with oil approximately 1 2 below the retaining ring groove Wrap the new piston band around the piston making sure the rounded edges face out Insert the shaft assembly into the body tube allowing oil to overflow Fig 39 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 bleeding process over Add oil as necessary Repeat the previous steps until there are no more bubbles rising to the oil surface vw 77 Hold the shaft assembly as straight as possible and hit the shaft eyelet a couple of times squarely from above with a rubber mallet Fig 40 This is done to momentarily open the shim
12. e a popping sound should be heard 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 EXTREMELY DANGEROUS j 83 Install the button head screw into the Fox air valve using a 3 32 Hex Key 84 Remove the shock from the vice 85 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 86 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 26 87 Compress shock completely Fig 46 Roughly 90 pounds of force 1s required to initiate movement of shaft 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 NOTE Time permitting we recommend allowing the shock to sit for 24 hours and repeating step 87 This hold period allows you to re inspect the shock and identify any possible oil leaks or nitrogen loss before t
13. f the metering rod 53 Use snap ring pliers to remove the retaining ring from the shaft end Fig 23 Usea scribe or dental pick to remove the brass support washer and metering rod o ring from end of shaft Fig 24 Use extreme caution not to scratch o ring gland Clean all thread locking compound from the end of the shaft Figure 23 Figure 24 1 54 Lubricate the new metering rod o ring and o ring gland with assembly lube Install the o ring making sure the o ring is properly seated in the gland Install brass support washer with the stepped side against o ring Install the new snap ring Make sure the rounded side of the snap ring faces the brass support washer Check to make sure snap ring 1s properly seated 18 55 56 57 58 59 60 Apply small amount of thread locking compound Loctite 271 to shaft threads and screw the eyelet assembly onto the shaft end Torque eyelet to 35ft Ibs Remove the shaft from clamps 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 Fig 25 Figure 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 Fig 26 Use a scribe or a dental pick to remove the o ring seal from center of the bearing assembly Fig 27 Use extreme caution when removing seals from bearing assembly Do not scratch the o
14. he shock is re installed J TT gi Lj l Ee Fe E j m gt f p ki G Ki e A Tot 7 4 a D d 3 A 1 n P i e n m r E Figure 46 88 Reinstall the stainless steel spring support washer the spring and the spring retainer Place the wire retaining ring into the groove on the spring retainer adapter and seat the spring retainer against it 89 Thread the spring preload ring down against the spring and set the preload to the measurement you took when you removed the spring Fig 1 Thread the preload lock ring down against the preload ring and tighten them together to lock them in place 90 Set the compression adjustment knob to the position recorded previously 91 Remove the shock from the vice 92 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 the beginning to ensure the shock and your vehicle s suspension is performing correctly Thanks again for choosing FOX Racing Shox 27
15. orch Fox 1 834 TC Seal Kit Fox P N 803 00 014 B Fox 5wt Shock Fluid 1 Qt Fox P N 803 11 000 A 0 21 422 23 24 Fox Depth Setting Tool Fox P N 803 00 034 A Fox Seal Installation Bullet 5 8 Fox P N 398 00 223 A Fox Nitrogen Safety Needle Fox P N 802 02 001 A 5 8 Shaft Clamps Fox P N 398 00 051 A Adjustable Wrench Pin Spanner Wrench 3 16 Pins 3 32 Hex Key Allen Wrench 5 32 Hex Key Allen Wrench Scribe or Dental Pick 1 4 Flat Blade Screwdriver 2 Phillips Screwdriver 1 4 Open End Wrench standard Pliers Small Needle Nose Pliers small Internal Snap Ring Pliers 040 Tip Diameter 4 Socket Torque Wrench Torque Driver Soft Faced Rubber Mallet Nitrogen Tank w Regulator Cleaning Solvent Vice w Soft Jaws Tape Measure Rebuild Instructions RRR Read through all of these instructions first to familiarize yourself with the rebuild procedure Make sure you have a clean work area and all of the necessary tools are available Always use proper safety equipment when working on shock absorbers Measure the spring set length Fig 1 Record this number along with the positions of the rebound and compression adjustment knobs Loosen the preload lock ring and back the preload adjustment ring off until spring 1s loose on the body Remove the lower spring retainer by pushing it toward the body and rem
16. our shock oil from body tube into a proper disposal container DO NOT RE USE OLD SHOCK OIL 20 Clamp the body cap of the shock securely in vice with the open end of the body tube Sch Gently pull IFP out of the reservoir tube using the Depth Setting Tool Fig 7 and place it on a 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 22 Remove the IFP o ring using a scribe or dental pick Use extreme caution not to 25 scratch the o ring groove Scratching the o ring groove will compromise the performance of your shock Place the IFP on clean lint free paper towel Push the compression damping CD housing into the reservoir tube to expose the wire retaining ring Locate the end of the ring and push inward with fingertip Remove retaining ring A scribe or dental pick can also be used for this step but use extreme caution not to scratch the bore of the reservoir tube Fig 8 10 24 Gently pull the CD housing out of reservoir tube using a twisting motion Do not pull directly on the hose Place reservoir tube on clean lint free paper towel 25 Push the end of a 3 32 Hex Key through the small access hole in the
17. oving the wire retaining ring Slide the lower spring retainer off Remove the spring and stainless steel spring support washer Remove the reducer bushings and o rings from both ends of the shock Clean 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 Back the rebound adjustment knob out until the clicking stops Set the compression adjustment knob to the 1 position Clamp the body cap of shock securely in 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 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 Fig 2 Remove shock from the vice Use a 3 32 Hex Key to remove the button head screw from the Fox air valve in the reservoir end cap Securely clamp Fox Nitrogen Safety Needle in vice CAUTION Point air valve away from face and body when charging or discharging any shock Insert the Fox Safety Needle squarely into center of gas valve Fig 3 Using a blunt object depress the air valve core to release pressure Fig 3 When the
18. r to expose the CD housing retaining ring groove Insert the retaining ring into groove Check to make sure ring 1s properly seated Pull CD housing out of reservoir until it engages securely with retaining ring 41 Set body assembly aside on a clean lint free paper towel 42 Clamp the shaft eyelet securely in vice with the piston end up 43 Using a 1 4 Flat Blade Screwdriver newer jets use a 5 32 internal hex remove rebound jet from end of shaft by rotating it in a counter clockwise direction Fig 17 15 Figure 17 44 Using 3 4 wrench remove piston lock nut from end of shaft 45 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 Fig 18 Slide a 12 inch tie wrap through the entire piston assembly Secure the two ends of the zip tie together and remove the screwdriver There are many pieces to the piston assembly and the assembly order of these pieces 1s 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 Figure 19 46 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 Fig 20
19. ring 1s properly seated in groove You may need to use a 5 32 hex key to twist the damp plate assembly clockwise slightly to get the wire ring to seat fully Figure 14 38 Fill the two holes that are on either side of the adjuster drum stub with assembly grease Insert one new spring into each hole Place one new clicker ball in the center of each spring Orient the 1 position of knob with the position indicator of the CD housing Fig 15 Install the compression adjustment knob onto adjuster drum stub Apply even pressure on knob and press down completely The clicker balls should recess down into the holes If they don t slowly remove the knob and re seat the clicker balls and try again Once knob 15 in position insert a 5 32 inch Hex Key into the bleed hole of the CD housing Secure knob with flat head screw using a 3 32 inch Hex Key Install dust shield o ring by stretching it over the top of the compression adjuster knob 14 Figure 15 i 39 Remove the CD housing outer o ring Use extreme caution to avoid scratching the o ring groove Lubricate the new o ring with assembly lube and install it onto the housing 40 Check the bore of reservoir for any visible signs of wear or damage Insert the CD housing into the end of the reservoir with the large chamfer on outside edge Some reservoirs will not have this chamfer Orientation is not critical on these reservoirs Fig 16 Push the CD housing far enough into the reservoi
20. ring groove or DU bushing Doing so will compromise the performance of your shock Figure 26 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 using 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 Ifa 19 tool is required to aid in proper seating of seal use the non writing end of a pen similar soft blunt object to push it in Fig 28 61 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 15 properly seated and is not twisted If a tool 1s 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 1n 62 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 Fig 29 A Mm 1 4 H d ar y k r t m 4 _ ef A
21. ty 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 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 15 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 15 recommended Methods of Payment VISA MasterCard and or Cashier s Check Methods of Shipping FOX Racing Shox uses UPS Ground Service within the USA
22. xposed Fig 42 Install the wire retaining ring and check to make sure retaining ring is properly seated 79 Push the IFP further into the reservoir As you do this the shaft and bearing assembly should rise until the bearing assembly engages with the wire retaining ring inside the body tube Remove the IFP depth setting tool by rotating it 90 degrees 80 Install the reservoir end cap with the Fox air valve facing the outside of the reservoir tube Fig 43 Push down on the reservoir end cap using even pressure until the retaining ring groove is exposed Fig 44 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 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 25 mr S d Vi i d j t A rE 81 Securely clamp Fox Nitrogen Safety Needle in the vice Be sure to point the air valve away from your face and body 82 Insert the safety needle squarely into center of Fox air valve and pressurize the reservoir to 300psi Fig 45 Continue charging with gas as you pull the reservoir away from the Fox Nitrogen Safety Needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the safety needle from bending As the safety needle is pulled free from the Fox air valv
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