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1. 12 HYDRAULIC BOTTOM OUT SYSTEM 13 CHECK BEFORE EVERY RIDE 13 SERVICE 5 13 SEALS AND FOAM 5 14 SEALAND FOAM RING SERVICE 6 esa ess ins ee ea 14 STRUCTURAL 5 14 UPPER TUBES edyan Eh wd osha x arog Reva en raya qa 14 CROWNS ai a anar des spa RN AAS E SAE 14 LOWER LEGS o s ma yaa wahaq A a e 14 BUSHING TECHNOLOGY AND 5 15 SHOWROOM TESTING J Get kane sn en a an 5 REAL WORLD TESTING coy asa na a 15 CHANGING OIL 36 TALAS 15 TALAS 17 CHANGING OIL 36 VAN ONLY 17 TUNING NOTES 19 INTERNATIONAL VERSIONS aaa rl SAAR els Esa RE a 20 ITALIANO iiss dct e A Aa ns 40 DEUTSCH arena 60 ESPA OL 2 2 eeeserveeeeeieiwewedeceaeaeeds ceeees aes 80 O 100 INTERNATIONAL SERVICE CENTERS 120 DENOTES INFORMATION THAT IF NOT FOLLOWED CAN LEAD TO SERIOUS INJURY OR DEATH OR CA
2. FOX 36 should be installed by a qualified bicycle mechanic Forks installed improperly are dangerous and can cause loss of control and serious or fatal injuries 1 Remove the existing fork from the bicycle Remove the crown race from the fork Measure the steerer tube length of the existing fork Transfer this measurement to the FOX 36 steerer Refer to stem manufacturer s instructions to be sure there will be enough clamping surface for the stem If it is necessary to cut the steerer tube measure twice and cut once It is also recommended that a cutting guide be used while cutting the steerer tube MUST BE REPLACED A NICK OR GOUGE CAN CAUSE THE STEERER TO FAIL PREMATURELY WHICH CAN CAUSE LOSS OF CONTROL OF THE BICYCLE RESULTING IN SERIOUS OR FATAL INJURIES 7 IF THE STEERER HAS NICKS OR GOUGES THE CROWN STEERER UPPER TUBE ASSEMBLY 2 Use a crown race setter to install the crown race firmly against the top of the crown Install the star fangled nut in the steerer tube with a star fangled nut installation tool 3 Install the fork on to the bicycle Install the stem stem cap and M6 stem bolt on to the bicycle Lightly tighten the stem cap bolt so that the fork turns freely without drag or free play TIRE SIZES 4 The FOX 36 can accept tire sizes up to 2 80 inches wide However any tire larger than 26 x 2 60 must be checked for clearance using the following method With the tire installed and inflated on the rim measure t
3. a complete separation of the upper tube from the bushing by a thin film of oil Hydrodynamic lubrication is characterized by very low friction and no wearing of the bushings or shaft since there is no metal to bushing contact During hydrodynamic lubrication normal bushing clearance will not be noticeable Bushings should be checked annually for excessive wear If excessive fore and aft movement is detected between the upper tubes and lower legs contact an Authorized FOX Racing Shox Service Center or FOX Racing Shox for further instructions Grasp the lower legs at the dropouts axle then push the fork straight back towards the rear wheel Now pull it towards you Next grasp the fork near the upper tube seal junction and try the same thing If excessive movement is noticed refer to the Quick Reference Guide and contact FOX Racing Shox or an Authorized FOX Racing Shox Service Center CHANGING OIL 36 TALAS ONLY The following tools and supplies will be needed A 32mm 6 point socket 10mm open end wrench or socket 15mm deep 6 point socket torque wrench 2mm hex key wrench RC2 only plastic hammer small screwdriver oil drain pan measuring container with cc or mL increments clean dry lint free towels as well as the following Oil change on the FOX 36 R or RC2 fork consists of changing the lower leg oil bath in each leg This oil bath service can be performed with the com mon tools listed above and the fork does not have to be removed from
4. extend ADJUSTING REBOUND ALL MODELS The rebound knob is the red knob located on top of the right fork leg and has 15 clicks of adjustment Rebound controls the speed at which the fork extends after compressing Turning the knob clockwise slows down rebound turning the knob counterclockwise speeds up rebound As astarting point turn the rebound adjuster knob all the way clockwise until it stops then turn counterclockwise 8 clicks P N 605 00 045 2006 FOX 36 OWNER S MANUAL ADJUSTING HIGH SPEED COMPRESSION 2 High speed compression damping controls the force it takes to move the fork through its travel and how the wheel reacts to a bump This adjuster rotates to stops at each end and has 15 clicks of adjustment It is preset from the factory at 1 click in from the full out counterclockwise position The knob is protected by the black protective cap Never ride your FOX 36 without the black protective cap BOOST FEATURE OF HIGH SPEED COMPRESSION ADJUSTER RC2 ONLY The high speed compression adjuster is equipped with a maximum Boost setting This setting offers increased bump force resistance well beyond the adjuster s linear range up until the stop at full firm clockwise To enable the Boost feature turn the high speed compression knob to the full in clockwise position to the stop with firm hand torque You can use a 3mm hex key to assist in turning the knob to the full in po
5. high speed compression adjuster knob Chrome ball and spring in hole on top side of Flat spot on low speed high speed knob compression adjuster shaft Low Speed Compression Flat spot on high speed compression adjuster shaft Protective High Speed Compression Using a mm deep socket wrench unscrew the bottom nut 4 turns Place a clean dry oil pan underneath the right side of the fork Using a 15mm deep socket on the bottom nut to protect the adjusters tap on the bottom nut with a plastic hammer to disengage the base stud from the lower leg Remove the bottom nut and 13mm crush washer from the base stud and set them aside Push up on the base stud to let the oil bath oil drain out of the fork into your drain pan If the oil looks black or a dark gray you could flush both sides of the lower leg with clean oil To flush the lower leg turn the fork upside down and add about 20cc into each leg If the fork is off the bike you can move it around to get the clean oil all over the inside of the fork Let the fork drain into the drain pan until it stops dripping aD Turn the bike or fork upside down and pull up on the lower leg Measure and add 25cc of FOX Suspension Fluid 7 wt into the right side bottom hole Damper side of the lower leg Keeping the lower leg in the up position add 15cc of FOX Suspension Fluid 7 wt into the left side bottom hole TALAS side of the lower leg Slide the lower leg down until
6. unscrew the set screw approximately two turns and remove the low speed compression adjuster knob Using a 2mm hex key wrench unscrew the set screw approximately two turns and remove the high speed compression adjuster knob Note that the 1 8 diameter chrome steel detent ball and detent spring are in the machined hole in the high speed compression adjuster knob gt Using a 15mm deep socket wrench unscrew the bottom nut four turns Place a clean dry oil pan underneath the right side of the fork Using a 15mm deep socket on the bottom nut to protect the adjusters tap on the bottom nut with a plastic hammer to disengage the base stud from the lower leg Remove the bottom nut and 13mm crush washer from the base stud and set them aside Push up on the base stud to let the oil bath oil drain out of the fork into the drain pan If the oil looks black or a dark gray flush both sides of the lower leg with clean oil To flush the lower leg turn the fork upside down and add about 20cc of oil into each leg If the fork is off the bike you can move it around to get the clean oil all over the inside of the fork Let the fork drain into the drain pan until it stops dripping Turn the bike or fork upside down and pull up on the lower leg Measure and add 25cc of FOX Suspension Fluid 7 wt into the right side bottom hole damper side of the lower leg Keeping the lower leg in the up position add 25cc of FOX Suspension Fluid 7 wt int
7. 2 Using the AIR SPRING SETTINGS table on the next page pump your TALAS fork to the appropriate pressure using a FOX High Pressure Air Pump see USING THE FOX HIGH PRESSURE AIR PUMP above 3 Install a zip tie with light friction on the upper tube and push it down until it contacts the fork seal Carefully sit on the bike and assume a normal riding position The fork should compress slightly Being careful not to further compress the fork dismount the bicycle Measure the distance between the seal and the zip tie This distance is sag 2006 FOX 36 OWNER S MANUAL P N 605 00 045 A 4 Compare your sag measurement to the 36 TALAS SAG SETUP table below IF SAG IS LOWER THAN ON THE TABLE remove the air topcap see diagram on left screw on the pump fitting note the current air pressure setting and depress the black bleed valve to reduce the gauge pressure by 5 psi Measure sag again and repeat adjustment if necessary IF SAG IS HIGHER THAN ON THE TABLE remove the air topcap screw on the pump fitting note the current air pressure setting and pump to increase the gauge pressure by 5 psi Measure sag again and repeat adjustment if necessary SETTING SAG 36 van is To get the best performance from your 36 VAN fork it is necessary to set and adjust sag Generally sag should be set to 15 25 of total fork travel To adjust sag on your FOX 36 TALAS fork 1 Install a zip tie with light frictio
8. 36 2006 TALAS RC2 R VAN RC2 R QUICK REFERENCE GUIDE TABLE OF CONTENTS QUICK REFERENCE WARRANTY INFORMATION INSIDE FRONT COVER CONGRATULATIONS 5 CONSUMER 5 5 IMPORTANT SAFETY 5 INSTALLING THE FOX 36 6 TIRE SIZES oia ee nn en paqu ee ias 6 DISCBRAKE INSTALLATION o 0000 nica a ee ov ad aba pa gq fos 1 FORK 8 USING THE FOX HIGH PRESSURE AIR PUMP 36 5 8 SETTING SAG 36 5 8 SETTING SAG 36 VAN 9 SPRING 10 CHANGING THE COIL 5 10 CHANGING TRAVEL 36 5 11 ADJUSTING REBOUND ALL 5 11 ADJUSTING HIGH SPEED COMPRESSION RC2 ONLY 12 BOOST FEATURE OF HIGH SPEED COMPRESSION ADJUSTER RZONN 2 ADJUSTING LOW SPEED COMPRESSION RC2 ONLY
9. 4 in Ib Turn the knobs to make sure they turn freely and install the black protective cap 10 Wipe down the lower leg Reinstall your disc brake caliper and torque fasteners to disc brake manufacturer s specifications Using a 5mm hex key socket and torque wrench reinstall the front wheel and thread in the axle and torque to 19 in Ib Tighten the 2 left side axle pinch bolts and torque to 19 in Ib Compress the fork a few times to allow the right side of the fork leg to settle into its low friction spot Tighten the 2 right side axle pinch bolts and torque to 19 in Ib You re done Go ride 2006 FOX 36 OWNER S MANUAL P N 605 00 045 TUNING NOTES P N 605 00 045 2006 FOX 36 OWNER S MANUAL
10. 6 s are designed to require minimal maintenance periodic inspection and cleaning of the fork sealing system is required It is normal on FOX 36 for a small amount of oil and or grease to accumulate on the upper tubes This is necessary to keep the fork working smoothly and to keep dirt out Furthermore fork seals are grease packed at the factory This grease tends to migrate out of the seals during the break in period SEAL AND FOAM RING SERVICE Storing the bicycle upside down and inverting the fork allows oil to run down to the foam rings and keeps them lubed and ready for your next ride To check the conditions of the seal and foam rings perform the following procedure Around the perimeter of the fork seals are small notches Use a thin flat blade screwdriver in these slots to gently pry the seal from the lower legs Once loose raise them all the way up to the lower crown It is recommended that the tip of the screwdriver be covered with tape or a piece of material to protect the paint on the fork from being damaged Wrap clean rag around the junction of the upper tubes and the lower legs This will keep dirt out while the seals are being cleaned Use a rag to wipe around the outside diameter of the seal Wipe until clean gt Remove the rags and check the foam rings which will be visible just inside the lower legs They should be soaked with oil and should not contain any dirt or debris If the foam rings are dry u
11. MANUAL P N 605 00 045 6 Setting handlebars straight and torquing stem holts Set the bike on the ground and sit on your bike to set the handlebars straight relative to the front wheel Tighten the stem pinch bolts and torque fasteners according to the stem manufacturer s specifications Check that the handlebar pinch bolts are torqued to the stem manufacturer s specifications DISC BRAKE INSTALLATION 7 Installing disc brakes The FOX 36 is designed with the international XC disc brake bolt pattern for use with disc brakes with disc rotor sizes of 160 205 mm only The FOX 36 can use XC or DH mechanical or hydraulic brake systems 7 NEVER MODIFY THE LOWER LEG OR USE CANTILEVER RIM BRAKES The FOX 36 disc bolt pattern uses For use with XC size rotor 160 180 mm outside diameter For use with DH size rotor 200 205 mm outside diameter XC caliper OR XC caliper XC caliper mount for international XC mount pattern DH caliper mount for international XC mount pattern a Install DH disc brake system according to disc brake manufacturer s specifications Be sure to torque all fasteners and bolts to manufacturer s recom mendations Consult the manual that came with your disc brakes for proper installation procedures It is recommended that NEW disc brake pads be installed to ensure proper alignment and to minimize drag Test brakes for proper operation on flat land before hitting the trails b Route the disc brake hose for hydraul
12. USE SERIOUS DAMAGE TO YOUR FORK DENOTES INFORMATION THAT MAY NOT BE OBVIOUS OR THAT CAN HELP THE RIDER OUT WITH A DIFFICULT SITUATION OPTIMIZED EASTON EA70 STEERER LASER ETCHED TALAS OR PRELOAD ADJUSTER LASER ETCHED REBOUND ADJUSTER FORGED 7050 T6 ALUMINUM CROWN 36MM EASTON EA70 STANCHIONS HIGH STRENGTH WEBBED TRUSS FORK BRACE DISC BRAKE HOSE GUIDE PROTECTIVE CAP RC2 MODELS ONLY DISC BRAKE TABS 20MM THRU AXLE HIGH AND LOW SPEED COMPRESSION ADJUST RC2 MODELS ONLY CONGRATULATIONS Thank you for choosing the FOX 36 for your bicycle In doing so you have chosen the finest suspension fork in the world FOX Racing Shox products are designed tested and manufactured by the finest professionals in the industry in Santa Cruz County California USA As consumer and supporter of FOX Racing Shox products you need to be aware of the importance of setting up your fork correctly to ensure maximum performance This manual provides step by step instructions of how to setup and maintain your fork It is a good idea to keep your receipts with this manual and refer to it for service and warranty issues For detailed service instructions consult a FOX Service Manual for your particular product This manual does not contain step by step detailed service instructions for a reason FOX recommends that detailed service be performed by an Authorized Service Center or FOX Racing Shox CONSUMER SAFETY gt Keep in you
13. he following three dimensions Maximum Peak Tire Diameter 694mm 27 3inch Maximum Edge Tire Diameter 670mm 26 4 inch Maximum Tire Width Timm 2 80 inch USING TIRES LARGER THAN THE DIMENSIONS SHOWN IS NOT RECOMMENDED AND CAN DO NOT USE TIRE IF ANY MEASUREMENT EXCEEDS THE MAXIMUM DIMENSIONS SHOWN CAUSE SERIOUS OR FATAL INJURIES KR 5 Installing the Front Wheel MN 0 YY VOR a Loosen the four axle pinch bolts on the lower leg with a 5mm hex key wrench XX b Using a 5mm hex key wrench turn counterclockwise to loosen and remove the axle 55 9 i i i Maximum Bese Maximum c Install the front wheel into the dropouts and install the axle into the lower leg Edge Tire Peak Tire d Using a 5mm hex key wrench turn clockwise and lightly tighten and torque the axle to the Diameter Diameter Oy 55500 57 lower leg to 19 in Ib 215 N cm Torque the two left side dropout pinch bolts to 19 in Ib 215 N cm OX XY x Y XX 57 x 5 0 7 Compress the fork on the bike a couple of times to let the right side of the dropout float and Settle to its low friction point Torque the two right side dropout pinch bolts to 19 in Ib 215 N cm X X A KAA KY RX RARI OR Q Tire Width 2006 FOX 36 OWNER S
14. ial in this region may be compromised as a result of the over torqued pinch bolts Contact a FOX Service Center if any of the above are present on your FOX 36 2006 FOX 36 OWNER S MANUAL P N 605 00 045 BUSHING TECHNOLOGY AND INSPECTION FOX 36 s use hydrodynamic lubrication This system force feeds oil into the tall slotted bushings during the compression stroke When the fork cycles up and down the oil is trapped between bushings upper tubes and seals Thermal expansion rates can cause the bushings to close in on the upper tubes causing high friction and binding during normal operation Correct bushing clearance is critical to prevent binding of the fork during normal operation Geometric dimensioning and tolerancing is a design practice used to ensure parts will work fit during the manufacturing process Bushings are sized before installation and re checked for size after installation Correct bushing tolerance is a diametric clearance of 0 0015 0 0090 SHOWROOM TESTING As you rock the fork back and forth while stopped with the front brake applied the bushings have only a small amount of lubricant separating the bushing upper tube At this time you may notice a small amount of bushing play Fork bushings must have clearance to perform correctly Too little clearance will cause high friction binding or bushing seizure when hot REAL WORLD TESTING During normal riding conditions hydrodynamic lubrication occurs when there is
15. ic disc brakes or brake cable housing for mechanical disc brakes from the caliper to the inside of the lower leg and through the supplied disc brake hose guide and assemble the FOX disc brake hose guide parts as shown in the figures below Cut your brake hose or brake cable housing to the correct length and assemble according to disc brake manufacturer s specifications Tighten the disc brake hose guide screw with a 2 5 mm hex key wrench and torque to 8 in Ib 90 N cm 3 Serrated Washer ROUTE DISC Disc Brake B 38 Hose Guide Plate HOSE GUIDE ROUTE DISC BRAKE HOSE ON THE INSIDE OF THE LOWER LEG Screw Torque to 8 in lb 90 N cm Disc Brake Hose Guide Parts Orientation Disc Brake Hose Guide Routing P N 605 00 045 2006 FOX 36 OWNER S MANUAL FORK TERMINOLOGY gt TRAVEL total amount the fork compresses gt SAG amount the fork compresses with the rider sitting on the bike in a normal riding position gt COMPRESSION DAMPING controls the rate at which the fork compresses gt REBOUND DAMPING controls the rate at which the fork extends gt PRELOAD intial force placed on a spring gt SPRING RATE force required to compress a spring one inch USING THE FOX HIGH PRESSURE AIR PUMP 36 TALAS Use a FOX High Pressure Air Pump see picture on right to change the air pressure in your FOX 36 TALAS K Toremove 1 Remove the aircap from inside the TALAS knob see diagram on lef
16. in pan clean dry lint free towels measuring container with cc or mL increments as well as the following Oil change on the FOX 36 R or RC2 fork consists of changing the lower leg oil bath in each leg This oil bath service can be performed with the common tools listed above and the fork does not have to be removed from the bicycle This service will not require any disassembly of the closed R or RQ cartridge UNLESS YOU ARE AN AUTHORIZED FOX RACING SHOX SERVICE CENTER WITH THE 7 DO ATTEMPT TO DISASSEMBLE THE FOX 36 RC2 OR R CLOSED CARTRIDGE SYSTEM APPROPRIATE TOOLS P N 605 00 045 2006 FOX 36 OWNER S MANUAL Place the bicycle or fork in a stand Remove the disc brake caliper from the lower leg and secure it to the handlebars or frame Using a 5mm hex key wrench loosen the four axle pinch bolts Using a 5mm hex key wrench unscrew the axle five full revolutions counterclockwise and remove from the lower leg Remove the front wheel from the bike Place a clean dry oil pan underneath the left side of the fork Using a 10mm open end wrench or socket loosen the bottom nut six full turns Tap on the bottom nut with a plastic faced hammer to disengage the plunger shaft from the lower leg Unscrew and remove the bottom nut and 8mm crush washer Pull the lower leg downward until you feel it stop Let the oil drain into the oil pan UN ONLY Unscrew and remove the black protective cap Using a 2mm hex key wrench
17. make sure they turn freely and install the RC2 protective cap 10 Wipe down the lower leg Reinstall your disc brake caliper and torque fasteners to disc brake manufacturer s specifications Using a 5mm hex key socket and torque wrench reinstall the front wheel and thread the axle and torque to 19 in Ib Tighten the 2 left side axle pinch bolts and torque to 19 in Ib Compress the fork a few times to allow the right side of the fork leg settle to its low friction spot Tighten the 2 right side axle pinch bolts and torque to 19 in Ib TALAS MAINTENANCE TALAS Forx feature proprietary seals that make it virtually maintenance free It is recommended that the TALAS system be rebuilt every eighteen 18 months or 300 hours For other preventive maintenance information please refer to the QUICK REFERENCE GUIDE on the inside front cover of this manual TO CHARGE THE IFP PISTON IT IS HIGHLY RECOMMENDED TO HAVE AN AUTHORIZED FOX CHANGING THE FLOAT FLUID AND SEALS IN A TALAS SYSTEM REQUIRES SPECIAL TOOLS RACING SHOX SERVICE CENTER PERFORM THIS MAINTENANCE Please note that the slot at the bottom of the left fork leg is NOT an adjustment It is used when loosening the bottom nut from the TALAS base stud CHANGING OIL 36 van ONLY The following tools and supplies will be needed A 32mm 6 point socket 10mm open end wrench or socket 15mm deep 6 point socket torque wrench 2mm hex key wrench RC2 only plastic hammer small screwdriver oil dra
18. n on the upper tube and push it down until it contacts the fork seal Carefully sit on the bike and assume a normal riding position The fork should compress slightly Being careful not to further compress the fork dismount the bicycle Measure the distance between the seal and the zip tie This distance is sag y q 2 Compare your sag measurement to the 36 VAN SAG SETUP table on the next page P N 605 00 045 2006 FOX 36 OWNER S MANUAL HE III IF SAG IS LOWER THAN ON THE TABLE turn the preload knob counter clockwise one 1 full turn Measure sag again and repeat adjustment if necessary IF SAG IS HIGHER THAN ON THE TABLE turn the preload knob clockwise one 1 full turn Measure sag again and repeat adjustment if necessary If correct sag cannot be achieved by adjusting the preload knob you will need to obtain a coil spring with a different spring rate Also consult the 36 VAN SAG TROUBLESHOOTING table on the next page to see whether or not you may have to change your coil spring SPRING TUNING Consult the COIL SPRING GUIDELINES table below to see if you need to change the coil spring on your FOX 36 VAN to achieve proper sag The FOX 36 VAN is tuned by changing only the left side coil spring The coil spring is color coded and may need to be changed depending on your weight CHANGING THE COIL SPRING 1 With a32mm 6 point socket wrench loosen and remove the preload top cap top of left leg Compress the f
19. o the left side bottom hole spring side of the lower leg Slide the lower leg down until you can put on a NEW right side 13mm crush washer with the old bottom nut Thread on the bottom nut 2 to 3 turns max Using a 15mm deep 6 point socket torque the cartridge bottom nut to 50 in Ib Slide the lower leg down further so the plunger stud on the left side of the fork goes through the hole of the lower leg You may need to use thin screwdriver move and align the plunger shaft so that it goes through the hole of the lower leg Install a NEW left side 8mm crush washer with the old bottom nut Thread on the bottom nut 2 to 3 turns max Using a 10mm socket torque the plunger bottom nut to 50 in Ib ONLY Turn the bicycle right side up Look at the two compression adjuster shafts on the bottom of the right side damper If you cannot find both flats spots rotate the adjuster shaft by lightly turning the shaft with needle nose pliers Using a 2mm hex key wrench align and install the RC2 high speed compression adjuster knob so that the set screw tightens on the flat spot of the shaft Be careful that the detent spring and chrome steel ball are in the top side of the machined hole Be careful not to over torque this knob because it will cause the knobs to bind Now align and install the RC2 low speed compression adjuster knob so that the set screw tightens on the flat spot of the shaft The torque for both compression knobs is
20. ork slightly and remove the coil spring You may need to firmly pull up on the spring to disengage it from the plunger shaft Wipe the spring dry with a rag and check the color code 2 Install the new spring by dropping it into the upper tube then torque the top cap to 165 in Ibs 1864 N cm 3 Measure and set sag as described in SETTING SAG on page 9 2006 FOX 36 OWNER S MANUAL P N 605 00 045 AAA CHANGING TRAVEL 36 TALAS The FOX 36 TALAS features externally adjustable travel from 6 3 150mm to 4 110mm which is easily adjusted using the TALAS knob on top of the left fork leg For safety reasons it is recommended that travel adjustment be done while off the bike If necessary travel can be adjusted on the fly be careful when using this extreme travel adjusting method which can be handy right before a grueling climb or steep descent Decreasing Travel From 150mm full extension travel turn the TALAS knob clockwise to shorten the travel Each click represents 3mm of travel change There are 15 positions in 3 5 rotations Turn knob desired number of clicks then compress and hold down the fork for a few seconds Cycle the fork a few times and it will hold down at its new shorter travel More Travel Increasing Travel From a shorter travel setting turn the TALAS knob counterclockwise to increase travel Turn knob desired number of clicks and unweight the fork for a few seconds to allow the fork to
21. r bicycle and suspension system in optimal working condition gt Wear protective clothing eye protection and helmet every time you ride gt Know and ride within your limits gt Follow IMBA s Rules of the Trail For more information go to www imba com 1 Ride on open trails only 2 Leave no trace 3 Control your bicycle 4 Always yield trail 5 Never scare animals 6 Plan ahead IMPORTANT SAFETY INFORMATION Verify that the brakes are installed and adjusted properly before riding the bicycle Improperly installed or adjusted brakes can cause loss of control and serious or fatal injuries to the rider Use only disc brakes designed by the manufacturer for use on the FOX 36 V style brakes CANNOT be used on the FOX 36 Do not route brake cables or housing through the stem If your fork loses oil tops out excessively or makes unusual noises immediately stop riding and contact FOX Racing Shox or an Authorized FOX Racing Shox Service Center for inspection Continued use of the fork can cause loss of control and serious or fatal injuries Some noises such as spring rattle oil flow and minor clicks are normal Use only FOX Racing Shox replacement parts Using aftermarket parts on the FOX 36 will void the warranty Aftermarket replacement parts can also cause structural failure resulting in loss of control and serious or fatal injuries If mounting the bicycle in a carrier designed to hold a fork by its dropouts use ca
22. se a few of FOX Suspension Fluid to saturate them Wipe the upper tubes and slide the seals down into the lower legs Carefully press the seals back into place A thin flat blade screwdriver can be used to press in between the upper tube and the fork brace It is recommended that the blade of the screwdriver be covered with tape or a rag to prevent damage to the seal Inspect that seal is firmly seated against top surface of the lower leg 6 Wipe off any excess oil and cycle the fork a few times to check for proper operation STRUCTURAL INSPECTION UPPER TUBES Look for scratches and dings on the upper tubes which will prematurely wear seals and bushings Big scratches and or dings could compromise the integrity of your fork Contact a FOX Service Center if any of the above are present on your FOX 36 CROWNS Check the crown for any damage deformation or cracks Contact a FOX Service Center if any are present LOWER LEGS Inspect the lower leg for any damage around the brace region tube sections disc brake mounts and thru axle dropouts Check for cracks or flaking in the paint which could be an indication of damage to the structure Inspect the dropouts using the following method With the axle in place torque the pinch bolts to the proper setting 19 in Ib There should be a gap present on the under side of the drops If there is no gap and the walls are touching this indicates the pinch bolts have been over torqued The mater
23. sition or to untorque when de turning the Boost feature THE HIGH SPEED COMPRESSION KNOB HAS A FEATURE THAT ALLOWS THE INSERTION OF A 3MM HEX KEY OR SIMILAR TOOL ASSIST TURNING THIS KNOB DO OVERTORQUE THE KNOB PAST THE STOP IN EITHER DIRECTION ADJUSTING LOW SPEED COMPRESSION gt CAMA A Low speed compression damping controls the influence of the rider s weight shifts and bike attitude under braking This adjuster rotates to stops at each end and has 17 clicks of adjustment It is preset from the factory at 1 click in from the full out counterclockwise position The knob is protected by the black protective cap Never ride your FOX 36 without the black protective cap 2006 FOX 36 OWNER S MANUAL P N 605 00 045 HYDRAULIC BOTTOM OUT SYSTEM The FOX 36 RC2 and R are equipped with a patent pending Internally Adjustable Hydraulic Bottom Out Control System This feature can be adjusted inside the cartridge by a FOX Service Center It comes preset from the factory at the medium setting DO NOT ATTEMPT TO DISASSEMBLE THE FOX 36 RC2 OR R CLOSED CARTRIDGE SYSTEM UNLESS YOU ARE AN AUTHORIZED FOX RACING SHOX SERVICE CENTER WITH THE APPROPRIATE TOOLS LOOSENING THE BOTTOM NUT FROM THE TALAS BASE STUD THE SLOT AT THE BOTTOM OF THE LEFT FORK LEG IS NOT AN ADJUSTMENT IT IS USED WHEN CHECK BEFORE EVERY RIDE 1 Check that the 20mm axle pinch bolts and crown pinch bolts are properly adjusted and tigh
24. t Connect the pump by threading the chuck onto the Schrader valve until the pump gauge registers pressure This takes about 6 turns If the fork has no air pressure the gauge will not register Don t over tighten as it can damage the pump chuck seal FOX High Pressure Pump gt 2 Increase the pressure by stroking the pump a few times Pressure should increase slowly If the pressure increases rapidly check that the pump is properly connected to the Schrader valve 3 Decrease the pressure by depressing the black bleed valve Push the bleed valve in halfway and hold to allow continuous pressure release Depress the bleed valve completely to release pressure incrementally micro adjust 4 Disconnect the pump by unthreading the chuck The sound of air loss is from the pump hose not the fork 5 Install the aircap and go ride TO AIR ENTERING THE PUMP HOSE NORMAL PRESSURE RANGE IS BETWEEN 45 AND 125 PSI 7 WHEN CONNECTING THE PUMP THE GAUGE WILL READ 2 8 PSI LESS THAN NORMAL DUE DO NOT EXCEED 200 PSI SETTING SAG 36 TALAS Toremove 10 get the best performance from your 36 TALAS fork it is necessary to set and adjust sag Generally sag should be set to 15 25 of total fork travel To adjust sag on your FOX 36 TALAS fork 1 Set your TALAS lever fully clockwise to the 160mm travel see CHANGING TRAVEL 36 TALAS on page 17 setting 9 o clock position and cycle the fork a few times so the fork is fully extended 1
25. tened 2 Clean the outside of your fork with soap and water and wipe dry with a soft dry rag Do not spray water directly on the seal uppertube junction DO NOT USE A HIGH PRESSURE WASHER ON YOUR FORK 2 Inspect entire exterior of fork for damage The fork should not be used if any of the exterior parts appear to be damaged Please contact your local dealer or FOX Racing Shox for further inspection and repair 4 Check headset adjustment Adjust headset if loose according to manufacturer s recommendations 5 Check that brake cables or hoses are properly fastened 6 Check that the front and rear brakes operate properly on flat land SERVICE INTERVALS Performance safety and the lifespan of your FOX 36 depend on timely and proper maintenance If you ride in extreme conditions service and maintain your FOX 36 more frequently Perform the following preventive maintenance procedures at the appropriate time interval P N 605 00 045 2006 FOX 36 OWNER S MANUAL SEALS AND FOAM RINGS FOX 36 features a sealing system designed to keep your fork moving smoothly in all conditions There are two parts to the system the fork seal and the foam ring The fork seal features a proprietary scraper lip geometry that keeps dirt out and oil in the fork The foam ring sits just below the fork seal It is saturated with oil and in turn applies oil to the upper tube as it passes by This keeps the fork moving up and down smoothly While FOX 3
26. the bicycle This service will not require any disassembly of the closed R or RC2 cartridge UNLESS YOU ARE AN AUTHORIZED FOX RACING SHOX SERVICE CENTER WITH THE 7 DO ATTEMPT TO DISASSEMBLE THE FOX 36 RC2 OR R CLOSED CARTRIDGE SYSTEM APPROPRIATE TOOLS P N 605 00 045 2006 FOX 36 OWNER S MANUAL 1 Place the bicycle or fork in a stand Remove the disc brake caliper from the lower leg and secure it to the handlebars or frame Using a 5mm hex key wrench loosen the 4 axle pinch bolts Using a 5mm hex key wrench unscrew the axle five full revolutions counterclockwise and remove from the lower leg Remove the front wheel from the bike Place a clean dry oil pan underneath the left side of the fork Using a 10mm open end wrench or socket remove the bottom nut You may need to use a small screwdriver in the slot of the lower stud when loosening the bottom nut Unscrew and remove the bottom nut and aluminum crush washer Pull the lower leg downward until you feel it stop Let the oil drain into the oil pan UN ONLY Unscrew and remove the black protective cap Using a 2mm hex key wrench unscrew the set screw approximately 2 turns and remove the low speed compression adjuster knob Using a 2mm hex key wrench unscrew the set screw approximately 2 turns and remove the high speed compression adjuster knob Be careful to note that the 1 8 diameter chrome steel detent ball and detent spring are in the machined hole in the
27. ution to not tilt the bicycle to either side Tilting the bike with the dropouts in the carrier can cause structural damage to the fork Ensure that the fork is fastened securely with the bike carrier s thru axle mount and that the rear wheel is properly held The four axle pinch bolts must be torqued to specification when mounting to the bike carrier If the bicycle ever tilts or falls from a bicycle carrier do not ride it until it is examined by a qualified dealer Authorized Service Center or FOX Racing Shox A fork leg or dropout failure can cause loss of control and serious or fatal injuries The FOX 36 does not include reflectors for on road use The FOX 36 is designed to be used in competitive off road riding and racing Proper reflectors meeting the Consumer Product Safety Commission s CPSC requirements should be installed if the fork will be used on public roads The FOX 36 has a crown steerer upper tube assembly These parts are pressed together in a one time precision press fit operation Replacement of any of these parts requires a completely new assembly Do not attempt to remove or replace the steerer or upper tubes independently of the crown DO NOT ATTEMPT TO ADD THREADS TO THREADLESS STEERERS Modifying the crown steerer upper tube assembly as described here can cause the rider to lose control of the bicycle resulting in serious or fatal injuries P N 605 00 045 2006 FOX 36 OWNER S MANUAL INSTALLING THE FOX 36 The
28. you can put on a NEW right side 13mm crush washer with the old bottom nut Thread on the bottom nut 2 to 3 turns max Using a 15mm deep 6 point socket torque the cartridge bottom nut to 50 in Ib co Slide the lower leg down further so the plunger stud on the left side of the fork goes through the hole of the lower leg You may need to use thin screwdriver move and align the plunger shaft so that it goes through the hole of the lower leg Install a NEW left side aluminum crush washer with the old bottom nut Thread on the bottom nut 2 to 3 turns max Using a 10mm socket torque the plunger bottom nut to 50 in Ib 2006 FOX 36 OWNER S MANUAL P N 605 00 045 9 RC2 only Turn the bicycle right side up Look at the two compression adjuster shafts on the bottom of the right side damper If you cannot find both flats spots rotate the adjuster shaft by lightly turning the shaft with needle nose pliers See figure on page 13 Using a 2mm hex key wrench align and install the RC2 High speed compression adjuster knob so that the set screw tightens on the flat spot of the shaft Be careful that the detent spring and chrome steel ball are in the top side of the machined hole Be careful not to over torque this knob because it will cause the knobs to bind Now align and install the RC2 low speed compression adjuster knob so that the set screw tightens on the flat spot of the shaft The torque for both compression knobs is 4 in Ib Turn the knobs to

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