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1. 14 SEALS AND FOAM 5 14 SEAL AND FOAM RING SERVICE 4 STRUCTURAL 5 15 UPPER TUBES ee sie sh at ote die Bee SE te 10 CROWNS 5 2 Ge rak Oe Bae a Q ee ee LOWER LEGS 5 BUSHING TECHNOLOGY AND 5 15 SHOWROOM TESTING 5 REAL WORLD TESTING 5 CHANGING 16 TUNING NOTES 18 INTERNATIONAL VERSIONS FRANCAIS L 20 ITALIANO 2 oc Se ee een 38 DEUTSCH ua 56 ESPANOL 74 O O 92 INTERNATIONAL SERVICE CENTERS 12 DENOTES INFORMATION THAT IF NOT FOLLOWED CAN LEAD TO SERIOUS INJURY OR DEATH OR CAUSE SERIOUS DAMAGE TO YOUR FORK DENOTES INFORMATION THAT MAY NOT BE OBVIOUS OR THAT CAN HELP THE RIDER OUT WITH A DIFFICULT SITUATION LASER ETCHED ALUMINUM PRELOAD ADJUSTER OPTIMIZED EASTON EA70 STEERER LASER ETCHED ALUMINUM REBOUND ADJUSTER FORGED 7050 T6 ALUMINUM UPPER AND LOWER CROWN INTERNAL TRAVEL ADJUST SYSTEM TITANIUM COIL SPRING HIGH STRENGTH WEBBED TRUSS FORK BRACE DISC BRAKE HOSE GUIDE PROTECTIVE CAP RC2 ONLY DH SPECIFIC DISC BRAKE TABS 20MM THRU AXLE HIGH AND LOW SPEED C
2. 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 1 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 2 Wrap a clean rag around the junction of the upper tubes and the lower legs This will keep dirt out while the seals are being cleaned 3 Use rag to wipe around the outside diameter of the seal Wipe until clean 4 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 use a few cc s of Fox Suspension Fluid to saturate them 5 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 2006 FOX 40 OWNER S MANUAL P N 605 00 046 used to press in between the upper tube and the fork brace It is recommended that the blade of the screwdriver
3. 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 40 CROWNS Check both upper and lower crowns 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 material 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 anomalies are present on your FOX 40 BUSHING TECHNOLOGY AND INSPECTION FOX 40 s use hydrodynamic lubrication This system force feeds oil into the tall slotted bushing
4. the instructions 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 o ao Route the disc brake hose for hydraulic 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 as shown in the figure on the next page Assemble the FOX disc brake hose guide parts as shown in the figure on the next page 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 2006 FOX 40 OWNER S MANUAL P N 605 00 046 N3 Serrated Washer ROUTE DISC B a Disc Brake GER k HROUGH cuide HOSE GUIDE l Disc Brake Hose Guide lt N3 x 12 en orque to O 8 in lb 90 N cm ROUTE DISC BRAKE HOSE ON THE INSIDE OF THE LOWER Disc Brake Hose Guide Parts Orientation 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 con
5. 0 to achieve proper sag The FOX 40 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 a 32mm 6 point socket wrench loosen and remove the preload top cap top of left leg Remove the black spring spacers 4 spacers for 8 in 203mm travel 3 for 7 5 in 191mm mm travel 2 for 7 in 178mm travel 1 for 6 5 in 165mm travel and 0 for 6 in 152mm travel Compress the fork 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 rag and check the color code 2 Install the new spring by dropping it into the upper tube Install the appropriate spacers according to your desired travel see CHANGING TRAVEL on page 13 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 40 OWNER S MANUAL P N 605 00 046 ADJUSTING REBOUND 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 Asa starting point turn the rebound adjuster knob all the way clockwise full in until it stops then turn counterclockwise 8 clicks
6. 40 2006 40 RC2 40 R QUICK REFERENCE GUIDE YO TABLE OF CONTENTS QUICK REFERENCE WARRANTY INFORMATION INSIDE FRONT COVER CONGRATULATIONS 5 CONSUMER 5 5 IMPORTANT SAFETY 5 INSTALLING THE FOX 40 6 4 rca a Gon ee en ee ee DISCBRAKE INSTALLATION 8 FORK 9 SETTING 5 9 SPRING 10 CHANGING THE COIL 5 10 ADJUSTING REBOUND u uununnnnunnunnununnnnnnnnnnnnnnnn nun nun nun nun 11 ADJUSTING HIGH SPEED COMPRESSION RC2 ONLY 11 BOOST FEATURE OF HIGH SPEED COMPRESSION ADJUSTER RCZ ADJUSTING LOW SPEED COMPRESSION RC2 ONLY 12 HYDRAULIC BOTTOM OUT SYSTEM 12 CHECK BEFORE EVERY RIDE 12 CHANGING TRAVEL cccecccnenccncccnsncuscneseucuessereessenssusnessy 13 SERVICE 6
7. ADJUSTING HIGH SPEED COMPRESSION rc2 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 40 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 position or to untorque when de tuning the Boost feature P N 605 00 046 2006 FOX 40 OWNER S MANUAL 3MM HEX KEY OR SIMILAR TOOL TO ASSIST IN TURNING THIS KNOB DO NOT OVERTORQUE THE HIGH SPEED COMPRESSION KNOB HAS A FEATURE THAT ALLOWS THE INSERTION OF A THE KNOB PAST THE STOP IN EITHER DIRECTION ADJUSTING LOW SPEED COMPRESSION rcov Gea Low speed compression damping controls the influence of the rider s weight shifts and bike attitude under braking This adjuster rotates to stops at e
8. OMPRESSION ADJUST RC2 ONLY CONGRATULATIONS Thank you for choosing FOX 40 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 a 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 your 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 r
9. ach 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 40 without the black protective cap HYDRAULIC BOTTOM OUT SYSTEM The FOX 40 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 UNLESS YOU ARE AN AUTHORIZED FOX RACING SHOX SERVICE CENTER WITH THE 7 DO NOT ATTEMPT DISASSEMBLE THE FOX 40 RC2 OR CLOSED CARTRIDGE SYSTEM APPROPRIATE TOOLS CHECK BEFORE EVERY RIDE Check that the 20mm axle pinch bolts and crown pinch bolts are properly adjusted and tightened Ss mmi Clean the outside of your fork with soap and water and wipe dry with soft dry rag Do not spray water directly on the seal uppertube junction DO NOT USE A HIGH PRESSURE WASHER ON YOUR FORK UN 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 an authorized dealer or FOX Racing Shox for further inspection and repair gt Check headset adjustment Adjust headset if loose according to manufacturer s recommendations Check that brake cables or hoses are properly fastened Dm Check that the front and rear brakes oper
10. 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 Your oil change is complete Now go ride P N 605 00 046 2006 FOX 40 OWNER S MANUAL TUNING NOTES 2006 FOX 40 OWNER S MANUAL P N 605 00 046 19 P N 605 00 046 2006 FOX 40 OWNER S MANUAL
11. ate properly on flat land 2006 FOX 40 OWNER S MANUAL P N 605 00 046 CHANGING TRAVEL Travel on the FOX 40 can be changed from 8 to 6 in 1 2 increments by rearranging the four internal travel spacers inside the left leg of the fork With the proper tools and oil changing travel can be done in about 15 minutes The following tools and supplies will be needed A 32mm 6 point socket 10mm open end wrench or socket torque wrench plastic hammer oil drain pan clean dry lint free towels measuring container as well as the following The fork does not have to be removed from the bicycle for changing travel Place the bicycle or fork if removed a bike stand Using a 32mm socket wrench remove the left side topcap Remove the spacer s on top of the coil spring 4 spacers for 8 3 spacers for 7 5 2 spacers for 7 1 Spacer for 6 5 0 spacers for 6 mn Using a 10mm socket wrench unscrew the left side bottom nut 6 turns Place a clean dry oil pan underneath the left side of the fork 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 crush washer Push up on the shaft with a thin screwdriver and let the oil drain UN Compress the fork and pull the coil spring plunger shaft assembly out of the top of the left side upper tube Pull the coil spring off the plunger assembly gt Looking at the diagram below det
12. e following method With the tire installed and inflated on the rim measure the following three dimensions Maximum Peak Tire Diameter 694 mm 27 3 inch Maximum Edge Tire Diameter 670 mm 26 4 inch Maximum Tire Width 71mm 2 80 inch SHOWN ABOVE USING TIRES LARGER THAN THE DIMENSIONS SHOWN ABOVE IS NOT DO NOT USE A TIRE IF ANY MEASUREMENT EXCEEDS THE MAXIMUM DIMENSIONS RECOMMENDED AND CAN CAUSE SERIOUS OR FATAL INJURIES ye YN ROR IA y XX KX X22 AAAANAK XXX KKK 7 5 7 XY Maximum es Maximum Edge Tire ES Peak Tire Diameter Diameter 9 A X ER O LY AN 90 xX KX RR X ODO X OR OX 7 Y Tire Width P N 605 00 046 2006 FOX 40 OWNER S MANUAL 5 Installing the Front Wheel Loosen the 4 axle pinch bolts on the lower leg with a 5mm hex key wrench m Using a 5mm hex key wrench turn counterclockwise to loosen and remove the axle Install the front wheel into the dropouts and install the axle into the lower leg a ri Using a5mm hex key wrench turn clockwise and lightly tighten and torque the axle to the lower leg to 19 in Ib 215 N cm Torque the two left side dropout pinch bolts to 19 in Ib 215 N cm m Compress the fork on the bike a couple of times to let the right sid
13. e 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 6 Setting handlebars straight and torquing stem bolts 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 7 Adjusting position of the steering stop bumpers Adjust the height and angle of the steering stop bumpers on the upper tubes so that you have the maximum turning angle and protect your frame and upper tubes from denting during a crash Depending on the shape and Size of the frame tubes you may need to use the tall part of the bumper to contact the frame tubes see figure on page 7 DISC BRAKE INSTALLATION 8 Installing disc brakes The FOX 40 is designed only for use with DH disc brakes with disc rotor sizes of 200 205 mm The FOX 40 can use DH mechanical or hydraulic brake systems 7 NEVER MODIFY THE LOWER LEG OR USE CANTILEVER RIM BRAKES The FOX 40 disc bolt pattern uses XC Caliper XC Caliper Mount for International XC mount pattern DH Size Rotor 200 205 mm outside diameter Install DH disc brake system according to disc brake manufacturer s specifications Be sure to torque all fasteners and bolts to manufacturer s recommendations Consult
14. eerer with a scribe at the top edge of the stem Remove the FOX 40 from the bicycle and cut the steerer 3mm below the scribed mark This 3mm clearance allows room for the stem cap to lightly tension the headset and eliminate any play Use a flat file to deburr the outer and inner top edges of the newly cut steerer Install star fangled nut and steering stop bumpers With a star fangled nut installation tool install the star fangled nut into the steerer so that it is 4 8 mm below the top edge of the steerer Install one steering stop bumper onto each uppertube and place midway on the uppertube gt Installing fork onto bicycle Install the FOX 40 on the bicycle with all of the headset parts and upper crown Install stem stem and M6 stem cap bolt With all three upper crown bolts loosened lightly tighten the headset stem cap bolt to remove play in the system so that it turns freely without drag With a 5mm hex key socket and torque wrench torque all three upper crown bolts see figure below to 65 in Ib Check that the torque on the four lower crown bolts see figure below is at 65 in Ib DO NOT OVERTORQUE the pinch bolts Over torquing can damage the bolt s fracture the crown or damage the threads and can cause failure of the fork and loss of control with serious or fatal injuries TIRE SIZES 5a The FOX 40 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 th
15. emove 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 mn 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 6 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 RC2 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 high speed compression adjuster knob 2006 FOX 40 OWNER S MANUAL P N 605 00 046 Flat spot on high speed compression adjuster shaft Flat spot on low speed compression adjuster shaft Low Speed Compression Protective Cap High Speed Compression Knob Chrome ball and spring in hole on top side of high speed knob gt Usi
16. ermine the number of travel spacer s needed on the plunger shaft for your desired travel Slide the black negative spring guide away from the flanged head of the aluminum plunger shaft Push and snap on the correct number of the travel spacers to the plunger shaft and slide back the black negative spring guide against the spacers PRELOAD COIL 2 TRAVEL PLUNGER TOPCAP SPRING SPACERS SHAFT Y 2 TRAVEL FLANGED HEAD OF BLACK NEGATIVE BOTTOM NUT SPACERS PLUNGER SHAFT SPRING GUIDE FOX 40 Travel Spacer Or ientation Diagram Set at 7 Travel 5 Push and snap on the coil spring to the plunger shaft assembly Install the coil spring plunger shaft assembly into the top of the left side upper tube Install the correct number of spacers on top of the coil spring and thread the topcap into the upper tube 6 Remove the bicycle from bike stand and turn the bike upside down Using a thin screwdriver and sliding the lower leg up or down push and align the plunger shaft so that it is aligned and comes through the hole in the lower leg Once aligned push the lower leg down and install the crush washer and bottom nut Using a 10mm socket and torque wrench torque the bottom nut to 50 in Ib 565 N cm P N 605 00 046 2006 FOX 40 OWNER S MANUAL 7 Turn the bike right side up and place it back into the bike stand Remove the left side preload topcap and pour in 40 cc of FOX Suspension Fluid 7 wt Install and torque the preload topcap to 165
17. iding 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 40 V style brakes CANNOT be used on the FOX 40 Do not route brake cables or housing through the stem Mr 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 40 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 caution 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 Cente
18. in Ib 1864 N cm 8 After changing the travel compress the fork a few times and check for proper operation before riding there should be no free movement or play in travel If there is free movement in the fork or if it makes strange noises disassemble the fork and check that all four spacers are in the fork and in the correct orientation for the desired travel SERVICE INTERVALS Performance safety and the lifespan of your FOX 40 depend on timely and proper maintenance If you ride in extreme conditions service and maintain your FOX 40 more frequently Perform the following preventive maintenance procedures at the appropriate time interval SEALS AND FOAM RINGS FOX 40 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 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 40 s are designed to require minimal maintenance periodic inspection and cleaning of the fork sealing system is required It is normal on FOX 40 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
19. led forks are dangerous and can cause loss of control and serious or fatal injuries The FOX 40 is assembled with the lower crown set to 176 4mm below the top of the upper tubes The lower crown position is set to allow a 6mm clearance between the bottom of the crown and the top of a 2 80 tire when bottomed out Do not change the position of the lower crown Measured from top of upper tube 1 Removing fork and installing crown race Place the bicycle in a repair stand Remove the existing fork from the bicycle Remove the crown race from the old fork with a crown race removal tool and install it with a crown race setter tool onto the new FOX 40 The crown race must be firmly seated against the top surface of the lower crown REPLACED A NICK OR GOUGE CAN CAUSE THE STEERER TO FAIL PREMATURELY WHICH CAN 7 IF THE STEERER HAS ANY NICKS OR GOUGES THE CROWN STEERER ASSEMBLY MUST CAUSE LOSS OF CONTROL OF THE BICYCLE RESULTING IN SERIOUS OR FATAL INJURIES 2006 FOX 40 OWNER S MANUAL P N 605 00 046 Cutting steerer to proper length Install the fork on the bicycle with all of the headset parts and upper crown The deep pocketed side of the upper crown faces downward on the bicycle After eliminating play in the headset lightly tighten the steerer pinch bolt on the upper crown with a 5mm hex wrench Install the headset spacers not required and stem on the steerer and lightly tighten the stem pinch bolt s Mark the st
20. ng a 15mm 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 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 aD Turn the bike or fork upside down pull up on the lower leg and add 40cc 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 40cc of FOX Suspension Fluid 7 wt into 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 co Slide the lower leg down further so the plunger stud on the left side of the fork goes thro
21. r or FOX Racing Shox A fork leg or dropout failure can cause loss of control and serious or fatal injuries W The FOX 40 does not include reflectors for on road use The FOX 40 is designed to be used in competitive off road riding and racing Proper re flectors meeting the Consumer Product Safety Commission s CPSC requirements should be installed if the fork will be used on public roads The FOX 40 has a crown steerer 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 independently of the crown DO NOT ATTEMPT TO ADD THREADS TO THREADLESS STEERERS Modifying the crown steerer assembly as described here can cause the rider to lose control of the bicycle resulting in serious or fatal injuries P N 605 00 046 2006 FOX 40 OWNER S MANUAL INSTALLING THE FOX 40 The FOX 40 is available in two upper crown sizes to cover the varying range of headset tube dimensions Measure the total stack height see the figure below to determine the proper upper crown size For total stack heights of 90 165mm your FOX 40 should have the SMALL LARGE UPPER CROWN For total stack heights of 165 181mm your FOX 40 should have the EXTRA LARGE UPPER CROWN Upper Headset Parts Frame Headtube Lower Headset Parts A qualified bicycle mechanic should install the FOX 40 Improperly instal
22. s 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 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 annuall
23. trols the rate at which the fork extends gt PRELOAD initial force placed on a spring gt SPRING RATE force required to compress a spring one inch SETTING SAG nn For best performance it is necessary to set and adjust sag Sag is how much the fork compresses or sags when the rider sits on the bicycle a normal riding position Generally this is 15 25 of the total travel 1 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 More Preload 2 Compare your sag measurement to the ones listed in the SAG SETUP table on the next page If your sag is lower than on the table turn the preload knob counterclockwise one 1 full turn Measure sag again and repeat adjustment if necessary If your 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 see the SPRING TUNING section on page 10 P N 605 00 046 2006 FOX 40 OWNER S MANUAL SPRING TUNING Consult the COIL SPRING GUIDELINES table below to see if you need to change the coil spring on your FOX 4
24. ugh 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 see figure above 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 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
25. y 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 on the inside front cover of this manual and contact FOX Racing Shox or an Authorized FOX Racing Shox Service Center P N 605 00 046 2006 FOX 40 OWNER S MANUAL 16 CHANGING OIL 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 clean dry lint free towels as well as the following Oil change on the FOX 40 RC2 or R 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 RC2 or R cartridge UNLESS YOU ARE AN AUTHORIZED FOX RACING SHOX SERVICE CENTER WITH THE 7 DO NOT ATTEMPT DISASSEMBLE THE FOX 40 RC2 OR R CLOSED CARTRIDGE SYSTEM APPROPRIATE TOOLS 1 Place the bicycle or fork in a stand R

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