Shock Absorber Rebuild Manual - Fox Racing Shox
Contents
1. oe ee RACING SHOX Shock Absorber Rebuild Manual Models FLOAT FLOAT 2 FOX RACING SHOX 150 Hangar Way Watsonville CA 95076 PHONE 800 369 7469 ext 7647 FAX 831 768 7026 Email info foxracingshox com Website www foxracingshox com O05 OU O560 KEV C TABLE OF CONTENTS DISCMAN 3 Consumer SAFECY eececccccccccesssseeeeeeeesseessneeeeeeeeseeessneeeeesy 3 Removal amp IMSTAN AU ON iavsntienesesnwnstneunceanmanevnenawenasznnveeenens 3 Recommended Service INtervallS cecescsccsessessesseseees 5 Tools amp Materials Required for Rebuild 4 ReDUIO IIS TU CHON serei eee sree ten Sern ttt 5 15 CGO ntact WAT ORO Meissenin 16 SEV CO E E E E ee 16 Warranty POliCy n ccccccccscssssceescccesssseeseeeeeessesssneeeeeeeeesens 16 Methods Of PayYMent ccccccccccccccccssssseseeeeeeseesssseeeeseeeesees 16 Methods Of SHIPPING iccccccssseeseeeeseesssseeeeeeeessesssseees 16 Page 2 O05 OU O560 Rev C Disclaimer FOX Racing Shox is not responsible for any damages to you or others arising from riding transporting or other use of your FOX equipped vehicle In the event that your shock breaks or malfunctions FOX Racing Shox shall have no 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 A2. 21 PUSU O Rev C from this point be sure the damping piston assembly stays in contact with the bearing When the bearing is threaded all the way down drop the steel ball into the bleed hole and thread the bleed screw into the bearing assembly and tighten it down using the 5 64 hex key Picture 18 Using the 398 00 249 bearing tool tighten the bearing assembly into the body Approximately 50 ft lb torque Push the shaft all the way down until the air sleeve cap lightly contacts the bearing assembly It should go all the way down without any feeling of contact or interference Picture 19 DO NOT attempt to pull the shaft back out of the body If there is any interference while pushing the shaft into the body the IFP is in the wrong location You must unthread the bearing assembly from the shock body and repeat steps 8 through 17 of assembly Failure to do so will result in improper performance potential damage to the shock absorber or even rider injury See the Consumer Safety section at the end of these instructions If there is no interference proceed to step 19 of assembly Remove the shock from the vice Page 16 22 ZS PUSU O Rev C Securely clamp Fox Nitrogen Safety Needle in the vice Be sure to point the air valve away from your face and body Insert the safety needle squarely into center of the nitrogen filler valve and pressurize the shock to 200psi The shock shaf
3. Fluid 29 Lightly grease the air sleeve wiper and back up wiper 30 Tightly wrap the new slide rings around the 2 Phillips screwdriver shaft to pre curve them Picture 23 This will keep them on the bearing assembly during air sleeve installation Page 18 O0o J0 OS0 Rev L 31 Grease and install both slide rings in their grooves on the bearing assembly SZ 53 54 59 56 37 Slide the air sleeve over the body until the leading edge of the air sleeve is at the air piston Picture 24 5 Carefully slide the air sleeve over the first installed slide ring and the air piston seal You will feel a slight drag from the seal and slide ring but no binding If you feel solid binding the slide ring may be out of its groove and you must pull back the air sleeve and repeat step 30 Carefully slide the air sleeve over the second installed slide ring and half way to the air sleeve cap Again you will feel a slight drag but no binding If you feel any solid binding the second slide ring may be out of its groove and you must pull back the air sleeve and repeat step 32 Remove the shock from the vice turn it over and put it back into the vice holding it by the impact body eyelet Add one pillow pack of float fluid to each shock each pack contains 5cc of fluid The float fluid packs are part of the rebuild kit Picture 25 Page 19 O05 OU O560 KEV C 38 Slide the air sleeve down to
4. Rev C 23 Using the scribe remove the rubber nitrogen valve pellet from the nitrogen filler valve by spearing it and pulling it straight out Dispose of the old nitrogen valve pellet 24 Fold a cloth shop towel into at least 4 layers Hold the body with the open end pointed down at the folded shop towel 25 To remove the IFP insert an air gun into the nitrogen filler valve opening and pressurize the shock body with compressed air Picture 9 This will safely blow the piston out into the folded shop towel WARNING USE ONLY COMPRESSED AIR NEVER USE HIGH PRESSURE NITROGEN 26 Clean the impact body and IFP with parts cleaner 27 Clamp the air sleeve cap eyelet securely in vice with the shaft and piston up 28 Using a 9 16 wrench remove the piston lock nut from the end of the shaft Page 9 OOS7U0 OS6 REV C 29 Hold the tip of the Phillips Head Screwdriver against the end of shaft Hold the piston assembly under the top out plate and lift uowards Slide the piston assembly onto the shaft of the screwdriver Picture 10 Pull the Screwdriver away from shock shaft while supporting the piston assembly Set this on a clean lint free towel There are many pieces to the piston assembly and the assembly order of these pieces is critical to the proper performance of your shock This step ensures that the proper order is kept He iee6e8 6 6 gt gt e eee eee e a oe 30 Slide bearing assembly and t
5. Warranty is limited to the repair or replacement of the FOX Racing Shox product FOX Racing Shox reserves the right of final decision with regards to all warranty related issues Warranty is void when damage to the shock has occurred from the following Abuse Seal damage due to power washing Damage to the exterior finish caused by debris rocks or crashes Any attempts to disassemble shock absorber Modifications Non factory oil use or improper service Shipping damage or loss purchase of full insurance is recommended Methods of Payment VISA MasterCard and or Cashier s Check Methods of Shipping FOX Racing Shox uses UPS Ground Service within the USA Customer may request UPS Air Service at an extra cost All non warranty shipping charges are the customer s responsibility Page 22
6. Scribe or Dental Pick 2 Phillips Screwdriver 9 16 Open End Wrench 9 16 Socket Torque Wrench Hammer Nitrogen Tank w Regulator Cleaning Solvent 8 Long Pin Punch with 1 8 to 1 4 Point Size Page 4 O05 OU O560 Rev C REBUILD INSTRUCTIONS Important notes e SAFETY FIRST Always wear safety glasses and read directions completely BEFORE disassembling the shock e Cleanliness is critical make sure your work area is clean and un cluttered prior to starting work Contamination of the shock will lead to premature wear and poor function of your shocks e IMPORTANT When replacing a seal during a service make sure that the new seal is the same size shape and material as the one you are replacing In some cases there may be two seals in the rebuild kit that look similar NITROGEN SAFETY NEEDLE You need to install the black needle guide bushing FOX part 200 02 002 on the FOX Nitrogen Safety Needle in order to assure a correct nitrogen fill and to prevent needle damage when charging your FOX AirShox To install the black guide bushing unthread the red bushing from the safety needle body and thread the black bushing in finger tight DISASSEMBLY 1 Remove the shock from the vehicle 2 Remove stainless steel reducers and clean with parts cleaner If your shock has polyurethane bushings and steel sleeves instead of stainless steel reducers remove them 3 Clean the entire sho
7. T 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 Float 2 Upgrade If you are doing a Float 2 upgrade ensure that your Float has the right internals for being target of the upgrade If you are upgrading your Float to a Float 2 please advise the upgrade instructions FOX P N 605 001 033 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 3 5000 Miles Change shock oil and seals Page 3 O05 OU O560 KEV C Tools amp Materials Required for Rebuild Safety Glasses Latex Gloves Lint Free Towels Vice w Soft Jaws Assembly grease FOX P N 025 01 013 FOX Float AirShox Seal Kit Fox P N 803 00 099 A Recommended Shock Fluid 1 Qt 5wt Fox P N 803 11 O05 12 Scale or Caliper for IFP depth setting Fox Seal Installation Bullet 1 2 Shaft Fox P N 398 00 026 B Fox Nitrogen Safety Needle Fox P N 802 01 O00 A 5 64 Hex Key Allen Wrench 5 32 Hex Key Allen Wrench 3 16 Hex Key Allen Wrench 3 16 Pin Spanner
8. US INJURIES OR DEATH FLOAT AIRSHOX IFP DEPTH es ooso22 es owz ar eso oom220 6 30 es oom2208 Page 21 O05 OU O560 KEV C Contact Information FOX Racing Shox Phone 800 369 7469 ext 7647 130 Hangar Way North America 800 369 7469 Watsonville CA 95076 Fax 831 768 7026 E mail info foxracingshox com 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 RA and shipping instructions 2 Satisfactory proof of purchase receipt is required for warranty consideration 3 Mark the Return Authorization Number CRAN 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 is valid for one year from the original date of purchase from an OEM Customer s authorized dealer
9. ck assembly with soapy water Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush Cleanliness is critical Never oressure 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 Page 5 4 10 11 12 13 14 O0o J0 OS0 Rev L Release all air pressure from the air valve Clamp the air sleeve cap eyelet in a vise with soft jaws Slide the travel indicator o ring off of the body and set it aside Loosen air sleeve turning it counter clockwise by hand and slide it up and off of the body Remove the air piston slide rings from the air piston Clean inside of the air sleeve with parts cleaner and set it on a clean lint free towel After cleaning any of the parts with parts cleaner dry them 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 Remove the shock from the vice and clean it with parts cleaner Place the shock in the vice holding it by the impact body eyelet Now is the best time to remove the air piston seal from the bearing assembly Use extreme caution when using a scribe to remove seals Always spear the seal with the point of the scribe Do not wedge the point of the scribe i
10. in Install the new shaft seal into bearing Check to make sure the seal is properly seated If a tool is required to aid in proper seating of the shaft seal use the non writing end of a pen or a similar soft blunt object to push it in Install the new well lubricated o ring into the out side of the bearing housing by very carefully sliding it over the bearing threads Page 11 OOS7U0 OS6 REV C 10 Install the new well lubricated air piston seal into the out side of the bearing housing by very carefully sliding it over the non threaded end of the bearing The grooved side of the seal concave should point towards the non threaded end of the bearing The orientation of this seal is critical Be sure it is oriented correctly Picture 12 11 Install the new well greased o ring onto the IFP 12 Install the new well greased o ring into the air sleeve cap 13 Install the new well greased o ring onto the damping piston if your shock has that type of piston Page 12 OOS7U0 OS6 REV C ASSEMBLY Clamp air sleeve cap eyelet securely in vice and place seal bullet tool on end of shaft Lubricate the bearing assembly seals with an ample amount of assembly lube Slide the bearing assembly onto shaft with the threaded end pointed up Picture 13 This should be done in a single smooth motion to avoid damaging the seals Slide the top out bumper onto the shaft Hold the piston assembly fro
11. m underneath the top out plate and place the end of the screwdriver onto the end of the shock shaft Slide the piston assembly onto the shaft end Check to make sure the piston assembly is properly seated then install the piston lock nut Torque the nut to 22 ft lb using the torque wrench and 9 16 socket Picture 14 Remove shaft assembly from vice and set it aside on a clean lint free paper towel 5 Clamp the impact body of the shock securely in the vice with the open end of the body facing up Page 13 CUSUB O Rev C 6 Generously lube the IFP o ring with assembly lube and wrap a new piston ring around it 7 Insert the IFP into the shock body with the dished side facing up toward the open end of the shock body to just below the bearing threads The IFP is a snug fit in the body Be sure it does not cock sideways and use plenty of grease to avoid damaging the o ring on the bearing threads 8 The correct IFP depth is listed by shock part on the back page of this instruction sheet The shock part number is stamped into the air sleeve cap eyelet The IFP depth is measured using either a 12 dial caliper or measuring scale with inches graduated in 10ths The measurement is from the edge of the open end of the body to the outside edge of the IFP Picture 15 Using the 8 Pin Punch at the center of the IFP slide the IFP into the body until it is at the proper depth specification 0 050 for your
12. n behind the Page 6 COS REV C seal This can scratch the surface of the seal groove which will compromise the performance and reliability of the shock absorber 15 Pointing the scribe downward spear the air piston seal in the center groove and pry it outward away from the bearing assembly 16 Insert the barrel of a pen or similar plastic part that will not scratch the aluminum behind the air piston seal and pry it all the way out of its groove Picture 4 and off of the bearing assembly Picture 5 Let it stay around the shock shaft for now 17 Using the point of the scribe remove the nylon ball from the nitrogen filler valve on the shock body Picture 6 Page 7 OOS7U0 0S0 Rev C 18 Insert the FOX Nitrogen Safety Needle into the nitrogen filler valve on the shock body and using a small blunt object such as and allen wrench to depress the Schrader valve release all of the nitrogen pressure Picture 7 19 Using the 3 16 pin spanner loosen and unthread the bearing assembly from the shock body Picture 8 20 Remove the shaft assembly from the shock body and set it on a clean lint free towel 21 Remove the shock body from the vice and pour shock oil from body tube into a proper disposal container DO NOT RE USE OLD SHOCK OIL 22 Using the 3 16 Allen wrench remove the air valve pellet retainer set screw from the nitrogen filler valve Page 8 PUSU O
13. op out pad off of the shaft and set them on a clean lint Sk free towel Use extreme caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft Remove the old air piston seal that is hanging around the shaft and dispose of it 32 Using the 5 64 Allen wrench loosen and remove the bleed screw and steel ball from the bearing and set them both on a clean lint free towel Page 10 DOS O0 OS0 REV C REBUILDING 1 D U NWN Use a scribe or dental pick to remove the shaft seal and all o ring seals from the bearing housing Be careful not to scratch the seal grooves or the DU bushing that is pressed into the bearing Picture 11 Thoroughly clean the bearing assembly with parts cleaner Use a scribe or dental pick to remove the o ring seal from the IFP Use a scribe or dental pick to remove the o ring seal from the air sleeve cap Use a scribe or dental pick to remove the two wipers from the air sleeve Use a scribe or dental pick to remove the o ring from the damping piston if your shock has that type of piston Install the new well lubricated o ring into the bearing housing Correct placement of the shaft seal o ring is in the groove next to the DU bushing Check to make sure the seals are properly seated and are not twisted If a tool is required to aid in proper seating of o ring use the non writing end of a pen or a similar soft blunt object to push it
14. particular shock You may either push the punch by hand or lightly tap with the hammer lkb DEbLH Page 14 OOS7U0 OS6 REV C 9 Install a new rubber nitrogen valve pellet into the nitrogen filler valve opening 10 Thread the nitrogen valve pellet retainer into the nitrogen filler valve opening and tighten it using the 3 16 Allen wrench 11 Fill the impact body with oil to the bottom of the bearing threads 12 Wrap the new piston band around the piston making sure the rounded edges face out Insert the shaft assembly into the impact body Picture 16 Slowly push shaft into body until piston assembly is approximately 12 inch below the oil surface pa 13 Slowly stroke the shaft assembly up and down over about a 1 inch range 2 or 3 times being very careful not to pull the piston assembly out of the oil There should be no air bubbles coming up from the piston assembly at this point 14 Top off the shock body with oil and slowly pull the shaft up until the piston assembly is about in the middle of the bearing threads 15 Holding the shaft in that position slide the bearing assembly down the shaft and start threading it into the body by hand Oil should flow out of the bearing bleed hole Picture 17 16 As you thread the bearing assembly down it will contact the damping piston assembly and pull it down into the shock body with it As you thread the bearing in Page 15 17 18 19 20
15. t should be fully extended from the pressure before you take the final pressure reading Picture 20 Continue charging with gas as you pull the shock away from the Fox Nitrogen Safety Needle using a smooth straight motion Keep the shock as straight as possible to prevent the safety needle from bending As the safety needle is pulled free from the Fox air valve a popping sound should be heard CHARGE THE SHOCK DAMPER IFP CHAMBER USING NITROGEN GAS ONLY DO NOT FILL WITH ANY OTHER GASSES Doing so will compromise the performance of your shock and may be EXTREMELY DANGEROUS 24 Hold the shock in the vice by the impact body eyelet in a horizontal orientation with the nitrogen filler valve facing up 25 Insert the end of the 5 32 Allen wrench into each of the pin insertion holes on the top of the bearing assembly and force the oil out of them Picture 21 Wipe off the oil with a clean lint free towel Page 17 OOS7U0 0S0 Rev C 26 Using the hammer and pin punch carefully tao a new nylon ball into the hex of the nitrogen valve pellet retainer Picture 22 Be extremely careful not to strike the surface of the shock body and damage it with the hammer 27 Lightly lube the air sleeve cap o ring and threads with FLOAT Fluid or Multi purpose Lithium based grease NLGI 2 Make sure the o ring is seated all the way around in the groove in the cap 28 Liberally lube the air piston seal with FLOAT
16. the air sleeve cap 39 Thread the air sleeve into air sleeve cap and hand tighten until the air sleeve makes contact with the o ring in the air sleeve cap 40 Remove the shock from the vice turn it over and put it back into the vice holding it by the air sleeve cap eyelet 41 Tighten the air sleeve by hand until it bottoms in the air sleeve cap 42 Do not over tighten air sleeve or use tools other than your hands 43 Inflate shock using inflation instructions listed in the Pump Instructions 44 Clean all oil residues 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 45 Slide the travel indicator o ring on to the body 46 Install reducers Cor polyurethane bushings and steel sleeves in eyelets 47 Congratulations you re done Page 20 O05 OU O560 Rev C CONSUMER SAFETY We highly recommend if for any reason your shock absorber ever loses damping oil air pressure behaves shock erratically or makes any unusual noises that you STOP RIDING IMMEDIATELY and have your absorber inspected by a FOX Racing Shox dealer or contact FOX Racing Shox directly at 1 800 FOX SHOxX RIDING ON A SHOCK ABSORBER THAT IS BROKEN OR MALFUNCTIONING CAN RESULT IN LOSS OF CONTROL CRASHING AND POSSIBLE SERIO
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