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FOX FORX F100X® ENDURO FORK SEALS™

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1. All rights reserved Zz enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 40 Put the lower slider assembly back onto the upper legs a Verify that the foam rings are not protrud ing past the oil seals see Step 29 Carefully start one wiper onto the beveled edge of its respective stanchion tube and hold it in place while you work the other wiper over its re spective stanchion b Slide the lowers part way onto the stan chion tubes and invert the fork the threads of the air piston rod should NOT be protruding through the hole in the bottom of the lower leg or you have pushed the lowers too far onto the stanchions 41 Inject approximately 20cc of 7wt suspension fluid into the bot tom of the air spring leg rider s left and slide the lowers down until the air piston rod prodrudes through the hole Recommended suspension fluid FOX SYNTHETIC RACING FORK FLUID 7 WT OR TORCO RACING SHOCK FLUID MEDIUM 2005 Real World Cycling enduroforkseals com All rights reserved 23 enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xoe 42 Install the air spring side crush washer and foot nut Always replace the crush washer The old crush washers fit too tightly and may inter fere with proper alignment of the rod Replace the foot nut and tighten by hand c Torque the foot nut to 40 50 inch pounds Set the fork aside to service the damper 2005 Real W
2. All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 10 Returning to the damper leg drive the rod up into the lower assembly Be prepared for oil 11 Remove the rebound adjuster knob Hold the knob securely to keep it from rotating Loosen the set screw with a 2mm Allen Wrench If you have difficulty pulling the knob straight up and off use some needle nosed pliers 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 12 Remove the damper assem bly a Use a 26mm 6 point socket to loosen the top cap b As you lift the damper assembly out of the fork the remaining damping oil will drain out the bottom of the lower leg c Over the oil collection bucket shake the damper up and down to activate the brass mass valve and drain out the oil Periodi cally pump the rod in and out and continue shaking the damper up and down until the bulk of the oil is drained I d Set the damper assembly pictured at right aside for now Tm 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 13 Pull the lowers off of the stanchion tubes 14 Remove the wiper seals Start by gently prying at the notches under the outer edge of the wiper moving from notch to notch un
3. 3 enduro fork seals com FOX FORX F100Xe 24 Start the new oil seal into the seal head as evenly as possible 25 Using a seal press or an inverted socket pictured press the new oil seal until it is evenly seated against the foam ring 2005 Real World Cycling enduroforkseals com All rights reserved 14 enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 26 Lubricate the outside edge of the new wiper 27 Start the wiper into the seat ing area by hand NOTE If you have difficulty starting them by hand place the wipers in the freezer for a few minutes This causes the steel ring inside of them to contract slightly reduc ing the outside diameter and easing instal lation 28 Fully seat the wiper against the lower assembly You may be able to do this by hand If necessary a short section of PVC pipe works well 2005 Real World Cycling enduroforkseals com All rights reserved 15 enduro fork seals com REAL WORLD CYCLING 29 Grease the insides of the seal and wiper and push the foam ring toward the outer cir cumference of the leg Be sure the foam ring does not protrude past the oil seal The idea is to keep the fork stanchions from catching on the foam rings when the fork is re assembled COMPLETE STEPS 21 29 FOR THE OTHER SIDE OF THE LOWERS THEN SET THE LOWERS ASIDE FOR NOW FOX FORX F100X e 2005 Real World Cycling enduro
4. DER LOWER ASSEMBLY RE INSTALLATION 23 24 SUSPENSION FLUID uo cccccnrnrcccccccccccccccccccccecceceeees 2357 DAMPER ASSEMBLY TEAR DOWN ccececccceeeeeeeeeeeees 25 27 DAMPER RE ASSEMBLY 0 eeeeeeeeeeeeteeeeeeeeeeeeeeeens 28 34 TERRKRALOGIC ea setts chosen ing ENEE EEE EE E 25 28 DAMPER RE INSTALLATION 0 0 0 cccccccccccceeeeeeeeeeeeeeees 34 38 AIR SPRING SETTINGS 0 cccccecceceeeeeeeeeeeeeeeeeeeeeeeeeeeees 39 ADJUSIMENIS ccdcccacasecconsrccetecssncadacacsntcncasaneenescdedecesaanadncacsietes 39 ENDURO FORK SEALS CARE OF 0 ee eeeeeeeeee 40 enduro fork seals com FOX FORX F100Xoe REAL WORLD CYCLING 1 Adjust the rebound dial to ap proximately mid point Right side of the fork from rider s view This is to avoild putting pressure on the re bound adjusting components while remov ing the retaining screw 2 Adjust the Bump Sensitivity Threshold knob to approximately mid point Right side bottom of the fork from rider s view 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xe 3 Remove the bump threshold adjusting knob Use a 2mm Allen wrench to loosen the set screw After loosening the set screw the bump threshold knob will drop off of the foot nut assembly 4 Use a 10mm wrench or socket to remove the foot nut from the bottom of the right leg NOTE Oil may discharge fro
5. G SHOCK FLUID MEDIUM 2005 Real World Cycling enduroforkseals com All rights reserved 37 enduro fork seals com FOX FORX F100X REAL WORLD CYCLING 58 Tighten the top cap Thread the top cap in by hand and torque to specification Fox recommends 165 inch pounds but anything over 55 inch pounds should be adequate 59 Install the rebound adjust ment knob Torque the retaining screw to 11 inch pounds 2005 Real World Cycling enduroforkseals com All rights reserved 38 enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xe 60 Set the initial air spring pressure on the left side RIDER WEIGHT AIR PRESSURE lt 125 LBS 45 PSI 125 135 LBS 50 PSI 135 145 LBS 55 PSI 145 155 LBS 65 PSI 155 170 LBS 75 PSI 170 185 LBS 85 PSI 185 200 LBS 95 PSI 200 215 LBS 105 PSI 215 230 LBS 115 PSI 230 250 LBS 125 PSI Use the above guidlines to get started adjusting the pres sure up or down based on desired ride quality whether or not the fork tends to bottom out etc Be sure to replace the blue air cap 61 Make initial rebound and bump threshold adjustments The red knob at the top of the right fork leg is the rebound adjuster knob Turning it clockwise will result in slower rebound Turning it counter clockwise will result in faster rebound _ BUMP In theory the FX fork series is always locked out to rider THRESHOLD input only being act
6. TH VERY HOT WATER The hot water not only helps to cut the oil it also heats up the lower assembly so that during the dry ing process much of the work is done by evaporation 2005 Real World Cycling enduroforkseals com All rights reserved 11 enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xo 19 Dry the lowers with a lint free absorbant towel If necessary use a blow drier to remove any remaining moisture 20 Don t forget to drop the bot tom out bumpers into each lower leg Use a rod to push them flat on the bottom of the legs 21 Use Super Slick Grease to lubricate the seal reception area of the lowers Note that the machining is stepped The foam rings go past this ledge and sit directly on top of the bushings The inner oil seal when pressed down onto the foam ring will rest just above this ledge 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xe 22 Insert a new foam ring into the seal head The foam ring will sit directly on top of the bushing 23 Lubricate the outside edge of the new inner oil seal before starting it inot the seal head Please take note of the correct orientation of the oil seal The writing faces up away The groove and garter spring from the oil face down toward the oil 2005 Real World Cycling enduroforkseals com All rights reserved 1
7. and loosen the top cap using a 6 point 26mm socket wrench 30 FOX FORX F100X b Remove the spring Ifthe detent ball is loose re move it now and set it aside If it does not want to roll out leave it in place for now ag ny T F ma T cu 7 EE Meares i et ego gM tinal N d Pull the top cap off the end of the shaft If the detent ball has not yet been removed be careful not to lose it e The easiest way to remove the detent ball is to push it straight back and let it fall out of the center of the top cap 2005 Real World Cycling enduroforkseals com All rights reserved k tc enduro fork seals com FOX FORX F100Xe 50 Remove inspect and re in stall the seal head from the damp er shaft a Slide the seal head off of the shaft b Inspect the seal located near the top of the seal head Lubricate with Super Slick Grease c Lubricate the end of the shaft to reduce the chance of damaging the seal when 1n stalling the seal head d Slide the seal head onto the shaft 2005 Real World Cycling enduroforkseals com All rights reserved 31 enduro fork seals com FOX FORX F100X e 51 Re install the damper shaft into the damper tube and torque the seal head to 55 inch pounds 52 Re install the top cap onto the damper rod a Lube the O ring s b Thread the top cap on by hand c Torque to 55 90 inch pounds _ m r
8. ead the top cap 3 or 4 turns into the top leg to keep the damper assembly properly aligned while you tighten the foot nut d Invert the fork and place a new crush washer over the shaft end Apply some grease or anti seize compond on the threads e Pry the old crush washers out of the foot nuts if you haven t already and hand tighten the foot nut 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xoe 56 Re install the bump thresh old adjuster knob a Line up the knob set screw with the detent on the shaft extention b Torque the set screw to 4 inch pounds 2005 Real World Cycling enduroforkseals com All rights reserved 36 f Torque the foot nut to about 50 inch pounds enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xoe 57 Add the proper amount of suspension fork fluid to the damper side a Unthread the top cap remember in Step 52c the top cap was only partially threaded in b Release the air from the air chamber left leg and partially compress the fork c Add 155cc of Fork Fluid in stages compressing and extending the fork and pumping the damper after adding the fluid incrementally NOTE 150cc for F80X Recommended suspension fluid _ i F ee mr f L i T E a 2 j i E a FOX SYNTHETIC RACING FLUID 7 WT or TORCO RACIN
9. enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xoe PICTORIAL SERVICE MANUAL THESE INSTRUCTIONS ARE OPTIMIZED FOR RECOMMENDED PARTS FOR SERVICING THE FOX FORX F100X Plastic bucket drain pan 2mm Allen wrench Flat bladed screwdriver Pocket screwdriver 26mm 6 point socket 10mm socket Ratchet wrench Adjustable flat jawed wrench Torque wrench Fox Bullet Piston Insertion Tool optional Clean lint free rags wt fork fluid Fox 5cc Float Fluid Pillow Pack or 80 wt fully synthetic gear oil Super Slick Grease or PrepM Oil syringe or other measuring device Shock pump 13mm wrench Rod clamps optional 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100Xe TABLE OF CONTENTS TOOLS REQUIRED 000 eeccssssesssessssessssssseseesssssssesssseeees l SLIDER LOWER ASSEMBLY REMOVAL seeeeeeeeeererrre 3 9 SEAL REMOVAL ccicancetacacncrancaseceonsncdeseatatacetnsacsetantasaneenerenetedtets 9 10 SLIDER LOWER ASSEMBLY CLEANING c cc cceeeeeees 10 12 ENDURO FORK SEALS INSTALLATION oiii 12 16 AIR PISTON REMOVAL cssncstesdenacedabonecacresescdtataneatensseacatabenssaens 17 18 STANCHION TUBES CLEANING cc cceeeeeeeeeeeeeees 19 AIR PISTON RE INSTALLATION ooer 19 22 FOX FLOAT FLUID srsciscscnncesnesescecasonncaencdececesancedecnasettecadacanass 21 SLI
10. forkseals com All rights reserved 16 enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 30 Release any remaining air from the air spring Schrader valve and remove the top cap Use a 26mm 6 point socket to remove the top cap 31 Drain the 5cc of FLOAT fluid or equivalent Not sure what was last used in this fork but it doesn t look so good 2005 Real World Cycling enduroforkseals com All rights reserved 17 enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 32 Remove the Air Shaft A ir Piston assembly a Push up on the shaft until just before it disappears into the upper leg b Use a rod or similar device to push the air piston up to the top of the fork crown c Carefully push the air piston past the top cap threads and remove it from the upper assembly 2005 Real World Cycling enduroforkseals com All rights reserved 18 enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 33 Clean and dry the inside of both stanchion tubes 34 Use Super Slick Grease or other suspension grease to lube the left side threads and the outer diameter of the air piston 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING 20 FOX FORX F100X 35 Re insert the Air Shaft Air Piston assembly into the left upper leg TIP To protect the air pis
11. ivated by actual bumps on the trail The size of bump required to overcome the lockout can be adjusted by use of the blue bump threshold adjustment As indicated full counter clockwise adjustment requires the least amount of input from the ground to activate the suspen sion Ifthe knob is turned clockwise a larger bump will be required to activate the suspension 2005 Real World Cycling enduroforkseals com All rights reserved 39 enduro fork seals com REAL WORLD CYCLING FOX FORX F100X e PROPER CARE OF YOUR Even in relatively clean and dry conditions you will find that the stanchions and top edges of the wipers get dirty Use a soft clean cloth to carefully clean the stanchion tubes and wip ers Drizzle some Stanchion Lube onto the clean stanchion tubes and allow it so settle on the tops of the wipers Stanchion Lube by Finish Line Compress the fork a few times Using a soft cloth work the ex cess Stanchion Lube into the upper legs Before each ride rotate your bike backwards over the rear wheel allowing the oil to pre lube the stanchion bushing interface and inner oil seal This will extend the life of your seals and bushings 2005 Real World Cycling enduroforkseals com All rights reserved 40
12. m the bottom of the fork at this stage so have an oil col lecting bucket in place underneath the fork 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 5 Invert the foot nut and thread it back part way onto the damper rod Do not thread the foot nut up higher than the threshold adjusting rod The purpose of this step is to allow the rod to be driven up into the fork leg without damaging the adjusting nub For now move to the other fork leg ii he mapa 6 Loosen the foot nut on the air spring side rider s left so that 4 or 5 threads are showing Again be sure and have something ready to catch the oil 7 Release air from the fork leg by depressing the Schrader valve at the top A small amount of oil may discharge with the air 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 8 Using a plastic faced mallet or other suitable means give the foot nut a sharp upwards blow to drive the rod into the lower leg Note that the exposed threads disappear when the rod is succesfully driven into the lower leg 9 Remove the foot nut and be ready for oil Push the rod up into the leg to allow proper drainage The left leg contains about 20cc of 7wt synthetic suspension fluid 2005 Real World Cycling enduroforkseals com
13. orld Cycling enduroforkseals com All rights reserved 24 enduro fork seals com FOX FORX F100Xoe 43 Remove the Terralogic Base Valve from the damper assembly Note In working with the various shafts and other cylindrical parts use the Fox Forx Shaft Clamps or a suitable substitue the pictured tool is part of a copper tubing flare tool The key point here 1s to se curely grasp the parts without scratching or distorting them a Clamp the base valve assembly b Use a 13mm wrench on the seal head as sembly to back the damper tube out of the base valve assembly If the seal head itself starts unthreading you may need to clamp the damper tube and use a wrench to wind off the base valve c Remove the base valve assembly from the clamp still pictured in the clamp 2005 Real World Cycling enduroforkseals com All rights reserved 25 enduro fork seals com REAL WORLD CYCLING 26 FOX FORX F100Xoe 44 Drain remaining oil from the Terralogic Base Valve assembly Shake the assembly over the oil collec tion bucket In the picture the clamp is removed for clarity but should be left attached for the next step 45 Remove the Terralogic base valve from its protective hous 99 ing a Use a good quality adjustable wrench on the flats of the base valve and unsrew it from the housing b Slide out the Brass Mass assembly 2005 Real World Cycling endu
14. roforkseals com All rights reserved Ge al enduro fork seals com FOX FORX F100Xe 46 Test the action of the Brass Mass valve As pictured at left the brass assembly rests in the up position concealing the oil port Simulating bumps by quickly thrusting the assembly upwards will cause the brass assembly to drop down exposing the oil prort see below 2005 Real World Cycling enduroforkseals com All rights reserved 21 enduro fork seals com FOX FORX F100Xo 47 Re install the assembly into its protective housing a Use a very small amount of blue Loc tite on the threads b Start the assembly by hand and tighten using the shaft clamp and a quality adjust able wrench Factory torque specification 1s 55 Inch Pounds Set the base valve assembly aside for now 2005 Real World Cycling enduroforkseals com All rights reserved 28 Ge enduro fork seals com FOX FORX F100Xe 48 Remove the damper assem bly from the damper tube a Clamp the damper tube and loosen the seal head with a 13mm wrench b Remove the damper assembly for in spection Ifthe seal head needs to be ang Ms can replaced proceed to step 49 a he Te 49 Remove the Top Cap from the Damper Assembly a Remove the detent ball set screw 2005 Real World Cycling enduroforkseals com All rights reserved 29 enduro fork seals com c Secure the shaft
15. s real l j Mary TAPE HF Mer abe fin oft a Sets es ae l m ett LET T Pi pe ee qidi Ti ne pe GS j Ti i d im eS T iR si See E ae ie E 2005 Real World Cycling enduroforkseals com All rights reserved 32 enduro fork seals com 33 FOX FORX F100Xoe 53 Re install the detent ball into the damper top cap a Put a small dab of grease on the ball bearing and drop it into place b Insert the spring into the hole on top of the detent ball Wipe the opening and threads clean of grease c Adequately coat the set screw threads with blue Lockite This not only keeps the screw in place put also FORMS AN AIR SEAL d Tighten the set screw until it is flush with the flat surface 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 54 Attach the base valve as sembly to the damper tube Apply a small amount of Locktite to the threads and torque to 55 inch pounds You are now ready to re install the damp er assembly into the fork leg 55 Install the damper assembly into the right leg a Lube the O rings at the bottom of the damper 2005 Real World Cycling enduroforkseals com All rights reserved 34 enduro fork seals com REAL WORLD CYCLING 35 FOX FORX F100Xoe b Guide the end of the damper rod through the hole in bottom of the leg c Hand thr
16. til the wiper begins to lift out of the seal head area 2005 Real World Cycling enduroforkseals com All rights reserved 9 enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 15 Remove and discard the foam rings New rings are provided with your Enduro Seal Kit 16 Inspect the lower slider as sembly If the lowers are excep tionally clean inside proceed to step 21 Otherwise proceed to step 17 17 This is a bottom out bum per There is one in the bottom of each of the lower legs It s easier to clean the lowers with these removed otherwise they trap dirt and moisture during the cleaning process Usually inverting the lowers and tapping the legs against the palm of your hand will break the bottom out bumpers loose Keeping the fork inverted use a small di ameter rod to push them past the bushings and out of the through the tops You can also pull them out of the top using a wire with a hook bent into the end 2005 Real World Cycling enduroforkseals com All rights reserved 10 enduro fork seals com REAL WORLD CYCLING FOX FORX F100X 18 Clean the lower assembly a Place the lowers in a suitable sink or container Spray the inside of the legs with a biodegradable degreaser b Using a suitable bottle brush scub the inside of the legs with the degreaser c ADD VERY HOT WATER AND DISH SOAP TO THE BRUSH and continue scrubing d RINSE THOROUGHLY WI
17. ton seals and make the job much easier use the Fox 32mm Bullet Tool to guide the piston back into the leg As you gently push the piston past the threads guide the rod through the hole at the bottom of the the stanchion tube You can then ease the piston head past the threads by pulling on the rod as you apply downward pressure on the piston At this point you may come to appreci ate the importance of the lubrication used in step 31 as it can be difficult to get the piston head past the threads 2005 Real World Cycling enduroforkseals com All rights reserved enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 36 Inject 5cc of FLOAT Fluid or 80wt fully synthetic gear oil into the air chamber This layer of oil sits on top of the piston helping to form the air seal and provide lubrication The S5cc Fox Float Fluid Pillow Pack is a convenient way to get just the right amount of fluid on top of the air piston 37 Lubricate the O ring and threads of the top cap Tighten the top cap by hand 2005 Real World Cycling enduroforkseals com All rights reserved 21 enduro fork seals com REAL WORLD CYCLING FOX FORX F1i00Xe 38 Torque the top cap FOX says to torque to 165 inch pounds Seems like about half of that would be adequate 39 Add about 50 PSI to the air chamber to keep the air shaft fully extended 2005 Real World Cycling enduroforkseals com

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