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2001-2005 Rear Shock service Manual

1. FIRE wasa aaa SAA SN ES D gt Wa MAN S Z 2 PE NS RIS NS FEN NEN NSS UNS SSS ERS N ASS RN SS Co BRE ES QU HS gt JET FAN SS ZA lt 30 21 19 17 Cu 14 15 9 11 6 5 A 2 FOX FACTORY INC PROPRIETARY RACING SHOX 36 1 808 14 011 2 210 03 016 3 010 01 00 A 4 039 00 003 A 5 008 01 005 A 6 229 27 002 B 229 27 003 B 229 27 004 B 229 27 005 B 229 27 006 B 7 812 06 005 A 812 06 023 A 8 803 00 028 A 9 803 00 028 A 10 003 07 000 A 11 803 00 028 A 12 233 00 021 A 13 805 02 005 A 14 002 02 005 A 15 050 01 012 A 16 044 04 080 A 044 04 070 A 044 04 060 A 044 04 050 A 17 044 10 060 A 18 050 01 011 A 19 290 90 016 A 20 204 12 000 D 204 12 001 D 204 12 002 D 204 12 004 D 204 12 007 D 204 47 001 A 2001 VANILLA R PARTS LIST Eyelet assembly Shaft 1 438 TLG Eyelet 213 07 015 B Damping adjust knob Red Ball 0 125 Steel Spring 125 TLG X 125 OD Bottom out bumper Shaft 2 355 TLG Shaft 2 605 TLG Shaft 2 855 TLG Shaft 3 105 TLG Shaft 3 355 TLG Bearing assembly 665 TLG Bearing assembly 1 030 TLG 036 01 004 A U cup 2 375 Shaft Damper rebuild kit part 035 00 110 Seals Q Ring 110 Bearing Internal 375 ID 6 375 Shaft Damper rebuild kit part 029 03 020 A Seals O Ring 020 Static Spacer shaft 0 378 ID X 700 OD X 050 TLG STEE
2. o H ON AU T H O RIZ E gt SERVICE CENTER 2001 BICYCLE SHOCKS SERVICE MANUAL www foxracingshox com Copyright 2001 by Fox Factory Inc lt lt 7 7 9 10 11 12 13 14 15 16 TABLE OF CONTENTS Policies and Shared Procedures Policies and Warranty Procedures Page 4 Reducers and Bushings Page 14 Nitrogen Pellets Page 18 Float Air Sleeve Service Page 24 Vanilla Vanilla Vanilla R and Vanilla RC Drawings and Parts Lists Page 30 Vanilla and Vanilla R Service Instructions Page 46 Vanilla RX and Vanilla RC Service Instructions Page 62 FLOAT FLOAT Drawings and Parts Lists Page76 FLOAT and FLOAT R Service Instructions Page94 FLOAT RC Service Instructions Page 110 Appendices Tool List Page 122 Torque Specification Table Page 126 Tuning Table Page 130 IFP Setting Table Page138 Seal kits Page 138 Warranty Records Master Sheets for Copier Page 146 RACING SHOX Policies and Warranty Procedures 2001 POLICIES AND PROCEDURES FOX RACING SHOX GLOBAL SERVICE CENTER FOX Racing Shox is proud of our racing heritage and of the sustained quality of our products With professional help of International Service Centers like yours we will maintain this Standard of quality and high performance worldwide The following describes FOX Policies relating to service and warranty The Policies and Procedures document contains infor
3. 30 wt Suspension Fluid oil Grease lithium base type Loctite 277 red Loctite 242 blue 6 inch calipers FLOAT Van Drill Index small range of bits 027 00 001 A Fox HP Pump w gauge Nitrogen bottle with 600 PSI minimum regulator and gauge 124 Required Tools 398 00 055 A Shaft Clamp 01 497 398 00 042 B Shaft Clamp 91 625 Alps shaft Air Vanilla Air Sleeve Float Air Sleeve RU 802 01 000 A Nitrogen Safety Needle Assembly 398 00 161 A Shaft Clamp Shaft Clamp 0 375 Body Clamp 0 0 940 Bore Vanilla Float shaft Van Body 803 00 046 A Eyelet Internal Bearing Removal Tool Torque Driver 398 00 032 ABullet Tool Inch Ibs Range 0 36 2 375 Shaft Float Van Nm Range 0 4 067 125 RACING SHOX Torque Specification Table 126 VANILLA COIL SHOCKS in lb Shaft to Eyelet 110 Piston Bolt to Shaft 75 Bearing to Body and Body to Body Reservoir End Cap 240 FLOAT SHOCKS in lb Shaift to Eyelet 110 Screw to Flapper Valve 2000 4 Screw to lock out Valve 2001 4 Compression Piston Assembly 75 Bearing to Body and Body to Body Cap Air Valve Assembly to Eyelet 75 NITROGEN PELLET RETAINER in lb Initial Torque 6 Final Torque 12 ft Ib 9 16 6 25 240 20 ft Ib 9 16 333 333 6 25 360 6 25 ft lb 128 20 27 1 30 40 6 RACING SHOX TUNING TABLES VANILLA TUNING TABLE Rebound bleed hole sizes Spring Rate Bleed Hole Ble
4. 92 48 018 01 006 49 029 03 022 50 024 02 037 A 024 02 040 2001 Float RC Screw 8 32 X 093 TLG Socket Set Cup Point O Ring 022 Static Decal Standard Decal Trunion OTHER NOTES 803 00 050 A Air sleeve rebuild kit 803 00 051 A Damper rebuild kit Damper charge 500 PSI Nitrogen Oil 10wt ISO 32 6 0 1 25 FP settings 1 850 6 5 X 1 5 IFP settings 2 060 6 37 X 1 5 IFP settings 2 060 Trunion Cannondale 6 55 X 1 5 IFP settings 2 060 strut 7 875 X 2 IFP settings 2 500 7 925 X 2 IFP settings 2 500 strut Un common parts Shock size specific 93 RACING SHOX FLOAT FLOAT R SERVICE INSTRUCITONS Pumping up shock figure 9 1 Hand dyno figure 9 2 Float Diagnosis 1 2 Clean shock with contact cleaner to remove all dirt and oil Remove reducers and bushings if used Hand dyno Float Shock 1 Co N Pressurize shock to appropriate pressure figure 9 1 Install shock into your hand dyno figure 9 2 Compress shock 19 mm 3 4 and let return freely 3 times This is done to pressurize air negative spring Compress shock fully 3 times the air If shock compresses and does not return check your air spring pressure If pressure has dropped more than 20 psi check for air leaks see Air Leak Test If shock is still pressurized but will not return there be something clogging bleed h
5. 018 01 007 805 02 006 002 02 005 043 10 001 018 01 015 210 03 017 039 00 005 4 Valves 600 252 X 010 Piston Bolt 784 TLG Body 3 437 TLG Body 4 312 TLG Body 3 187 TLG Body 3 687 TLG Body Strut 3 710 TLG Body Strut 4 335 TLG Floating piston assembly w Q ring molded two piece Rebuild kit part Damper 035 00 116 A Q ring 116 Sleeve assembly 2 710 TLG Sleeve assembly 2 960 TLG Sleeve assembly 3 210 TLG Sleeve assembly 3 960 TLG Trunion Sleeve assembly 3 210 TLG less Trunion Rebuild kit Float air sleeve 036 02 014 A Wiper 21 060 Rebuild kit part Float air sleeve 003 09 000 A Bearing Rebuild kit part Float air sleeve 035 01 215 A Q Ring Adjuster rod 2 825 TLG Adjuster rod 3 075 TLG Adjuster rod 3 325 TLG Adjuster rod 4 075 TLG Seals O Ring Fastner Internal rebound adjuster stop 375 TLG Pellet Durometer 90A Pellet Retainer Set Screw 24 X 220 TLG Ball 2 1875 Nylon Ball 2 125 Steel Screw 48 32 X 250 TLG Socket Set Half Dog Point Valve 3X 700 OD X 252 ID X 0045 TH Lock out piston assembly 222 01 021 B Lock out piston Bearing 0 135 W X 0 879 ID X 0 032 TH 2 0 940 Bore Blue Valve Compression Lock Out 850 OD X 076 ID X 015 TH Screw 41 64 188 TLG Button Head Cap Red dial 800 OD 180 Spring 125 TLG X 125 OD X 36 45 LBS IN
6. 1 Submerge shock into a container of water figure 9 3 2 Shake off any initial bubbles Look for air bubbles around Schrader valve and valve housing Look for air bubbles at the lower air sleeve seal NOTE FLOAT R Look for air bubbles at rebound adjuster knob red Look for nitrogen bubbles at nitrogen fill pellet or set screw 99 Removing bearing housing Blowing out IFP with air gun figure 9 4 figure 9 5 Shaft Assembly Removal and IFP Removal X JON Remove air sleeve see air sleeve section FLOAT R only Open rebound adjuster knob all the way fast counter clockwise so oil will drain when removing shaft assembly Remove nylon ball from threaded pellet retainer hex with a picking tool Loosen threaded pellet retainer to release nitrogen pressure Remove threaded pellet retainer and pick out pellet Wear Saftey Glasses Clamp body eyelet in vice Using a 3 4 open end wrench carefully loosen the aluminum bearing housing figure 9 4 Make sure to put the pressure point of the 3 4 wrench away from the bleed hole screw Note If it takes excessive force to loosen the bearing the contents may still be under pressure Open a few turns and let pressure dissipate before continuing Remove bearing housing bleed screw 5 64ths and steel ball Be careful oil may squirt out Loosen bearing completely and carefully work the shaft assembly up and out of the shock body and set aside on lint free towel Carefully remove body fro
7. 39 0473 56 3107 info pepi it Brazil Plimax 2 Fast Rua Pamplona 818 51 Sao Paulo SP Brazil 01405 030 Ph 011 3 pcuri attglobal net plimax nw com br Japan Mom amp Pop s 3 26 10 Hanaike chinomiya Aichi Japan 491 0914 Ph 011 81 586 43 6810 mamapapa mig biglobe ne jp Switzerland Fox Europe Gurnigelstrasse 11 CH 3132 Riggisberg Switzerland 3132 Ph 011 41 31 809 30 20 Frs europe bluewin ch Canada West Cycle Works 9918 71 Ave Edmonton Alberta Canada T6E 7 Ph 780 440 3200 mail cycleworks com 148 France FMF Sport Group 1 Rue Condorcet Coglin France 83310 Ph 011 33 494 541950 fmfsportgroup wanadoo fr New Zealand Blue Shark Enterprises 19 Korokoro Road Korokoro Lower Hutt New Zealand Ph 011 64 4 589 4535 alastair mountainbikes co nz United Kingdom Mojo Suspension Unit 15 Pontymister Ind Est Risca Gwent United Kingdom NP1 6NP Ph 011 44 1633 615 815 chris porter virgin net Canada East Velocycle Inc 4308 Hotel De Ville Ave Montreal QC Canada H2W 2H4 Ph 514 849 5299 info velocycle com WARRANTY RECORD Servi De Je 5 Customer Name legos l 3751 B Charter Park Drive fa San Jose Ca 95196 emm 408 269 9201 WARRANTY SHOCK REPAIR of BRACING SHOK SERV201 Alps 4 Rebuild Make and Modei ot i SERV206 Alps Ap Rebuild Origi chase Date File NO SERV211 Alps 5
8. Spacer shaft 8 378 ID X 700 OD X 100 Steel Piston Damping 2 940 Bore 220 Piston Damping Downhill Hi Flow 2 940 Bore 315 TLG Bearing 050 C S X 0 154 ID PTFE Blue Ring Plate Back Up 700 OD X 252 ID X 050 TH 1 800 X 252 X 004 1 700 X 252 X 004 1 600 X 252 X 004 1 500 X 252 X 004 4 600 X 252 X 010 Plate Back Up 400 OD X 252 ID X 020 TH Piston Bolt 1 4 28 X 593 SHLG BODY 2 930 TLG BODY 3 180 TLG 42 204 05 004 G BODY 3 430 TLG 204 05 005 G BODY 3 680 204 05 019 G BODY 3 805 TLG 204 05 021 G BODY 4 180 204 05 020 G BODY 4 405 204 05 023 G BODY 4 680 21 050 0 6 0 154 ID 22 803 00 051 Rebuild kit damper 035 00 116 A Q Ring 116 23 234 00 009 Preload ring Stanadard for 1 25 spring ID 234 00 038 A Preload ring Downhill Heavy Duty for 1 375 spring ID 24 804 01 016 Piggyback Body cap assembly 206 03 013 A RC Body end cap 206 03 011 B RX Body end 25 803 00 051 A Rebuild kit damper 02 03 023 A O ring 023 26 210 15 016 A Check valve 27 039 00 009 A Spring 280 108 OD 28 210 03 018 A Compression adjuster knob blue 29 029 00 009 O ring 009 30 018 01 007 A Socket set screw 8 32 X 250 TLG 31 210 19 012 A Metering Rod 2 705 TLG 210 19 013 A Metering Rod 2 955 TLG 210 19 015 A Metering Rod 3 455 TLG 210 19 016 Metering Rod 3 705 TLG 210
9. Standard N 70 Static Seals Q Ring 116 103 C S X 0 737 ID 366 or equivalent Kit Rebuild FLOAT Air Sleeve Bearing External 0 120 W X 1 266 ID X 0 050 TH 1 50 Bore PTFE Bearing Internal 1 065 ID X 0 050 TLG X 1 060 Shaft PTFE Seals O Ring 022 070 C S X 864 ID Standard N 70 Static Seals O Ring 126 103 C S X 1 362 ID Standard N 70 Static Seals Q Ring 218 139 C S X 1 234 ID 366Y Seals Q Ring 215 139 C S X 1 046 ID Buna 80 A EF Treatement Seals Wiper 1 060 Shaft 4611 Urethane Kit Rebuild FLOAT Damper Air Valve Parts Pellet 0 275 X 0 125 TLG nitrile durometer A 0 Seals O Ring 110 0 103 C S X 0 362 ID Polyurethane Parker 4300 92 A Or Disogrin 9250 90 A Seals O Ring 023 070 C S X 1 051 ID Standard N 70 Static Seals Q Ring 116 103 C S X 0 737 ID 366Y or equivalent 144 RACING SHOX Warranty Records Master sheets for copier 146 Global Service Centers Australia Dirt Works Unit 4 39 Fourth Ave Blacktown NSW Australia 2148 Ph 011 612 9679 8400 dirtworks dirtworks com au Germany Shock Therapy Zum Haingraben 2 65510 Hunstetten Wallrabenstein Germany Ph 49 6126 22677 00 support shock therapy com Spain Dirt Racing Isla de Palma 32 Nave 8 28700 S S De Los Reyes Madrid Spain Ph 011 34 91 663 71 25 mrojo dirt nexo es Italy Pepi Innerhofer Via Monte Leone 4 Cermes BZ Italy 39010 Ph 011
10. 00 028 A VANILLA DAMPER REBUILD KIT VANILLA R REBUILD 803 00 028 A VANILLA DAMPER REBUILD KIT 029 00 003 A METERING ROD O RING VANILLA REBUIILD 803 00 028 A VANILLA DAMPER REBUILD KIT VANILLA RX REBUILD 803 00 028 A VANILLA DAMPER REBUILD KIT 029 03 020 A RESERVOIR END CAP SEAL 029 03 023 A RESERVOIR BODY CAP SEAL 029 00 003 A METERING ROD O RING VANILLA TC RC REBUILD 803 00 028 A VANILLA DAMPER REBUILD KIT 029 03 020 A RESERVOIR END CAP SEAL 029 03 023 A RESERVOIR BODY CAP SEAL 029 00 003 A METERING ROD O RING VANILLA RC SMALL RES REBUILD 803 00 028 A VANILLA DAMPER REBUILD KIT 035 00 113 A IFP Q RING 029 00 003 A METERING ROD O RING VANILLA RC REMOTE REBUILD 803 00 028 A VANILLA DAMPER REBUILD KIT RESERVOIR END CAP 8 BEARING SEAL x2 029 03 023 A SERV251 SERV256 SERV246 SERV290 SERV261 KIT SERV266 KIT SERV271 KIT SERV291 KIT SERV295 SERV276 SERV281 RESERVOIR BODY TOBODY CAP SEAL SHAFT Q RING METERING ROD O RING 035 00 112 A 029 00 003 A AIR VANILLA REBUILD 803 00 044 AIR VANILLA DAMPER REBUILD KIT 803 00 041 B AIR VANILLA AIR SLEEVE REBUILD KIT AIR VANILLA R REBUILD 803 00 044 A AIR VANILLA DAMPER REBUILD KIT 803 00 041 B AIR VANILLA AIR SLEEVE REBUILD KIT 029 00 003 A METERING ROD O RING AIR VANILLA RC REMOTE 803 00 044 A AIR VANILLA DAMPER REBUILD KIT 803 00 041 B AIR VANILLA AIR SLEEVE REBUILD KIT 029 03 020 A RESERVOIR END CAP SEAL 029 03 023 A R
11. 218 Q ring Make sure Q ring is not twisted 9 Install second white bearing Make sure both white bearings are seated flat in groove 104 IFP Seal Replacement 1 Carefully use a picking tool to remove the quad ring seal from the quad ring groove in the IFP Internal Floating Piston Use caution with picking tool as the IFP is made of plastic and will damage easily figure 9 10 2 Inspect IFP for damage Replace if necessary 3 To install your new quad ring place one side of quad ring into groove in IFP and stretch the quad ring around the IFP snapping it into the groove Make sure the Q ring is not twisted and is seated in the quad ring groove figure 9 11 IFP Installation 1 Clean inside of shock body with cleaner and inspect for scratches or wear Replace body if necessary 2 Grease quad ring on IFP 3 Insert greased IFP into body Use IFP depth table to find proper IFP setting 4 Set aside for final assembly 105 Removing seal figure 9 10 Installing IFPseal figure 9 11 106 Shaft eye assembly figure 9 12 Threading in pinton bolt before torquing figure 9 13 FLOAT Shaft Assembly 1 Slide washer and bottom out pad o ring onto shaft and eye assembly figure 9 12 2 Install shaft bullet tool 3 Grease polyurethane O ring and inside of bearing 4 Slide Bearing assembly over bullet tool and onto shaft 5 Remove bullet tool 6 Clamp eyelet in vice 7 Refer to tuning tables for a
12. Lockout valve figure 10 16 120 Torque bearing housing Torquing pellet figure figure 10 17 screw figure 10 18 Mating Shaft Assembly to Body yo 15 oo Place IFP set tool to height specified in IFP table and slide body over it Fill body up with 10 wt oil Clamp body eyelet in vise Turn compression lever blue to open position Make sure bleed screw and ball are not in bearing housing Oil needs to flow out as you screw on bearing housing to body Slide bearing assembly down shaft toward piston Insert shaft assembly into body by carefully rocking back and forth to remove air bubbles from the oil Torque bearing assembly to 35 ft lbs 47 45 NM figure 10 17 Install bleed hole screw and ball and tighten Install 90 durometer pellet in body Tighten pellet retainer with torque wrench Initial torque 6 inch lbs 68NM Final 12 in lbs 1 36 NM figure 10 18 Charge shock with five hundred psi of nitrogen Tighten pellet retainer with torque wrench screwdriver to final torque setting shown in torque table Push in damper all the way with hand dyno If damper does not get full travel or gets very difficult to compress nitrogen chamber may be too small and damper will need to be rebuilt again Usually this is caused by IFP moving during assembly If piston hits IFP nitrogen chamber may be too large and damper will need to be refilled Install air sleeve Do an air leak test figure 10 19 figure 10 19
13. Rebuild iginal Pur e Receipt on File YES SERV216 Alps 5R Rebuild SERV221 Vanilla Rebuild SERV226 Vanilla Rebuild SERV236 Vanilla X Rebuild SERV231 Vanilla RX Rebuild L SERV231 Vanilla RX 0 750 res Rebuild SERV241 Vanilla TC RC Rebuild SERV241 Vanilla RC Remote Rebuild SERV251 Air Vanilla Rebuild SERV256 Air Vanilla R Rebuild SERV246 Air Vanilla RC Remote Rebuild SERV290 Air Vanilla Air Sleeve Rebuild SERV261 Air Vanilla FLOAT SERV266 Air Vanilla FLOAT R Rebuild SERV271 Air Vanilla FLOAT RC Rebuild SERV291 Air Van FLOAT Air Sleeve Re SERV295 Air Vanilla FLOAT Stuck Re SERV276 FLOAT Rebuild SERV281 FLOAT R Rebuild SERV286 FLOAT RC Rebuild SERV292 FLOAT Air Sleeve Rebuild SERV C SERV Additional Parts Needed ENTER ALL AMOUNTS IN US DOLLARS E WARRANTY PARTS SUMMARY FORM Service Center Number Date FOX RACING SHOX 3751 B Charter Park Drive San Jose Ca 95136 WARRANTY SERVICE TOTALS SERV201 x 21 50 SERV206 x 21 50 SERV211 x 21 50 SERV216 x 21 50 SERV221 x 21 50 SERV226 26 50 SERV236 21 50 _SERV231 26 50 SERV231 x 26 50 _SERV241 x 26 50 SERV241 x 26 50 SERV251 x 26 50 SERV256 x 26 50 SERV246 x 26 50 S
14. VI LIS ay Xr 5 Z KAY NN Sigue SA SE EE RASI pec M PS AZA A Y gt 4 N BR 85255505509 555252 INC PROPRIETARY K lt 4 2 2 2 57 E ZAN SA Ca 222 Z N 2 3 Som lt gt A SUN A SA N EEE EE Ak FOX FACTORY 89 1 808 14 030 A 808 14 033 A 808 14 035 A 2 802 00 001 A 3 029 03 126 A 4 ox 0 9 210 15 014 210 15 015 018 01 004 210 15 013 018 01 005 029 03 011 029 03 110 10 229 27 000 B 11 229 27 001 B 229 27 002 B 229 27 005 B 018 01 004 A 12 812 06 021 A 13 14 15 16 17 18 19 20 21 22 23 803 00 051 A 003 07 000 A 803 00 051 A 803 00 050 A 803 00 050 A 040 15 110 A 805 02 005 A 002 02 005 A 233 00 021 A 050 01 012 B 044 04 080 A 044 04 070 A 044 04 060 A 044 04 050 A 044 10 040 A 2001 FLOAT RC PARTS LIST Eyelet 45 Assembly 1 700 TLG with short lever 1 230 Eyelet 45 Trunion Assembly 1 070 TLG with short lever 1 230 Eyelet 180 Assembly 1 700 TLG with short lever 1 230 Assembly air valve O Ring 2 126 45 Adjust 180 Adjust Screw 8 32x 250 TLG Socket set half dog point Lever Short 1 230 TLG Screw 8 32 X 125 TL
15. by a problem with the hydraulic top out check the shaft groove above rebound bleed hole Check for undersized piston glide ring also 49 Spring preload adjuster figure 6 2 Spring Removal 1 Clamp shock body eyelet in vice with soft jaws 2 Turn spring preload adjuster ring counter clockwise and unthread completely from shock body fig 6 2 3 Remove shock from vice 4 Slide preload adjuster ring and spring off of shock 50 Y 15 16 loosen bearing figure 6 3 Blow IFP into a rag figure 6 4 Shaft Assembly Removal and IFP Removal BUDE Vanilla R only Open rebound knob all the way fast counter clockwise so oil will drain when removing shaft assembly Remove nylon ball from threaded pellet retainer hex with a dental pick Unthread socket hex pellet retainer to release nitrogen pressure NOTE For older press in pellet retainer shocks this type has no socket hex feature to unscew Release nitrogen charge through the pellet hole with filler needle Remove threaded pellet retainer and pellet Clamp body eyelet in vice Using a 15 16 open end wrench carefully loosen the aluminum bearing housing figure 6 3 Note Ifit takes excessive force to loosen the bearing the shock may still have nitrogen pressure inside it Unscrew the bearing housing a few turns and let pressure dissipate for several minutes before going any further Loosen bearing completely and carefully work the shaft assembly
16. in mm in mm 6 000 152 4 1 25 31 75 1 850 46 99 TRUNION 6 370 161 80 1 00 25 40 2 060 52 37 TRUNION 6 370 161 80 1 500 38 13 2 060 52 37 6 500 165 01 1 000 25 40 2 060 52 37 6 500 165 01 1 500 38 13 2 060 52 37 7 875 200 03 2 000 50 84 2 500 63 50 TITUSSTRUT 7 925 201 30 2 000 50 84 2 250 57 15 Nitrogen charge 500 PSI 10 wt oil ISO 32 HAND MADE PVC PIPE SETTING TOOL INEXPENSIVE TIME SAVER CALIPER METHOD 141 RACING SHOX Seal Kits 142 2001 FOX SEAL KIT CONTENTS Revised 3 28 01 803 00 028 A 029 03 020 A 029 03 023 A 035 00 110 A 035 00 116 A 036 01 004 A 010 00 011 A 029 00 003 A 029 05 105 A 803 00 033 A 008 00 001 E 029 03 008 A 029 03 029 A 029 03 124 A 029 03 220 A 035 00 216 A 035 00 222 A 036 02 006 A 803 00 041 B 002 00 007 A 029 03 124 A 035 00 216 A 803 00 042 B 002 00 007 A 029 03 029 A 029 03 124 A 035 00 216 A 035 01 215 A 803 00 044 A 010 00 011 A 029 02 110 A 029 03 020 A 035 00 116 A 803 00 050 A 002 02 007 A 003 09 000 A 029 03 022 A 029 03 126 A 035 00 218 A 035 01 215 A 036 02 014 A 803 00 051 A 010 00 011 A 029 02 110 A 029 03 023 A 035 00 116 A Kit Rebuild Vanilla 0 940 Bore Seals O Ring 020 070 C S X 0 864 ID Standard N 70 Static Seals O Ring 023 070 0 6 X 1 051 ID Standard N 70 Static Seals Q Ring 110 103 C S X 0 362 ID 366Y or equivalent Seals Q Ring 116 103 C S X 0 737 1D 366Y or equiva
17. on the shock cam figure1 0 2 Ifthe lever squeaks the cam shaft may need to be greased or replaced 10 Compress the shock The shock should be much harder to compress If shock does not lock out check compression check lock out piston and valves piston surface and glide ring size Itis very important on the Float RC shock to have a full 500 PSI Nitrogen Set aside for assembly on bike 114 Air Leak Test Air leak test figure 10 3 1 Submerge shock in a container of water figure 10 3 2 Shake off any initial bubbles Look for air bubbles around Schrader valve Look for air bubbles at the lower air sleeve seal Look for nitrogen bubbles at nitrogen fill pellet or set screw Set aside for assembly on bike Bearing housing removal figure Shaft Assembly Removal and IFP Removal 10 4 1 Open rebound adjuster knob all the way fast counter clockwise so oil will drain when removing shaft assembly Remove nylon ball from threaded pellet retainer hex with a picking tool Unthread threaded pellet retainer to release nitrogen pressure Remove threaded pellet retainer and pellet Clamp body eyelet in vise Using a 3 4 open end wrench carefully loosen the aluminum bearing housing figure 10 4 AAA Make sure to put the pressure point of the 3 4 wrench away from the bleed hole screw Note If it takes excessive force to loosen the bearing the contents may still be under pressure Open a few turns and let pressure dissipate fo
18. propane torch to heat the shaft at the eyelet this will soften the Loctite and allow the eyeletto be removed easily figure 10 8 4 Slide a 2 1 2 inch breaker bar through the eyelet and turn counter clockwise to re move 5 Slide rebound adjuster dial red out of eyelet and clean 6 Clean shaftthoroughly of old Loctite 7 Remove eyelet shaft O ring Use picking tool to remove eyelet shaft O ring Thoroughly clean threads and insert new O ring Make sure O ring is seated flat and not twisted 8 Remove metering rod and inspect for damage and replace shaft meter rod seal 9 Grease both ends of the adjuster rod that follows the cam 10 Insert greased adjuster rod holed end first into shaft 11 Clean shaft threads of any oil and grease 12 Lay a bead of red Loctite around the base of the larger shaft threads Keep Loctite away from metering rod Slide rebound adjuster dial red into eyelet Thread shaft into eyelet and slide rebound adjuster rod into rebound adjuster dial 15 Clamp shaft in vise Torque eyelet to shaft 110 inch lbs 12 4 NM Install ball spring and Allen set screw into base of eyelet Allen set screw should be flush with eyelet use a small drop of blue loctite on set screw 117 Removing shaft O ring Removing inner Removing Q Ring figure 10 9 bearing O ring figure from bearing figure 10 10 10 11 FLOAT RC Bearing Assembly E Il Pick out the polyurethane O ring figure 10 9 Pick out inne
19. revalving situations Float with no rebound adjuster Vanilla with no rebound adjuster Revalving of shox can be done under warranty within 90 days of purchase again with dated copy of original FOX charges 8 00 in addition to standard service labor costs for non warranty revalving Parts are extra SECTION 6 THE FOX SERVICE SYSTEM Many of you have your own internal service system for keeping track of service work which will work fine The following is a basic description of the FOX system Customer calls in for service and it is determined the shock must come in for repair Our customer representative issues a Return Authorization number and asks the customer to write this on the outside of the package along with a note inside describing the shocks failure The shock is entered in the computer as received The RA written on a paper toe tag which is attached to the top of the shock This allows identification at any stage of repair The shock now goes to the shop for diagnosis and repair Once the shock is repaired the service technician writes down every part used and services rendered using FOX service codes and part numbers This information is then entered in to the order and the proper charges are calculated and charged either to credit cared or COD etc The shock then goes to shipping Shipping double checks the toe tag to the paper work to make sure everything matches and then the shock ships SECTION 7 CERTIFI
20. your service center here 6 Contact Who to contact in case of a question on the form For the Labor Form 1 Enter the corresponding information from each of your Warranty Reimbursement Forms For the Parts Form 2 Enter each part only once List the total quantity of that part number used for the entire month 12 RACING SHOX REDUCERS AND BUSHINGS Diagnosis On Clamp shock with reducers installed into soft jaw vice figure 1 1 Rotate shock on bearing figure 1 1 Feel for side play Ifthere is excessive side play or any free play replace bearing B Disassembly Reducer Removal 1 Figure 4 1 Bearing Removal Bearing Removal Mi 7 S Sr Remove reducer by inserting a small flat bladed screwdriver 1 under the flange ofthe reducer and twisting figure 1 2 Be careful not to damage the eyelet Ifthe reducer does not come out with reasonable pressure use and easy out to remove the reducer Insert easy out into reducer bore and turn clockwise while pulling the reducer out of the bearing figure 1 3 Remove second reducer Second reducer may be pounded out with a 0 5 inch bar Be careful not to damage shock If their is excessive wear or corrosion replace reducers Clean up any burs with a debur tool or file and Scotchbrite off any Teflon from good reducers figure 1 2 Insert internal bearing removal pin through the internal bearing Inspect bore of bearing r
21. 0 7 700 X 1 875 IFP settings 2 60 7 875 X 2 00 IFP settings 2 60 7 875 X 2 25 IFP settings 2 60 Un common parts Shock size specific 39 O EI lt gt 2 S a 2 2 ci NOS X P N 05 XX INC FOX FACTORY PROPRIETARY 9 40 1 808 14 026 2 210 03 016 3 010 01 00 A 4 039 00 003 A 5 008 01 005 A 6 229 27 002 B 229 27 003 B 229 27 004 B 229 27 005 B 229 27 006 B 229 27 007 229 27 008 229 27 009 7 812 06 011 812 06 012 8 803 00 028 9 029 02 110 10 003 07 000 11 803 00 028 A 12 233 00 021 A 13 805 02 005 A 805 02 004 A 14 002 02 005 A 15 050 01 012 A 16 044 04 080 044 04 070 044 04 060 044 04 050 17 044 10 060 A 18 050 01 011 A 19 290 90 016 A 20 204 05 003 G 204 05 018 D 2001 VANILLA RC PARTS LIST Eyelet assembly Shaft 1 190 TLG Eyelet 213 07 0035 A Damping adjust knob Red Ball 0 125 Steel Spring 125 TLG X 125 OD Bottom out bumper Shaft 2 355 TLG Shaft 2 605 TLG Shaft 2 855 TLG Shaft 3 105 TLG Shaft 3 355 TLG Shaft 3 605 TLG Shaft 3 855 TLG Shaft 4 105 TLG Bearing assembly 665 TLG Bearing assembly 1 030 TLG Damper rebuild kit part 036 01 004 A U cup 8 375 Shaft Seals O Ring urethane 110 Bearing Internal 375 ID Q 375 Shaft Damper rebuild kit part Seals O Ring 020 Static 029 03 015 A
22. 02 00 001 3 029 03 126 4 029 03 110 5 229 15 009 B 229 15 001 B 229 15 005 B 6 812 06 020 A 812 06 021 A 7 803 00 051 A 8 003 07 000 A 9 803 00 051 A 10 803 00 051 A 11 803 00 051 A 12 040 15 110 A 13 805 02 101 A 14 002 02 005 15 050 01 012 A 16 050 01 011 A 17 044 04 080 044 04 070 044 04 060 044 04 050 18 018 04 005 19 204 54 005 A 204 54 006 A 204 54 007 A 20 805 00 005 A 21 803 00 051 A 22 806 29 000 A 806 29 002 A 806 29 004 A 2001 FLOAT PARTS LIST Float eyelet Assembly Float eyelet Assembly Trunion Assembly air valve O Ring 2 126 O Ring 2 110 Shaft 1 905 TLG Shaft 2 405 TLG Shaft 3 155 Bearing assembly 815 TLG Bearing assembly 1 065 TLG Rebuild kit part Damper 029 02 110 O Ring Polyurethane Bearing Internal Rebuild kit part Damper 029 03 023 A O Ring Rebuild kit part Damper 002 02 007 A Bearing Rebuild kit part Damper 035 00 218 A Q Ring Valve 1 100 OD 377 ID X 015 TH Piston assembly 0280 bleed Pilot hole size Bearing 0 135 W X 0 879 ID X 0 032 TH 0 0 940 Bore Blue Plate Back Up 750 OD X 250 ID X 050 TH Plate Back Up 350 OD X 253 ID X 020 TH 1 Comp Shim 8000D X 252 ID X 0045 1 Comp Shim 700OD X 252 ID X 0045 1 Comp Shim 6000D X 252 ID X 0045 TH 1 Comp Shim 5000D X 252 ID X 0045 TH Piston Bolt 1 4 28 X 750 TLG Body 3 687
23. 121 RACING SHOX Tool List 122 2001 TOOL LIST In Kit Fox Part Number QTY 1 Yes 1 Yes 2 Yes 2 Yes 2 Yes 1 Yes 803 00 046 A Eyelet Internal Bearing Removal Tool 803 00 045 A Fixture IFP Depth Set Tool Assembly 802 02 001 A Safety Needle w Gauge Schrader Port 802 01 000 A Nitrogen Safety Needle Assembly 010 02 001 A Gauge 0 600 psi 398 00 042 B Shaft Clamp 01 625 Float Air Sleeve 398 00 161 A Shaft Clamp Shaft Clamp 0 375 Body Clamp 0 940 Bore Vanilla Float shaft Van Body 398 00 055 A Shaft Clamp 91 497 Alps shaft Air Vanilla Air Sleeve 398 00 032 A Bullet Tool 0 375 Shaft Float Van 398 00 210 A Bullet Tool 175 OD Adjuster Rod Float RC Torque Wrench 41 N m 30 ft Ib Torque Wrench 14 Nem 120 in Ib 398 00 227 A Piston Tool Weldment Float RC 2001 398 00 218 A Piston Tool Weldment Float RC 2000 15 16 inch low profile crows foot 3 4 inch low profile crows foot 3 8 inch socket 1 2 inch socket 7 16 inch socket Allen Wrenches set metric and set Standard fractional inch 5 64 inch Allen wrench socket style 3 16 inch Allen wrench socket style 7 16 inch combination wrench 15 16 inch combination wrench 3 4 inch combination wrench 1 2 inch Bar stock eyelet tool Pliers assorted Snap ring pliers best to have range of size from small to large Soft jaw pliers Channel lock pliers Brass Brush Dental pick Propane torch 10wt Suspension Fluid
24. 19 017 Metering Rod 3 955 210 19 018 A Metering Rod 4 205 TLG 32 029 05 105 O ring 050 C S X 0 154 ID 33 227 09 004 B Reservoir Cap Style 2 030 TLG 34 813 00 021 A Assembly Reservoir end cap with pellet retainer 226 00 009 B Res End Cap 35 010 00 011 A Pellet 0 275 X 125 TLG Nitrile Durometer 90A 36 010 00 010 A Pellet Retainer Set Screw 24 X 220 TLG 37 010 01 003 A Ball 9 1875 Nylon 38 029 03 020 O ring 020 39 222 01 015 B Damping Reservoir compression piston 40 029 03 019 A O ring 019 41 210 10 009 A 2001 Reservoir compression piston bolt 116 orifice high flow 43 42 43 44 45 46 47 48 018 00 009 Nut 1 4 24 X 450 044 04 060 A Valving 1 600 OD X 252 X 0045 044 20 060 Valving 4 600 OD X 252 X 020 029 02 009 A O ring 009 Polyurethane See spring charts 234 00 008 E Spring retainer Standard for 1 25 spring ID 234 00 069 A Spring retainer Downhill Heavy Duty for 1 375 spring ID 024 02 034 A Decal Other Notes 803 00 028 Damper rebuild kit IFP 200 PSI Oil 10 wt ISO 32 Un common parts Shock size specific 24 RACING SHOX VANILLA AND VANILLA R SERVICE INSTRUCTIONS Vanilla hand dyno figure 6 1 A Diagnosis 1 Clean shock with contact cleaner to remove all dirt and oil 2 Remove reducers and bushings if used Hand Dyno Vanilla 1 Install appropriate spring on damper check spr
25. 27 Polishing Cylinder figure 4 4 3 Clean out old dirty grease from body and shaft with solvent 4 Replace air sleeve seals Note If shock was stuck down it is recommended that you replace all air sleeve seals and Teflon bearings on the Float shocks figure 4 2 figure 4 3 figure 4 4 Bearing Seal Replacement 1 Use a picking tool to remove the bearing seal 218 Q ring Figure 4 5 5 Replace the white bearings if worn 2 Install new 218 Q ring Make sure Q ring is not twisted and white bearings are seated flat in groove 27 Sleeve Bearing Outer Seal Replacement Use a picking tool to remove 215 Q ring and the two white bearings figure 4 6 Install one white bearing Install 215 Q ring Make sure Q ring is not twisted Install second white bearing Make sure both white bearings are seated flat in groove Air Sleeve Installation 9 Clamp shaft eyelet in vise Grease air sleeve bearings Q ring and dust wiper with grease Grease bearing Q ring and bearings with grease Slide air sleeve over bearing fig 4 7 Thread air sleeve onto eyelet It may be necessary to compress the shock in a hand dyno to thread the sleeve onto the eyelet float RC can be hard to thread air sleeve onto eyelet threads Pressurize air chamber to appropriate pressure Hand dyno See hand dyno section Air leak test See air leak test Inspect and install reducers and DU bushings as needed 10 Set aside for assembly on bik
26. 3 960 TLG Sleeve assembly Cannondale Jekyll 3 210 TLG Rebuild kit Float air sleeve 036 02 014 Wiper 21 060 Rebuild kit part Float air sleeve 003 09 000 A Bearing 2X Rebuild kit part Float air sleeve 035 01 215 A Q Ring Metering Rods 2 580 Metering Rod 3 330 Metering Rods 2 080 Metering Rods 2 330 Metering Rods 3 455 Seals O Ring Spacer shaft 378 ID 700 OD 050 TLG Pellet Durometer 90A Pellet Retainer Set Screw 24 X 220 TLG Ball 2 1875 Nylon Ball 2 125 Steel Screw 48 32 X 250 TLG Socket Set Half Dog Point O Ring 022 Static Decal Float R Decal Float R Trunion 86 OTHER NOTES 803 00 050 A Air sleeve rebuild kit 803 00 051 A Damper rebuild kit 2000 Float R Damper charge 200 PSI Nitrogen Oil 10wt ISO 32 Sizes 5 50 X 1 00 IFP settings 1 40 6 00 X 1 25 IFP settings 1 50 6 120 X 1 500 IFP settings 1 850 6 50 X 1 5 IFP settings 1 850 6 37 X 1 5 IFP settings 1 850 Trunion Cannondale 6 55 X 1 5 IFP settings 1 850 strut 7 875 X 2 IFP settings 2 500 7 925 X 2 IFP settings 2 500 strut Un common parts Shock size specific 87 2001 FLOAT RC 5 S e s N aR 5 2 st a 9 JA E x b Tj a 38 Q D a A 8 30 el 29 A 54 1 1 o SY lt j sch A 4 LI
27. 6 7 Clean eyelet and shaft thoroughly of any old Loctite Clamp shaft in vice Lay a bead of red Loctite around the base of the shafts threads Torque eyelet to shaft using eyelet torque wrench see Torque Tables for proper torque oS 53 5 6 7 8 9 Metering rod O ring figure 6 8 Loctite Shaft threads figure 6 9 Vanilla R Shaft Replacement Spray shaft and 375 shaft clamps with contact cleaner and clamp shaft in vise using 375 shaft clamps to hold shaft securely in the vise Use a small propane torch to heat the shaft at the eyelet this will soften the Loctite and allow the eyelet to be removed easily Slide a Y 1 2 inch breaker bar through the eyelet and turn counter clockwise to remove If EE adjuster knob is damaged rebuild eyelet assembly Turn rebound adjuster knob clockwise to remove Remove spring and Ball from red knob Grease knob at threads taper and spring hole Insert ball and spring into rebound knob hole Install rebound adjuster knob by turning all the way counterclockwise then clock wise until the edge of the small ball is visible Remove metering rod and inspect for damage replace seal Replace metering rod o ring in the shaff and grease figure 6 8 Lay a bead of red Loctite around the base ofthe shafts threads Keep Loctite away from metering rod figure 6 9 Using shaft clamps clamp the shaft in vice Torque eyelet to shaft using eyelet torque wrench see Torque Tables for proper torque S
28. 9 Clamp shock body in body clamps with vise 10 Carefully remove bearing assembly and dump remaining oil into waste oil container 11 Clamp shock body in vise and remove the body cap from form shock body 12 Remove the body from vice 67 1 2 Bar to remove eyelet figure Torch eyelet to soften Loctite figure Piston Removal Clean shaft assembly with contact cleaner Clamp eyelet in vice Do not smash rebound adjuster knob red Remove piston bolt with 3 8 open end wrench figure 7 4 Remove piston valves and top out plate and set on lint free towel Remove bearing assembly and spacer Remove bottom out bumper Remove eyelet and shaft assembly from vice Inspect shaft for any nicks pits wear marks or damage If the shaft fails inspection replace it as described in Vanilla RC Shaft Replace ment section S ACL E o 68 Taking out dust wiper seal figure 7 7 Vanilla RC Shaft Replacement 1 2 e NDNA 8 9 Spray shaft and 375 shaft clamps with contact cleaner and clamp shaft in vise wet using 375 shaft clamps to hold shaft securely in the vise Use a small propane torch to heat the shaft at the eyelet this will soften the Loctite and allow the eyelet to be removed easily figure 7 5 Slide a 1 2 inch breaker bar through the eyelet and turn counter clockwise to remove figure 7 6 If rebound adjuster knob is damaged you should rebuild eyelet assembly Turn rebound adjuster k
29. Air Pressure Compression Valves Rebound Valves psi 105 1x 800 OD 252 ID 0045 TH 4x 600 0D 2 5 1 x 700 OD 252 ID 0045 TH 140 1 x 600 OD 252 ID 0045 TH 160 1 x 500 OD 252 ID 0045 TH 4 x 400 OD x 252 ID 010 TH 175 1x 8000D 252 ID 0045 TH 4x 600 CD 2 195 1x 700 OD 252 ID 0045 TH 210 1 600 OD 252 ID 0045 TH 230 1 x 500 OD 252 ID 0045 TH 245 2 400 OD 252 ID 010 TH Add or remove one 400 OD 252 1D 010 TH compression valve to get 11 to 18 rebound adjuster knob red clicks Suspension fluid 10 wt 15032 Nitrogen PSI 200 PSI 136 FLOAT RC TUNING TABLE Compression Valves Standard production settings 1 x 800 OD 252 ID 0045 TH 1x 700 OD 252 ID 0045 TH 1 x 600 OD 252 ID 0045 TH 1 x 500 OD 252 ID 0045 TH 3x 4000D 252 ID 010 TH Rebound Valves 4 x 600 OD x 252 ID 010 TH Blow off valve 3x 700 OD x 252 ID x 0045 TH Lock out 1x 850 OD X 076 ID X 015 TH Note if lock out is not firm enough Check 1 Lock out piston glide ring fit 2 Air in oil 3 Make sure lock out piston is flat and working correct 4 500PSI is required for proper lock out function Suspension fluid 10 wt 15032 Nitrogen PSI 500 PSI 137 RACI
30. CATION A B All FOX products are precise high quality pieces of equipment and must be handled as such We know that you are highly qualified to service our equipment however FOX engineers have specified proprietary tech niques in assembly and tooling that will be necessary for you to know and follow to achieve the top mance that FOX is known for Your technicians need to be trained and certified by our FOX technicians Certification courses take place at FOX Racing Shox facility in the United States and will cover all serviceable FOX shox bicycle products Your Service Center will also be listed on our Web site FOX as an official Service Center Fill out the Warranty Reimbursement Form as described below Date The date the warranty started RA Assign the shock an Return Authorization Number RA It is important to assign a number to the shock for use in the Warranty Summary 11 Customer Name of the customer or shop returning the shock for repair Phone Number Customer s phone number Contact Name of person calling Shock Model The model of shock to be worked on Make and Model of Bike The brand of bike and which model Original Purchase Date Get this information from the customer s copy of sales receipt This is very important no warranties will be processed without this information Receipt on File Fill this box in with a yes or no Country of Origin The country the s
31. ERV290 x 12 50 SERV261 x 26 50 SERV266 x 26 50 SERV271 x 26 50 SERV291 x 12 50 SERV295 x 18 00 SERV276 x 26 50 _SERV281 x 26 50 SERV286 x 26 50 SERV292 x 12 50 SERV x SERV x __ SERV x SER V_x 45 4b 45 4b 4 4b 4 45 4 45 45 4 ih ih th 4 4b 4 4 ih 4 EH 4 6 4 RACINE SHON Phone 408 269 9201 ADDITIONAL WARRANTY PART TOTALS FOX Part Number Description Total Total Total ENTER ALL AMOUNTS IN US DOLLARS 52 1 WARRANTY PARTS AUTOMATICALLY INCLUDED WITH CORRESPONDING WARRANTY SERVICE CODES SERV201 SERV206 SERV211 SERV216 SERV221 SERV226 SERV236 SERV231 SERV241 SERV241 SERV241 x2 029 03 020 A ALPS 4 REBUILD 812 06 000 A 035 00 216 A 029 03 124 A 029 03 010 A 029 03 220 A ALPS 5 BEARING ASSEMBLY IFP QUAD RING EYELET O RING AIR VALVE ASSM O RING TRAVEL INDICATOR O RING ALPS 4R REBUILD 812 06 000 A 035 00 216 A 029 03 124 A 029 03 010 A 029 03 008 A 029 00 110 A 029 03 220 A ALPS 5 BEARING ASSEMBLY IFP QUAD RING EYELET O RING AIR VALVE ASSM O RING REBOUND KNOB O RING SMALL REBOUND KNOB O RING LARGE TRAVEL INDICATOR O RING ALPS 5 REBUILD 803 00 028 A 029 03 220 A ALPS 5 SEAL KIT TRAVEL INDICATOR O RING ALPS 5R REBUILD 803 00 033 A 029 03 220 A ALPS 5 SEAL KIT TRAVEL INDICATOR O RING VANILLA REBUILD 803
32. ESERVOIR BODY CAP SEAL 029 00 003 A METERING ROD O RING AIR VANILLA AIR SLEEVE REBUILD 803 00 041 B AIR VANILLA AIR SLEEVE REBUILD KIT AIR VANILLA FLOAT 803 00 044 A AIR VANILLA DAMPER REBUILD KIT 803 00 042 B AIR VANILLA FLOAT AIR SLEEVE REBUILD AIR VANILLA FLOAT R 803 00 044 A AIR VANILLA DAMPER REBUILD KIT 803 00 042 B AIR VANILLA FLOAT AIR SLEEVE REBUILD 029 00 003 A METERING ROD O RING AIR VANILLA FLOAT RC 803 00 044 A AIR VANILLA DAMPER REBUILD KIT 803 00 042 B AIR VANILLA FLOAT AIR SLEEVE REBUILD 029 00 003 A METERING ROD O RING AV FLOAT AIR SLEEVE REBUILD 803 00 042 B AIR VANILLA FLOAT AIR SLEEVE REBUILD AV FLOAT BODY COLLAR REBUILD 231 01 004 A AIR VANILLA FLOAT BODY COLLAR 029 08 000 A M 26 X 1 O RING FLOAT 2000 REBUILD 803 00 051 A FLOAT DAMPER REBUILD KIT 803 00 050 A FLOAT AIR SLEEVE REBUILD KIT FLOAT R 2000 REBUILD 803 00 051 A FLOAT DAMPER REBUILD KIT 803 00 050 A FLOAT AIR SLEEVE REBUILD KIT 029 00 003 A METERING ROD O RING FLOAT RC 2000 REBUILD 803 00 051 A FLOAT DAMPER REBUILD KIT 54 1
33. G Socket set cup point O Ring 2 011 O Ring 2 110 Shaft 1 855 TLG Shaft 2 105 TLG Shaft 2 355 TLG Shaft 3 105 TLG Screw 48 32 X 0 250 TLG 303 SS Socket Set Half Dog Point Bearing assembly Poly O ring 940 Bore 0 375 Shaft Rebuild kit part Damper 029 02 110 A O Ring 110 Poly type Bearing Internal 375 ID 0 375 Shaft Rebuild kit part Damper 029 03 023 A O Ring 023 Rebuild kit part Float air sleeve 002 02 007 Bearing Rebuild kit part Float air sleeve 035 00 218 A Q Ring 218 Valve 1 100 OD X 377 ID X 015 TH Piston assembly w glide ring Bearing 0 135 W X 0 879 ID X 0 032 TH Y 0 940 Bore Blue Spacer Shaft 378 ID X 700 OD X 050 TLG Plate Back up 700 OD X 252 ID X 050 TH 1 Valve 800 X 252 X 004 1 Valve 700 X 252 X 004 1 Valve 600 X 252 X 004 1 Valve 500 X 252 X 004 3 Valves 400 X 252 X 010 91 24 044 10 060 25 210 10 010 26 204 54 008 27 28 29 806 29 000 A 30 31 32 33 210 20 000 210 20 001 210 20 002 210 20 003 34 35 36 37 38 39 40 044 04 070 42 43 44 45 46 47 41 204 54 006 204 54 007 204 54 005 204 58 000 204 58 001 805 00 005 803 00 051 806 29 001 806 29 002 806 29 004 806 15 007 803 00 050 803 00 050 803 00 050 029 05 015 241 02 006 010 00 011 010 00 010 010 01 003 010 01 000
34. L Piston Damping 0 940 Bore 220 TLG Bearing 0 135 W 0 879 ID X 0 032 Y 0 940 Bore PTFE Blue Ring Plate Back Up 700 OD X 252 ID X 050 TH 1 800 X 252 X 004 1 700 X 252 X 004 1 600 X 252 X 004 1 500 X 252 X 004 4 600 X 252 X 010 Plate Back Up 400 OD 252 ID 020 TH Piston Bolt 1 4 28 X 593 SHLG BODY 3 625 TLG BODY 3 875 TLG BODY 4 125 TLG BODY 4 750 TLG BODY 5 000 TLG BODY 4 425 TLG SCHWINN STRAIGHT 6 TRUNION Damper rebuild kit part 38 21 22 805 00 005 803 00 051 23 210 19 011 A 24 25 26 27 28 29 30 Piston Floating 0 940 Bore Rebuild kit damper 035 00 116 A Q Ring 116 Metering Rods 2 455 210 19012 A Metering Rod 2 705 210 19 013 A Metering Rods 2 955 210 19 014 A Metering Rods 3 205 210 19 015 A Metering Rods 3 455 029 05 105 A O ring 050 C S X 0 154 ID 234 00 009 B Preload ring See spring chart 010 00 011 A Pellet 9 275 X 125 TLG Nitrile Durometer 90A 010 00 010 A Pellet Retainer Set Screw 24 X 220 TLG 010 01 003 A Ball 8 1875 Nylon 024 02 033 A Vanilla R Decal OTHER NOTES 4 803 00 028 A Damper rebuild kit 2001 Vanilla R Damper charge 200 PSI Nitrogen 10 WT Suspension fluid ISO 32 5 75 X 1 25 IFP settings 1 60 6 5 X 1 50 IFP settings 2 00 6 750 X 1 75 IFP settings 2 10 7 500 X 2 00 IFP settings 2 4
35. NG SHOX IFP SETTING TABLES IFP SETTING TABLES 2001 FOX BICYCLE SHOCKS VANILLA Eye to Eye Length Shaft Travel IFP Setting Shaft Out in mm in mm in mm 5 75 146 05 1 250 31 75 1 600 40 64 6 500 165 10 1 250 31 75 2 000 57 15 6 500 165 10 1 500 38 13 2 000 53 38 6 750 171 45 1 750 44 45 2 100 53 38 7 500 190 50 2 000 50 80 2 400 60 96 7 700 195 58 1 875 46 62 2 600 68 63 7 875 200 03 2 000 50 80 2 600 68 63 7 875 200 03 2 250 57 20 2 600 68 63 Nitrogen charge 200 PSI 10 wt oil ISO 32 VANILLA R Eye to Eye Length Shock Travel IFP Setting Shaft Out in mm in mm in mm 5 75 146 05 1 250 31 75 1 600 40 64 6 500 165 10 1 250 31 75 2 000 57 15 6 500 165 10 1 500 38 13 2 000 53 38 6 750 171 45 1 750 44 45 2 100 53 38 7 500 190 50 2 000 50 80 2 400 60 96 7 700 195 58 1 875 46 62 2 600 68 63 7 875 200 03 2 000 50 80 2 600 68 63 7 875 200 03 2 250 57 20 2 600 68 63 Nitrogen charge 200 PSI 10 wt oil ISO 32 140 IFP SETTING TABLES 2001 FOX BICYCLE SHOCKS FLOAT 8 FLOAT R Eye to Eye Length Shock Travel IFP Setting Shaft Out mm in mm TRUNION 6 110 155 19 1 500 38 13 1 900 48 26 6 500 165 01 1 500 38 13 1 900 48 26 TITUSSTRUT 6 550 166 37 1 500 38 13 1 900 48 26 7 875 200 03 2 000 50 84 2 225 57 15 TITUS STRUT 7 925 201 30 0 50 84 2 250 57 15 Nitrogen charge 200 PSI 10 wt oil ISO 32 FLOAT RC Eye to Eye Length Shock Travel IFP Setting Shaft Out in mm
36. TLG Body 4 312 TLG Body 3 187 TLG Floating piston assembly w Q ring Rebuild kit part Damper 035 00 116 A Q ring 116 Sleeve assembly 2 710 TLG Sleeve assembly 3 210 TLG Sleeve assembly 3 960 TLG 81 23 24 25 26 27 28 29 30 31 32 33 024 02 035 806 15 007 803 00 050 803 00 050 803 00 050 233 00 009 B 010 00 011 A 010 00 010 A 010 01 003 A 018 01 007 A 010 01 000 A 029 03 022 A 024 02 038 A 2000 Float Sizes Sleeve assembly Trunion 3 210 TLG Rebuild kit Float air sleeve 036 02 014 A Wiper 21 060 Rebuild kit part Float air sleeve 003 09 000 A Bearing 2X Rebuild kit part Float air sleeve 035 01 215 A Q Ring Spacer shaft 378 ID X 700 OD 100 TLG Pellet Durometer 90 Pellet Retainer Set Screw 24 X 220 TLG Ball 2 1875 Nylon Screw 48 32 X 250 TLG Socket Set Half Dog Point Ball 2 125 Steel O Ring 022 Static Decal Decal Trunion OTHER NOTES 803 00 050 Air sleeve rebuild kit 803 00 051 Damper rebuild kit Damper charge 200 PSI Nitrogen Oil 10wt ISO 32 5 5 X 1 00 IFP settings 1 40 6 5 X 1 5 IFP settings 1 850 6 37 X 1 5 IFP settings 1 850 Trunion Cannondale 6 55 X 1 5 IFP settings 1 850 strut 7 875 X 2 IFP settings 2 500 7 925 X 2 FP settings 2 500 strut Piston assembly 805 02 101 A 0280 Bleed hole use as pilot for larger hole size for tuning Un common parts S
37. ace valves Check for nics on the sealing surface for check valve in bodycap 66 Disassembly a y d L Spring R l See RT Removing piston bolt figure 7 4 1 Clamp shock body eyelet in your vice with soft jaws 2 Turn spring preload adjuster ring counter clockwise and unthread to loosen spring 3 Remove slotted spring retainer 4 Remove Spring 5 Remove shock from vice Shaft Assembly Removal and IFP Removal 1 Open rebound adjuster knob red all the way fast counter clockwise so that oil will drain when removing shaft assembly 2 Remove nylon ball from threaded pellet retainer hex with a the dental pick 3 Unthread threaded pellet retainer to release nitrogen pressure figure 7 2 Wear Safety Glasses when you remove rubber pellet oil may squirt out Note Release nitrogen charge with filler needle for old 99 press in pellet re tainer 4 Clamp body cap eyelet into soft jaw vice figure 7 3 5 Loosen the reservoir from the body cap by turning the reservoir end cap counter clock wise Note If it takes excessive force to loosen the reservoir the contents may be under pressure Open a few turns and let pressure dissipate for several min utes 6 Using a 15 16 open end wrench loosen the bearing assembly from the body shock body 7 Unthread reservoir the rest of the way from body cap and pour oil into waste oil con tainer 8 Push IFP and Compression damping piston used on Vanilla RC out of reservoir
38. al Rebuild kit part Damper 029 03 023 A O Ring Rebuild kit part Air sleeve 002 02 007 A Bearing Rebuild kit part Damper 035 00 218 A Q Ring Valve 1 100 OD X 377 ID X 015 TH Piston assembly Piston 222 01 014 D Bearing 0 135 W X 0 879 ID X 0 032 TH 2 0 940 Bore Blue Plate back up 7000D X 252 ID X 050 TH 1 044 04 080 A 800 X 252 X 004 1 044 04 070 A 700 X 252 X 004 1 044 04 060 A 600 X 252 X 004 1 044 04 050 A 500 X 252 X 004 4 044 10 060 A 600 X 252 X 010 Plate back up 400 OD x 252 ID x 020 TH Piston Bolt 1 4 28 593 SHLG Body 3 187 TLG Body 3 437 TLG 85 204 54 006 204 54 005 204 58 000 204 58 001 25 26 805 00 005 A 803 00 051 A 27 806 29 000 A 28 29 30 31 32 33 34 35 36 37 38 39 806 29 001 806 29 002 806 29 004 806 15 007 803 00 050 803 00 050 803 00 050 210 19 002 210 19 003 210 19 000 210 19 001 210 19 015 029 05 105 233 00 021 010 00 011 010 00 010 010 01 003 010 01 000 018 01 007 029 03 022 40 024 02 036 024 02 039 Body 3 687 TLG Body 4 312 TLG Body Strut 3 710 TLG Body Strut 4 335 TLG Floating piston assembly w Q ring Rebuild kit part Damper 035 00 116 A Q ring 116 Sleeve assembly 2 710 Sleeve assembly 2 960 TLG Sleeve assembly 3 210 TLG Sleeve assembly
39. and inspect for damage Replace metering rod o ring in shaft Grease end of metering rod and insert into shaft Lay a bead of red Loctite around the base of the shafts threads Keep Loctite away from metering rod 10 Clamp shaft in vise with 0 375 shaft clamps 11 Torque eyelet to shaft using Torque wrench see tip Shaft Torque Tip Use piston bolt with 4 back up plates 093 thick and thread into shaft clamp eyelet in vise and torque bolt Be careful when removing bolt as shaft may turn if this happens re torque and clamp shaft in vise with shaft clamps before removing bolt Torque 120 inch Ibs 103 Removing shaft O ring Removing inner bear Removing out Q ring figure 9 7 ing O ring figure 9 8 figure 9 9 FLOAT Bearing Assembly 1 Pick out the polyurethane O ring figure 9 7 2 Pick out inner bearing O ring figure 9 8 3 Remove outer 218 Q ring and two white Teflon bearings figure 9 9 4 Thoroughly clean bearing Inspect the bearing by sliding the bearing assembly with seals removed along the shaft You are checking for clearance and wear The bearing should slide freely If you feel excessive friction the bearing assem bly should be replaced 5 Install a new polyurethane O ring in the top groove of the bearing housing NOTE Make sure that the O ring is seated completely in its groove and is not twisted 6 Install inner bearing O ring Make sure O ring is not twisted 7 Install one white bearing 8 Install
40. bly Grease seals and inside of bearing Slide bearing assembly onto shaft Adjustable Vanilla shafts have a generous radius so bullet tool is not needed Clamp eyelet in vice Refer to tuning tables for appropriate valve stack if necessary Replace compression valves Make sure piston and valves are clean and bur free Take fresh piston assembly and thread piston bolt into shaft Torque piston bolt to torque specified in torque tables figure 6 14 Check the number of rebound adjuster clicks figure 6 15 Count the number of clicks it takes to go from all the way closed rebound bleed to all the way open rebound bleed Shock should have at least 12 18 clicks of rebound clicks may vary because of shim stack thickness Close the rebound bleed by turning the rebound adjuster knob red all the way clockwise while using an Allen key to press up on the metering rod Open the rebound bleed by turning the rebound adjuster knob red all the way counterclockwise while pressing on the metering rod with an Allen key Leave the rebound bleed all the way open so that air is not trapped in the oil during final assembly Adjust the number of clicks If you need more clicks you can add 400 x 010 compression valve spacer If you need less clicks you can replace the 400 010 compression valve with one 400X 010 Compression valve spacer Set aside on lint free towel for final assembly 58 Bleeding oil out figure 6 16 Torq
41. bullet tool is not needed 4 Clamp eyelet in vice 5 Refer to tuning tables for appropriate valve stack if necessary Replace compression valves Make sure piston and valves are clean and bur free ON un 6 Take fresh piston assembly and thread piston bolt into shaft 7 Torque piston bolt to torque specified in torque tables figure 7 11 8 Check the number of rebound adjuster clicks figure 7 12 SES must 12 18 clicks of rebound Count the number of clicks ittakes to go from all the way closed rebound bleed to all the way open rebound bleed Close the rebound bleed by turning the rebound adjuster knob red all the way clockwise while using an Allen key to press up on the metering rod Open the rebound bleed by turning the rebound adjuster knob red all the way counterclockwise while pressing on the metering rod with an Allen key Leave the rebound bleed all the way open so that air is not trapped in the oil during final assembly 9 Adjust the number of clicks If you need more clicks you can add one 400 x 010 compression spacer If you need less clicks you can remove 400 X 020 compression spacer with one 400 X 010 compression valve spacer 10 Setaside on lint free towel for final assembly 72 Installing shaft assembly figure 7 15 Bleeding Shock Thread preload ring onto body Thread body cap eyelet onto body Clamp body cap eyelet in vice figure 7 13 Fill body cap with oil up to th
42. driver to final torque setting shown in torque table 11 damper all the way by hand If damper does not get full travel or gets very difficult to compress nitrogen Chamber may be too small and damper will need to be rebuilt Usually this 5 caused by IFP moving during assembly If damper piston hits the IFP during hand dyno testing You will need to rebuild the damper and with the correct height 12 Install air sleeve see air sleeve section 13 Doan air nitrogen leak test figure 9 17 Air leak test figure 9 17 109 RACING SHOX FLOAT RC SERVICE INSTRUCTIONS Diagnosis 1 2 Pumping air into shock for testing figure10 1 Clean shock with contact cleaner to remove all dirt and oil Remove reducers and bushings Hand Dyno FLOAT RC Co N 4 00 Pressurize shock to appropriate pressure figure 10 1 Install the Float RC into your shock hand dyno Set rebound adjuster dial red to full fast position all the way counter clockwise If the rebound adjuster dial red is difficult to turn the adjuster rod O ring will need to be replaced and relubed see FLOAT shaft replacement section Mis shock and let return freely several times If shock compresses and does not return check your air spring pressure If pressure read on FOX high pressure pump gauge has decreased more than 20 psi check for air leaks see Air Leak Test If shock is still pressurized but will not
43. e figure 4 6 figure 4 7 28 RACING SHOX VANILLA DRAWINGS AND PART LIST 2001 VANILLA e ie W Se kil ANNI 4 E at WER ARRAS 2 NY s9 S KAA e Vier Z M 2 2 u E 5 4 2 22 2 7 6555 SS 9 We 19 WP u 13 ee a EN 7 re 5 Y E BACING SHOK FOX FACTORY INC PROPRIETARY 32 1 213 07 023 2 008 01 005 3 229 04 000 229 15 003 229 04 005 229 15 006 4 812 06 022 A 812 06 023 A 803 00 028 A 035 00 110 A 003 07 000 A 029 03 015 A 9 008 00 002 10 805 02 201 A 11 002 02 005 A 12 050 01 012 A 13 050 01 011 A 14 044 04 080 044 04 070 A 044 04 060 A 044 04 050 A 15 018 04 005 A 16 204 01 000 E 204 12 002 D 204 12 004 D 204 12 007 D 17 805 00 005 A 18 803 00 051 A 19 234 00 009 B ox O 2001 VANILLA PARTS LIST Eyelet Shaft 1 1438 TLG Bumper B O 9 375 Shaft 400 TLG Nitrile Shaft 2 010 TLG Shaft 2 655 TLG Shaft 3 155 TLG Shaft 3 405 TLG Bearing assembly 780 TLG Bearing assembly 1 030 TLG Damper rebuild kit part 036 01 004 A U cup 8 375 Shaft Seals Q Ring 110 Bearing Internal 375 ID 0 375 Shaft Seals O Ring 020 Static Bumper T O 8 375 Shaft 100 TLG Nitrile Piston Damping 028 bleed 220 TLG Bearing 0 135 W X 0 879 ID X 0 032 TH 2 0 940 Bore PTFE Blue R
44. e middle thread Turn compression adjuster knob blue in and out until bubbles stop appearing Fill reservoir with oil Insert reservoir damping piston into reservoir Note Be careful oil can squirt out into your face Thread reservoir onto body cap Remove shock from vice Turn compression adjuster knob blue all the way counter clockwise soft setting While pushing on IFP so that oil is flowing through body cap rotate body and reservoir assembly such that the body is above the reservoir figure 7 14 Note Be careful oil can squirt out onto your shoes ect ect This will force all of the air out of the reservoir and body cap leaving only pure oil Pour oil into the body up to the middle of bearing housing threads Make sure that the rebound adjuster knob red is all the way counter clockwise fastest setting on your shaft assembly Open metering rod by pushing up into the piston bolt hole with a small Allen key Hold the IFP down with a blunt rounded tipped tool Insert shaft assembly into body by carefully rocking back and forth to remove air bubbles from the oil figure 7 15 73 Torquing Bearing housing Torquing resorvoir cap figure7 16 figure7 17 Torquing pellet filler screw 200 PSI Nitrogen charge figure 7 18 figure 7 19 Torquing and Pressurizing 1 Slide bearing assembly down and thread into body 2 Tighten bearing assembly Torque to specification shown in torque specification table figure7 16 3 T
45. ed Hole bim in mm 300 0 052 1 32 350 0 047 1 19 400 0 047 1 19 450 0 043 1 09 500 0 041 1 04 550 0 038 0 97 600 0 036 0 92 650 0 035 0 89 700 0 033 0 84 750 0 033 0 84 800 0 032 0 81 850 0 031 0 79 900 0 029 0 74 950 0 029 0 74 1000 0 026 0 66 1050 0 025 0 64 Compression valves Standard production settings 1x 800 OD 252 ID 0045 TH 1x 700 OD 252 ID 0045 TH 1 x 600 OD 252 ID 0045 TH 1 x 500 OD 252 ID 0045 TH Suspension fluid 10 wt 15032 Nitrogen PSI 200 PSI 132 VANILLA R TUNING TABLE Compression Valves Standard production settings 1 800 OD 252 ID 0045 TH 1x 700 OD 252 ID 0045 TH 1 600 OD 252 ID 0045 TH 1 500 OD 252 ID 0045 TH 3 x 400 OD 252 ID 010 TH BIG DROP compression settings 5X 800 OD x 252 ID x 0060 TH 1 700 OD 252 ID 0045 TH 1 x 600 OD x 252 ID 0045 TH 1 x 500 OD x 252 ID 0045 TH 3 x 400 OD 252 ID 010 TH Rebound Valves 4 x 600 OD 252 ID x 010 TH Slower high speed rebound 5 x 600 OD 252 ID x 010 TH Add or remove shims to achieve proper amount of rebound adjuster clicks 11 18 Suspension fluid 10 wt 15032 Nitrogen PSI 200 PSI 133 VANILLA RC TUNING TABLE Compression Valves damper shaft piston Standard production se
46. emoval sleeve If an internal bearing is in the sleeve remove it Slide the internal bearing removal sleeve over the small end of the pin large bore first Compress this assembly in a vice Remove from vice Remove internal bearing from bearing removal sleeve 16 figure 1 3 Internal Bearing Assembly Slide a new internal bearing on the bearing removal pin Insert the pin through the hole in the shock eyelet Slide the internal bearing removal sleeve over the pin small bore first Compress this assembly in a vice Remove from vice Remove tools ESI Reducer Assembly 1 Lubricate bore of internal bearing with grease figure 1 4 2 Press reducers into bearing by hand 3 Clamp reducers in the vice and rotate Make sure that the reducers rotate freely in the bearing with no free play figure 1 4 17 RACING SHOX NITROGEN PELLETS figure 3 1 Diagnosis Nitrogen Air Leak Test 1 Submerge shock in a container of water figure3 1 2 Shake off any initial bubbles Look for nitrogen bubbles at nitrogen fill pellet or set screw Both fill pellet and air sleeve and valve use same water check method 20 figure 3 2 figure 3 3 D Repairing Leaking Thread in Pellet Retainer Sometimes all that is needed to fix a leaking nitrogen chamber is to tighten the existing pellet retainer 1 2 3 4 m BD I mx Tighten pellet retainer with torque wrench screwdriver to init
47. ervice Centers are required to keep ALL parts used in the warranty repair of a FOX shock in an organized and cataloged manner for a period of one year All service enters will be required to produce said parts upon demand by FOX Racing Shox for this one year period Warranty Labor Reimbursement FOX will pay a warranty reimbursement fee for warranty services rendered Note The amounts listed represent reimbursement for shop time administrative cost handling and packaging material fees Warranty Codes and corresponding Reimbursement Values US DOLLARS SERV201 ALPS4 Out of warranty period SERV206 ALPS4R Out of warranty period SERV211 ALPS 5 Out of warranty period SERV216 ALPS5R Out of warranty period SERV221 Vanilla 21 50 SERV226 Vanilla R 26 50 SERV231 Vanilla RX 26 50 SERV236 Vanilla X Out of warranty period SERV241 Vanilla RC 26 50 SERV246 Air Vanilla RC Out of warranty period SERV251 Air Vanilla Out of warranty period SERV256 Air Vanilla R Out of warranty period SERV261 Air Vanilla Float Out of warranty period SERV266 Air vanilla Float R Out of warranty period SERV271 Air Vanilla Float RC Out of warranty period SERV276 FLOAT 2000 26 50 SERV281 FLOAT R 2000 26 50 SERV286 FLOAT RC 2000 26 50 SERV290 Air Vanilla Air Sleeve Rebuild 12 50 SERV291 Air Vanilla FLOAT Air Sleeve Rebuild 12 50 SERV292 FLOAT 2000 Air Sleeve Rebuild 12 50 SERV295 Stuck Air Vanilla FLOAT Rework 18 00 H Warranty Auditing Autho
48. ey to press up on the metering rod Open the rebound bleed by turning the rebound adjuster knob red all the way counterclockwise while pressing on the metering rod with an Allen key Leave the rebound bleed all the way open so that air is not trapped in the oil during final assembly 9 Adjust the number of clicks If you need more clicks you can add one 400 x 020 compression valve If you need less clicks you can remove one 400 x 010 compression valve spacer and replace it with 400 x 010 compression valve spacer 10 Slide bearing assembly all the way down to the top out backing plate 11 Setaside on lint free towel for final assembly 108 IFP height Float R Assembly Shaft to Body figure 9 16 1 Remove bleed hole screw and ball from bearing assembly 2 Using IFP set tool or calipers setthe IFP to correct height figure 9 16 3 Fill body with oil 4 Clamp body eyelet in vise NOTE FLOAT R Make sure that the rebound adjuster knob red is all the way counter clockwise with the metering rod pushed up 5 Insert shaft assembly into body and carefully screw bearing into body See torque table for proper torque 6 Install small ball and screw into bearing bleed hole 7 Install 90 durometer pellet in body 8 Tighten pellet retainer with torque wrench screwdriver to initial torque setting shown in torque table 9 Charge shock with 200 psi of nitrogen 10 Tighten pellet retainer with torque wrench screw
49. filiation and other informative information should be available to the FOX customer when a service center representative is not The use of e mail is highly recommended E mail is particularly useful when working with a person in another time zone i e when communicating with FOX Authorized Service Centers are expected to complete the repair service of all FOX shocks in a timely manner In the event that a timely repair service cannot be achieved i e part availability the Service Center is required to inform the FOX customer of the delay and its estimated completion date Any changes in the completion date should be immediately communicated to the FOX customer D All Authorized Service Centers required to use only Original FOX Racing Shox Parts the repair service of all FOX shocks Any substitute parts must be of equal quality and APPROVED BY FOX RACING SHOX BEFORE BEING USED Only Authorized FOX Service Centers are able to obtain many of FOX Racing Shox proprietary parts These items are of a technical nature to be used by a trained technician in the repair or service of FOX shocks Only items appearing on the FOX Retail Price List may be resold by the Authorized Service Center outside the repair or service of a FOX shock without first obtaining written permission from FOX GENERAL SERVICE WARRANTY POLICY cont A 0 Authorized FOX Service Centers will receive 35 discount off the FOX suggested retail price FOX requi
50. fts threads 6 Clamp shaft in vice with 0 375 shaft clamps 7 Torque eyelet to shaft using Torque wrench see tip Shaft Torque Tip Use piston bolt with 4 back up plates 093 thick and thread into shaft clamp eyelet in vise and torque bolt Be careful when removing bolt as shaft may turn if this happens re torque and clamp shaft in vise with shaft clamps before removing bolt Torque 120 inch Ibs 102 FLOAT R Shaft Replacement 1 Spray shaft and Y 375 shaft clamps with contact cleaner and clamp shaft in vise wet using Y 375 shaft clamps to hold shaft securely in the vise 2 Use a small propane torch to heat the shaft at the eyelet this will soften the Loctite and allow the eyelet to be removed easily figure 9 7 3 Slide a Y 1 2 inch breaker bar through the eyelet and turn counter clockwise to remove 4 If rengana adjuster knob is damaged rebuild eyelet assembly Turn rebound adjuster knob counter clockwise to remove Clean small ball spring and knob Grease knob at taper threads and small ball and spring Install rebound adjuster knob by turning clockwise several turns Use finger to push ball and spring down in hole Screw adjuster knob all the way counterclockwise then clockwise until the edge of small ball is visible 5 Remove eyelet shaft O ring Use a picking tool to remove eyelet shaft O ring Thoroughly clean threads and insert new O ring Make sure O ring is seated flat and not twisted Remove metering rod
51. haft Torque Tip Use piston bolt with 4 back up plates 093 thick and thread into shaft clamp eyelet in vise and torque bolt Be careful when removing bolt as shaft may turn if this happens re torque and clamp shaft in vise with shaft clamps before removing bolt 54 Picking out dust wiper figure 6 10 Installing shaft seal figure 6 11 Bearing Assembly With dental pick carefully pick out dust wiper seal from the shaft bearing housing figure 6 10 With dental pick carefully pick out out the shock shaft seal With dental pick carefully pick off the bearing housing outer threads o ring Inspect the bearing by sliding the bearing assembly with seals removed along the shaft You are checking for excessive clearance and wear 5 Install a new shaft seal in the bearing housing Slide seal into the groove from the bearing end Press remainder of shaft seal into groove figure 6 11 NOTE Make sure that the shaft quad ring or O ring is not twisted and that it is seated com pletely in its groove 6 Replace dust wiper seal in the top groove 7 Replace bearing housing outer O ring 8 Set completed bearing assembly aside on lint free towel on 55 Removing quad ring seal Installing quad ring seal figure 6 12 figure 6 13 IFP Seal Replacement 1 Carefully use a picking tool to remove the quad ring seal from the groove in the figure 6 12 Use extreme caution with picking tool as the IFP is plastic and will da
52. hock body with contact cleaner and inspect for scratches or wear Replace body if necessary 2 Grease quad ring on IFP 3 Insert greased IFP into body Use IFP depth table to find proper IFP depth The flat end of the IFP should be inserted first The IFP pocket should face the oil Refer to Float drawings if you any concerns about this orientation 4 Get aside for final as 119 figure 10 14 figure 10 15 FLOAT Shaft Assembly 1 Slide the large 1 100 OD 0 015 TH 0 375 ID spacer onto shaft 2 Install bottom out o ring onto shaft 3 Slide bearing assembly onto shaft 4 Install piston assembly 5 Install 3X 7000DX 252 IDX 0045 thick compression valves 6 Install lock out piston assembly Torque Lock out piston assembly to 8 5 NM 75 inch lbs figure 10 14 7 Install Lock out piston valve and small socket screw Note use one drop of blue loctite on screw threads Torque to 4 inch Ibs 5 4 NM figure 10 15 8 Push lock out valve with finger and move lever as needed to the make valve close 9 Move blue lock out lever back and forth while pushing lock out valve down to make sure There is a small amount of free play Free play implies that the lock out valve can close Excessive free play is an indication that the valve in not opening far enough working If there is no free play add 400 X 252 X 010 valve If there is excessive free play remove a 400 X 252 X 010 valve figure 10 16 Checking
53. hock size specific or tuning spec 82 lt gt XX Z 2001 FLOAT R 52 1 CRVA lt lt AAA ZEN KONS CR N 5 s RO TY lt 7 ROR lt N N AN e s DIN N ES SSS KARA eee N ER V Eat 8 EE TR A MESTIZO SEN l SANN 92413 LA NS 55525 4 N ER REDE 4 sav mouv 9 2 a A 4 D a a i L BACING SHOX FOX FACTORY INC PROPRIETARY 83 ON DO C I 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 808 14 029 A 808 14 032 A 802 00 001 A 029 03 126 A 210 03 016 A 010 01 000 A 039 00 003 A 029 03 011 A 029 03 110 229 27 000 229 27 001 229 27 002 229 27 005 812 06 020 812 06 021 803 00 051 003 07 000 803 00 051 803 00 050 803 00 050 040 15 110 805 02 005 002 02 005 050 01 012 Comp shims Rebound shims 050 01 011 A 210 10 008 A 24 204 54 007 A 204 54 008 A 2001 FLOAT R PARTS LIST Float R Eyelet Assembly Float R Eyelet Assembly Trunion Assembly air valve O Ring 2 126 Red Knob RD adjuster Ball 8 125 steel Spring 190 TLG X 120 OD O Ring 1 O Ring 2 110 Shaft 1 855 TLG Shaft 2 105 TLG Shaft 2 355 TLG Shaft 3 105 TLG Bearing assembly 815 TLG Bearing assembly 1 065 TLG Rebuild kit part Damper 029 02 110 A O Ring Polyurethane Bearing Intern
54. hock was sent from for repair Service Code Write the FOX service code here Repair Symptom List the symptoms the shock has upon first examination Parts Needed List all parts necessary for the repair of the shock Labor Reimbursement Write the labor reimbursement amount in US dollars associated with this repair Shipping Reimbursement Write the total shipping charge associated with this repair At the end of each month summarize your Warranty Reimbursement Forms onto the Warranty Labor Summary Form and the Warranty Parts Order Form ALPS 4 bearing assemblies are no longer available there are still seal kits available however in many cases we are upgrading to ALPS 5 bearing assemblies at 35 00 dollars retail Note you should not run into many ALPS 4 warranties due to the length of time these have been in the market Fill out the Warranty Labor Summary Form 8 Warranty Parts Summary Form as described below 1 Date Date form is started 2 Page of Number the pages For example a two page claim Page 1 is 1 of 2 Page 2 is 2012 etc 3 Service Center Write your service center number here 4 Invoice Number Please assign an invoice number to your claim Use any numbering system you like Each month s claim must have a unique number Use the same invoice number for both the Warranty labor Summary Form and the Warranty Parts Summary Form 5 Service Center Name Enter the name of
55. ial torque setting shown in torque table figure 3 2 Charge shock with nitrogen figure 3 3 Tighten pellet retainer with torque wrench screwdriver to final torque setting shown in torque table Doan nitrogen leak test Replacing Leaking Thread in Pellet Unthread pellet retainer Remove rubber pellet with pick Replace rubber pellet with 90 durometer pellet Tighten pellet retainer with torque wrench screwdriver torque wrench to initial torque setting shown in torque table Charge with two hundred psi of nitrogen FLOAT RC uses 500 psi Tighten pellet retainer with torque wrench screwdriver torque wrench to final torque setting shown in torque table Doan nitrogen leak test 21 Se 0 Sr Si figure 3 5 Repairing Press in Pellet Sometimes all that is needed to fix a leaking nitrogen chamber is to press the existing pellet retainer in a little figure 3 5 Use a new pellet retainer and place it over the existing plug Secure the whole assembly into your vise and tighten using the new pellet retainer to push in the existing pellet retainer figure 3 4 Recharge with nitrogen Do an nitrogen leak test Replacing Press in Pellet Always wear safety glasses Point air valve away from you and release air pressure with nitrogen safety needle Drill out aluminum plug and rubber filler pellet Use appropriate Easy out to turn out bad pellet Replace rubber pellet and secure with pellet retainer by press
56. ice Centers may make copies or order additional forms from FOX when necessary There are 2 forms required to make a warranty claim the Warranty Record Form one per warranty shock serviced and the Warranty Summary Form Warranty Record Form A Warranty Record Form must be completed for each shock serviced A compilation of the information on these forms is used to complete the Warranty Summary Form Warranty Summary Form The Warranty Summary Form is to be completed by the Service Center and submitted with the corresponding Warranty Record Forms to FOX Racing Shox for processing of the warranty claim Warranty claims may be submitted on a monthly bimonthly or quarterly basis F Warranty Parts Replacement FOX will ship all parts used by an individual Service Center in the warranty repair of FOX shocks with the same or equivalent part at a 100 discount Limited to parts on hand and or not discontinued Shipping of the warranty replacement parts to the Service Center will be paid by FOX not including any import taxes tariffs customs or broker fees Shipping charges on warranty parts orders and service parts orders when shipped together will be shared by FOX and the Service Center based on the weights of the individual orders At FOX s discretion the Service Center may be permitted to add a small service parts order to the warranty parts order and maintain the free shipping status All S
57. ing Plate Back Up 750 OD X 250 ID X 050 TH Plate Back Up 350 OD X 253 ID X 020 TH 1 Comp Shim 8000D X 252 ID X 0045 1 Comp Shim 7000D 252 ID 0045 TH 1 Comp Shim 6000D X 252 ID X 0045 TH 1 Comp Shim 5000D 252 ID X 0045 TH Fastener Standard Bolt 28 X 750 TLG Socket Head Body One Piece Clevis 3 400 THG Body One Piece 4 125 TLG Body One Piece 4 625TLG Body One Piece 5 000 TLG Piston Floating 0 940 Bore Acetron GP Rebuild kit damper 035 00 116 A Q Ring 116 Preload Ring 1 740 OD X 300 TLG 34 Coil Springs See spring chart travel and spring rates 010 00 011 A Pellet 2 275 X 125 TLG Nitrile Durometer 90A 010 00 010 A Pellet Retainer Set Screw 24 X 220 TLG 010 01 003 A Ball 2 1875 Nylon 024 02 032 A Vanilla Decal OTHER NOTES 803 00 028 A Damper rebuild kit 2000 Vanilla Damper charge 200 PSI Nitrogen 10 WT Suspension fluid ISO 32 5 75 X 1 25 IFP settings 1 60 6 5 X 1 50 IFP settings 2 00 6 750 X 1 75 IFP settings 2 10 7 500 X 2 00 IFP settings 2 40 7 700 X 1 875 IFP settings 2 60 7 875 X 2 00 IFP settings 2 60 7 875 X 2 25 FP settings 2 60 Piston assembly 805 02 201 0280 bleed is smallest hole size use as Pilot hole for tuning size according to Vanilla tuning table Uncommon parts Shock size specific 35 2001 VANILLA R 25 26 7 2 866880 20
58. ing pellet retainer into body with vise Recharge with nitrogen Do an nitrogen leak test 22 RACING SHOX FLOAT AIR SLEEVE SERVICE Warnina FLOAT Air Sleeve Service Itis possible that high pressure air may be trapped in the negative side of the air sleeve chamber This is known as a STUCK DOWN condition It is very important that the air sleeve is removed carefully The trapped high pressure air may blow the sleeve assembly off of the body at high speed possibly causing an injury or death Use a shop rag through the body elelet will prevent the air sleeve from blowing off the body and harming anyone figure 4 1 26 Air Sleeve Removal 1 Remove reducers if used 2 Discharge the air pressure from the air chamber 3 Inserta rag through the body eyelet very important figure 4 1 4 Clamp the air sleeve in 1 625 shaft clamps figure 4 2 Use 1 2 bar to to turn eyelet until the eyelet O ring is exposed Caution Do not turn eyelet more than 2 full turns assembly may blow off 5 Unclamp shock 6 Use the rest of the rag to wrap around the sleeve for best grip fig 4 3 7 Use 1 2 inch bar to turn eyelet until the shock comes apart If the shock was stuck down you will hear a loud noise as the air escapes from sleeve body figure 4 1 Air Sleeve Inspection 1 Clean air sleeve with solvent 2 Inspect air bypass port in the air sleeve for sharp edges with finger Use Dremel tool with bit 4
59. ing table if necessary 2 Install shock in dyno fig 6 1 3 Compress shock and let return freely several times Watch shock rebound If shock compresses and does not return there may be something clog ging the bleed hole If shock extends very quickly and makes a squealing noise on extension the shock may have lost nitrogen pressure Listen for squeals on rebound Loud squeals indicate air mixed with oil This could be inadequate bleeding when the shock was built or a leaking IFP Listen for loud squeaks This could be the spring rubbing on the body Check for excessive friction on rebound Sticky shaft stroke may indicate a tight bearing Listen for zipper noises inside shock body These noises may indicate a surface finish problem on the bore of the shock body Feel for hard top out Hard top out can be caused by a damaged top out bumper NOTE You may find from time to thatthe Top out pad is deformed or has been smashed into damper piston causing the shock to become stuck down Replace top out pad with a new one P N 008 00 002 A and make sure the bearing housing is the cup type Correct Bearing housing is P N 812 06 022 A TLG 780 and 812 06 023 A TLG 1 030 48 Hand Dyno Vanilla R Sey ud Hand dyno Vanilla R figure 6 1a Install appropriate spring on damper check spring table if necessary Install shock in dyno figure 6 1 Set rebound adjuster knob red to full fast position all the way counter cl
60. l installation tool NOTE Make sure that the seal is not twisted and that it is seated completely in its groove 6 7 8 Replace wiper seal Replace bearing housing outer O ring Set completed bearing assembly aside on lint free towel figure 7 10 70 Torquing piston bolt Checking rebound clicks figure 7 11 figure 7 12 IFP Seal Replacement 1 Carefully use a picking tool to remove the quad ring seal from the quad ring groove in the IFP Internal Floating Piston Use caution with picking tool as the IFP is plastic and will scratch and damage easily figure 7 8 2 Inspect IFP for damage Replace if necessary 3 To install your new quad ring place one side of quad ring into groove in IFP and stretch the quad ring around the IFP snapping it into the groove figure 7 9 Make sure the Q ring is not twisted and is seated in the quad ring groove IFP Installation 1 Clean inside of reservoir with contact cleaner and inspect for scratches or wear Replace reservoir if necessary Grease quad ring on IFP Grease internal threads of reservoir Insert greased IFP into reservoir cup side down towards oil side figure 7 10 Rr 71 Body cap in vise figure 7 13 Pushing oil through body cap figure 7 14 Vanilla RC Shaft Assembly Slide bottom out bumper onto shaft and eye assembly Grease seals and inside of bearing Slide bearing assembly onto shaft Adjustable Vanilla shafts have a generous radius so
61. lent Seals U cup 0 375 Shaft 4181 Nitrile durometer 70 Pellet O ring Adj Rod O ring Adj Rod 2000 2001 Kit Rebuild ALPS 5 9 1 630 Bore Bumper T O O 1 497 Shaft 0 180 TLG Hytril Seals O Ring 008 070 C S X 0 176 ID Standard N 70 Static Seals O Ring 029 070 C S X 1 489 ID Standard N 70 Static Seals O Ring 124 103 C S X 1 237 ID Standard N 70 Static Seals O Ring 220 139 C S X 1 359 ID Standard N 70 Static Seals Q Ring 216 139 C S X 1 109 ID 366Y Seals Q Ring 222 139 C S X 1 484 ID 366Y or equivalent Seals Wiper SH 1 497 Shaft Urethane durometer 90 SPL Kit Rebuild Air Vanilla Air Sleeve Bearing External 0 200 W X 4 120 TLG X 0 050 TH 1 375 Bore Seals O Ring 124 103 C S X 1 237 ID Standard N 70 Static Seals Q Ring 216 139 C S X 1 109 ID 366Y Kit Rebuild Air Vanilla FLOAT Air Sleeve Bearing External 0 200 W X 4 120 TLG X 0 050 TH 1 375 Bore Seals O Ring 029 070 C S X 1 489 ID Standard N 70 Static Seals O Ring 124 103 C S X 1 237 ID Standard N 70 Static Seals Q Ring 216 139 C S X 1 109 ID 366Y Seals Q Ring 215 139 C S X 1 046 ID Buna 80 A EF Treatement Kit Rebuild Air Vanilla and Air Vanilla FLOAT Damper Air Valve Parts Pellet 0 275 X 0 125 TLG nitrile durometer A 0 Seals O Ring 110 0 103 C S X 0 362 ID Polyurethane Parker 4300 Seals O Ring 020 070 C S X 0 864 ID
62. m vice and dump oil into your waste oil container Remove IFP Blow IFP into a rag by pressurizing shock body through the pellet hole with pressurized air figure 9 5 100 Removing piston bolt figure 9 6 Float Damper Piston Removal Clean shaft assembly with contact cleaner 2 Clamp eyelet in vice Do not smash air valve or rebound adjuster knob red 3 FLOAT Remove piston bolt with 3 16 Allen wrench figure 9 6 NOTE FLOAT R Remove piston bolt with 3 8 wrench Remove piston valves and top out plate and set on lint free towel Remove bearing assembly and spacer if used Remove bottom out bumper O ring and washer Remove eyelet and shaft assembly from vise Inspect shaft for any nicks pits wear marks or damage If the shaft fails inspection replace it as described in the FLOAT FLOAT R Shaft Replacement section Sooo 101 Using torch to soften Loctite on Float RC figure 9 7 FLOAT Shaft Replacement 1 Spray shaft and 375 shaft clamps with contact cleaner and clamp shaft in vise wet using 375 shaft clamps to hold shaft assembly securely in the vise 2 Use a small propane torch to heat the shaft at the eyelet this will soften the Loctite and allow the eyelet to be removed easily figure 9 7 3 Slide a Y 1 2 inch breaker bar through the eyelet and turn counter clockwise to remove 4 Clean eyelet and shaft thoroughly of any old Loctite 5 Lay a bead of red Loctite around the base of the sha
63. mage easily Inspect IFP for damage and make sure the piston groove has no scratches or nicks Replace if necessary To install your new quad ring place one side of quad ring into groove and stretch the quad ring around the IFP snapping it into the groove figure 6 13 Make sure the Q ring is not twisted and is seated in the ring groove correctly IFP Installation Clean inside of shock body with contact cleaner and inspect for scratches or wear Replace body if necessary Grease quad ring on IFP Grease Threads of Body Insert greased IFP into body pocket side up Use IFP depth table for proper IFP set ting Set aside for final assembly 56 Piston bolt to torque figure 6 14 Vanilla Shaft Assembly 1 Slide bottom out bumper onto shaft and eye assembly 2 Install shaft bullet tool 3 Grease dust wiper Q ring and inside of bearing 4 Slide Bearing assembly over bullet tool and onto shaft 5 Remove bullet tool 6 Clamp eyelet in vice 7 Referto tuning tables for appropriate bleed hole size if necessary Replace compression valves Make sure piston and valves are clean and bur free 8 Take fresh piston assembly and thread piston bolt into shaft 9 Torque piston bolt to torque specified in torque tables figure 6 14 Sri Piston bolt torque Checking rebound clicks figure 6 14 figure 6 15 Vanilla R Shaft Assembly RS ee RL 10 Slide bottom out bumper onto shaft and eye assem
64. mation on nomm oma Starting your Fox Service Center General Service Warranty Policies Warranty Procedures Service Re Valving Policy The Fox Service System Certification SECTION 1 STARTING YOUR FOX SERVICE CENTER Welcome to FOX Racing Shox we are excited to start working with you All FOX service centers are required to have a broad and complete assortment of parts allowing them to provide prompt and quality service to FOX customers get you up and running quickly FOX has compiled Start Up Kit All new Service Centers are required to purchase the Start Up Kit The Start Up Kit includes most common daily warranty parts and tools needed Kit includes A Detailed selection of parts FOX Parts Catalog USA Suggested Retail Price List Special FOX Tools FOX Specific Forms FOX Set Up Manuals FOX Rebuild Manual FOX Window Decals Service Center Training Our comprehensive FOX parts catalog lists more than 300 additional parts not found in the Start Up Kit All the parts listed in our Bicycle Catalog may be ordered individually to effectively handle most FOX Shox repairs SECTION 2 GENERAL SERVICE WARRANTY POLICIES A B C Authorized Service Centers are required to maintain a high standard of excellence when working with FOX customers and the repair and service of their FOX shocks FOX Authorized Service Centers should be easy to contact A recorded message clearly stating the service center s FOX af
65. n preload adjuster one half turn past snug figure 6 18 Hand dyno 6 19 1 2 3 4 Hand dyno figure 6 19 60 RACING SHOX VANNILLA RX AND RC SERVICE INSTRUCTIONS m Vanilla RC in hand dydno figure 7 1 A Diagnosis 1 Clean shock with cleaner to remove all dirt and oil 2 Remove reducers and bushings if used Hand Dyno Vanilla RC 1 Install appropriate spring on damper 2 Install shock into your hand dyno figure 7 1 3 Set rebound adjuster knob red to full fast position all the way counter clockwise 4 Set compression adjuster knob blue to softest position all the way counter clockwise 5 Compress shock and let return freely several times If shock compresses and does not return there may be something clogging the shaft bleed hole or the metering rod may be damaged or stuck Listen for loud squeaks This could be the spring rubbing on the body 6 Adjust rebound adjuster knob red clockwise to full slow 7 Compress shock and let return freely several times The shock should rebound very slowly at this setting If shock rebounds quickly the valves may be damaged Check the fit between metering rod shaft and piston bolt Watch shock rebound If shock extends very quickly and makes excessive noise on extension the shock may have lost nitrogen pressure or shock oil has excessive air in oil Next check the middle of the rebound range by turning the rebound adju
66. nob clockwise to remove Remove spring and Ball from red knob Grease knob at taper threads and spring hole a Insert ball and spring into rebound knob hole Install rebound adjuster knob by turning clockwise several turns Remove metering rod and inspect for damage 10 Replace metering rod o ring in shaft 11 Lay a bead of red Loctite around the base of the shafts threads Keep Loctite away from metering rod 12 Clamp shaft in vice 13 Torque eyelet to shaft using eyelet torque wrench see Torque Tables for proper torque Shaft Torque Use piston bolt with 4 back up plates 093 thick and thread into shaft clamp eyelet in vise and torque bolt Be careful when removing bolt as shaft may turn if this happens re torque and clamp shaft in vise with shaft clamps before removing bolt 69 Removing Q ring Installing Q ring figure 7 8 figure 7 9 Bearing Assembly BEI 5 Pick out the wiper seal figure 7 7 Pick out the polyurethane O ring for Vanilla RC Pick off the O ring by the bearing housing outer threads Inspect the bearing by sliding the bearing assembly with seals removed along the shaft You are checking for clearance and wear The bearing should slide freely If you feel excessive friction the bearing assem bly should be replaced Install a new seal polyurethane O ring in the top groove of the bearing housing Slide seal into the groove from the bearing end Press remainder of seal into groove with sea
67. ockwise Compress shock and let return freely several times Listen for loud squeaks This could be the spring rubbing on the body If shock compresses and does not return there be something clogging the shaft bleed hole or the metering rod may be damaged or stuck Adjust rebound adjuster knob red clockwise to full slow Compress shock and let return freely several times The shock should rebound very slowly at this setting If shock rebounds quickly the valves may be damaged Check seal between metering rod shaft and piston bolt Watch shock rebound If shock extends very quickly and makes a squealing noise on extension the shock may have lost nitrogen pressure Next check the middle of the rebound range by turning the rebound adjuster knob red counter clockwise six clicks Compress shock and let return freely several times There should be a substantial increase in rebound speed from the fully closed position If not check the valves for damage Listen for squeals on rebound Loud squeals indicate air mixed with oil This could be air trapped in oil when the shock was built or a leaking IFP This could also could be caused by a bur on the piston piston bolt or shaft bleed hole Check for excessive friction on rebound Sticky areas may indicate a tight bearing Listen for zipper noises inside shock body These noises may indicate a surface finish problem on the bore of the shock bogy Feel for hard top out Hard top out can be caused
68. ole If shock does not compress fully the IFP may be set too deep If shock extends very quickly and makes a squealing noise on extension the shock may have lost nitrogen pressure or is emulsified air mixed in oil If shock extends too slowly or too quickly shock may not be valved for the current pressure Listen for squeals on rebound Loud squeals indicate air mixed with oil This could be inadequate bleeding when the shock was built or a leaking IFP This could also could be caused by a burr on the rebound hole Check for excessive friction on rebound Sticky areas may indicate a tight bearing Listen for zipper noises inside shock body and air sleeve These noises may indicate a surface finish problem on the bore of the shock body or air sleeve Feel for hard top out Hard top out can be caused by a problem with the nega tive air spring 97 Float R Diagnosis 1 2 Clean shock with contact cleaner to remove all dirt and oil Remove reducers and bushings if used Hand Dyno FLOAT R DONS Pressurize shock to appropriate pressure figure 9 1 Set rebound adjuster knob to full fast position all the way counter clockwise Install shock in dyno figure 9 2 Compress shock 19mm 3 4 and let return freely 3 times This is done to pressurize air negative spring SOInpfess shock fully 3 times If shock compresses and does not return check your air pressure If pressure has dropped more than 20 psi check f
69. or air leaks see Air Leak Test If shock is still pressurized but will not return there may be something clogging the bleed hole or the metering rod may be damaged or stuck If shock does not compress fully the IFP may be set too deep Verity number of clicks 12 18 on rebound knob and turn clockwise to full slow Compress shock 1 time The shock should return very slow If shock rebounds quickly the valves may be damaged or check the seal be tween metering rod and piston bolt If shock makes a squealing noise on extension the shock may have lost nitrogen pressure Turn the rebound knob 6 7 clicks counterclockwise this is middle of range Compress the shock fully 3 times There should be a substantial increase in rebound speed from the fully closed position If not check your valving If there are loud noises the piston piston bolt or rebound hole may have a burr on it or there may be air in the oil Listen for squeals on rebound Squeals indicate air mixed with oil This could be inadequate bleeding when the shock was built or a leaking IFP Check for excessive friction on rebound Sticky areas may indicate a tightbearing Listen for zipper noises inside shock body and air sleeve These noises may indicate a surface finish problem on the bore of the shock body or air sleeve Feel for hard top out Hard top out can be caused by a problem with the air negative spring 98 Under water air leak testing figure 9 3 Air Leak Test
70. ppropriate bleed hole size for custom tuned rebound if necessary for customer Replace compression valves Make sure piston and valves are clean and burr free Install backup plate and topout plate 8 Take fresh piston assembly and thread piston bolt into shaft figure 9 13 9 Torque piston bolt to torque specified in torque tables 107 Shaft eye assembly figure Piston bolt torque figure 9 14 9 15 FLOAT R Shaft Assembly 1 Slide washer and bottom out bumper onto shaft and eye assembly figure 9 14 2 Grease polyurethane O ring and inside of bearing 3 Slide bearing assembly onto shaft Adjustable FLOAT shafts have a generous radius so bullet tool is not needed 4 Clamp eyelet in vice Take care not to smash adjuster knob red knob 5 Refer to tuning tables for appropriate valve stack if necessary Replace compression valves Inspect rebound valves Replace if worn Make sure piston and valves are clean and burr free 6 Take fresh piston assembly and thread piston bolt into shaft figure 9 15 Make sure adjuster knob is set to full fast 7 Torque piston bolt to torque specified in torque tables 8 Check the number of rebound adjuster clicks Shock must have 12 18 clicks of rebound Count the number of clicks it takes to go from all the way closed rebound bleed to all the way open rebound bleed Close the rebound bleed by turning the rebound adjuster knob red all the way clockwise while using an Allen k
71. r bearing O ring figure 10 10 Pick off outer 218 Q ring and two white bearings figure 10 11 Thoroughly clean bearing Inspect the bearing by sliding the bearing assembly with seals removed along the shaft You are checking for clearance and wear The bearing should slide freely If you feel excessive friction the bearing assem bly should be replaced Install a new polyurethane O ring in the top groove of the bearing housing NOTE Make sure that the O ring is seated completely in its groove and is not twisted Install inner bearing O ring Make sure O ring is not twisted Install one white bearing Install 218 Q ring Make sure Q ring is not twisted Install second white bearing Make sure both white bearings are seated flat in groove Set completed bearing assembly aside on lint free towel 118 Removing Quad ring figure 10 12 Installing IFP Quad ring figure 10 13 IFP Seal Replacement 1 Carefully use a picking tool to remove the quad ring seal from the quad ring groove in the IFP Internal Floating Piston Use caution with picking tool as the IFP is plastic and will damage easily figure 10 12 2 Inspect IFP for damage Replace if necessary 3 To install your new quad ring place one side of quad ring into groove in IFP and Seleh the quad ring around the IFP snapping it into the groove figure10 13 Make sure the Quad ring is not twisted and is seated in the quad ring groove IFP Installation 1 Clean inside of s
72. r several minutes before going any further 7 Loosen bearing completely and carefully work the shaft assembly up and out of the shock body Set aside on lint free towel Carefully remove body from vise and dump oil into your waste oil container oo 115 IFP removal Removal of lockout valve Compression piston tool figure 10 5 screw figure 10 6 figure 10 7 9 Blow IFP into a rag by pressurizing shock body through the pellet hole with pressurized air figure 10 5 Piston Removal 1 Clean shaft assembly with contact cleaner 2 Clamp eyelet in vice 4 Do not smash air valve rebound adjuster dial red or compression adjuster lever blue Remove Compression lock out screw and valve figure 10 6 Remove compression piston with 2001 pin socket P N 398 00 227 A figure 10 7 Remove piston bolt valves and top out plate Remove bearing assembly Remove bottom out o ring and washer Remove eyelet and shaft assembly from vise Inspect shaft for any damage i e nicks scraps pits wear marks If shaft fails inspection replace it as described in the shaft replacement section 116 Heating eyelet to soften loctite figure 10 8 FLOAT RC Shaft Replacement 1 Remove set screw at base of eyelet spring and ball rebound detent system 2 Spray shaft and Y 375 shaft clamps with contact cleaner and clamp shaft in vise wet using Y 375 shaft clamps to hold shaft securely in the vise 3 Use a small
73. read reservoir end cap into reservoir Torque to specification shown in torque specifi cation table figure7 17 4 Install 90 durometer pellet in resorvoir body cap with pellet retainer 5 Tighten pellet retainer with torque wrench screwdriver to initial torque setting shown in torque table figure 7 18 Charge shock with two hundred psi of nitrogen figure 7 19 Tighten pellet retainer with torque wrench screwdriver to final torque setting shown in torque table 8 damper all the way by hand If damper does not get full travel or gets very difficult to compress nitrogen chamber may be too small and damper will need to be rebuilt again Usually this is caused by IFP moving during assembly The shock shaft should also return back to full extension after charging with Nitrogen with the rebound knob is full open counter clockwise fast 9 Do an air leak test 2 74 Spring Collar Installation Spring Installation 1 Slide spring over damper body 2 Slide slotted spring retainer onto eyelet figure 7 20 3 Tighten preload adjuster one half turn past snug 4 Hand dyno figure 7 21 pP Installing spring retainer figure 7 20 Kevin Blair using the hand dyno figure 7 21 75 RACING SHOX FLOAT DRAWINGS AND PART LIST 2001 FLOAT LA I SS lt gt ES WEN SS SNS BOX FACTORY ING PROPRIETARY RACING SHOX 79 1 808 14 028 808 14 031 2 8
74. res all Authorized Service Centers to warranty all service performed on FOX shocks for a period of 3 months All cost incurred by the Service Center in the event of a 3 month warranty repair rework is the responsibility of the Service Center with the exception of abuse neglect design defects tampering or lack of service SECTION 3 WARRANTY PROCEDURES A B C WARRANTY THE WARRANTY PERIOD FOR A FOX SHOCK IS ONE YEAR FROM DATE OF PURCHASE OF BICYCLE SHOCK This warranty is void when damage to the shock has occurred from the following Abuse Damage to the exterior finish Disassembly or any attempt to disassemble Modifications Non factory oil changes Shipping damages loss purchase of full value insurance is recommended Absence of Proof of Purchase Each Service Center is required to validate the age of the shock being considered for warranty It is the responsibility of the Service Center to keep any and all documents or notes obtained during the validation process for a period of one year after the completion of the warranty service All service centers will be randomly audited for accuracy in this area FOX will perform random audits of original warranty validation paperwork at their discretion Warranty Requirements for Bike Shops and Customers on used shocks Bicycle shops and retail customers must provide the Service Center with a valid copy of sales receipt showing the original purchase at less than one year and mee
75. return there may be something clogging the rebound bleed hole If shock does not compress fully the IFP may be set too deep Turn rebound adjuster dial clockwise 23 26 clicks to full slow When knob stops omnes shock and let return freely several times The shock should return very slowly at this setting If shock still rebounds quickly the rebound adjuster set screw may not be sealing Watch shock rebound If shock extends very quickly and makes a squealing noise on extension the shock may have lost nitrogen pressure or the oil has air in it Next check the middle of the rebound range by turning the rebound adjuster dial counter clockwise 8 11 clicks Compress shock and let return freely several times There should be a substantial increase in rebound speed from the fully closed position If not check the rebound adjuster set screw Listen for squeals on rebound Loud squeals indicate air mixed in with oil This could be inadequate bleeding when the shock was built or a leaking IFP Check for excessive friction on rebound Sticky areas may indicate a tight bearing 113 10 2 Listen for zipper noises inside shock body and air sleeve These noises may indicate a surface finish problem on the bore of the shock body or air sleeve Feel for hard top out Hard top out can be caused by a problem with the air negative spring 9 Check compression damping lever by rotating the compression adjuster lever 90 or 180 degrees depending
76. rform OEM service as soon as possible as to allow the OEM time to return the shock to their customer in a timely manner Please do not allow questions or problems with OEM shocks to linger When a shock s must be submitted without proper documentation the Service Center will visually inspect the shock s on arrival for warranty consideration The Service Center is then authorized by FOX to determine whether the shock should be warranty or not The Service Center would then inform the OEM Distributor of its findings Service centers are encouraged to contact FOX with any questionable situations All service centers are required to record sufficient explanations for all OEM Distributor shocks repaired under warranty without proper documentation on the FOX warranty form Excessive claims of this type will be audited This method of visual warranty may only be used for OEM s or their distributors NOT BIKE SHOPS or INDIVIDU ALS E Shipping FOX will reimburse Authorized Service Centers for return ground standard shipping to their customers on warranty shocks FOX will reimburse for standard ground shipping up to maximum amount US 8 00 per shock warranty claim Any expedited return shipping is the responsibility of the customer Shipping to the service center in the case of a service or warranty shock is the responsibility of the customer Warranty Forms The necessary warranty reimbursement forms are supplied with the Start Up Kit Serv
77. rized FOX Service Centers will be subject to random audits For this reason it will not be necessary to send original purchase receipts or old parts back to FOX with your warranty claims Service Centers must be prepared to provide FOX Racing Shox with the required paper work used to validate previous warranty claims and all warranty replacement parts used in the repair of warranty shocks in an organized manner upon demand for up to a 12 month period from the time the warranty work was completed SECTION 4 FOX SERVICE After the one year warranty period we move into the service life cycle of the FOX shock This would entail all service necessary for maintenance and repair of Fox Bicycle Shox Regular service charges in the United States range from 25 00 dollars to 40 00 dollars This service charge covers the labor to disassemble replace seals and oil and reassemble There is additional charges for parts used Suggested US retail prices are supplied in parts catalog Additional service parts can be purchased from the FOX parts catalog for general service FOX Racing Shox will provide Service Centers with an approved resale parts list that can be sold to general public and bicycle dealers Non resale parts and tooling are not for resale to general public Bicycle dealers or non authorized service centers Any sales of this type will void your FOX Authorized Service Center status immediately 10 SECTION 5 REVALVE POLICY Most common
78. ster knob red counter clockwise six clicks 9 Compress shock and let return freely severaltimes There should be a substantial increase in rebound speed from the fully closed 00 65 Untread pellet retainer figure 7 2 RC body end cap in vise figure 7 3 posi tion If not check the shock compression rebound valves Listen for squeals on rebound Loud squeals indicate air mixed in with oil This could be a inadequate bleeding when the shock was built or a leaking IFP This could also be caused by a bur on the piston or piston bolt Check for excessive friction on rebound Sticky areas may indicate a tight piston bearing Listen for zipper noises inside shock body These noises may indicate a surface finish problem on the bore of the shock body Feel for hard top out Hard top out can be caused by a problem with the hydraulic top out check the shock shaft top out rebound bleed groove and undersized glide ring 10 Turn compression adjuster knob blue six clicks clockwise harder Hand feel compression stroke it should become harder 11 Han compression adjuster knob blue all the way clockwise hardest Hand feel compression it should become very hard If compression is not becoming harder check reservoir damping piston and check all valves and compression adjuster check valve for proper seal facing surface If valves are not laying flat on the reservoir damping piston flat sand the reservoir damping piston and repl
79. t the FOX warranty policy requirements to be eligible for warranty Any shocks that do not meet these requirement but are still being considered for warranty because of extenuating circumstances must be approved by FOX before the work is performed to insure warranty reimbursement Warranty Requirements for Bike Shops on new shocks Sometimes shocks are deemed faulty before the bike is ever sold so there is no original purchase documentation In this situation the following information is to be obtained Bike Manufacture Year 8 Model Serial Number When a bike shop submits a shock warranty consideration by this method the shock must be of new condition No warranty work should be performed on any shocks received with obvious signs of use until a copy of the original proof of purchase is obtained by the Service Center D Warranty Requirements for OEM s and their distributors Ideally all shocks being submitted for warranty by an OEM Distributor to a Service Center will be accompanied by proper documentation a valid copy of the original proof of purchase showing the shock to be less than a year old and meet the FOX warranty policy requirements It is sometimes difficult for OEM s and or their distributors to supply receipts because of the many hands a receipt would have to go through to accompany the shock to the Service Center FOX will accept shocks from OEM s and or their distributors without receipts when necessary It is critical to pe
80. ttings 1 x 800 OD x 252 ID x 0060 TH 1x 700 OD 252 ID x 0045 TH 1 600 OD 252 ID 0045 TH 1 500 OD 252 ID 0045 TH 3x 400 OD x 252 ID x 010 TH BIG DROP compression settings 5X 800 OD x 252 ID x 0060 TH 1x 700 OD x 252 ID x 0045 TH 1x 600 OD x 252 ID x 0045 TH 1x 500 OD x 252 ID x 0045 TH 3x 400 OD x 252 ID x 010 TH Rebound Valves 4 x 600 OD x 252 ID x 010 TH Slower Rebound for higher rate springs 5 x 600 OD 252 ID x 010 TH Compression Valves on Reservoir damper piston 4 x 600 OD x 252 ID x 020 TH Rebound Valves on Reservoir damper piston 1x 700 OD x 252 ID x 0045 TH 1x 600 OD x 252 ID x 0045 TH Add or remove shims to achieve proper amount of rebound adjuster clicks 11 18 Suspension fluid 10 wt 15032 Nitrogen PSI 200 PSI 134 TUNING TABLE Rebound bleed hole sizes General guide for fine tunning of fixed rebound port size PSI Air pressure Bleed Hole Bleed Hole in mm 105 0 063 1 60 125 0 060 1 53 140 0 055 1 40 160 0 052 1 32 175 0 047 1 19 195 0 047 1 19 210 0 043 1 09 230 0 041 1 04 245 0 039 0 99 265 0 038 0 97 280 0 037 0 94 300 0 037 0 94 Compression valves 2 x 800 OD x 252 ID x 0045 TH Suspension fluid 10 wt 15032 Nitrogen PSI 200 PSI 135 FLOAT R TUNING TABLE TH Light 006 TH Heavy 010
81. ue bearing assembly figure 6 17 Mating Shaft Assembly to Body Place IFP set tool at predetermined height and slide body over it Press down on IFP to make sure it is seated at the correct height or use Calipers to set proper height Fill body with oil up to the middle thread Clamp body eyelet in vice Vanilla R Make sure that the rebound adjuster knob red is all the way counter clock wise Slide bearing assembly down to the top of rebound hole Insert shaft assembly into body by carefully rocking back and forth to remove air bubbles from the oil and thread into body figure 6 16 Tighten bearing assembly Torque to specification shown in torque specification table figure 6 17 Install 90 durometer pellet in body Tighten pellet retainer with torque wrench screwdriver to initial torque setting shown in torque table Charge shock with two hundred psi of nitrogen Tighten pellet retainer with torque wrench screwdriver to final torque setting shown in torque table i in damper allthe way by hand If damper does not get full travel or gets very difficult to compress nitrogen chamber may be too small and damper will need to be refilled Usually this is caused by IFP moving during assembly If piston hits IFP nitrogen chamber may be too large and damper will need to be refilled Do an air leak test 59 Preload adjuster figure 6 18 Spring Installation Slide spring over damper Thread preload adjuster onto body Tighte
82. up and out of the shock body and set aside on lint free towel Carefully remove body from vice and dump oil into your waste oil container IFP Internal Floating Piston removal Blow IFP into a rag by pressurizing shock body through the pellet hole with pressurized air firgure 6 4 51 Removal of 3 8 Piston bolt figure 6 5 Piston Removal 1 Clean shaft assembly with contact cleaner 2 Clamp eyelet in vice Do not smash rebound adjuster knob red 3 Vanilla Remove piston bolt with 3 16 Allen wrench Vanilla R Remove piston bolt with 3 8 open end wrench figure 6 5 4 Remove piston valves and top out plate and set on lint free towel 5 Remove bearing assembly and spacer if used 6 Remove bottom out bumper 7 Remove eyelet and shaft assembly from vice 8 Inspect shaft for any nicks pits wear marks or damage If the shaft fails inspection replace it as described in Vanilla Shaft Replacement section 52 Warm with torch to soften Loctite 1 2 Bar in eyelet figure 6 7 figure 6 6 Vanilla Shaft Replacement 1 Spray shaft and Q 375 shaft clamps with contact cleaner and clamp shaft in vise wet using 375 shaft clamps to hold shaft securely in the vise 2 Use a small propane torch to heat the shaft at the eyelet this will soften the Loctite and allow the eyelet to be removed easily figure 6 6 3 Slide a 1 2 inch breaker bar through the eyelet and turn counter clockwise to remove figure

2001-2005 Rear Shock service Manual

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