WTB FLOAT 100R User's Manual
Contents
1. Q QU X XX o0 xX XY OY RK OLX Do not use a tire if ANY measurement exceeds the maximum dimensions shown above Using tires larger than the dimen sions shown above is NOT RECOMMENDED and can cause serious or fatal injury Brakes Maximum Linear pull Brakes Tire Width XY RY X Q XXX KK 0 AX Q XX RY X 9 NA QU e XX A V D Q Linear pull brakes i e V brakes can be used on FOX FORX Use only the FOX brake posts supplied with the fork Install brake posts and torque to 80 in lbs Install and adjust linear pull brakes according to the manufacturer s recom mendations Test brakes for proper operation on flat land FOX FORX use a hangerless lower leg design and cannot use any cantilever style brakes Disc Brakes Disc brakes with 160 180mm rotors can be used on FOX FORX Do not use DH rotors larger than 180mm Install disc brakes and torque all fasteners according to manufacturer s recommendations Install route and check that all cables or hydraulic hoses are securely fastened to the lower leg and will not move during compression of the fork Test brakes for proper operation on flat land Maintenance Performance safety and the life span of your FOX FORX depend on maintenance If you ride in extreme conditions service and maintain your FOX FORX more frequently NOTE In this manual reference being made to the left and right2. RACING SHOK 2002 FOX FORX Owners Manual FLOAT 80R FLOAT 80RL FLOAT 80RLC FLOAT 100R FLOAT 100RL FLOAT100RLC Vanilla 100R Vanilla 100RL Vanilla 100RLC Vanilla 125R Vanilla 125RL Vanilla 125RLC FOX RACING SHOX 130 Hangar Way Watsonville CA 95076 831 768 1100 FAX 831 768 9342 E Mail service foxracingshox com Website www foxracingshox com Steerer Tube Rebound Adjuster Knob All FORX Compression Lockout RL amp RLC Low Speed Compression Adjuster Knob RLC Only Blow off Threshold Adjuster Knob RLC Only FLOAT Forx Features One piece Magnesium Lower Leg Double butted Aluminum Steerer PSC Precision Steering Control CLS Coil Lubrication System SDC Shimmed Damping Control Rebound Adjustment FLOAT Air Spring Technology Adjustable Travel 80 amp 100mm Brake Post NJ Dropout Air Top Cap FLOAT Preload Adjuster Knob Vanilla Fork Crown Upper Tube Lower Leg Bottom Nut Vanilla Forx Features One piece Magnesium Lower Leg Double butted Aluminum Steerer PSC Precision Steering Control CLS Coil Lubrication System SDC Shimmed Damping Control Rebound Adjustment Vanilla Coil Spring Technology Adjustable Travel 80 100 amp 125mm Table of Contents gyro e Uri o EE 4 Contact Information see 4 Service Warranty a 4 International Service Centers 4 Warranty Policy lai 5 Metho
3. Mojo Suspension 44 1633 615 815 chris porter virgin net United States FOX Racing Shox 831 768 1100 service foxracingshox com Warranty Policy The factory warranty period for your fork is one year from the original date of purchase of the bicycle or fork A copy of the original purchase receipt must accompany any fork being considered for warranty service Warranty is at the full discre tion of FOX Racing Shox and will cover only defective materials and workmanship This warranty is void when damage to the fork has occurred from the following Abuse Seal damage due to power washing Damage to the exterior finish caused by improper cable routing rocks crashes dents Any attempt to disassemble damper assembly Modifications Non Factory oil use or improper service Shipping damages or loss purchase of full value insurance is recommended To ensure peak performance repairs and service to the fork must be performed by FOX Racing Shox in the USA or outside the USA by a FOX Racing Shox Authorized Service Center FOX Racing Shox reserves the right to all final warranty or non warranty decisions Method of Payment Visa MasterCard and or Cashier s Check Method of Shipping FOX Racing Shox uses UPS Ground service within the USA Disclaimer FOX Racing Shox is not responsible for any damages to you or others arising from riding transporting or other use of your fork or bicycle In the event that your fork breaks or m
4. assembly into the upper tube Push the shaft until it approaches the bottom hole of the fork Do not push the shaft all the way through the bottom hole Step 6 Turn the fork upside down Pour 30cc of fresh FOX Suspension Fluid through the bottom hole Step 7 Push the air shaft assembly up until the shaft comes through the bottom hole Install the crush washer and bottom nut Torque to 50 in Ibs Step 8 Turn the fork right side up Pour 5cc of FOX FLOAT Fluid on top of the air piston Step 9 Lubricate the o ring on the air topcap with FOX FLOAT Fluid Re install the topcap and torque to 165 in Ibs Step 10 Air up the fork to the desired pressure and cycle it several times to check for proper operation Re install the blue air cap FLOAT amp Vanilla Forx Right Side The right leg of FOX FORX contains the damper The damper is a precision component that controls the compression and rebound of your FOX FORX If your cartridge ever loses oil be sure to complete these 9 steps to ensure that you have the proper volume of oil in the damper Use only FOX Suspension Fluid in your FOX FORX NOTE Too much oil will cause hydraulic lock out of the fork This is a serious condition and could lead to loss of control and serious or fatal injury The following tools and supplies will be needed 26mm 6 sided socket 10mm wrench 2mm hex wrench 1 5mm hex wrench torque wrench plastic faced hammer small screw driver drain pan FOX Suspension Flui
5. lever is located below the red rebound RI adjuster knob It allows the rider to close the compression damping in the fork This keeps the fork at the top of its travel and it will be hard to com press The fork is said to be locked out in this position Rotate the lever Slower clockwise to the six o clock position to achieve lock out This position is CO useful in climbing and sprinting situations The fork will blow off in the pe eren event that a big hit is encountered with the fork locked out To unlock the 6 o clock position fork simply rotate the lever counter clockwise to the three o clock position This puts the cartridge in open mode and you will have normal compres sion damping The lock out lever will rotate past the three o clock position This is normal and does not affect performance Note The fork may cycle a couple times after activating the lock out Once complete lock out is achieved the fork may continue to move 3 5mm This is normal and does not affect performance Faster Rebound A Open Lock out Compression Adjustment RLC Only Faster Compression Low speed compression damping is adjusted with the blue bezel ring below the blue lockout lever Compression damping controls the quickness with eh which the fork moves through its travel Rotate the bezel clockwise for slower Rebound harder compression and counter clockwise for faster easier compression espera There are 9 clicks of adjustment The p
6. manual will provide you with the step by step instructions of how to set up your fork It is a good idea to keep your receipts with this manual and refer to it for service and warranty issues Contact Information FOX Racing Shox Phone 831 768 1100 130 Hangar Way North America 800 369 7469 Watsonville CA 95076 Fax 831 738 9312 E mail service foxracingshox com Website www foxracingshox com Business Hours Monday Friday 8 00AM 5 00PM Pacific Time Service Warranty FOX Racing Shox is pleased to offer 48 hour turnaround for product service provided the following steps are taken 1 Contact FOX Racing Shox at 800 FOX SHOX to obtain a Return Authorization R A Number and shipping address For International Service Centers please refer to the list below or contact FOX Racing Shox to determine the Service Center nearest you 2 Satisfactory proof of purchase receipt is required for warranty consideration 3 Mark the Return Authorization Number and the Return Address clearly on the outside of the package and send item to FOX Racing Shox or your International Service Center with shipping charges pre paid by sender 4 Include a description of the problem bicycle information manufacturer year and model type of FOX product spring rate and return address with daytime phone number International Service Centers operate independently Service and Warranty turnaround times may vary International Service Centers United Kingdom
7. side of the fork is from the seated rider s perspective Important Check Before Every Ride 1 Check that quick release skewer is properly adjusted and tight 2 Clean the outside of your fork with soap and water and wipe dry with a soft dry rag Do not spray water directly on the Seal Uppertube junction DO NOT USE A HIGH PRESSURE WASHER ON YOUR FORK 3 Inspect entire exterior of fork for damage The fork should not be used if any of the exterior parts appear to be damaged Please contact your local dealer or FOX Racing Shox for further inspection and repair Check headset adjustment Adjust headset if loose according to manufacturer s recommendations Check that brake cables or hoses are properly fastened Check that the front and rear brakes operate properly on flat land S OQ Service Intervals Your FOX FORX will perform best if serviced at the regular intervals shown below After Each Every25 Every 100 Instructions sib T x let Clean Fork Seals amp Inspect ade 16 Lube Foam Rings pag Clean and Refill FLOAT Fluid in aqe 15 Air Chamber FLOAT Forx Only pag iis oe did 1L Bj iid i oe EMT UM Required Tools and Supplies Torque Settin Used for Safety Glasses n a Protecting Eyes Bucket or Drain Pan n a Changing Oil Travel Paper towels and or rags Absorbing oils amp fluids Plastic Faced Mallet n a Tap loose bottom shafts Torque Wrench n a Torque fasteners FOX Suspension Fluid n a Travel ch
8. 25 039 05 002 A 35 bin Green 80 100 125 Standard on Vanilla 100 039 05 003 A 45 Ib in Yelow 80 100 125 Standard for 80mm travel 039 05 004 A 60 Ib in 80 100 only 039 05 005 A 75 Ib in E 80 100 only EN 9 Increase spring rate Excessive bottoming of FE travel during riding pring Measured sag is too high and Preload Knob is Decrease spring rate adjusted fully clockwise Ride is too harsh and Decrease spring rate never use full travel Changing your Coil Spring 1 With a 26mm 6 point socket wrench loosen and remove the preload topcap Remove the black spring spacers two spacers for 125mm travel 1 for 100mm travel none for 80mm travel Compress the fork slightly and remove the coil spring You may need to firmly pull up on the spring to disengage it from the plunger shaft Wipe the spring dry with a rag and check the color code 2 Install the new spring by dropping it into the upper tube Install the spacer s Install and torque the topcap to 165 in Ibs 1864 N cm 3 Measure and adjust sag as described on page 10 Happy Trails FLOAT Forx Setting Sag on FLOAT Forx To get the best performance from your FOX FLOAT fork it is necessary to set and adjust sag Sag is how much the fork compresses or sags when the rider sits on the bicycle Generally this is 15 2596 of the total travel Measuring and adjusting sag 1 Install a zip tie on the upper tube and push it down until it contacts the fork se
9. al Carefully sit on the bike and assume a normal riding position The fork should compress slightly Being careful not to further compress the fork dismount the bicycle Measure the distance between the seal and the zip tie This distance is the sag 2 Compare your sag measurement to the table If your sag is lower than on the table remove the air topcap screw on the FOX High Pressure Air Pump fitting note the current air pressure setting and depress the black bleed valve to reduce the gauge pressure by 5 psi Measure sag again and repeat adjustment if necessary FLOAT F Sag Tabl orx Sag Table If your sag is higher than on the table remove the air topcap screw on the FOX High TRAVEL XC Race Freeride Pressure Air Pump fitting note the current air Sum cet pressure setting and pump to increase the gauge 12mm 20mm pressure by 5 psi Measure sag again and repeat 1 2 13 16 adjustment if necessary 15mm 25mm Air Spring Tuning on FLOAT Forx 9 16 1 Read the FLOAT Air Spring Tuning Guide chart below to see if you need to change your air pressure FLOAT Forx are tuned by changing air pressure at the left topcap See page 8 for instructions for the FOX High Pressure Air Pump FLOAT Air Spring Tuning Guide Symptom Do the following FLOAT Air Spring Guidelines Measured sag is too Increase air low pressure by 5 psi Under 125 Ibs Excessive bottoming TES RANS opsi pe OENAVAL naq s i 133414910 S S dino Haina press
10. alfunctions FOX Racing Shox shall have no liability or obligation beyond the repair or replacement of your fork pursuant to the terms outlined in the Service and Warranty provisions of this Manual Consumer Safety RIDING A BICYCLE IS DANGEROUS AND CAN RESULT IN DEATH OR SERIOUS INJURY TAKE YOUR RESPONSIBIL ITY TO YOURSELF AND OTHERS SERIOUSLY Maintain your bicycle and suspension Always wear a helmet protective clothing and eye protection Ride within your limits i Tread lightly Your bike is equipped with FOX Racing Shox suspension Before riding take the time to read the FOX Racing Shox manual on setup use and service of your fork If you have questions call your Authorized FOX Racing Shox Service Center or call FOX Racing Shox directly at 831 768 1100 If your fork ever loses oil or if it makes unusual noise stop riding immediately and have the fork inspected by a dealer Service Center or contact FOX Racing Shox RIDING WITH A BROKEN OR MALFUNCTIONING FORK CAN RESULT IN LOSS OF CONTROL CRASHING AND POSSIBLE DEATH OR SERIOUS INJURY Never modify your bike frame or fork Only use genuine FOX Racing Shox parts for your fork Any modification improper service or use of after market replacement parts will void the warranty and could damage the fork or cause loss of control of the bike resulting in serious injury or death Follow the scheduled service recommendations in this manual Always have your fork serviced by a qual
11. alified dealer Service Center or FOX Racing Shox A fork leg or drop out failure could cause loss of control and serious or fatal injuries 5 FOX FORX do not include reflectors for on road use FOX FORX are designed to be used in competitive off road riding and racing Proper reflectors meeting the Consumer Product Safety Commission s CPSC requirements should be installed if the fork will be used on public roads 6 FOX FORX have a crown steerer upper tube assembly These parts are pressed together in a one time precision press fit operation Replacement of any of these parts requires a complete new assembly Do not attempt to remove or replace the steerer or upper tubes independently of the crown DO NOT ATTEMPT TO ADD THREADS TO THREADLESS STEERERS Modifying the crown steerer upper tube assembly as de scribed here could cause the rider to lose control of the bicycle resulting in serious or fatal injuries Installation Step 1 Your FOX FORX should be installed by a qualified bicycle mechanic Forks installed improperly are dangerous and can cause loss of control and serious or fatal injuries Step 2 Remove existing fork from the bicycle Remove the crown race from the fork Measure the steerer tube length of the existing fork Transfer this measurement to the FOX FORX steerer Refer to stem manufacturer s instructions to be sure there will be enough clamping surface for the stem If it is necessary to cut the steerer tube measure
12. ange FLOAT Forx Oil change All Forx FOX FLOAT Fluid n a Travel amp Oil change FLOAT Forx FOX High Pressure Air Pump n a Setting air pressure FLOAT Forx 26mm 6 point socket 165 in Ibs 1864 N cm All Topcaps 10mm open end or socket wrench 50 in Ibs 565 N cm All Bottom Nuts 8mm Crawfoot socket wrench 80 in Ibs 904 N cm Brake Posts 3 8 Deep socket wrench 75 in Ibs 847 N cm Air Tank Valve FLOAT Forx Schrader valve core wrench 4 in Ibs 45 N cm Schrader Valve Core FLOAT Forx 2mm Hex key wrench 11 in Ibs 124 N cm Rebound Knob R RL RLC 4 in Ibs 45 N cm Blow off Threshold Knob RLC 1 5mm Hex key wrench Seated back off 1 4 turn Lockout Lever RL RLC Pump A FOX high pressure air pump is available for FLOAT Forx It is used to make changes in air pressure on your fork 1 Remove the air topcap from the top of the left fork leg 2 Thread the pump s valve chuck onto the fork s air valve until pressure registers on the pump gauge This takes approximately 6 turns Do not over tighten pump on air valve as this will damage the pump chuck seal 3 To increase the pressure stroke the pump a few cycles The pressure should increase slowly If pressure increases rapidly check to make sure the pump is properly fitted and tightened onto the air valve Note If the fork has no air pressure the gauge will not register pressure 4 To decrease the pressure push the black bleed valve Pushing the bleed valve halfway down and
13. ation of spacers Step 1 Remove the blue air cap from the top of the left fork leg Let the air out of the fork Refer to Pump Instructions for details about letting the air out with a pump Remove left top cap with a 26mm socket 6 point socket wrench Step 2 Loosen the bottom nut 3 4 turns with a 10mm wrench With a plastic mallet gently tap the bottom of the shaft to disengage it from the lower leg Allow oil to drain into a bucket Remove the bottom nut and crush washer Step 3 Compress the fork as much as possible The air piston will be visible about one inch below the top of the upper tube Push the bottom of the shaft upwards to push the air piston out of the top of the upper tube If necessary use a small screwdriver to push the bottom of the shaft up through the hole in the bottom of the lower leg Step 4 Pull the air shaft assembly from the fork Refer to the drawings below and add or remove the appropriate spacer s to achieve the desired travel NOTE FLOAT FORX can be configured for 80 or 100mm of travel Do not exceed 100mm of travel Spacers snap on to the air shaft between the Spring Guide and the Topout Plate Step 5 Lubricate the o ring on the air piston with FOX FLOAT Fluid and re install the air shaft assembly into the upper tube Push the shaft until it approaches the bottom hole of the fork Do not push the shaft all the way through the bottom hole Step 6 Turn the fork upside down Pour 30cc of FOX Suspension Flu
14. d plus a FOX High Pressure Air Pump and FOX FLOAT Fluid Step 1 Step 1a On R models simply remove the right damper side top cap with a 26mm 6 sided socket Step 1b RL and RLC models require that the adjuster knobs be removed as shown on page 14 Remove the red rebound knob by firmly holding the red knob from turning and loosen screw with a 2mm hex wrench Step 1c Remove the lock out lever with a 1 5mm hex wrench by loosening the three set screws and carefully lifting the lever Do not remove the set screws There are 3 balls in the lockout lever The 3 balls are held in place by grease Do not lose the three balls in the lock out lever Step 1d Remove the low speed compression knob on RLC models Below the low speed compression knob is a detent ball and spring which sit in a counterbore in the topcap Check that the ball is positioned in the hole by pressing on it with a small screwdriver and feeling for the force of the spring Step 1e Loosen and unscrew the damper topcap with a 26mm 6 sided socket Step 2 On RLC models remove the blue blow off threshold knob with a 2mm hex key wrench Step 3 Loosen the right side bottom nut with a 10mm wrench or socket 3 4 full turns Place a clean drain pan under the right leg and tap lightly with a plastic hammer on the nut to loosen the damper from the lower leg Unscrew and remove bottom nut and washer Push up on the shaft and let the oil drain 15 Changing Oil con t Step 4 Care
15. ds of Payment 5 Method of Shipping a 5 Disclaimer nanna eie ipte pda 5 Consumer Safety err 5 Important Safety Information 6 Installation lk 6 Tire SIZes Ia a aa de Maa agna adda 7 LIC m 7 Maintenance eec re cei Eon ask ss ar 7 Service Intervals aaa 8 PUMP sanpaolo io tete io ento iei iic e dde 8 General Set Up Instructions 9 Fork Terminology eene 9 Sag amp Spring Tuning Vanilla FOIX 2 u treten 9 FLOAT FOX iiec aio 10 Damping Adjustment Guidelines 11 Changing Travel FLOAT EOD iiie oit a deed 12 Vanilla F R reete eee 13 Changing Oil tsir aaa 14 Seals and Foam Rings sese 16 International Versions Francais i4 eif a is a eias 17 ItaliahQ uan mne ine ti tec 33 Deutsch aska aed aa 49 Espa ol M EE 65 Japanese iit aate tees Lisio dii 81 Introduction Congratulations on choosing FOX FORX for your bicycle In doing so you have chosen the best suspension fork in the industry All FOX Racing Shox products are designed manufactured and assembled by the finest professionals in the industry As a consumer and supporter of FOX Racing Shox products you need to be aware of the importance of setting up your fork correctly to ensure maximum performance This
16. emove the right cartridge side top cap with a 26mm 6 sided socket Step 1c RL and RLC models require that the adjuster knobs be removed as shown in the drawing see page 14 Remove the red rebound knob by firmly holding the red knob from turning and loosen Screw with a 2mm hex wrench Step 1d Remove the lock out lever with a 1 5mm hex wrench by loosening the three set screws and carefully lifting the lever Do not remove the set screws The 3 balls are held in place by grease Do not lose the three balls in the lock out lever Step 1e Remove the low speed compression knob on RLC models Below the low speed compression knob is a detent ball and spring which sit in a counterbore in the topcap Check that the ball is positioned in the hole by pressing on it with a small screwdriver and feeling for the force of the spring Step 1f Loosen and unscrew the damper topcap with a 26mm 6 sided socket Step 2 Compress fork slowly until the travel spacers are exposed on the damper side Pull the damper topcap up until it stops Snap on or off the correct length spacers to match the orientation shown in the Travel Spacer Diagram see page 14 If removing spacers from the cartridge make sure to keep them in a safe place for future use Step 3 Step 3a Extend the fork by pulling down on the lower leg Push down on the damper topcap and carefully thread into upper tube Torque to 165 in lIbs Step 3b Re install adjuster knobs On RLC models instal
17. fully pull the damper from the fork It will still contain oil Step 5 Place the damper upright in a deep bucket and carefully cycle the shaft up and down several times to pump out the remaining oil Gently shake the damper to check whether it is empty Step 6 When the damper is empty pull it to its maximum length and install it into the fork Install the crush washer and bottom nut and torque to 50 in Ibs Step 7 Measure 160cc of fresh FOX Suspension Fluid and pour it into the right fork leg Add it slowly to avoid overflowing and spillage Step 8 Push down on the damper topcap and thread it carefully into the upper tube Torque to 165 in Ibs Step 9 Step 9a Re install adjuster knobs On RLC models install the low speed compression knob so that the groove on the bottom is positioned over the aluminum pin in the topcap Step 9b On RL and RLC models install the lockout lever onto the hex and rotate clockwise until it stops It may take multiple rotations to seat the lockout shaft Orient the lever so the lockout tab faces approximately the six o clock position While pressing the lockout lever down lightly tighten the three set screws Back each screw off 1 4 turn Step 9c On all models install red rebound knob so that the slot feature on the bottom is aligned with the flats on the center of the rebound shaft Apply blue loctite to screw and tighten with 2mm hex wrench while holding red rebound knob from spinning Warning Dampe
18. he upper tube and push it down until it contacts the fork seal Carefully sit on the bike and assume a normal riding position The fork should compress slightly Being careful not to further compress the fork dismount the bicycle Measure the distance between the seal and the zip tie This distance is the sag 2 Compare your sag measurement to the table If your sag is lower than on the table turn the preload knob counter clockwise one 1 full turn Measure sag again and repeat adjustment if necessary If your sag is higher than on the table turn the preload Vanilla Forx knob clockwise one 1 full turn Measure sag again and Sag Table repeat adjustment if necessary If correct sag cannot be achieved by adjusting the preload knob 16mm 5 8 see the Spring Tuning Guide below Spring Tuning on Vanilla Forx 20mm 13 16 Read the Vanilla Spring Tuning Guide chart below to see if you need to change your x spring rate Vanilla Forx are tuned by changing only the left side coil spring 25mm 1 The coil spring has a painted color code stripe on one end of the spring Refer to the chart to select the optimum spring Vanilla Forx Spring Chart Vanilla Spring Tuning Guide Spring Color Travel FOX Part Notes Measured sag is too low 039 05 000 A 10 Ib in 80 100 125 and Preload Knob is adjusted fully counter clockwise 039 05 007 A 18 Ib in Purple 80 100 125 039 05 001 A 25 Ibn Blue 80 100 125 Standard on Vanilla 1
19. holding it there will allow pressure to escape from the pump and fork Pushing the bleed valve all the way down and releasing it will release a small amount of pressure micro adjust When unthreading the pump from the air valve fitting the sound of the air loss is from the pump hose not the fork itself Note When attaching the pump to the fork the hose will need to fill with air This will result in a lower pressure registering approximately 10 to 20 PSI on the gauge Note Average setting range is from 45 to 125 PSI DO NOT EXCEED 200 PSI 5 Replace the air topcap before riding General Set Up Instructions Fork Terminology Travel The total amount the fork compresses Sag The amount the fork compresses with the rider sitting on the bike in a normal riding position Compression Damping This controls the rate at which the fork compresses Rebound Damping This controls the rate at which the fork extends Preload The initial force place on a spring Spring Rate The amount of force required to compress a spring one inch FLOAT This is FOX air spring technology Vanilla This is FOX coil spring technology Vanilla Forx Setting Sag on Vanilla Forx To get the best performance from your FOX Vanilla fork it is necessary to set and adjust sag Sag is how much the fork compresses or sags when the rider sits on the bicycle Generally this is 15 25 of the total travel Measuring and adjusting sag 1 Install a zip tie on t
20. id through the bottom hole Step 7 Push the air shaft assembly up until the shaft comes through the bottom hole Install the crush washer and bottom nut Torque to 50 in Ibs Step 8 Turn the fork right side up Pour 5cc of FOX FLOAT Fluid on top of the air piston Step 9 Lubricate the o ring on the air topcap with FOX FLOAT Fluid Re install the topcap and torque to 165 in Ibs Step 10 Air up the fork to the desired pressure and cycle it several times to check for proper operation Re install the blue air cap 80mm 100mm Bottom Nut and Crush Washer S Air topcap Air piston Air Shaft Assembly Negative Negative n 20mm Travel Spring Spring ft ER Spacer Plate Ti Retainer E EI Ld ma Q L L 12 FLOAT Forx Travel Spacer Diagram Changing Travel Vanilla Forx FOX FORX travel can be changed by rearranging the travel spacers as shown in the drawings below After changing travel check the fork for proper operation before riding If there is free movement in the fork or if it makes strange noises disassemble the fork and check for complete number and correct orientation of spacers The following tools and supplies will be needed 26mm 6 sided socket 10mm wrench 2mm hex wrench 1 5mm hex wrench torque wrench plastic faced hammer small screw driver drain pan FOX Suspension Fluid Step 1 Step 1a Remove the left spring side top cap with a 26mm 6 sided socket Step 1b On R models simply r
21. ified bicycle mechanic dealer or Authorized FOX Racing Shox Service Center Important Safety Information 1 Verify that the brakes are installed and adjusted properly before riding the bicycle Improperly installed or adjusted brakes can cause loss of control and serious or fatal injuries to the rider Use only V style or hydraulic cantilever brakes or disc brakes designed by the manufacturer for use on FOX FORX Do not use brace mounted cable leverage devices Do not route brake cables or housing through the stem 2 If your fork loses oil tops out excessively or makes unusual noises immediately stop riding and contact FOX Racing Shox or an Authorized FOX Racing Shox Service Center for inspection Continued use of the fork could cause loss of control and serious or fatal injuries 3 Use only FOX Racing Shox replacement parts Using aftermarket parts on FOX FORX will void the warranty Aftermarket replacement parts could also cause structural failure resulting in loss of control and serious or fatal injuries 4 If mounting the bicycle in a carrier designed to hold a fork by its drop outs use caution to not tilt the bicycle to either side Tilting the bike with the drop outs in the carrier can cause structural damage to the fork Ensure that the fork is fastened securely with the quick release and that the rear wheel is properly held If the bicycle ever tilts or falls from a bicycle carrier do not ride it until it is examined by a qu
22. l the low speed compression knob so that the groove on the bottom is positioned over the aluminum pin in the topcap Step 3c On RL and RLC models install the lockout lever onto the hex and rotate clockwise until it stops It may take multiple rotations to seat the lockout shaft Orient the lever so the lockout tab faces approximately the six o clock position While pressing the lockout lever down lightly tighten the three set screws Back each screw off 1 4 turn Step 3d On all models install red rebound knob so that the slot feature on the bottom is aligned with the flats on the center of the rebound shaft Apply blue loctite to screw and tighten with 2mm hex wrench while holding red rebound knob from spinning Warning Damper internals will be damaged if the rebound knob is not held turning while the screw is tightened Step 4 Loosen the left spring side with a 10mm wrench or socket 3 4 full turns Place a clean drain pan under the left leg and tap lightly with a plastic hammer on the nut to loosen the plunger from the lower leg Unscrew and remove bottom nut and washer Push up on the shaft and let oil drain Step 5 Make sure all oil is drained from left side leg and right topcap is tight Turn bike upside down and push out plunger shaft Step 6 Looking at the Travel Spacer Diagram add or remove spacers between the black negativespring guide and the aluminum coil insert Spacers snap onto the shaft Slide the black negative spring g
23. ll be visible just inside the lower legs They should be soaked with oil and should not contain any dirt or debris If the foam rings are dry use a few cc s of FOX Suspension Fluid to saturate them Step 5 Wipe the upper tubes and slide the seals down into the lower legs Carefully press the seals into place A thin flat bladed screw driver can be used to press in between the upper tube and the fork brace It is recommended that the blade of the screw driver be covered with tape or a rag to prevent damage to the seal Inspect that seal is firmly seated against top surface of the lower leg Step 6 Wipe off any excess oil and cycle the fork a few times to check for proper operation p n 605 00 003 A 2001 FOX Racing Shox Inc FOX Forx Owner s Manual The information herein is provided as a guide 16 FOX Racing Shox reserves the right to change all or part without notice
24. r internals will be damaged if the rebound knob is not held turning while the screw is tightened Step 10 Cycle the fork several times and run the adjusters through their full ranges of adjustment You should feel damper fill with oil after several cycles Adjust all damper settings to your preferences and head out for a nice ride Seals and Foam Rings FOX FORX feature a sealing system designed to keep your fork moving smoothly in all conditions There are two parts to the System the fork seal and the foam ring The fork seal features a proprietary scraper lip geometry that keeps dirt out and oil in the fork The foam ring sits just below the fork seal It is saturated with oil and in turn applies oil to the upper tube as it passes by This keeps the fork moving up and down smoothly While FOX FORX are designed to require minimal mainte nance periodic inspection and cleaning of the fork sealing system is recommended Step 1 Around the perimeter of the fork seals are small notches Use a small flat blade screw driver in these slots to gently pry the seal from the lower legs of the fork Once loose raise them all the way up to the crown on the upper tubes Step 2 Wrap a clean rag around the junction of the upper tubes and the lower legs This will keep dirt out while the seals are being cleaned Step 3 Use a rag to wipe around the outside diameter of the seal Wipe until clean Step 4 Remove the rags and check the foam rings which wi
25. roper setting is a personal preference ei and varies depending on your weight and riding style Determining the proper compression setting may take a few rides to fine tune On those first few rides adjust the compression and note the different ride characteristics Your compression damping setting may change with different riding conditions As a starting point for tuning your compression turn the bezel clockwise until it stops the back off 5 clicks RLC Blow off Threshold Adjustment RLC Only FLOAT RLC and Vanilla RLC feature Blow off Threshold Adjustment capabilities It is adjusted with the blue knob located at the bottom of the right fork leg This gives the rider the ability to adjust the force required to cause the fork to blow off when it is in the locked out position Turn the knob clockwise to make it harder to blow off and counter clockwise to make it easier There are twelve 12 clicks of adjustment in Enver Birao the full range of motion As a starting point for tuning your blow off threshold turn the knob all the way clockwise until it stops then back off one click RLC 11 Changing Travel FLOAT Forx FOX FORX travel can be changed by rearranging the travel spacers as shown in the drawings below After changing travel check the fork for proper operation before riding If there is free movement in the fork or if it makes strange noises disassemble the fork and check for complete number and correct orient
26. twice and cut once It is also recommended that a cutting guide be used while cutting the steerer tube Step 3 Use a crown race setter to install the crown race firmly against the top of the crown Install the star fangled nut in the steerer tube This should be done with a star fangled nut installation tool Step 4 Install the fork on the bicycle The headset should be adjusted so it turns freely without drag or free play Step 5 Re install the brakes and adjust the brake pads Refer to the brake manufacturer s instructions Step 6 Mount the front wheel being sure that the quick release nuts sit in the fork drop out counter bores The quick release should engage four 4 or more threads Close the quick release with the lever in front of and parallel to the left fork leg Tire Sizes FOX FORX will accept tires sizes up to 2 40 inches wide e g WTB MotoRaptor 55 60 26 x 2 40 Any tire larger than 26 x 2 30 must be checked for clearance by the following method Q D XS QOO A VI AI x X Q 0 9 XS A OX XX Determining Tire Size With the tire installed and inflated on the rim measure the following three dimensions XY VA XXX AMA 7 4 Q x Maximum Peak Tire Diameter Maximum Maximum Peak Tire Diameter 343mm 27 00 inch Edge Tire Maximum Edge Tire Diameter 326mm 25 67 inch Diameter Maximum Tire Width 61mm 2 40 inch XXOQQQO OK RK
27. ube seal junction and try the same thing Once again there should be no free movement If any movement is noticed refer to page 4 of this manual and contact FOX Racing Shox or and Authorized FOX Racing Shox Service Center Changing Oil Vanilla Forks Left Side The left leg of FOX Vanilla Forx contain the parts shown on the Vanilla Travel Spacer Diagram The following tools and supplies will be needed 26mm 6 sided socket 10mm wrench 2mm hex wrench 1 5mm hex wrench torque wrench plastic faced hammer small screw driver drain pan FOX Suspension Fluid Step 1 Remove the Preload Topcap with a 26mm socket wrench Remove all of the travel spacers from the top of the main spring Step 2 Loosen the bottom nut 3 4 full turns with a 10mm wrench Place a drain pan under the fork leg and then lightly tap the bottom nut with a plastic faced hammer to loosen the shaft from the lower leg Remove bottom nut and crush washer Push plunger shaft up into the lower leg with a small screwdriver and let the oil drain from the fork leg Step 3 With all the oil drained use the small screwdriver to carefully guide the plunger shaft back down through the hole in the bottom of the lower leg Install the crush washer and bottom nut Torque bottom nut to 50 in Ibs Wipe excess oil from exterior of fork with a towel Step 4 Pour 30cc of FOX Suspension Fluid into the top of the left upper tube Step 5 Install travel spacers on top of main spring Carefull
28. uide up against the spacers Step 7 Reinstall the plunger shaft spring and spacers into the left fork leg and install the crush washer and bottom nut Torque the bottom nut to 50 in Ibs Step 8 Pour in 30cc of new FOX Suspension Fluid or re use oil from clean drain pan into the left upper tube Step 9 Install left top cap and torque to 165 in lbs Step 10 Cycle the fork several times to check for proper operation before riding If there is free movement in the fork or if it makes strange noises disassemble fork to check for complete number and orientation of spacers 13 Changing Travel Vanilla Forx con t 80mm 100mm 125mm Adjuster Knobs Preload Aa F Topcap n 20mm Travel 25mm All Forx Miu dr 20mm VA z Main z Spring RL RLC 25mm f RLC Only Negative 20mm 2 Spring Guide m Plunger 20mm 25mm Shaft f 20Mm Vanilla Forx Travel Spacer Diagram Bushings Bushings should be checked annually for excessive wear If fore and aft movement is detected between the upper tubes and lower legs contact an Authorized FOX Racing Shox Service Center or FOX Racing Shox for further instructions Grasp the lower legs at the drop outs axle Push the fork straight back towards the rear wheel Then pull it towards you There should not be any free movement or clicking sounds Next grasp the fork near the upper t
29. ure by 5 psi pel Measured sag is too Decrease air high pressure by 5 psi 155 170 Ibs Ride is too harsh and Decrease air 170 185 Ibs pressure by 5 psi never use full travel 200 215 Ibs 105 psi 215 230 Ibs 115 psi 10 230 250 Ibs 125 psi Damping Adjustment Guidelines Rebound Adjustment R RL RLC FOX FORX feature a rebound adjuster This allows the rider to control the speed at which the fork extends after compression The Rebound Adjustment Knob is the red knob located on top of the right fork leg Turn it clockwise for slower rebound and counter clockwise for faster rebound There are 12 clicks Slower of adjustment in the full range of motion The proper rebound setting is a Rebound personal preference and varies depending upon spring preload spring rate and riding style Rebound should be as fast as possible without kicking back If the rebound is too slow the suspension will not function properly and the wheel will not follow the changing terrain Determining the proper rebound setting may take a few rides to fine tune On those first few rides adjust the rebound and note the different ride characteristics Your rebound adjustment may change for different riding conditions As a starting point for tuning your rebound adjustment turn the rebound adjuster knob all the way clockwise until it stops then turn counter clockwise 6 clicks Faster Compression Lock out Lever RL RLC IE The blue compression lock out
30. y thread Preload Topcap into upper tube and torque to 165 in Ibs FLOAT Forks Left Side The left leg of FOX FLOAT Forx contains the parts shown on page 12 in the FLOAT Forx Travel Spacer Diagram The following tools and supplies will be needed 26mm 6 sided socket 10mm wrench 2mm hex wrench 1 5mm hex wrench torque wrench plastic faced hammer small screw driver drain pan FOX Suspension Fluid plus a FOX High Pressure Air Pump and FOX FLOAT Fluid 44 Changing Oil con t Step 1 Remove the blue air cap from the top of the left fork leg Let the air out of the fork Refer to Pump Instructions for details about letting the air out with a pump Remove left top cap with a 26mm socket 6 point socket wrench Step 2 Loosen the bottom nut 3 4 turns with a 10mm wrench With a plastic mallet gently tap the bottom of the shaft to disengage it from the lower leg Allow oil to drain into a bucket Remove the bottom nut and crush washer Step 3 Compress the fork as much as possible The air piston will be visible about one inch below the top of the upper tube Push the bottom of the shaft upwards to push the air piston out of the top of the upper tube If necessary use a small screwdriver to push the bottom of the shaft up through the hole in the bottom of the lower leg Step 4 Pull the air shaft assembly from the fork Clean and dry assembly Step 5 Lubricate the o ring on the air piston with FOX FLOAT Fluid and re install the air shaft
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