There are many myths associated with the service of Fox suspension forks. Often you read that if you delve into the inner workings of the forks you will no longer be covered by a warranty! This is utter Nonsense! Forks need attention and according to Fox they are glad if everybody with the confidence to service their own fork, does it. It is very important that the fork get’s serviced regularly!
To this end, Fox recommends a service period every 30-hours of riding. Because Fox is a global company, and their products have to prove themselves all over the world, they have opted for this conservative service interval
We will now talk you through a basic lower leg service, often all that is needed to get your fork running sweet again. It is up to the rider, if he would like to replace the dust seals every service or only when they are damaged.
Fox sells the special tools that are needed for the maintenance of the fork on there website. However, for this basic service you can manage just fine with some regular tools.
2 mm Allen Key
10 and 15 mm sockets plus ratchet, ideally a torque wrench
FOX Suspension Fluid 10 WT green
Possible Dust Wiper Set
Possible Fox Leg Seal Driver Tool
Special Tool to protect the rebound adjuster / Or you can make do with a bit driver from a power tool
The Fox Tools
But it works well with simpler tools too. For example, replacing the special tool with a bit driver special tool.
For the service green lubricating oil as well as the optional new dust seals are required.
At the beginning the rebound adjuster knob gets removed with a 2mm Allen key.
Subsequently, the bolt underneath can be undone.
In contrast to the RockShox these can now be removed.
The process is repeated on the opposite side with a 10 mm nut.
The special tool is now screwed onto the damper side to protect the rebound adjustment needle.
Alternatively, here also a bit holder, or any other tool matching the diameter of the bolt, could be used.
This adjuster has to be protected.
On the opposite side, this protection is not necessary. Here you can directly use the rubber hammer.
Order makes it easier. We recommend to keep parts in the order they are removed from each side.
Now the lower assembly can be drawn downward. NOTE: Oil will now pour out, this has to be collected and disposed of properly.
Following the foam rings are removed from beneath the dust seals.
If the dust seals are not be replaced it is important to clean the foam rings.
Thus, the foam rings are soaked properly with oil, insert directly into the green fork oil.
The casting should be held upside down for cleaning so that no dirt can fall into it.
An old toothbrush is wonderful for a thorough cleaning.
If the dust seals are damaged they must be replaced, a big wrench helps to remove them.
It requires quite a bit of force to remove it from the casting.
When pressing the new seal into the fork, Fox offers a special tool. But you can use what ever helps you to push them back in.
IMPORTANT: The dust wiper has to be completely flush with the casting.
The oil-soaked rings are re-inserted.
And find a place within a recess below the dust seal.
The lower assembly can now be pushed back over the stanchions again.
For the lubrication, the fork gets refilled with the matching green fork oil. The exact amount of oil for each model can be found here HERE
The lubricating oil gets injected into the bottom of the lower assembly.
Now the bottom nuts can be replaced after the crush rings again.
The seal on the air side should always be exchanged for a new one. This one is included in the dust seals package.
Important is the correct seating of the seal. They should not be squeezed by the bolt.
According to Fox the torque is 6 Nm.
After the rebound adjuster is placed back in position the service is done and the fork is ready for the trail again!
We continue next Monday with the next exciting topic for your bike!
Words: Christoph Bayer / Trevor Worsey Picutres: Christoph Bayer
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