F2. 9 RLC/RLNote: Before you jump into the service procedures, be sure that you understand. FOX 2. 00. 8 F2. 9 fork, each having a unique rake specification: the after market (AM) model, with 4. TREK- Fisher original equipment (OE) model, with 5. Note: Some of these photos, while adequately serving to demonstrate service procedure, may not accurately show the fork model. Before starting the following procedure, open this diagram to view a graphic cross- sectional overview of the RLC topcap hardware.
Remove the RLC Topcap. With a. hex key wrench, remove the hex key on top of the red rebound knob. Note: Before removing the RLC topcap, you must first remove the rebound knob, lockout lever, and the low- speed compression knob. Then, remove the nut at the bottom of the fork leg. Remove the rebound knob.
Using a hex key. wrench, loosen but do not remove the three set screws on top of the lockout. Lift up and remove the. If it will not come off, you may need to loosen the set.
Lift up and remove the. After all the controls. The pin does not need to be removed.
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FLOAT RL. Note: Some of these. and install new ones from the FOX 32 mm dust wiper kit. see the 2007 32 mm RL and RLC cartridge servicing procedure. F29 RLC/RL. Note: Before you. and install new ones from the FOX 32 mm dust wiper kit. click this link to open the 2007 32 mm RL and RLC cartridge servicing procedure. Cycling Plus is the manual for the modern road cyclist. Fox F120 RLC. especially when Fox has basically stretched a race fork that wasn’t particularly stiff in the first place.
Using a dental pick. Also remove the spring that is underneath the. Unscrew—but do not remove—the damper topcap with a 2. Tip: You may opt to grind down the socket as shown below, to improve its meshing with the wrench flats of the topcap. Leave the topcap assembly.
Secure your fork so that the fluid inside of the fork does not spill. After loosening the RLC topcap assembly, you are. RLC damper assembly from the lower leg assembly. Place an oil pan underneath the fork before loosening. Make sure the topcap assembly is screwed in a.
You will not want suspension fluid spilling all over your. Hush Puppies. Remove the Lockout Force Threshold Knob. Using a 1. 5 mm hex key wrench, loosen—but.
Once the bolt is loose enough, remove the knob. Remove the RLC Damper. Using a 1. 0 mm socket, remove the bottom nut. Screw the bottom nut back on until it is flush. This is to protect the adjuster rod. Using a plastic faced hammer, gently strike the.
Holding the fork over an oil pan, remove the bottom. If the crush washer isn't attached to the nut, check.
Suspension fluid. Making sure the fork is right- side up, remove.
Pull up on the topcap and remove the RLC damper. Note: The photo shown below may not match the product exactly. Remove the Air Topcap.
Note: Before removing the air topcap, you must release. CAUTION: There is a small amount of FLOAT Fluid in the. This fluid can shoot out at high speeds when depressing the. Schrader valve. Cover the Air Topcap assembly with a rag when depressing. Schrader valve. Remove the aircap. While holding a rag over. Schrader valve to release air pressure.
Unscrew—but do not. Be careful not to slip and damage. Tip: You may opt to grind down the socket as shown below, to improve its meshing with the wrench flats of the topcap.
Leave the topcap assembly. Secure your fork so that the fluid inside of the fork does not spill.
After loosening the air topcap, you are now ready. Place an oil pan underneath the fork before loosening.
Make sure the air topcap is screwed in a few turns. Remove the 3. 2 mm Air Spring. Using a 1. 0 mm socket, remove the bottom nut. If. the washer is not stuck to the bottom of the lower leg, check the inside. Screw the bottom nut back on until it is flush.
You should be able to push down on the. If you cannot dislodge the damper by pushing down. Both the damper shaft and air spring shaft should. Remove the air spring from the upper tube. Remove the Crown Steerer Assembly. If the damper and spring assemblies are still. Unscrew the topcap assembly from the crown and lift. The upper tubes and steerer tube are pressed into.
The crown steerer assembly is not a serviceable item; any deformation of this assembly. Both the damper shaft and air spring shaft. Drain the lower leg assembly into an oil pan before putting. Clean the crown steerer assembly. Inspect the. assembly for any nicks, cuts, scrapes, scratches or gouges, and replace.
The assemblies that normally prevent the removal. Removal of the lower legs should be done with. Remove the 3. 2 mm Lower Assembly. Making sure the fork. Remove the topcap assemblies. If not already done.
Gently pull up on the. Drain any remaining fluid. After removal of the lower assembly, it is best practice to replace the dust wipers and foam rings. When possible, the bicycle/fork should be stored. Remove the Dust Wipers from the Lowers. Using an open- end wrench. Be careful not to scratch the inner surface of the lower.
After the dust wipers. Lift them out of the lower. If they cannot be located, check under the dust wipers; they might. Tip: You can get a general sense of the condition of the fork by examining. Dry foam rings indicate a lack of fluids or, possibly. Dirty foam rings may indicate a faulty dust wiper. In either condition.
If the anodizing. Lower Leg Bushings: FOX Racing Shox recommends that you have your bushings serviced at a Factory Authorized Service Center. Refer to http: //www. Bottom- out Bumpers: Bottom- out bumpers are technically not a serviceable item.
CDATA[ ]]>Dropouts: Replacing the Dust Wipers. Discard the original dust wipers and foam rings. FOX 3. 2 mm dust wiper kit (PN 8.
Presoak the new foam rings in 1. Place the oil- soaked foam rings in the lower legs as shown. Install the new dust wipers over the foam rings and seat them fully into place using thumb pressure, as shown. You can apply a thin coat of oil to the sides of the dust wipers, to ease their installation. Note: be sure to seat the dust wipers into the lower assembly completely and evenly. Damper Cartridge Service. For specific service instructions for internal assemblies, click this link to open the 2.
RL and RLC cartridge servicing procedure. Note: Before proceeding from this point, be sure that you have drained all oil from the damper cartridge. Go to for more information about this procedure. Install the 3. 2 mm Air Spring and Lower Assembly. Grease the threads on the upper tube. Drop the air spring into the upper tube. While tilting and gently pressing the upper tubes into the lower leg assembly, push past the newly installed dust wipers and foam rings, sliding the.
Tip: slightly stretching the outer lip of the dust wipers in this step won't risk damaging them. Turn the fork upside- down. FOX suspension oil through the hole in the bottom of the lower leg.
Consult the Oil Volumes table for suspension oil weight and amount specifications per fork year and model. Push the air shaft until it protrudes from. With a new crush washer.
Tighten the bottom nut to 5. N- m) torque with. Turn the fork right- side up and place 5 cc of FLOAT.
Fluid (one pillow pack) into the left upper tube. Install the Air Topcap.
Tighten the damper topcap. N- m) torque with a 2. Be careful not to.
Remove the air topcap. Using a FOX High Pressure. Pump, inflate the spring- side topcap Schrader valve to between 4. Consult the table below. CAUTION: Never exceed 2. AIR SPRING SETTING guidelines. Rider Weight. Air Pressure< 1.
Screw on the air topcap. Install the RLC Damper. Insert the damper assembly into the right upper. Make sure the adjuster shaft protrudes from the bottom of the lower. Place a new crush washer on the end of the adjuster.
Screw on the bottom nut. Using a torque wrench. N- m) torque. Turn the fork right- side up and pull up on the. FOX suspension oil into the right upper tube. Consult the Oil Volumes table for suspension oil weight and amount specifications per fork year and model.
Screw the topcap assembly. N- m) torque with a 2. Install the RLC Topcap. Before starting the following procedure, open this diagram to view a graphic cross- sectional overview of the RLC topcap hardware.
Place the spring the. Place the low- speed compression. Align the multiple divots with the ball bearing.
Place the lockout lever. Using the lever as a wrench. Take the lever. off, replace it and turn again until you are sure that you have turned. Remove the lever one more time and. Turning the lever counterclockwise will unlock the fork. However, note that the fork will mechanically be locked out once the lever. Using a 1. 5 mm hex key.
Do not. over- tighten these set screws; doing so will damage the lockout lever, and. Over- tightening the screws cause.
To be safe, lightly tighten the screws, then. Turn the lockout lever and check for proper, smooth. Place the rebound knob. The lever and adjuster shaft are indexed. Using a 1. 3 mm (0.
Install the Lockout Force Threshold Knob. Place the knob on to the adjuster shaft. Align. the set screw on the knob with the divot on the end of the adjuster shaft.
Using a 1. 5 mm hex key wrench, tighten the set screw.