Step 1

Remove the blue air cap and cover the air valve with a rag as you release the air pressure. 

Step 2

Use a 2mm hex wrench to unthread the set screw in the red rebound knob. Remove the knob and set it aside. 

Step 3

Use a 10mm socket to unthread and remove the air side bottom nut. Remove and discard the original crushwasher.

Step 4

Use a 15mm socket to remove the damper side bottom nut. Make sure to remove and discard the orginal crushwasher which may be stuck to the bottom nut.

Step 5

Use Damper Removal Tools 398-00-681 and 398-00-682 to dislodge the shafts from the lowers. Make sure that you have approximately half of the available threads engaged with your tool before striking with your mallet. Remove the damper removal tools, then bring the fork upright over an oil basin to drain. After oil stops draining from the lowers, pull the lowers off of the upper tubes and set them aside.

Step 6

With a chamfer-less 6-point 28mm socket, unthread the topcap (counter-clockwise) then pull up to remove. Pour out any Float Fluid from the air chamber into your oil drain.

Step 7

Push the air shaft into the upper tube, then remove the retaining ring.

Step 8

Pull the original air shaft assembly out of the upper tube. Your original FLOAT air spring system may appear different than that shown. Clean the inside of the upper tube with Isopropyl alcohol, a lint-free paper towel, and a wooden or plastic dowel.

Step 1

Turn the TALAS adjuster to the short travel setting. Remove the blue air cap and cover the air valve with a rag as you release the air pressure.

Step 2

Use a 2mm hex wrench to unthread the set screw in the red rebound knob. Remove the knob and set it aside. 

Step 3

Use a 15mm socket to remove the damper side bottom nut. Make sure to remove and discard the orginal crush washer which may be stuck to the bottom nut.

Step 4

Use a 10mm socket to unthread and remove the air side bottom nut. Remove and discard the original crushwasher.

Step 5

Use Damper Removal Tool 398-00-682 to dislodge the damper-side shaft from the lowers. Make sure that you have approximately half of the available damper-side threads engaged with your tool before striking with your mallet. No tools are needed for dislodging the TALAS 4 shaft from the lowers. Remove the damper removal tool, then bring the fork upright over an oil basin to drain. After oil stops draining from the lowers, pull the lowers off of the upper tubes and set them aside.

Step 6

Use a 1/16in hex wrench to fully unthread (counter-clockwise) the two set screws from the blue TALAS lever. Lift the blue lever to remove it.

Step 7

Remove the retaining ring from within the topcap. Lift straight up on the Schrader valve to remove the inner TALAS assembly from the topcap. If difficult to pull up, push down once on the Schrader valve to loosen it up and make pulling up easier.

Step 8

With a chamfer-less 6-point 28mm socket, unthread the topcap assembly (counter-clockwise) then pull up to remove. Pour out any Float Fluid from the air chamber into your oil drain.

Step 9

Push the lower TALAS air shaft up into the upper tube to access the retaining ring. Remove the retaining ring.

Step 10

Pull the lower TALAS air shaft assembly out of the upper tube. Clean the inside of the upper tube with Isopropyl alcohol, a lint-free paper towel, and a wooden or plastic dowel.

Step 1

Remove the blue air cap and cover the air valve with a rag as you release the air pressure. 

Step 2

Use a 2mm hex wrench to unthread the set screw in the red rebound knob. Remove the knob and set it aside. 

Step 3

Use a 10mm socket to unthread and remove the air side bottom nut. Remove and discard the original crushwasher.

Step 4

Use a 15mm socket to remove the damper side bottom nut. Make sure to remove and discard the orginal crushwasher which may be stuck to the bottom nut.

Step 5

Use Damper Removal Tools 398-00-681 and 398-00-682 to dislodge the shafts from the lowers. Make sure that you have approximately half of the available threads engaged with your tool before striking with your mallet. Remove the damper removal tools, then bring the fork upright over an oil basin to drain. After oil stops draining from the lowers, pull the lowers off of the upper tubes and set them aside.

Step 6

Hold the lever in the short travel position while you unthread (counter-clockwise) the tank valve nut with a 7/16in (11mm) socket. Remove the blue TALAS lever. 

Step 7

With a chamfer-less 6-point 28mm socket, unthread the topcap (counter-clockwise) then pull up to remove the entire TALAS 5 assembly. Clean the inside of the upper tube with Isopropyl alcohol, a lint-free paper towel, and a wooden or plastic dowel.

Step 1

Open the new dust wiper kit and soak the new foam rings from the Dust Wiper kit in a small cup of FOX 20wt. Gold bath oil.

Step 2

Using a wooden or plastic dowel is the recommended method for removing the dust wipers and foam rings. If you choose to use a wrench or other metallic tool, use extra caution not to scratch the inner wall of the magnesium lower leg, as you lever out the dust wiper. Do this by making sure the tip of your metallic tool is cushioned from the magnesium lower leg by the foam ring, just below the dust wiper.

Step 3

Repeat the process on the other side, turning your wrench or dowel so you are levering across the fork for best stability. Discard the original foam rings and dust wipers as they are not reusable once removed due to potential distortion.

Step 4

Thoroughly clean the seal bore and the inside of the lower legs with warm soapy water or Isopropyl alcohol. Blow the lowers dry with clean compressed air. Install new foam rings soaked in FOX 20wt. Gold Oil.

Step 5

Use a small amount of FOX 20wt. Gold oil to coat the outside ribs and exposed metal base of the new dust wiper. Rest the oiled wiper on top of the seal bore as level as possible. Position your lower leg seal driver on the wiper using the tool to keep the wiper level.

Step 6

While holding the lower leg driver straight and level, tap the driver with a plastic faced mallet until the wiper is flush with the edges of the seal bore.

Step 7

Verify correct installation of the dust wipers. Wipers should be flush with the top of the seal bore. Do not drive wipers past the seal bore.

Step 8

Remove the travel indicator o-ring from the air side upper tube and replace it with the new one from the kit. There is no need to lubricate this o-ring as lubrication on external parts can attract dirt and debris from the trail.

Step 1

Coat the first 2 inches (50mm) of the inside of the air side upper tube with a thin film of Slick Honey. Grease the Piston and Piston Shaft above the Negative Plate with Slick Honey.

Insert the Air Shaft Assembly into the upper tube, seating the Negative Plate Tube fully into the upper tube to expose the retaining ring groove.

Step 2

Install the retaining ring. Pull on the air shaft to verify proper retaining ring installation.

Step 3

Coat the Transfer Shaft with a thin film of Slick Honey. Insert the Transfer Shaft into the center of the Piston Bolt. Use a chamfer-less 6-point 28mm socket to tighten the Topcap to 220in-lb (24.8 Nm) torque.

Step 4

Pressurize the air chamber to 50psi before installing the lower legs. Install the blue air cap and clean the exterior of your fork.

Step 5

Install the Lower Leg Assembly onto the upper tubes. Inject the approprate amount of FOX 20wt. Gold oil into each leg through the bottom hole.

Damper-side bath oil volumes specific to your fork can be found under "Fork- Basic Maintenance" by clicking: All Service Procedures »

Step 6

Install a new crushwasher on each side followed by the appropriate bottom nut. Torque both bottom nuts to 50in-lb (5.7 Nm). 

Step 7

Use a 2mm hex wrench to install the red rebound knob. Make sure that the set screw lines up with the depression in the rebound adjuster shaft. Clean the exterior of your fork.

Step 8

After assembly you must compress the fork 3-5mm into its travel very slowly. Repeat until you feel/hear the chamber pressures equalize. Clean the exterior of your fork.