2014-2017 TALAS 5 Air Seal Replacement

Required Parts

Required Tools

  • 398-00-681 2002-017 32 Damper-side and ALL 32-34-36-40 Spring-side Removal Tool
  • 398-00-702 Tooling: Fork Topcap Socket, 26mm, 3/8 Drive
  • 398-00-704 Tooling: Fork Topcap Socket, 28mm, 3/8 Drive
  • 398-00-705 Tooling: Fork Topcap Socket, 32mm, 3/8 Drive

Supplies Needed

  • 10mm Socket
  • 7/16" Socket
  • Mallet
  • Ratchet
  • Seal Pick
  • Torque Wrench
  • Waste Oil Basin

WARNING: FOX products should be serviced by a qualified bicycle service technician, in accordance with FOX specifications. If you have any doubt whether or not you can properly service your FOX product, then DO NOT attempt it. Improperly serviced products can fail, causing the rider to lose control resulting in SERIOUS INJURY OR DEATH.

This procedure guides you through the replacement of air seals in any TALAS 5 system. For additional information and assembly drawings specific to your model please go to the appropriate page below:

PARTLIST - FORK- 2014 32mm TALAS 5 26/27.5 »

PARTLIST - FORK- 2014 32mm TALAS 5 29 »

PARTLIST - FORK- 2014 34mm TALAS 5 26/27.5 »

PARTLIST - FORK- 2014 34mm TALAS 5 29 »

PARTLIST - FORK- 2014 36mm 160 TALAS 5 »

PARTLIST - FORK- 2014 36mm 170-180 TALAS 5 »

Cartridge Removal and Disassembly

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Step 1

Remove the blue air cap. While holding the lever away from the counter-clockwise hard stop, remove the nut with a 7/16" socket. Remove the lever.

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Step 2

Use a 10mm socket to remove the bottom nut. Remove the crush washer and use Damper Removal Tool 398-00-601 to free the cartridge from the lowers. Drain the oil into your waste oil basin.

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Step 3

Use a 6-point Chamfer-less socket to remove the cartridge from the fork crown. 

32mm Forks: 26mm socket

34mm Forks: 28mm socket

36mm Forks: 32mm socket

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Step 4

Release the air pressure from the cartridge, then remove the wire retaining ring with a shim or pick tool without damaging the inside surface of the cartridge tube. 

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Step 5

Hold the air valve core down with a small tool while you remove the air shaft assembly and negative plate from the cartridge tube by pulling down.

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Step 6

Remove the scraper seal followed by the U-cup seal. Coat a new U-cup seal with a thin film of Slick Honey and install in the upper piston groove so its lip is facing up. Coat a new scraper seal with a thin film of Slick Honey and install into the lower piston groove so its lip is facing down. Invert the air shaft assembly and set it aside to allow any trapped Float Fluid to drain out through the hollow piston bolt.

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Step 7

Remove the wire retaining ring that secures the XV (Extra-Volume) sleeve to the cartridge tube. Remove the XV sleeve by sliding it down and off the cartridge tube. Clean the XV sleeve and cartridge tube of any Float Fluid and replace the two o-rings with new ones coated with a thin film of Slick Honey. Reinstall the XV sleeve followed by the wire retaining ring.

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Cartridge Reassembly and Installation

Do not use more than the specified amount of FLOAT Fluid for your specific model of TALAS 5 cartridge. 

TALAS 5 cartridges have shipped both with and without XV sleeves. Pay careful attention to the Float Fluid volume chart.

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Step 1

Inject the appropriate amount of Float Fluid for your fork into the Cartridge Tube while rotating the tube to coat the entire inner surface.

Fork Family Wheel Size Float Fluid Volume (With XV Sleeve) Float Fluid Volume (No XV Sleeve)
32mm 26/27.5 15cc 5cc
32mm 29 17cc  7cc
34mm 26/27.5/29 15cc  5cc
36mm 160 26 15cc  5cc
36mm 180 26 5cc  N/A

 

 

 

 

 

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Step 2

Coat the air piston seals and topout/negative springs with Float Fluid then install the Air Shaft assembly into the Cartridge Tube. Holding the air valve open during this step can assist in Air Shaft Assembly installation. Install the negative plate and wire retaining ring. Pull on the air shaft to verify that the wire retaining ring is properly seated. 

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Step 3

Add 135psi to the TALAS 5 cartridge, then install into the fork crown and torque to 220 in-lb (24.8 Nm) with your 6-point Chamfer-less topcap socket.

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Step 4

With the TALAS set to the Long-Travel position (fully clockwise) install the lever so it is oriented toward the riders 10 o'clock. Install the tank valve nut with a 7/16" socket to 25 in-lb (2.8 Nm) torque while holding the lever away from the full clockwise hard stop.

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Step 5

Invert the fork and pour in the appropriate amount of FOX 20wt. Gold bath oil.

Fork TALAS-side Bath Oil Volume
All 32mm/34mm 30cc
All 36mm  40cc
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Step 6

Install a new crush washer followed by the bottom nut. Torque to 50 in-lb (5.7 Nm) with your 10mm socket.

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Step 7

Replace the blue air cap and thouroughly clean the exterior of your fork.

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