2016 32mm/34mm Dust Wiper Replacement
The following procedure guides you through dust wiper replacement for 2016+ 32mm and 34mm forks.
These instructions can be utilized for basic guidance on dust wiper replacement for older pre-2016 model forks. Please consult the appropriate oil volume chart if servicing a pre-2016 32mm or 34mm fork and note that some details may have changed for 2016. Pre-2016 bath oil volumes can be found under "Fork- Basic Maintenance" by clicking: All Service Procedures »
WARNING: FOX products should be serviced by a trained 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.
WARNING: FOX suspension products contain pressurized nitrogen, air, oil, or all 3. Suspension misuse can cause property damage, SERIOUS INJURY OR DEATH. DO NOT puncture, incinerate or crush any portion of a FOX suspension product. DO NOT attempt to disassemble any portion of a FOX suspension product, unless expressly instructed to do so by the applicable FOX technical documentation, and then ONLY while strictly adhering to all FOX instructions and warnings in that instance.
WARNING: Modification, improper service, or use of aftermarket replacement parts with FOX forks and shocks may cause the product to malfunction, resulting in SERIOUS INJURY OR DEATH. DO NOT modify any part of a fork or shock, including the fork brace (lower leg cross brace), crown, steerer, upper and lower leg tubes, or internal parts, except as instructed herein. Any unauthorized modification may void the warranty, and may cause failure or the fork or shock, resulting in SERIOUS INJURY OR DEATH.
FLOAT fork model shown, but these same instructions will apply for 32mm and 34mm TALAS fork models.
Use a 2mm hex wrench to unthread the set screw in the red rebound knob (blue threshold adjust knob for TerraLogic forks). Remove the knob and set it aside.
Use a 10mm socket to unthread and remove the air side bottom nut. Remove and discard the original crushwasher.
32mm: Use a 10mm socket to remove the damper side bottom nut. Remove and discard the original crushwasher.
34mm: 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.
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.
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.
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.
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.
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.
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.
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.
The air spring must be fully extended before reinstalling the lower legs. Add air pressure to your desired setting using a FOX high pressure pump. See the Setting Fork Air Pressure section for more information. Reinstall the blue air cap.
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.
|2016 Air Side Bath Volume||20wt. Gold Oil|
|32mm FLOAT 80mm-120mm||25cc|
|32mm FLOAT 130mm-150mm||10cc|
|34mm FLOAT 110mm-120mm||25cc|
|34mm FLOAT 130mm-160mm||10cc|
|All 32mm/34mm TALAS||30cc|
|2016 Damper Side Bath Volume||20wt. Gold Oil|
|All 32mm/34mm FIT4||15cc|
Pre-2016 bath oil volumes can be found under "Fork- Basic Maintenance" by clicking: All Service Procedures »
Install a new crushwasher on each side followed by the appropriate bottom nut. Torque both bottom nuts to 50in-lb (5.7 Nm).
Use a 2mm hex wrench to install the red rebound knob (blue threshold adjust knob for TerraLogic forks). Make sure that the set screw lines up with the depression in the rebound adjuster shaft. Clean the exterior of your fork.