2018 Cannondale Gemini Dual Travel 2 Air Sleeve Rebuild

Required Parts

  • 029-10-222 Ramp Ring (for Air Volume Tuning, not needed for service)
  • 803-01-154 Seal Kit: Cannondale Gemini, Dual Travel 2, Air Sleeve Rebuild

Required Tools

  • 398-00-752 Service Tool: Dual Travel 2, Pulley
  • 398-00-786 Service Tool: Dual Travel 2, Static Sleeve Installation Press
  • 398-00-787 Service Tool: Dual Travel 2, Static Sleeve Removal Press, Eyelet Side
  • 398-00-788 Service Tool: Dual Travel 2, Static Sleeve Removal Press, Body Side

Supplies Needed

  • Flat Screwdriver
  • M2.5 Bolt (such as PN: 019-01-115)
  • Plastic Seal Pick
  • Seal Pick
  • Strap Wrench
  • T8 Torx Driver
  • Torque Wrench

The following procedure guides you through the air sleeve rebuild for Cannondale Gemini shocks with Dual Travel 2 Air Sleeves.

 

To service the damper of your shock please click on one of the following links: 

FLOAT X Rebuild »

FLOAT DPS Rebuild » 



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.

The shock shown in this procedure is a FLOAT X, but this procedure applies to FLOAT DPS and FLOAT DPX2 shocks as well. 

Disassembly

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Step 1

With no cable connected, verify that the Dual Travel 2 pulley is fully clockwise. Remove the black air cap and thread on your FOX shock pump. Slowly release all air from the main air chamber with your pump, then remove the pump. Verify that all air has been released by depressing the Schrader valve with a lint-free towel covering the valve to prevent any oil spray.

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Step 2

Clamp your Dual Travel 2 shock in your soft-jawed vise by the adjuster eyelet. Unseat the flat wire retaining ring closest to the static Dual Travel 2 sleeve assembly.

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Step 3

Remove the round wire retaining ring at the body end of the EVOL sleeve. 

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Step 4

Remove the outer EVOL sleeve by pulling it off of the shock toward the body end. Remove the 2 o-rings for the EVOL sleeve.

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Step 5

Place the eyelet of the shock into the Eyelet Side Static Sleeve Removal Press (PN: 398-00-787), then thread the large bolt through the tool and eyelet tightening clockwise until hand tight. 

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Step 6

Install the small pin from the Eyelet Side Static Sleeve Removal Press into the cable housing stop of the Dual Travel 2 sleeve.

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Step 7

Install the Body Side Static Sleeve Removal Press tool (PN: 398-00-788) over the shock body as shown.

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Step 8

Slide the prepared shock and tools onto your shock dyno. Pull down gently on the dyno handle to dislodge the Dual Travel 2 sleeve. Verify that the Dual Travel 2 sleeve is not cocked on an angle and can rotate freely.

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Step 9

Remove the remaining round wire retaining ring and the flat wire retaining ring that held the static Dual Travel 2 sleeve assembly. Clean the inner air sleeve with Isopropyl alcohol and a lint-free paper towel.

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Step 10

Use a strap wrench to unthread the inner air sleeve with Dual Travel 2 sleeve assembly from the eyelet assembly by turning it counter-clockwise. Set the air sleeve assembly aside.

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Step 11

If removing Ramp Rings, you may use a flat tool to gently pry up the volume spacer from within the eyelet. You can install ramp rings without removing the volume spacer by carefully pushing them into the space between the eyelet and volume spacer, but you must make sure that they are properly seated as shown. Remove or add Ramp Rings by stretching them over the shock body, bulkhead, and bearing. Make sure all Ramp Rings are fully seated within the volume spacer and that the volume spacer is seated within the eyelet when complete.

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WARNING: Do not use more than the FOX Factory specified quantity of Ramp Rings for your shock. 

  • Maximum quantity of ramp rings for FLOAT X is 3.
  • Maximum quantity of ramp rings for FLOAT DPS is 2.
img/help/page835-OKMZ/IMG_0859-m.jpg

Step 12

Remove the main air seal and back-up rings from the bearing assembly using a plastic pick to prevent damage to the sealing surface. Remove the o-ring from the Bulkhead.

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Step 13

Install a new greased o-ring from the kit onto the Bulkhead. Install a new greased main air seal and back-up rings onto the bearing assembly. 

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Step 14

Remove the wiper, negative air seal, and back-up rings from the end of the air sleeve assembly using a plastic pick to prevent damage to the sealing surface.

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Step 15

Slide the Dual Travel 2 sleeve assembly off of the inner air sleeve. You may encounter some resistance as the Dual Travel 2 sleeve passes o-rings on the inner air sleeve.

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Step 16

Remove the 3 o-rings from the inner air sleeve then set it aside. Note that the o-ring closest to the eyelet is slightly larger in diameter than the other two matching o-rings.

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Step 17

Slowly unthread the T8 torx screw counter-clockwise until pulley and cam assembly pops up and is no longer retained. Do not remove the T8 torx screw completely.

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Step 18

Do not separate the pulley, cam, and torsion spring. Clean these components then set them aside.

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Step 19

Remove the small round wire retaining ring that retains the small cap with the M2.5 threaded hole.

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Step 20

Thread an M2.5 bolt (such as PN: 019-01-115) into the cap then pull out to remove. Replace the o-ring on the cap with a new greased one from the kit. Invert the Dual Travel 2 sleeve to allow the 0.25" diameter ball bearing and check spring to fall out. 

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Step 21

Use a small L-shaped hex wrench to push the plunger out of the Dual Travel 2 sleeve. Replace the o-ring on the plunger with a new greased one from the kit. 

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Step 22

Make sure that there is a 0.0938in diameter ball bearing (PN: 010-01-002) present, both in the pocket in the end of the plunger and within the Dual Travel 2 sleeve above the T8 torx screw. These ball bearings are retained by grease.

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Reassembly

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Step 1

Install new greased o-rings from the kit onto the inner air sleeve. Note that the o-ring closest to the eyelet is slightly larger in diameter than the other two matching o-rings.

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img/help/page835-OKMZ/IMG_0890-m.jpg

Step 2

Install a new negative air seal, back-up rings, and wiper in the end of the air sleeve.

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img/help/page835-OKMZ/IMG_0913-m.jpg

Step 3

Insert the plunger, ball bearing first, into the Dual Travel 2 sleeve as shown. Use a blunt tool like a small hex wrench to push the plunger into position so it can be seen through the cam/pulley hole.

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Step 4

Drop the 0.25in diameter ball bearing into the Dual Travel 2 sleeve.

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Step 5

Install the check spring after the ball bearing as shown.

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Step 6

Use an M2.5 bolt to help install the cap. Push the cap in to fully seat it, then remove the bolt.

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Step 7

Reinstall the small round wire retaining ring above the cap. Use a blunt tool to make sure that the retaining ring is fully seated.

img/help/page835-OKMZ/IMG_0923.jpg
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img/help/page835-OKMZ/IMG_0904b-m.jpg

Step 8

Thread the M2.5 bolt into the cap and pull to test correct installation of the retaining ring. 

img/help/page835-OKMZ/IMG_0904b.jpg


img/help/page835-OKMZ/IMG_0926-m.jpg

Step 9

Apply a thick coating of waterproof grease (Sta-Lube SL3125) to the cam, pulley, torsion spring assembly. 

img/help/page835-OKMZ/IMG_0926.jpg
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img/help/page835-OKMZ/IMG_0929-m.jpg

Step 10

Align the exposed tang of the torsion spring with the small hole in the lower left area of the bore for the cam/pulley, then loosely insert the cam/pulley/torsion spring assembly. 

img/help/page835-OKMZ/IMG_0929.jpg
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img/help/page835-OKMZ/IMG_0935-m.jpg

Step 11

Use the Dual Travel 2 Pulley Service Tool (PN: 398-00-752) to turn the pulley counter-clockwise until the set screw on the pulley aligns with the set screw on the static Dual Travel 2 sleeve assembly. Hold the pulley in this position while you thread in the T8 torx screw and tighten until you stat to feel binding in the pulley when you turn it. Then loosen the set screw by 1/4 turn.

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img/help/page835-OKMZ/IMG_0944-m.jpg

Step 12

Apply a coating of Float Fluid to the main air seal at the bearing assembly, then reinstall the inner air sleeve by threading it clockwise and tightening to 45 in-lb (5.1 Nm) torque by hand.

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img/help/page835-OKMZ/IMG_0950-m.jpg

Step 13

Slide the Dual Travel 2 sleeve assembly onto the inner air sleeve. Push the Dual Travel 2 sleeve up as close to the eyelet as possible by hand.

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Step 14

Install the Static Sleeve Installation Press (PN: 398-00-786) onto the shock with its larger open end oriented toward the Dual Travel 2 sleeve. Position the Body Side Static Sleeve Removal Press tool so it contacts the Installation Press and has its dyno pin hole at the bottom.

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img/help/page835-OKMZ/IMG_0139-m.jpg

Step 15

Slide the prepared shock and tools onto your shock dyno. Pull down gently on the dyno handle to install the Dual Travel 2 sleeve. Verify that the Dual Travel 2 sleeve is fully seated against the eyelet. 

img/help/page835-OKMZ/IMG_0139.jpg
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Step 16

Carefully work the flat wire retaining ring onto the inner air sleeve without allowing the ends of the retaining ring to scratch the inner air sleeve. Seat the retaining ring against the bottom of the Dual Travel 2 sleeve assembly. Make sure that the flat wire retaining ring is fully seated in its groove.

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Step 17

A modified EVOL outer air sleeve with one flared end cut off can be used as an installation tool for the round wire retaining rings that support the outer EVOL air sleeve. Load the round wire retaining ring onto the cut end of the modified EVOL sleeve. 

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Step 18

Slide the modified EVOL sleeve onto the inner air sleeve with the cut end and ring first. Slide the retaining ring off of the modified sleeve and into position. Remove the modified EVOL sleeve.

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Step 19

Install two new greased EVOL sleeve o-rings from the kit into the inner air sleeve.

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Step 20

Reinstall the outer EVOL sleeve by sliding over the inner air sleeve and into position against the round wire retaining ring.

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Step 21

Install the last round wire retaining ring. Clean the exterior of the shock. Test the shock for proper function on your hand dyno.

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