INSTALLING THE 36

FOX Racing Shox highly recommends that a qualified bicycle technician install the 36 on your bicycle. Improperly installed forks are dangerous, and can cause loss of control and serious or fatal injuries. Read this section in its entirety before beginning the installation of your FOX 36.

To install the FOX 36 fork on your bicycle:

  1. Remove the existing fork from the bicycle.

  2. Remove the crown race from the old fork.

  3. Measure the steerer tube length of the existing fork. Transfer this measurement to your new FOX fork's steerer tube.
    If you don't have an existing fork to measure, measure the headset stack height (shown in the diagram below). Cut your steerer to the same measurement as the Total Stack Height measurement. Refer to your stem manufacturer's instructions to be sure there will be enough clamping surface for the stem. In this case you may need to cut your steerer tube slightly shorter to allow enough clamping surface so that the stem cap bolt can pull up on the steerer tube, ensuring a snug fit.

  1. If it is necessary to cut the steerer tube, measure twice and cut once. It is also recommended that a cutting guide be used while cutting the steerer tube.

If the steerer has any nicks or gouges, the crown/steerer/upper tube assembly must be replaced. A nick or gouge can cause the steerer to fail prematurely, and cause loss of control of the bicycle and serious or fatal injuries.

  1. Use a crown race setter to install the crown race firmly against the top of the crown. Install the star-fangled nut in the steerer tube with a star-fangled nut installation too to the proper depth (see Star-fangled nut installation depth diagram below).

  2. Install the fork on to the bicycle. Install the stem, stem cap and M6 stem cap bolt on to the bicycle. Lightly tighten the stem cap bolt so that the fork turns freely without drag or free play.

Star-fangled nut installation depth

Tire Sizes

The 36 will accept tire sizes up to 2.80 inches wide. Any tire larger than 26 x 2.60 must be checked for clearance using the following method.

Determining correct tire size

With the tire installed and inflated on the rim, measure the following three dimensions:

Maximum Peak Tire Diameter = 694 mm = 27.3 inch

Maximum Edge Tire Diameter = 670 mm = 26.41 inch

Maximum Tire Width =   71 mm = 2.80 inch

Do not use a tire if any measurement exceeds the maximum dimensions shown above. Using larger tires is not recommended and can cause serious of fatal injuries.

  1. Installing the front wheel:

  1. Loosen the four axle pinch bolts on the lower leg with a 5mm hex-key wrench.

  2. Using a 5mm hex-key wrench, turn counterclockwise to loosen and remove the axle.

  3. Install the front wheel into the dropouts and install the axle into the lower leg.

  4. Using a 5mm hex-key wrench, turn clockwise and lightly tighten and torque the axle to the lower leg to 19 in-lb (215 N-cm).

  5. Torque the two left-side dropout pinch-bolts to 19 in-lb (215 N-cm).

  6. Compress the fork on the bike a couple of times to let the right side of the dropout float and settle to its low-friction point. Torque the two right side dropout pinch-bolts to 19 in-lb (215 N-cm).

  1. Setting handlebars straight and torquing stem bolts:

    1. Set the bike on the ground and sit on your bike to set the handlebars straight relative to the front wheel.

    2. Tighten the stem pinch bolts and torque fasteners according to the stem manufacturer's specifications.

    3. Check that the handlebar pinch bolts are torqued to the stem manufacturer's specifications.

Disc Brake Installation

The 36 is designed with the international XC disc brake bolt pattern for use with disc brakes with disc rotor sizes of 160 205mm only. The 36 can use XC or DH mechanical or hydraulic brake systems.

Never modify the lower leg or use cantilever rim brakes.

The 36 disc bolt pattern uses:

For use with XC size rotor (160 180 mm outside diameter):

- XC caliper

- XC caliper mount for international XC mount pattern

OR

For use with DH size rotor (200 205 mm outside diameter):

- XC caliper

- DH caliper mount for international XC mount pattern

 

  1. Install DH disc brake system according to disc brake manufacturer's specifications. Be sure to torque all fasteners and bolts to manufacturer's recommendations.

  2. Consult the manual that came with your disc brakes for proper installation procedures. It is recommended that NEW disc brake pads be installed to ensure proper alignment and to minimize drag.

  3. Test brakes for proper operation on flat land before hitting the trails.

  4. Route the disc brake hose (for hydraulic disc brakes) or brake cable housing (for mechanical disc brakes) from the caliper to the inside of the lower leg and through the supplied disc brake hose guide, and assemble the FOX disc brake hose guide parts as shown in the figures below.

  5. Cut your brake hose or brake cable housing to the correct length and assemble according to disc brake manufacturer's specifications.

  6. Tighten the disc brake hose guide screw with a 2.5 mm-hex key wrench and torque to 8 in-lb (90 N-cm).

 

 

eng059