Step 1

Disconnect the remote cable and remove the shock from the frame. Remove the black air cap and release all air pressure from the main air chamber by depressing the Schrader valve core.

Step 2

Unthread the air sleeve by turning the base of the air sleeve assembly (the area covered by the EVOL decal) counter-clockwise.

Step 3

Remove the Main Chamber Volume Spacer by pulling it up with a pick. You may pry against the edge of the Air Sleeve Assembly but only if you protect it with a non-marring tool to prevent damaging the critical sealing surface. Be careful not to scratch the damper shaft as that can lead to an oil or air leak.

Step 4

Remove the Air Sleeve Assembly by pulling it off of the shock damper.

For Nude TR shocks: Remove the Air Sleeve Check Valve and set it aside.

Step 5

Replace the wiper, air seal, and back-up rings in the end of the Air Sleeve Assembly with new greased ones from the kit.

Step 6

Remove the white Delrin ball from the Pellet Retainer with a pick. Slowly unthread the pellet retainer counter-clockwise with a 5/32" hex wrench to release the Nitrogen charge. Remove the black Pellet with a pick.

Step 7

Slowly unthread the bleed screw in the Bearing Assembly counter-clockwise with a 5/64" hex wrench. Remove the bleed screw then remove the ball bearing with a magnet.

Step 8

Unthread the Bearing Assembly from the body by turning it counter-clockwise with a 3/4" wrench or crowsfoot. Position your wrench on the Bearing Assembly so the wrench does not apply force toward the empty bleed hole. This prevents the possibility of distorting the bleed hole.

Step 9

Drain the oil from the body into a waste oil basin. Cover the open end of the body with a rag, then remove the IFP using carefully applied air pressure. Inspect the body for damage or excessive wear.

Step 10

Remove the IFP o-ring and inspect its gland on the piston itself for any damage or contamination. Apply Slick Honey grease to the new IFP o-ring from the replacement seal kit, and install it on the piston.

Step 11

Apply a very thin film of Slick Honey to the inside of the shock body, then insert the IFP with it's slot facing up. Adjust your IFP depth setting tool (PN: 803-00-566) to the correct IFP depth for your shock. Use your IFP depth setting tool to push the IFP down to it's appropriate depth.

Step 12

Invert the Eyelet Assembly then gently clamp it in your soft jawed vise by clamping the flats of the Trunnion mounting holes. Lift the Compression Rod out by lifting the Tri-lobe lockout plate.

Step 13

Unthread the Lockout Piston counter-clockwise with the 3 pin Lockout Piston Tool (PN: 398-00-638). Remove the Lockout Valve Stack and set it aside.

Step 14

Unthread the Piston Bolt counter-clockwise with the 5/8" Piston Bolt Tool (PN: 398-00-637). Remove the Piston Bolt with Piston and Valving. Keep the valves in their original order as you replace the Glide Band with a new one from the kit.

Step 15

Remove the Bearing Assembly by pulling it up off of the shaft. Replace the 2 o-rings inside the Bearing Housing Assembly with new greased ones from the kit. Remove the Bottom Out O-ring and Bottom Out Plate from the shaft.

Step 16

Remove the Wave Spring from within the Eyelet Base, then remove the Check Valve.

Step 17

Remove the small Retaining Ring that retains the Eyelet Base.

For Nude TR shocks: Remove the large wave spring from within the eyelet.

Step 18

Lift the Eyelet Base up out of the eyelet to remove it.

Step 19

Separate the Eyelet Volume Spacer (if present) from the Eyelet Base. Replace the Eyelet Base o-rings with new greased ones from the kit.

Step 20

Clean the shaft with Isopropyl Alcohol, then dry it completely with a lint-free paper towel. Clamp the shaft in your shaft clamps (PN: 803-00-805) just tightly enough for you to unthread the Eyelet Assembly from the shaft without allowing the shaft to rotate in the clamps.

Step 21

Install the Trunnion Eyelet Tool (PN: 398-00-099) onto the Eyelet Assembly making sure to thread the bolts fully clockwise into the Trunnion Eyelet holes. Heat the shaft for 4-5 seconds with a propane torch to break down the red Loctite bond. Unthread the Eyelet Assembly counter-clockwise to remove it from the shaft.

Step 22

Lift the Rebound Metering Rod with ball bearing out of the shaft and set them aside.

Step 23

Remove the blue pulley by partially unthreading the set screw counter-clockwise with a 1.5mm hex wrench (you do not need to fully remove the screw from the pulley).  

Step 24

Remove the two screws holding the Cable Housing Stop by unthreading them counter-clockwise with a 2.5mm hex wrench. Remove the Cable Housing Stop.

Step 25

Remove the red Rebound Lever with Travel Adjust Cam. Remove the 0.0938" ball bearings and detent springs. Separate the red Rebound Lever from the Travel Adjust Cam for cleaning.

Step 26

Gently tap the face of the Eyelet Assembly against your work surface to allow the Compression Cam and Torsion Spring to drop out.

Step 27

Remove the Travel Adjuster Rod from the Eyelet Assembly by pulling it out with needle-nosed pliers. 

Step 28

Remove the O-ring Retainer Insert by pulling it out with a pick. Remove the o-ring from underneath the O-ring Retainer Insert.

Step 29

Remove the shaft o-ring from within the Eyelet Assembly and clean any Loctite residue from the eyelet threads.

Step 30

Install a new greased shaft o-ring from the kit into the larger open hole in the Eyelet Assembly. 

Step 31

Install a new greased o-ring from the kit into the hole for the Travel Adjust Rod. Make sure that the o-ring is seated at the bottom of the bore and not caught on the shoulder marked by red arrows. Reinstall the O-ring Retainer Insert, making sure to press it fully into the Eyelet Assembly.

Step 32

Coat the two rebound detent springs with water-proof marine grease, then reinstall into the two small holes in the Eyelet Assembly as shown. Position the two rebound detent ball bearings on the ends of the greased detent springs.

Step 33

Coat the Torsion Spring with blue Hi-Temp grease (Sta-Lube SL3125 or similar) and insert its non-marked tang into the pocket on the cam. The red tang should face away from the cam.

Step 34

Coat the Travel Adjust Cam with a copious amount of waterproof grease then install into the red Rebound Lever. Coat the red Rebound Lever with a film of waterproof grease.

Step 35

Engage the end of the Travel Adjust Cam with the keyhole feature in the end of the Compression Cam. Insert the Compression Cam/Greased Torsion Spring/ Travel Adjust Cam assembly into the eyelet with the red tang of the Torsion Spring in the 3 o’clock position. Push the assembly against the back wall of the eyelet and slowly rotate clockwise 90 degrees until the red spring tang drops into the hole in the eyelet. Check to make sure the spring tang has engaged its hole by rotating the Camshaft a few degrees in both directions, you should feel the spring winding rather than spinning. When installed correctly, the counterbore on the Camshaft for the pulley set screw will face away from the air valve (approximately 4 o’clock).

Step 36

While holding the red Rebound Lever against the rebound detent balls, install the Cable Housing Stop. Reinstall the two screws tightening them clockwise to 11 in-lb (1.2 Nm) torque with a 2.5mm hex wrench.

Step 37

Line up the blue Nude pulley with the exposed Travel Adjust Cam so the set screw that attaches the pulley to the Cam is in line with the counterbore. The tang of the blue Nude pulley will sit against the housing stop in this step, preventing the pulley from sitting down in its fully seated position.

Step 38

Rotate the blue Nude pulley clockwise with snap-ring pliers or the Cam Tensioner Tool (PN: 398-00-628) . Use the pliers or Cam Tensioner Tool to help you continue to rotate the pulley clockwise until the tang of the pulley passes the Housing Stop and lets the pulley drop down into its fully seated position. Tighten the pulley fixing set screw to 3.5in.-lb (0.4 Nm) torque with your 1.5mm hex wrench.

Step 39

Reinstall the Travel Adjuster Rod by inserting it, tapered end first, into O-ring Retainer Insert.

Step 40

Clean all Loctite residue from the Shaft threads. Replace the O-ring inside the Shaft with a new greased one from the kit. Replace the Square Cut O-ring inside the Rebound Metering Rod with a new greased one from the kit. Reinstall the Rebound Metering Rod into the Shaft through the end with external threads.

Step 41

Leave the Rebound Metering Rod sticking out of the Shaft by 1-2cm. Clean all oil and grease residue from the shaft threads. Apply one drop of red Loctite 277 to the external threads of the Shaft. Insert the Rebound Metering Rod into the Eyelet Assembly with its ball bearing oriented toward the front of the eyelet. Thread the Shaft into the Eyelet Assembly clockwise by hand until tight.

Step 42

Clean the Shaft with Isopropyl Alcohol, then dry it completely with a lint-free paper towel. Clamp the Shaft in your Shaft Clamps (PN: 803-00-805) leaving enough Shaft exposed above the clamps to allow the Eyelet Assembly to thread fully onto the Shaft without contacting the Shaft Clamps. Install the Trunnion Eyelet Tool (PN: 398-00-099) onto the Eyelet Assembly making sure to thread the bolts fully clockwise into the Trunnion Eyelet holes. Tighten the Eyelet Assembly clockwise onto the shaft to 85 in-lb (9.6 Nm) torque.

Step 43

Reinstall the Eyelet Volume Spacer (if present) onto the Eyelet Base so their smaller diameter ends are oriented toward each other. Snap the Eyelet Volume Spacer onto the Eyelet Base.

Step 44

Install the Eyelet Base with Eyelet Volume Spacer into the Eyelet Assembly with the Spacer orented toward the Eyelet. Align the Eyelet Base so the Travel Adjust Rod protrudes through the indicated hole in the Eyelet Base as shown.

Step 45

Reinstall the Check Valve. Install the Wave Spring making sure to align the high spot of the wave spring opposite the opening in the wave spring with the notch in the Eyelet Base near the Travel Adjust Rod location.

Step 46

Reinstall the Retaining Ring that holds down the Eyelet Base. 

Step 47

Reinstall the Bottom Out Plate followed by a new greased Bottom Out O-ring from the kit.

Step 48

Reinstall the Bearing Assembly (with new greased seals from the kit) onto the shaft as shown.

Step 49

Reinstall the Piston and Valving Assembly. Tighten the Piston Bolt clockwise with your 5/8" Piston Bolt Tool (PN: 398-00-637).

Step 50

Reinstall the Lockout Valve Stack followed by the Lockout Piston. Tighten the Lockout Piston clockwise with your 3 Pin Lockout Piston Tool (PN: 398-00-638) to 22 in-lb (2.5 Nm) torque.

Step 51

Slowly reinstall the Compression Rod with Tri-Lobe Lockout Plate so the hole in the Lockout Plate aligns with the dowel pin protruding from the Lockout Piston. Push the Compression Rod in slowly to prevent damage to the o-ring within the Metering Rod.

Step 52

Insert a new Pellet into the threaded port in the Body so the flat side of the Pellet faces out. Reinstall the Pellet Retainer with your 5/32" hex wrench. Tighten until just snug by hand.

Step 53

Fill the body with FOX 10wt. Red oil (PN: 025-02-003).

Step 54

Move the Bearing Assembly to the Piston end of the Shaft. Fill the Piston Assembly with FOX 10wt. Red oil then invert onto the oil-filled Body. Thread the Bearing Assembly clockwise onto the Body by hand.

Step 55

Tighten the Bearing Assembly clockwise onto the body with your 3/4" crowsfoot to 240 in-lb (27.1 Nm) torque.

Step 56

Reinstall the 0.125" diameter ball bearing into the bleed port of the Bearing Assembly. Reinstall the Bleed Screw with your 5/64" hex wrench, tightening clockwise to 10-15 in-lb (1.1-1.7 Nm) torque. Clean excess oil from the damper with a lint-free paper towel.

Step 57

Insert the Nitrogen Fill Pellet Retainer tool (PN: 398-00-374) into the pellet retainer near the end of the body. Use the Pellet Retainer tool to unthread the pellet retainer 1/4 turn. Depress the safety button on the nitrogen fill needle (PN: 802-01-000-KIT), then slide the shock onto the needle by pressing toward the nitrogen fill needle. Charge the IFP chamber to 500 psi. Use the Pellet Retainer tool to gently tighten the pellet retainer by 1/4 turn. Quickly pull the shock straight away from the nitrogen fill needle. A loud pop will be heard. Use a 5/32" hex wrench to tighten the pellet retainer to 14 in-lb (1.6 Nm).

Step 58

Compress the shock in all modes to test its function. Insert a new Delrin ball from the kit into the pellet retainer. Press the Delrin ball into the pellet retainer with your soft-jawed vice. 

Step 59

For Nude TR shocks: Reinstall the large wave spring into the eyelet so the split is opposite the remote pulley. Clean the Air Sleeve Check Valve thoroughly with Isopropyl alcohol. Reinstall the Air Sleeve Check Valve taking care not to scratch the body or shaft.

Step 60

Remove the main air seal and two back-up rings from the Bearing Assembly. Install new back-up rings and a new greased main air seal from the kit. Make sure the main air seal is not twisted after installation.

Step 61

Coat the main air seals on the Bearing Assembly and the seals in the end of the Air Sleeve Assembly with a film of Slick Honey. Slide the Air Sleeve Assembly over the Body of the shock past the Bearing Assembly. Clean the large open end of the Air Sleeve Assembly with alcohol and a lint-free paper towel to ensure no debris is on the sealing surface.

Step 62

Reinstall the Main Chamber Spacer according to the text molded into it. The side of the spacer with the part number should face toward the Eyelet when installed. Press the Spacer into the Air Sleeve Assembly so it sits flat.

For Nude TR shocks: Clean the check valve sealing surface thoroughly with Isopropyl alcohol.

Step 63

Slide the Air Sleeve Assembly up to the Eyelet Assembly. Thread the Air Sleeve Assembly clockwise into the Eyelet Assembly by turning the base of the air sleeve assembly (the area covered by the EVOL decal) by hand to approximately 45 in-lb (5.1 Nm) torque (Hand Tight).

Step 64

Add your desired air pressure to the main air chamber with a FOX digital pump (PN: 027-00-013) then replace the black air valve cap. Dyno the shock to test all functions. Clean the exterior of your shock.

Step 1

Remove the black air cap and release all air pressure from the main air chamber by depressing the Schrader valve core. Hold the Schrader valve core down while you actuate the Nude TR lever.

Step 2

Remove the Wire Retaining Ring from under the Nude TR Sleeve. Do not let the ends of the Retaining Ring scratch any portion of the shock on removal.

Step 3

Compress the shock fully on your Dyno to increase pressure in the Air Sleeve Assembly that will dislodge the Nude TR sleeve. 

Step 4

Pull the Nude TR sleeve off of the base Air Sleeve.

Step 5

Unthread the Nude TR Lever set screw by turning it counter-clockwise with a T10 Torx wrench. Remove the Nude TR Lever slowly taking care not to lose the four 0.0938" ball bearings and two detent springs. 

Step 6

Push the Nude TR Lever Cam into the Nude TR sleeve to remove it from the inside. Replace the Nude TR Lever Cam O-ring with a new greased one from the kit.

Step 7

Remove the two detent springs for cleaning. Clean the Nude TR Sleeve with Isopropyl Alcohol and a lint-free paper towel. Coat the two detent springs with a film of waterproof grease (SL3125) then reinstall in the two holes of the Nude TR Sleeve.

Step 8

Reinstall two of the 0.0938" ball bearings onto the greased detent springs. Position 2 greased 0.0938" ball bearings into the 2 holes in the back of the Nude TR Lever that are inline with the lever paddle. Reinstall the Nude TR Lever Cam in through the inside of the Nude TR Sleeve so the small flat in the cam is oriented approximately 90 degrees clockwise from the small groove in the outside of the Nude TR Sleeve.

Step 9

Reinstall the Nude TR Lever so it engages with the Nude TR Lever Cam, the two ball bearings from the lever fit into the kidney-shaped grooves in the Nude TR Sleeve, and the paddle of the Nude TR Lever is oriented toward the small groove on the outside of the Nude TR Sleeve.

Step 10

Apply one drop of Blue Loctite 243 to the set screw, then reinstall, tightening clockwise to 7 in-lb (1.3 Nm) torque with your T10 Torx wrench.

Step 11

Remove the XV Chamber Spacers by unclipping them from each other. 

Step 12

Remove the 3 o-rings from the outside of the base Air Sleeve. Note that the two o-rings closest to the eyelet threads are the same size, while the o-ring nearest the body-end of the Air Sleeve is slightly smaller. Replace all three o-rings with new greased ones from the kit.

Step 13

Reinstall the XV Chamber Spacers by clipping them together. Always orient them as indicated by the text molded into the spacer (highlighted to show detail in image). Align the notch in the spacers with the Nude TR Cam Follower/Plunger Assembly.

Step 14

If needed, reinstall the base Air Sleeve onto the Nude TR shock by threading it clockwise into the eyelet to 45 in-lb (5.1 Nm) torque. 

Step 15

Align the Nude TR Lever with the Nude TR Cam Follower/Plunger Assembly then slide the Nude TR sleeve over the base sleeve. Press the Nude TR Sleeve against the eyelet firmly to fully seat it on the base air sleeve. 

Step 16

Reinstall the Wire Retaining Ring into the groove just past the Nude TR Sleeve. Do not let the ends of the Retaining Ring scratch any portion of the shock on installation. Orient the Retaining Ring so the open ends are opposite of the Nude TR Lever.