FOX RACING SHOX F80RLT Owner's Manual page 19

Changing Oil – Float Forx:
The following tools and supplies will be needed: 26mm 6-sided socket, 10mm socket, torque wrench, 2mm hex key
wrench, 1.5mm hex key wrench, plastic faced hammer, small screwdriver, oil drain pan.
Quantity
1
1
2
1
Step 1 - Place the bicycle or fork in a bike stand. Remove the LEFT side Air Knob and depressurize the Main Air
pressure by pressing on the air valve with a small screwdriver. Using a 26mm socket wrench, remove the left side Air
Topcap.
Step 2 - Using a 10mm socket wrench, unscrew the LEFT side bottom nut 6 turns. Place a clean dry oil pan under-
neath the left side of the fork. Tap on the bottom nut with a plastic face hammer to disengage the air shaft from the
lower leg. Unscrew and remove the bottom nut and washer. Carefully push the air shaft stud up into the lower leg with
a thin screwdriver and let the oil drain. Compress the fork by pushing up on the lower leg. Carefully push with a long
thin screwdriver through the left bottom hole of the lower leg to push the air shaft assembly out of the top of the
Uppertube.
Step 3- Clean, degrease and air off the Air Shaft Assembly.
On 2002 Fox Float Forx: Inspect the O-ring on the Air Piston for wear (i.e. flat spots on the peak outside diameter of
the sealing surface). Replace the seal if worn.
The Float Air Seal kit is #803-00-078
There are multiple seals in the Air Seal Kit. Replace the O-ring with the following U-cup seal: #036-01-010 (the seal
has the number stamped on the bottom surface). Install the Air Piston Seal with the "triangular shaped peak outside
sealing edge" towards the top of the piston.
On 2003 Fox Float Forx: The U-cup seal on the Air Piston has a triangular shaped peak outside sealing edge on the
upper half of the seal. Inspect the U-cup on the Air Piston for wear. If the sealing edge on the upper half of the seal U-
cup has rounded edges, replace the U-cup seal.
The Float Air Seal kit is #803-00-078
There are multiple seals in the Air Seal Kit. Replace the U-cup seal with the correct seal for your fork model (the seal
has the number stamped on the bottom surface).
P/N
036-01-011
036-01-010
Install the Air Piston Seal with the "triangular shaped peak outside sealing edge" towards the top of the piston.
On 2004 Fox Float Forx: The U-cup seal on the Air Pistion has a triangular shaped peak outside sealing edge on the
upper half of the seal. Inspect the U-cup on the Air Piston for wear. If the sealing edge on the upper half of the seal U-
cup rounded edges, replace the U-cup seal.
The Float Air Seal kit is #803-00-078
There are multiple seals in the Air Seal Kit. Replace the U-cup seal with the correct seal for your fork model (the seal
has the number stamped on the bottom surface).
P/N
036-01-010
Install the Air Piston Seal with the "triangular shaped peak outside sealing edge" towards the top of the piston.
Step 4 - Wipe out with a clean lint-free towel in the ID of the LEFT Uppertube. Open the 5cc "pillow pack" of Float
Suspension Fluid. Put a thin film of Float Fluid around the outside of the Air Piston Seal. Install the Air Shaft Assembly
into the LEFT Uppertube. Turn over the fork in the bike stand. Put in 30cc of NEW Fox Fully Synthetic Suspension
Fluid (7.5 wt) into the bottom hole of the LEFT lower leg. With the fork still upside down, push up on the Air Piston with
an NON-SHARP object to make the air-shaft stud protrude through the hole in the Lower Leg. Install the NEW crush
washer. Thread on the bottom nut and torque to 50 in-lb. Turn the fork right side up.
Part Number
025-03-004-A
025-03-002-A
241-01-002-B
803-00-078
Fork Models
2003 F80 RLT
2003 Float 80, Float 100, F80X
Fork Models
2004 F80RLT, F80X, F100X, Float 80 & Float 100
Partname
1 qt. bottle of Fox Suspension Fluid (7.5 wt.)
5cc Pillow Pack of Fox FLOAT Fluid
crush washer
Float Forx Air Piston Seal Kit (optional)
19