FOX RACING SHOX F80RLT Owner's Manual page 20

Step 5 - Removing the Damper Knobs:
On R models: Unscrew the right side Damper Topcap with a 26mm socket wrench.
On RL, RLT & RLC models: You will need to remove all of the right side Damper topcap knobs before you can
unscrew the Damper Topcap.
a) Hold the red rebound knob firmly and remove the flathead screw with a 2mm hex key wrench. Lift off the red
rebound knob.
b) With a 1.5mm hex key wrench, unscrew each of the 3 set screws on the blue lockout lever 1 ½ turns. Lift off the
blue lockout lever.
Note about the 3 chrome balls in the lockout lever: The 3 chrome balls are held in by a dab of grease. Do not go
beyond 1 ½ turns on the set screws or the chrome balls may move outward in the side holes beyond the pointed set
screws. If this happens, push with a 1.5mm hex key wrench thru the side holes to get the chrome ball back towards
the center of and inside of the set screw.
c) On RLC models, lift off the Low-speed compression knob. Look at the bottom of the Low-speed knob. The 1/8"
diameter chrome detent ball might be stuck to the bottom of the knob from grease. If this happened, grease the detent
ball and put it back in the hole in the recess of the damper topcap. Press on the detent ball with a small screwdriver
and you should feel it spring back.
d) With a 26mm socket wrench, loosen and unscrew the damper topcap from the uppertube.
Step 6 - On RLT and RLC models: Use a 2mm hex key wrench to loosen and remove the "Lockout Threshold Knob"
on the lower right side of the lower leg.
On all models: Use a 10mm socket wrench to unscrew the RIGHT side bottom nut
6 turns. Place a clean dry oil pan underneath the right side of the fork. Tap on the
bottom nut with a plastic faced hammer to loosen the plunger shaft from the lower
leg. Loosening the bottom nut 6 turns will make the nut lower than the small
Lockout Threshold shaft and protect it from damage while tapping out the damper
out shaft. Unscrew and remove the bottom nut and washer. Push up on the shaft
with a thin screwdriver and let the oil drain.
Step 7 - Remove the damper from the fork and place over a drain pan. Holding the
upper insert with a 12mm Cone Nut wrench, loosen the topcap with a 26mm socket
wrench and unscrew one turn. Loosening the topcap unclamps the compression shims
and allows the oil to drain during the next step.
Step 8 - Extend the damper over a drain pan, carefully push a 1.5mm hex wrench
through 1 of the 5 base valve ports in the bottom of the damper and cycle the
damper for 1 minute to drain all of the oil. Holding the upper insert with a 12mm
cone wrench, torque the damper topcap to 75 in-lb. DO NOT OVERTORQUE.
THIS WILL WARP THE SHIMS. Inspect that the #1 compression shim is com-
pletely flat against the three raised surfaces of the compression piston.
Step 9 - Extend the damper to full length and install the damper into the fork. Thread
the damper topcap into the Uppertube for 1-2 turns. Install a NEW crush washer and
thread on the bottom nut. Torque the bottom nut to 50 in-lb. On RLT & RLC forks,
align the set screw of the Lockout Threshold Knob with the drilled feature on the
Lockout Threshold Shaft and tighten with a 2 mm hex key wrench.
Step 10 - Unscrew the damper topcap out of the Uppertube and compress the lower
leg of the fork upward. Pour into the RIGHT Uppertube 155cc of Fox Fully Synthetic
Suspension Fluid (7.5 wt).
Step 11 - Extend the fork. Pour into the LEFT Uppertube 5cc of NEW FOX Float Fluid.
Using a 26mm socket, install and torque the left side Air Topcap to 165 in-lb. Using a Fox
High Pressure Air Pump, pump air into left side Schrader valve to the recommended air
pressure for the rider weight. Install the Blue Air Knob.
Step 12 - Thread the RIGHT side Damper Topcap into the Uppertube. Using a 26mm
socket, torque the Damper Topcap to 165 in-lb.
Step 7
Step 8
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