97
Servicing Zero-X Shock Absorbers
This procedure shows the proper method for servicing
the front arm shock absorber w/“piggy-back” reservoir.
NOTE: Some illustrations and photographs used
in the following sub-sections are used for clarity
purposes and are not designed to depict actual
conditions.
Disassembling
1. Remove the bearings and retaining rings from the
eyelets.
2. Clean the entire shock assembly with soapy water.
Dry the shock assembly with compressed air.
NOTE: If compressed air is not available, use
clean towel to dry the shock assembly.
3. Clamp the shock body eyelet securely in a soft-
jawed vise and remove the ball from the end cap;
then using a 3/16-in. hex key, slowly loosen the set
screw (FAV3 valve) on the shock reservoir.
FS383
NOTE: At this point, remove the set screw and
discard the valve plug. Always install a new plug
when servicing the shock absorber.
4. Depress the reservoir end cap and remove the end
cap retaining ring.
FS331
5. Using a 3/8-24 cap screw, remove the reservoir
end cap from the reservoir; then discard the end
cap O-ring.
FS378
6. Loosen and unscrew the bearing assembly from
the shock body.
FS333
7. Slowly remove the shaft assembly from the shock
body and place it on a clean, lint-free rag or towel.
! WARNING
Before starting, read through all of these instructions
first to become familiar with the procedure. Make sure
the work area is clean and all of the necessary tools
are available. These shocks contain high pressure
nitrogen gas. Always use proper safety equipment
such as latex gloves and safety glasses when working
on shock absorbers.
CAUTION
Use a soft-bristle brush to remove as much dirt and
debris as possible. Do not pressure wash the shock
as this can force water and debris inside causing dam-
age to the seals.
! WARNING
When using compressed air to dry components,
always wear safety glasses.
! WARNING
Always place a rag or towel over the valve and hex key
for protection when releasing the nitrogen from the
reservoir.
