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Step 6 - Remove the damper from the fork and place over a drain pan.
Step 9 - 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). On Vanilla forks, you will need to pull the
damper to the side slightly to pour in the oil past the spring.
Step 10 - Extend the fork. Pour into the LEFT Uppertube 30cc of NEW FOX
Suspension Fluid (7.5 wt.). On the LEFT side of the fork, reinstall the Travel
Spacers on top of the coil (2 on 125mm, 1 on 100mm, 0 on 80mm). Using a
26mm socket, install and torque the left side Preload Topcap to 165 in-lb.
Step 11 - Thread the RIGHT side Damper Topcap into the Uppertube. Using a
26mm socket, torque the Damper Topcap to 165 in-lb.
Installing the damper knobs on RL, RLT and RLC:
a) Low-Speed Compression knob on RLC models only: Clean the blue Low-speed compression knob with
degreaser and grease the bottom-side groove and detent bump surface. Install the blue Low-speed compres-
sion knob so that the groove on the bottom of the knob is positioned over the Aluminum pin in the Damper Topcap.
b) Lockout Lever Installation: Using the blue Lockout Lever as a wrench, screw the Lockout Screw (octagon
wrench flats) in the clockwise direction until you feel it stop. Put the Lockout Lever on the lockout screw so
that the lever faces approximately 6 o’clock position.
Installing Lockout Lever on RL and RLT models: Using a 1.5mm hex key wrench, lightly tighten each of the 3 set
screws on the Lockout Lever. Loosen each set screw 1/4 turn.
Installing Lockout Lever on RLC models: The Lockout Lever and Low-speed compression knob are spring-loaded
upward (this is normal). Push down on the lockout lever until you feel it stop. Using a 1.5mm hex key wrench, lightly
tighten each of the 3 set screws on the Lockout Lever. Loosen each set screw 1/4 turn.
c) Rebound knob installation: Install the red rebound knob so that the slot feature on the bottom of the knob
lines up with the flats on the rebound adjuster shaft. Put on one drop of Blue Loc-tite 242 to the flathead
screw. Holding the rebound knob firmly, install and tighten the flathead screw with a 2mm hex key wrench.
WARNING: Damper internals will be damaged if the rebound knob is not held firmly when tightening the rebound knob screw.
Step 12 - Adjust all damper knobs as shown below and functionally test damper.
On RL, RLT, RLC forks: Adjust the Lockout Lever to open (3 o’clock) position.
On RLT & RLC forks: Adjust the Lockout Threshold knob to the fully turned in clockwise, then turn 1 click out counterclockwise.
On RLC forks: Adjust the Low-speed compression knob to fully counterclockwise open position.
On ALL forks: Adjust Rebound knob to the fully closed position (0 clicks out from full in clockwise). Slowly compress
fork for 10 deep cycles to purge air out of damper. The fork should have slow rebound. Adjust Rebound knob to 6
clicks out counterclockwise from full in. Cycle fork again a few strokes. Fork should have faster controlled rebound
speed (factory setting). If there is free movement in the fork during compression or if it makes strange noises, disas-
semble the fork to check for complete number and orientation of spacers.
On RL, RLT, RLC forks: Close the Lockout Lever to 6 o’clock position and feel the lockout firmness. Lockout lag
should be between 2-6mm. Open Lockout Lever. HAPPY TRAILS!!!
Step 7 - 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 7
Step 8
