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36 mm TALAS III RC2

The full "TALAS System" fork service overhaul procedures on this page require specialized tools and a higher level of technical expertise. The full service procedures are intended for the qualified service technicians having this higher level of technical service skill, and the proper tools.

For simplified TALAS dust wiper and open bath oil change procedures, click here.
For the full "TALAS System" fork service overhaul, continue with the procedures below.

Note: Some photos may not show the actual model of fork.

Damper Cartridge Removal

Remove the 36 RC2 Topcap

With a 2 mm hex key wrench, remove the hex screw on top of the red rebound knob.
Unscrew—but do not remove—the damper topcap with a 32 mm 6-point socket. Be careful not to slip and damage the wrench flats. You may need to grind down the socket so that it properly grips the wrench flats on the topcap.
Leave the topcap assembly on. Secure your fork so that the fluid inside of the fork does not spill out.
Note:
- After loosening the RC2 topcap assembly, you are now ready to remove the bottom nut on the damper, which will allow you to fully remove the 36 RC2 Damper assembly from the lower leg assembly.
- Place an oil pan underneath the fork before loosening the bottom nut.
- Make sure the topcap assembly is screwed in a few turns, as you'll need to turn the fork upside-down to access the bottom nut. You won't want suspension fluid to spill all over your new Hush Puppies!

Remove the 36 RC2 Damper

Remove the black protective cap.
Line up the bolt holes on the high and low-speed compression knobs.
Using a 2 mm hex key wrench, loosen—but do not remove—the hex fixing bolt on the low-speed compression knob.
When the fixing bolt is loosened enough, lift and remove the low-speed compression knob and set it aside.
Using a 2 mm hex key wrench, loosen—but do not remove—the hex bolt on the high-speed compression knob.
When the bolt is loose enough, lift and remove the high-speed compression knob and set it aside.
Using a 15 mm socket, loosen the bottom nut three (3) full turns.
Thread the black protective cap back onto the nut, this cap will protect the adjuster during the next procedure.
Using a plastic faced hammer, gently strike the bottom nut to release the damper assembly.
Holding the fork over an oil pan, remove the bottom nut and crush washer. If the crush washer isn't attached to the nut, check the bottom of the lower leg; it might be stuck there. Suspension fluid should flow out.
Turn the fork right-side up and remove the 36 RC2 damper assembly.

TALAS III Disassembly

Note: Inspect all o-rings during these procedures; replace these if necessary.

Caution! Put on your safety glasses!

Remove the TALAS aircap. To aid removal, hold the TALAS lever with your other hand as you turn the aircap.
While holding a shop towel over the topcap assembly, depress the main air chamber Schrader valve to release air pressure.
With a 1/16" hex key, remove the two small screws.
Remove the TALAS III lever and set it aside on a clean shop towel.
Using a dental pick, remove the TALAS III spiral retaining ring, and set it aside.
Remove the TALAS III adjusting mechanism, by hand if possible; pull straight upwards to remove.
Caution! If the adjusting mechanism is too difficult to remove by hand, do not use pliers directly on the bare valve threads, as damage may easily result.
Note: TIP: thread on a plastic or metal valve cap, before using pliers to remove the adjusting mechanism.
Remove the TALAS III adjuster tension spring, and set it aside.
Remove the 36 mm TALAS III topcap housing with a 32 mm socket. Be careful not to slip and damage the wrench flats. You may need to grind down the socket to reduce lead-in chamfer, which will improve the engagement with the topcap wrench flats.
Remove the TALAS III upper assembly by pulling it straight upwards and out, and set it aside.
Caution! Be careful not to bend the TALAS III outer tube assembly as you remove it.

TALAS III Lower Air Shaft: Disassembly

Turn the fork upside-down and, and with a 10 mm socket, remove the TALAS air lower shaft bottom nut.
Push down on the protruding TALAS air lower shaft to push up the air shaft plunger. If it can't be dislodged, screw the bottom nut on to the shaft at least 2 full turns and softly tap the bottom nut with a soft-faced mallet and remove the bottom nut.
Push down on the end of the TALAS lower shaft that is protruding from the bottom of the upper tube. Hold your hand under the topcap area so that the lower shaft doesn't fall on the ground as you push it down and out of the upper tube.
Slide the lowers off the crown steerer and set aside for now.

TALAS III Outer Tube: Disassembly

Note: The following sub-procedure is only necessary if you suspect TALAS adjuster tube issues, such as travel steps not properly adjusting or evidence of travel creep.

With a 16 mm open-end wrench and a 32 mm socket, unthread the topcap housing from the TALAS III air chamber volume spacer.

Note: Blue Loctite #242 is used at this part thread connection during factory assembly.
Using the 7 and 11 mm box end wrenches, unthread the outer ferrule nut with the 7 mm wrench as you hold the tube nut with the 11 mm wrench.
Using a 32 mm socket and the 11 mm box wrench, remove the tube nut from the topcap.
Unscrew the inner tube valve nut three (3) full turns.

At this point, as everything has been disassembled with the 36 mm TALAS III fork, this is your best opportunity to clean or replace any parts before beginning the following reassembly procedures.

TALAS III Reassembly Procedures

TALAS Lower Air Shaft: Reassembly

Clean or replace seals as needed. Pre-lube the TALAS lower air shaft seals with FLOAT Fluid. Pour 3 cc of Float Fluid into the upper tube and push the air shaft assembly down into the upper tube.
Use a 15 mm deep socket with extension to push the air shaft assembly down, until it protrudes from the bottom of the upper tube. Set it aside for now.

TALAS III Outer Tube: Reassembly

Note: Before reassembling the TALAS III outer tube assembly, be sure all parts are clean and free of Loctite debris.

Place a single drop of #242 blue Loctite onto the outer ferrule nut.
Note: Be sure that the long tapered end of the white nylon outer ferrule is oriented towards the outer ferrule nut.
Insert and press the outer tube assembly into the tube nut, while using the 7 and 11 mm box end wrenches to thread the two parts together. When you feel resistance on the compression ferrule, only tighten the compression tube nut 1/2 turn further.
Using a flat blade screwdriver, thread in the inner tube valve nut until you feel a slight amount of resistance as the parts engage together, without using any Loctite.
Caution! CRITICAL: at this point, do not tighten any more than 1/8 of a turn further.
Inspect the travel adjustment ports in the side of the outer tube. Be sure that you see brass color through the middle set of four holes. On the 36 mm TALAS III fork, you should also be able to see the color red through the upper two port holes and red through the bottom-most two port holes, besides the brass color viewed through the four middle port holes.
Place a single drop of #242 blue Loctite onto the threads of the tube nut.
Using the 11 mm open end and 32 mm socket wrenches, torque the tube nut to the topcap and tighten to 50 in. lbs.
Place a single drop of #242 blue Loctite onto the lower threads of the topcap.
After threading the volume space onto the topcap lower threads, apply grease to the lower topcap o-ring.
Using a 16 mm open end wrench and a 32 mm socket, torque the volume spacer to the topcap assembly lower threads, and tighten to 50 in. lbs.

Remove the Dust Wipers from the Lowers

Using an 18 mm open-end wrench, pry up the dust wipers. Be careful not to scratch the ID of the lower legs.
Note: If you are planning to reuse the dust wipers, make sure to pull off the garter springs before you pry out the dust wipers.
After the dust wipers are removed, the foam rings will be visible. Lift them out of the lower legs. If they cannot be located, check under the dust wipers; they might be stuck underneath.

You can get a general sense of the condition of the fork by examining the foam rings. Dry foam rings indicate a lack of fluids or, possibly, a leak. Dirty foam rings may indicate a faulty dust wiper. In either condition, the anodizing on the upper tubes should be examined. If the anodizing has worn off due to insufficient lubrication, replacement of the crown/steerer/upper tube assembly might be necessary.
After examining the dust wipers and foam rings, they can be discarded and replaced using the following replacement kits:
FOX 36 mm Dust Wiper Kit (FOX P/N: 803-00-124)
Lower Leg Bushings:
FOX Racing Shox recommends that you have your bushings serviced at a Factory Authorized Service Center. Refer to http://www.foxracingshox.com/fox_tech_center/service.htm.
Bottom-out Bumpers:
Bottom-out bumpers are technically not a serviceable item, so they rarely need to be replaced.

Dust Wiper and Lower Leg Reassembly

Slide a new set of dust wipers onto the upper tubes. Lubricate the upper tube with a light coat of suspension fluid to facilitate installation.
Slide a new set of foam rings onto the upper tubes and slide them up under the dust wipers.
Line them up so that they are about halfway up on the upper tubes.
Slide the crown/steerer/upper tube assembly into the lower leg assembly. Do not slide the crown/steerer/upper tube assembly in all the way yet.

Damper Cartridge Service

For specific service instructions for RC2 damper cartridge assemblies, see the 36 mm RC2 cartridge servicing procedure.

Install the RC2 Damper

Insert the damper assembly into the right upper tube. Make sure the adjuster shaft protrudes from the bottom of the lower leg.
Screw the damper topcap into the upper tube with a 32 mm 6-point socket and torque to 165 in/lb (18.64 N-m).
Pour 25 cc of FOX 7 wt. suspension fluid in through the bottom hole, into the right lower leg (the cartridge side).
Next, pour 25 cc of FOX 7 wt suspension fluid in through the bottom hole, into the left lower leg (the TALAS side).
Place a new crush washer on the end of the damper shaft, and also the TALAS shaft stud.
Screw on the bottom nuts. Using a torque wrench and 15 mm socket (for the cartridge side) and 10 mm (for the TALAS side), torque the bottom nuts to 50 in/lb (5.65 N-m).

Install the RC2 Compression Knobs

Ensure the ball bearing inside the high-speed compression knob is present. Lightly grease the inside of the knob.
Place the high-speed compression knob onto the adjuster shaft, aligning the hole with the hex nut with the divot on the adjuster shaft (note that there are three other empty holes). The side of the knob with ball should be right next to the adjuster shaft. Make sure the ball doesn't fall out as you install the knob.
Tighten the hex nut to 4 in/lb. using a 2 mm hex wrench.
Place the low-speed compression knob onto the adjuster shaft, aligning the hex nut with the divot on the adjuster shaft.
Tighten the hex nut to 4 in/lb. using a 2 mm hex wrench.
Place the black protective cap over the knobs.

TALAS III Topcap: Reassembly

Add 3 cc of the 5 cc FLOAT fluid pillow pack into the upper tube.
Note: Hold the fork tube at a slight angle as you pour the oil in, to coat the inside of the tube (to avoid dousing the seal head).
Apply grease to the volume spacer o-ring and upper threads of the topcap. Insert the topcap assembly into the upper tube, making sure not to bend the outer tube as you guide it into the lower air shaft seal head.
Torque it into the left fork leg to 165 in. lbs. with a 32 mm socket.

TALAS III Inner Adjuster Rod: Reassembly

Note: Before proceeding, be sure that all parts are thoroughly clean and ready for assembly.

Grease the TALAS III adjuster screw. Be sure to cover the spline gear, o-ring, and ramp with grease.
Place the TALAS III detent adjuster onto the adjuster screw.

Note: Be sure that both detent ball bearings in the detent adjuster are properly in place.
Drop the lower adjuster spring into the topcap.
Orient the detent bearing post (on the detent adjuster, as indicated by the red arrow in the left-hand graphic below) to the 11 o'clock position, relative to the front of the fork legs set at 12 o'clock, as you insert the TALAS III adjuster assembly into the topcap.
Caution! As you insert the inner adjuster needle on the TALAS III adjuster assembly down into the topcap, carefully insert the needle tip into the inner tube valve nut hole deep within the topcap assembly.
Install the retaining ring into the topcap retaining ring groove. Pull upwards on the Schrader valve, to position the adjuster up to the retaining ring. This will assist making it easier to thread in the knob screws.
Note: It's very important to be certain the retaining ring is secure in the topcap retaining ring groove.
Install the adjuster knob, with the engraved travel indicator mark default positioned at approximately 11 o'clock (relative to the front of the fork legs set at 12 o'clock).
Tighten the two screws with a 1/16" hex key.
With a FOX High Pressure pump, air up to your desired pressure level and replace the air valve cap.