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Replacing the Remote RL Actuator Control Cable and Housing

Disassembly

Located in the bottom of the steerer under the fork crown is the cable holder assembly (820-00-204). With a 3 mm Allen key wrench, loosen the fastener holding the assembly in place.
Figure 1: Removing the Cable Holder Assembly
As you avoid pulling on the RL cable, pull the cable holder assembly straight down to remove.
Figure 2: Removing the Cable Holder Assembly cont'd
With a 2 mm Allen key wrench, remove the rebound knob (210-03-097).
Figure 3: Removing the Rebound Knob
While removing the five (5) M2 screw fasteners (019-01-005 x 5) that secure the Remote RL assembly to the topcap, press lightly down on the Remote RL stamped cover (210-22-240) with your thumb, to prevent the assembly from popping out. Use a 1.5 mm Allen key wrench to remove these five screws.
Figure 4: Remove the Five M2 Screw Fasteners
Remove the stamped cover (210-22-240) and cover shim (241-01-023) by pulling these together straight upwards.
Figure 5: Stamped Cover and Cover Shim
Loosen the Shimano inner cable set screw (019-01-044) enough with a 1.5 mm Allen key wrench to allow you to pull the cable out of the Remote RL assembly; see "Remove the Inner Cable Set Screw".
Figure 6: Remove the Inner Cable Set Screw
Re-install three (3) of the M2 screws back into the topcap, allowing the Remote RL housing and all parts underneath to be securely held in place. Be sure the Remote RL housing securely settles to the bottom of the topcap, tightening it down lightly with the 1.5 mm hex wrench.
Figure 7: Loosely Re-install Three M2 Screws
Using a pick, pry the original or damaged inner cable stop end from the Shimano Actuation Lever, and pull the inner cable all the way out.
Figure 8: Remove the Original Inner Cable

Install/Adjust a New SIS Inner Cable/SIS SP40 Housing

Note: Be sure the cable adjusting barrel on the Remote RL lever assembly is turned in all the way clockwise, and the actuation lever is set to the unlocked position.

CAUTION: Fox recommends keeping the cable housing at the Fox specified length (21 inches or 533.4 mm). However, if a shorter or longer cable housing is preferred over the Fox specified length, please thoroughly note the following bullet points:

For evenly cutting SIS-SP40 cable housing, the use of proper bicycle cable cutters is strongly recommended, such as Shimano's SIS cable/housing cutter.
It’s very handy to have a scribe or some kind of sharp pick device in your tool set, for poking into the cable housing ends after cutting, to clear the inner lining.
You will also need two 4 mm plastic ferrules to install on each end of the housing after cutting the housing.
When determining the new desired length of the SIS-SP40 housing (not the brake cable and brake housing type), make sure the length selected will allow smooth, gradual curves, with no sharp bends. For example, the length needs to be enough as to allow the turning of the handlebar to full lock in either direction (a sweep of 180 degrees side to side). As a starting point, lay the old piece of housing along side with the new housing, and cut the new housing to at least the same length as the original piece. You can then adjust the length as is necessary. If the cable near the handlebar is too long and floppy, you would likely desire the new one to be shorter. However, you must be careful not to make it so short that your handlebar won't fully rotate side to side. Also, consider how the cable will fit around other items, such as reflectors, brake levers, etcetera. You may need to adjust the cable housing length to accommodate these items.
The cable housing must be long enough to travel through the cable holder assembly attached to the under side of the steerer crown (see "Removing the Cable Holder Assembly"). Failure to comply with this will result in failure of the Remote Lockout system.
Be sure to measure correctly, to give you the proper length that allows full handlebar turns (a full 180 degrees of sweep) before you make your final cut. Cut the SIS-SP40 housing clean across, using the Shimano or comparable cable cutter. After cutting the SIS housing to length, clear the plastic lining with your pick tool at both ends of the housing, to ensure free movement of the inner cable.

Feed a new derailleur cable (OD = 1.1-1.2 mm) into the Shimano Actuation Lever, and thread it all the way through until the cable stops.
Note: If you are using a housing length that differs from the Fox specification, be sure to read the cautionary bullet items above.
Run the inner cable through the cable outer casing and pull it completely through, until the inner cable stop end and the cable housing fully seat into the Shimano Actuation Lever. Next, ensuring the inner cable is protruding from the Shimano SIS-SP40 outer casing 0.480” ± 0.026”, mark the inner cable with a felt tip ink pen and cut the inner cable with a quality cable cutting hand tool.
Note: Be sure to use a sharp Shimano or comparable quality cable cutter, to ensure a clean (non-frayed) cut.
Figure 9: Cut the Exposed Inner Cable End to Specification
Push on the upper cam so that there is a 0.050” gap between the back edge of the upper cam and the opening on top of the Remote RL housing; see "Pushed Upper Cam in Remote RL Housing With 0.050" Gap".
Figure 10: Pushed Upper Cam in Remote RL Housing With 0.050" Gap
Note: Be sure the barrel adjuster on the Remote RL assembly (820-00-248) is turned all the way clockwise, and that the Shimano lockout lever (210-15-062) is in its unlocked position.
With the upper cam (210-22-239) being steadily pushed to allow the 0.050” gap (as shown in "Pushed Upper Cam in Remote RL Housing With 0.050" Gap"), install the control cable through the holes in the Remote RL housing and the upper cam. See "Attaching the Shimano Control Cable" and "Tightening the Shimano Inner Cable Set Screw".
Figure 11: Attaching the Shimano Control Cable
Make sure your Shimano outer cable casing end is seated all the way into the hole in the Remote RL housing, and that the inner cable is cut long enough to pass beyond the cable set screw in the upper cam; this will serve to ensure the best set screw attachment.
Figure 12: Tightening the Shimano Inner Cable Set Screw
Tighten the inner cable set screw (019-01-044) to 3 in-lbs.
Allow the upper cam (210-22-239) to return to its starting position.

Ensure Proper Lockout Engagement

On the Remote RL assembly (820-00-248), turn the barrel adjuster out ten (10) clicks.
Push the lockout lever down to its locked-out position.
Measure the gap between the inner window edge of the Remote RL housing to the inner edge of the upper cam (210-22-239); this measurement must be 0.185” ± 0.005” (see "Remote RL Housing and Upper Cam Gap Specification"). If this measurement is not set to specification, adjust the barrel adjuster until it is.
Figure 13: Remote RL Housing and Upper Cam Gap Specification
Push the release button to unlock the system.

Reassemble the RL System

Remove the three M2 screws loosely securing the Remote RL assembly in the topcap, as originally instructed in Step #7 of the "Disassembly" procedure.
Install the shim (241-01-023) over the bottom lip of the Remote RL stamped cover (210-22-240). Install the shim from the bottom of the cover, making sure the opening of the shim is placed underneath the rectangular opening in the cover (see "Install Shim Over Bottom Lip of Stamped Remote RL Cover").
Figure 14: Install Shim Over Bottom Lip of Stamped Remote RL Cover
Slip the Remote RL stamped cover (210-22-240) over the Remote RL housing (210-22-241), pushing on the cover until the cover is fully seated onto the housing.
Position the housing so that the left edge of the outer cable casing just contacts the crown, as shown in "Remote RL Assembly, Top View".
Figure 15: Remote RL Assembly, Top View
Install the five M2 screws (019-01-005) to secure the Remote RL assembly, as shown in "Installing Five (5) M2 Screws". Tighten the screws down with your 1.5 mm hex wrench in a counterclockwise sequence, to 0.75 in-lb each. At this point, make sure that the bottom of the socket head contacts the top face of the shim (241-01-023). Continue with the counterclockwise sequence tightening of the screws, until the final torque value of 1.5 in-lb for each screw is achieved.
CAUTION: Four M2 screws are the absolute minimum required for safely securing the Remote system.
Note: Forks may ship with either four (4) or five (5) screws securing the Remote system. In no case will forks ever ship with all six (6) screws installed, as this is not physically possible due to the orientation of the remote housing relative to the installed topcap. Whenever possible, a minimum of five (5) screws is the prevailing recommendation for the most secure installation of the Remote system.
Note: Any M2 screw holes that are not being used will not pose a potential for dirt intrusion into the Remote system.
Figure 16: Installing Five (5) M2 Screws
Place the rebound knob (210-03-097) onto the rebound rod. Make sure to align the flats located on the rebound knob to the flats located on the rebound rod.
Apply one drop of purple Loctite 222 to the rebound knob screw (019-01-007) and with a 2 mm Allen key wrench, torque the rebound knob screw to 2.5 in-lb.
Figure 17: Tightening the Rebound Knob Screw

Install the Cable Holder Assembly

With the Cable Holder Assembly (820-00-204), hook the steel bracket (026-03-012) around the cable housing located in front of the steerer; see "Cable Housing With Cable Holder Assembly".
Figure 18: Cable Housing With Cable Holder Assembly
While keeping the cable housing inside of the hook on the steel bracket, place the nut (019-00-005) end of the assembly up into the steerer from the underside of the crown.
Push the assembly in the steerer until the large washer (241-01-021) contacts the bottom of the steerer.
Position the Cable Holder Assembly so that the cable housing runs parallel with the crown.
While holding the front of the assembly to keep it from turning, tighten the M5 bolt (019-01-043) to ~8 in-lb torque with a 3 mm hex wrench, as shown in "Securing the Cable Holder Assembly".
Figure 19: Securing the Cable Holder Assembly

Ensure Proper Remote RL Functionality

Push the Shimano actuation lever down to its locked-out position.
Push down on the handlebars vigorously to check whether the fork is completely locked out.
If the fork is not locked out completely, turn the barrel adjuster clockwise (that is, from the standpoint of the rider facing the front of the bike) until the fork completely locks out. If there are more than 6 clicks out, the cable length must be readjusted.
Push the release button to unlock the fork, making sure the fork is completely unlocked.
Rotate the handlebar side to side full sweep (180 degrees), checking for proper cable and housing length. No binding or catching on other parts should occur.

Notes About Bike Washing

When you're washing your bicycle, be sure to keep any high pressure spray away from the Remote RL fork topcap mechanism. As a basic rule of thumb, never use a pressure washer.
Directly spraying the Remote RL topcap mechanism will result in the loss of internal mechanism lubrication, which will cause poor performance of the Remote Lockout.
Directly spraying the Remote RL topcap mechanism will also likely result with fine grit dirt deposits entering the topcap mechanism, probably resulting in poor performance as well.