VANILLA R

Note:  Some photos may not depict the actual model of fork

Disassembly

The R Topcap does not need to removed to disassemble the topcap assembly. If you do not wish to remove the rebound knob, skip to step #3.

Before removing the R Topcap, you must first remove the retaining nut at the bottom of the fork leg. The retaining nut will be removed in the next step.

To remove the R Topcap:

1. With a hex key wrench, remove the hex key on top of the red rebound knob.
   
   
2. Remove the rebound knob by lifting it.
   
   
3. Unscrew—but do not remove—the damper topcap with a 26 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.
   
    
4. Leave the topcap assembly on. Secure your fork so that the fluid inside of the fork does not spill out.
   • After loosening the R Topcap assembly, you are now ready to remove the bottom nut on the damper, which will allow you to fully remove the R 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 since you will need to turn the fork upside-down to access the bottom nut. You will not want suspension fluid spilling all over your new Hush Puppies.

To remove the R Damper:

1. Using a 10 mm socket, remove the bottom nut.
   
   
2. Screw the bottom nut back on two full turns. Using a plastic faced hammer, gently strike the bottom nut to release the damper assembly.
   
   
3. 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.
   
   
4. Making sure the fork is right-side up, remove the topcap.
   
   
5. Pull up on the topcap and remove the R Damper assembly.
   
   

To remove the Preload Topcap:

1. Before removing the Preload Topcap, turn the preload knob (shown below) fully counterclockwise. This releases the load on the coil spring.
   
   

   CAUTION:  There is a small amount of suspension fluid in the left leg. Screw in the topcap at least 2 full turns before turning the fork upside-down, to prevent the fluid from spilling out.

2. Unscrew the preload topcap with a 26 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.
   
    

To remove the 32MM Vanilla Spring:

1. The Preload Topcap was loosened in the previous step. You can now fully unthread the topcap to expose the coil spring.
   
   
2. Simply pull out the coil spring.

   Note:  The 2007 VANILLA 140 does not have a shorter travel option. Therefore, you should not find any travel spacers on top of the coil spring.

   
   
3. Sometimes the plunger shaft will come out when the coil spring is pulled out. If that is not the case, turn the fork upside-down and allow the plunger shaft to drop out.
   
   

To remove the crown/steerer/upper tube assembly:

1. Both the damper shaft and air spring shaft should be dislodged from the lower legs, allowing you to remove the lower leg assembly. Drain the lower leg assembly into an oil pan before putting it aside.
   
   
2. Clean the crown/steerer/upper tube assembly with parts cleaner.
3. Inspect the assembly for any nicks, cuts, scrapes, scratches or gouges, and replace if necessary.
   • The assemblies that normally prevent the removal of the lower legs should already have been removed.
   • Removal of the lower legs should be done with the fork secured in a bike stand and over an oil pan.

To remove the 32MM lower legs:

1. Making sure the fork is secured in a bike stand or soft-jawed vise and over an oil pan, turn the fork upside-down.
2. Remove the topcap assemblies from both sides of the fork, and let the oil drain out.
   
   
3. If not already done, remove all base valve bolts and/or knobs.
4. Gently pull up on the lower legs to fully disengage them from the upper tubes.
   
   
5. Drain any remaining fluid from the lower legs into an oil pan.
   • After removal of the lower legs, it is a good idea to replace the dust wipers and foam rings
   • When possible, the bicycle/fork should be stored upside-down to keep the dust wipers and foam rings lubricated.

To remove the seals and dust wipers:

1. Using an 18 mm open-end wrench, pry up the dust wipers. Be careful not to scratch the ID of the lower legs.
   
   
2. 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 them.
   
   

   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 32MM Dust Wiper Kit (FOX P/N: 803-00-079)

   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.

   Dropouts:

   • Over time the knurled surfaces of the front wheel hub and quick-release skewer wear out the dropout region of the lower leg (see Dropout photo below).
   • Inspect and measure the thickness of the dropouts every 6 months or 100 hours. Ensure that any point on the surface is above the minimum specification of 6.20 mm (see Measure Dropout photo below).
   • Replace the lower leg assembly if the dropout thickness is at the minimum specification or less.

     Dropout

     Measure Dropout

Service

For specific service instructions for internal assemblies, see service procedures for the 2007 32 mm R cartridge.

Assembly

Note:  Before proceeding from this point, be sure that you have drained all oil from the damper cartridge.

Go to Damper Cartridge Oil Removal for more information about this procedure.

To install the crown/steerer/upper tube assembly into the lower leg assembly:

1. 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.
   
   
2. Slide a new set of foam rings onto the upper tubes and slide them up under the dust wipers.
   
   
3. Line them up so that they are about halfway up on the upper tubes.
   
   
4. 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.
   
    
5. Slowly push the crown/steerer/upper tube assembly into the lower legs. Make sure the bottom rods of the damper and spring assemblies properly protrude from the bottom of the lower legs. You might need to guide them through using a dental pick; if they are off-center they will hit the bottom-out bumper and you will not be able to push the crown/steerer/upper tube assembly all the way down.

To install the 32MM Vanilla spring:

1. Drop the spring plunger shaft into the left upper tube.
   
   
2. The bottom of the plunger shaft should protrude from the bottom of the lower leg. Place a new crush washer on the shaft, then screw the bottom nut on.
   
    
3. Torque the bottom nut to 50 in/lb (5.65 N-m) using a 10 mm socket and torque wrench.
   
   
4. Turn the fork right-side up, then drop the coil spring into the upper tube. (Make sure you are inserting the proper-rated coil spring into the fork. If the rider wishes to switch springs, now is the time to do it. Consult the Coil Spring Guidelines table below for spring settings.)

   Note:  The 2007 VANILLA 140 does not have a shorter travel option. Therefore, you should not find any travel spacers on top of the coil spring.

   
   

   COIL SPRING GUIDELINES
   FOX Part #	Approximate Spring Rate	Color Code	Travel (mm)	Rider Weight lbs. (kg)
   039-05-080	40.6 lb/in	Black	140	<90–115 (40.8-52.2)
   039-05-081	48.5 lb/in	Purple	140	115–150 (52.2-68.0)
   039-05-082	56.4 lb/in	Blue	140	150–180 (68.0-81.6)
   039-05-083	60.9 lb/in	Green	140	180–210 (81.6-95.3)

5. Pour 30cc of FOX 7wt. suspension fluid into the spring-side upper tube (see the Oil Volumes table for complete suspension fluid specifications for all fork models).

   Note:  The picture below shows the damper side, but this step applies to the spring side; that is, the left side from a seated rider's perspective.

   
   
    

To Install the Preload Topcap:

1. Screw on the preload topcap.
   
   
2. Torque the topcap to 165 in/lb (18.64 N-m) with a 26 mm 6-point socket. Be careful not to slip and damage the wrench flats.
   
     
3. Adjust preload on the fork in accordance with the owner's manual. The table below shows proper sag settings for a 2007 VANILLA 140MM fork.

   SAG SETUP
   Travel	XC/Race FIRM	Freeride/All-Mountain PLUSH
   140 mm (5.5")	20 mm (3/4")	30 mm (1.25")

To install the R Damper:

1. Insert the damper assembly into the right upper tube. Make sure the damper shaft protrudes from the bottom of the lower leg.
   
   
2. Place a new crush washer on the end of the damper shaft.
   
   
3. Screw on the bottom nut. Using a torque wrench and 10 mm socket, torque the bottom nut to 50 in/lb (5.65 N-m).
   
   
4. Turn the fork right-side up and pull up on the topcap assembly. Pour in the proper amount of FOX 7 wt. suspension fluid into the right upper tube. Consult the Oil Volumes table for oil bath suspension fluid amounts to specification, depending on your fork model.
   
   
5. Screw the topcap assembly on and torque to 165 in/lb (18.64 N-m) using a 26 mm socket and torque wrench.
   
   

To install the R Topcap:

1. Screw the damper topcap into the upper tube with a 26 mm 6-point socket.
   
   
2. Place the rebound knob on the topcap assembly. The lever and adjuster shaft are indexed.
   
   
3. Using a 1.3 mm (0.050") hex key wrench, tighten the hex key on top of the rebound knob.
   
   

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FOX Factory Inc.