Inspection Guidelines

When servicing FOX forks, inspect the following parts for defects and/or damage:

O-rings: Inspect for deformation, twists, nicks, cuts and wear. These issues can lead to air loss, fluid loss and sub-standard performance.
Dust Wipers (Oil seals): Inspect for deformation, nicks, cuts, excessive dryness and wear. These issues can lead to loss of oil. Always replace the seals if any of these conditions are found. It is normal to see a slight amount of oil on the upper tube. This small amount of oil creates a film on the upper tube which keeps the seal lubricated insuring a long life for the fork and ultra-smooth fork action while riding.
Bushings: Inspect for a diametric clearance of .0015”-.0090” between the upper tube and bushing. This small amount of clearance is a key part of the smooth action of FOX FORX. It is normal to feel this small amount of play during static testing (i.e. rocking the front wheel back and forth with the brake applied). If diametric clearance greater than .0090” is found, the lower leg assembly should be replaced.
Rebound Piston Glide Ring: Inspect for wear, damage and rough edges. Inspect that the Z-cut interfaces properly. If any of these issues are present, replace the glide ring.
Suspension Fluid (Oil): Inspect oil for suspended particles of dirt, rubber, Loctite or other contaminants, such as water. The oil will appear “milky” if contaminated by moisture. Inspect the fork to determine the cause of contamination and correct. Replace contaminated oil with fresh FOX Racing Shox Suspension Fluid. Always use FOX Racing Shox approved suspension fluids and lubricants.
Fasteners: Inspect that threads are intact and not deformed. Inspect that wrench flats or hex flats are intact and not deformed. Inspect that the fastener is not cracked or damaged. Replace fastener if damaged. Remove old Loctite from threads with a wire brush or dental pick before reusing.
Steerer: Inspect steerer for straightness. Inspect for damage such as gouges, scratches, cuts, nicks and wear marks. Ensure the steerer is completely seated in crown. Replace crown-steerer-upper tube assembly (FOX 40: lower crown-steerer assembly) if steerer damage is found.
Crown: Inspect crown for deformation and damage such as gouges, scratches, cracks, nicks and wear marks. Inspect interface between the steerer and crown for damage or deformation. Inspect interface between upper tubes and crown for damage or deformation. Upper tubes should be pressed in completely to the lip at the top of the crown (except the FOX 40). Replace crown-steerer-upper tube assembly (FOX 40: lower crown-steerer assembly) if crown damage is found.
Upper Tubes: Inspect for wear, damage, scratches, dents and rough spots. Inspect that threads at the topcap interface are in good condition. Inspect that inside of the upper tube is free from foreign materials and is smooth and clean. Inspect the lower end of the tube for dings or other damage. Replace crown-steerer-upper tube assembly if upper tube(s) damage is found (FOX 40: the upper tubes can be replaced separately from the crown-steerer assembly).
Lower Leg Assembly: Inspect the lower leg for deformation and damage such as gouges, scratches, cracks, nicks and dents. Inspect around brake bosses and/or disc brake tabs for signs of damage. Inspect dropout area for wear and damage. The dropout and wheel skewer interface can become excessively worn. The thickness of the dropout is 7.20mm +/- 0.25mm when new and unworn (except 36 and 40). Inspect that thickness is not less than the minimum specification of 6.20mm (except 36 and 40). (FOX 36 and 40: Check the pinch-bolt torque). Replace lower leg assembly if necessary.
Roll Crimps: Inspect roll crimps on steel damper, air and plunger shafts for a maximum axial gap of .004”. The insert should be held securely by the roll crimp and staking. Shafts with acceptable axial movement but rotating inserts can be re-staked and used. Axial movement greater than .004” or inserts that cannot be held securely require that the complete shaft assembly be replaced.