Simple 36 mm TALAS Dust Wiper & Oil Change

Disassembly

36 RC2 only: Remove the black protective cap on the bottom of the right side lower leg.
If you have an R, jump to "Remove the RC2 & R Damper Assembly Bottom Nut".
Line up the bolt holes on the high and low-speed compression knobs.
With a 2 mm hex key wrench, loosen—but do not completely remove—the hex screw on the low-speed compression knob.
When the screw is loose enough, lift and remove the low-speed compression knob and set it aside.
With a 2 mm hex key wrench, loosen—but do not remove—the hex screw on the high-speed compression knob.
When the screw is loose enough, lift and remove the high-speed compression knob and set it aside.
Note: On the bottom of this knob you will find a detent ball and spring; be careful not to lose these.

With a 10 mm socket, remove the nut located on the left side lower leg and the aluminum crush washer.
Push down on the shaft to dislodge the lower TALAS air shaft plunger. If it can't be dislodged, screw the bottom nut on to the shaft at least 2 full turns. Strike the bottom nut with a soft-faced mallet and remove the bottom nut.
With a 15 mm socket, remove the bottom nut on the cartridge side, and also remove the black crush washer.
RC2 and R: screw the bottom nut back onto the threaded stud with two full turns. RC2 only: screw the black protective cap back onto the bottom nut.
RC2 only: using a plastic-faced hammer, gently strike the black protective cap to dislodge the damper assembly stud from the lower assembly. With the R, you can strike the threaded post with the plastic-faced hammer to dislodge the damper assembly stud from the lower assembly.
Holding the fork over an oil pan, remove the bottom nut (and the black protective cap if you're using it) and drain the old suspension fluid out of the lowers.
Secure the fork in a bike stand. Gently pull down on the lower legs to fully disengage them from the upper tubes. Again, drain any remaining oil into the drain pan from the lower and upper tube assembly.

Using an 18 mm open-end wrench, pry up the dust wipers. Be careful not to scratch the ID (inner diameter) of the lower legs.
After the dust wipers are removed, the foam rings will be visible. Remove the foam rings now.
Clean upper tube assemblies and lower legs with cleaning solvent and set these aside to dry.
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. Check the anodisation on the upper tubes. If the upper tubes have excessive wear, replacement of the upper tube assembly will be necessary.
After examining the dust wipers and foam rings, they must be replaced with the following dust wiper kit:
- FOX 36MM Dust Wiper Kit (FOX P/N: 803-00-124)

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 to locate the service center nearest you.

For specific servicing instructions for internal assemblies of the 36 mm FIT damper:

Gently slide the new 36 dust wipers onto each upper tube.
Note: Dust wipers are pre-lubed from the factory.
Dip the foam rings into fresh 7 wt. suspension oil, and slide them up to the dust wipers.
Push the seals and foam rings about halfway up the upper tubes.
Slide the upper tube assembly into the lower leg assembly.

Slide dust foam ring and dust wiper seal down into seal gland bore.
In most cases you will be able to push the seal in by hand.
If you cannot push the seal in all the way by hand, use a 10 mm socket driver tool or 10 mm socket with extension to help with pushing them into place. Push on the side edge of the seal. Move around the seals outer edge to several locations as you push the seal into place.
CAUTION: Do not push on the dust wiper lip and spring, or damage to the seal and spring may result.

When you get the seal to be flush with the lower assembly, repeat the procedure on the other side.

Turn the fork upside-down and pour 25 cc of FOX 7 wt. suspension fluid through the hole on the bottom end of the right lower leg (damper side).
Next, pour 15 cc of FOX 7 wt suspension fluid in through the bottom hole, into the left lower leg (the TALAS side).
Push the lowers down to bring the threaded studs through the holes. Place a new black crush washer on the end of the damper threaded stud and a new aluminum crush washer on the TALAS threaded stud.
Screw on the two bottom nuts (10 mm TALAS side, 15 mm cartridge side). With a torque wrench, torque the bottom nuts to 50 in/lb (5.65 N-m) each.

Be sure the spring and detent ball are in place inside the high-speed compression knob. Lightly grease the detent ball.
Place the high-speed compression knob onto the adjuster shaft, aligning the screw pocket with the hex screw.
CAUTION: Make sure you don't let the detent ball drop out onto the floor.
Tighten the hex screw to 4 in/lb with a 2 mm hex wrench.
Place the low-speed compression knob onto the adjuster shaft, aligning the hex screw with the screw pocket on the adjuster shaft.
Tighten the hex nut to 4 in/lb. with a 2 mm hex wrench.
Place the black protective cap on the knobs.

Now you're finished; go out and have a great ride!