Fox DHX Coil Rebuild Introduction: This is a guide to tearing down and rebuilding a Fox Racing Shox DHX 3/4/5 Coil shock. It shows the user how to: Dismantle the shock Clean internal parts Disassemble the Propedal valve and spring Disassemble the Rebound assembly (see disclaimer) Replace internal orings Replace main shaft seal oring Replace oil Reassembly of the shock unit Note: Disclaimer: Fox Racing Shox does not endorse this guide! By proceeding with this guide, the instant you open your shock, you voluntarily and knowingly forfeit any warranty that came with the shock. Rebound Disassembly requires the use of a propane torch to soften loctite used to secure rebound adjuster eyelet to shock shaft. Soften of the loctite is required to remove the eyelet. BE EXTREMELY CAREFUL WHEN HEATING THE EYELET; ONLY HEAT GENTLY UNTIL IT IS HOT TO TOUCH. PROLONGED HEATING WILL CAUSE DAMAGE TO EYELET AND SHAFT ASSEMBLY. Do not proceed with these procedures if you are not mechanically inclined! If you have a tendency to round/strip every screw you touch, put the tools down NOW! Any damage you cause to your shock due to your own mistakes is YOUR FAULT. Do not expect any sympathy from me, or any sympathy from Fox (or warranty). YOU have to pay to have the unit fixed. This guide was devised with care, with information gained from a number of sources. This procedure works if carried out CAREFULLY and with PATIENCE. I AM NOT RESPONSIBLE FOR ANY DAMAGE YOU CAUSE TO YOUR SHOCK, BIKE, PERSONA OR SURROUNDS, USE COMMON SENSE AND TAKE THE FIRST FEW RIDES EASY, TO ENSURE YOU HAVE CORRECTLY REPAIRED THE SHOCK. WARNING! READ ALL Instructions twice before you commence with the rebuild, and ensure you understand its procedures PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor
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Transcript
Fox DHX Coil Rebuild Introduction:
This is a guide to tearing down and rebuilding a Fox Racing Shox DHX 3/4/5 Coil shock. It shows the user how to:
-‐ Dismantle the shock
-‐ Clean internal parts -‐ Disassemble the Propedal valve and spring
-‐ Disassemble the Rebound assembly (see disclaimer) -‐ Replace internal o-‐rings -‐ Replace main shaft seal o-‐ring -‐ Replace oil -‐ Reassembly of the shock unit
Note:
Disclaimer:
Fox Racing Shox does not endorse this guide!
By proceeding with this guide, the instant you open your shock, you voluntarily and knowingly forfeit any warranty that came with the shock.
Rebound Disassembly requires the use of a propane torch to soften loctite used to secure rebound adjuster eyelet to
shock shaft. Soften of the loctite is required to remove the eyelet. BE EXTREMELY CAREFUL WHEN HEATING THE EYELET; ONLY HEAT GENTLY UNTIL IT IS HOT TO TOUCH. PROLONGED HEATING WILL CAUSE DAMAGE TO EYELET
AND SHAFT ASSEMBLY.
Do not proceed with these procedures if you are not mechanically inclined!
If you have a tendency to round/strip every screw you touch, put the tools down NOW! Any damage you cause to
your shock due to your own mistakes is YOUR FAULT. Do not expect any sympathy from me, or any sympathy from Fox (or warranty). YOU have to pay to have the unit fixed. This guide was devised with care, with information gained
from a number of sources. This procedure works if carried out CAREFULLY and with PATIENCE.
I AM NOT RESPONSIBLE FOR ANY DAMAGE YOU CAUSE TO YOUR SHOCK, BIKE, PERSONA OR SURROUNDS, USE COMMON SENSE AND TAKE THE FIRST FEW RIDES EASY, TO ENSURE YOU HAVE CORRECTLY REPAIRED THE SHOCK.
WARNING!
READ ALL Instructions twice before you commence with the rebuild, and ensure you understand its procedures
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-‐ Spanners -‐ Long Nose Snap ring pliers -‐ Small block of wood (to create makeshift shaft clamp) -‐ Propane torch -‐ Loctite thread lock -‐ Wooden vice
-‐ Soft jaw vice -‐ Long nose pliers -‐ O-‐ring / Dental picks (for removal of o-‐rings) -‐ Clean rags -‐ Clean work bench -‐ Oil drip Pan -‐ Safety glasses -‐ Small Breaker Bar
-‐ 11mm Drill bit
Parts list:
-‐ Replacement o-‐rings, the best way to get these is to take the removed o-‐rings to a local 0-‐ring supplier and get
them sized up properly for replacement ones, I also recommend you buy a good amount of each, it’s always good to have spares for next time, label them and put them in a compartment container
-‐ Fork/shock oil. Ensure you use a high quality, fully synthetic oil. I use 10W Castrol Fully synthetic fork fluid. The DHX comes stock with 10W Fox Fluid (rebadged Silkolene pro RSF 10) If you wish to use a different weight oil,
this sight has a lot of useful info on shock oil; http://www.peterverdonedesigns.com/bikesuspension.htm-‐
Further Information:
Here is a list of websites that have a lot of useful information on rear shocks, for anyone who is interested in learning
more about their rear shocks.
• Information on EVERYTHING regarding suspension, explaining different types of damper systems, set
up info on a range of shocks etc; these site’s are well worth reading through! :
STEP 7: Removing Bottom Out assembly o-‐rings and cleaning shock internals
39. Using your pick, remove the bottom out plunger o-‐ring, label and set aside the o-‐ring
40. Using your pick, remove the Bottom out housing o-‐ring, label and set aside the o-‐ring
41. The Bottom out assembly with its o-‐rings
42. Using a clean cloth, wipe out the main shaft chamber
43. Using a clean cloth, wipe out the piggyback chamber
44. You have now disassembled you shock. Take the o-‐rings to a local supplier and have them sized up and
replaced, I recommend getting a quantity of each, labelling them and putting them in a container for next time, it’s always good to have a supply of them
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STEP 8: Replacing main shaft o-‐ring and shaft housing o-‐ring
45. Take your new main shaft o-‐ring, apply a few drops of suspension oil to it and pinch as shown
46. Insert the pinched o-‐ring into shaft housing as shown
47. Place your pinkie in opposite end as shown
48. Using you other pinkie, squash the o-‐ring into the housing and use your fingers to set the o-‐ring in its housing, this can be tricky, take your time and it will go in
49. Take you new shaft housing seal, and place a few drops of suspension oil onto it
50. Insert it back onto housing
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63. Reinsert the shaft into the clamps, place a small amount of loctite on threads, ensure loctite does not spill into rebound needle or on shaft surface
64. Reinstall the eyelet onto the shaft, hand tighten, the ensure clamps are tight
65. Using breaker bar, retighten the eyelet, the clamps will needed to be significantly tight to ensure that
eyelet tightens properly
66. Remove shaft from the clamps and clamp the eyelets into the vice. Using a small Allen key, gently push down on the rebound needle so that it engages the adjuster
67. Using a syringe, inject suspension oil down into the rebound assembly to purge air, cover the rebound
hole if needed. The rebound assembly is now rebuilt.
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68. To Access Propedal Spring and plate o-‐ring, with shock clamped upright in vice, remove the snap ring
using long nose circlip pliers
69. Replace o-‐ring, then reinstall spring back in reservoir, along with Propedal base plate, then reinstall circlip, insuring the it is properly seated in the recess. (Second Picture shows reservoir with Propedal
assembly removed
70. Unscrew black bottom out plunger from grey housing
71. Remove and replace o-‐ring, then reinstall black bottom out plunger in grey housing
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STEP 11: Replacing IFP and Bottom Out assembly o-‐rings, reassembling shaft assembly
72. Place a few drops of suspension fluid on a new IFP o-‐ring, and place it back on the IFP (In picture, new o-‐ring in place on IFP, old one next to IFP)
73. Place a few drops of suspension fluid on new bottom out housing and adjuster o-‐rings, then place them back on the assembly (the position of the old o-‐rings on the table is respective of where they go on
the BO assembly)
74. Wipe some suspension fluid on shaft, and replace rubber bottom out bumper
75. Reinsert the shaft seal housing back onto the shaft, be careful to put it on straight, take your time, DO
NOT FORCE IT, otherwise damage to the shaft or bushing may result
76. Replace the piston/shim assembly, and retighten. Just snug it tight, if you over tighten it too much, you may crush the shims and prevent them flexing
77. After you have retightened the piston, pull the shaft housing all the way up. Coat Piston and shim stack in oil, as to minimize air in shim, piston assembly. You have now successfully rebuild the shaft assembly
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STEP 13: Reinserting IFP and reinstalling Bottom Out assembly
84. Depress IFP past threads, ensure bleed screw is removed, and wear safety glasses, as oil will squirt through bleed hole
85. Using you measuring tool, push IFP to its correct depth. If you did not record your IFP depth, use the depth chart at the end of this document. Tap body to displace any trapped air as your pushing the IFP
in, this will ensure a good bleed
86. Reinstall bleed screw, drain and wipe excess oil from IFP chamber
87. Using spanner or wrenches, retighten the shaft housing. Its recommended that you use the old tube to
protect the shaft
88. Reinsert the bottom out assembly
89. Using a spanner or wrench, tighten the grey cap
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92. Reinflate the boost valve to a minimum of 125PSI
93. Clean the shock over with Isopropyl Alcohol or a wet cloth
94. Reinstall spring, any reducers and valve cap (and in my case, my shock boot)
95. Reinstall the shock back onto your bike
96. Do the bounce test on your bike to lube internal parts, then set adjustments to you settings, bounce check again to make sure everything is working correctly
97. Success = BEER!
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Big thanks to the people who contributed their valuable knowledge to help me compile this guide, id name you individually, but you know who you are!
Info obtained from people on:
-‐ MTBR
-‐ Pinkbike
-‐ ROTORBURN AUSTRALIA (formally FARKIN)
-‐ Ride Monkey
Compiled By me, Nick_M2R on 18th May 2009
Updated: 28th January 2010
While I have proof read this guide carefully, but I’m only human. If you have notice any mistakes or have any improvements, PM me on MTBR and ill include them in future releases.
Enjoy Guys and Girls!
Version: 4
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