Manual Fox Talas
Manual Fox Talas
Manual Fox Talas
Steerer
Rebound
Knob (All forks)
Upper Tube
Lock-out
Lever (RL,
RLC & RLT)
Low-speed
Compression
Adjuster (RLC only)
Lower Leg
Dust Wiper
Threshold Adjuster
(RLC, RLT & X)
Drop-out
Table of Contents
Introduction
Consumer Safety
Important Safety Information
4
4
Installation
Tire Sizes
Brakes
Check before every ride
5
5
5
5
6
6
6
6
6
7
8
Changing Travel
F80, F100 & FLOAT 130
Vanilla
10
10
12
Changing Oil
Vanilla
F80, F100 & FLOAT 130
14
14
16
Service Intervals
Bushing Technology and Inspection
Drop-out Thickness Inspection
Seals and Foam Rings
19
20
20
21
Service / Warranty
Warranty Policy
Disclaimer
Contact Information
Methods of Payment
Method of Shipping
21
22
23
23
23
23
International Versions
Japanese
Franais
Italiano
Deutsch
Espaol
24
46
68
90
112
134
Introduction
Thank you for choosing FOX FORX for your bicycle. In doing so, you have chosen the best
suspension fork in the industry! All FOX Racing Shox products are designed, manufactured
and assembled by the finest professionals in the industry. As a consumer and supporter of
FOX Racing Shox products, you need to be aware of the importance of setting up your fork
correctly to ensure maximum performance. This manual provides step-by-step instructions of
how to set up and maintain your fork. It is a good idea to keep your receipts with this manual
and refer to it for service and warranty issues.
Consult page 22 for further information about Service and Warranty issues.
Consumer Safety
RIDING A BICYCLE CAN BE DANGEROUS AND CAN RESULT IN DEATH OR SERIOUS
INJURY. TAKE YOUR RESPONSIBILITY TO YOURSELF AND OTHERS SERIOUSLY.
Maintain your bicycle and suspension.
Wear protective clothing, eye protection and a helmet.
Know and ride within your limits.
Follow IMBA's Rules of the Trail - 1) Ride on open trails only 2) Leave no trace 3) Control
your bicycle 4) Always yield trail 5) Never scare animals 6) Plan ahead.
Important Safety Information
1. Verify that the brakes are installed and adjusted properly before riding the bicycle. Improperly installed or adjusted brakes can cause loss of control and serious or fatal injuries
to the rider. Use only V-style or hydraulic cantilever brakes or disc brakes designed by the
manufacturer for use on FOX FORX. Do not use brace mounted cable leverage devices.
Do not route brake cables or housing through the stem.
2. If your fork loses oil, tops out excessively or makes unusual noises, immediately stop
riding and contact FOX Racing Shox or an Authorized FOX Racing Shox Service Center
for inspection. Continued use of the fork could cause loss of control and serious or fatal
injuries. Some noises such as spring rattle, oil flow and minor clicks are normal.
3. Use only FOX Racing Shox replacement parts. Using aftermarket parts on FOX FORX
will void the warranty.
Aftermarket replacement parts could also cause structural failure resulting in loss of control
and serious or fatal injuries.
4. If mounting the bicycle in a carrier designed to hold a fork by its drop-outs, use caution to not tilt the bicycle to either side. Tilting the bike with the drop-outs in the carrier can
cause structural damage to the fork. Ensure that the fork is fastened securely with the
quick release and that the rear wheel is properly held. If the bicycle ever tilts or falls from
a bicycle carrier, do not ride it until it is examined by a qualified dealer, Service Center or
FOX Racing Shox. A fork leg or drop-out failure could cause loss of control and serious or
fatal injuries.
5. FOX FORX do not include reflectors for on-road use. FOX FORX are designed to be
used in competitive off-road riding and racing. Proper reflectors meeting the Consumer
Product Safety Commissions (CPSC) requirements should be installed if the fork will be
used on public roads.
6. FOX FORX have a crown / steerer / upper tube assembly. These parts are pressed
together in a one-time, precision press-fit operation. Replacement of any of these
parts requires a complete new assembly. Do not attempt to remove or replace the
steerer or upper tubes independently of the crown. DO NOT ATTEMPT TO ADD
THREADS TO THREADLESS STEERERS. Modifying the crown / steerer / upper
tube assembly as described here could cause the rider to lose control of the bicycle
resulting in serious or fatal injuries.
4
Installation
1. FOX FORX should be installed by a qualified bicycle mechanic. Forks installed improperly
are dangerous and can cause loss of control and serious or fatal injuries.
2. Remove existing fork from the bicycle. Remove the crown race from the fork. Measure the
steerer tube length of the existing fork. Transfer this measurement to the FOX FORX steerer.
Refer to stem manufacturers instructions to be sure there will be enough clamping surface
for the stem. If it is necessary to cut the steerer tube, measure twice and cut once. It is also
recommended that a cutting guide be used while cutting the steerer tube.
Note: If the steerer has any nicks or gouges the crown/steerer/upper tube assembly
must be replaced. A nick or gouge can cause the steerer to fail prematurely and
cause loss of control with serious injury or death.
3. Use a crown race setter to install the crown race firmly against the top of the crown. Install
the star fangled nut in the steerer tube with a star fangled nut installation tool.
4. Install the fork on the bicycle. The headset should be adjusted so it turns freely without
drag or free play.
5. Re-install the brakes and adjust the brake pads according to the brake manufacturers instructions.
6. Mount the front wheel Check that the quick release nuts sit in the fork drop-out counter
bores. The quick release should engage four (4) or more threads. Close the quick release
with the lever in front of and parallel to the left fork leg.
Tire Sizes
FOX FORX will accept tires sizes up to 2.40 inches wide (e.g. WTB
MotoRaptor 55/60, 26 x 2.40). Any tire larger than 26 x 2.30 must be
checked for clearance by the following method.
Determining Tire Size - With the tire installed and inflated
on the rim, measure the following three dimensions.
Maximum Peak Tire Diameter = 343mm = 27.00 inch
Maximum Edge Tire Diameter = 326mm = 25.67 inch
Maximum Tire Width
= 61mm = 2.40 inch
Maximum
Edge Tire
Diameter
Maximum
Peak Tire
Diameter
Use a FOX High Pressure Air Pump to change pressure on FLOAT, TALAS, F80 and F100 forks.
1. Remove the air topcap from the top of the left fork leg and connect the pump by threading the chuck onto the tank valve until the pump gauge registers pressure. If the fork has
no air pressure, the gauge will not register. This takes about 6 turns. Don't over-tighten as it
can damage the pump chuck seal.
2. Increase the pressure by stroking the pump a few cycles. Pressure should increase slowly.
If the pressure increases rapidly, check the pump is properly connected to the tank valve.
3. Decrease the pressure by depressing the black bleed-valve. Push the bleed valve halfway and hold to allow continuous pressure release. Depress the bleed-valve completely to
release pressure incrementally (micro-adjust).
4. Disconnect the pump by unthreading the chuck. The sound of air loss is from the pump
hose and not the fork.
5. Install the air topcap and go ride.
Note: When connecting the pump, the hose fills with air resulting in a 10-20PSI lower gauge
reading. Normal pressure range is between 45 and 125PSI. DO NOT EXCEED 200PSI.
Sag and Spring Tuning on Vanilla Forx
Setting Sag on Vanilla Forx
For best performance, it is necessary to set and adjust sag. Sag is how much the fork compresses or sags when the rider sits on the bicycle. Generally, this is 15-25% of the total travel.
Measuring and adjusting sag
1. Install a zip tie with light friction on the upper tube and push it down until it contacts the
fork seal. Carefully sit on the bike and assume a normal riding position. The fork should
compress slightly. Being careful not to further compress the fork, dismount the bicycle.
Measure the distance between the seal and the zip tie. This distance is the sag.
2. Compare your sag measurement to the table:
If your sag is lower than on the table, turn the preload knob counter-clockwise one (1)
full turn. Measure sag again and repeat adjustment if necessary.
If your sag is higher than on the table, turn the preload knob clockwise one (1) full turn.
Measure sag again and repeat adjustment if necessary. If correct sag cannot be achieved
by adjusting the preload knob, see the Spring Tuning Guide below.
Spring Tuning on Vanilla Forx
Read the Vanilla Spring Tuning Guide chart below to see if you need to change your spring
rate. Vanilla Forx are tuned by changing only the left side coil spring. The coil spring
has a painted color code stripe on one end of the spring. Refer to the chart to select the
correct spring for your rider weight.
Symptom
Do the following:
Vanilla Spring Tuning Guide
Vanilla Sag Table
Travel
XC/Race
Firm
Freeride
Plush
100mm
15mm
(9/16")
25mm
(1")
130mm
20mm
(13/16")
33mm
(1 5/16")
Change to higher
rate coil spring
Excessive bottoming
during riding
Change to higher
rate coil spring
Change to lower
rate coil spring
Change to lower
rate coil spring
6
Spring
Rate
Color
Code
Travel
Range
Rider Weight
Lbs. / Travel
Notes
039-05-010
10 lb/in
Black
100 - 130
<90-115 / 130
<90-110 / 100
039-05-011
18 lb/in
Purple
100 - 130
115-155 / 130
110-130 / 100
039-05-012
25 lb/in
Blue
100 - 130
150-180 / 130
130-150 / 100
Standard on
Vanilla 130
039-05-013
35 lb/in
Green
100 - 130
175-210 / 130
150-180 / 100
Standard on
Vanilla 100
039-05-014
45 lb/in
Yellow
100 - 130
205-240+ / 130
175-200 / 100
039-05-015
60 lb/in
Orange
100
195-225 / 100
100mm
Maximum
039-05-016
75 lb/in
Red
100
220-245+ / 100
100mm
Maximum
F80, F100,
FLOAT130
45 psi
50 psi
55 psi
65 psi
75 psi
85 psi
95 psi
105 psi
115 psi
125 psi
XC / Race
Firm
Freeride
Plush
80mm
(3 ")
12mm
(1/2")
20mm
(13/16")
100mm
(4")
15mm
(9/16")
25mm
(1")
130mm
(5")
20mm
(13/16")
33mm
(1 5/16")
Symptom
Do the following:
Excessive bottoming
during riding
Rider Weight
Air Pressure
50 psi
55 psi
60 psi
65 psi
70 psi
80 psi
90 psi
100 psi
115 psi
125 psi
Rebound Adjuster
Lock-out Lever
Low-speed
Compression
Adjuster
Blow-off / Bump
Threshold Adjuster
Step 1 - Remove the blue air cap from the top of the left fork leg. Let the air out of the fork.
Refer to Pump Instructions for details about letting the air out with a pump. Remove left top
cap with a 26mm socket 6-point socket wrench.
Step 2 - Loosen the bottom nut 3-4 turns with a 10mm wrench. With a plastic mallet, gently
tap the bottom of the shaft to disengage it from the lower leg. Allow oil to drain into a
bucket. Remove the bottom nut and crush washer.
Step 3 - Compress the fork as much as possible. The air piston will be visible about one
inch below the top of the upper tube. Push the bottom of the air shaft upwards to push the
air piston out of the top of the upper tube. Using a long thin shaft screwdriver, push the bottom of the air shaft up through the hole in the bottom of the lower leg.
Step 4 - Pull the air-shaft assembly from the fork. Refer to the drawings below and add or
remove the appropriate spacer(s) to achieve the desired travel. NOTE: Spacers snap on to
the air shaft between the Negative Spring Guide and the Topout Plate.
Step 5 - Lubricate the U-cup seal on the air piston with FOX FLOAT Fluid and re-install the
air shaft assembly into the upper tube. Push the shaft until it approaches the bottom hole of
the fork. Do not push the shaft all the way through the bottom hole.
Step 6 - Turn the fork upside down. Pour 30cc of FOX Suspension Fluid through the bottom
hole.
Step 7 - Push the air shaft assembly up until the shaft comes through the bottom hole.
Install the crush washer and bottom nut. Torque to 50 in-lbs.
Step 8 - Turn the fork right side up. Pour 5cc of FOX FLOAT Fluid on top of the air piston.
Step 9 - Lubricate the o-ring on the air topcap with FOX FLOAT Fluid. Re-install the topcap
and torque to 165 in-lbs.
Step 10 - Air up the fork to the desired pressure and cycle it several times to check for
proper operation. Re-install the blue air cap.
130mm
100mm
FLOAT Forx Travel Configurations
11
c) On RLC models, lift off the Low-speed compression knob. Check the bottom of the Lowspeed knob. The 1/8 diameter chrome detent ball might be stuck to the bottom of the knob
from grease. If so, grease the detent ball and put it back in the hole in the recess of the
damper topcap. Press on the detent ball with a small screwdriver and it should spring back.
d) With a 26mm socket wrench, loosen and unscrew the damper topcap from the uppertube.
Step 5 - Compress the fork lower leg upward until the travel spacer on the right side
damper shaft is exposed. Pull up on the damper topcap until it stops. Snap on or off the
correct length spacers to match the orientation shown on the DAMPER side in the Vanilla
Forx Travel Spacer Diagram on page 16. If removing the spacer from the damper, make
sure to keep it in a safe place for future use.
12
Step 6 - Looking at the Vanilla Forx Travel Spacer Diagram, add or remove the Travel
Spacers between the black negative spring guide and the Aluminum coil insert on the left
side plunger shaft.
Step 7 - Reinstall the plunger shaft assembly into the left Uppertube. You may need to
guide it through the bottom lower leg hole using a long thin screwdriver. Install the crush
washer and bottom nut and torque to 50 in-lb.
Step 8 - On the Left Side: Pour into the left Uppertube 30cc of NEW FOX Suspension Fluid
(7.5 wt.) or if clean reuse the oil from the clean drain pan. Install the Coil Spring. Install the
Travel Spacers on top of the coil as shown in the Vanilla Forx Travel Spacer Diagram for
your correct travel. Install the Preload topcap and torque to 165 in-lb.
Step 9 - Thread in the right side Damper topcap and torque to 165 in-lb.
Step 10 - Installing the damper knobs on RL, RLT and RLC:
a) Low-Speed Compression knob on RLC models only: Install the blue Low-speed compression knob so that the groove on the bottom of the knob is positioned over the Aluminum
pin in the Damper Topcap.
b) Lockout Lever Installation: Using the blue Lockout Lever as a wrench, screw the Lockout
Screw (octagon wrench flats) in the clockwise direction until you feel it stop. Put the Lockout Lever on lockout screw so that the lever faces approximately 6 oclock position.
Installing Lockout Lever on RL and RLT models: Using a 1.5mm hex key wrench, lightly
tighten each of the 3 set screws on the Lockout Lever. Loosen each set screw 1/4 turn.
Installing Lockout Lever on RLC models: The Lockout Lever and Low-speed compression
knob are spring-loaded upward (this is normal). Push down on the lockout lever until you
feel it stop. Using a 1.5mm hex key wrench, lightly tighten each of the 3 set screws on the
Lockout Lever. Loosen each set screw 1/4 turn.
c) Rebound knob installation: Install the red rebound knob so that the slot feature on the
bottom of the knob lines up with the flats on the rebound adjuster shaft. Put on one drop of
Blue Loc-tite 242 to the flathead screw. Holding the rebound knob firmly, install and tighten
the flathead screw with a 2mm hex key wrench.
WARNING: Damper internals will be damaged if the rebound knob is not held firmly when
tightening the rebound knob screw.
Step 11- Adjusting Damper Knobs and cycling fork:
RL, RLT and RLC forks: Turn the Lockout Lever to the open position (3 oclock position).
ALL forx: Check that your rebound setting is correct (factory setting is turn knob fully in
clockwise, then 6 clicks out). Cycle the fork several times to check for proper operation before riding. If there is free movement in the fork during compressing or if it makes strange
noises, disassemble the fork to check for complete number and orientation of spacers.
100mm
130mm
Adjuster Knobs
13
c) On RLC models, lift off the Low-speed compression knob. Look at the bottom of the
Low-speed knob. The 1/8 diameter chrome detent ball might be stuck to the bottom of the
knob from grease. If this happened, grease the detent ball and put it back in the hole in the
recess of the damper topcap. Press on the detent ball with a small screwdriver and you
should feel it spring back.
d) With a 26mm socket wrench, loosen and unscrew the damper topcap from the uppertube.
Step 5 - On RLT and RLC models: Use a 2mm hex key wrench to loosen and remove the
Lockout Threshold Knob on the lower right side of the lower leg.
All models: Use a 10mm socket wrench to unscrew the RIGHT side bottom nut 6 turns.
Place a clean dry oil pan underneath the right side of the fork. Tap on the bottom nut with a
plastic face hammer to loosen the plunger shaft from the lower leg. Loosening the bottom
nut 6 turns will make the nut lower than the small Lockout Threshold shaft and protect it
from damage while tapping out the damper out shaft. Unscrew and remove the bottom nut
and washer. Push up on the shaft with a thin screwdriver and let the oil drain.
Step 6 - Remove the damper from the fork and place over a drain pan.
14
c) On RLC models, lift off the Low-speed compression knob. Look at the bottom of the
Low-speed knob. The 1/8 diameter chrome detent ball might be stuck to the bottom of the
knob from grease. If this happened, grease the detent ball and put it back in the hole in the
recess of the damper topcap. Press on the detent ball with a small screwdriver and you
should feel it spring back.
d) With a 26mm socket wrench, loosen and unscrew the damper topcap from the uppertube.
Step 6 - On RLT and RLC models: Use a 2mm hex key wrench to loosen and remove the
Lockout Threshold Knob on the lower right side of the lower leg.
On all models: Use a 10mm socket wrench to unscrew the
RIGHT side bottom nut 6 turns. Place a clean dry oil pan
underneath the right side of the fork. Tap on the bottom nut
with a plastic faced hammer to loosen the plunger shaft from
the lower leg. Loosening the bottom nut 6 turns will make
the nut lower than the small Lockout Threshold shaft and
protect it from damage while tapping out the damper out shaft.
Unscrew and remove the bottom nut and washer. Push up on
the shaft with a thin screwdriver and let the oil drain.
Step 7 - Remove the damper from the fork and place over
a drain pan. Holding the upper insert with a 12mm wrench,
loosen the topcap with a 26mm socket wrench and unscrew
one turn. Loosening the topcap unclamps the compression
shims and allows the oil to drain during the next step.
17
Step 9 - Extend the damper to full length and install the damper into the fork. Thread the
damper topcap into the Uppertube for 1-2 turns. Install a NEW crush washer and thread on
the bottom nut. Torque the bottom nut to 50 in-lb. On RLT & RLC forks, align the set screw
of the Lockout Threshold Knob with the drilled feature on the Lockout Threshold Shaft and
tighten with a 2 mm hex key wrench.
Step 10 - Unscrew the damper topcap out of the Uppertube and compress the lower leg of
the fork upward. Pour into the RIGHT Uppertube 155cc of Fox Fully Synthetic Suspension
Fluid (7.5 wt).
Step 11 - Extend the fork. Pour into the LEFT Uppertube 5cc of NEW FOX Float Fluid.
Using a 26mm socket, install and torque the left side Air Topcap to 165 in-lb. Using a Fox
High Pressure Air Pump, pump air into left side Schrader valve to the recommended air
pressure for the rider weight. Install the Blue Air Knob.
Step 12 - Thread the RIGHT side Damper Topcap into the Uppertube. Using a 26mm
socket, torque the Damper Topcap to 165 in-lb.
Service Intervals
Performance, safety and the life-span of FOX FORX depend on maintenance. If you ride in
extreme conditions, service and maintain your FOX FORX more frequently.
NOTE: In this manual, reference being made to the left and right side of the fork is from the
seated riders perspective.
Important - Check Before Every Ride
1. Check that quick release skewer is properly adjusted and tight.
2. Clean the outside of your fork with soap and water and wipe dry with a soft dry rag. Do
not spray water directly on the Seal/Uppertube junction. DO NOT USE A HIGH PRESSURE
WASHER ON YOUR FORK.
3. Inspect entire exterior of fork for damage. The fork should not be used if any of the exterior parts appear to be damaged. Please contact your local dealer or FOX Racing Shox for
further inspection and repair.
4. Check headset adjustment. Adjust headset if loose according to manufacturers recommendations.
5. Check that brake cables or hoses are properly fastened.
6. Check that the front and rear brakes operate properly on flat land.
FOX FORX require service at the regular intervals shown below.
Item
Wash and dry
exterior
Each
Ride
25
Hours
100
Hours
Annually or
200 Hours
Instructions
on Page
Inspect drop-out
thickness
Inspect bushings
Change FLOAT
Fluid in air chamber
(FLOAT, F80 & F100)
Change oil
Torque Setting
Needed for:
Safety Glasses
n/a
Eye protection
n/a
n/a
n/a
n/a
Torquing fasteners
n/a
FLOAT Fluid
n/a
n/a
Topcaps
Bottom nuts
Brake posts
Fig. 1 Drop-out
20
Warranty Policy
The factory warranty period for your fork is one year (two years in countries in the EU) from
the original date of purchase of the bicycle or fork. A copy of the original purchase receipt
must accompany any fork being considered for warranty service. Warranty is at the full
discretion of FOX Racing Shox and will cover only defective materials and workmanship.
Warranty duration and laws may vary from state to state and/or country to country.
Parts, components and assemblies subject to normal wear and tear are not covered under
this warranty.
FOX Racing Shox reserves the right to all final warranty or non-warranty decisions.
General Exclusions from this warranty shall include but are not limited to any failures
caused by:
Installation of parts or accessories that are not qualitatively equivalent to genuine FOX Racing
Shox parts.
Abnormal strain, neglect, abuse and/or misuse.
Accident and/or collision damage.
Modification of original parts.
Lack of proper maintenance.
Shipping damages or loss (purchase of full value insurance is recommended).
Damage to interior or exterior caused by improper cable routing, rocks, crashes or improper
installation.
Oil changes or service not performed by FOX Racing Shox or an Authorized Service Center.
Specific Exclusions from this warranty shall include:
Parts replaced due to normal wear and tear and/or routine maintenance.
Parts subject to normal wear and tear and/or routine maintenance:
Bushings
Seals
Suspension fluids
Drop-outs
Disc brake tabs
FOX Racing Shox makes no other warranty of any kind, expressed or implied. All implied
warranties of merchantability and fitness for a particular purpose which exceed the obligations
and time limits stated in this warranty are hereby disclaimed by FOX Racing Shox and excluded
from this warranty.
Warranty Q & A
Q. What costs are my responsibility during the warranty period?
A. The customer is responsible for all costs of maintenance services, non-warranty repairs,
accident and collision damages, oil, seals, bushings and reducers, and mounting hardware.
Q. What are some examples of abnormal strain, neglect or abuse?
A. These terms are general and overlap each other in areas. Specific examples are: Hucking,
ghost riding, big drop, stunt / dare-devil riding, riding with broken parts, riding without oil in
fork, wrong spring rate, etc.
Q. Does the warranty cover incidental costs such as shipping or transportation?
A. No. The warranty is limited to repair of materials and/or workmanship.
Q. May I perform any or all of the recommended maintenance shown in the owners manual?
A. You may perform seal and suspension fluid maintenance as well as bushing and drop-out
inspections. If bushings or drop-outs are worn, they should be replaced by FOX Racing Shox
or an Authorized Service Center.
Q. May I perform service and repairs on my fork?
A. FOX FORX are mostly end user serviceable. Oil and travel changes and damper or spring
replacement can be performed by the consumer. To ensure peak performance, extensive repairs and service to the fork should be performed by a qualified bicycle suspension mechanic,
FOX Racing Shox or an Authorized Service Center. If in doubt as to whether or not you are
capable of fixing your fork, contact FOX Racing Shox or an Authorized Service Center.
22
Disclaimer
FOX Racing Shox is not responsible for any damages to you or others arising from riding,
transporting, or other use of your fork or bicycle. In the event that your fork breaks or malfunctions, FOX Racing Shox shall have no liability or obligation beyond the repair or replacement
of your fork pursuant to the terms outlined in the warranty provisions of this manual.
Contact Information
FOX Racing Shox
130 Hangar Way
Watsonville, CA 95076
Phone: 831.274.6500
North America: 800.FOX.SHOX (369.7469)
Fax: 831.768.9312
E-mail: [email protected]
Website: www.foxracingshox.com
Business Hours: Monday-Friday 8AM-5PM Pacific Time
Method of Payment
Method of Shipping
FOX Racing Shox uses UPS Ground service
Visa, MasterCard and/or Cashiers Check within the USA.
Tuning Notes:
p/n: 605-00-039 2004 FOX Racing Shox. 2005 FOX FORX Owners Manual. The information herein is provided as a
guide. FOX Racing Shox reserves the right to change all or part without notice.
23