Rebuilding Fox Air SH Ox
Rebuilding Fox Air SH Ox
Rebuilding Fox Air SH Ox
HOW TO
REBUILD
FOX
AIR SHOX
FIGURE 1
Start by inspecting the condition of the Air Shox. The shock should be
cleaned before inspecting. Since we are going to be replacing the
seals, etc., we cleaned the shock using a standard solvent parts
cleaner. Clean out between the fins using a stiff brush. For normal
maintenance, a good soap and water mixture should be used.
The FOX Air Shox is not painted, but uses an anodized finish to protect the
aluminum body. You should not paint the body, as that will reduce the shocks
cooling ability. The body needs to be as clean as possible, as any dirt on the
body will decrease the cooling ability of the shock.
Check the shock parts for any physical damage. While scrapes on the main
body don't look nice, they will not impair the shocks operation. Inspect the
eyelets and lower shaft for physical damage. Figure 2 shows an example of
shaft damage. The shaft is pitted and rough. While the shock can still be
used, the seals will wear out quickly. Improperly installed shocks were
prone to shaft damage from the drive chain. If the shock eyelets, main
body or shaft have major physical damage stop here. Replacement parts
are not available for these components. The only value the shocks have is
as parts.
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FIGURE 2
It is possible to fix some types of shaft damage. Pro Action will grind the
existing shaft to remove any pitting. The shaft is then chromed plated to the
original dimensions and finish. As for the other parts, it may be possible to
have a local machine shop build you a new part, but it will not be cheap.
After physically inspecting the external parts of the shocks, its time to
check if the high-pressure bladder is okay. Holding the shock with the
large-finned end up, carefully depress the upper air valve to release
the low-pressure air. It is normal if the air comes out oily, or if oil
spurts out the valve. The upper (low-pressure) chamber is an air/oil
emulsion. Still holding the shock up right, depress the lower air valve
to release the high pressure chamber. If oil comes from the lower air
valve, it means the bladder is leaking and needs to be replaced. J.R.s
Machine manufacturers a set of replacement bladders for the FOX Air
Shox. See Page 11 for instructions on replacing the high-pressure
bladder.
If no bladder is available for your specific size of FOX shock, it is still possible
to use the shocks. Both shocks will have to be modified to run without the
bladder installed. See the page 13 No Bladder Available for more details.
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FIGURE 3
Mount the shock upside down in a vise using the top eyelet. Use a set
of jaw covers to protect the soft aluminum of the shock from being
damaged by the vise. Using a 2-inch wrench or a very hi-quality,
adjustable wrench, loosen the bearing housing from the upper shock
body. See Figure 3.
It is possible for the eyelet to start to unthread from the shock body before the
bearing housing starts to loosen. If this happens, tighten the eyelet and then
carefully apply heat to the shock body around the bearing section. This will
help expand the shock body and loosen the threads on the bearing housing.
Remove the shaft assembly. Clean out the inside of the shock body.
Pay careful attention that no small seal particles or other matter
remain in the shock body. Leave the shock body in a position to drain
any fluids left inside. Cover the opening in the shock body and place it
aside for the assembly phase.
Remember that cleanliness is next to Godliness when working on any precision
components such as the FOX Air Shox.
PISTON DISASSEMBLY
Figure 4 shows the shaft assembly after removal from the body.
Carefully remove the piston ring from the piston. Be very careful with
the piston ring, as there are no replacements available.
Remove the nut holding the piston assembly to the shaft. Use care in
holding the shaft still while removing the nut. Any damage to the
surface of the shaft will affect the seal life and shock performance.
Josef held the shaft still with a set of aluminum blocks clamped
securely in the vise.
If the shaft continues to turn, try cleaning the shaft and clamp blocks with
contact cleaner. It is also possible to carefully use heat to expand the nut and
help make the removal of the nut easier.
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FIGURE 4
Disassemble the piston assembly. Figures 5,6,7 and 8 show the various
stages of disassembly. Remove the top out bumper from the shaft.
Clean the parts. Figure 9 shows all the parts that make up the piston
assembly. Check the shaft for any nicks or small pits. These should be
polished out to improve the seal life. Clean all the parts and inspect
them for damage.
If the top out bumper is brittle, replace it. Josef uses a US-324 O-ring on each
shock as the original top out rubber is no longer available. The US-324 O-ring
is .210cross section and 1.350 inside diameter.
FIGURE 5
FIGURE 6
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FIGURE 7
FIGURE 8
FIGURE 9
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SEAL REPLACEMENT
Using a seal removal pick, carefully insert the tool into the wiper seal
and pull the seal away from the housing, see Figure 10. A second pick
can be inserted behind the seal once it has been pulled away from the
housing. The second pick can be used to get a better grip on the seal
to help remove the seal without slipping and scratching the bearing
housing. If required, the bearing housing can be lightly held in a vise
or a helper can insert the second pick while you hold the bearing
housing. Remove the seal from the bearing housings. Repeat for the
oil seal, see Figure 11. Carefully clean the bearing housing. Use a
cotton swab and contact cleaner to make sure all seal parts and
residue are removed from the housing.
FIGURE 10
FIGURE 11
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FIGURE 14
FIGURE 15
FIGURE 16
FIGURE 17
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SHOCK ASSEMBLY
Place a small amount of grease
on the top edge of the shaft.
Carefully slide the bearing
housing onto the shaft. Take care
not to nick the seals when
installing the bearing housing.
Install the top out bumper. Install
the new o-ring on the bearing
housing.
FIGURE 19
FIGURE 20
FIGURE 21
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FIGURE 22
FIGURE 23
FIGURE 24
FIGURE 25
FIGURE 26
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FIGURE 27
Fill the shock body with the correct amount of shock oil. Josef used
the FOX Racing Shoxs own special shock oil. See page 21, Important
Data for a table showing the amount of oil required for the various
shock lengths.
Carefully insert the shaft assembly into the body. Thread the bearing
housing into the shock body by hand. Tighten the bearing housing to
the shock body using a 2-inch wrench or a hi-quality adjustable
wrench.
Fully extend the shocks. Orient the shocks the same way they will be
installed on the bike, large end of the shock at the top. Set the high
pressure first. This is the lower air valve. Then set the low pressure. It
is easier to over pressurize the shocks slightly and then adjust them to
the required setting. See page 19, "Recommended FOX Air Shox
Settings for the recommended pressure settings.
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Clamp the shaft tightly in a vise. Be careful not to damage the shaft
with the vise. Jeff uses a pair of aluminum blocks to hold and protect
the shaft, see Figure 28. The shock has been completely rebuilt on the
example used. The shaft assembly does not need to be disassembled
in order to replace the bladder.
The Aluminum blocks, used to hold the shock shaft from turning, has a 1-3/8 bore.
FIGURE 28
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FIGURE 29
FIGURE 30
FIGURE 31
FIGURE 31
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When pressurizing the modified Air Shox, you must only use the upperor low-pressure air valve to pressurize the shock. The initial air
pressure should be set at the midpoint between the two air pressures
calculated for the original shock application. For example, if the
shock was previously set at 85 Psi for the low pressure and 120 Psi for
the high pressure, then the modified shock you should use is 102 Psi.
Further tuning will be required to optimize the settings. It may also
be necessary to modify the amount of oil in the shock to obtain the
full travel and performance from the shock.
An alternative recommendation for the air pressure setting is the original
single chamber air pressure values. See page 20 for the recommended air
pressure settings.
FIGURE 32
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The FOX Air Shox allows for changes in the high and low-pressures
values, damping characteristics and oil quantity when tuning the
shocks. The single most important variable is the pressure settings.
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up the shaft, riding through the section and verify the shock is
traveling the full stroke and bottoming out.
A pressure too high will result in a rough ride and a shock that is
possibly not delivering the full travel available. Ensure that you are
using all the shock travel by moving the bumper up the shaft. Ride
the track and verify the bumper is pushed back to the bottom of the
shock.
It is also possible to adjust the spring characteristics of the shock by varying
the amount of oil in the shock. If the shock performance is optimal except for a
couple of specific sections, consider adjusting the amount of oil in the shock.
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FIGURE 33
If you notice when you come back to check the shock pressure, it is always
lower than you set itremember that a specific volume of the air in the shock
goes into the hose and pressure valve every time you measure the pressure.
Therefore it is always important to have documentation of what the air
pressure was set toyou can not come back and accurately measure it again.
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FOX Racing Shox still services the original Air Shox, Gas Shock and Twin
Clickers designed for Motocross applications. Jeff and his crew are dirt bike
enthusiasts and really give the extra effort to help any customer with current
or out of production product. A rebuild kit costs 28.00. FOX Racing Shox can
rebuild a set of Air Shox, parts and labor, for 95.00. Twin Clickers can be
rebuilt for 99.00. (all prices in US$) FOX Racing Shox also sell its own special
shock oil for Air Shox.
J.R.S MACHINE
JR Ott at J.R.'s Machine Shop in Texas has almost 25 years of experience with
the Air Shox. JR has built the tooling required to build the high pressure
bladders for all sizes of the Air Shox. JR also sells seal kits and eyelet bushings
for the Air Shoxs. JR is a long time Vintage MX racer and a wonderful resource
for anyone working on FOX Air Shoxs or Vintage MX bikes. JR sells bladder kits
for 42.00, seal kits for 35.00, shock eyelet bushings for 60.00 and a complete
shock rebuild (Parts and Labor) for 150.00. (all prices in US$)
Contact JR at:
J.R.'s Machine Shop
838 North Dick Price Rd., Kennedale, Texas 76060
Tel.: 817-572-1025 Fax: 817-478-4307
WWW.ELSINORE.AU.COM (AUSTRALIA)
Geoff Bull sell rebuild kits and bladders. Geoff's kit includes a newer design
"Moly" impregnated seal and a super shaft bumper. Geoff's kit also includes a
set of reproduction second generation shock decals and a copy of the original
user's manual. The rebuild kit is 45.00 (Including Air Freight) and a set of long
bladders cost 69.00. (all prices in US Funds) North American customers can
contact Perry Sconzert.
PRO ACTION
Pro Action (Beaver Falls, PA) also offers a rebuild service for FOX Air Shoxs.
Pro Action (Greg Workman) also has experience in repairing damaged shafts.
Of course Pro Action can also help you with a wide variety of shock services
for other makes of shocks. Pro Action charges 100.00 US to rebuild a set of
FOX Air Shoxs. (Parts and Labor)
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If the tables below do not have data for your scenario, just do the following:
Step 1) Multiply your bike weight by 0.10 (10%)
Step 2) Multiply your riding weight by 0.15 (15%)
Step 3) Add the numbers from Steps 1 and 2 and then multiply this by your SLR. This
number is the recommended pressure for the low-pressure chamber. To
determine the recommended pressure for the high-pressure chamber, multiply
the low-pressure number by 1.5. (1.8 if you are pro or fast expert.)
BIKE WEIGHT 170-190 LBS.
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If the tables below do not have data for your scenario, just do the following:
Step 4) Multiply your bike weight by 0.14 (14%)
Step 5) Multiply your riding weight by 0.21 (21%)
Step 6) Add the numbers from Steps 1 and 2, and then multiply this by your SLR. This
number is the recommended pressure for the low-pressure chamber. To
determine the recommended pressure for the high-pressure chamber, multiply
the low-pressure number by 1.5. (1.8 if you are pro or fast expert.)
BIKE WEIGHT 170-190 LBS.
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The single chamber Air Shox featured an external damping adjustment. Table 2 shows
the recommended damping settings for the air pressure being used. The damping
setting is the number of turns out from the full in position.
TABLE 2
IMPORTANT DATA
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