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 Post subject: Fox RP2 & RP3 Rebuild
PostPosted: Tue Jun 04, 2013 2:10 am 
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big hucker
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Joined: Wed Jan 16, 2013 7:32 pm
Posts: 3086
Location: Dallas, TX
If you directly linked to this thread, please visit our Fox Factory Service Information - Main Index for additional resources.

RP2 & RP3 Rebuild

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The RP2 and the RP3 shocks are very similar, so the general service instructions will be basically the same. The main difference between the two shocks is the compression adjuster lever cam. The RP2 has two positions and the RP3 has three positions of compression adjustment with this lever cam. Note: Some photos shown on this page may not actually be of this shock model. We reserve the option to preserve system bandwidth by substituting generic pictures whenever it's possible and appropriate.

Disassembly

1. Prepare your work area. Lay out a clean shop towel upon which to stage and organize your parts assemblies.

2. Wear your safety glasses (always protect your eyes), and use rubber gloves if so desired.

3. Remove the mounting hardware, and clean the exterior of the shock before starting disassembly. This is a good time to record the eye-to-eye length of the shock and its travel. This information will assist you in determining the IFP setting and for ordering replacement parts.

4. Remove the air valve cap and release all air pressure from the main air chamber's Schrader valve.

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Warning! FOX air shocks contain high air pressures. Before continuing this service procedure, make sure the shock is not "stuck-down". Always wear eye protection when servicing any FOX product.

5. Remove the travel indicator O-ring.

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6. Placing the eyelet assembly into a soft-jaw vice, remove air sleeve from the damper by turning the air sleeve counter-clockwise.

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7. Clean the inside area of the damper, and also clean the air sleeve at this time.

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8. Remove bearing housing seal with plastic pick and also remove white bearings.

Note: Do not scratch the seal gland.

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9. Remove the IFP filler plastic ball from the damper body with a sharp metal pick.

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10. With a 5/32" (4 mm) hex key wrench, slowly remove the set screw. Remove the rubber pellet from the damper body.

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11. Slowly remove the bearing housing bleed screw (pressure may still be in the shock, even if you have already released it from the nitrogen filler port). Also, make sure to remove the sealing ball, and set these items aside.

Warning! Be careful; wear safety glasses.

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12. Unthread the bearing housing from the damper body with a 3/4" open-end wrench or crows-foot (counter-clockwise). Make sure the torquing force is not applied onto the bleed screw hole, or thread damage may result.

Tech Tip: The shock's serial number is located on top of the bearing housing.

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13. Remove the bearing housing from the damper body over an oil drain pan.

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14. Clean and inspect the body and remove the IFP. Hold a shop towel over the open end of the shock body. Using an air nozzle, blow air into filler port at the eyelet end. This will blow the IFP out of the body and into your hand. Clean the IFP and install new seals as necessary. Lube the IFP, seal with grease, and set aside.

15. Place the shaft end eyelet into a soft-jaw vise and unthread the 3/8” piston bolt.

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16. Carefully remove the piston bolt and piston assembly. Grip them so that all the piston parts come off together and set the assembly aside on a clean shop towel.

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17. If you suspect an issue with the shim stack or wish to change the valving, lay all the parts out in assembly order on a clean shop towel. For more details about valving, see PN 807-72-010.

Note: This is one of many valving codes. The shock valving setup you are working on could be different.

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18. Remove the ProPedal plunger assembly tip, spring, and very small spring preload washer (or washers).

Note: The number of preload washers may vary (one or more), due to the shock tuning configuration.

Lay the parts out on a clean shop towel.

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19. Remove bearing housing and bottom-out O-ring and washer.

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20. Clean the bearing housing; inspect and replace seals in the housing if necessary. Make sure to grease the O-ring inside diameter of the bearing housing body threads, and the shaft seal.

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21. Place the damper shaft into shaft clamps up close to eyelet.

Tech Tip: The damper shaft is made of aluminum, so be extra careful when using the shaft clamps. Do not allow the shaft to spin as you unthread the eyelet. Do not use excessive force on the vise, or you may damage the aluminum shaft.

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22. Remove the eyelet with a ½-inch bar for increased leverage, turning counter-clockwise.

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23. The damper shaft has been put together at the factory with the use of red Loctite. If excessive force is required to remove the damper shaft, use a heat source to soften the Loctite.

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24. The inner adjuster rod has a very small steel ball on top of it. This little ball sits in a drilled pocket in the inner adjuster rod. Pull the ball out and place it in a safe spot.

Tech Tip: Pencil magnets work great for extracting little parts.

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25. If you suspect the O-ring inside of the damper shaft has failed and wish to replace it with a new one, do not scratch the seal gland surfaces as you pull the original O-ring out. Grease the new O-ring and install it.

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26. The photo below shows the top of the ProPedal adjuster rod (outer and inner). Note the small O-ring inside the outer adjuster rod. Be careful when removing this O-ring. Lube and install a new O-ring as required.

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27. Remove the set screw on the side of the eyelet first, and set aside.

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28. Remove the set screw in the RP2 blue lever.

29. Remove the blue compression lever and adjuster cam parts. Clean, inspect and re-grease these as necessary.

    1. Review drawing PN 808-17-026 for more detail about these parts for the RP2

    2. Review drawing PN 808-17-014 for more detail about these parts for the RP3



Assembly


1. Insert the blue compression lever/rebound adjuster assembly into the eyelet hole.

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2. Place a single drop of blue Loctite onto the long set screw that holds the assembly in place. Gently tighten it up until resistance is felt, then back the screw off ½ turn. If you do not back it out, the set screw will pinch the adjuster shaft and it will not freely turn.

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3. Install the rebound ball spring and set screw. Place a single drop of Loctite onto the set screw and thread it in until the top of the screw is flush with the outside surface. This will give the rebound knob a proper feel. Turn the rebound knob; test and adjust as needed.

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4. Double check the lever and knob for movement. You can view the action by peeking into the damper shaft threaded hole.

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5. Prepare the compression and rebound rods. Make sure they are clean, and that the O-rings have been inspected and replaced if necessary. Be sure the small steel ball is lubricated and in position at the top end of the inner rod.

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6. Inspect and grease the O-ring in the damper shaft.

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7. Grease the adjuster rod end without the ball. With a gentle push and wiggle motion, insert it into the damper shaft gently. NEVER jam the adjuster rod into the shaft, or damage will be the result.

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8. Place two drops of red Loctite onto the outside diameter threads on the damper shaft. Keep the Loctite below the non-threaded portion.

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9. Pull the adjuster rod out of the damper shaft about 12 mm. Engage the slot of the outer adjuster rod to the adjuster mechanism in the eyelet housing.

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10. Thread the shaft in by hand as far as possible. Test the compression lever (turn the lever back and forth). Place your index finger on the adjuster rod at the end of the damper shaft. You should feel the adjuster move up and down. If it does not move up and down, you will need to go back and repeat the prior step.

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11. Place the damper shaft into the shaft clamps, and using the FOX Racing Shox ½-inch bar and torque wrench tip tool (FOX P/N 398-00-031-A), torque the eyelet to 110 in-lbs. (7.58 N-m).

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12. Install the bottom-out washer and bottom-out O-ring onto the damper shaft.

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13. Inspect and replace, if necessary, the seals in the bearing housing: the body thread inside diameter O-ring and the shaft seal. Lubricate before sliding it onto the damper shaft.

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14. Slide the bearing housing onto the damper shaft. Gently push and wiggle as you slide the damper shaft past the bearing housing seal.

15. Insert the ProPedal check valve, spring, and preload washer(s) onto the adjuster rod end.

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16. Put the damper piston assembly onto the damper shaft. Thread the piston bolt in by hand, and double-check action of the ProPedal compression lever. Depress the check valve at the center of the bolt about 1 mm with a 2mm hex key wrench, and turn the ProPedal compression lever back and forth. You should feel the check valve move up and down.

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17. After finishing testing the check valve, torque the 3/8" piston bolt to 75 in-lbs. (5.17 N-m). Set it aside.

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18. Use the 2007 or 2008 Rear Shock Cheat Sheet for determining the IFP setting for your shock. Adjust the calipers to this setting.

19. Set the IFP according to the shock's IFP specification (an IFP setting tool, if available, can be handy in this step).

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20. Place the damper body into a soft-jaw vise and fill the body to the top with 10 wt. FOX Suspension Fluid.

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21. Push the bearing housing all the way down to the topout plate on the back side of the damper piston.

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22. Push the bearing housing downward into the oil, and wiggle it back and forth as you thread the bearing housing onto the body threads. This will help oil pass around the damper piston as it lowers into the damper body. As you thread the bearing housing onto the body, you will see oil flow out of the bleed port on top of the bearing housing; this is normal. If oil does not come out, you should unthread the bearing housing, top off the body with oil, and try again.

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23. Drop the steel ball into the bleed port and thread in the set screw. Tighten to 15 in-lbs (1.03 N-m).

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24. Install a new rubber pellet into the damper body. Using nitrogen, pressurize to 400 psi and torque the filler screw to 14 in-lbs. (0.97 N-m).

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25. Press in a new plastic ball by using a soft-jaw vise.

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26. Clean the reservoir with isopropyl alcohol, and replace the decal if necessary.

27. Perform the Air Sleeve Maintenance procedure, if necessary. Otherwise, install the air sleeve and travel indicator O-ring.

28. Return the shock back to your now-happy customer. Smile! :-]

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PostPosted: Tue Feb 21, 2017 12:50 pm 
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lurkin' kitty

Joined: Tue Feb 21, 2017 7:58 am
Posts: 1
Great article. I wish the pictures were still available though? Not sure if I am not doing something that would make the pictures viewable?
Help.
Thanks


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