The Ultimate Guide To Changing The Travel On A Fox 40

Are you tired of using the default travel settings on your Fox 40 suspension fork? Look no further! In this ultimate guide, we will take you through the step-by-step process of changing the travel on your Fox 40 fork to suit your personal riding style and preferences. Whether you're an experienced rider looking for a more aggressive setup or a beginner wanting a smoother ride, this guide has got you covered. So grab your tools and get ready to unlock the full potential of your Fox 40 fork!

Fox 40 Travel: Understanding the Basics

The Fox 40 is one of the most popular downhill forks on the market, known for its robustness and performance. One of the key features of the Fox 40 is its ability to adjust the travel, allowing riders to fine-tune their suspension for various riding conditions. Changing the travel can greatly affect the fork's handling characteristics, so it's important to understand the basics of how to change the Fox 40 travel.

Before we dive into the process, it's crucial to note that changing the travel on the Fox 40 requires some technical knowledge and the right tools. If you're not confident in your ability to perform this procedure, it's best to take your fork to a qualified bike shop for assistance.

Here are the steps to change the travel on a Fox 40:

Step 1: Preparing the Fork

First, ensure that you have all the necessary tools. You will need a set of Allen keys, a torque wrench, a Fox 40-specific top cap socket, and a 24mm socket. Additionally, make sure you have a clean workspace and a mounting stand or bike repair stand to secure the fork.

Step 2: Removing the Fork from the Bike

If the fork is still mounted on your bike, you'll need to remove it before you can change the travel. This can typically be done by loosening the axle pinch bolts on the lower legs and removing the front wheel. Next, remove the brake caliper from the fork by loosening the mounting bolts. Finally, remove the stem cap and loosen the headset bolts to release the fork from the frame.

Step 3: Draining the Oil

To change the travel, you'll need to drain the oil from the lower legs. Flip the fork upside down and remove the lower leg screws using a 5mm Allen key. Be careful as the oil may drip out once the screws are removed. To speed up the process, you can push the fork down to force the oil out.

Step 4: Changing the Travel Spacer

With the oil drained, you'll now have access to the travel spacer. The travel spacer is a small plastic or metal piece that determines the fork's travel. Depending on the model and year of your Fox 40, the travel spacer may be located on the air spring rod or inside the air chamber. Check the Fox website or consult the user manual for specific instructions on locating and changing the travel spacer for your fork.

Using the appropriate tool, carefully remove the travel spacer. In most cases, you'll need a 24mm socket to unscrew the air spring rod and access the travel spacer. If the travel spacer is inside the air chamber, you may need a Fox 40-specific top cap socket to remove the top cap and access the spacer.

Step 5: Adjusting the Travel

Once you have removed the travel spacer, it's time to determine the desired travel and install the appropriate spacer. Fox 40 forks usually come with multiple travel spacer options, allowing you to adjust the travel within a specific range. Refer to the Fox website or user manual to find the recommended travel settings for your specific fork.

Install the new travel spacer and ensure it is securely in place. If you're using a metal travel spacer, make sure it is aligned correctly and tightened to the manufacturer's specifications. For plastic spacers, check for any signs of wear or damage and replace if necessary.

Step 6: Refilling the Oil

With the new travel spacer installed, it's time to refill the lower legs with fresh suspension oil. Use the appropriate suspension oil for your fork model and refer to the user manual for the recommended oil volume and weight. Slowly pour the oil into the lower leg, taking care not to overfill. Once filled, gently cycle the fork up and down to remove any air bubbles and ensure proper oil distribution.

Step 7: Reassembling the Fork

Now that the travel has been adjusted, it's time to reassemble the fork. Begin by reinstalling the lower leg screws, ensuring they are tightened to the manufacturer's specifications. Next, reinstall the fork onto the bike frame, tightening the headset and stem bolts securely. Finally, reinstall the front wheel and brake caliper, torquing the mounting bolts to the manufacturer's specifications.

Step 8: Testing and Fine-Tuning

Once the fork is reassembled, it's important to test the suspension and fine-tune the settings. Inflate the air spring to the recommended pressure and adjust the rebound and compression settings to your preference. Take the bike out for a test ride to gauge the comfort and performance of the new travel setting. If needed, make further adjustments to achieve optimal suspension performance for your riding style and terrain.

Changing the travel on a Fox 40 can significantly influence the fork's characteristics, allowing you to optimize your bike's setup for different riding conditions. By following these steps and exercising caution, you can safely and effectively change the travel on your Fox 40 and enjoy a more tailored suspension experience.

Tools and Materials Needed for Changing Fox 40 Travel

To change the travel on a Fox 40 fork, you will need a few tools and materials to ensure a smooth and successful process. Here is a list of everything you will need:

• Allen wrench set: A variety of sizes, typically ranging from 2mm to 8mm, will be necessary to loosen and tighten bolts throughout the process.
• Torque wrench: This tool will allow you to tighten the bolts to the manufacturer's recommended torque specifications without over-tightening or damaging any components.
• Fox 40 service kit: This kit will contain all the necessary seals, o-rings, and lubricants needed to complete the travel change. It is important to use genuine Fox parts to ensure proper fit and performance.
• Suspension pump: You will need a suspension pump with a pressure gauge to adjust the air pressure in the air chamber of the fork. This will determine the desired ride height and feel of your fork.
• Cable ties: These will be used to secure and organize cables and hoses throughout the process, preventing any potential issues or damage.
• Clean rags and rubbing alcohol: These materials are essential for cleaning and degreasing components, such as the stanchions and seals, to ensure optimal performance and longevity. It is crucial to remove any dirt or debris before reassembly.
• Plastic mallet or rubber hammer: This tool will be used to lightly tap the stanchions or other components into place if needed. Avoid using excessive force to prevent damage.
• Work stand or bike stand: To properly secure your bike during the process, a sturdy work stand or bike stand is recommended. This will give you easy access to the fork and prevent any unnecessary stress or strain on the frame.
• Owner's manual: The Fox 40 owner's manual will provide detailed instructions specific to your fork model. It is highly recommended to consult the manual throughout the process to ensure proper steps are followed.

Having all these tools and materials ready before you start the travel change will save you time and frustration, and ensure that the process goes smoothly. Additionally, it is always a good idea to have a clean and organized workspace to make the task more efficient and enjoyable.

Step-by-Step Guide for Changing Fox 40 Travel

Changing the travel of your Fox 40 suspension fork can greatly enhance your riding experience. Whether you want more travel for hitting bigger drops and jumps, or less travel for improved climbing and stability, adjusting the travel is fairly simple. In this step-by-step guide, we will walk you through the process of changing the travel on your Fox 40 fork.

Step 1: Gather the necessary tools and materials

Before you begin, make sure you have all the tools and materials you will need for the job. You will need a set of Allen wrenches, a torque wrench, a tape measure, suspension grease, and the appropriate travel spacers or tokens for your fork. You can usually find the spacers or tokens in a Fox 40 service kit or purchase them separately.

Step 2: Prepare your workspace

Find a clean, well-lit area to work on your bike. Make sure you have enough room to move around and access the front of the bike. Lay down a clean towel or mat to protect your bike and prevent any small parts from rolling away.

Step 3: Remove the front wheel and brace your fork

To change the travel of your Fox 40 fork, you will need to remove the front wheel. This will allow you to access the lower legs of the fork. Once the wheel is removed, brace the fork by placing something sturdy, such as a block of wood or a bike stand, under the lower legs. This will prevent the fork from compressing while you are working on it.

Step 4: Release the air pressure and remove the top cap

Using an Allen wrench, slowly release the air pressure from both the positive and negative air chambers of your fork. This will prevent any sudden movements or rebounds while you are working on it. Once the pressure is released, remove the top cap by unscrewing it counter-clockwise. Be careful not to lose any small parts, like the rebound adjuster knob or the top-out bumper.

Step 5: Remove the spring assembly

With the top cap removed, you can now remove the spring assembly from the fork. Carefully pull the spring out of the fork leg and set it aside. Some forks may have a bottom-out bumper located on the spring assembly. If this is the case, remove the bottom-out bumper as well.

Step 6: Install the travel spacers or tokens

To change the travel of your Fox 40 fork, you will need to add or remove travel spacers or tokens. These spacers or tokens will adjust the amount of travel available in your fork. Consult your fork's user manual or the Fox website to determine the recommended number of spacers or tokens for your desired travel.

Using suspension grease, lubricate the travel spacers or tokens and insert them into the fork leg. Make sure they are seated properly and evenly. The number of spacers or tokens you insert will determine the amount of travel adjustment.

Step 7: Reassemble the fork

Once the spacers or tokens are installed, you can reassemble the fork. Slide the spring assembly back into the fork leg, making sure it engages properly. If you removed a bottom-out bumper, reinstall it at this time. Carefully thread the top cap back onto the fork leg clockwise, making sure it is tightened to the recommended torque specification.

Step 8: Inflate the fork and test the travel

Using a shock pump, inflate the positive and negative air chambers of your fork to the recommended air pressure specified by Fox. Refer to your fork's user manual or the Fox website for the correct air pressure settings.

Once the fork is inflated, remove the brace from under the fork and compress the fork a few times to ensure the travel is working properly. Check for any unwanted noises or resistance. If everything feels and sounds good, you're ready to reinstall the front wheel.

Step 9: Fine-tuning and adjustments

After changing the travel of your Fox 40 fork, you may need to make some additional adjustments to fine-tune the performance. This can include adjusting the rebound, compression, and air pressure settings. Refer to your fork's user manual or the Fox website for guidance on these adjustments.

In conclusion, changing the travel of your Fox 40 suspension fork is a straightforward process that can greatly improve your riding experience. By following this step-by-step guide, you can easily adjust the travel to suit your preferences and trail conditions. Remember to always consult your fork's user manual or the manufacturer's website for specific instructions and recommendations. Happy riding!

Tips and Troubleshooting for a Successful Fox 40 Travel Change

Changing the travel on your Fox 40 suspension fork can greatly enhance your riding experience. Whether you want to increase or decrease the amount of travel, it's important to follow the proper steps to ensure a successful modification. In this article, we'll provide you with some tips and troubleshooting advice to help you achieve the desired travel change on your Fox 40 fork.

Before starting, make sure you have the necessary tools and equipment. You'll need a set of Allen keys, a torque wrench, suspension grease, and possibly some additional spacers or parts, depending on your specific fork model.

• Determine the desired travel change: The first step is to decide whether you want to increase or decrease the travel on your Fox 40 fork. This decision will affect the type of modifications you need to make.
• Understand the limitations: It's important to note that changing the travel on a Fox 40 fork beyond the manufacturer's recommendations can void the warranty, and may also impact the performance and safety of your fork. Make sure you understand the implications before proceeding.
• Consult the Fox 40 user manual: The Fox 40 user manual is a valuable resource that provides detailed instructions specific to your fork model. Refer to the manual to understand the recommended travel change procedures and any specific considerations.
• Prepare your workspace: Find a suitable workspace with enough room to maneuver your bike and work on the fork. Ensure you have good lighting and a clean area to prevent any dirt or debris from entering the fork internals.
• Remove the fork: Start by removing the front wheel and disconnecting the front brake caliper. Loosen the bolts securing the fork to the frame and carefully remove it from the bike.
• Disassemble the fork: Follow the steps outlined in the user manual to disassemble your Fox 40 fork. This typically involves removing the lower legs and the air spring or coil, depending on your fork model.
• Change the travel spacers: To increase the travel, you'll need to remove spacers from inside the fork. These spacers limit the maximum extension of the fork and can be found between the air spring or coil and the lower leg. Remove them one at a time, as per the manufacturer's instructions, until you achieve the desired travel increase. To reduce the travel, you may need to add spacers or utilize different internal parts, as recommended by Fox.
• Reassemble the fork: Once you've made the necessary travel changes, reassemble the fork by following the reverse steps outlined in the user manual. Ensure all parts are properly lubricated with suspension grease, and use the recommended torque settings when tightening the bolts.
• Test the fork: After reassembling the fork, reinstall it on your bike and perform a thorough test ride. Pay attention to any unusual sounds, excessive bottoming out, or discomfort. If you experience any issues, consult a professional bike mechanic for further assistance.
• Fine-tune the setup: It's normal to fine-tune the suspension setup after a travel change. Adjust the compression and rebound settings according to your riding preferences, and consider consulting the Fox 40 user manual for recommended settings based on your weight and riding style.

In summary, changing the travel on your Fox 40 fork can be an effective way to improve your riding experience. Following these tips and troubleshooting advice will help you successfully modify the travel while maintaining the performance and safety of your suspension fork. Remember to consult the user manual for model-specific instructions and recommendations. Happy riding!

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