Fox 40 Float missing travel....

Discussion in 'The Workshop' started by bing!, Dec 3, 2014.

  1. bing!

    bing! Active Member

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    I bought a Fox 40 Float (air) a couple of months ago. I didnt install it as I did not wanna mess around setting the fork up at the end of the season. My old fork was running at what I think is as good as a fork can run. No harshness, used 95% of travel and that oh so satisfying muffled thump thump sound when it goes through gnar. Bought the new fork just to take 1 pound of my 41 pound steed.

    So the season ended, and I was motivated this weekend to install the Float 40 on my Knolly just for kicks. Honestly, I just wanted to see how well the Kashima coating matched the gold on the CCDB :)

    Changed the lower oil, checked the seals, made sure I had foam rings (some went out without them) put a measure amount of Float fluid in the air chamber and put her aside. Pulled the old fork and set that beside the new one. As I was picking the other one up, I noticed sumthin. dang, that new fork is quite a bit shorter than the old one. Hmmmm.

    Took out a ruler, I'm missing 1 inch of travel. WTF? Also, I had set up the crowns at the old 164mm. If you look hard enough, there is info out there that the new fork should be at 157mm (lower crown to top of stanchion). I reset the crowns to the proper height. Measure the travel again, I'm still missing 3/4 of an inch set at the stock 60 psi for my weight. If I pump it up to 70 (for 180 pound rider) I get a little more, if I pump it up to 90 psi (200 pound rider), I get the whole 8 inches of travel. What is going on?

    Looked it up online and some people are getting the same thing. Called Fox, and they said to send it in. Oh, crap.

    I suspect they need to change the negative spring. I asked to just get the spring, but they strongly suggested to send it in. Some people online are saying that Fox has redesigned the air spring due to this exact problem, so just in case, I will send it in. Have it packaged up and dropping it off this pm.

    [​IMG]

    To their credit, they sent me a free return shipping label. I'm still scared that this might cost me some coin :(

    edit: if you look at the air spring assembly, there are only 2 seals to replace for a leaky spring. Sweet.
     
  2. Neccros

    Neccros Technically Canadian

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  3. pperrelle

    pperrelle Member

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    I had to deal with Fox customer service earlier this year and they were great. I sent my Evolution fork in for the Fit Damper upgrade. When I got it back something was wrong with the work. Lot's of stiction and it was making noise. Called and they immediately e-mailed me a shipping tag and off it went. The service manager called and said they agreed something was done wrong and would get back to me shortly with an update. I told him that I had a couple of rides planned that weekend and he assured me that he'd have it fixed and back to me by Friday. About an hour later I got an overnight delivery shipping notice from them so I figured they just found the issue, repaired it and packaged it back up. I was stoked the next day when the package arrived to see that they sent me a brand new 2015 Fit fork with Kashima coat! I know it was brand new because the steerer was stull uncut. This fork works beautifully.
     
  4. bing!

    bing! Active Member

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    From some research, I think the new Fox 40 Float won't sag correctly outta the box for riders below 175 pounds.
     
  5. Fearless Fly

    Fearless Fly anachronistic and impulsi

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    Sag also has issues with riders over 175.1 # also.
     
  6. bing!

    bing! Active Member

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    Leave it to a scientist to get down to the decimals :)
     
  7. bing!

    bing! Active Member

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    Was not feeling spending money on my DH fork this holiday. Money's been tight with one of my kid's prepping for college admissions stuff.

    I'd sent my fork in for not extending it's full 8 inches. A little bummed I couldnt fix it myself. Personal pride thing :) Fox called today, I got a new redesigned 2015 air spring assembly plus a custom tune on the negative spring after chatting with the tech. Not to mention, a free round trip via UPS 2 day :)

    Whew heew! Thank you FOX!
     

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