32MM TALAS II Spring Service

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32MM TALAS II Spring Service

VIEW AND DOWNLOAD PDF OF THIS PROCEDURE DISASSEMBLY | SERVICE | TALAS KNOB TIMING | ASSEMBLY

Tools Required
TALAS IFP Charging Tool (FOX P/N: 803-00-127)

26mm socket and wrench 10mm socket 7/16" socket Plastic dental pick Torque wrench Needlenose pliers Rotoclip removal tool 2mm hex wrench 13mm open-end wrench 8mm open-end wrench 5mm open-end wrench Ruler (metric preferred) 1/2" O-ring (for reference measurement only) FOX High Pressure Pump Soft-faced mallet TALAS I Travel Adjust knob (or 3/8" socket), used to turn tank valve nut during adjustment

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FOX 7 wt. Suspension Fluid 1 pillow pack of FLOAT Fluid

Disassembly
1. Remove the TALAS aircap. To aid removal, hold the TALAS lever with your other hand as you turn the aircap.

2. While holding a rag over the topcap assembly, depress the main air chamber Schrader valve to release air pressure.

3. Using a 3/8" socket, remove the TALAS lever locknut. Hold the TALAS lever with your other hand as you loosen the nut. After the nut is removed, simply lift the TALAS lever off the topcap assembly.

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4. Remove the detent ring. Use needlenose pliers to grab the small dowels on either side of the Schrader valve, and pull the detent ring straight up. Before removing the detent ring, look at the notches to find the ball bearing; prepare to catch the ball bearing as you pull the detent ring up and off.

5. Using a 3/8" socket, remove the TALAS inner tube by turning the socket counterclockwise. The inner tube assembly is not screwed in. Rather, it is corkscrewed into the topcap assembly and will rise up and out of as you turn the socket.

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6. Remove the red IFP chamber screw with a 2mm hex wrench.

7. Screw in the TALAS IFP Charging Tool into the IFP chamber port. Cover the Schrader valve with rag and release all air pressure from the IFP chamber.

8. Remove the IFP Tool. 9. Unscrewbut do not removethe damper topcap with a 26mm 6-point socket. Be careful not to slip and damage the wrench flats. You may need to grind down the socket so that it properly grips the wrench flats on the topcap.

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10. Leave the topcap assembly on. Secure your fork so that the fluid inside of the fork does not spill out. 11. Turn the fork upside-down and, using a 10mm socket, remove the spring-side bottom nut.

12. Push down on the protruding spring-side shaft to push up the air shaft plunger. If it can't be dislodged, screw the bottom nut on to the shaft at least 2 full turns and softly tap the bottom nut with a soft-faced mallet and remove the bottom nut.

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13. Unscrew the TALAS Topcap Assembly from the upper tube.

14. Lift up on the TALAS Topcap Assembly to remove it from the upper tube.

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15. Turn the fork upside-down. Push down on the end of the TALAS Lower Shaft that is protruding from the bottom of the upper tube. Hold your hand under the topcap area so that the Lower Shaft doesn't fall on the ground as you push it down and out of the upper tube.

Service
1. Unscrew the Upper Check Valve Bolt (P/N: 234-04-082) with an 8mm wrench by holding the Inner Ferrule Nut (P/N: 234-04-103) with a 5mm wrench.

2. Look inside the Upper Check Valve Bolt to find the O-Ring (P/N: 029-08-043). If it is not

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there, check the top of the Inner Ferrule (P/N: 234-04-102).

3. Unscrew the Upper Check Valve Bolt from the Adjuster Screw. Inside the Adjuster Screw find and examine another O-Ring (P/N: 029-00-003).

4. Replace this O-Ring if the TALAS forks sinks past normal sag adjustment statically, although it will be more noticeable at the longest travel setting (i.e., 140mm or 130mm). The following drawing illustrates the difference between a properly situated O-Ring and one that is oriented incorrectly:

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5. When re-installing, place O-Ring on end of Inner Ferrule instead of inside the Upper Check Valve Bolt, as shown below. This will ensure that O-Ring is properly centered and oriented upon re-assembly. Lubricate the Inner Ferrule and O-Ring before re-assembly.

6. Screw the Inner Ferrule Nut to the Upper Check Valve Bolt and torque to 16 in/lb. (181 Ncm).

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7. The Adjuster Screw O-Ring (P/N: 029-03-010-A) can be replaced if necessary. 8. If the seals on the IFP need to be replaced, remove the Retaining Ring Rotoclip (P/N: 03800-006) using a clip removal tool. After removing the clip, remove the shim and square ORing and then slide the IFP off the outer tube.

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9. The IFP TALAS II Main Seal (P/N: 036-01-009) on the IFP (P/N: 222-01-093) can be replaced as well as the Inner Seal (P/N: 036-01-012) on the IFP.

10. The TALAS II Topcap Assembly (P/N: 234-04-073) O-Rings (P/N: 029-03-022-A [Top] & 02903-021 [Bottom]) can be replaced if necessary.

11. The TALAS Lower Air Shaft assembly usually does not require any service other than potential replacement of the U-Cup Seal (P/N: 036-01-018) and Urethane O-Ring (P/N: 02908-024) on top of the Lower Piston Bolt (P/N: 234-04-034). When placing the U-Cup Seal back on to the Lower Outer Piston, ensure the OD U-Cup lip is oriented towards the top of the air shaft.

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12. To replace the Urethane O-Ring, place the Lower Air Shaft assembly in TALAS shaft clamps. Use a 13mm open-end wrench to unscrew the Lower Piston Bolt (P/N: 234-04-034). Use a plastic dental pick to remove the Urethane O-Ring. Removal of the Lower Piston Bolt is optional, but prevents the O-Ring from falling inside the air shaft. Place the O-Ring into the Lower Piston Bolt groove then hold it there with the plastic dental pick. As you hold the pick in place, push the protruding portion of the O-Ring in with your other hand.

Assembly

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1. Place 3cc of FLOAT Fluid into the upper tube.

2. Pre-lube with FLOAT Fluid the TALAS Lower Air Shaft seal and push it into the upper tube.

3. Use a 15mm deep socket with extension to push the Air Shaft assembly down until it protrudes from the bottom of the upper tube.

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4. Place 5cc of FLOAT Fluid inside the upper tube.

5. From the bottom, push up on the lower TALAS Lower Shaft assembly a few inches. Place the TALAS Topcap Assembly into the upper tube carefully; remember, you need to insert the travel adjust rod into the lower seal head hole. Once it is engaged, you can push down on the Topcap Assembly. Screw the Topcap on and torque to 165 in/lb. (1864 N-cm) using a torque wrench.

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6. Screw the TALAS IFP Recharge tool (P/N: 803-00-127) into the IFP port and pressurize the IFP chamber to 150 psi (10.34 bar) using a FOX High Pressure Pump. Screw on the red IFP chamber socket head screw with a 2mm hex key.

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7. Lubricate the O-Ring on the Adjuster Screw assembly and then gently push the assembly into the center hole of the TALAS ll Topcap Assembly.

8. Using a 3/8" socket, screw the Adjuster Screw in by hand.

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9. Using the FOX High Pressure Pump, pressurize the TALAS main air chamber to 75 psi (5.17bar).

Use care when unscrewing the pump from the adjuster screw Schrader valve. The adjuster screw may unintentionally be removed. Hold the adjuster screw nut with your fingers or a wrench as the pump is unscrewed from the Schrader valve.

TALAS II Knob Timing Procedure (View and print out 605-04-371: TALAS II KNOB TIMING to assist
with this procedure)

Now that the TALAS main air chamber is charged, use care when turning the adjuster screw during the knob timing procedure. Injury can occur if the adjuster screw is turned too far as it may shoot out due to the pressure inside the chamber. If possible, use a TALAS I travel adjuster knob for the following procedure.
10. You can use TALAS I travel knob (P/N: 234-04-013) or a 3/8" socket to turn the TALAS

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Adjuster Assembly. Ensure it is engaged with the 3/8" tank valve nut, then turn the knob fully clockwise (FULL IN on the TALAS II KNOB TIMING sheet).

11. Turn the TALAS knob out half turn (1/2 TURN OUT), or 180-degrees counterclockwise. (Use a reference point on the travel knob to assist you.)

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12. Compress the TALAS lower shaft so that it settles at the lowest travel setting. Confirm by measuring.

When hand dyno-ing the fork, do not place your hand on the travel topcap. This places pressure on the travel topcap assembly and will adversely affect your travel measurements.

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13. Place an O-Ring on the lower shaft to visually confirm the travel adjustments (jumps) that will be performed in the next steps.

14. SLOWLY start turning in (TURN IN, or counterclockwise) the TALAS travel knob until the lower shaft jumps out of the upper tube (JUMP 1). The fork just went from the shortest to the middle travel setting.

15. SLOWLY continue turning in (TURN IN) the TALAS travel knob until the lower shaft jumps again (JUMP 2). The fork just went from the middle to the longest travel setting.

The 2007 TALAS 32 RLC/RL/R have 140mm of travel, and the 2007 TALAS X has130mm of travel. 140, 120 or 100mm of exact travel will not always be achieved. Please refer to the 32MM Fork User Specifications to view these tolerances.

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16. Now you must turn the TALAS travel knob in 2 degrees (TURN IN 2 degrees). Two degrees is a very small distance! The diagrams below illustrate how small the adjustment needs to be. Each hole on the adjuster screw (as shown below) represents a 10 segment. Therefore, the adjuster screw needs to be turned 1/5 of the distance between the center of each hole: 2 degrees. Use a reference point on the edge of the topcap assembly to make this adjustment. It also helps to use the 3/8" socket and turn it by hand.

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17. Once the proper travel settings are achieved, remove the TALAS I travel adjuster knob, or the 3/8" socket if that was used instead. Place the TALAS Centering Tool (P/N: 399-27-382)

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on top of the tank valve.

18. Slide the Detent Ring over the Centering Tool and into the Topcap Assembly. Align the Detent Ring so that the ball bearing lines up with notch #3 in the Topcap Assembly, as shown below. For added reference, notch #3 is the last notch going in a clockwise direction.

19. Notice the short dowels on the topside of the Detent Ring (see drawing below); on the bottom side of the detent ring you will see longer dowels. These longer dowels need to slide

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into the holes on top of the adjuster screw. Grease the spring and ball (on early 07 32mm TALAS ll, a spacer (P/N: 234-04-136) is used) and place it into the side hole. You can use the flat side of a flat-blade screwdriver to press the ball into detent hole as you push the Detent Ring down. As you slide the Detent Ring down the TALAS Centering Tool and onto the Adjuster Screw, you should be able to feel when the dowels have properly been inserted into the holes on top of the Adjuster Screw.

20. Place the TALAS II Travel Adjust Lever onto the Detent Ring. Orient the knob so that the lever is at or near the 9 o'clock position (rider's perspective), which is the longest travel setting.

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21. Place the 7/16" lock nut on the valve stem and torque it to 45 in/lb (5.08 N-m) using a torque wrench.

22. Don't forget to take the O-Ring off the lower shaft.

*END*

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