This article provides detailed technical guidance for the installation of a hex spool spacer on a FOX Transfer seatpost. The procedure is based on the official service manual and rebuild instructions provided by FOX for the 2017 model of the seatpost. The content is structured to align with the tools, steps, and warnings documented in the source material, ensuring accuracy and adherence to the manufacturer's specifications.
The article is intended for qualified bicycle technicians or experienced DIY users who are familiar with bicycle suspension systems and have access to the necessary tools and replacement parts. It is not recommended for users without prior mechanical experience or access to specialized equipment such as a nitrogen fill station or torque wrench.
Installation of a hex spool spacer is a critical step in the rebuild process of a FOX Transfer seatpost. This component helps regulate internal pressure and ensures the smooth operation of the remote-activated suspension. The installation process involves multiple steps, including the use of specific tools, the application of lubricants, and the proper tightening of various components.
The following sections outline the tools required, the detailed installation steps, and the safety precautions necessary to perform the task correctly and safely.
Tools and Materials Required
Before beginning the installation of the hex spool spacer, ensure that the following tools and materials are available:
- Spool Valve Cap
- New o-ring (from rebuild kit)
- M6 screw
- 4mm hex wrench
- 1.5mm hex wrench
- 8mm wrench (or 8mm 6-point socket)
- Gas Fill Support Tool (PN: 398-00-758)
- Gas Fill Assembly (PN: 803-01-595)
- 8mm Shaft Bullet (PN: 398-00-738)
- Slick Honey lubricant
- Lint-free paper towel
- Shaft clamps (PN: 803-00-147)
- IFP Height tool (398-00-691 for 100mm or 125mm travel, 398-00-690 for 150mm travel)
- Funnel tool
- Wooden dowel
- Wire retaining ring pliers
- Magnet (for retrieving small parts)
- Safety glasses and protective gloves
These tools are essential for the proper installation and function of the hex spool spacer. It is important to note that some tools are specific to certain models or travel lengths of the seatpost, as indicated in the source material.
Installation Steps
The installation of the hex spool spacer involves multiple steps that must be followed in sequence to ensure the correct assembly of the seatpost. Below is a detailed breakdown of the process, based on the steps outlined in the source material.
Step 1: Preparation and Disassembly
Before installing the hex spool spacer, it is necessary to disassemble the seatpost to access the internal components. This process includes:
- Clamping the upper post in a bike work stand.
- Slowly unthreading the bleed screw to release IFP pressure.
- Removing the 0.083" ball bearing from beneath the bleed screw using a magnet.
- Covering the post with a lint-free paper towel to contain any oil that may spray during the process.
- Pressing the Spool Valve Cap down into the upper post to access the wire retaining ring.
- Removing the wire retaining ring using appropriate pliers.
This step is crucial for preparing the seatpost for the installation of the new spool spacer and other internal components.
Step 2: Installing the Spool Valve Assembly
Once the Spool Valve Cap has been removed, the next step is to install the new Spool Valve Assembly from the rebuild kit. The process involves:
- Coating the first 2 inches of the inside of the upper post with a thin film of Slick Honey.
- Installing the IFP into the upper post using a finger to push it until it bottoms out.
- Installing the 8mm Shaft Bullet and coating it with a thin film of Slick Honey.
- Installing the Piston Assembly into the top of the upper post with the greased bullet first.
- Pushing the assembly into the upper post until the seals on the piston are seated.
This step ensures that the internal components are properly lubricated and positioned for the installation of the spool spacer.
Step 3: Reassembly of the Spool Valve Cap
The Spool Valve Cap must be reinstalled after the Spool Valve Assembly is in place. The steps for this include:
- Topping off the Spool Valve Cap with oil.
- Installing a new o-ring from the rebuild kit into the Spool Valve Cap.
- Holding the Spool Valve Cap with a pin spanner while tightening the M6 screw with a 4mm hex wrench.
- Ensuring that the o-ring is not installed onto the M6 screw, as it will not seat properly.
- Tightening the M6 screw to 30 in-lb (3.4 Nm) torque.
This step ensures that the Spool Valve Cap is properly sealed and secured to the upper post.
Step 4: Installing the Bleed System Components
The bleed system components must also be reinstalled to ensure proper function of the seatpost. This includes:
- Installing the 0.083" ball bearing into the bleed hole.
- Applying blue Loctite 242 to the M3 set screw.
- Installing the set screw and an M3 screw in the fill port.
- Holding the M3 screw to prevent Sealhead rotation while tightening to 8 in-lb (0.9 Nm) torque with a 1.5mm hex wrench.
These steps are essential for ensuring that the bleed system is properly sealed and functional.
Step 5: Installing the Gas Fill Assembly
The Gas Fill Assembly is installed to allow for the filling of the seatpost with nitrogen. The process involves:
- Installing the Gas Fill Assembly (PN: 803-01-595) into the fill port.
- Taking care not to scratch the shaft during installation.
- Using the Gas Fill Support Tool (PN: 398-00-758) or wrapping a small piece of tape around the shaft and Gas Fill Assembly to prevent damage.
This step is crucial for the proper function of the seatpost and must be completed carefully to avoid damage to the components.
Step 6: Final Assembly and Testing
Once all components have been installed, the seatpost must be reassembled and tested to ensure proper function. This includes:
- Aligning the anti-rotation ball bearing with the groove in the lower post.
- Aligning the Actuation Beam with the Linkage Connector.
- Feeding the upper post assembly into the lower post.
- Ensuring that the wire retaining ring is still present in the lower post.
This step ensures that the seatpost is fully assembled and ready for testing.
Safety Precautions
Safety is a critical aspect of any mechanical work, and it is especially important when working with high-pressure systems such as the FOX Transfer seatpost. The following safety precautions must be followed to prevent injury:
- Always wear safety glasses and protective gloves during the installation process.
- Do not unthread the 6mm hex at the top of the seatpost until after the IFP pressure has been fully released.
- Failure to release IFP pressure before unthreading the 6mm hex can result in oil escaping at high pressure, which may cause serious injury.
- FOX products should be serviced by a qualified bicycle service technician in accordance with FOX specifications.
- Modification or improper service of the seatpost can lead to malfunction and potential injury.
- Unauthorized modification of any part of the seatpost may void the warranty and lead to failure or malfunction.
These precautions are essential for ensuring the safety of the technician and the proper function of the seatpost.
Conclusion
The installation of a hex spool spacer on a FOX Transfer seatpost is a detailed and precise process that requires the use of specific tools and materials. The procedure involves multiple steps, including the disassembly of the seatpost, the installation of the Spool Valve Assembly, and the reassembly of the internal components. It is important to follow the steps carefully and to adhere to the safety precautions outlined in the source material.
This process is intended for qualified bicycle technicians or experienced DIY users who are familiar with the necessary tools and procedures. It is not recommended for users without prior mechanical experience or access to specialized equipment such as a nitrogen fill station or torque wrench.
By following the steps outlined in this article, users can ensure that the seatpost is properly rebuilt and ready for use. The process is essential for maintaining the performance and reliability of the seatpost and must be completed with care and attention to detail.