Project Overview
This project involved the complete diagnosis, repair, and re-tuning of a damaged Fox Float DPS (Dual Piston System) suspension shock that experienced catastrophic failure due to improper assembly.
Issue
Due to improper tightening of the linkage bolt, the bicycle frame experienced significant flex in the suspension linkage system, leading to shear stress that caused the 9 mm shaft to fracture. This, in turn, also damaged the compression rod and lockout plate. The shock was completely non-functional with no damping response.
Solution & Repair Process
Replacement parts were ordered from Fox Racing, and a complete overhaul was carried out. The repair process included:
- Disassembly and inspection of all internal components
- Installation of new seals to prevent oil leakage
- Replacement of the fractured shaft and compression rod
- Fresh suspension fluid (synthetic oil) fill
- Nitrogen refill of IFP Chamber
- Systematic re-tuning of rebound, compression, and lockout circuits
- Performance verification using a hand dynamometer to confirm damping force
Result
Restored full shock functionality with verified damping performance. The shock now operates smoothly across all compression and rebound settings. The lockout feature engages correctly, and the overall responsiveness matches factory specifications.
Key Learnings
- Importance of proper torque specifications and assembly procedures
- Understanding suspension linkage kinematics and stress distribution
- Proficiency with suspension tuning tools and hand dynamometers
- Hands-on problem-solving and diagnostic methodology