FOX Float DPS Factory Series EVOL 200 damper & 50 hour + dials FULL Service Guide for Beginners.

This video is a FULL 200-hour damper and 50-hour air can service video for a FOX Float DPS Factory Series Evol rear shock. The video also goes over how to service the compression and rebound dials, which is an optional service
This service isn't particularly difficult, but there are some details that I go over that you should be aware of. There are also some warnings that you should take into consideration
At a MINIMUM, keep up with the ~50-hour service. This shock loves running when fresh. The 50-hour service is super easy and quick to do. You won't regret the few minutes it takes to get it done.
As always, please leave questions in the comment section, and I will respond to them the first chance I get
Chapters
00:00 Intro tools and parts
08:58 50-hour service start (air can removal)
14:08 200-hour service part 1 (disassembly)
42:45 Servicing the dial (optional)
01:02:13 200-hour service Part 2 (assembly)
01:30:58 50-hour service part 2
Below are part numbers and links to some tools that you will need to get this service done. I would look for the best price possible. Some tools can be found as aftermarket tools on eBay
Parts and oil
025-03-008 Oil: AM, FOX Suspension Fluid [32 oz.], 10 WT green
amzn.to/3PG7JTp
803-00-142 Kit: Rebuild, FLOAT Line Air Sleeve, Special Q-Ring
amzn.to/3VGsAd8
803-00-816 Seal Kit: CTD Boost Valve and Dish Shock Rebuild
amzn.to/3vxrlCD
Tools
Needles for IFP air fill:
The following needles work good.
Option 1
amzn.to/4aDmtKO
Option 2
amzn.to/43JKFcf
Needle tip
The below needle has worked very well for me. it’s a bit shorter than typical needle but its seems stronger overall. It will work with both options above
spare retaining pellet
qty 1
www.kartek.com/parts/fox-perf...
QTY 50
amzn.to/49pFuj0
Spare delrin balls
Qty 50
amzn.to/3PK3K8u
High pressure pump (buy wherever is cheaper)
amzn.to/49f5q0M
398-00-280 Tooling: Eyelet Torque Tool (Optional, Wrench and crows foot will work as well)
amzn.to/3vAajng
Dial Indicator
amzn.to/4ae3SFu
398-00-637 Tooling: Custom Socket, 5/8", 2016 Float DPS, Piston Bolt
(Aftermarket can be found on Ebay for less)
398-00-638 Tooling: Custom Spanner Socket, 3 pin, Float DPS, Lockout Piston
(Aftermarket can be found on Ebay for less)
www.ebay.com/itm/256280088953...
803-00-566 Kit:Bike IFP Depth Setting Tool Set (Optional)
A caliper can be used for this task, but this tool will make it easier overall
www.amazon.com/GICB-Depth-Set...
803-00-805 Kit: Shaft Clamps, Shocks, CTD 9mm, 3/8in, 1/2in, 5/8in
Any shaft clamps (Soft Jaw) with this sizing will work. Aluminium will work better than the 3d printed versions
803-00-806 Kit: Tooling, iCD/CTD Dish Shock Dial Indicator Attachment for Plate Lift Measurement
(This tool is only needed if you service the control/dials/knobs (whatever you like calling them).
amzn.to/3TJ7pV9

[@a8f235]

Very clever to have a clean white background to make the details stand out. It makes it so much easier to follow because there's nothing there that shouldn't be there. Just simply a very clean and detailed video that anyone can follow, so kudos for a top notch job there.

[@zoubtube]

Thank you very much for such a thoughtful comment. My goal is to make them as easy as possible for everyone around the world to follow. I Still have a lot to learn as far as presentation goes. Slowly we're getting there.👍

[@xlightsxoutx]

1:51:21🎉🎉🎉 that’ll be me tomorrow at the shop. Thanks again Zoub!

[@zoubtube]

Anytime! Let me know if you have any questions. If it wasn't for the two proprietary tools and the needle fill for the ifp chamber this would be a very simple and cost effective shock to work on.

[@bcr1973.]

I need to get my popcorn for this one 😅

[@zoubtube]

I recommend watching it while lying on a bed or couch. This way, when you're starting to nod off and your head tilts back, it'll have a comfy pillow to fall on. 😁

[@a8f235]

Popcorn and a bucket of Slick Honey.

[@rorylatrobe4736]

Hi, great vid thanks! Not much else out there in as good a level of detail as this. I have a remote pulley eyelet on my DPS and took that apart as my cable release from my lockout lever was getting a little sticky at the shock end. Having cleaned up and greased and put it back together I now no longer have rebound 'clicks' from the red rebound dial on the shock, the dial still spins within the same parameters as it should do (it hits the limit at either end which would have been considered the last 'click' of adjustment). Also worth mentioning that my compression/lockout assembly acts as it should. I don't see why it would be important but thought I'd mention that I did not unthread the 'head' or 'top eyelet' off from the metering rod as my shock isn't old and wouldn't need new seals etc in that area so I figured I'd leave those steps out (also considering I don't have those specialist tools for that part!) If you could help me out with any suggestions or potential solutions that would be much appreciated, I could definitely live with my rebound not having definitive clicks as long as it still worked as it should! But I thought I'd ask now before reassembling it all to find I may have made a silly mistake leading to my rebound not working! Thanks for any response, much appreciated.

[@zoubtube]

Thanks for the kind words. Just to make sure I'm clear, you only took apart the rebound and compression knobs, right, you didn't take out the spring and the cam shaft that the knobs connect to. If the above is accurate, then I'm pretty sure what you're experiencing is the cam isn't sitting as aggressively on the rebound rod as it was. This could change after your first ride. You can easily test the rebound to make sure it works. It will either work or it won't. Now, if you removed the cam to clean it, grease it, and then reinstall it, and the rebound knob stopped working, then the cam isn't sitting correctly on the rebound rod. To fix this, it'll require you to remove the main shaft from the eyelet, then align everything correctly, before screwing them back together. Let me know if you tested the rebound to see if it works.

[@kasparondrej2938]

RockShox seems to be more DIY oriented :) Amazing video, as always. I envy you all your tools. Are you a bike mechanic by profession?

[@zoubtube]

Yup! It shows that rockshox considers servicing products when it comes to product design. Which makes sense as it would make it more profitable for them. I've been into tools for a long time, pretty much since I was a kid, tearing apart dirt bikes, cars, etc, but I have never worked as a mechanic as a profession. I grew up in a time when my high school literally had a large, full-blown mechanic shop, paint booths and everything. I learned a lot in those years. Many of us worked on large projects back then and learned from each other. It was truly a different time. There was a time when I used to fully maintain street bikes (motorcycles) back in my track racing days, which included fully serving engines (if I never see a shim under bucket again, it would still be too soon 😉). This is where my obsession with proper torque specs started. The last thing you want is a bolt head breaking off at 160+ mph before heading into a chicane. 😱 I've had one of those high-stress jobs for a very long time now. Working on mountain bikes and other projects is a form of mental therapy for me. I've been doing it for many years. I will say that it has never been more fun working on mountain bikes than it has been for the last decade or so. It truly is a great time to be a mountain biker. 👍 Let me know if you have any questions.

[@marnusdege]

Where can I order the adapter for the shock pump…

[@zoubtube]

Apologies for the late response. Are you asking about the nitrogen needle? There are many places that sell them. if you search "shock nitrogen needle" in google you will see a list. I have a few, including the following which seems to do the job, but make sure you buy extra needles. The needles are pretty sensitive. I plan on making a detailed video just about filling a shock using a shock pump. www.amazon.com/Nicecnc-Nitrogen-Needle-Replace-snowmobile/dp/B082FJS17D/ref=asc_df_B082FJS17D/?tag=hyprod-20&linkCode=df0&hvadid=693505325168&hvpos=&hvnetw=g&hvrand=6275939685577655622&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9016979&hvtargid=pla-965680038216&psc=1&mcid=31ab4823b6fa33bd9bb6a05d8982aa7f&gad_source=1 Schmidtyracing sells a good kit as well. they has aluminum hum needles which are more durable www.schmidtyracing.com/Nitrogen-Needle-Fill-Tool-Adaptor-p/n-ft-ne-shr.htm

[@brendenwestin8785]

Hi Zoub, why is it important to remove all the air bubbles when filling the body with 10wt green? Is it the same place that the air/nitrogen gets pressurized into?

[@zoubtube]

Apologies for the delayed response. Great question. A shock is basically a hydraulic system. Any air within the oil of a hydraulic system will act as suspension since air can be squeezed, so it is imperative to remove ALL air from the oil side of the system in order for oil to freely flow without anything inside it to compress. If there is air in the oil, then the response will be a soft, mushy type of feeling. The more air, the more mushy (Now that I think about it, how did "mushy" ever become a word) The damper body has an IFP in it, which separates the oil on one side, and the air on the other side. The air side is literally acting as a suspension for the oil on the other side of the IFP. We never want air from the air side of the IFP chamber to enter the oil side. Ultimately, the seal on the IFP itself will fail over time, which will let air into the oil side. This is the reason we do a 200-hour service. 200 hours is just a reference point. Some people might need to do this service sooner, others later, but it's a good average for most shock (though not the X2, that thing can pop anytime). Hopefully this helps, and let me know if you have any questions

[@scottmack9066]

Hi, can you adjust the stroke length of these shocks?

[@zoubtube]

Yes. shock companies sell travel limiters. NOT to be confused with air can spacers. limiters are installed on the inner shaft in order to reduce travel. ex, a 185x55 shock can be limited to 52.5mm or even 50mm etc. there are limits to how much you can reduce the stroke though. let me know if you have anymore questions on this. thanks