Thank you for purchasing a Corset air sleeve upgrade kit for your Fox shock! These sleeves are very easy to install. First, refer to FOX'S AIR SLEEVE MAINTENANCE INSTRUCTIONS for the entire duration of this procedure. You may also need to alter your volume spacer configuration as per FOX'S VOLUME SPACER INSTALLATION INSTRUCTIONS. Be particularly attentive to the instructions for REMOVAL of the sleeve, listed at the bottom!
1. Remove your shock from the bike and clean it thoroughly. We recommend cleaning with isopropyl alcohol. Remove any reducer hardware from the eyelets (beige IGUS polymer bushings & DU bushings may remain in the eyelets however).
2. Record your existing air pressure, then depressurise the shock. Remove the travel indicator o-ring and set it aside (don't lose it).
3. Unscrew the existing air sleeve, remove it from the shock and set it aside. You should not need any tools, although if the sleeve has jammed for some reason you may require a rubber strap wrench.
4. If desired, you may opt to perform an air sleeve service at this time as per Fox's service instructions. This will require a Fox air sleeve seal kit (not included with the Corset). If not, proceed from step 6 onwards.
5. Your Corset may come with seals already pre-installed. If it does not, install the backup rings and air seal into the end of the Corset's inner sleeve. Once properly seated, install the dust wiper.
6. Wipe all seals (piston seal, air seal, and dust wiper) with Float fluid. You don't need much - enough to make the white PTFE backup rings visibly blue-tinged is enough. More than this hurts performance.
7a: LARGE DIAMETER EYELET VERSION ONLY: Install the air sleeve onto the shock body, and screw it into the eyelet by hand. Do it up firmly by hand - tools are not necessary.
7b: SMALL DIAMETER EYELET VERSION ONLY: Your sleeve will arrive either fully assembled, or in two parts, an inner and an outer sleeve:
If Fully Assembled:
Remove the retaining o-ring right at the end of the sleeve, on the outside, far end from the threads.This o-ring is just a retaining o-ring, not a seal, and can be removed using a sharp pick if you should ever need to remove the outer sleeve at a later date. You can re-use it many times as long as it's not broken. Next, remove the outer sleeve from the inner sleeve - it can slide off, away from the threaded inner sleeve. Be careful whenever installing or removing the outer sleeve - twist and pull or push simultaneously, and be gentle - to make sure that you don't damage any of the o-rings. Once they're separated done, follow the instructions below.
If in two pieces:
The inner sleeve should have four o-rings seated in thin grooves on its outside. This can be screwed into the eyelet by hand as per the large diameter version above, making sure you do it up firmly by hand. Once it's on, grease all 4 o-rings thoroughly, then carefully install the outer sleeve, taking care not to pinch any of the o-rings. Gently twist the outer sleeve as you slide it on to make life easier.Once it is on and fully seated up against the flange on the inner sleeve (approx 4mm from where it threads into the eyelet), you can install the thick retainer o-ring in the groove at the opposite end from the threads.
8. Reinstall the travel indicator o-ring on the shaft.
9. Reinstall the reducer hardware.
10. Bolt the shock back into the bike.
11. Inflate the shock to a pressure approximately 25% higher than the air pressure you were previously running - note that this is just a starting point!
12. Compress the shock several times to let the air pressure equalise on either side of the piston. Once this has been done, set your sag - between 28-31% is a good starting point, but don't be too afraid to stray outside these values as every frame has different requirements.
13. Go ride!
Removal of the Corset Air Sleeve
1. With the shock still on the bike, slowly depressurise the shock, using the air bleed button on your shock pump to do this. This must be done slowly enough that the shock does not get "stuck down" - it equalises air between the positive and negative chambers slowly to avoid the notchy feel found in other shocks. If the shock compresses fully when you release air, pump it back up and release the air more slowly - do NOT unthread the sleeve from the shock yet! It may help to cycle the shock up and down whilst depressurising it - you will hear a faint clicking noise as air equalises between the chambers at a certain point. We recommend depressurising whilst on the bike so that you can do this.
2. Remove the shock from the bike.
3. (This step for Small Diameter Eyelet sleeves only): Once all the air has been released, use a pick to remove the thick retainer o-ring at the seal end of the sleeve. This o-ring isn't a seal, so don't worry about piercing or scratching it as long as you don't break it. When this has been removed, gently slide the outer sleeve off over the inner sleeve. Be gentle - twist and pull gently to break the stiction.
3. Unthread the sleeve from the shock eyelet, holding the inner sleeve only.
Setup & Tuning:
Start with the recommended sag (28-31%). This is more than you would typically run with a Fox air sleeve, AND will still require a substantially higher air pressure than you previously ran. Once you've worked out how much sag (and therefore air pressure) you prefer to run for bump absorption purposes in the middle of the stroke, the next step is to tune the end of the stroke. If you need more bottoming resistance, install a volume spacer (or a larger spacer than you currently have). If you can't use full travel, install a smaller volume spacer than you currently have (or remove altogether).
To change the volume spacers (sold separately), refer to FOX'S VOLUME SPACER INSTALLATION INSTRUCTIONS. It's very easy to do.
Starting Points for Volume Spacers Configurations:
Depending on what your previous air sleeve configuration was, you should be able to start with the following volume spacer configurations. If you're not sure which type of sleeve (SV, XV or LV) you have, you can find out here: FOX AIR SLEEVE TYPES
Fox SV (Small Volume) sleeve: These are found on certainFloat RP series (R/RP/RP2/RP23/Triad) shocks and certain Float CTD shocks. These are fairly progressive, particularly in the longer stroke applications.
Recommended beginning volume spacer: Medium (approx 0.4ci). Increase or decrease spacer size as necessary.
Fox XV (Extra Volume) sleeve: These are found on certain Float RP series shocks and all DHX Airs. They are not found on any Float CTD shocks. In some lengths there are actually two size XV sleeves (XV1 and XV2).
Recommended beginning volume spacer: None. Increase spacer size as necessary.
Fox LV (Large Volume) sleeve: These are found on some Float CTDs and all Float Xs.
Recommended beginning volume spacer: None, or 2 sizes smaller than the one that came installed on your bike. (In some cases we've heard of people finding their bike is much too easy to bottom out with the stock Fox sleeve. In this case, leave whatever spacer you already had in there).
If you have any further queries about setup, please email Steve [at] VorsprungSuspension.com and we'll get you sorted out!