RZR XPT. Fox Interbypass Rebuild

Discussion in 'UTV Chassis & Suspension' started by robin hood, May 8, 2017.

  1. robin hood

    robin hood New Member

    Joined:
    Feb 21, 2016
    Well I got back to it today. I got the tools made and was able to get the second shock apart. For some reason I can't upload a photo so I will have to post a picture later.

    The compression adjuster does not need a spanner wrench...just push it in, remove the clip and it will pull straight out.

    Now I am having trouble getting the seal head, wiper seal installed and onto the shaft. Does anyone know any tricks?
     
    Last edited: May 27, 2017
  2. Glamisfan

    Glamisfan Active Member

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    Oct 26, 2009
    Location:
    imperial valley
    I know they make a "bullet" to make it easier to get the shaft through the seal head.
     
  3. Rynomx785

    Rynomx785 Active Member

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    Jun 21, 2015
    Location:
    Wickenburg, AZ
    Sounds like the IB Fox Shocks are way more of a PITA than standard coilover. Is that more of a Fox thing or just an IB thing?
     
  4. Glamisfan

    Glamisfan Active Member

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    Oct 26, 2009
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    imperial valley
    Fox has what I'd consider the proper way to make an IBP. Which makes them hard to custom set up properly. Walker and King make theirs differently. And look like they would be easier to tune?
     
  5. robin hood

    robin hood New Member

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    Feb 21, 2016
    So here are the "special" tools it takes. If I had more time I would have machined them. Anyways...not so special but you'll probably need them to rebuild/revolve the shocks.
     

    Attached Files:

  6. Glamisfan

    Glamisfan Active Member

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    The T handle is for the reservoir piston. Are the other two for the unscrewing the seal head out of the shock body? Got anymore pictures of the internals?
     
  7. robin hood

    robin hood New Member

    Joined:
    Feb 21, 2016
    The t-handle as you mentioned is for the resivor piston. It is a #10/24(?) course thread.

    The other tools are for the seal head pictured below. One came out pretty easy, but the other I couldn't get without making the tools.


    IMG_2404.JPG IMG_2405.JPG
     
    Last edited: Jun 3, 2017
  8. Glamisfan

    Glamisfan Active Member

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    I still can't quite figure out what is going on here. I don't see what taking the black part off the gold part does? Do I need the tools to get the shock apart for a revalve? Does the gold part hold the inner sleeve in place and the black part is a double locking ring?

    Your the first person on the internet to take these shocks apart and share any information, so all the details and pictures you could share would be greatly appreciated!
     
  9. Glamisfan

    Glamisfan Active Member

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    Oct 26, 2009
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    OK, I got it figured out. I went out to the garage and knocked the dust cap off of my front shock and saw that it's what I thought, the gold part holds the inner sleeve in and the black part is a locking ring for it. And I'm assuming since the front is 2 1/2's and the rears are three inch, that it will take four of these tools to take the two different sizes apart.
    [​IMG]
     
  10. Glamisfan

    Glamisfan Active Member

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    imperial valley
    What are the pin diameters on the spanner wrenches you made?
     
  11. Glamisfan

    Glamisfan Active Member

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    So now I'm confused again. I'm sitting here thinking about it as I watch the Baja 500, and I decided to go pop the dust cap off again and look up there with a mirror and a flashlight. The shock does in fact have the wire clip holding the bearing/seal head in place. So it looks like any other shock, release the nitrogen pressure, push in on the head a little bit and remove the wire ring and then pull the shaft out. So I still don't understand what this black and gold not assembly is about.
     
  12. Glamisfan

    Glamisfan Active Member

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    Oct 26, 2009
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    But with that inner sleeve needing to be held in place, I would think that you would not be able to push in on the head to get the wire ring out? Because that would mean that that sleeve has enough room to slide up and down a little bit which can't be true. I'm so confused.
     
  13. Glamisfan

    Glamisfan Active Member

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    I think I finally figured it out. To remove the seal head, you hold the gold piece in place and then you screw the black piece in which will then give you slack and allow you to remove the wire clip. The whole purpose of the black and gold part is once you're putting it back together the black part you screw out which will push against the wire clip pushing the gold piece in locking the inner sleeve in place. Correct?
     
  14. Glamisfan

    Glamisfan Active Member

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  15. robin hood

    robin hood New Member

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    Feb 21, 2016
    Sorry...I didn't realize I had missed all these post. I've been real busy and this project is low on the list right now.

    Yes, you are correct in your assessment. Did you purchase the service manual or is it on line?

    The inner is 1/4" and the outer is 3/16".

     
  16. Glamisfan

    Glamisfan Active Member

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    imperial valley
    I'll pm you a link to the service Manual
     
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  17. robin hood

    robin hood New Member

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    Feb 21, 2016
    Just finished reassembling the front shocks. Between my work, the heat and other projects, this just doesn't seem to get enough of my time. Not to mention...I've been waiting on replacement axles for my Lone Star long travel kit that just showed up last week. I'll be starting a whole other thread on that issue which I'm not to happy about.
     
    Last edited: Jul 1, 2017

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