How to Service Your Float 40 Factory eMTB Suspension Fork at Home

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Servicing the Float 40 Factory eMTB suspension fork is essential for maintaining top-tier downhill performance and ensuring longevity on aggressive trails. Designed specifically for electric mountain bikes, this fork handles increased weight and high-speed descents. This guide offers detailed, step-by-step instructions to help you perform basic and intermediate servicing at home without compromising fork integrity.

Tools Required

  • 32mm and 6-point sockets
  • Torque wrench [paid link] (with Nm settings)
  • Fox Float 40 specific seal driver
  • Pick set or dental tool
  • Clean lint-free rags
  • Suspension-specific grease
  • Isopropyl alcohol (99%)
  • Fox Gold 20wt and Float Fluid
  • Fork oil measuring syringe or graduated cylinder
  • Allen keys [paid link] (4mm, 5mm, 6mm)
  • Rubber mallet
  • Clean workspace and fork stand

Understanding the Float 40 Factory eMTB Fork

The Float 40 Factory is a dual-crown, air-sprung fork built for performance-oriented eMTB riders. It features Kashima-coated 40mm stanchions, GRIP2 damper with external HSC/LSC and HSR/LSR adjustments, and EVOL air spring technology. With a recommended service interval every 40 riding hours for lower leg service, and 125 hours for full damper and air spring service, it is essential to follow the correct schedule to prevent wear.

Lower Leg Service Procedure

Performing a lower leg service involves cleaning and re-lubricating the fork’s sliding surfaces.

Removing the Fork from the Bike

Start by removing the fork from the bike to facilitate a clean and controlled work environment. Disconnect the front brake caliper, remove the front wheel, and unthread the stem bolts. Carefully lower the fork.

Removing the Lower Legs

With the fork inverted, remove the rebound knob using a 2mm Allen key. Loosen and remove the bottom bolts with a 10mm socket. Gently tap each shaft with a rubber mallet to free it from the lower leg. Pull the lowers downward, letting residual oil drain.

Cleaning and Inspecting Internals

Wipe the stanchions with isopropyl alcohol and inspect for wear. Clean the lower legs thoroughly, especially around the bushings. Use a pick to remove old wiper seals if replacing them.

Lubrication and Reassembly

Apply suspension-specific grease around the new wiper seals. Inject 20ml of Fox Gold 20wt oil into each lower leg. Carefully slide the lowers onto the stanchions, ensuring a smooth, straight alignment. Reinstall and torque the bottom bolts to 5.7 Nm. Reinstall the rebound knob.

Air Spring Service

The EVOL air spring requires disassembly for inspection and lubrication.

Accessing the Air Spring Assembly

Release all air from the fork using the Schrader valve. Remove the top cap with a 6-point socket. Pull the air spring assembly from the stanchion.

Inspecting and Lubricating

Check O-rings for nicks or damage. Clean all components and replace any worn seals. Apply Float Fluid to the negative air spring and light grease to all O-rings before reinstalling.

Reassembly

Insert the air spring assembly and torque the top cap to 24 Nm. Reinflate the fork to your desired pressure, referencing the rider weight chart from Fox.

Damper Maintenance Overview

Servicing the GRIP2 damper requires precision and may be best left to experienced users or professional technicians. However, you can replace the bath oil and check damper integrity as part of a full service. Full damper rebuilds involve bleeding the system and replacing internal shims and seals.

Troubleshooting Common Issues

Several symptoms may indicate the need for service or correction:

  • Hissing or squelching sounds: Usually caused by dirty oil or air in the damper; requires inspection.
  • Sticky travel: Worn seals or insufficient lubrication are common culprits.
  • Harsh compression: Air spring volume spacers may need adjustment or the damping may be set too high.
  • Inconsistent rebound: Check rebound knob for debris or bent shaft internals.

Customization and Performance Optimization

The Float 40 Factory eMTB fork supports various customizations to match rider preference and terrain.

Air Pressure Tuning

Use a digital shock pump for accurate settings. Tune based on sag (15-20% is typical). Lower pressures increase sensitivity but may bottom out on aggressive drops.

Volume Spacers

Adding volume spacers increases end-stroke ramp-up, helpful for bigger hits. Removing spacers allows a more linear feel, suited for flowing trails.

GRIP2 Damper Adjustments

Fine-tune with external dials:

  • HSC/LSC: Adjust for square-edge hits and brake dive.
  • HSR/LSR: Tune rebound speed based on terrain and rider preference.

Compatibility with Drivetrain and Frame Standards

While the Float 40 is primarily a suspension component, its compatibility affects frame and braking choices:

  • Steerer tube: 1.5” tapered, dual crown only.
  • Axle: 20mm x 110mm Boost standard.
  • Brake mounts: Post mount, up to 203mm rotors (direct fit).
  • Crown spacing: Ensure adequate clearance with eMTB battery housing or downtube profiles.

Model Comparison: Float 40 Factory vs. Fox 38 Factory

While both models cater to aggressive riders, the Float 40 targets dedicated downhill and eMTB riders:

  • Stanchion diameter: 40mm vs. 38mm – stiffer and better for heavier eMTBs.
  • Travel: Up to 203mm vs. 180mm.
  • Crown: Dual vs. single – offering superior chassis stiffness.
  • Weight: Heavier but offers enhanced durability and stability.

Preventive Maintenance Tips

  • Wipe down stanchions after every ride.
  • Avoid pressure washing seals directly.
  • Reapply sag settings monthly.
  • Check torque specs quarterly.
  • Store the bike upside-down briefly to redistribute internal fluids.

Frequently Asked Questions

How often should I service my Float 40 Factory eMTB fork?
Lower leg service every 40 hours, full service every 125 hours.

Can I install the Float 40 Factory on a non-eMTB bike?
Technically yes, but it’s optimized for eMTBs due to its weight and stiffness.

Do I need special tools to service the fork?
Yes, including a seal driver, torque wrench [paid link], and Fox-specific fluids.

Why does my fork feel harsh even after servicing?
Check for incorrect damping settings, worn bushings, or over-pressurized air spring.

Can I use third-party seals or fluids?
Using Fox-branded parts and fluids is recommended for optimal performance.

Is the GRIP2 damper user-serviceable?
Basic fluid changes are possible, but full rebuilds are best handled by professionals.

Conclusion

Maintaining your Float 40 Factory eMTB fork at home is not only feasible but essential for performance and safety. With correct tools, precise steps, and a regular maintenance schedule, you can ensure your fork delivers consistent control and comfort on demanding trails. Regular inspection and basic services significantly extend the fork’s life and preserve its top-tier feel.