Rebuilding your Fox 34 AWL suspension fork is a crucial maintenance task that ensures consistent performance and extends the life of the fork. Designed for all-weather reliability, the Fox 34 AWL is tailored for riders who need dependable suspension across a range of conditions. This guide walks you through the entire rebuild process—covering installation of new seals, cleaning procedures, troubleshooting tips, and best practices for optimal performance.
Tools Required
- 10mm and 15mm socket wrenches
- 2mm to 6mm hex wrenches
- Torque wrench [paid link]
- Pick tool or seal puller
- Suspension-specific grease
- Isopropyl alcohol (minimum 90%)
- Clean rags or lint-free wipes
- Plastic mallet
- Oil syringe or graduated measuring cup
- Genuine Fox 34 AWL seal kit
- Fox 20wt Gold Bath Oil (or manufacturer-specified equivalent)
- Nitrile gloves
Understanding the Fox 34 AWL Design
The Fox 34 AWL fork features a 34mm stanchion chassis optimized for adventure and utility use, equipped with a GRIP damper and EVOL air spring. The robust design is intended for off-road reliability and minimal maintenance, but periodic servicing is essential to maintain small bump sensitivity and eliminate stiction.
Service Interval and Rebuild Frequency
Fox recommends a lower leg service every 50 riding hours and a full rebuild—including damper and air spring inspection—every 125 hours or annually, whichever comes first. Consistent intervals prevent contamination build-up and internal wear.
Disassembling the Fork for Service
Begin by removing the fork from the bike. Carefully deflate the air spring using the Schrader valve and ensure no pressure remains. Loosen the bottom bolts using a 10mm socket (air side) and a 15mm socket (damper side). Tap the bolts gently with a plastic mallet to free the lower legs from the stanchions. Use a catch basin to collect used oil as it drains.
Once separated, set aside the lower legs and clean thoroughly. Avoid damaging internal bushings during handling.
Cleaning and Inspecting Internal Components
Use isopropyl alcohol and clean rags to remove any oil residue from the stanchions, lowers, and internal cavities. Pay close attention to the foam rings and dust wipers—replace them if they show signs of deformation or dirt saturation.
Inspect the damper shaft for scoring or fluid discoloration. If wear is detected, consider a full damper rebuild or replacement. Check the air spring assembly for oil migration or seal compression. Replace any worn internal o-rings or spacers as part of a comprehensive rebuild.
Installing New Dust Wipers and Foam Rings
Press-fit the new dust wipers into the fork lowers using a seal driver of the correct diameter. Do not use makeshift tools that can deform the seals. Lightly coat the foam rings with Fox 20wt Gold oil and position them beneath the dust wipers. Ensure even seating without wrinkling.
Lubricate the inner walls of the lower legs using a light application of suspension grease to reduce stiction on reassembly.
Reassembling the Fork
Carefully slide the fork lowers back onto the stanchions while aligning the bushings. Do not force them into place. Once seated, reinstall the bottom bolts with fresh crush washers and tighten to the manufacturer’s torque specifications—typically 5-7 Nm for the damper and air bolts.
Inject 10-15cc of Fox 20wt Gold oil into each leg through the open bolt holes before final tightening. This replenishes the oil bath and maintains lubrication during compression.
Inflating the Air Spring and Final Adjustments
Re-pressurize the air spring to your desired setting using a shock pump. Fox recommends an initial baseline based on rider weight, which can be fine-tuned for sag and rebound after a test ride.
Adjust rebound damping using the red dial at the fork’s base. For forks with a GRIP damper, set the compression via the top cap blue dial.
Troubleshooting Common Issues Post-Rebuild
Excessive Top-Out Clunk:
This usually points to insufficient bath oil or misaligned internals. Re-inspect oil levels and ensure bolt torque is correct.
Sticky Travel or Harsh Initial Stroke:
Contaminated stanchions or dry seals may be the culprit. Ensure foam rings are properly saturated and verify internal cleanliness.
Oil Leaks Around Dust Seals:
Indicates improperly seated wipers or damaged seals. Reinstall using correct tools and replace seals if damage is visible.
Optimizing Performance with Custom Settings
The Fox 34 AWL can be fine-tuned beyond factory presets:
- Air Volume Spacers: Adjusting volume spacers changes ramp-up behavior. Removing spacers softens progression, while adding increases bottom-out resistance.
- Oil Viscosity: Using manufacturer-approved oil grades allows customization of damping feel, although deviations from spec must be tested cautiously.
- Aftermarket Damper Kits: Some advanced users may upgrade to a higher-tier GRIP2 damper for broader adjustability.
Compatibility With Other Components
The Fox 34 AWL is designed to integrate seamlessly with most modern 29-inch wheels using a Boost 110x15mm axle spacing. It supports both flat and post-mount brakes, with clearance for rotors up to 203mm. It is compatible with Fox’s remote lockout levers and designed for straight or tapered steerer tubes.
Drivetrain compatibility is generally universal, though fender mounts and cable routing options may influence setup with full-length housing or external dropper posts.
Comparing the Fox 34 AWL With Similar Models
Compared to the Fox 34 Rhythm or Fox 34 Factory, the AWL is built for utility and all-weather reliability over outright performance. It lacks high-speed compression adjustability but compensates with ease of maintenance and robust construction.
- Fox 34 Rhythm: Offers more tunability but slightly heavier chassis.
- Fox 34 Factory: Designed for aggressive trail use with Kashima-coated stanchions and advanced dampers.
- Fox 34 AWL: Best suited for e-bikes, bikepacking, and riders prioritizing durability over race-ready tuning.
Conclusion
Rebuilding your Fox 34 AWL fork is a straightforward yet essential task to maintain its performance and extend its service life. With the right tools and careful attention to detail, even intermediate riders can complete the rebuild effectively. Regular service ensures your fork remains smooth, reliable, and ready for any terrain or weather condition.