Clean fork. Inspect fork for any damage. Particularly scratches on legs. Remove axle if installed.

Remove seal head guard. Use pick if necessary. With fork inverted to prevent oil loss, loosen lower seal head on AIR SPRING SIDE ONLY using Bottom Bracket Wrench or strap wrench. Back seal head all the way off and dump splash oil. Dispose of oil properly.

Using pick, remove air side plug on top of fork upper. Using non-ball end 4mm Allen, loosen air shaft nut until completely disengaged. Nut is contained within upper. Remove air spring leg. Remove air cap and bleed all air from air spring.

Using pick, remove upper bushing. Take care to not overexpand bushing as it will be reinstalled.

Clamp shaft in 8mm shaft clamp, allowing space to access seal head. Using 12mm box wrench on air seal head nut and Knipex on circlip retaining puck flats, free retaining puck from seal head. Fully unthread retaining puck while clamped to capture the seal head in the event of residual air pressure. Once circlip retaining puck is completely free, unclamp shaft and remove puck completely.

***Use extreme caution as negative air chamber may have residual pressure. Releasing circlip can cause rapid depressurization***

Reclamp shaft into vice. Locate circlip access hole. Wedge L-pick underneath circlip and hold in place. With secondary pick, pry circlip free. Take care to keep fingers away from circlip in the event of residual air pressure. Keeping L-pick in access hole, remove circlip while keeping seal head secured in place.

***Use caution as negative air chamber may have residual pressure.***

With shaft still firmly clamped, pull down on leg to remove from air shaft assembly. Use of Knipex on seal head nut flats to aid removal by twisting may be necessary.

Stock air spring has a single volume reducer installed on end of piston. Maximum number is three. Not recommended to run zero reducers.

To add reduction, thread new volume reducer (ABG0323) onto original reducer. Using Knipex, tighten to snug.

To remove reduction, use Knipex to free and then remove volume reducer.

Lightly grease piston & quad ring and seal head & o-ring. Insert air spring assembly into air leg. Rotation and wiggling will aid install. Apply pressure on seal head nut until fully seated. If necessary, use 8mm shaft clamp as surface to apply pressure. Seal head will click into place when seated.

Align circlip so one end is behind access hole. Install circlip into leg, securing air spring assembly. Using pick, follow circlip all the way around to ensure it is fully seated.

Apply 243 (Blue) Loctite to seal head threads. Install circlip retaining puck and thread into place. Clamp shaft. Using 12mm box wrench on seal head flats and 24mm crowfoot on circlip retaining puck, torque to 5 Nm.

Precompress bushing and install on air spring leg.

Clean threads on air shaft with pick. Apply fresh 243 (Blue) Loctite to shaft threads. While pinching bushing, insert air leg into air side of fork upper. Gently slide leg into upper until first contact with shaft and fork upper. While gently applying pressure, rotate air leg assembly until you feel the flats on the air shaft slot into place. Maintain pressure to keep shaft engaged. Using non-ball end 4mm Allen, thread air shaft bolt onto air shaft through fork upper. Torque to 5 Nm. Reinstall air side plug on uppers.

Secure fork with legs up. Using syringe, add 10ml of 15wt Motorex Racing Fork Oil to air spring leg.

Thread lower seal heads onto fork upper. Using Bottom Bracket Tool, torque to 15 Nm. Reinstall seal head guards. Make sure they are properly seated and aligned.