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Discussion Starter · #1 ·
Hoping someone has experience with an issue I'm having...

I have an '04 Float 100 RLC that I bought used last October with a fresh rebuild (included a bag of the replaced parts).

From the time I got it, it leaked out of the right topcap, through the adjusters. It was worst at first, and actually leaked the most during transport (while the bike was on the car rack); every time I reached the destination, I'd have to wipe it down. It would weep a little while riding, but no big deal, not as much as transport. Over time, it leaked less and less, so I figured that whoever did the rebuild must've overfilled it, and it would eventually stop... which it almost did...

Until last weekend... by the end of the ride, it was covered, from the top down to the seal, in oil-mud.

Anyone seen this before? I haven't been able to find a topcap schematic or anything on disassembling the topcap, just how to service the damper. I'm guessing there has to be a seal or o-ring to keep oil from leaking through the adjuster assembly, but don't care to tear into it without having an idea of what exactly I'm looking for and how to specifically get to it...
 

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Discussion Starter · #3 ·
the-one1 said:
Here's a cross section of the RLC magic. Where is it leaking oil from?
Check the O rings I have circled in red and green.
Yep, I did find that cross section in my searches, but it's not quite enough for me to be able to tell how to disassemble it to get to those 2 o-rings, and yes those are the ones I suspect.
As for where it's leaking from, all I can tell is that it is from the top... no way to really pinpoint which adjuster (if not both)
 

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I'm not sure as I've never fully undone this on mine, but I think that after removing the rebound knob, compression dial, and lockout lever from the top, you can probably just unscrew the topcap, clamp the "C" bit in a spanner/adjustable wrench, then rotate "A" until it unscrews. I think this is how you get to access the compression shims at "B" and I guess probably will also allow access to the internal o-rings there as the topcap should come off the damper shaft completely.

That's all guesswork there, so be careful in case it turns out to be different.

 

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Discussion Starter · #5 ·
EmanResu said:
I'm not sure as I've never fully undone this on mine, but I think that after removing the rebound knob, compression dial, and lockout lever from the top, you can probably just unscrew the topcap, clamp the "C" bit in a spanner/adjustable wrench, then rotate "A" until it unscrews. I think this is how you get to access the compression shims at "B" and I guess probably will also allow access to the internal o-rings there as the topcap should come off the damper shaft completely.

That's all guesswork there, so be careful in case it turns out to be different.
Yea, that makes sense...

A guy at Fox sent me a good technical schematic of the topcap assembly; I'd attach it, except that it is labeled as confidential, proprietary info and not to disclose except as authorized by Fox... so if anyone wants it, PM me and I'll share (although that's technically "against the rules too"). Anyway, I think I have enough to dive in with minimal damage :D Thanks for y'all's help :thumbsup:
 
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