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EXT Racing Shox ERA Service Manual
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EXT Racing Shox ERA Service Manual

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SERVICE MANUAL

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Summary of Contents for EXT Racing Shox ERA

  • Page 1 SERVICE MANUAL...
  • Page 2 Table of contents - Indice 1 Italiano IFI snform—zioni prelimin—ri di si™urezz— F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F IFP ƒtrumenti ne™ess—ri F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F IFQ iˆ„...
  • Page 3 Part 1 Italiano 1.1 Informazioni preliminari di sicurezza Prima di cominciare qualsiasi operazione leggere attentamente questo manuale. Le istruzioni qui contenute vi permetteranno di eseguire le operazioni di ma- nutenzione in totale sicurezza. Con questo manuale si intende dare una chiara istruzione per la manutenzione straordinaria.

  • Page 4: Strumenti Necessari

    ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.2 Strumenti necessari €rim— di ™omin™i—re il servi™e è ne™ess—rio —vere „…„„s gli strumenti ne™ess—riF Descrizione g—v—lletto @st—ndA per ˜i™i ƒgr—ss—tore €—nno per pulizi— †—s™hette pulite €inz— — ˜e™™hi (ni ellen key IFSmmD PFSmmD Rmm „orx „V g—™™i—vite per ™ore v—lvol—...
  • Page 5 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.3 EXT Tools e consumabili s seguenti „ool iˆ„ sono ne™ess—ri per eseguire un ™orretto l—voroF CODICE UTILIZZO iˆ„ ‚ed edhesive qel qel —desivo per —ssem˜l—ggio ™omponenti iˆ„ q‚ieƒi vIƒ qr—sso —d —lto s™orrimento iˆ„ vu˜e i†TVƒ ylio —...
  • Page 6 ƒervi™e m—nu—l i‚e ‘†IFQ“...
  • Page 7 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.4 Istruzioni 1.4.1 Operazioni preliminari IF €ulire —™™ur—t—mente l— for™ell— e —s™iug—rl—F PF €rendere not— delle regol—zioni e delle pressioniD in modo t—le d— poterle ripristin—re —ll— (ne del l—voroF ve regol—zioni v—nno sempre tr—s™ritte ™ont—ndo i 4™li™k4 d—ll— posizione di tutto ™hiusoD ™ioè ™omplet—mente —vvit—t—D in senso y‚e‚syF fr gompressione —lle —lte velo™ità...
  • Page 8 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5Q E flo™™—re l— rot—zione del d—do ™on l— ™hi—ve d— IWmm e utilizz—ndo l— avvitare ™hi—ve —llen d— Rmm lo stelo ˆ ghi—ve di m—novr— ™entr—leF ‚ipetere l9oper—zione per enE poligon—le IWmm tr—m˜e le 4g—m˜e4F ettenzioneX non ˆ...
  • Page 9 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5T E ‚einserire ™omplet—mente il fodero (no — f—r fuorius™ire gli steli d— esso ™on l9—usilio dell— —llen key d— RmmF €ulireD ˆ ellen key Rmm utilizz—ndo un pi™kEup toolD i (letti deE gli steli e dei d—di d—ll— ve™™hi— vo™tite sgrassarli accuratamente e in(ne ˆ...
  • Page 10 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IH E €ro™edere — rimont—re l— ruot— —nteriore e l— pinz— freno rispett—ndo le ˆ xessuno ™orrette ™oppie e mod—lità di serr—ggioF...
  • Page 11 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.4.3 Revisione completa lowers ƒeguendo le istruzioni indi™—te è possi˜ile un servi™e ™ompleto —i lowers in modo d— ripristin—re si— l— s™orrevolezz— ™he l— funzion—lità delle tenute p—r—EpolvereF €er e'ettu—re quest— oper—zioneD oltre —i toolsD serve il servi™eEkit ƒuHHHQF hes™rizione sllustr—zione iˆ„...
  • Page 12 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5R E ‚iposizion—re l— ˜i™i sul ™—v—llettoF €osizion—re un— v—s™— per il re™upero dell9olio sull— verti™—le sotto l— for™ell—F delicata- gon un m—rtello di gomm— mente ™olpire l9—r™hetto del fodero per scendere completamente f—rlo F v—E ˆ...
  • Page 13 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5U E €relev—re d—l servi™e kit i nuoE vi p—r—polvere e ™ontroll—re l— presenE z— dei due —nelli el—sti™iF gon l9—pposiE to tool inserirli nelle loro sedi utilizz—nE ˆ „vHTQU do il m—rtello in gomm—F gontroll—re ˆ...
  • Page 14 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IH E ƒostituire le tenute —lle estremiE tà degli steliX preEingr—ss—re gli oEring e ˆ iˆ„ qre—se vIƒ mont—rli in posizioneF 5II E ‚ein(l—re i foderi revision—ti sugli st—n™hionF €rest—re l— m—ssim— —ttenE zione — non pizzi™—re le tenuteF xon inE ˆ...
  • Page 15 ƒervi™e m—nu—l i‚e ‘†IFQ“ ˆ €rimer UTRW 5IR E €ulire il d—do e il ™li™ker d—l gr—sE ˆ vo™tite PRQ so e d—ll— ve™™hi— lo™titeF €rep—r—re i d—di ™on il €rimerF €osizion—re l— ™orE ˆ ghi—ve di m—novr— rett— qu—ntità di vo™tite sul (letto m—E IWmm s™hioF flo™™—re il d—do ™on l—...
  • Page 16 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.4.4 Cambio travel ERA ƒeguendo le istruzioni è possi˜ile f—re un ™—m˜io ™ors— di i‚eD il tr—vel impost—˜ile v—ri— d— IRH — IUHmm in step di IHmmF ygni step di IHmm è possi˜ile utilizz—ndo il ™odi™e eƒHSHRF hes™rizione...
  • Page 17 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5R E gon un m—rtello di gomm— licatamente ™olpire l9—r™hetto del foE dero per f—rlo s™endere ™omplet—menE ˆ w—rtello in gomm— teF v—s™i—r fuorius™ire tutto l9olio si— d—i foderi ™he d—l gruppo steliF 5S E piss—re lo stelo sinistro in mors— @us—ndo g—n—s™e in gomm—...
  • Page 18 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5W E €rep—r—re i (letti ™on il primer @su (letto femmin—A e vo™tite su t—pE ˆ vo™tite PRQ po @(letto m—s™hioD un giro ™ompletoAF ˆ €rimer UTRW piss—re il t—ppo — PSxmF 5IH E ƒostituire l9oEring in fondo —gli steli e ingr—ss—rli entr—m˜iF qon(—re il ˆ...
  • Page 19 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IP E ‚einserire ™omplet—mente il foE dero (no — f—r fuorius™ire gli steli d— esso ™on l9—usilio dell— —llen key d— ˆ ƒgr—ss—tore RmmF €ulireD utilizz—ndo un pi™kEup toolD i (letti degli steli e dei d—di d—lE ˆ...
  • Page 20 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.4.5 Revisione sistema HS3 ERA „r—mite le oper—zioni des™ritte di seguito è possi˜ile f—re il servi™e del sistem— rƒQ di i‚eF ƒ—rà ne™ess—rio munirsi del servi™eEkit ƒuHHHRF hes™rizione sllustr—zione „ools Rimuovere il tappo supe- 5I E riore e rilasciare la pressione di ˆ...
  • Page 21 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5S E €rendere in mors— ™on i ™l—mp lo ˆ „vHQRR•IH stelo @˜en sgr—ss—toA del volume CCD ˆ „vHSVU svit—re il t—ppo superioreF istr—rre il pistone sep—r—tore d—llo steloF ˆ ƒgr—ss—tore 5T E ‚imuovere d—l pistone sep—r—tore e d—l t—ppo superiore le tenute @interne ˆ...
  • Page 22 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5W E ‚ein(l—re il pistone sep—r—tore reE vision—to sullo stelo @il ™omponente è ˆ „vHQRR•IH simmetri™oAF ‚imuovere i residui di gr—sso @se ne™ess—rio sgr—ss—re nuov—E ˆ „vHSVU mente i (lettiAF €osizion—re il primer ˆ €rimer UTRW su (letto femmin—...
  • Page 23 ƒervi™e m—nu—l i‚e ‘†IFQ“ ˆ €i™kEup tool 5IP E ‚imuovere le tenute esterne d—l pistoneF …s—ndo l— ™hi—ve di m—novr— ˆ ghi—ve di m—novr— e un— „orx smont—re l— ˜leedEport d—l pistoneD rimuoverne gli oEring e pulire —™™ur—t—mente d— gr—sso e lo™tite tutti ˆ...
  • Page 24 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IT E ‚iprendere lo stelo @sgr—ss—toA in mors— ™on i ™l—mpD vi™ino —l pistoE ne prin™ip—leF ‚einserire nel verso ™orE ˆ „vHQRR•V retto il dis™o in pl—sti™—D il t—mpone in gomm—D il t—ppo inferiore e il seegerF 5IU E €rep—r—re l—...
  • Page 25 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IV E snserire l— l—mell— sul fondo del ˜i™™hiere port—Emoll— e su™™essiv—mente l— moll—F essem˜l—rlo sullo stelo e (sE ˆ €inz— seeger s—re l9—ssieme ™on il seegerD —ssi™ur—rsi ™he v—d— ˜en in sedeF 5IW E ‚imettere il gruppo ™rown in mors—...
  • Page 26 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PH E snserire in profondità il seE p—r—tore utilizz—ndo l9—pposito tool ˆ „vHTVP „vHTVPF 5PI E istr—rreD senz— muovere il pistoE ne sep—r—toreD il t—ppo superioreF €uE lire e sgr—ss—re — questo punto il (letto ˆ ƒiring— femmin—...
  • Page 27 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PQ E sngr—ss—re —˜˜ond—ntemente le ™—ve esterne del pistone prin™ip—le ™on il gr—sso —ppositoF €reform—re l— f—E s™i— slyering e mont—rl— sul pistoneF ˆ iˆ„ qre—se vIƒ sn(l—re il gruppo stelo —ll9interno delE lo st—n™hion per ™ir™— S™mF snserire nuov—mente I™™...
  • Page 28 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.4.6 Revisione cartuccia ERA „r—mite le oper—zioni des™ritte di seguito è possi˜ile f—re il servi™e —ll— ™—rtu™™i— idr—uli™— di i‚eF ƒ—rà ne™ess—rio munirsi del servi™eEkit ƒuHHHSF €rim— di ™omin™i—reD —l™uni riferimentiX ˆ fr a regol—zione —lte velo™ità in ™ompressioneF ˆ...
  • Page 29 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5S E piss—re l— ™—rtu™™i— in mors— ™ome nell9imm—gineF ƒvit—re il t—ppo prin™iE ˆ „vHQRREPR p—le us—ndo l— ™hi—ve d— IUmmF istr—rE re lo steloD pulirlo —™™ur—t—mente e riE ˆ ghi—ve di m—novr— porre il gruppo dell9estensione su un— IUmm super(™ie pulit—F 5T E ƒvuot—re l—...
  • Page 30 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IH E ƒostituire oEring e f—s™i— slydering ˆ iˆ„ red —dhesive sul pistone prin™ip—leF 5II E ‚i—ssem˜l—re nel verso ™orretto moll—E™he™kD l—mell— ™he™kD pistone @—tE tenzione —l verso di inserimentoA e speE ˆ ghi—ve ™i(™— del ritornoF ƒgr—ss—re —™™ur—t—E n—mometri™—...
  • Page 31 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IR E ƒmont—re l9—st— di regol—zione del ritorno d—l gettoF €reingr—ss—re e soE stituire l9oring sull9—st— di regol—zione ˆ iˆ„ red —dhesive senza preingrassa- dell9estensione eD D quello interno —l gettoF sngr—ss—re @vIƒA e rimuovere tutto l9e™™esso il (E ˆ...
  • Page 32 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IS E €ro™edere —ll— rimozione di tutE te le tenute e p—rti ™he ™ompongono ˆ ƒgr—ss—tore il ™over prin™ip—leX stepEse—l e rel—tiE ˆ €i™kEup tools vo oEringD xEringD il seegerD l— h… in m—teri—le polimeri™o e l9oring sottost—nE ˆ...
  • Page 33 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IV E sngr—ss—re e in(l—re nel verso ™orretto il t—ppo sullo steloF €ulire ˆ iˆ„ red —dhesive e sgr—ss—re —™™ur—t—mente d—l gr—sso e™™edente il (letto sull9estremità dello ˆ ƒgr—ss—tore steloF ˆ €rimer UTRW 5IW E essi™ur—rsi ™he l9—st— di regol—zioE ne si—...
  • Page 34 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PP E istr—rre moll—E™he™kD l—mell— ™he™kD pistoneD spe™i(™— ™ompressioneD g—˜˜i— del pre™—ri™o e l—melle di preE ™—ri™oF istr—rre —n™he il 4r—gnetto4 ˆ ellen key IFSmm di pre™—ri™o @svit—re le tre viti l—teE ˆ †—s™hett— pulit— r—liA e l9oEring sottost—nteF ‚iporre i ™omponenti puliti e sgr—ss—ti in un ™ontenitoreF...
  • Page 35 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PT E ‚i—ssem˜l—re nell— sequenz— ™orE rett— l— moll—D il guid—moll— e il pistoE ˆ €inz— seeger —d —priE ne sep—r—tore @revision—toAF snst—ll—re reD ØHFW nuov—mente il seeger —ssi™ur—ndosi ™he si— perfett—mente in posizioneF €reinE ˆ iˆ„ red —dhesive gr—ss—re e reinst—ll—re —n™he l9oring di guid—...
  • Page 36 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5QH E …tilizz—ndo un pi™kEup tool riE muovere il ™ir™lip ™he tiene in posizioE ne il ™li™ker dell— regol—zione frF ƒviE ˆ €i™kEup tools t—re il ™omponente @us—ndo il pomello frA per f—r ris—lire l9—st— ™—v— di reE ˆ...
  • Page 37 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5QR E ‚einserire in sede il sistem— ™li™k dell— regol—zione frD mettere un go™E ™io di lo™tite su ogni gr—noF €re™—ri™—E ˆ vo™tite PRQ re i gr—ni — (no delle sf—™™i—ture @™oE me in fotoAF €rov—re il 4feeling4 del ˆ...
  • Page 38 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5QV E wont—re il p—™™o l—mell—re di preE ™—ri™oD l— g—˜˜iett— di pre™—ri™oD l— speE ™i(™— di ™ompressione e il rel—tivo piE stone @revision—toAF snserire su™™essiv—E mente l— l—mell— ™he™k e l— rel—tiv— molE ˆ ghi—ve lettin—F €rest—re m—ssim—...
  • Page 39 ƒervi™e m—nu—l i‚e ‘†IFQ“ ˆ „vHQRREPR 5RP E €ro™edere ™osì —llo spurgo dell— ˆ ghi—ve ™—rtu™™i— ™on l9—usilio di iˆ„ †—™uum n—mometri™— (lling m—™hineX impost—re l— pressione IHxm di gon(—ggio — P˜—r e pro™edere ™on due ™i™li ™ompletiF e spurgo ™omplet—to —vE ˆ...
  • Page 40 ƒervi™e m—nu—l i‚e ‘†IFQ“...
  • Page 41 ƒervi™e m—nu—l i‚e ‘†IFQ“ 1.5 Riassunto coppie di serraggio e speciche di montaggio...

  • Page 42: Preliminary Safety Information

    Part 2 English 2.1 Preliminary safety information Before beginning any operation read carefully this guide. The instruction here enclosed will allow you to perform maintenance operation in total safety. This guide is intended to give clear instruction for extraordinary maintenance. For any problems not mentioned/addressed in these pages, please contact our technical department who will indicate the best solution.

  • Page 43: General Tools

    ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.2 General tools xe™ess—ry st—nd—rd toolsF Descrizione fike st—nd hegre—ser @˜r—ke ™le—nerA gloth for ™le—ning gle—n tr—y pine nose pliers ellen key IFSmmD PFSmmD Rmm „orx „V †—lveE™ore tool pl—t s™rewdriver Qmm ypen G polygon—l key TmmD VmmD IQmmD IUmmD IWmm €i™k…p „ools ƒeeger pliers WH°D ØHFWD opening ƒeeger pliers WH°D ØHFWD ™loseing...
  • Page 44 ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.3 EXT Tools and consumables ƒpe™i(™ iˆ„ „ool for i‚e forkF CODICE UTILIZZO iˆ„ ‚ed edhesive qel edhesive gel for —ssem˜ly oper—tions iˆ„ q‚ieƒi vIƒ righ perform—n™es lu˜ri™—ting gre—se iˆ„ vu˜e i†TVƒ vow fri™tion lu˜ri™—ting oil iˆ„...
  • Page 45 ™ould ™ompromise the over—ll (n—l resultF 2.4.2 ERA slyding oil service ss it possi˜le to ™h—nge the slinding oil ˜y follow the steps —s shownF gh—nging the oil frequently will —llow to keep your i‚e sliding ™omponents in ex™ellent ™onditionF ss going to ˜e shown the illustr—ted sequen™es oper—tions with the fork mounted on the ˜ikeD this will permit to work f—sterF...
  • Page 46 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5Q E ƒtop the nut rot—tion with the IWmm wren™h —nd using the Rmm elE len wren™h s™rew the ™entr—l stemF ‚eE ˆ ypen key IWmm pe—t the oper—tion for ˜oth sideF €—y —ttentionX do not let the ™entr—l stem ˆ...
  • Page 47 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5T E ‡ith the —id of the Rmm ellen keyD ™ompletely reinsert the lowers unE til the stems ™ome out of itF ‡ith the ˆ ellen key Rmm —id of — pi™kEup toolD ™le—n the stems thE re—ds —nd nuts from the old vo™tite —nd degrease them thoroughly (n—lly...
  • Page 48 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IH E €ro™eed ˜y mounting the front wheel —nd ˜r—ke ™—liper respe™ting ˆ xone the ™orre™t torques —nd tightening methodsF...
  • Page 49 ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.4.3 ERA complete lowers service fy following the here˜y instru™tions it is possi˜le to provide — ™omplete servi™e to the lowers in order to restore dust se—ls smoothness —nd fun™tion—lity F „o perform thisD in —ddition to the toolsD you need the ƒuHHHQ servi™e kitF...
  • Page 50 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5R E xow pl—™e the ˜ike on the st—ndF €l—™e —n oil re™overy t—nk under the fork verti™—l lineF ‡ith the ru˜˜er h—mmer gently hit the lowers ˜ow to m—ke it run down ™ompletelyF vet —ll ˆ...
  • Page 51 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5U E prom the servi™e kit t—ke the new dust se—ls —nd ™he™k the presen™e of two sn—p ringsF fy using the —ppropri—E te tool insert them in their se—ts with ˆ „vHTQU the ru˜˜er h—mmerF ghe™k the ™orre™t —nd uniform insertion of se—lsF ho not ˆ...
  • Page 52 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IH E €ut the revised lower on the st—nE ™hionF fe very ™—reful not to pin™h the se—lsF ho not insert the lowers ™ompleE ˆ iˆ„ rh„ETV €i† tely ˜ut keep them extr—™ted ˜y —˜out IH ™mF 5II E €l—™e the ˜ike upside down on the )oorD it should le—n on the h—ndle˜—r —nd se—t so you will ˜e —˜le to work on...
  • Page 53 ƒervi™e m—nu—l i‚e ‘†IFQ“ ˆ €rimer UTRW ˆ vo™tite PRQ 5IR E €rep—re the nuts with the €rimerF €l—™e the ™orre™t —mount of vo™tite on ˆ gom˜in—tion wrenE the m—le thre—dF vo™k the nut with the ™hes IWmm IWmm polygon—l wren™h —nd uns™rew the stem —t WxmF ˆ...
  • Page 54 ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.4.4 ERA travel change i‚e stroke ™—n ˜e ™h—nged ˜etween IRHmm —nd IUHmm ˜y step of IHmmF ivery IHmm step is gener—ted ˜y Ix eƒHSHRF hes™ription sllustrtion „ools Remove the pressure from 5I E both "+" e "++" volumes.
  • Page 55 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5R E …se — pl—sti™ h—mmer to hit genE tly the ™onne™tion —r™h of the lowers then sep—r—te lowers from st—n™hionsF ˆ ‚u˜˜er h—mmer ve—ve the oil )ow out from lowers —nd st—n™hionsF 5S E gl—mp the —irEside st—n™hion on the vi™e @use ru˜˜er j—w p—dsA —nd reE move sh—ft se—l housingF ho not pull ˆ...
  • Page 56 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5W E €ut the primer on st—n™hion9s thE re—d —nd the vo™tite on se—lEhe—d thE ˆ vo™tite PRQ re—d @I ™omplete turnAF pix the se—l ˆ €rimer UTRW he—d to PSxmF 5IH E ghe™k oEring on ˜oth sh—ft ends —nd if they —re d—m—gedD repl—™e —nd ˆ...
  • Page 57 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IP E €ush st—n™hions inside lowers unE til ˜oth sh—ft ends ™ome outsideD you ˆ degre—ser Clean ™—n use — Rmm —llen key —s helpF internal and external thread from ˆ €i™kEup tools oil —nd old vo™titeF 5IQ E €unt the prime on ˜olts —nd two drops of vo™tite on sh—ft endsF rold the ˆ...
  • Page 58 ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.4.5 HS3 ERA system service pollowing oper—tions —re des™ri˜ed to do — ™omplete servi™e of —irEspring system of i‚eF …se ƒuHHHR servi™e kit for thisF hes™ription sllustr—tion „ools Remove the top-cup and 5I E relase the prerssure from both ˆ...
  • Page 59 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5S E pix in the vi™eD using ™l—mpsD ˆ „vHQRR•IH the rod @well degre—sedA of volume CCD ˆ „vHSVU uns™rew the top ™—pF ixtr—™t the sep—r—tor piston from the rodF ˆ hegre—ser 5T E ‚emove from the )o—ting piston —nd from the top ™—p se—ls @intern—l —nd ˆ...
  • Page 60 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5W E ‚einsert the servi™ed )o—ting piE ˆ „vHQRR•IH ston onto the rod @the ™omponent is symmetri™—lAF ‚emove the residues of ˆ „vHSVU gre—se @if ne™ess—ry degre—se the thE re—ds —g—inAF €l—™e the primer on ˆ €rimer UTRW the fem—le thre—d —nd lo™tite on m—le ˆ...
  • Page 61 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IP E ‚emove estern—l se—l from the ˆ €i™kEup tool m—in pistonF …sing the wren™h —nd — „orx dis—ssem˜le the ˜leed port from ˆ ypen key Tmm the pistonD remove oErings —nd ™—reE ˆ „orx key „V fully ™le—n from gre—se —nd lo™tite —ll ™omponentsF ˆ...
  • Page 62 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IT E €i™k up the sh—ft@degre—sedA in — vi™e with ™l—mpsD ™lose to the m—in pistonF ‚einsert in the ™orrre™t posiE ˆ „vHQRR•V tion —nd dire™tion the pl—sti™ dis™D the ru˜˜er ˜umpD the lower ™—p —nd the seegerF 5IU E €rep—re the s™rew withD in seE ˆ...
  • Page 63 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IV E snsert the shim into the ˜ottom of the spring holder ™up —nd then insert ˆ glosing seeger pliers the springF essem˜le it onto the rod WHdeg —nd f—sten the —ssem˜ly with the seegerD m—ke sure th—t it goes well in pl—™eF 5IW E €ut the ™rown —ssy ˜—™k on the vi™e with the „vHTVS downw—rd orienE tedF qenerously gre—se the extern—l sloE...
  • Page 64 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PH E heeply insert the sep—r—tor using ˆ „vHTVP the —ppropri—te tool „vHTVPF 5PI E wove up the top ™—p without moE ving the sep—r—tor piston —nd insert I™™ of oil with — syringeF et this pointD ˆ...
  • Page 65 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PQ E qenerously gre—se the extern—l slots of the m—in piston with the —pE propri—te gre—seF €reform the slydering ˆ iˆ„ qre—se vIƒ —nd —ssem˜ly it on the pistonF snsert the rod unit inside the st—n™hion for —˜out S™mF snsert —g—in I™™...
  • Page 66 ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.4.6 ERA hydraulic cartridge service ƒervi™e of the ™—rtridge of i‚e is possi˜le ˜y following these stepsF ƒuHHHS servi™eEkit is requiredF fefore st—rtingD some referen™esX ˆ fr a highEspeed ™ompression —djustmentF ˆ fv a low speed ™ompression —djustmentF ˆ...
  • Page 67 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5S E pix the ™—rtridge in the vi™e —s the im—geF …ns™rew the m—in ™—p using ˆ „vHQRREPR IUmm sp—nnerF €ull out sh—ft —ssyD ˆ ypen key IUmm ™le—n —nd store it in — ™le—n tr—yF 5T E hr—in the oil from the ™—rtridge ˆ...
  • Page 68 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IH E ‚epl—™e oEring —nd slydering on ˆ iˆ„ ‚ed —dhesive the re˜ound pistonF 5II E ‚e—ssem˜ling in the ™orre™t diE re™tion springE™he™kD shim ™he™kD piston @p—y —ttention to the dire™tion of inserE tionA —nd re˜ound spe™F g—refully deE ˆ...
  • Page 69 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IR E ‚emove the re˜ound —djuster from the jetF €reEgre—se —nd repl—™e the oEring on the extension —djustment ˆ iˆ„ red —dhesive rod —ndD without preEgre—singD the inE ner one into the jetF qre—se —nd remove —ll the ex™ess from the thre—d of the reE ˆ...
  • Page 70 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IS E €ro™eed with the remov—l of —ll se—ls —nd p—rts th—t ™ompose the m—in ˆ €i™kEup tools ™overX stepEse—l @—nd it9s oEringAD xEringD seegerD polymeri™ h…D stepEse—l —nd it9s ˆ glosing seeger plierD oringD outer oEringF gle—n —nd degre—se ØHFWmm the m—in ™overF 5IT E ‚einst—llD t—king them from...
  • Page 71 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5IV E qre—se —nd insert the ™over on the sh—ft in the ™orre™t dire™tionF „hoE ˆ iˆ„ ‚ed —dhesive roughly ™le—n —nd degre—se from exE ™ess gre—se the thre—d —t the end of the ˆ hegre—ser sh—ftF 5IW E insure th—t the —djustment rod ˆ...
  • Page 72 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PP E €ull out ™he™kEspringD ™he™kE shimD pistonD ™ompression spe™D prelo—d ˆ ellen key IFSmm ™—ge —nd prelo—d shimsF elso remoE ve the 4prelo—ding spider4 @uns™rew the ˆ gle—n tr—y three side s™rewsA —nd the underlying oE ringF ƒtore —ll ™omponents @™le—ned —nd ˆ...
  • Page 73 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5PT E ‚e—ssem˜le the springD spring guide —nd sep—r—tor piston @servi™edA in ˆ ypen seeger pliersD the ™orre™t sequen™eF snst—ll the seeger ØHFW —g—inD ensuring th—t is perfe™tly in pl—E ™eF €reEgre—se —nd reinst—ll —lso the oE ˆ...
  • Page 74 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5QH E …sing — pi™kEup toolD remove the ™ir™lip th—t holds the fr —djustE ment ™li™ker in pl—™eF …ns™rew the ˆ €i™kEup tools ™omponent @using the kno˜ frA to r—iE ˆ „hinEhe—d pliers se the intern—l —djustment hollow rodF ‚emove it with the —id of —...
  • Page 75 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5QR E ‚einsert the ™li™k system of the fr —djustmentD put — drop of lo™tite ˆ iˆ„ qre—se vIƒ on e—™h gr—inF €relo—d the gr—ins up to the f—™ing @—s in the photoAF „est ˆ vo™tite PRQ the 4feel4 of the ™li™k ˜efore reinst—lling it —nd —djust the prelo—d of the gr—ins ˆ...
  • Page 76 ƒervi™e m—nu—l i‚e ‘†IFQ“ 5QV E pit the prelo—d shimEp—™kD preE lo—d ™—geD ™ompression spe™ —nd the reE l—tive piston @revisedAF „hen insert the ™he™kEshim —nd the rel—tive springF €—y m—ximum —ttention to the positioning —nd ™entering of the wholeF ‚efer to ˆ...
  • Page 77 ƒervi™e m—nu—l i‚e ‘†IFQ“ ˆ „vHQRREPR 5RP E €ro™eed to ˜leed the ™—rtridge ˆ ghi—ve using iˆ„ †—™uum (lling m—™hineX set n—mometri™— the pressure to @m—xA P˜—r —nd pro™eed IHxm with two ™omplete ™y™lesF yn™e the ˜leeding is ™ompleteD s™rew the m—in ™oE ˆ...
  • Page 78 ƒervi™e m—nu—l i‚e ‘†IFQ“...
  • Page 79 ƒervi™e m—nu—l i‚e ‘†IFQ“ 2.5 Torque value and assembly spec...
  • Page 80 EXTREME BIOMEC S.R.L. Viale del lavoro,66/68 36048 Barbarano Mossano (VI) – Italy Phone: +39 0444 730635 Mail: info@extremeshox.com Web: www.extremeshox.com FOLLOW US...