Related Manuals for BOS Suspension IDYLLE 2014
Summary of Contents for BOS Suspension IDYLLE 2014
- Page 1 Manual type Model Year XXXX to XXXX IDYLLE since year 2014 All serial numbers Service manual SM_150707_A...
-
Page 2: Table Of Contents
Glossary of terms ..............................2 Exploded views of the fork ............................4 Idylle Rare FCV (Ø37mm stanchions) ........................ 4 Idylle Air (Ø36mm stanchions) .......................... 5 BOS Suspension Service ............................6 Safety ................................6 Cleanliness ................................ 6 Tools required for service ..........................7 Components required for service ........................ -
Page 3: Bos S.a.r.l. Warranty
Service Manual IDYLLE since year 2014 BOS S.A.R.L. Warranty BOS MTB offers warranty on its products on the following terms: BOS MTB guarantees to the original purchaser that the BOS product for which they received this warranty is free from defects in material and workmanship for one year from the date of original retail purchase. -
Page 4: Environment
Service Manual IDYLLE since year 2014 1 Environment Mountain biking is a marvelous sport which gives you a lot of happiness. However it is potentially a source of environmental conflict with other people. A responsible behavior when using your bicycle automatically defuse problems and conflicts. - Page 5 Service Manual IDYLLE since year 2014 Negative Spring: A negative spring functions to control the return of the suspension when it reaches full extension. Negative springs can be air, coil spring, rubber bumper or a combination of both. A negative spring also functions to soften the “top out feel” when the wheel/suspension rapidly extends and it also helps initiate compression providing a smoother or more sensitive initial feel.
-
Page 6: Exploded Views Of The Fork
Service Manual IDYLLE since year 2014 3 Exploded views of the fork IDYLLE RARE FCV (Ø37MM STANCHIONS) Air valve cap Air cartridge cap Purge screw Oil cartridge Air cartridge body Oil cartridge shaft Oil cartridge body Air cartridge shaft Air cartridge Oil cartridge SM_150707_A... -
Page 7: Idylle Air (Ø36Mm Stanchions)
Service Manual IDYLLE since year 2014 IDYLLE AIR (Ø36MM STANCHIONS) Air valve cap Air cartridge cap Purge screw Oil cartridge Air cartridge body Oil cartridge shaft Oil cartridge body Air cartridge shaft Air cartridge Oil cartridge SM_150707_A... -
Page 8: Bos Suspension Service
While working on BOS suspension please wear appropriate safety equipment’s as apron, safety gloves and glasses. When manipulating suspension oil, please wear nitrile gloves and glasses. CLEANLINESS When servicing your BOS suspension, be sure that you are working in conditions that will not affect the performance: • Work in dust free environment •... -
Page 9: Tools Required For Service
- Bicycle stand (optional) BOS specific tools – Pack 1: - 32mm socket / ref. 150707-O-108 - BOS suspension vise block / ref. 150707-O-011 - Oil level gauge / ref. 150707-SEO-002 - BOS Push air shaft / ref. 150707-O-063 BOS specific tools – Pack 2: - BOS seal installation tools / ref. -
Page 10: Components Required For Service
Service Manual IDYLLE since year 2014 COMPONENTS REQUIRED FOR SERVICE For operations on the suspension, you may have to order components according to the table below: Operations Components Quantity Tools required Step by step Basic Service: Standard + Pack 1 §... -
Page 11: Fluid Table
Oil quantity Oil quantity Serial n° Product Oil type (ml) (mm) left air (ml) right (ml) 002xxxx IDYLLE 2014 Bio Oil 006xxxx IDYLLE Rare 2014 Bio Oil 007xxxx IDYLLE Air 2014 Bio Oil IDYLLE SC Air Tapered Bio Oil 008xxxx... -
Page 12: Traveler For Service Control (Printable Document)
Service Manual IDYLLE since year 2014 TRAVELER FOR SERVICE CONTROL (PRINTABLE DOCUMENT) General information: Product Designation: ___________________________________ Serial number: ___________________________ Owner of the product: __________________________________ Date of service: ___________________________ Technician: __________________________ VISA: _________________ Shop Order #: _______________ Customer initial settings: Pressure (psi) Low speed (clicks) High speed (clicks) -
Page 13: Operations Summary
Service Manual IDYLLE since year 2014 5 Operations Summary STEP BY STEP CHART For all BOS suspension’s service, the following chart is followed: 1. Receive the suspension Fill the traveler included in this manual page 10 b. Attribute a shop order #, apply this # on the traveler and on the suspension thanks to a tape 2. -
Page 14: Step By Step
Service Manual IDYLLE since year 2014 6 Step by Step CLEANING Cleaning is very important and part of the BOS service. Do not forget the cleaning steps during service. Inspect the fork: Check eventual loose Control parts damaged Seek for oil leakages (see picture) If one of those inspection points shows that something needs to be replaced, you should quote it to the customer and replace it. -
Page 15: Disassemble
Place the fork on the vise block thanks to the specific tool. Tighten the screws to hold the fork on the vise block. CAUTION Tool(s) required : BOS suspension vise block / ref. 151108-O-021A 4mm HEX wrench Loosen the air valve cap. Clean it. - Page 16 Service Manual IDYLLE since year 2014 Connect air pump on the valve. Read the pressure. Save this information on the traveler (page 10 of this manual). Deflate slowly the fork by pushing the grey button. INFORMATION CAUTION Deflating slowly the fork will allow balancing of the air chambers. Tool(s) required : Air pump Save the rebound setting:...
- Page 17 Service Manual IDYLLE since year 2014 Untighten the oil and air cartridge cap. Tool(s) required : 32mm socket Socket wrench Remove the inferior crown: Measure and save the height from the cap to the crown Untighten the screws Extract the crown from the fork Tool(s) required : 4mm HEX wrench Rotate the fork upside down on its vise block.
- Page 18 Service Manual IDYLLE since year 2014 Save the high speed compression setting (red knob): Screw clockwise the knob While screwing, count the number of clicks until the stop Write down the number of clicks on the traveler (included in this manual) INFORMATION The low comp setting will turn with the high speed.
- Page 19 Service Manual IDYLLE since year 2014 Place an oil pan under the fork. Pull the stanchion out from the fork. CAUTION Act slowly to avoid splash. Tool(s) required : n/a (by hand) Purge the oil cartridge: Let the cartridge inside the stanchion. Pull back and forth the cartridge until no more oil comes out.
- Page 20 Service Manual IDYLLE since year 2014 Clean the stanchion, use a long dowel to clean inside. Store it. Tool(s) required : Spray of isopropyl alcohol Long dowel Remove the air stanchion from the fork. Empty the oil from the stanchion into an oil pan. Clean and inspect the cartridge.
- Page 21 Service Manual IDYLLE since year 2014 Shaft guide clamped with a circlip (skip to step 23 if shaft guide screwed) Unscrew and remove the cartridge cap. Tool(s) required : Large retaining ring pliers Shaft guide clamped with a circlip Place the tips of large retaining ring pliers into the eyelets of the retaining ring. Press firmly on the pliers and remove the retaining ring.
- Page 22 Service Manual IDYLLE since year 2014 Shaft guide clamped with a circlip Push the air shaft through the cartridge. You should see the piston coming out of the cartridge to remove the O-ring. Tool(s) required : n/a (by hand) Shaft guide screwed on the cartridge (skip to step 25 if shaft guide clamped) Unscrew the cap and extract the cartridge from the stanchion.
- Page 23 Service Manual IDYLLE since year 2014 Take the air shaft with pistons. Change the O-ring of the piston mounted at the end of the shaft. Slide a small screwdriver grounded (remove sharp edges) between the O-ring and the piston, and extract it. Tool(s) required : Small screwdriver grounded Take a new O-ring.
- Page 24 Service Manual IDYLLE since year 2014 Shaft guide clamped with a circlip (skip to step 32 if shaft guide screwed) Push the piston back inside the cartridge. Pull the shaft until the equilibration point to balance air chambers. Tool(s) required : n/a (by hand) Shaft guide clamped with a circlip Apply grease on ALL the O-rings on the cartridge with the silicone brush.
- Page 25 Service Manual IDYLLE since year 2014 Shaft guide clamped with a circlip Place the tips of large retaining ring pliers into the eyelets of the retaining ring. Press firmly on the pliers and install the retaining ring into the groove. Check with a screwdriver that the retaining ring is well positioned in the groove.
- Page 26 Service Manual IDYLLE since year 2014 Shaft guide screwed on the cartridge Squeeze the top of the cartridge (close to the cartridge cap) into a vise block, thanks to half shells. Screw the shaft guide at torque. CAUTION Scratches on the air shaft will reduce spring performance. Maximum attention should be taken while screwing shaft guide.
- Page 27 Service Manual IDYLLE since year 2014 Clean the stanchions: Spray isopropyl alcohol inside and outside stanchions. Clean with a rag outside the stanchions. Wrap a rag around a long dowel to clean inside stanchions or use a bottle brush. CAUTION Scratches on stanchions will generate oil leakages.
-
Page 28: Slide Bushings Replacement
Rotate the fork at 45° in front of you. Tool(s) required : BOS suspension vise block / ref. 151108-O-021A Take the slide bushing extractor tool. This tool is used for all Idylle models. Locate the right side (36 / 37mm). - Page 29 Service Manual IDYLLE since year 2014 Maintain the central nut with a 16mm or 17mm open wrench. Place a 16mm open wrench at the bottom of the tool. Unscrew (anticlockwise) the bottom of the tool. You will feel that the lower slide bushing will release from its housing. Keep traction on the tool to keep washer under this bushing.
- Page 30 Service Manual IDYLLE since year 2014 Clean the tool and throw away the old bushings Clean the casting: Oil fountain with brush + bottlebrush OR (if not equipped): Isopropyl alcohol + brush + bottlebrush Tool(s) required : Oil fountain with brush Bottlebrush Lower slide bushing are thinner than upper slide bushings.
- Page 31 Service Manual IDYLLE since year 2014 Joint Insert the upper slide bushing and the strike tip on the tool. outside Place the tool on the casting and orient its joint to the outside of the fork. Hit the tool with the rubber mallet to insert the bushing. Stop to strike the tool once it touch the casting.
-
Page 32: Reassemble
Service Manual IDYLLE since year 2014 REASSEMBLE Degrease the scraper seal groove on the casting. Use isopropyl alcohol and rag to clean the groove. CAUTION Greasy surface will generate scraper seal extraction while riding! Tool(s) required : Spray of isopropyl alcohol Remove the spring from the scraper seals. - Page 33 Mount the casting on the vise block. Insert the oil stanchion inside the casting. Insert the oil cartridge inside the stanchion. Tool(s) required : BOS suspension vise block / ref. 151108-O-021A Screw the oil cartridge nut by hand. Tool(s) required : n/a (by hand) Screw the oil cartridge cap on the first threads by hand.
- Page 34 Service Manual IDYLLE since year 2014 Screw back the high speed setting. Be sure that the screw will point the hole in the shaft before screwing. Tool(s) required : 1.5mm HEX wrench Apply back the customer’s settings: High speed compression Low speed compression Open the rebound setting at the maximum (fully unscrewed).
- Page 35 Service Manual IDYLLE since year 2014 Screw by hand the oil cartridge cap until the stop. Compress and release slowly the fork 4-5 times. INFORMATION To facilitate, put the rebound setting at 2 clics from closed. Tool(s) required : n/a (by hand) Check oil level according to column “Oil level”...
- Page 36 Service Manual IDYLLE since year 2014 Screw the oil cartridge cap on the first thread. Pull the fork to reach the maximum length of the fork and maintain. Screw the oil cartridge cap with the wrench + 32mm socket. Apply back the rebound setting from the customer. Tool(s) required : Socket wrench 32mm socket...
- Page 37 Service Manual IDYLLE since year 2014 Take off the oil level gauge from the syringe. Fill the syringe with Y ml* of oil (see Fluid table, page 9 of this document). Place the fork horizontally. Empty the oil from the syringe into the air fork leg for lubrication. * Refers to “Oil quantity left air”...
- Page 38 Service Manual IDYLLE since year 2014 Place back the superior crown: Insert the crown on the stanchions Tighten the screws to contact Remove the bumpers if installed. INFORMATION It is not necessary to tighten at torque the superior crown as it will be disassembled to mount the fork back on the bicycle.
- Page 39 Service Manual IDYLLE since year 2014 Screw air valve cap by hand. Tool(s) required : n/a (by hand) Clean the casting with a rag and alcohol. CAUTION Tool(s) required : Spray of isopropyl alcohol Install the stickers on the casting (see §7 for templates). CAUTION Tool(s) required : n/a (by hand)
- Page 40 Service Manual IDYLLE since year 2014 Clean the fork: Washer. OR (if not equipped): Hot water + soap. CAUTION Tool(s) required : Washer Soap SM_150707_A...
-
Page 41: Oil Cartridge Opening
Service Manual IDYLLE since year 2014 OIL CARTRIDGE OPENING Place half-shells on the oil cartridge. Squeeze them moderately on the cartridge thanks to the vise block. CAUTION Take care to the position of the half-shells on the cartridge before squeezing. Tool(s) required : Half shell Ø21 / ref. - Page 42 Service Manual IDYLLE since year 2014 Lock the cartridge cap with the 26mm open end wrench. Unscrewing the nut under the cap. Unscrew the cap. Screw the nut to remove it from the shaft. Take the cartridge off the vise block. Tool(s) required : 32mm open end wrench 13mm open end wrench...
- Page 43 Service Manual IDYLLE since year 2014 Open the compression block: Squeeze the 14mm socket into a vise block thanks to the half shells Place the compression block into the socket Unscrew the nut Photo positionnement douille dans étau Photo mise en place du bloc de comp dans la douille Photo desserrage du bloc de comp Tool(s) required :...
- Page 44 Service Manual IDYLLE since year 2014 Reassemble the stack-up on the compression block following the order that you took it off. Screw the nut by hand on the first threads. CAUTION Clean the elements before putting them back on the compression block (remove dust, foreign objects, fibers…).
- Page 45 Service Manual IDYLLE since year 2014 Put a drop of Loctite on the first thread of the nut. Slide the nut on the shaft. Place back the lock ring in the groove where you found it. Mount the piston, then screw it while holding the counter nut. Tool(s) required : 16mm open ends wrench 14mm open ends wrench...
- Page 46 Service Manual IDYLLE since year 2014 Apply Loctite 243: 1cm on the 1 threads. Screw the compression block by hand. Place half shell on the cartridge and squeeze it into the vise block. Screw the compression block with a torque wrench. Tool(s) required : 24mm open end socket Torque wrench...
-
Page 47: Stickers Replacement
Service Manual IDYLLE since year 2014 STICKERS REPLACEMENT Clean the fork/casting: Washer. OR (if not equipped): Hot water + soap. Tool(s) required : Washer Soap Take off the stickers from the casting: Peel off the sticker from the casting by hand (you could use a plastic tool to start in an angle). -
Page 48: Stickers Templates
Service Manual IDYLLE since year 2014 7 Stickers templates Place centered on the top of the fork. “BOS” on top, logo on front. Follow the shape Center the decals when you place the fork in front of you Start the decal at ≈5mm from the rib SM_150707_A... -
Page 49: Additional Information
Service Manual IDYLLE since year 2014 8 Additional Information SETTINGS To start setting your fork, turn clockwise completely the knobs (=click 0). Then turn counterclockwise one click at a time. 8.1.1 Idylle FCV Weight (kg) Weight (lbs) Recreational use : Pressure (psi) Racing use : Pressure (psi) - Page 50 Service Manual IDYLLE since year 2014 8.1.4 Idylle Air 2014 Weight (kg) Weight (lbs) Recreational use : Pressure (psi) Racing use : Pressure (psi) Recreational Use: Racing Use: Compression: 15 clicks Compression: 8 clicks Rebound: 18 clicks Rebound: 16 clicks 8.1.5 Idylle SC 2014 Weight (kg)
- Page 51 Service Manual IDYLLE since year 2014 My fork is lowering as I deflate it, what is happening? When you deflate the fork by the Schrader valve, you are only emptying the positive air chamber. The negative air chamber stays under pressure and exerts an opposing force on the air piston and pulls the fork down. To avoid this phenomenon, deflate the fork in steps of 30-40 PSI and equalize the air chambers between steps (compress and release the fork 5-10 times over the first 20mm –...
Need help?
Do you have a question about the IDYLLE 2014 and is the answer not in the manual?
Questions and answers