Related Manuals for BOS Suspension DEVILLE 35
Summary of Contents for BOS Suspension DEVILLE 35
- Page 1 Manual type Model Year XXXX to XXXX DEVILLE 35 : since year 2017 Service manual SM_151815_rev00...
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Page 2: Table Of Contents
Service Manual DEVILLE 35 since year 2017 Table of contents Environment ................................1 Glossary of terms ..............................1 Exploded views of the fork ............................3 DEVILLE 150 / 160 / 170 ............................ 3 BOS Suspension Service ............................4 Safety ................................4 Cleanliness ................................ -
Page 3: Environment
Service Manual DEVILLE 35 since year 2017 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 defuses problems and conflicts. - Page 4 Service Manual DEVILLE 35 since year 2017 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.
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Page 5: Exploded Views Of The Fork
Service Manual DEVILLE 35 since year 2017 3 Exploded views of the fork DEVILLE 35 140 / 160 / 170 SM_151815_rev00... -
Page 6: 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 7: Tools Required For Service
Service Manual DEVILLE 35 since year 2017 TOOLS REQUIRED FOR SERVICE Cleaning + Safety: - Safety glasses - Clean, lint-free rags - Soap (+ hot water) - Nitrile gloves - Long plastic or wooden dowel - Pressure washer - Apron... -
Page 8: Components Required For Service
Service Manual DEVILLE 35 since year 2017 COMPONENTS REQUIRED FOR SERVICE For operations on the suspension, you may have to order components according to the table below: Operations Components Quantity Step by step Basic Service: § § 6.1, 6.2, 6.4:... -
Page 9: Periodical Service Information
Service Manual DEVILLE 35 since year 2017 PERIODICAL SERVICE INFORMATION To ensure that your fork will keep its best performance, be sure to respect the following program: Every Every Every Every Item ride 6 months year two years Clean fork exterior... -
Page 10: Traveler For Service Control (Printable Document)
Service Manual DEVILLE 35 since year 2017 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:... -
Page 11: Operations Summary
Service Manual DEVILLE 35 since year 2017 5 Operations Summary STEP BY STEP CHART For all BOS suspension’s service, the following chart is followed: 1. Receive the suspension a. Fill the traveler included in this manual page 8 b. Attribute a shop order #, apply this # on the traveler and on the suspension thanks to a tape 2. -
Page 12: Step By Step
Service Manual DEVILLE 35 since year 2017 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... -
Page 13: Disassemble
Service Manual DEVILLE 35 since year 2017 DISASSEMBLE Unscrew the axle screw. Remove the wheel axle. Clean and wheel axle. Use sand paper to remove rust on the wheel axle if necessary. Tool(s) required : - 6 mm HEX wrench - 600 sand paper Place the fork on the vise block. - Page 14 Service Manual DEVILLE 35 since year 2017 Connect air pump on the valve. Read the pressure. Save this information on the traveler (page 9 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.
- Page 15 Service Manual DEVILLE 35 since year 2017 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 (page 11 of this manual) Unscrew the black knob (anticlockwise) at its maximum.
- Page 16 Service Manual DEVILLE 35 since year 2017 Use the 1.3mm HEX wrench to loosen the screw of the black knob. Clean the knob + screw. Store it. CAUTION If the screw is too tight, heat the knob and try again.
- Page 17 Service Manual DEVILLE 35 since year 2017 Remove O-ring. Use magnet to remove ball. CAUTION There is ball under O-ring take care, don’t lose it. Tool(s) required : - Magnet Loosen the oil cartridge nut. CAUTION While loosen the oil cartridge nut, oil leakage may appears.
- Page 18 Service Manual DEVILLE 35 since year 2017 Place the oil cartridge on the assembly support. Maintain by hand the oil cartridge then unscrew the compression bloc thanks to socket wrench. Check the O-ring and store it. CAUTION When you take off the compression block of the cartridge, Oil may drop from the cartridge.
- Page 19 Service Manual DEVILLE 35 since year 2017 Place an oil pan under the fork. Rotate back the fork to its normal position. Oil will drop from the bottom of the casting. CAUTION Rotate slowly the fork to avoid splash. Tool(s) required :...
- Page 20 Service Manual DEVILLE 35 since year 2017 Remove the scraper seals from the casting: - Place the inferior beak of the open wrench under the seal. - Pry on the seal itself to remove the scraper seal from the casting.
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Page 21: Slide Bushings Replacement
Service Manual DEVILLE 35 since year 2017 SLIDE BUSHINGS REPLACEMENT Place the fork on the vise block. Rotate the fork at 45° in front of you. Tool(s) required : - BOS suspension vise block / ref. 151815-O-012 Take the slide bushing extractor tool. - Page 22 Service Manual DEVILLE 35 since year 2017 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.
- Page 23 Service Manual DEVILLE 35 since year 2017 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 :...
- Page 24 Service Manual DEVILLE 35 since year 2017 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.
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Page 25: Reassemble
Service Manual DEVILLE 35 since year 2017 REASSEMBLE 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. - Page 26 Service Manual DEVILLE 35 since year 2017 Insert the air shaft inside the left stanchion, greased piston first. Firmly push by hand on the second piston. You should feel that the piston went through a “click”. Check if you see the groove in the stanchion to place the retaining ring.
- Page 27 Service Manual DEVILLE 35 since year 2017 Push the air valve at the top of the fork. Push the air cartridge inside the stanchion at the maximum. CAUTION The air shaft should not exceed the stanchion more than 2-3cm. Tool(s) required : - n/a (by hand) Remove the travel checker O-ring.
- Page 28 Service Manual DEVILLE 35 since year 2017 Take the upper slide bushing tool and apply the scraper seal tool & the strike tip. Place a new scraper seal on the tool and apply the tool on the casting. Hit the tool until the scraper seal has touched all around the casting.
- Page 29 Service Manual DEVILLE 35 since year 2017 Fill the oil cartridge with new oil.(level page 7) Bleed the shaft by slowly moving it into the cartridge. Then pull it quickly Repeat this operation until you this no bubble i n the upper tube oil.
- Page 30 Service Manual DEVILLE 35 since year 2017 Reassemble the oil cartridge on the casting. Tool(s) required : -n/a (by hand) Degrease and clean the bottom of the oil cartridge (seal and thread). Degrease and clean the bottom of the casting Insert the oil cartridge in the fork.
- Page 31 Service Manual DEVILLE 35 since year 2017 Rotate the fork upside down. Screw the oil cartridge nut with the torque wrench. Tool(s) required : - Torque wrench - 21mm socket Torque = 10Nm Put O-ring in the groove at the end of the shaft Use the magnet to put ball and in the hole with grease.
- Page 32 Service Manual DEVILLE 35 since year 2017 Put back the customer settings on the red knobs by unscrewing and counting the clicks. Tool(s) required : - n/a (by hand) Screw the platform adjustment with two screws. Locate the hole on the shaft, then place the black knob( high speed ) on the fork with the screw in front of the hole Gently screw the knob with 1.3mm HEX wrench.
- Page 33 Service Manual DEVILLE 35 since year 2017 Place the fork horizontally. Empty the oil from the syringe into the “air” fork for Lubrication. (oil level page 7) CAUTION Keep the suspension horizontal until the air cartridge bolt has not been tighten.
- Page 34 Service Manual DEVILLE 35 since year 2017 Screw wheel axle back on the fork. Tool(s) required : - n/a (by hand) Clean the fork: - Washer. OR (if not equipped): - Hot water + soap. CAUTION Tool(s) required : - Washer...
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Page 35: Stickers Replacement
Service Manual DEVILLE 35 since year 2017 STICKERS REPLACEMENT If stickers replacement starts from scratch: Clean the fork: - Washer. OR (if not equipped): - Hot water + soap. If stickers replacement is part of the complete service: Go to step 3... -
Page 36: Stickers Templates
Service Manual DEVILLE 35 since year 2017 7 Stickers templates Place centered on the top of the fork Start the decal at ≈4mm From the top of the crown Center the decals when you place the fork in Start the decal at ≈7mm front of you Start the decal at ≈10mm... -
Page 37: Additional Information
Service Manual DEVILLE 35 since year 2017 8 Additional Information AIR SETTINGS Weight (Kg/lbs.) 55/120 65/143 75/165 85/187 95/210 105/132 Air pressure (psi) HYDRAULIC SETTINGS To start setting your fork, turn clockwise completely the knobs (=click 0). Then turn counterclockwise one click at a time. - Page 38 Service Manual DEVILLE 35 since year 2017 If you’ve equalized your fork, you may have some internal pressure from the production process. You can eliminate this pressure by slipping a thin zip tie between your left dust seal and your stanchion until you hear the sound of air escaping.
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