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Summary of Contents for Formula NEBBIA
- Page 1 NEBBIA Service Manual – This manual is meant for authorized Formula Service Centers. The manual contains information regarding the complete servicing of the Nebbia.
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Page 2: Table Of Contents
Index Important Information and Maintenance Intervals: ................3 Parts list ..............................4 Exploded View ............................5 Required Tools ............................6 Air Seal Replacement (60h)........................7 Complete Maintenance (125h) ......................... 10 Disassembly procedure ............................10 Replacement of body shock o-rings (14, 41) and stem (30) assembly ..............14 Extension needle o-rings replacement (29) ...................... -
Page 3: Important Information And Maintenance Intervals
The use of high-pressure washing methods, non-original spare parts and non- recommended solvents and lubricants reduces the lifespan of our products. IMPORTANT Formula recommends only ORIGINAL spare parts and lubricant products. Formula recommends consulting servicing technicians for these activities. SAFETY INFORMATION Always wear nitrile gloves and safety glasses when working on the shock absorber. -
Page 4: Spare Parts List
Spare Parts List Description Position Part Number CAP VALVE WITH RING SB-T100-05 Air Sleeve - Stroke 45 mm AM-S046-05 Air Sleeve - Stroke 55 mm AM-S045-05 Air Sleeve - Stroke 65 mm AM-S038-05 Air Sleeve - Stroke 75 mm AM-S047-05 SUPPORT FOR NEGATIVE WAVE SPRING AM-D031-00 CARTRIDGE CAP KIT... -
Page 5: Exploded View
Exploded View... -
Page 6: Required Tools
9 mm, 13 mm ▪ Combined wrench: o 9 mm, 25 mm ▪ Torque wrench from 4 to 35 Nm ▪ Knipex ® pliers ▪ Valve stem removal tool with tightening torque of 0,5 Nm ▪ Formula grease ▪ Bench vise... -
Page 7: Air Seal Replacement (60H)
Air Seal Replacement (60h) Required items: Part number Description AM40055-00 Kit 60h Nebbia Required tools: Bench vise, Formula grease. Procedure: 1. Place the shock absorber in a bench vise with plastic jaws to prevent damage. Remove the sag indicator o-ring (42);... - Page 8 Assemble the new components; 6. Insert the quad-ring (37) into its housing and apply Formula grease to the internal diameter of the quad-ring; 7. Insert the backup ring (38) by inserting the longer side of the 45° cut first. After assembly, ensure there are no deformations on the quad-ring (37).
- Page 9 11. Slide the negative wave spring (3) onto the cartridge, then the spacer (4) pushing them against the cartridge cap (5). Apply grease to the air sleeve (2) where highlighted in red and insert it onto the shock absorber, tightening it by hand. 12.
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Page 10: Complete Maintenance (125H)
AM40059-00 Kit 125h Nebbia - Stroke 75 mm Required tools: Bench vise, Formula grease, Hex key 4mm, 25 mm, Combined wrench 9 mm, 30 mm, Torx T10, Socket wrench 5,5 mm. Disassembly procedure 1. Place the shock absorber in a bench vise with plastic jaws to prevent damage. Remove the sag indicator o-ring (42);... - Page 11 5. Place the cartridge eyelet in a bench vise with plastic jaws to prevent damage. Push the piston into the cartridge so that the cartridge cap (5) is touching the bumper (11) and keep it compressed. Unscrew the cartridge cap (5) from the cartridge (12) using Knipex® pliers and remove the shock absorber from the cartridge;...
- Page 12 7. Unscrew the nut of hydraulic piston (17) with a 13 mm key and remove the components in order (from 18 to 26). Pay attention to the disassembly sequence and the orientation of the components. Unscrew the piston pin (27) using Knipex®, then remove the cartridge cap (5), the bumper (11) and the support for the bumper (28) from the stem.
- Page 13 11. Unscrew the piggyback (44) with the correct tool (104) and replace the o-ring (43). Apply Formula grease on the new o-ring (43) and insert it into its housing. Apply Loctite 420 on the thread of the shock bleed and tighten...
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Page 14: Replacement Of Body Shock O-Rings (14, 41) And Stem (30) Assembly
AMU049-05 and AM-U050-05 (103 – AM40054-00) for trunnion shocks. Screw the stem (30) on the body shock, tighten to 18 Nm of torque; Extension needle o-ring replacement (29) 14. Remove the worn-out o-rings (29A, 27A) from the extension needle (29) and insert new ones while applying Formula grease;... -
Page 15: Rebound Adjuster O-Ring Replacement (33)
Rebound adjuster o-ring replacement (33) 15. Ensure the ball and the spring (33A, 33B) are still inside the rebound adjuster (33). Remove the worn o-rings (33C, 33D) and insert new ones; 16. Screw the rebound adjuster (33) into the shock until it stops, without tightening it, using a 4 mm hex key. Then, unscrew the adjuster by 12 clicks. -
Page 16: Cts O-Rings Replacement (59, 60)
21. Carefully clean the cartridge cap (5) and ensure there is no damage. Remove the worn o-rings (5A, 5B) and replace with new ones. Apply Formula grease on the o-ring (5A). The bushing cannot be removed from the cap (5), if the bushing is worn replace the cartridge cap;... -
Page 17: Stem Components Assembly
Stem components assembly 22. Carefully clean the stem (30) and ensure there is no damage. Insert the bumper support (28) and insert a new bumper (11). Insert the cartridge cap (5) onto the stem (30). Carefully insert the extension needle (29) inside the stem (30);... - Page 18 24. Insert in order, the piston spacer (26), the compression setting spacer (25), compression setting (24), piston (23) with the area highlighted in red facing upwards, and finally, the rebound shim stack (22). Insert in order the spacer (21), shim (20) and the spring (19) as shown in the picture. Insert the washer (18) and tighten the nut (17) with a 13 mm hex key to 7 Nm of torque;...
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Page 19: Bladder Assembly
Ensure the valve is assembled as shown below. Replace the bladder (15) with a new one and apply Formula grease on all outer surfaces (highlighted in red) and all inner surfaces (highlighted in blue). Insert the bladder cap (16) inside the bladder (15);... -
Page 20: Air Sleeve Seals Replacement (2)
Air sleeve seals replacement (2) Follow steps n°5 to n°12 of the “Air Seals Replacement (60h)” procedure. - Page 21 FORMULA S.R.L. Via Erbosa, 63 - 59100 Prato (Italia) Tel. +39 0574 603 609 Fax +39 0574 611 046 Reg. Imprese Prato / C.F. / P.IVA 02081070977 PEC: formula-italy@legalmail.it Cap. Soc. 500.000,00 € i.v. The content of this document can be altered without notice. All rights reserved.
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