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BOS Suspension Deville 35, Service Manual

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BOS Suspension Deville 35 Service Manual Download Page 6

  

 

 

4 

 SM_151815_rev00 

Service Manual DEVILLE 35 since year 2017

 

4

 

BOS Suspension Service 

4.1

 

SAFETY 

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. 

 

4.2

 

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 

 

Work on clean and organized workstation 

 

Use aluminum soft jaws to protect the equipment when using a vice 

 

Do not scratch any of the surface when using tools 

 

Clean elements when your disassemble them 

 

Drop sub-assemblies on your station in order to easily find how to reassemble them together 

 

Wear long sleeves is recommended or shaved arms 

 

If you are servicing your BOS suspension outside a workshop, you should have at least: 

 

Avoid dust and air flow around your working area 

 

A clean tarpaulin to place underneath the suspension on the floor 

 

A bicycle repair stand to lock and maintain the suspension 

 

An oil pan 

 

All necessary tools listed below 

 

 

 

 

Summary of Contents for Deville 35

Page 1: ...0 Manual type Model Year XXXX to XXXX DEVILLE 35 since year 2017 Service manual SM_151815_rev00 ...

Page 2: ... service 6 4 5 Periodical Service Information 7 4 6 Fluid Table 7 4 7 Traveler for service control printable document 8 5 Operations Summary 9 5 1 Step by step chart 9 5 2 How to use this document 9 6 Step by Step 10 6 1 Cleaning 10 6 2 Disassemble 11 6 3 Slide Bushings replacement 19 6 4 Reassemble 23 6 5 Oil cartridge opening Erreur Signet non défini 6 6 Stickers replacement 33 7 Stickers templa...

Page 3: ...ing the bike has soft mushy feeling to it and will compress through its travel with little damping resistance Fork Oil Level The level of oil inside the fork It s typically measured in cc s by fully compressing the fork without the spring installed It is used in tuning the amount of air contained inside the fork Since compressing air acts like a spring raising the oil level leaves less room for ai...

Page 4: ...t as compression and it is very important to properly tune this performance feature The rebound valve is best located on the MV with a tapered shim stack controlling oil flow Damping systems that use orifice or small holes to control damping simply cannot control the dynamics of high performance suspension Spring Preload The preload ring or collar compresses the shock or fork spring and either sho...

Page 5: ...3 SM_151815_rev00 Service Manual DEVILLE 35 since year 2017 3 Exploded views of the fork 3 1 DEVILLE 35 140 160 170 ...

Page 6: ...Work on clean and organized workstation Use aluminum soft jaws to protect the equipment when using a vice Do not scratch any of the surface when using tools Clean elements when your disassemble them Drop sub assemblies on your station in order to easily find how to reassemble them together Wear long sleeves is recommended or shaved arms If you are servicing your BOS suspension outside a workshop y...

Page 7: ...des Universal grease Socket wrench Small grounded screwdriver Reglet metallic ruler Syringe Air pump Graduated pitcher Bench vise with aluminum soft jaws Downhill tire lever or 22mm open wrench BOS specific tools 26mm grounded socket ref 151108 O 084 BOS suspension vise block ref 151815 O 012 Oil level gauge ref 150707 SEO 002 BOS Push air shaft ref 150707 O 063 BOS seal installation tools ref 151...

Page 8: ...s please contact BOS for more information Operations Components Quantity Step by step Basic Service Change lubrication Oil Bio Oil 0 25 L 6 1 6 2 6 4 Complete service Change lubrication Oil Traveler checker replacement Scraper seals replacement Change cartridge oil Main piston O ring replacement Air piston O ring replacement Stickers replacement Bio Oil DEVILLE service kit ref 151108 SE 002 AMX1 K...

Page 9: ...tions x Racing frequent use x Dry dusty conditions x Complete service Wet Muddy conditions x Racing frequent use x Dry dusty conditions x Inspect Bushings Wet Muddy conditions x Racing frequent use x Dry dusty conditions x 4 6 FLUID TABLE Cartridge Lubrication Serial n Product Oil quantity ml Oil level mm Oil type Oil quantity left air ml Oil quantity right ml Oil type 001xxxx DEVILLE 35 150 70 AM...

Page 10: ...__________________ Complete service operations Cleaning YES NO Note _____________________________________________ Lubrication Oil change YES NO Note _____________________________________________ Complete control YES NO Note _____________________________________________ Travel checker replacement YES NO Note _____________________________________________ Dust seals replacement YES NO Note __________...

Page 11: ... Pressure washing b Hot water soap c Oil bath brush d Alcohol spray 4 Note the customer s settings of the suspension You could use page 11 of this manual to do so 5 Disassemble the suspension following the 6 Step by Step 6 Clean the sub assemblies and control them when removing from the suspension 7 Change parts reassemble and control the suspension 8 Apply back the suspension s settings 9 Clean t...

Page 12: ...ing 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 Tool s required n a by hand Clean the fork Washer OR if not equipped Hot water soap Tool s required Washer Soap CAUTION CAUTION ...

Page 13: ...and 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 Screw the axle screw to tighten the fork on the vise block Tool s required BOS suspension vise block ref 151815 O 012 6 mm HEX wrench Loosen the air valve cap Clean it Store it Tool s required n a by hand 2 1 CAUTION 1 2 ...

Page 14: ...he stop Write down the number of clicks on the traveler page 9 of this manual Re open the 5 clic the rebound that will help you for bleeding process Tool s required n a by hand Save the low speed compression setting grey 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 9 of this manual Unscrew the grey knob ...

Page 15: ...the black knob anticlockwise at its maximum Tool s required n a by hand Loosen the air cartridge bolt Clean the bolt and seals x2 Store it Tool s required 5mm HEX wrench Use the 2 5mm HEX wrench to loosen the screw of the grey knob Clean the knob screw Store it Tool s required 2 5mm HEX wrench CAUTION While loosening the bolt oil may drop from the bottom of the fork Be sure to apply oil pan under ...

Page 16: ...ench Use 1 5mm HEX wrench to loosen the two screws of the platform adjustment Clean the platform adjustment screw x2 Store it Tool s required 1 5 mm HEX wrench Reverse the fork to remove rebound adjustment Use the 1 5mm HEX wrench to loosen the screw of the red knob Clean the knob screw Strore it Tool s required 1 5 mm HEX wrench CAUTION If the screw is too tight heat the knob and try again ...

Page 17: ... nut Tool s required Socket wrench 21mm socket Disassemble the oil cartridge from the chassis Loosen the cartridge from the crown Remove slowly the cartridge from the chassis clean it Tool s required Socket wrench 26mm socket CAUTION While loosen the oil cartridge nut oil leakage may appears 1 CAUTION There is ball under O ring take care don t lose it 2 2 1 ...

Page 18: ...the O ring and store it Tool s required 26mm Socket wrench Empty the oil in the cartridge on pitcher Clean the cartridge tube Store it Tool s required Remove the stanchions from the fork by lifting it up Clean and inspect the stanchions Store it Tool s required n a by hand 2 1 CAUTION When you take off the compression block of the cartridge Oil may drop from the cartridge Be sure to apply oil pan ...

Page 19: ...ng Tool s required 2 5 mm HEX wrench Large retaining ring pliers 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 Tool s required Spray of isopropyl alcohol Rag Long dowel CAUTION Scratches on the air shaft will reduce spring performance Maximum attention should be taken whil...

Page 20: ... Oil fountain with brush bottlebrush Washer OR if not equipped Isopropyl alcohol brush bottle brush Hot water soap Tool s required Oil fountain with brush Bottlebrush Washer Isopropyl alcohol brush 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 Clean the casting with isopropyl alcohol and rag Tool s requir...

Page 21: ...rew the middle nut to push it away from the DEVILLE side Place the aluminum brace on the tool Tool s required BOS slide bushing extractor ref 150707 SE 003A Place the washer parallel to the ground Push the tool inside the casting until the washer is under the lower bushing Once the washer is located under the lower bushing pull back on the tool The washer will then be locked under the lower bushin...

Page 22: ...ired 2x 16mm open wrench OR 1x 16mm 1x 17mm open wrenches Pull on the tool until the lower bushing will stop on the upper bushing Keep traction on the tool while screwing the nut until it touch the tool Tool s required BOS slide bushing extractor ref 150707 SE 003A Maintain the central nut with a 16mm open wrench Place another 16mm open wrench at the bottom of the tool Unscrew anticlockwise the bo...

Page 23: ...er slide bushing and orient its joint inside the fork Drop it inside the casting Do the same for the other lower slide bushing Tool s required n a by hand Take the lower slide bushing tool and insert it inside the casting Place the strike tip on the tool Hit the tool with the rubber mallet to insert the bushing Stop to strike the tool once it touch the casting Repeat these operations for the other...

Page 24: ... 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 Repeat these operations for the other side of the casting Tool s required BOS upper slide bushing tool ref 151815 O 002 Rubber mallet INFORMATION Joints from lower and upper bushings should be mounted opposite 1 Joint outside 2 3 ...

Page 25: ...ed Take a new O ring Insert one side in the groove by hand and maintain it Use a small screwdriver grounded to insert the other side of the O ring into the groove Keep your screwdriver between the shaft and the O ring and turn around the shaft 2 3 times This will ensure that the O ring is not twisted on itself Tool s required Small screwdriver grounded Apply universal grease on this piston O ring ...

Page 26: ...ress firmly the pliers and insert one side of the retaining ring Push the other side inside the groove if necessary you could use a small screwdriver Rotate the retaining ring in its groove to ensure that the retaining ring is properly seated inside the groove Use special tool to verify that the retaining ring is in correct position inside the groove Screw the screw between the eyelets of the reta...

Page 27: ... travel checker O ring Hold one side of the O ring on the stanchion Pull the O ring to insert it on the stanchion Tool s required n a by hand Degrease the scraper seal groove on the casting Use isopropyl alcohol and rag to clean the groove Tool s required Spray of isopropyl alcohol Rag 1 2 CAUTION The air shaft should not exceed the stanchion more than 2 3cm CAUTION Greasy surface will generate sc...

Page 28: ...003 Rubber mallet Present the stanchions slantwise on the scraper seals Push and straighten the stanchions to insert them into the casting Compress the fork at its maximum Tool s required n a by hand Change the upper O ring in the floating piston Change the main piston O ring Keep your screwdriver between the shaft and the O ring and turn around the shaft 2 3 times This will ensure that the O ring...

Page 29: ...ce the oil cartridge on the assembly support Maintain by hand the oil cartridge then screw the compression bloc thanks to socket wrench Tool s required 26mm Socket wrench Assembly support Once you re cartridge is closed Close completely the Compression knob black knob Compress the cartridge until you heard a little noise then release pressure Repeat this operation until cartridge bottom out Then e...

Page 30: ...f the oil cartridge seal and thread Degrease and clean the bottom of the casting Insert the oil cartridge in the fork Screw the oil cartridge nut on the first threads Tool s required Spray of isopropyl alcohol Rag Take X ml of Bi oil in a graduated syringe see page 7 Then screw the upper cartridge tube in the fork Tool s required Syringe Socket wrench 26 mm socket 1 2 1 2 ...

Page 31: ...oove at the end of the shaft Use the magnet to put ball and in the hole with grease Tool s required Magnet Put complete oil cartridge inside the casting Locate the hole on the shaft then place the red knob rebound on the fork with the screw in front of the hole Gently screw the knob Turn the knob until you feel that the screw fall in the hole Tighten the screw Tool s required 1 5mm HEX wrench No t...

Page 32: ... 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 Turn the knob until you feel that the screw fall in the hole Tighten the screw Screw the grey knob low speed on the fork with 2mm HEX wrench Tool s required 1 3mm HEX wrench 2mm HEX wrench No torque tighten to contact Put back the customer settings on the knobs by unscr...

Page 33: ...y grease by hand on the air cartridge bolt and O rings Screw the bolt in the shaft with a torque wrench 5mm HEX socket Increase pressure until the user pressure has been reached Tool s required Air pump Torque wrench 5mm HEX socket Torque 10Nm CAUTION Keep the suspension horizontal until the air cartridge bolt has not been tighten CAUTION Keep the suspension horizontal until the air cartridge bolt...

Page 34: ..._rev00 Service Manual DEVILLE 35 since year 2017 28 29 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 Tool s required Washer Soap 2 1 2 CAUTION ...

Page 35: ...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 Clean the casting with isopropyl alcohol and rag Doing this operation after washing with washer OR hot water will make it easier to remove the adhesive Tool s required Spray of isopropyl alcohol Rag Place new stickers back on the fork Clean the fork See 7 Stickers Templ...

Page 36: ...017 7 Stickers templates Place centered on the top of the fork Center the decals when you place the fork in front of you Start the decal at 10mm from the rib Start the decal at 7mm from the bottom of the lower Start the decal at 4mm From the top of the crown ...

Page 37: ...lay from new what should I do The unique bushing alignment and tolerance on BOS forks results in less friction more sensitivity and some bushing play from new If the bushing play feels abnormally excessive please contact a BOS certified service center for expertise 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 positi...

Page 38: ... be used on the biggest hits or when you case a landing You can think of them as insurance to get you out of the trickiest situations If you have more than about 5 of your travel unused try lowering your air pressure by 5PSI and check your compression settings If your compression settings are much harder than our recommended values try bringing them closer to the base settings in your product s us...

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