BOS Suspension Factory Series Service Manual Download

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Table of contents

DEAR CUSTOMER ................................................................................................................................................. 3

SAFETY INSTRUCTIONS ........................................................................................................................................ 4

GENERAL WARNINGS ...................................................................................................................................... 4

MANUAL .......................................................................................................................................................... 4

USE IN SAFETY ................................................................................................................................................. 4

OPERATING RULES ON YOUR SHOCK .............................................................................................................. 5

ENVIRONNEMENT ........................................................................................................................................... 5

NUMERO DE SERIE ........................................................................................................................................... 5

WARRANTY .......................................................................................................................................................... 6

CLEANLINESS ....................................................................................................................................................... 7

TOOLS .................................................................................................................................................................. 8

EXPLODED VIEW .................................................................................................................................................. 9

CLEANING .......................................................................................................................................................... 10

DISASSEMBLY ..................................................................................................................................................... 10

PREREQUISITE ................................................................................................................................................ 10

HEAD SET/FOOT SET DISASSEMBLY ............................................................................................................... 11

DISASSEMBLY OF CYLINDER SET .................................................................................................................... 13

ROD SET DISASSEMBLY .................................................................................................................................. 16

ROD GUIDE SEALS CHANGE ........................................................................................................................... 18

ROD SET REASSEMBLY ................................................................................................................................... 20

REASSEMBLY OF CYLINDER SET ..................................................................................................................... 22

REASSEMBLY OF ROD CYLINDER SET ............................................................................................................ 24

SPRING REASSEMBLY ..................................................................................................................................... 26

SETTINGS TABLE ................................................................................................................................................ 28

NOTES ................................................................................................................................................................ 29

SUMMARY

Summary of Contents for Factory Series

Page 1: ...BOS MX SHOCK Factory Factory R BOS Suspension 4 Impasse Léonce Couture ZA du Mont Blanc 31200 Toulouse FRANCE All serial numbers Service manual Manuel de service SM 43115 001 EN ...

Page 2: ... DE SERIE 5 WARRANTY 6 CLEANLINESS 7 TOOLS 8 EXPLODED VIEW 9 CLEANING 10 DISASSEMBLY 10 PREREQUISITE 10 HEAD SET FOOT SET DISASSEMBLY 11 DISASSEMBLY OF CYLINDER SET 13 ROD SET DISASSEMBLY 16 ROD GUIDE SEALS CHANGE 18 ROD SET REASSEMBLY 20 REASSEMBLY OF CYLINDER SET 22 REASSEMBLY OF ROD CYLINDER SET 24 SPRING REASSEMBLY 26 SETTINGS TABLE 28 NOTES 29 SUMMARY ...

Page 3: ... make the most of the potential of your suspensions Thank you for choosing BOS suspension This document was written at the time of the creation of this product however BOS Suspension does not exclude the existence of possible discrepancies due to the evolution of the product since its initial version BOS Suspension reserves the right to update the information in this document during the life of th...

Page 4: ...llow it to cool before attempting any work on it SAFETY INSTRUCTIONS CAUTION operations may impair your safety or cause damage to your suspension Be sure to take note of these warnings These indications are provided to enable you to perform the operations described in this manual and to optimize the performance of your suspension GENERAL WARNINGS The shock absorber is an important element which ha...

Page 5: ...eassemble your shock absorber otherwise change the worn parts ENVIRONNEMENT Motocross is a wonderful sport that brings you a lot of happiness However it is po tentially a source of environmental conflict with other people Responsible behaviour when using your motocross bike automatically defuses prob lems and conflicts Make sure that you comply with the legislation in force in your country regardi...

Page 6: ...ply in the following cases Failure to comply with the installation instructions as described in the installation and adjustment manual Failure to follow the disassembly assembly instructions as described in the service manual Modifications made to the product by the owner or a third party Inappropriate use Damage resulting from an accident violent shock fall under any circumstances Failure to comp...

Page 7: ...e components when disassembling them Remove the sub assemblies in the order of disassembly so that you can easily find out how to reassemble them together Long sleeves are recommended or shaved arms If you carry out maintenance on your BOS suspension outside a workshop you should at least Avoid dust and air circulation around your work area A clean tarpaulin to be placed under the suspension on th...

Page 8: ... R KREVC 46X18 FTY Complete service Factory KREVC 46X18 FTYR Complete service Factory R Cleaning and safety Standard tools Specific tools Oil Grease Glues TOOLS Safety goggles Clean cloths lint free Soap hot water Nitrile gloves High pressure cleaner Apron Oil pan Oil fountain optional Torque spanner Socket 32 24 19 Mallet Wide flat screwdriver Thermal stripper AMX1 0 5L White grease Copper grease...

Page 9: ...9 EXPLODED VIEW ...

Page 10: ...ISITE 1 Before any dismantling make sure to note down your compression 1 rebound 2 and preload 3 settings on a notebook To do this count the number of clicks until the position is completely closed Once the setting has been noted unscrew your settings completely for operations on your shock absorber 2 Once the pre load value has been noted unscrew the clamp against nut and then the pre load nut un...

Page 11: ...eration Place the tool on the rod guide cap of your shock and then unlock it only Be carefull not to scratch the rod of your shock during this operation Do not unscrew your cap your shock is still under pressure Unscrew the gas cap screw Remove it and the seal Required tools 3mm allen key Required tools Open end spanner 32 adjustable spanner Rod guide cap tool ref 42312 O 012 Required tools 3mm al...

Page 12: ... retaining ring Make sure your settings are fully open and leave your needle in the gas cap port for your comfort Remove the retaining ring of the rod guide Pull gently on the rod until the rod guide is completely free of the cylinder Beware of oil splashes please wear protective glasses Required tools Needle Required tools By hand Required tools By hand Required tools Flat screwdriver hooking too...

Page 13: ...r Be sure to put an oil pan under your vise to collect the used oil Pour the contents of your shock into an oil pan and let it drain for a fex moments Don t throw your oils into nature recycle them to protect our environment DISASSEMBLY OF CYLINDER SET Tap the gas cap with a mallet to make the locking ring accessible Required tools By hand Required tools By hand Required tools Mallet ...

Page 14: ...the cap from the canister Remove the canister seal with a hook and loop tool and replace with a new one Screw the separating piston extractor tool into the separating piston and pull vertically until the piston is extracted from the canister Make sure your shock absorber is properly locked in the vise to avoid damaging it Requiered tools Flat screwdriver Hooking tool Requiered tools Corkscrew 1507...

Page 15: ...ock and the one in the head and replace them with new ones Then clean the inside of the cylinder and canister properly with a clean cloth or a washing machine if you have one available Clean the compression block splitter piston and inflation cap properly with a clean cloth as well Place all the elements on your workbench before proceeding to the disassembly of the rod assembly Required tools Hook...

Page 16: ...19 mm open end wrench Position a valve or screwdriver at the end of the rod and slide the piston assembly over it Clean the valve assembly and the piston Use a clean cloth and some degreaser Dry the parts well afterwards When cleaning place all the parts in the order of disassembly on a clean cloth on your workbench to ensure proper reassembly A wrong order of assembly of the valves will induce a ...

Page 17: ...ber rebound stop Remove the rod guide the ring and the cap Finish by removing the bump rubber Clean all the components you have removed with a clean cloth Required tools By hand Required tools By hand Required toold By hand ...

Page 18: ... 013 Position the sleeve on the guide ring and then screw the screw in so that the grooves are pressed into the ring Then tap the top of the tool to remove the ring Replace the seals with white grease and press fit the rings refer to the sectional views below Required tools Extractor tool with screw ref 000020 SEO 001 Extractor socket D18 ref 91707 O 013 Mallet ...

Page 19: ...19 FACTORY Model FACTORY R Model ...

Page 20: ...sert the new bump rubber Insert the rod guide cap and the ring Insert the reconditioned and greased rod guide Insert the rebound stop Required tools By hand Required tools By hand Required tools By hand Required tools By hand ...

Page 21: ...t the piston assembly in the same order as during disassembly Apply Loctite 243 on the nut Tighten the nut with a torque of 30Nm Required tools Degreaser Clean cloth Required tools Valve screwdriver Required tools Loctite 243 Required tools Torque wrench 19mm socket ...

Page 22: ...e head Screw the compression bloc with a torque of 30 Nm Apply white grease on the floating piston o ring Spread the white grease on the top strip Required tools White grease Required tools By hand Required tools Tork wrench 32mm socket Factory R 24mm socket Factory Required Tools White grease Required tools By hand ...

Page 23: ... a cloth or oil pan under your shock absorber oil will flow out when installing the floating piston Insert the inflation cap and put the retaining ring in position Make sure the snap ring is correctly positioned in its groove Inflate the shock absorber slightly so as to position the cap against the ring and to keep the dividing piston at the bottom of the canister Required tools Measuring cup BOS ...

Page 24: ...rface of the oil Be sure to keep the rebound stop submerged at all times or air will be drawn back in between the components Top up the oil level if necessary to have an oil height equal to the size of the rod guide Once the purge is done let the air in your canister escape Maintain the rod in extended position with the trigger stop immersed flush with the oil Gently push the rod guide into the cy...

Page 25: ...enfoncement est gage d une bonne purge de votre amortisseur If your rod does not return properly please re purge your shock Position the seal of the inflation screw previously greased with white grease Tighten the inflation screw with a 3mm Allen key Required tools Clean cloth Washing machine Required tools Nitrogen Pressure gauge Required tools White grease Required tools 3mm Allen key ...

Page 26: ...on your shock absorber Position the snap ring and the cup Apply the spring preload and the compression and rebound settings found before disassembly If you forgot your values refer to your motorcycle manual to perform your SAG and apply the recommended compression and rebound settings Required tools Copper grease Required tools By hand Required tools Rod guide tool 42312 O 012 32mm fork tip 390115...

Page 27: ...OS shock absorber Reinstall your shock on your motorcycle refer to the installation instructions in your motorcycle manual Ride slowly at first to make sure your motorcycle and shock absorber are working properly Thank you again for choosing BOS Suspension products ...

Page 28: ...28 Type of terrain circuit High speed compression clicks Low speed compression clicks Rebound clicks Spring preload mm SETTINGS TABLE ...

Page 29: ...29 NOTES ...

Page 30: ...30 NOTES ...

Page 31: ...31 NOTES ...

Page 32: ...32 ...

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