BOS Suspension IDYLLE 2014 Service Manual Download

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SM_150707_A

Service Manual IDYLLE since year 2014

4.3

TOOLS REQUIRED FOR SERVICE

Cl Safety:

- Safety glasses

- Clean, lint-free rags

- Soap (+ hot water)

- Nitrile gloves

- Long plastic or wooden dowel

- Pressure washer

- Apron

- Oil pan

- Isopropyl alcohol

- Bottlebrush

- Spray bottle

- Oil fountain (optional)

Standard tools:

- 1.5 / 4 / 6 mm HEX wrenches

- 10 / 13 / 14 / 16 / 19 / 21 / 24 mm open end wrenches

- Torque wrench

- Socket wrench

- Large internal retaining ring pliers

- 10mm socket

- 21mm socket (6 sides)

- Small screwdriver grounded

- 13mm open end socket

- 19mm open end socket

- 24mm open end socket

- Bench vise with aluminum soft jaws

- Reglet

- Silicone paint brush

- Air pump

- Syringe

- Rubber mallet

- Graduated pitcher

- Internal extending micrometer 30-40mm - Universal grease

- Downhill tire lever

- 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. 150707-SEO-001

- BOS slide bushing extractor / ref. 150707-SE-003A

BOS specific tools – Pack 3:

- Half shell Ø10 / ref. 150707-O-058

- Half shell Ø21 / ref. 150707-O-060

- Half shell Ø27 / ref. 150707-O-061

BOS suspension vise block

BOS oil gauge

BOS half shell

BOS lower slide bushing tool

BOS upper slide bushing tool

BOS scraper seal tool

Summary of Contents for IDYLLE 2014

Page 1: ...0 Manual type Model Year XXXX to XXXX IDYLLE since year 2014 All serial numbers Service manual SM_150707_A ...

Page 2: ...fety 6 4 2 Cleanliness 6 4 3 Tools required for service 7 4 4 Components required for service 8 4 5 Periodical Service Information 8 4 6 Fluid Table 8 4 7 Traveler for service control printable document 10 5 Operations Summary 11 5 1 Step by step chart 11 5 2 How to use this document 11 6 Step by Step 12 6 1 Cleaning 12 6 2 Disassemble 13 6 3 Slide Bushings replacement 26 6 4 Reassemble 30 6 5 Oil...

Page 3: ...idental consequential resulting from the use of its products local legislation prevailing Warranty exclusions This warranty does not cover the following cases Damage to products resulting from improper assembly other than listed below Products that have been modified by the owner or a third party Improper use Damages resulting from an accident crash under any circumstances Invalid servicing proced...

Page 4: ...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 air re...

Page 5: ... 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 shorten...

Page 6: ... 2014 3 Exploded views of the fork 3 1 IDYLLE RARE FCV Ø37MM STANCHIONS Oil cartridge cap Air cartridge body Air cartridge cap Air valve cap Air cartridge shaft Purge screw Oil cartridge shaft Oil cartridge body Oil cartridge nut Air cartridge nut ...

Page 7: ...IDYLLE since year 2014 3 2 IDYLLE AIR Ø36MM STANCHIONS Oil cartridge cap Air cartridge body Air cartridge cap Air valve cap Air cartridge shaft Purge screw Oil cartridge shaft Oil cartridge body Oil cartridge nut Air cartridge nut ...

Page 8: ... 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 s...

Page 9: ...t Bench vise with aluminum soft jaws Reglet Silicone paint brush Air pump Syringe Rubber mallet Graduated pitcher Internal extending micrometer 30 40mm Universal grease Downhill tire lever 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 ...

Page 10: ...tments x Clean fork exterior x Basic Service Wet Muddy conditions 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 Operations Components Quantity Tools required Step by step Basic Service Change Oil Bio Oil 0 4 L Standard Pack 1 6 1...

Page 11: ... 55 Bio Oil 10 x 012xxxx IDYLLE SCR 3 Voies Tapered 013xxxx IDYLLE Air 650B 330 185 Bio Oil 10 x IDYLLE Air 650B COM06 330 185 Bio Oil 10 x 014xxxx IDYLLE Rare 650B 380 130 Bio Oil 10 x IDYLLE Rare 650B COM07 380 130 Bio Oil 10 x 015xxxx IDYLLE Rare FCV 2015 365 155 Bio Oil 20 in the casting 3 in the cartridge x IDYLLE Rare FCV 2015 RM03 365 155 Bio Oil 20 in the casting 3 in the cartridge x IDYLL...

Page 12: ..._____________________ Travel checker replacement YES NO Note _____________________________________________ Complete service operations Cleaning YES NO Note _____________________________________________ Oil change YES NO Note _____________________________________________ Complete control YES NO Note _____________________________________________ Travel checker replacement YES NO Note _______________...

Page 13: ...essure 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 10 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 the ...

Page 14: ...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 15: ... paper to remove rust on the wheel axle if necessary Tool s required 4mm HEX wrench 6mm HEX wrench 600 sand paper Place the fork on the vise block thanks to the specific tool Tighten the screws to hold the fork on the vise block Tool s required BOS suspension vise block ref 151108 O 021A 4mm HEX wrench Loosen the air valve cap Clean it Store it Tool s required n a by hand CAUTION 1 2 1 2 ...

Page 16: ... Save the rebound setting 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 Tool s required Screwdriver Remove the superior crown Untighten the screws Extract the crown from the fork Remove the bumpers if installed Tool s required 4mm HEX wrench CAUTION INFORMATION Deflating slowly the fork will...

Page 17: ...wn Untighten the screws Extract the crown from the fork Tool s required 4mm HEX wrench Rotate the fork upside down on its vise block 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 included in this manual Unscrew the grey knob anticlockwise at its maximum Tool s requir...

Page 18: ...en ends wrench Loosen the air cartridge nut Clean the bolt and seals x2 Store it Tool s required 21mm open ends wrench Untighten the high speed compression screw and remove the knob Loosen the oil cartridge nut Clean it Store it Tool s required 21mm socket Socket wrench 1 5mm HEX wrench CAUTION While loosening the nut oil may drop from the bottom of the fork Be sure to apply oil pan under the fork...

Page 19: ...e oil cartridge Let the cartridge inside the stanchion Pull back and forth the cartridge until no more oil comes out Tool s required n a by hand Unscrew the oil cartridge cap from the stanchion Remove the oil cartridge by pulling it up from the stanchion Clean and inspect the cartridge Store it Tool s required n a by hand CAUTION Act slowly to avoid splash 1 2 3 1 2 ...

Page 20: ...stanchion from the fork Empty the oil from the stanchion into an oil pan Clean and inspect the cartridge Tool s required n a by hand There is 2 different air cartridge and 2 different way to open it Shaft guide clamped with a circlip picture 1 Shaft guide screwed on the cartridge picture 2 Follow the bold description on the next steps according to your fork Tool s required n a by hand 1 2 3 1 2 3 ...

Page 21: ... into the eyelets of the retaining ring Press firmly on the pliers and remove the retaining ring Tool s required Large retaining ring pliers Shaft guide clamped with a circlip Pull the air shaft to remove the cartridge from the stanchion If difficult you could use a dowel to push the cartridge from the other side Tool s required BOS Dowel ref 150707 O 062 CAUTION Scratches on the air shaft will re...

Page 22: ...ct the cartridge from the stanchion Squeeze the top of the cartridge close to the cartridge cap into a vise block thanks to half shells Heat the shaft guide to melt the Loctite and unscrew the shaft guide Tool s required BOS half shells Ø27mm ref 150707 O 061 19mm open ends wrench Heat gun Shaft guide screwed on the cartridge Pull out the shaft from the cartridge Empty the oil from the cartridge i...

Page 23: ...g 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 with a silicone bru...

Page 24: ...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 Apply grease on the stanchion by hand Tool s required Universal grease Silicone brush Shaft guide clamped with a circlip Place and push the cartridge inside the stanchion You should hear a clic once the cartridge is well in place The groove for the retaining ring should ...

Page 25: ...n the cartridge see Fluid table page 9 of this document Clean the shaft guide thread and the cartridge thread with a rag and alcohol Refers to Oil quantity column in Fluid table page 9 of this document Refers to Oil type column in Fluid table page 9 of this document Tool s required Syringe Oil Spray of Isopropyl alcohol Rag Shaft guide screwed on the cartridge Insert the air shaft inside the cartr...

Page 26: ... on the cartridge Place back the air cartridge inside the stanchion Screw the cartridge cap on the stanchion Tool s required 32mm socket Socket wrench No torque Hand tight 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 Do the same operation on the other seal Tool s required 22mm ...

Page 27: ...ipped 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 required Spray of isopropyl alcohol Rag 1 INFORMATION Doing thi...

Page 28: ...he 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 SEO 003 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 bushing Kee...

Page 29: ... 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 bottom...

Page 30: ... 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 side of the casting Tool s required ...

Page 31: ...he 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 36 ref 150707 O 007 BOS lower slide bushing tool 37 ref 151613 O 002 Hammer INFORMATION Joints from lower and upper bushings should be mounted opposite Joint outside 1 2 3 ...

Page 32: ...the tool and apply the tool on the casting Hit the tool until the scraper seal has touched all around the casting Repeat operations for the other scraper seal Tool s required BOS lower slide bushing tool ref 151108 O 007C BOS scraper seal tool ref 151108 O 009C Rubber mallet Apply universal grease on the inside of the scraper seal Remove excess of grease Tool s required Universal grease Teflon bru...

Page 33: ...e 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 Rotate the fork upside down Screw the oil cartridge nut at torque Tool s required 21mm socket Torque wrench Torque 10Nm 1 2 1 2 1 2 ...

Page 34: ...e rebound setting at the maximum fully unscrewed Tool s required Screwdriver 14mm open ends wrench Rotate back the fork to its normal position Take X ml of oil in a pitcher see Fluid table page 9 of this document Unscrew the oil cartridge cap Extend the fork at its maximum Fill the fork with all the oil Refers to Oil quantity column in Fluid table page 9 of this document Refers to Oil type column ...

Page 35: ...the tube Mount the oil level gauge on the syringe Tool s required Oil level gauge ref 150707 SEO 002 Syringe Reglet Unscrew the oil cartridge cap Compress the fork at its maximum and pull the cartridge Place the syringe oil gauge on the fork Aspirate oil with the syringe until air bubbles appears you may add some oil if only air is coming in the syringe Tool s required Oil level gauge ref 150707 S...

Page 36: ...aintain 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 Small screwdriver No torque tighten to contact Take the air stanchion Replace the travel checker Tool s required n a by hand Insert the air cartridge stanchion in the fork left side Tool s required n a by hand 1 2 3 ...

Page 37: ... Push the air cartridge to see the shaft threads out from the casting Screw the nut on the shaft with a torque wrench 5mm HEX socket Tool s required Torque wrench 21mm socket Torque 10Nm Place back the inferior crown Insert the crown on the stanchion Measure the height from the top of the stanchion to the crown Tighten the screw at torque Place back the bumpers if present at the disassembling step...

Page 38: ...wheel axle Tool s required 4mm HEX wrench Torque 3Nm Connect the air pump on the fork Increase pressure 50 psi per 50 psi Every 50 psi cycle 3 4 times the fork on the first centimeters to balance the air release gently during the rebound balancing period Tool s required Air pump 1 2 INFORMATION It is not necessary to tighten at torque the superior crown as it will be disassembled to mount the fork...

Page 39: ... 24 Screw air valve cap by hand Tool s required n a by hand Clean the casting with a rag and alcohol Tool s required Spray of isopropyl alcohol Rag Install the stickers on the casting see 7 for templates Tool s required n a by hand CAUTION CAUTION 1 2 1 2 3 4 ...

Page 40: ...38 SM_150707_A Service Manual IDYLLE since year 2014 25 Clean the fork Washer OR if not equipped Hot water soap Tool s required Washer Soap CAUTION ...

Page 41: ...and remove the compression block Take the cartridge off the vise block Tool s required 24mm open end wrench Turn around the cartridge and place the half shells on the shaft Squeeze them moderately thanks to the vise block Tool s required Half shell Ø10 ref 150707 O 058 Vise block CAUTION Take care to the position of the half shells on the cartridge before squeezing CAUTION Take care to the positio...

Page 42: ...h a 14mm open ends wrench Save the position of the lock ring on the shaft and remove it Remove the piston and nut from the shaft Dry clean the threads to remove the Loctite Tool s required 16mm open ends wrench 14mm open ends wrench Open the cartridge Pull the rebound transmission Push the shaft through the cartridge Grab back the shaft and extract it from the cartridge Clean inspect and store the...

Page 43: ...the tool on the compression block Slide the stack up from the block to the tube Tool s required Long and thin tube OR tool Take off each part from the stack up and sort them shipshape on a clean workstation Control the elements If necessary replace elements or change the setting Tool s required n a by hand Photo positionnement douille dans étau Photo mise en place du bloc de comp dans la douille P...

Page 44: ...the nut with the torque wrench while still pressing the stack up Check that the stack up is well centered and free to turn Tool s required 10mm socket Torque wrench Torque 3Nm Reassemble the shaft inside the cartridge Insert the rebound transmission inside the shaft Tool s required n a by hand 1 2 CAUTION Clean the elements before putting them back on the compression block remove dust foreign obje...

Page 45: ...ew the nut on the shaft until the end of the thread do not tighten Screw the cartridge cap tighten by hand Hold the cartridge cap with the 32mm open end wrench Screw the nut against the cartridge cap with the torque wrench Tool s required 32mm open end wrench 13mm open end socket Torque wrench Torque 7Nm Degrease and dry clean the threads with isopropyl alcohol and a rag Insert the compression blo...

Page 46: ...the 1st 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 Loctite 243 Half shell Ø21 ref 150707 O 060 Torque 12Nm 1 2 3 ...

Page 47: ... 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 required Spray of isopropyl alcohol Rag Install the stickers on the casting see 7 for templates Tool s required n a by hand INFORMATION Doing this operation after HOT washing will make it easier to remove the adhesive 1 2 3 CAUTION 1 2...

Page 48: ...Manual IDYLLE since year 2014 7 Stickers templates Place centered on the top of the fork BOS on top logo on front Center the decals when you place the fork in front of you Start the decal at 5mm from the rib Follow the shape ...

Page 49: ...und 19 clicks 8 1 2 Idylle R 2016 Weight kg 55 60 65 70 75 80 85 95 105 110 Weight lbs 120 132 143 154 165 176 187 210 231 242 Recreational use Pressure psi 155 160 165 170 175 180 185 190 195 205 Racing use Pressure psi 160 165 170 175 185 190 195 200 210 215 Recreational Use Racing Use Low speed compression 15 clicks Low speed compression 10 clicks High speed compression 18 clicks High speed com...

Page 50: ... m 132 lbs 60 m 80 kg 132 m 176 lbs 80 m 105 kg 176 m 231 lbs m 105 kg m 131 lbs Spring green orange grey purple Availibility extra origin extra option Recreational Use Racing Use Compression 15 clicks Compression 8 clicks Rebound 18 clicks Rebound 16 clicks 8 2 F A Q My fork loses pressure when I remove the pump what can I do Check the valve core tightness using a Schrader valve core tool My fork...

Page 51: ...el 5 10 times If it is becoming increasingly difficult to purge your cartridge it may be time for an oil change Contact your closest BOS authorized service center for a basic or a full service I have about 5mm of travel unused when I ride normally Our forks are designed to be very progressive at the end of travel to give you a bottomless feeling This means that those last couple millimeters of tra...

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BOS Suspension IDYLLE 2014, Service Manual

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