BOS Suspension Factory Series User manual

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

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

Congratulations, you have just acquired one of our suspensions and we thank you for it.

We have a common passion, motorcycling!

This passion has led us to design our products with all the care and expertise that you, as a user can expect.

Our suspensions are the result of advanced research from our research department, bench validations and

many test sessions with our professional riders.

The goal of all this work is to provide you the best of our technologies for your greatest satisfaction.

In order to make the most of your new acquisition, we invite you to read this user manual carefully. The

mounting instructions and tips for use contained on it will allow you to 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 the product.

BOS Suspension accepts no liability for any printing problems or errors. All information in this document is

provided without any obligation on the part of BOS Suspension.

©BOS Suspension, Toulouse France

Any reproduction, even partial, is forbidden without the written permission of the author.

BOS Suspension

4 Impasse Léonce Couture

ZA du Mont Blanc

31200 Toulouse - FRANCE

Valid for all BOS Factory and Factory-R shock absorbers.

DEAR CUSTOMER

When working on a BOS suspension, please wear appropriate safety equipment such as an apron, safety gloves

and goggles.

When handling the suspension oil, please wear goggles and nitrile gloves.

MANUAL SYMBOLS

USE IN SAFETY

-When using BOS products, make sure you are in good physical shape and not under the

influence of products that affect your lucidity and decision-making capacity (alcohol, drugs,

etc.). If you are not able to ride, do not endanger yourself or any other person.

-The shock absorber has the effect of absorbing shocks, which can generate strong heat. Do not

touch the shock absorber after use. Allow 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 has a direct influence on the behaviour of

your vehicle.

This manual must be consulted before using the

BOS shock absorber and during its entire service

life. It is an integral part of the shock absorber.

If necessary, or for any service operation, please

contact an authorized BOS Suspension centre or

consult this manual.

After installation, test your vehicle at low speed

to make sure that it works properly.

OPERATING RULES ON YOUR SHOCK

Before carrying out any operation, check that you have the necessary tools to perform it. Some tools will be

specific to BOS shock absorbers, they will be indicated in this manual when using them and can be ordered

directly on our website www.bos-suspension.com.

The disassembly of your shock absorber implies the replacement of certain parts which cannot be reassembled

worn without risk of malfunction of your product (O-rings, seals, wiper seals, rings...).

Before reassembly, clean the parts thoroughly of any impurities and check their state of wear. If this seems

correct, you can reassemble 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 regarding the disposal of used shock absorber oils and components.

To ensure the continued existence of MX, make sure that you stay within the legal

framework, are environmentally friendly and recognise the rights of others.

NUMERO DE SERIE

The part number of your shock absorber is engraved on the cap (1) of your

shock. It is a sequence of 15 characters including the letter E in the

seventh position. (0000-E-0000000).

BOS SUSPENSION grants a contractual guarantee under the following conditions:

BOS guarantees its products against all defects in form and manufacturing faults for a period of one year from

the date of original purchase. Proof of purchase will be required for any application of the guarantee. The

warranty is granted to the original owner and is non-transferable. Wearing parts such as wiper seals, O-rings,

guide rings, pins, bushings, screws and bolts are not covered by the warranty.

Application

The application of the warranty is subject to the laws in force in the country or state in which the original

owner resides. If the local legislation differs from the warranty as described here, the warranty is deemed to

be amendable to comply with it.

Limitation

BOS SUSPENSION is not liable for direct, indirect, special, incidental or unforeseen damage resulting from the

use of its products, subject to compliance with local legislation.

Exclusion

The guarantee does not apply 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 comply with the instructions and maintenance intervals.

Replacement of original parts with parts from manufacturers other than BOS SUSPENSION.

Alteration of the serial numbers with the obvious aim of making it illegible.

Procedure

Regardless of where the product was purchased, the owner must contact an authorised BOS centre to apply

for the guarantee. It is compulsory to produce the purchase invoice. Otherwise, the warranty will not apply.

Sending the product is subject to the prior agreement of the BOS SUSPENSION after-sales service department.

Outward carriage, dismantling and packaging costs are the responsibility of the customer. In the event of

refusal to apply the guarantee, the packaging and return shipping costs are the responsibility of the customer.

WARRANTY

When servicing your BOS suspension, make sure that you are working in conditions that will not affect

performance:

Work in a dust-free environment

Work at a clean and organised workstation

Use soft aluminium jaws to protect the equipment when using a vice.

Do not scratch any surfaces when using tools.

Clean the 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 the floor

A repair bracket to maintain the suspension

An oil pan

All the necessary tools listed below

CLEANLINESS

-Half shell D18 (ref : 99006)

-Dividing piston tool (ref: 000019-O-031/000019-O-037)

-Rod guide cover tool (ref: 42312-O-012)

-32mm fork tip (ref: 390115-O-024A)

-Corkscrew (ref: 150707-O-030)

-Rod guide ring extractor (ref: 000020-SEO-001/91707-O-013)

Service kit :

-KREVL-46X18-FTY (Lite service Factory)

-KREVL-46X18-FTYR (Lite service Factory-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

- Ratchet key

- Allen key 3 and 5mm

- Spanner

- Pouring spout

- Valve

- Hooking tool

- Soft bite vice

- Needle

-Loctite 243

Degreaser

EXPLODED VIEW

Clean your shock absorber with a washing machine if you have one

available.

Otherwise, use the high pressure cleaner and finish cleaning with hot

water and soap.

Absolutely prohibited : any aggressive product such as

degreaser on joints and spherical bearing. If you use a high-

pressure washer, never direct the jet directly onto the

joints. Regularly remove any soil that may accumulate in the rubber

stop.

PREREQUISITE

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 until the spring is free.

3) Remove the retaining ring (5) from the cup (4)

and remove it and the spring.

CLEANING

Required tools :

- Washing machine

- Soap

DISASSEMBLY

Required tools :

- Réglet

- Tournevis plat

- Clé ergot

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