EXT Racing Shox ERA V2S User manual

MTB
UTV&SSV ATV
USER MANUAL
MANUALE UTENTE

3
TABLE OF CONTENTS
INDICE
EXT WORLD 4
CONGRATULATIONS 4
EXT R&D DEPARTMENT 4
SAFETY PRECAUTIONS 5
WARRANTY 7
FORK PARTS 9
GENERAL DIMENSION 10
FORK INSTALLATION 11
ADJUSTMENTS 13
FORK SETUP 14
SETUP QUICK TIPS 19
SERVICE & MAINTENANCE 20
EXT WORLD 22
CONGRATULAZIONI 22
REPARTO R&S EXT 22
PRECAUZIONI DI SICUREZZA 23
GARANZIA 25
COMPONENTI DELLA FORCELLA 27
DIMENSIONI GENERALI 28
MONTAGGIO DELLA FORCELLA 29
REGOLAZIONI 31
SETTARE LA FORCELLA 32
CONSIGLI PER IL SETUP 37
REVISIONE & MANUTENZIONE 38

4
EXT WORLD
CONGRATULATIONS
EXT R&D DEPARTMENT
With over 55 years of collective experience, EXT Racing Shox is one of the most
successful European engineering company capable to meet all your needs in the
field of automotive, two wheeler systems and vehicle dynamics. From F1 to Rally, GT/
Le Mans, WTCC/WTCR and motorbikes, off-road applications with special dedicated
projects for production cars. EXT is specialized in hydraulic damping systems and
has diversified in different industrial applications such as damping motion control,
seismic and defense. EXT is most well known for the development of shock absorbers
for extreme racing conditions. From the world of F1 to biomechanics the passion is
the same, a factor that has set us apart for the last 55 years.
Thank you for choosing EXT Racing Shox. All EXT products are designed, engineered,
machined, assembled, tested and developed by EXT staff in Italy. Every product has
gone through rigorous tests and is directly developed through racing. This owner
manual contains important information about your shock absorber.
Please read it carefully.
We strongly believe in innovation, developing new technologies to reach a new level of
absolute performance while assuming the maximum safety.
Innovation is our aim and strength.
EXT Research & Development department designed this fork with one philospy:
YOUR PODIUM IS OUR GOAL.
This is possible by enclosing in every single product the essende of our experience
within the racing sport, and by implementing the most sophisticated technologies
and developing new ones.

5
SAFETY PRECAUTIONS
SYMBOLS
In this manual, instructions and relevant information concerning safety or
technical documents are distinguished by the following symbols:
EXT ERA V2-S fork contains pressurized gas. Do not open, service or modify this
product, Contact an authorized service point.
Do not modify any part of the fork, all components are precisely designed as they
are.
If the fork function is irregular, or if you notice any leakage, stop riding immediately
and return this product to sn EXT authorized center.
Stanction, crown and steering tube are assembled together with a very precise
operation. It is not possible to replace only one of those parts.
If necessary all the upper structure assembly could be replaced.
ERA V2-S fork is specifically designed for Enduro/Allmountain use. This product is
developed and designed for bike industry and must be installed on related vehicles,
including pedal assisted motorized cycles that produce a maximum of 250 Watt
of power. DO NOT USE this fork on throttle-equipped motorized cycle or any vehicle
carrying more than one rider.
Any such unauthorized use may result in failure of the suspension, which may
cause a crash and result in property damage, SERIOUS INJURY or DEATH and void
warranty.
YOUR SAFETY IS
INVOLVED
IMPORTANT
INFORMATIONS

6
External visual inspection may reveal cracks or defects, if you notice them please
refer immediately to an EXT service point or EXT directly.
The product warranty shall only apply if product has been operated and maintained
in accordance with reccomendations in this manual.
An improperly installed fork can be extremely dangerous. We recommend to have it
installed by a qualified mechanic.
If your riding weight is more than 90kg/188lbs inspection must be more frequent.
Following the scheduled inspections allows you to have a functional and safe fork.
NOTE WARNING
Read and ensure you have understood
the information in this manual and other
technical documents related to this pro-
duct before using this fork. This manual,
as for others EXT manuals, is periodically
improved and updated. Visit our website
or contact us to get the most updated
one.
ExtremeBiomec Srl can not be hold
responsible for any damage to the
product, vehicle, other property or injury
to persons.
Always use EXT Racing Shox original
parts. Use of other parts or self built
ones void warranty and could cause a
structural failure.
If the shock absorber function is irregular
or if you notice any leakage, stop riding
immediately and return the product to an
EXT authorized center.
The product warranty shall only apply if
product has been operated and maintained
in accordance with recommendations in
this manual.
An improperly installed fork can be
extremely dangerous.
We recommend to have them installed by
a qualified mechanic.
Before disassembly or service always
remove gas pressure.
It’s now possible to perform the lower legs service of your fork indipendently.
All the instructions and the list of materials needed are included in a dedicated
manual that you can download from our website on the Era V2-S product page or by
clicking on the following link:
ERA LOWERS SERVICE MANUAL

WARRANTY
Extreme Biomec Srl, owner of EXT Racing Shox, an italian limited-liability company
based in Viale del Lavoro 66/68, 36021 Barbarano Mossano, Vicenza, Italy, applies
the following limited warranty conditions to all products.
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LIMITED TWO (2) YEARS WARRANTY
WARRANTY EXCLUSION
DAMAGE
DISCLAIMER
Ext guarantees their damper systems are free from defects for the period of two (2)
years from date of purchase, according to 99/44/EC decree.
Invoice, documents of transport or receipt are proof of warranty start date, and it’s
mandatory they are presented to EXT for every warranty service required.
In case of a warranty claim, the purchaser can return the product to Ext or to an
authorized dealer, presenting the requested proof of purchase within 2 years period
of warranty cover, and specifying the nature of the shock absorber failure and
warranty claim.
This warranty does not cover defects like: crash damage, alterations, neglect,
improper use, abuse, incorrect use, improper assembly, improper service,
improper fixings, use of non EXT spare parts, modifications not allowed unless
specifically authorized by EXT in written form.
This warranty does not cover parts subject to wear like hydraulic seals, o-ring seals,
sliding bushing, oil, dust seals and oil seals.
This warrany will be immediately voided in case of removal or tampering of serial
numbers or they identifying marks.
Original EXT spare parts have a warranty period of six (6) months.
Extreme Biomec Srl WILL NOT ASSUME ANY RESPONSIBILITY FOR DAMAGE TO
PERSON OR THINGS RESULTING FROM PRODUCT USE.
In some countries this clause is not accepted, this limitation could not be applied to
your country.
This warranty contract is the one and only way for customers to raise a claim on EXT
products, No EXT dealer, agent, distributor or employee can modify, extend or amplify
this warranty.

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FORK PARTS
1. Steering tube
2. Upper legs assembly
3. Damper cartridge
(Inside right stanction/leg):
3.1 Compression adjusters
3.2 Rebound adjusters
4. Air springs system
(Inside left stanction/leg):
4.1 Air side top cover
5. Dust wipers
6. Lower
7. Wheel axle
8. Pinch bolt
1
5
3
3.1
4.1
2
4
6
7
8
3.2

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GENERAL DIMENSIONS
TRAVEL [mm]
AXLE to CROWN [mm]
MAX TIRE DIMENSIONS * 29” x 2.5”
110, BOOST
PM STANDARD
180 mm(7”) / 203 mm (8”)
44
HUB SPACING [mm]
BRAKE CALIPER
BRAKE DISK SIZE [min/max]
OFFSET [mm]
120
542 ± 5 552 ± 5 562 ± 5
130 140 150
* Please verify the clearance in full
compressed position on every new tire
you’re going to use: wheel must rotate
without any interface.
AXLE to CROWN
HUB SPACING
MAX TIRE DIMENSIONS
160
572 ± 5
532 ± 5

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FORK INSTALLATION
1. Clean the headset and put some fresh grease;
2. Cut the stem at the correct length accordingly to your riding height and length
of steering tube; Keep in mind the height of the stem also;
3. Remove burrs for the top of the stem tube;
4. Install lower headset ring and the bearing on the crown according to your head
set manufacturer’s instructions;
5. Use a “star nut setter” to install the star nut 15 mm under the steering tube;
6. Install the ERA fork on the bike
7. Tighten top-cup and stem accordingly to headset manufacturer’s instructions
8. Loosen the pinch bolt, then remove the axle and install the front wheel into the
fork dropouts, slide the axle through the drive side dropout and hub.
9. Use a 5 mm hex wrench to torque the axle clockwise to 9 ÷ 13 Nm
10. Compress the fork a few times to ensure the lower leg settled in it’s lowest
friction configuration.
11. Tighten the pinch bolt on the drive side dropout to 5 ÷ 6 Nm
12. Assembly back the brake caliper with correct adapter related to disc dimension;
Front brake tube must be installed in front of the arch and then inside the lower
(between the wheel and left leg). Do not exceed 10.2 Nm of torque when you
tighten the brake caliper to the lower leg in according to brake manufacturer
indications.
1122
3344

11
55
6677
8-98-9 10-1110-11
1212

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ADJUSTMENTS
Your fork has 2 damping adjustments on the right leg:
1. Compression located on top;
2. Rebound adjuster is red and placed at the bottom of the fork;
and 1 air valve on the top of the left leg/stanction, to which you can access by
simply removing the air top cap (see picture 4);
Due to assembly tolerances, the total number of the fork clicks may vary.

13
Below you can find the suggested pressures based on rider weight:
SAG SETTING
SAG is the fork compression caused by your own weight (when you are in ready-to-ri-
de condition). Its value is determined by the air pressure you’ll inflate.
It should be in the range of 15-20% of the total fork travel.
Lower SAG value means a firmer setup
SAG RANGE
FORK TRAVEL SAG
[mm] [mm]
120
21 - 28
22.5 - 30
24 - 32
19.5 - 26
130
140
150
PRESSURE
WEIGHT
PESO PRESSIONE
[kg] [lb] [bar] [psi]
< 60 < 132
60 - 69 130 - 155
70 - 79 155 - 175
80 - 89 175 - 195
90 - 99 195 - 220
> 100 220+
4.1 60-
4.1 - 4.8 60 - 69
4.8 - 5.4 70 - 79
5.5 - 6.1 80 - 89
6.2 - 6.8 90 - 99
6.9 + 100+
160
18 - 24
FORK SETUP
In the following pages we will show you how to move among the possible adjustments
you can do. Please consider the recommended settings as a starting point to find the
setup and balance that best meets your needs.

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Follow these steps to reach your SAG in as few steps as possible:
1. Inflate the fork with the suggested air pressures;
2. Set the O-ring lean on the wiper;
3. Get on your bike in your normal riding position;
4. Get off the bike and measure the distance among the O-ring and the wiper,
that’s your sag value
DAMPING
Damping tuning can be sometimes a mine field. Where to start? Trail surfaces
change continuously, wet or dry, steep or flat and the list can go on.
Taking note of the setup you’re riding on a well-known trail will help understand how
the adjustments affect your feeling and your performance.
Keep in mind that focusing on a single adjustment at a time will make your life easier
in understading your bike.
Remember, MAXIMUM CLOCKWISE = FULL CLOSED = MAXIMUM FORCE
for all the adjusters.
We consider FULL CLOSED position as CLICK 0(ZERO)
Keep safety, stability and comfort as your priority when setting the shock.
This will allow you to ride safer with more confidence.
COMPRESSION CLICKS = 4
REBOUND CLICKS = 20

15
COMPRESSION
REBOUND
Compression manages changes of the bike stance due to weight
translation and helps your bike to skip across obstacles before it is
transmitted to you. You can obtain a very consistent grip and fee-
dback when you find the correct setup.
You have 4 clicks available: starting from a full closed position
(clockwise) where the compression is completely close, you can
adjust the fork according to the track conditions and preferences.
The adjuster fully open (counter clockwise) gives the maximum dam-
pening force to the fork.
This is responsible for you feeling of control while riding but also for
your comfort giving the bike the ability to glue wheels to the ground.
Start by having a controlled rebound feelind and move from this point
until you find the correct setup. You should feel your bike like it sticks
to the ground, goes through corners consistently by not getting pu-
shed out of it. Keep in mind that if rebound is too fast your ride could
be uncomfortable and nervous, If it’s too slow your fork will not have
enough time to recover the full stroke through the bumps.

16
SETUP QUICK TIPS
Remember to always us the correct type of tire with the correct pressure.
It is a good idea to do some tire pressure testing. You’ll be surprised by how much
grip you can get when your tires and fork are perfectly set.
Take note of your setup for any kind of trail or weather condition, and the riding
feeling you have: this will help you keep track of your preferred setup and
improvements.
Take one adjustment at a time: understanding what influence has each adjustment
on your riding style will ease the achievement of the perfect setup for you and your
riding style.
Remember that the tyre is an almost undamped linear air spring that also affects
steering.
Storing the bike upside-down or in vertical position (fork upper) allows the
lubricating oil to flow through bushings so your fork will be ready and perfectly
lubricated every new ride.

17
SERVICE & MAINTENANCE
Only EXT or authorized Service points can perform a complete service.
A complete service includes: oil, seals, O-rings, wipers and bump rubber.
RACE CONDITION
LOWERS SERVICE
NOT RACE CONDITION
To ensure maximum performance we suggest a complete service after 50 hours
riding or 6 months.
It’s now possible to perform the lower legs service of your fork indipendently.
All the instructions and the list of materials needed are inclued in a dedicated manual
that you can download from our website on the Era V2-S product page or by clicking
on the following link:
The lower legs service is recommended every 25 hours of use in racing conditions or
50 hours of use in non racing use conditions.
We suggest a complete service after 100 hours riding or 1 year.
ERA LOWERS SERVICE MANUAL

18
EXT WORLD
CONGRATULAZIONI
REPARTO R&S EXT
Con oltre 55 anni di esperienza, EXT Racing Shox è tra le aziende di ingegneria
meccanica di maggior successo in Europa, in grado di soddisfare tutte le necessità
relative a sistemi ammortizzanti per due e quattro ruote. Dalla F1 al Rally, passando
per il Gran Turismo e l’endurance. Con progetti specializzati dedicati alle autovetture
di serie. EXT Racing Shox è specializzata in sistemi di smorzamento idraulico ed
opera nel settore dell’automotive, dell’industria meccanica, della sismologia, della
difesa e della biomeccanica. Dal mondo della F1 alla biomeccanica la passione è
sempre la stessa: un fattore che ci accompagna da sempre.
Grazie per aver scelto EXT Racing Shox. Tutti i prodotti EXT sono disegnati, studiati,
lavorati, sviluppati e prodotti in Italia. Ogni prodotto è testato diverse volte ed è frutto
di innumerevoli test sul campo. Questo manuale contiene importanti informazioni
sull’utilizzo della tua forcella.
Ti preghiamo di leggerlo attentamente.
EXT crede fortemente nell’innovazione, sviluppando nuove tecnologie per raggiungere
un nuovo livello di performance assicurando allo stesso tempo la massima sicurezza.
Il dipartimento Ricerca e Sviluppo di EXT Racing Shox ha pensato questa forcella con
un unico obbiettivo: creare la miglior forcella per mountain bike di sempre per
racchiudere in un unico prodotto l’essenza dell’esperienza e delle tecnologie EXT.
Ogni forcella è frutto di diversi test sul campo gara e al banco prova. I setup
della parte elastica e idraulica sono studiati e affinati dai nostri ingegneri
esclusivamente e appositamente per la tua mountain bike.
Con una forcella EXT utilizzerai le stesse tecnologie che noi abbiamo sviluppato
durante le gare di coppa del mondo di downhill e nell’Enduro World Series.

PRECAUZIONI DI SICUEZZA
SIMBOLI
In questo manuale le istruzioni e informazioni importanti relative a
sicurezza o aspetti tecnici sono contrassegnate dai seguenti simboli:
La forcella EXT ERA V2-S contiene gas in pressione. Non aprire, fare manutenzione
o modificare questo prodotto. Se necessario rivolgersi ad un service point autorizza-
to.
Non modificare alcuna parte della forcella, tutti i componenti sono progettati
esattamente come sono.
L’utilizzo e/o il mantenimento non conforme a quanto indicato nel presente manuale
comporterà l’annullamento della garanzia.
Se il funzionamento della forcella è irregolare o si notano perdite, interrompere
subito l’utilizzo e consegnare il prodotto a un centro autorizzato EXT.
Steli, piastra e tubo dello sterzo sono assemblati con un accoppiamento molto
preciso. Non è possibile sostituire solo una di queste parti. Qualora fosse necessario
è possibile sostituire tutto il gruppo della struttura superiore
La forcella ERA V2-S è specificatamente progettata per un utilizzo Enduro-Allmoun-
tain.
Il prodotto è progettato e sviluppato per il mercato della bici e deve essere
installato sui relativi prodotti, compresi i cicli con pedalata assistita che producono
un massimo di 250W di potenza. NON USARE la forcella su cicli motorizzati dotati
di controllo al manubrio/acceleratore, o su veicoli che possono portare 2 o più per-
sone. Ogni utilizzo non autorizzato può portare alla rottura del prodotto, a incidenti e
ATTENZIONE!
POSSIBILE PERICOLO
INFORMAZIONE
IMPORTANTE
19

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L’ispezione visiva esterna può rivelare crepe/cricche o difetti, se li noti contatta
immediatamente un punto di assistenza EXT o EXT direttamente.
Una forcella installata in modo errato può essere estremamente pericolosa.
Si consiglia di farla installare da un meccanico qualificato.
Se il tuo peso è superiore a 90kg l’ispezione deve essere più frequente.
Rispettare i tempi di ispezione programmata permette di disporre di una forcella
funzionale e sicura.
NOTE ATTENZIONE
Leggere ed assicurarsi di comprendere
le informazioni contenute in questo
manuale ed altri documenti tecnici relativi
a questo prodotto prima di utilizzarlo.
Extreme Biomec Srl non può essere
ritenuta responsabile per eventuali danni
alla forcella, alla bici, ad altre proprietà o
alle persone.
Utilizzare sempre parti di ricambio
originali EXT Racing Shox. L’uso di altre
parti invalida la garanzia.
Se la forcella funziona in modo irregolare,
o si notano perdite, interrompere
l’utilizzo e restituire il prodotto a un centro
di assistenza Ext.
La garanzia si applica solo se il prodotto è
stato utilizzato e sottoposto a
manutenzione conformemente alle
raccomandazioni del presente manuale.
È ora possibile eseguire il service dei foderi in maniera autonoma.
Tutte le istruzioni e la lista dei materiali necessari sono incluse in un manuale dedicato
scaricabile dalla pagina prodotto di Era V2-S sul nostro sito o cliccando al link sottostante:
ERA LOWERS SERVICE MANUAL