EXT Racing Shox ERA User manual

Preliminary Safety Information
Before beginning any operation read this guide carefully. These
instructions will allow you to perform the specified maintenance operations
safely. For any problems not mentioned/addressed in these pages, please
contact our technical department who will indicate the best solution. This
guide is intended for use by professional suspension technicians. Any
damage that occurs during service performed by non authorized
personnel may not be covered under warranty.
Be aware:
•Before starting maintenance equip yourself with adeguate protective
equipment, we recommend the use of protective gloves and glasses.
•Read carefully the guide’s instructions, for any inquiry please do not hesi-
tate to contact your EXT authorized distributor or our technical
department.
•The fork contains high pressure gas inside. Before carrying out any kind
of maintenance , please make sure you have removed all the pressure from
chamber “+” and then “++”.
•For best maintenance practices we suggest to be equipped with the
appropriate tools listed in this guide.
1

Service manual ERA [V1.0]
2.2 General tools
Necessary standard tools.
Description
Bike stand
Degreaser (brake cleaner)
Cleaning wipes
Clean bowls
Fine nose plier
Allen key 2.5mm, 4mm
Valve core screwdriver
Pass through Socket Wrench(19mm)
Box end wrench 13mm, 19mm
PickUp Tools
Rubber hammer
Torque wrench 0-25Nm ( to unscrew and screw ) + adapters
Loctite blu 273
Primer Loctite 7649
2

Service manual ERA [V1.0]
2.3 EXT Tools and consumables
Specific EXT Tool for ERA fork.
CODE USE
EXT RED ADHESIVE GEL adhesive gel for component assembly
EXT GREASE L1S high -flow grease
EXT LUBE EV68S low friction oil for slinding sliders
TL0464 stanctions lower covers
TL0637 scrapers insertion tool
3

Service manual ERA [V1.0]
Instructions
Preliminary operations
1. 1 Carefully clean and dry the fork.
2. Take note of pressure adjustments in order to restore them at the end of work. Adjustments must always
be trascribed by counting clicks from the fully closed positions ,which means completely screwed in
clockwise.
-LSC
-HSC
-LSR
-Pressure for “++” and “+” volumes.
3. Prepare a clean work surface. Any minimal contamination during assembly/disassembly maintenance
operations could compromise the overall final result.
2.4.2 ERA basic oil service
It is possible to change the oil by following the steps as shown. Changing the oil frequently(20-30hrs) will
allow you to keep the ERA sliding components in excellent condition, and increase wiper seal longevity. This
operation may be performed with the fork installed on the bike.
Description Illustration EXT Tools
Place the bike on the stand and remove
the front wheel. Remove the front brake
caliper( also the tube holder) and fix it
(as for example with a cable tie) to the
handlebar in order to protect it from
any oil contamination.
• None
Rotate bike in stand or place the bike
upside down on the floor (it should lean
on the handlebar and seat). Rotate
rebound knob to full open
(counterclockwise) Remove the
rebound adjust-ment knob (to make it
easier to remove, jiggle back and forth).
• None
4

Service manual ERA [V1.0]
Stop the foot stud rotation with the 4mm
Allen wrench and use the 19mm to
unscrew the outer nut. Repeat the
operation each side.
Attention: Rotating the 4mm instead of
the 19mm may result in damage to the
foot nut. If foot stud does not break free
under normal pressure apply heat. Do
not let the central stem fall back into the
lower to avoid introducing dirt and
impurities. Clean both stems ends with a
cloth and put the removed nuts in a safe
place.
•Box End Wrench
19mm
• Allen key 4mm
•Clean bowl for storage
Now replace the bike to the normal
position on the stand. Place an oil
recovery tank under the fork. With
the rubber hammer gently hit the
lower arch to make it run down about
10 cm. Do not fully extract the lowers.
Let all the oil run out from them, for
about 10 minutes.
• Rubber hammer
Once again rotate the bike upside down
or place on the floor so you will be able
to work on the bottom of the lower.
Keep the lowers drawn down about 10
cm. Using a graduated syringe insert
the correct quantity of oil inside the
lowers.
• Hydraulic side: 25cc
• Air side: 10cc
Quantities are slightly lower than those
indicated in the rest of this guide due
to residues that will remain inside the
lowers.
• Syringe 30cc min.
• EXT Lube EV68S
5

Service manual ERA [V1.0]
With the aid of the 4mm Allen key,
completely reinsert the lowers until the
stems come out of it. With the aid of a
pick-up tool, clean the stems, threads
and nuts from the old Loctite and finally
degrease them thoroughly.
• Allen key 4mm
Prepare the nuts with the Primer. Pla-
ce the correct amount of Loctite on the
male thread. Lock the nut with the
19mm polygonal wrench and tighten
the stem to 9Nm.
• Primer 7649
• Loctite 243
•Wrench 19mm
•Torque wrench
• Allen key 4mm
Abundantly grease the clicker rebound
on the outside and press the red
knob back in position. • EXT grease L1S
Proceed by mounting the front wheel
and brake caliper respecting the correct
torques and tightening methods. • None
6

Service manual ERA [V1.0]
2.4.3 ERA complete lowers service
By following these instructions it is possible to provide a complete service to the lowers in order to
restore dust seals smoothness and functionality . To perform this, in addition to the tools, you need the
"type A" service kit.
Descrizione Illustrazione EXT Tools
Place the bike on the stand and remove
the front wheel. Remove the front brake
caliper (also the tube holder) and fix it
(for example with a cable tie) to the
handlebar in order to protect it from
any oil spurt.
• None
Rotate bike in stand or place the bike
upside down on the floor (it should lean
on the handlebar and seat). Rotate
rebound knob to full open
(counterclockwise) Remove the rebound
adjust-ment knob (to make it easier to
remove, jiggle back and forth).
• None
Stop the foot stud rotation with the 4mm
Allen wrench and use the 19mm to
unscrew the outer nut. Repeat the
operation each side.
Attention: Rotating the 4mm instead of
the 19mm may result in damage to the
foot nut. If foot stud does not break free
under normal pressure apply heat. Do
not let the central stem fall back into the
lower to avoid introducing dirt and
impurities. Clean both stems ends with a
cloth and put the removed nuts in a safe
place.
•Wrench 19mm
• Allen key 4mm
• Clean bowl for
storage
7

Service manual ERA [V1.0]
Now place the bike in the normal
position on the stand. Place an oil
recovery tank under the fork legs.
With the rubber hammer gently hit the
lowers bow to make it run down
completely. Let all the oil run out from
the stems. Completely remove the
lowers, carefully clean the stems bot-
tom and stanchion from any impurities
collected by passing over the scrapers.
• Rubber hammer
Remove the sponge rings under the
scrapers. Pry with the 13mm wrench
and force the scrapers out of their
housing using the wrench round part.
Clean the inside of the lowers by using
a clean cloth.
•Box end wrench 13mm
Thoroughly clean the scraper seats
using the degreaser. This is essential to
ensure the correct level of sealing bet-
ween the dust cover and lower. Be ca-
reful not to contaminate the DU with
the degreaser.
• Degreaser
8

Service manual ERA [V1.0]
From the service kit take the new du-
st seals and check the presence of two
snap rings. Using the TL0637 tool, insert
them in their seats with the rubber
hammer. Check the correct and
uniform insertion of seals. Do not use
grease to lubricate the dust cover
casing/seats.
• TL0637
• Rubber hammer
Using a container large enough to
contain two sponge rings, fill with EXT
HDT-68 PEV oil and soak the sponge
rings. Insert them in their seats under-
neath the dust seals, taking care not to
twist them.
• EXT Lube EV68S
Dip a brush with EXT Lube EV68S oil
and wet the upper and lower DU on
both sides. Grease the scrapers inside.
Check and if necessary clean the o-ring
stroke indicator.
• EXT Lube EV68S
• EXT Grease L1S
9

Service manual ERA [V1.0]
Put the lower on the stanchion. Be
very careful not to pinch the seals. Do
not insert the lowers completely but
keep them extracted by about 10 cm.
• EXT HDT-68 PEV
Replace the bike upside down. Using a
graduated syringe insert the correct
quantity of oil inside the lowers.
• Hydraulic side: 30cc
• Air side: 15cc • None
Replace the seals at the stems ends:
pre-grease the o-rings and put them in
place. • None
With the aid of the 4mm Allen key,
completely reinsert the lowers until the
stems come out of it. With the aid
of a pick-up tool, clean the stems th-
reads and nuts from the old Loctite and
finally degrease them thoroughly.
•None
10

Basic Service Manual ERA
Prepare the nuts with the Primer. Place
the correct amount of Loctite on the male
thread. Lock the nut with the 19mm
polygonal wrench and tighten the stem to
9Nm.
• Primer 7649
• Loctite 243
•Wrench 19mm
• Screw/Unscrew
tor-que wrench
• Allen key 4mm
Abundantly grease the clicker rebound
on the outside and then put the red
knob back in position. • EXT grease L1S
Proceed by mounting the front wheel
and brake caliper respecting the correct
torques and tightening methods. • None
11