Formula NERO R User manual

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Vers. 03

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TORX® è un marchio registrato di CAMCAR / TEXTRON INC. Tutti i marchi appartengono ai
rispettivi proprietati.
TORX® is a registered trademark of CAMCAR / TEXTRON INC. All trademarks are the property
of their respective owners.
TORX® est une marque déposée de CAMCAR / TEXTRON INC. Toutes les marques appartien-
nent aux propriétaires respectifs.
TORX® ist ein registriertes Warenzeichen der CAMCAR / TEXTRON INC. Alle Warenzeichen
gehören den respektiven Eigentümern an.
TORX® es una marca registrada de CAMCAR / TEXTRON INC. Todas las marcas pertenecen a
los respectivos propietarios.

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WARNING! BEFORE INSTALLING AND USING THIS NEW FORMULA. PRODUCT IT IS
CRITICAL TO YOUR SAFETY THAT YOU READ AND STRICTLY ADHERE TO THE IN-
STRUCTIONS IN THIS MANUAL. FAILURE TO DO SO COULD CAUSE SERIOUS INJURY
AND/OR INVALIDATE YOUR LEGAL RIGHTS.
KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE AS IT CONTAINS
INFORMATION CRITICAL TO YOUR SAFETY.
WARNING! DO NOT INSTALL OR DISASSEMBLE THIS FORMULA. PRODUCT ON
YOUR OWN!
Always seek the help of a professional mechanic. If you decide to ignore this im-
portant warning, keep in mind that you are doing so EXCLUSIVELY at your own risk.
Note: AS WITH ANY MANUAL, THIS ONE MAY BE UPDATED. CONTACT YOUR FOR-
MULA. DEALER, OR CHECK OUR WEB SITE, (www.rideformula.com) TO RECEIVE
ANY SUCH UPDATES.
This manual contains information for the safe use, proper mounting and mainte-
nance of NERO forks. Following the rules contained in this manual will ensure the
safe use and longest life of your NERO forks.
Carefully follow the SAFETY GUIDELINES to assure appropriate use and service of
NERO forks.
In this handbook you will find the following safety symbols:
CAUTION: Directs your attention toward unsafe practices, which could result in
damage to the equipment or minor injury.
WARNING: Directs your attention toward unsafe practices, which could result
in serious injury or death.
It is impossible to anticipate every situation that may occur while riding a bicycle. This
manual makes no representation about the safe use of the bicycle under all condi-
tions. There are risks associated with the use of any bicycle that cannot be predicted
or avoided. By choosing to ride a bicycle, you assume the responsibility for that risk.
Read and understand your bicycle owner’s manual before using your bicycle.
GENERAL SAFETY GUIDELINES
•Never put your hands near or inside rotating parts. Protective five-finger gloves that
do not reduce sensitivity or your ability to grip should be used during repair.
•Before starting any mounting operations, carefully check for dangerous conditions at
the work site. If too dark, use all available light sources and make sure they work prop-
erly before starting work.
•All maintenance operations must be carried out solely by personnel authorized by FOR-
MULA.
•Make sure that the Wheel Pin is correctly adjusted. Bounce your bicycle off the
ground from about 10cm/4” to check the presence of loose parts.
TRANSLATION OF THE ORIGINAL INSTRUCTION MANUAL

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A locking device not correctly adjusted can cause the wheel detachment..
• After inserting the wheel, first screw the wheel pin (1) to 18 Nm, then tighten the
safety lock nut (5). The lock nut has a left-hand thread so it is screwed counterclock-
wise and unscrewed clockwise.
•Before riding, verify that the brakes on your bicycle are installed and adjusted cor-
rectly. Improperly installed and adjusted brakes may cause a crash and result in
property damage, serious injury, or death.
•Make sure cables and hoses do not impede the steering of the bicycle.
•When using the bicycle in the wet, remember that the grip of the tires on the ground
decreases, making it more difficult to control the vehicle. Furthermore, it must be
borne in mind that due to the progressive drying of the braking surface during brak-
ing, the braking power may vary abruptly, so pay more attention when driving in
wet conditions to avoid possible accidents. NERO forks are not designed for use on
public roads.
•NERO forks are designed for competitive off-road riding and racing.
5 1
4 1
3 1
21
1 1
Pos DENOMINAZIONE COMPONENTI - PART NAME Q. CODICE / CODE
LOCK NUT with LEFT HAND THREAD SB-B043-05
SHIM FOR CONICAL AXEL SB-R052-15
CONICAL BUSH WHEEL AXLE SB-B035-05
AXLE BUSH Ø20 SB-B037-05
WHEEL AXLE CONICAL SEAT Ø20 DH SB-P089-05
4
3
1
Legs
2
5
Use the tightening
torque marked on
the pin surface.

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NERO FORKS SAFETY GUIDELINES
•The NERO forks produced by FORMULA. are designed exclusively for use on two
wheel bicycles. Any other use is to be considered hazardous. FORMULA. shall not be
held liable for any consequences from improper use.
•If the fork ever loses oil or makes unusual noises, stop riding and have it inspected
by FORMULA. or an authorized dealer. Continuing to use a malfunctioning fork can
cause a sudden loss of control, resulting in serious injury or death. Some sounds,
such as oil flow, minor clicks, and spring rattle, are considered normal. When in
doubt, consult your local FORMULA dealer.
•NERO forks have a crown / steerer . These parts are pressed together through a
single precision pressing operation. Replacing any of these parts requires a com-
plete new upper assembly. Never attempt to remove or replace the steerer indepen-
dently from the crown. NEVER ATTEMPT TO CUT THREADS INTO THE THREADLESS
STEERER. Modifying the crown / steerer assembly can cause loss of control of the
bicycle and serious injury or death.
•Impact, falls, improper or harsh use of the bicycle may compromise the structural
integrity of the forks, significantly reducing their lifespan.
•Have the forks regularly inspected by a qualified mechanic for any cracks, deforma-
tion, signs of fatigue or wear. Use of penetrating fluid or other visual enhancers to
locate cracks on parts is recommended.
•If inspection reveals any deformation, cracks, signs of impact or stress, no matter
how slight, immediately replace the component. Excessively worn components also
require immediate replacement.
•The frequency at which inspection is required depends on many factors. Ask a FOR-
MULA. dealer to recommend an inspection and service schedule that is right for you.
•If you weigh more than 90kg/198 Ibs be especially careful and have the bike in-
spected more frequently.
•Parts that have been bent or damaged in an accident, or as the result of impact,
must be imme-diately replaced with genuine FORMULA. replacement parts.
•The user of NERO forks expressly recognizes that there are risks inherent in bicycle
riding, including but not limited to failure of a bike component, resulting in an ac-
cident, personal injury or death.
•By purchasing and using these NERO forks the user expressly, voluntarily and
knowingly accepts and/or assumes these risks, including but not limited to the risk
of passive negligence on the part of FORMULA., i.e. hidden, latent or obvious defects
and exempts FORMULA. from liability to the fullest extent permitted by law against
any resulting damage.
•Carefully read the NERO forks instructions before use.
•Carefully follow the scheduled maintenance program as indicated in the relative
paragraph.
•Always use genuine FORMULA. replacement parts.
By purchasing and using these NERO fork, the user expressly, voluntarily and know-
ingly accepts and/or assumes these risks, including but not limited to the risk of pas-
sive negligence on the part of FORMULA., i.e. hidden, latent or obvious defects and
exempts FORMULA. from liability to the fullest extent permitted by law against any
resulting damage.

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ENVIRONMENTAL NOTES
In order to protect the environment, please follow to these simple instructions to
correctly dispose of FORMULA. products:
1)The packaging does not require special disposal because it is not dangerous in any
way; we suggest recycling paper and plastic.
2) It is also recommended to recycle the metal parts after use.
For both points mentioned above, it is recommended to dispose of waste following
national regulations through specialized waste disposal companies.
L= ø
1
9
5
6
78
2
4
11 12 10
13
3
14
15
Pos Name
1
Steering tube
2 Upper triple clamp
Lower triple clamp
3
Stanchion tube
4
Lower leg
5
Disc brake connection
6
Rebound knob
7
Wheel connection
8
Low speed compression adjustment
9
Gold air valve
10
High speed compression adjustment
11
Silver air valve
12
13
Bronze air valve
Upper clamp screws
14
15
Bottom clamp screws
* It is possible to request an upper triple clamp with different height to adapt to frames with a shorter tube

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1TECHNICAL SPECIFICATIONS NERO
FORKS 27.5”
FORKS 29”
* The value for “axle to crown” can be changed removing the pipes from the plates.
Fork
Travel
Axle To Crown
± 5.0 mm (*) Tire Size limit
200mm 581 27.5 x 2.50 inch wide
Any tire size greater than 2.35 inch wide
must be checked
with fork fully compressed and have a
minimum of 6.0 mm
“tire to crown” clearance.
190mm 571
180 mm 561
200mm 593 29 x 2.50 inch wide
Any 29 inch tire size greater than 2.35 inch wide
must be checked with fork fully compressed and
have a minimum of 6.0mm “tire to crown”
clearence
27.5 x 3.0 inch wide
Any tire size greater than 2.70 inch wide must be
checked with fork fully compressed and have a
minimum of 6.0 mm “tire to crown” clearance.
190mm 583
180mm 573
Axle To Crown
± 5.0 mm (*)
Fork
Travel Tire Size limit

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WARNING: Every time the value “axle to crown” is changed, make sure that
the distance between the crown and the tire is greater than 6 mm.
In addition, make sure that the words “end stroke” on the pipe remains below the
lower plate (3).
Gap / Tire / Crown control
It can also be checked by defeating the
air and checking that 6mm remains.
END STROKE written control
1.1 Triple clamp screws tightening torque
Upper steering triple clamp screws = 6 Nm
Lower steering triple clamp screws = 8 Nm (2 screw per side model).
Corsa + 6mm

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1.2 Disc brakes
Install disc brakes and torque all fasteners according to manufacturer’s specifica-
tions. Install, route and check that all cables or hydraulic hoses are securely fastened
to the lower leg and will not move during compression of the fork.
WARNING: Tighten the brake calipers to the brake manufacturer’s torque
specifications.
1.3 Wheels
Consult the technical specifications provided by the wheel manufacturer to install
and secure the wheels to the forks.
1.4 Lubricants
Only use hydraulic oil, lubricant and grease included in the kit sold by FORMULA.
Hydraulic oil Idemitsu OJ01, Formula FX and Grease Formula Fork Seal.
In the cartridge, use hydraulic oil Idemitsu OJ01 only.
For lubrication of legs and tubes, use Formula FX only.
CAUTION: Do not use lubricants other than those recommended above. Use
of other lubricants may damage the fork and make it unsafe.
Threadlocker for screws
Apply a liberal mount (where indicated) of medium strength threadlocker all the way
around the thread. After applying, clean any excess threadlocker with a cloth. Let dry
at least 24 hours before installing.
WARNING: The threadlocker used for assembly is dangerous to skin and
eyes. Consult and adhere to the warnings on the threadlocker container be-
fore use.

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2 INSTALLATION
WARNING: Installation of NERO suspension forks requires specific knowl-
edge, equipment and expertise. General mechanical skills are not sufficient
to correctly install the NERO suspension forks.
FORMULA strongly recommends that a qualified service center authorized by
FORMULA install the fork on your bicycle. Improperly installed forks can cause
damage to the NERO suspension and serious injury or death.
-FORMULA does not authorize the end user to
install the fork on the bike.
WARNING: Failure to follow these guide-
lines may result in serious injury or death.
2.1 Installing the hose clamp
-Secure the disc brake hose to the fork with clamp
(8).
-Loosen the screw (9) and move the clamp over
the hose (8).
-Insert the hose inside the hose clamp (8).
-Tighten to 2/3 Nm.
3 USE
GENERAL SAFETY NOTE: Do not keep the
fork fully at the end of the race for a period
exceeding 10 days.
If that happens you can verify that the hydraulic
system is not working properly.
3.1 Suspension Adjustments
-Use the rebound adjuster (10) to adjust how
quickly the fork returns to its extended position
after being compressed.
-Correctly setting the rebound speed allows the
bicycle to properly track the terrain.
-Rebound that is set too fast will cause the fork to
feel springy and uncontrolled and exhibit exces-
sive return speed
-Rebound that is set too slow will not allow the fork to extend quickly enough to
prepare for the next bump.
-Turning the adjuster (10) clockwise (toward the + sign) adds hydraulic damping and
slows the rebound speed.
-Turning the adjuster (10) counter-clockwise (toward the - sign) removes hydraulic
damping and speeds up the fork rebound speed.
8
9

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3.2 Adjusting hydraulic compression
- The knob (11) is used to progressively adjust hy-
draulic compression in high speeds.
- The knob (25) is used to progressively adjust hy-
draulic compression in low speeds.
3.3 Adjusting the air pressure
The setting of the 3Air system is used to adjust the
curve of the air spring specific for any type of need.
Changing pressures in the Gold chamber (end
stroke - Fig. 1), Silver chamber (main Fig. 2), Bronze
chamber (negative Fig. 3), it is possible to obtain a
spring where initial sensitivity as well as end stroke
progression vary, with the same central support.
11 25
Fig. 2
Fig. 1
T
O
R
Q
U
E
1
8
N
m
INFLATING
Silver (positive)
Bronze (negative)
Fig. 3
+10 PSI
-10 PSI
(N)
3 AIR SPRING FORCE
(mm)
FORK TRAVEL
Gold
+10 PSI
-10 PSI
(N)
3 AIR SPRING FORCE
(mm)
FORK TRAVEL
Bronze

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If pressure in the Silver chamber is chan-
ged, also the stiffness of the spring can be
changed to fit the weight of the rider.
For a simpler and more accurate operation, the
Nero R fork is equipped with an innovative high
pressure pump (Fig. 4) compatible with all the su-
spensions.
A quick-release pump has been used instead of a
traditional second screw, so as to avoid any air leak
when the pump is disconnected from the valve.
The 3Air system provides unlimited possibilities for trying customized settings.
Just follow a few simple rules:
1) always follow this inflation sequence: Gold - Silver - Bronze;
2) set the Gold valve with a pressure that is greater than or equal to pressure in the
Silver chamber;
3) always inflate the Bronze chamber with a pressure which is at least 20 PSI greater
than pressure in the Silver chamber.
4) you cannot check the Silver chamber without first deflating the Bronze.
The table below is given for reference on the
leg of the fork.
Follow the instructions given in the video tu-
torial found in link bit.ly/3air-setup to know
how to easily set the 3Air system in Nero R.
80kg Rider
70kg Rider
60kg Rider
(N)
3 AIR SPRING FORCE
(mm)
FORK TRAVEL
17
14
16 12
Fig. 4
Silver

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3.4 NEOPOS
Formula air suspensions can be provided with Neopos system.
Neopos is an innovation that will change your riding experience.
it is a technology that improves the positive chamber behaviour by allowing your air
fork to achieve levels of comfort, response and predictability once unthinkable.
Neopos has been designed to be compatible with Formula forks only.
To install Neopos on Nero R:
1- Deflate the chambers following the inflation steps in reverse order: bronze, silver
e gold.
2- Loosen the top plug with the specific tool delivered in the aftermarket package
and remove the upper unit.
3- Add one or more Neopos items inside the positive chamber (up to three Neopos
items, regardless of the stroke of the fork).
4- Reinstall the upper unit with a 30 Nm tightening torque.
5- Add the desired pressure again starting from the deflated chambers.
Further information about installation is available in our website:
www.rideformula.com
4 MAINTENANCE
MAINTENANCE INTERVAL TABLE
Comply with the following maintenance in-
tervals in order to preserve the functionality
and performance of your FORMULA fork..
WARNING: In case of frequent use of the
fork under extreme stresses, maintenance
operations will have to be carried out more
frequently, based on the actual use condi-
tions.
(*) Do not use high-pressure water
(**) Do not use solvents and degreasing products that may damage fork compo-
nents
Use genuine spare parts and lubricants recommended by FORMULA.
Procedure
First
Use
Every
Ride/
Competition
Every
30 Hours/
6 Months
Every
100 Hours
/1 Year
External cleaning
with water and
neutral detergent (*)(**)
Internal fork leg cleaning
- oil seal and bushing
wear check
Hydraulic oil cartridge
replacement
Air spring
maintenance

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4.2 Issues - Causes - Remedies
This chart mentions some issues that may be encountered when using the fork along
with the possible causes and remedies.
WARNING: The operations listed below and accompanied by this symbol
must be carried out only by authorized service centers.
Fork extends too quic-
kly, violent rebound af-
ter bumps
Rebound damping insuf-
ficient
Increase rebound damping
Steerer tends to “close”
when turning
Excessive rebound dam-
ping
Decrease rebound dam-
ping
Fork slow during exten-
tion or “packs-up” over
multiple bumps
Excessive rebound dam-
ping
Decrease rebound dam-
ping
Bump noise during re-
turn but without violent
rebound
Excessive rebound dam-
ping
Decrease rebound dam-
ping
Dust seal leaks oil Dust seal damaged ( ) Replace dust seal
Large amount of oil on
upper tubes or oil leaks
from bottom of fork
Seals damaged, uppers
may be damaged
( ) Replace all seals and
have uppers inspected
Fork “sticky”, does not
work like new
Seals dirty, fork requires
maintenance
( ) Replace all seals
Oil loss from bottom of
fork
Bottom nut/screw loose
O-ring damaged
Tighten the nut or screw
( ) Replace O-ring
Loss of sensitivity Slide bushings worn
Oil old
( ) Replace slide bushings
( ) Change oil

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WARNING: If the fork ever loses oil, do not use the bike.
Find and repair any oil loses before using the bike again.
WARNING: Seals and upper tubes should be kept clean to avoid damage to
fork seals and upper tubes.
WARNING: If the fork sags, immediately adjust compression or the pressure
of the chambers.
Incorrect compression adjustment may cause damage to the fork, serious
injury or death.
READ CAREFULLY!
FORMULA. extends to the original purchaser of its forks a limited warranty that the
forks are free of defects in material and/or workmanship for a period of two years
from date of purchase.
WHAT PROTECTION DO I RECEIVE FROM THE WARRANTY?
FORMULA. will, at its discretion, repair or replace the defective product under war-
ranty.
WARRANTY CONDITIONS AND LIMITATIONS
1. The manufacturer guarantees its products to be free from defects in materials or
workmanship for 24 months from the date of purchase. You must establish proof
of purchase with a mandatory document (sales receipt or invoice) showing the
date and place of retail purchase of the product in order to obtain warranty service.
.
2. The validity of this warranty is subject to the following:
(a)-The claim must be initiated within eight (8) days of discovery of the potential
defect;
(b)- Every claim must be submitted to the FORMULA. dealer from which the prod-
uct was purchased, with the understanding, however, that the discretion as to
the acceptability of the claim is exclusively FORMULA’s ;
(c)-Only a FORMULA. Dealer can ship the allegedly defective product, with the
accompanying documentation.
Failure to comply with these procedures will invalidate the claim; in which case
the product will be made available to the owner for thirty (30) days and then de-
stroyed.

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3. This warranty does not cover damages resulting from:
a. Incorrect transport and installation. Incorrect installation refers to failure
to follow the safety guidelines and instructions outlined in the Instructions
manual.
b. Unintended and inappropriate use of the product. Unintended and inap-
propriate use refers to use of the product for purposes different from those
for which it was specifically designed and manufactured. Some unintended
purposes include cross country and UCI sanctioned downhill races.
c. Use of materials or spare parts that do not carry the FORMULA trademark
NERO forks. FORMULA. shall not guarantee conformity, safety, service life
and performance of FORMULA NERO forks if materials and spare parts that
do not carry the FORMULA trademark and/or are non-compatible and/or
are not suitable and/or are not expressly authorized are used.
d. Lack of appropriate or reasonable maintenance or storage, washing with
harsh materials, use of corrosive agents, prolonged exposure to solvents.
e. Products on which the serial number and/or production code have been
altered, damaged and/or removed.
f. Modifications made by persons not duly authorized by FORMULA without
being approved by FORMULA.
g. Normal wear and tear or deterioration due to the use of the product.
h. The result of rider mishap or crash.
4. Retailers, wholesalers, importers or anyone else apart from FORMULA. may not
modify this warranty in any way.
5. This warranty does not affect the statutory rights of the consumer or any rights
the purchaser may have against the dealer pursuant to the sales contract.
6. The laws of Italy govern all matters arising out of or relating to this warranty. Any
disputes or legal actions by purchaser arising out of or relating to this warranty
shall be brought in court in Prato.

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Information may be enhanced for improvement without prior notice. All rights reserved.
Le informazioni possono essere modificate senza preavviso. Tutti i diritti riservati.
www.rideformula.com
FORMULA S.a.s. di “Formula Group S.r.l.” & C.
Via Erbosa, 63 - 59100 Prato (Italia)
Tel. [phone]
Fax [phone]
Reg. Imprese Prato / C.F. / P.IVA 02081070977
PEC: [email protected]
Cap. Soc. 500.000,00 € i.v.