Formula TECH SUSPENSION TJ2 User manual

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Shock Absorber TJ2, TJ3, TJ3GP
User Manual –
This user manual contains all the relevant information regarding the correct use and
maintenance of TJ2, TJ3 and TJ3GP shock absorbers.

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Index
Important Informations .........................................................................................................................................3
Safety Guidelines...................................................................................................................................................4
Maintenance Intervals ...........................................................................................................................................4
Required Tools .......................................................................................................................................................5
Shock Absorber Installation and Interference Check .....................................................................................5
Shock Absorber Characteristic ...........................................................................................................................6
Rebound Control.....................................................................................................................................................6
Compression Regulation (TJ3/TJ3GP) ......................................................................................................................7
Pressure Check........................................................................................................................................................8
Spring Adjustment & Replacement..........................................................................................................................9
Dust Seal & Spacer Assembly ................................................................................................................................11
Troubleshooting...................................................................................................................................................12
Warranty and Conditions....................................................................................................................................13

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Important Informations
IMPORTANT
Constantly referring to this manual ensures the best performance, a long-lasting shock
absorber and ensures avoiding the most common cause of inconvenience and
accidents that could happen during its use or maintenance.
Repeatedly using our products in extreme conditions requires more frequent servicing.
Using unrecommended high-pressure washing methods, using unrecommended
spare parts, solvents and lubricants not recommended by Formula reduce the life
span of our products.
IMPORTANT
Formula recommends only ORIGINAL spare parts and lubricant products
Do not attempt assembly and disassembly operations on this product. Formula
recommends consulting servicing technicians for these activities and finding eventual
cracks, deformations, or evidence of damage due to fatigue or wear: if the inspection
shows the presence of such problems, even if minor, immediately replace the
component –with no attempts of repair.
SAFETY INFORMATION
Always wear nitrile gloves and safety glasses when working on the shock
absorber. Ensure correct disposal of waste materials and liquids.
Always ensure the shock absorber's reservoir is depressurized and the spring
preload is loosened when requested in the manual. Servicing the shock
absorber with a preloaded spring and a pressurized reservoir can cause
severe or fatal injuries

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Safety Guidelines
•Regularly check the spring ensuring there is no damage and replace it if necessary.
•Accidents and excessive or improper use of the bike can alter the structural integrity of the shock absorbers,
greatly affecting their life span;
•Parts that have been bent or damaged following an accident must be replaced immediately with original
Formula spare parts.
•Formula products and tools could be incompatible with third-party products or tools and vice-versa. Before using
third-party items, ensure compatibility with a qualified technician or a tool manufacturer. The company declines
any responsibility for malfunctions caused by improper tool use.
•The shock absorber's user is aware that there are risks from riding a bike, including, but not limited to, failure of
the bike components which could lead to accidents with personal injuries or death.
•By buying and using the shock absorber, the user explicitly accepts, voluntarily and consciously and knows the
risks, including passive negligence from Formula, such as hidden defects and exempts Formula from their
responsibility in the highest measure allowed by the law against any damage derived from their use.
Maintenance Intervals
To keep the rear shock absorber efficient during normal usage and ensure proper maintenance, follow the
maintenance intervals chosen by Formula:
Procedure
Before and
After any use
Every 8 Hours
1 Month
Every 35 Hours
3 Month
Every 100 Hours
1 Year
Washing with water and mild soap. Visual inspection.
Shock SAG and spring preload check
Reservoir pressure check
Oil change and inspection
Use the table below to keep track of the spring preload measurement and return to the pre-service settings
once the servicing has been completed:
Date
Spring Preload Measure
Notes

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Required Tools
Descrizione
Posizione
Q.ty
Part number
Preload Shock Ring Key Tool
113
1
080033201
This tool is sold separately
▪Hex key:
o2 mm –Compression Control;
o2,5 mm –Screw for the Rebound knob;
o6 mm –Rebound Control (without knob);
▪Formula Grease;
▪Bench vise.
Shock Absorber Installation and Interference Check
After buying the TJ Shock Absorber it’s necessary to ensure there are no interferences between the shock absorber
and the bike’s chassis for the entirety of the shock absorber travel. The check must be performed without the spring
and the knob (if assembled).

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Shock Absorber Characteristic
Rebound Control
1. All TJ Shock Absorbers allow controlling the rebound thanks to a knob on the shock absorber's head. The knob
allows for a regulation of up to 24 "clicks" settings;
Do not use the 2,5 mm hex key to control the rebound: only use the knob. Controlling the rebound by using the
knob's screw could cause malfunctions. If it's impossible to control the rebound manually with the knob, it must be
disassembled with a 2,5 mm hex key and the rebound control must be performed with a 6 mm hex key.
2. This adjustment affects the 2nd phase of the shock absorber which happens after the compression phase. The
extension range is strictly related to the stiffness of the spring used (N/mm): a spring with a higher stiffness has a
higher restoring force, consequentially the shock absorber will require a higher hydraulic force;
3. In order to increase the rebound, rotate the knob CLOCKWISE (+);
4. The higher the stiffness, the faster the rebound for the same amount of "clicks". For example, moving from a
spring with 68,7 Nm to one with 73,6 N/mm, to obtain the same rebound it's necessary to rotate clockwise the
know by one or two clicks. Vice-versa for springs with lower stiffness.
It's not always possible to control the rebound. Get in touch with a specialized technician before working on the
bike and disassemble the shock absorber to avoid activities that could compromise its proper function.
-End of Procedure-

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Compression Regulation (TJ3/TJ3GP)
1. The regulation of the compression is a feature exclusive to the TJ3 and TJ3GP shock absorbers;
2. The compression phase is the first event that happens after landing on the ground for example. The compression
range can be influenced by the spring. Screw the cap CLOCKWISE with a 2 mm hex key to increase the hydraulic
force the shock absorber exercises when compressed; this allows for increased hydraulic support on the rear
side of the bike;
3. Rotating the cap ANTI-CLOCKWISE will provide smaller support on the rear.
-End of Procedure-

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Pressure Check
Required tools:
Bench vise, Formula Pump.
Procedure:
You can find the complete tutorial on Formula’s YouTube channel.
1. Remove the uniball spacers and place the shock absorber in a bench vise;
2. It’s highly recommended to use a Formula Pump. Using different tools could cause issues;
3. Unscrew the reservoir cap;
4. Screw the air pump to the reservoir valve without enabling the valve duct;
5. Pressurise the pump at 200 psi;
6. Enable the valve duct and the pressure in the pump will be normalised with the pressure inside the reservoir;
7. Check the pressure and ensure it’s between 10 and 12 bar;
If the pressure is lower than 10 bars, inflate the shock absorber with nitrogen. Do not use air to inflate the shock
absorber as it could affect its performance and correct functioning.
8. If the pressure is correct, close the pump valve duct and remove the pump. Screw the reservoir cap;
9. Remove the shock absorber from the bench vise and reassemble the uniball spacers.
-End of Procedure-

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Spring Adjustment & Replacement
Required tools:
Bench vise, Formula Grease, Hex key 2,5 mm.
Procedure:
1. Remove the uniball spacers (100). Check the state of spacers and dust seals before proceeding. Place the shock
absorber in a bench vise with plastic jaws to prevent damage. Measure and track the preload spring;
2. Unscrew the preload ring grub screws (94) and unscrew the spring regulation ring (8) until the spring is moving
freely;
3. Disassembly the rebound knob (87) by unscrewing its screw with a 2,5 mm hex key;
4. Remove the seeger ring (14) and the ring spring support (15);
5. Extract the shock absorber's spring (20), the preload spacer (61) and the washer spring (40);
6. Clean the shock absorber with isopropyl alcohol and ensure there are no oil leaks or damages. Get in touch with
customer support if there are anomalies;

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7. Replace the spring (20) and the spacer (61) if necessary. The spacer (61) is sold with a laser marking that shows
the spring it needs to be coupled with in order to ensure that the maximum preload is 10 mm. Using a different
spacer could compromise the preload range and the proper function of the spring. As it's possible to see in the
photo, each spacer is coupled with the respective spring:
Refer to the table below:
Spring Code (20)
K (N/mm)
Pre-Load Spacer Code (61)
Spacer Height (mm)
090821251
83,6
042032015
1,5
Each spacer must be
coupled with the
respective spring
090801231
78,7
042032030
3
090781211
73,6
042032045
4,5
090761191
68,7
042032060
6
090741171
63,6
042032075
7,5
8. Assembly the washer spring (40), the preload spacer (61) and the spring (20);
9. Set the spring preload with the measure recorded in step n°1. Screw the preload ring grub screws with a 2,5 mm
hex key with a tightening torque of 4 Nm;
10. Assembly the rebound knob (87), apply Loctite 242 on the thread of its screw and tighten it with 10 Nm;
11. Reassemble the uniball spacers.
-End of Procedure-

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Dust Seal & Spacer Assembly
Procedure:
1. The shock absorber is supplied with dust seals and spacers already assembled;
2. If they need to be disassembled and replaced, ensure that during the dust seal assembly, its spring stays in place
and does not get damaged;
3. Apply Formula grease on the outer diameters of the dust seal and assemble it in its housing;
4. Assemble the uniball spacers.
-End of Procedure-

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Troubleshooting
Problem
Cause
Solution
Following a jump the rear end of
the bike dashes me forward
Rebound regulation is too
open
Rotate clockwise the rebound with 1/2 click and try
again
The spring can rotate axially on the
shock absorber
Preload lower than the
minimum allowed (10 mm)
Rotate clockwise the shock preload ring
The shock absorber feels slow and is
too supportive on the rear end, the
bike is too unbalanced towards the
front end
Spring too preloaded or
compression too slow
Rotate anti-clockwise the shock preload ring or rotate
anti-clockwise the compression regulator with 1/2 click
I can't obtain the compression I
want by working on the entire
preload
Spring too soft or too stiff
Change the spring
Backlash on the extension regulator
The screw is loose
Tighten the screw
Metallic noise between the bike and
the shock absorber
No clearance or backlash
between the components
Visually inspect the shock absorber. Inspect the
couplings based on the bike manufacturer's
specifications. Inspect the uniball and verify the correct
functioning
The shock absorber is too soft and
the setting seems to be different
than usual
Check the reservoir
pressure
If the pressure is correct and the issue isn't solved, do
not use the shock absorber. Get in touch with customer
support for inspection and servicing
Oil leakage
Leakage from the seals
Do not use the shock absorber. Get in touch with
customer support for inspection and servicing
Scratched stem
Debris or accidents have
carved the anodized surface
Noise/Whistle coming from the
shock absorber hydraulics
Pressure below the required
specs or air inside the ducts
The performance of the shock
absorber changes too quickly
Excessive use of the
damping. Exhausted oil or
the presence of air inside
the ducts. Excessive
ambient temperature or
overheating caused by the
bike

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Warranty and Conditions
1. The following warranty has a duration of 24 months starting from the date of purchase which must be proved
with a receipt.
2. The validity of this warranty is covered by a "complaint procedure" as follows:
a. The complaint must be sent within 8 days after the defect has been found;
b. Each complaint must be sent to the Formula reseller where the product was bought. The complaint
acceptance is of exclusive competence of Formula if the product has been bought directly from Formula;
c. Formula will receive potentially defective products exclusively from Formula resellers with the required
documentation.
If the procedure is not compliant, the claim won't be considered; in that case, the returned item will be preserved
for 30 days to be sent back to the owner, if the item does not get returned it will be destroyed.
3. This warranty does not apply to damage derived from:
a. Transportation or incorrect assembly;
b. Improper use of the product;
c. Not original spare parts;
d. Improper maintenance of the product, washing with aggressive products, corrosive agents, the
prolonged exposition to solvents;
e. Altering, damaging or removing the serial number or production number;
f. Modifying the product without Formula's consent;
g. Normal wear.
4. Retail sellers, wholesale sellers, importers or anyone outside of Formula cannot modify this warranty in any way.
5. This warranty refers to the European Union's Consumer guarantees. Further implementations of this warranty
will refer to Italy's Consumer guarantees. Any legal controversy will be handled by Prato (Italy) Courthouse.

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https://www.rideformula.com/it/
FORMULA S.r.l. of “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: formu[email protected]
Cap. Soc. 500.000,00 € i.v.
The content of this document can be altered without notice. All rights reserved.
Revision 0 –May 2023