Formula THIRTYFIVE QR15 User manual

MANUALE ISTRUZIONI
OPERATING MANUAL
MANUEL D’INSTRUCTIONS
BETRIEBSANLEITUNG
MANUAL DE INSTRUCCIONES
29"

17
WARNING! BEFORE INSTALLING AND USING THIS NEW FORMULA S.a.s. 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 S.a.s. PRODUCT ON
YOUR OWN!
Always seek the help of a professional mechanic. If you decide to ignore this impor-
tant 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 FORMU-
LA S.a.s. DEALER, OR CHECK OUR WEB SITE, (www.formula-italy.com) TO RECEIVE
ANY SUCH UPDATES.
This manual contains information for the safe use, proper mounting and maintenance of THIR-
TYFIVE forks. Following the rules contained in this manual will ensure the safe use and longest
life of your THIRTYFIVE forks.
Carefully follow the SAFETY GUIDELINES to assure appropriate use and service of
THIRTYFIVE 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 conditions. 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 properly before starting work.
•AllmaintenanceoperationsmustbecarriedoutsolelybypersonnelauthorizedbyFORMULAS.a.s.
•Ensurethatthequickreleaseistightenedcorrectly.Bouncethebikeonthegroundfromaheight
GB TRANSLATION OF THE ORIGINAL INSTRUCTION MANUAL

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of about 10cm/4” to ensure that there are no loose parts. Riding with an improperly adjusted
wheel quick release can allow the wheel to wobble or fall off the bicycle causing injury or
death.
•Beforeriding,verifythatthebrakesonyourbicycleareinstalledandadjustedcorrectly.Improp-
erly 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.
•Ifmountingthebicycleinarackdesignedtoholdtheforkbyitsdropouts,avoidtiltingthe
bicycle to either side. Doing so could cause structural damage to the fork. Be sure the bike is
fastened securely, with the quick-release mechanism tight and the rear wheel properly secured.
If the bicycle ever tilts on, or falls from a bicycle rack, do not ride it until it has been examined
byanauthorizeddealer,servicecenter,orbyFORMULAS.a.s..Astructurallydamagedforkleg
or dropout failure can cause a sudden loss of control, resulting in serious injury or death.
•Wetweatherimpairstractionandbraking,makingitmuchmoredifficulttocontrolthebike.
Moreattentionmustbepaidwhileridinginwetconditionsinordertoavoidaccidents.
•THIRTYFIVEforksdonotincludereflectorsforpublicroaduse.THIRTYFIVEforksaredesigned
foruseincompetitiveoff-roadridingandracing.ProperreflectorsmeetingtheConsumerProd-
uctSafetyCommission’s(CPSC)requirementsshouldbeinstallediftheforkwillbeusedon
public roads.
•Alwayswearaproperlyfittedandfastenedhelmetwhileriding.Makesurethehelmetisap-
proved in the country of use.
•Learnandcomplywiththelocalrulesoftheroadandcyclingregulations.Alwaysridecarefully
and responsibly.
•Wearclose-fittingclothesthatmakeyoueasytosee(fluorescentorbrightcolors).
•Ifyourideatnight,useadequatelightsandreflectorsthatarecleanandfittedsecurely.
THIRTYFIVE FORKS SAFETY GUIDELINES
•TheTHIRTYFIVEforksproducedbyFORMULAS.a.s.aredesignedexclusivelyforuseontwo
wheelbicycles. THIRTYFIVE forksshould notbeused forelectric bicyclesor tandem(multi-
person)bicycles.Anyotheruseistobeconsideredhazardous.FORMULAS.a.s.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
S.a.s.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.
•THIRTYFIVEforkshaveacrown/steerer/uppertubeassembly.Thesepartsarepressedto-
gether through a single precision pressing operation. Replacing any of these parts requires a
completenewupperassembly.Neverattempttoremoveorreplacethesteereroruppertubes
independentlyfromthecrown. NEVERATTEMPTTOCUT THREADSINTO THE THREADLESS
STEERER.Modifyingthecrown/steerer/uppertube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,deformation,signsof
fatigueorwear.Useofpenetratingfluidorothervisualenhancerstolocatecracksonpartsis

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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 re-
placement.
•Thefrequencyatwhichinspectionisrequireddependsonmanyfactors.AskaFORMULAS.a.s.
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inspected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S.a.s.replacementparts.
•TheuserofTHIRTYFIVEforksexpresslyrecognizesthattherearerisksinherentinbicycleriding,
including but not limited to failure of a bike component, resulting in an accident, personal injury
or death.
•BypurchasingandusingtheseTHIRTYFIVE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S.a.s.,i.e.hidden,latentorobviousdefectsandexemptsFORMULAS.a.s.
from liability to the fullest extent permitted by law against any resulting damage.
•CarefullyreadtheTHIRTYFIVEforksinstructionsbeforeuse.
•Carefullyfollowthescheduledmaintenanceprogramasindicatedintherelativeparagraph.
•AlwaysusegenuineFORMULAS.a.s.replacementparts.
By purchasing and using these THIRTYFIVE fork, 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S.a.s.,i.e.hidden,latentorobviousdefectsandexemptsFORMULAS.a.s.
from liability to the fullest extent permitted by law against any resulting damage.
ENVIRONMENTAL NOTES
In order to protect the environment, please follow to these simple instructions to correctly dis-
poseofFORMULAS.a.s.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.

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1TECHNICAL SPECIFICATIONS THIRTYFIVE 35-29” 100-140
ThemaincomponentsandspecificationsoftheFORMULATHIRTYFIVEforksaregivenbelow:
Ref Name
1Steerertube
2Crown
3Uppertube
4Lowerleg
5 Disc brake posts
6 Rebound knob
7 Dropout
8Compressionadjustment
9Airvalve
10 Lockoutlever
11 Lockoutthresholdadjustment
Description Tire
Color Type Head sleeve Travel in mm L = mm Ø C S
White
QR15 1/5”TAPERED 100 120 140 746(mm)
29,3(inch)
61(mm)
2,4(inch)
Black
WARNING: Do not use a tire if any measurement exceeds the maximum dimen-
sions shown above. Using larger tires is not recommended and can cause serious
or fatal injuries.
L=
S
ø
Ø C
1
8
4
5
67
2
3
9
10
11

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1TECHNICAL SPECIFICATIONS THIRTYFIVE 35-29” 150-160
ThemaincomponentsandspecificationsoftheFORMULATHIRTYFIVEforksaregivenbelow:
Ref Name
WARNING:
The monolith ref. 4 and the internal com-
ponents are NOT INTERCHANGEABLE
with the version of fork
Thirtyfive 35-29“100-140
1Steerertube
2Crown
3Uppertube
4Lowerleg
5 Disc brake posts
6 Rebound knob
7 Dropout
8Compressionadjustment
9Airvalve
10 Lockoutlever
11 Lockoutthresholdadjustment
Description Tire
Color Type Head sleeve Travel in mm L = mm Ø C S
White
QR15 1/5”TAPERED 150 160 746(mm)
29,3(inch)
61(mm)
2,4(inch)
Black
WARNING: Do not use a tire if any measurement exceeds the maximum dimen-
sions shown above. Using larger tires is not recommended and can cause serious
or fatal injuries.
L=
S
ø
Ø C
1
8
4
5
67
2
3
9
10
11

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1.1 Disc brakes
Disc brakes with 203 mm rotors may be used on FORMULA THIRTYFIVE forks. Do not use rotors
larger than 203 mm. Install disc brakes and torque all fasteners according to manufacturer’s
specifications. 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 spec-
ifications.
1.2 Wheels
Consult the technical specifications provided by the wheel manufacturer to install and secure the
wheels to the forks.
1.3 Lubricants
Only use hydraulic oil, lubricant and grease included in the kit sold by FORMULA.
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 before use.
Our kit include:
Hydraulic Oil Idemitsu OJ01 and Lubricating Oil Ballistol.
For the cartridge use only hydraulic oil Idemitsu OJ01. For the air spring chamber use a mix
composed by 50 % of Idemitsu OJ01 and 50% by Ballistol. For the legs lubrication, use a mix
composed by 50 % of Idemitsu OJ01 and 50% by Ballistol.

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2 INSTALLATION
WARNING: Installation of THIRTYFIVE suspension forks requires specific knowl-
edge, equipment and expertise. General mechanical skills are not sufficient to
correctly install the THIRTYFIVE 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
THIRTYFIVE 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 hy
draulic 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 com-
pressed.
-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
excessive 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

24
3.2 Adjusting hydraulic compression
Lever(11)isusedtograduallyadjusthydrauliccompres-
sion.
-Lever(25)canbeusedtoopenorclosethefastener.
-Adjuster(30)istoadjustthelockoutthresholdwhenit’s
in the closed setting.
WARNING: NEVER use lever (25) in the closed position when riding downhill
since the hydraulic suspension will not work in the proper way in case of obsta-
cles and this may lead to loss of control of the bike and to serious accidents or death.
3.3 Adjusting the air pressure
-Use a high pressure pneumatic shock pump (12) to
change the pressure in the THIRTYTREE.
-Removethevalvecap(13).
-Connecttheend(14)ofthepumptoforkvalve(15)so
thatpressuregauge(16)willreadthepressure.
CAUTION: Do not over tighten the pump (14)
as the seal will be damaged.
WARNING: The maximum allowable pres-
sure is 125psi.
-If there is no pressure in the fork, the pressure gauge
(16)willnotreadavalue.
-Compress the pump (12) a few times to increase the
pressure. The pressure should increase slowly.
-If the pressure rapidly increases, make sure the pump is
properlyconnectedtothevalve(15).
-The pressure can be reduced by pressing the black relief
valve(17)onthepump(12).
-Pressthereliefvalvehalfwaytosteadilyreleasepressure.
-Pressthereliefvalvecompletelydowntorelievesmallamountsofpressure(slightadjustment).
-Detachthepump(12)byunscrewing(14).
-Installthevalvecap(13).
17
14
16 12
13
15
11
25 30

25
WARNING: When pump (12) is connect-
ed, pressure will (16) read 2-8 PSI (0.114-
0.55 BAR) less than the actual reading
due to the air that enters the pump
hose. Consult table 1 to obtain informa-
tion about the pressure to be used.
4 MAINTENANCE
MAINTENANCEINTERVALTABLE
Complywiththefollowingmaintenanceintervals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 con-
ditions.
(*) Do not use high-pressure water
(**) Do not use solvents and degreasing pro
ducts that may damage fork components
(***) http://support.formula-suspension.com
Use genuine spare parts and lubricants recommended
by Formula.
4.1 Modifying fork travel
TomodifyFORMULATHIRTYFIVEforktravel,addorre-
move inner travel spacers.
WARNING: Before making any changes, bring the
positive chamber pressure to 0 (zero), see the
relevant paragraph.
Failure to carry out this operation may lead to
serious damage to components and even to the
operator.
-Removetheairvalvecap(1).
1
2
Procedure
First
Use
Every
Ride/
Competition
Every
30 Hours/
6 Months
Every
100 Hours
/1 Year
Basic setting (***)
Expert setting (***)
External cleaning
with water and
neutral detergent (*)(**)
Internal fork leg cleaning
- oil seal and bushing
wear check (***)
Hydraulic oil cartridge
replacement (***)
Air spring
maintenance(***)

26
-Install the pneumatic pump as di-
rected in paragraph 3.3. Bring the
air pressure to 0(zero) making
sure all the air has been let out.
-Use a 10 mm socket wrench to
loosentheairvalve(2).
-Turn over the fork and empty the
oil present in the air cylinder.
-Removethereboundknob(3)by
pulling it up.
-Usea4mmhexwrenchtoloosen
thelockscrews(4)and(5).
-Removethelowerlegby(6)pull-
ing it up.
-Pushthepiston(7)fullyinsidethe
cylinder.
-Removetheretentionring(8)with
asmallflatbladescrewdriver(9).
-Removetheentiresleeve(7)with
the piston and spring assembly
from the cylinder.
-Placethesleeve(7)onatablewiththepiston
(11)facingdown.
-Deviatethespringassembly(12)bypushing
on the plastic part and not directly pulling the
springs. Release the retainer that holds the
spring assembly.
-Insertspacers(13)whereneeded,asshown
in the figure, and then engage the retainer
again.
3
4
5
6
9
87
7
10
12

27
WARNING: The travel of the FOR-
MULA THIRTYFIVE 29 fork cannot exceed
140 mm.
- Lubricate the O-Ring (14) with grease (see
“Recommendedlubricants”).
- Install the piston and spring assembly (7)
back into the lower leg. The piston assembly
should be at the same height as the cylinder.
- Install cap (10) into the lower leg with the
larger circumference on top. Secure the cap
withtheretentionring(8).
WARNING: Incorrectly positio-
ning the snap-ring (8) may cause the
fork to malfunction and therefore
may cause serious injury or death.
14
7
8
10

28
2
16
7
15
6
-
WARNING: Before assembling, make
sure the threads of the valve and cap
are clean and degreased.
- Apply threadlocker completely around the valve thread (2). Install the valve using a 10 mm
socket wrench, tightening to 5 Nm. Use the high pressure pneumatic shock pump to inflate the
fork (as directed in paragraph 3.3) to the required pressure.
-Align the keyway on the two piston assemblies (7-15).
-Install the lower legs (6). Be extremely careful not to damage or bend the dust seals (16). Repla-
ce them if they are damaged in any way.
-Before placing the lower legs (6) against the piston assemblies(7-15), add 10cc of
-Slide the lower leg (6) until it contacts the piston keyways (7-15).
Turn the fork upright and put 5cc of oil
composed by 50% of Idemitsu OJ01 and
by 50% of Ballistol into the air cylinder
(2).
oil composed
by 50% of Idemitsu OJ01 and by 50% of Ballistol with a syringe, as shown in the figure below.

29
-Apply medium strength threadlocker
aroundthethreadofscrews(4-5).Ap-
ply grease to the o-rings on the screws.
-Install the screws (4-5) and tighten to
6-7 Nm.
-Push the rebound knob (3) fully into
place, making sure it is secure.
-Actuatetheforkafewtimestoverifyit
works properly.
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 not using full travel Oilleveltoohigh,airpressure
too high
Checkoillevel( )
Reduce air pressure
Fork extends too quickly,
violent rebound after bum-
ps
Rebound damping insufficient Increase rebound damping
Steerer tends to “close”
when turning
Excessive rebound damping Decrease rebound damping
Fork slow during extention
or “packs-up” over multiple
bumps
Excessive rebound damping Decrease rebound damping
Bump noise during return
but without violent re-
bound
Excessive rebound damping Decrease rebound damping
Dust seal leaks oil Dust seal damaged ( )Replacedustseal
Largeamountofoilonup-
per 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main-
tenance
( )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
3
4
5

30
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 check the oil
level.
Incorrect compression adjustment may cause damage to the fork, serious injury
or death.
Only a qualified bicycle technician or authorized suspension service center
should adjust the oil level.
READ CAREFULLY!
FORMULAS.a.s.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S.a.s.will,atitsdiscretion,repairorreplacethedefectiveproductunderwarranty.
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 manda-
tory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S.a.s.dealerfromwhichtheproductwas
purchased, with the understanding, however, that the discretion as to the acceptability of
theclaimisexclusivelyFORMULA’s;
 (c)-OnlyaFORMULAS.a.s.Dealercanshiptheallegedlydefectiveproduct,withtheaccom-
panying 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 destroyed.

31
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 inappropri-
ate use refers to use of the product for purposes different from those for which
it was specifically designed and manufactured. Some unintended purposes in-
clude cross country and UCI sanctioned downhill races.
c. Use of materials or spare parts that do not carry the Formula trademark THIR-
TYFIVE forks. FORMULA S.a.s. shall not guarantee conformity, safety, service
life and performance of Formula THIRTYFIVE 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 al-
tered, 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S.a.s.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.

76
Formula S.a.s. di “Formula Group S.r.l.” & C.
Via Erbosa, 63 - 59100 Prato (Italia)
Tel. [phone]
Fax [phone]
Information may be enhanced for improvement without prior notice. All rights reserved.
Le informazioni possono essere modificate senza preavviso. Tutti i diritti riservati.
REV. Luglio2015