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.

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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

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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

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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 • None
handlebar in order to protect it from
any oil contamination.

Rotate bike in stand or place the bike

upside down on the floor (it should lean
on the handlebar and seat). Rotate • None
rebound knob to full open
(counterclockwise) Remove the
rebound adjust-ment knob (to make it
easier to remove, jiggle back and forth).

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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 • Box End Wrench
the 19mm may result in damage to the 19mm
foot nut. If foot stud does not break free • Allen key 4mm
under normal pressure apply heat. Do
not let the central stem fall back into the • Clean bowl for storage
lower to avoid introducing dirt and
impurities. Clean both stems ends with a
cloth and put the removed nuts in a safe
place.

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 • Rubber hammer
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.

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.
• Syringe 30cc min.
• Hydraulic side: 25cc
• EXT Lube EV68S
• 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.

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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 • Allen key 4mm
and nuts from the old Loctite and finally
degrease them thoroughly.

• Primer 7649

Prepare the nuts with the Primer. Pla- • Loctite 243

ce the correct amount of Loctite on the • Wrench 19mm
male thread. Lock the nut with the
19mm polygonal wrench and tighten • Torque wrench
the stem to 9Nm.
• Allen key 4mm

Abundantly grease the clicker rebound

on the outside and press the red • EXT grease L1S
knob back in position.

Proceed by mounting the front wheel

and brake caliper respecting the correct • None
torques and tightening methods.

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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 • None
handlebar in order to protect it from
any oil spurt.

Rotate bike in stand or place the bike

upside down on the floor (it should lean
on the handlebar and seat). Rotate • None
rebound knob to full open
(counterclockwise) Remove the rebound
adjust-ment knob (to make it easier to
remove, jiggle back and forth).

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 • Wrench 19mm
the 19mm may result in damage to the
foot nut. If foot stud does not break free • Allen key 4mm
under normal pressure apply heat. Do • Clean bowl for
not let the central stem fall back into the storage
lower to avoid introducing dirt and
impurities. Clean both stems ends with a
cloth and put the removed nuts in a safe
place.

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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 • Rubber hammer
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.

Remove the sponge rings under the

scrapers. Pry with the 13mm wrench
and force the scrapers out of their • Box end wrench 13mm
housing using the wrench round part.
Clean the inside of the lowers by using
a clean cloth.

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- • Degreaser
reful not to contaminate the DU with
the degreaser.

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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 • TL0637
uniform insertion of seals. Do not use
grease to lubricate the dust cover • Rubber hammer
casing/seats.

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- • EXT Lube EV68S
neath the dust seals, taking care not to
twist them.

Dip a brush with EXT Lube EV68S oil

and wet the upper and lower DU on
• EXT Lube EV68S
both sides. Grease the scrapers inside.
Check and if necessary clean the o-ring • EXT Grease L1S
stroke indicator.

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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 • EXT HDT-68 PEV
keep them extracted by about 10 cm.

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 • None
place.

With the aid of the 4mm Allen key,

completely reinsert the lowers until the
stems come out of it. With the aid • None
of a pick-up tool, clean the stems th-
reads and nuts from the old Loctite and
finally degrease them thoroughly.

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Basic Service Manual ERA

• Primer 7649

Prepare the nuts with the Primer. Place • Loctite 243

the correct amount of Loctite on the male • Wrench 19mm
thread. Lock the nut with the 19mm
polygonal wrench and tighten the stem to • Screw/Unscrew
9Nm. tor-que wrench

• Allen key 4mm

Abundantly grease the clicker rebound

on the outside and then put the red • EXT grease L1S
knob back in position.

Proceed by mounting the front wheel

and brake caliper respecting the correct • None
torques and tightening methods.

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