OWNER’S MANUAL – MONOSHOCK

Mod.10/12 - Rev-1
Dear Customer,

I would like to thank you for your preference towards our product.
The shock you have purchased is a summary of experience on race tracks in 35 years of development, passion and victories.
Our company owns a highly professional skilled staff who can offer you a complete and personalized service for the product you
purchased.
For a total and safe use of the shock in your possession, we recommend to run the installation from professional staff; we also
recommend a review every 20000 Km or 2 years to maintain the shock’s high performance.
Please note that your damper has been designed and set according to the data you provided when ordering, but we specify that the
proper setup must still be sought by the customer after careful testing and evaluation in order to customize as much as possible the
response of the shock to their needs.

Sincerely,

Katia Persico
Amministratore unico

GENERAL INFORMATIONS

This Gas charged Mono-tube damper is designed primarily for the Race-Motocross industry and offers high performance with low
friction and is manufactured to the highest standards. To operate at the design performance, all disassembly and assembly operations
should be undertaken in a “clean” environment by skilled personnel.
At each stage, parts need to be checked for wear and abrasion and replaced if necessary. Some areas of wear can be detected
externally; others can only be detected internally.
Before embarking upon an internal repair or alteration, read this manual and have ready the required special tools and soft fixtures for
your vice jaws. Information on special tooling can be found at the rear of this manual.
Our technical department will always be happy to discuss and advise our customers; we offer a rebuild service to most specifications.
Contact information can be found at the rear of this manual.
For spare parts – components – rebuild kit and tools consult Extreme Shox or our distributors.
If you require to change the characteristics of the damper by re-valving, we can supply the required parts but would suggest that
returning the damper to Extreme Shox may be the most appropriate route.

GENERAL EXTERNAL MAINTENANCE

External threads:
Most Extreme Shox dampers utilise an adjustable spring platform, or perch, which seats on an external screw thread over the
main tube. This enables the engineer to use different length springs and also the pre-loading of these springs. This thread
must be kept clean and dry to function properly. If greases or lubricants are used, the ingress of dirt can lead to the grease
acting similar to a grinding paste and eventually binding.

Reservoir Gas charge:

All Extreme Shox Dampers use a Gas charge in the reservoir to charge the hydraulic oil to prevent or limit cavitation.
Reservoir pressure must be checked prior to each test or race. Some teams check the pressure each morning. For charging
device see the rear of the manual.
Most dampers with remote reservoir function adequately at 10 to 12 bar. If the damper has no remote reservoir the pressure
should be 14 to 16 Bar (232 PSI).
Use Nitrogen only.
Should you suspect a leaking valve, submersing in water after charging the unit is normal practice. If replacing is required,
remember to de-pressurise the damper before removing and refit using the appropriate torque and loctite.

Shaft inspection:
Monitoring the shaft during its normal life occasionally can be a good preventative maintenance inspection.
Check for wear, scratches, or highly polished zones. A small amount of oil on the shaft is not of great concern. Should the
presence of oil on the shaft persist to leak from the damper, a new seal is required.
 HOW TO ADJUST THE DAMPER
1.1 REBOUND ADJUSTEMENT

To adjust the damper’s rebound follow the instructions below:

1. Fully close the adjuster turning clockwise, as viewed from the top of the adjuster. Do not over tighten the adjuster, as this will
damage the valve face.
2. With the adjuster now closed, this is maximum damping this adjustment offers in this configuration.
3. This fully closed position is termed as 0 (zero). Each hole position is termed a ‘sweep’ or ‘click’. One full revolution usually
incorporates 6 clicks; the maximum soft setting this adjustment gives is 35 clicks. (15 clicks for screw type adjuster)

Do not open more than this as damping can dramatically decrease and eventually lead to leakage through the adjuster system.

4. We suggest a medium setting of 18 clicks as an initial starting point (9 clicks for screw type adjuster). Each initial adjustment there
after being ± 2 clicks.
5. Note: Adjustments have a greater effect as the adjustment system approaches full closed, compared to the softer of the positions.

1.2 TWO-WAY ADJUSTABLE DAMPER – TECH 2

The two-way adjustable damper incorporates the same rebound adjuster system as described on Paragraph 1.1.
In addition to this an extra adjuster is located on the reservoir close to the link to the main body. To adjust the damper’s compression
follow the instructions below:

1. Fully close the adjuster turning clockwise, as viewed from the top of the adjuster. Do not over tighten the adjuster, as this will
damage the valve face.
2. With the adjuster now closed, this is maximum damping this adjustment offers in this configuration.
3. This fully closed position is termed as 0 (zero). Each hole position is termed a ‘sweep’ or ‘click’. One full revolution usually
incorporates 6 clicks; the maximum soft setting this adjustment gives is 15 clicks.

Do not open more than this as damping can dramatically decrease and eventually lead to leakage through the adjuster system.

We suggest a medium setting of 8 clicks as an initial starting point. Each initial adjustment there after being ± 2 clicks.
 1.3 THREE-WAY ADJUSTABLE DAMPER – TECH 3

Tech3R’s compression valve has 2 regulations, which control respectively Low Speed and High Speed flow.
Low Speed: use 5mm allen key.
High Speed: use 15 mm wrench.
To adjust the damper’s compression follow the instructions below:

Both adjustments work following the same orientation:

1. Fully close the adjuster turning clockwise, as viewed from the top of the adjuster. Do not over tighten the adjuster, as this will
damage the valve face.
2. With the adjuster now closed, this is maximum damping this adjustment offers in this configuration.
3. This fully closed position is termed as 0 (zero). Each hole position is termed a ‘sweep’ or ‘click’. One full revolution usually
incorporates 6 clicks; the maximum soft setting this adjustment gives is 14 clicks at High Speed and 22 at Low Speed.

Do not open more than this as damping can dramatically decrease and eventually lead to leakage through the adjuster system.

We suggest a medium setting of 8 clicks as an initial starting point for High Speed and 12 clicks for Low Speed. Each initial adjustment
there after being ± 2 clicks.

1.4 FOUR-WAY ADJUSTABLE DAMPER – TECH 4

Tech4’s compression valve (BLACK) has 2 regulations, which control respectively Low Speed and High Speed flow.
Tech4’s rebound valve (RED) has 2 regulations, which control respectively Low Speed and High Speed flow.
Both adjustments work following the same orientation:
1. Fully close the adjuster turning clockwise, as viewed from the top of the adjuster. Do not over tighten the adjuster, as this will
damage the valve face.
2. With the adjuster now closed, this is maximum damping this adjustment offers in this configuration.
3. This fully closed position is termed as 0 (zero). Each hole position is termed a ‘sweep’ or ‘click’. One full revolution usually
incorporates 6 clicks; the maximum soft setting this adjustment gives is 14 clicks at High Speed and 22 at Low Speed.

Do not open more than this as damping can dramatically decrease and eventually lead to leakage through the adjuster system.

We suggest to start from this setting:

Compression 9 clicks for high speed and 12 clicks for low speed
Rebound 8 clicks for high speed and 11 clicks for low speed

1.5 MECHANICAL SPRING PRELOAD

Situated on the main threaded body just under the spring, termed “Spring Platform Abutment”.
The setting of this abutment does not involve any dedicated tool. Just act with a punch in one of the holes to turn the abutment.

1. Release the Nylon Grub Screw or the Locking Ring.

2. Options hereafter:
a) To increase preload turn the Platform clockwise; each complete turn gives a 2.0 mm increment.
b) To decrease preload turn the Platform counter clockwise; each complete turn gives a 2.0 mm decrement.
3. Tighten Grub Screw or Locking Ring.

The nylon grub screw should never be tight on the damper body threads, otherwise the deformation of the material will
compromise the unscrew of nylon grub. Tighten the grain into the dampers body grooves as shown in figure above.
 1.6 HYDRAULIC SPRING PRELOAD

In case you have purchased the accessory "hydraulic spring preload":

Options hereafter:
a) To increase preload turn the Platform anticlockwise; each complete turn gives a 1.0 mm increment.
b) To decrease preload turn the Platform clockwise; each complete turn gives a 1.0 mm decrement.
c)

1.7 MECHANICAL RIDE HEIGTH ADJUSTMENT

Situated at the bottom of the damper.

1. Release the Lock Nut turning it clockwise.

2. Options hereafter:
a) To increase ride height turn the Eye Support counter clockwise; each complete turn gives a 1.0 mm increment.
b) To decrease ride height the Eye Support clockwise; each complete turn gives a 1.0 mm decrement.
3. Tighten Lock Nut clockwise.

NOTE: do not pass the groove on the main threads!

 CERTIFICATE OF GUARANTEE

Date: ____/____/________ Order N.: _________ Valve Cod.: __________

Dear Customer,
The following Certificate of Guarantee ensures for 2 years from date of purchase its product.
Are guaranteed all components not subject to wear, or damaged due to improper installation, careless handling and failure
to comply with periodic maintenance.
The warranty is void completely when not used genuine parts.
To see all the clauses and exemptions to this certificate, please visit our website
www.extremeshox.com section GARANZIA

Extreme Shox

INFORMATION TO ALL OUR CUSTOMER

We would like to inform you, about some information reference dampers you send us for service:

All the material need to come with a delivery note

In the delivery note need to be written the code of each damper (number printed in the adjuster knob that is in the reservoir ex.
AA9678) and all your reference

You need to let us know on time you need to receive parts back, keeping in mind we need minimum 2 week for servicing; for any
particular request you need to call us in advance

All the dampers need to be clean, if not we will charge you euro 15.00 each damper

You need to take off the dampers springs and all other accessories that don’t need servicing

We would like to inform all the costumers that during the service we will change damper adjustments so it is important that previous
shipment you take care of the existing adjustments position
 WARRANTY BOOKLET
DATE OF PURCHASE: _______________________

COMPRESSION VALVE CODE: ________________________ BIKE MODEL: __________________________________________

1° SERVICE

DATE: ______________________ OPERATOR: __________________________

SPARE PARTS: _____________________________________ NOTE: _____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

STAMP E SIGNATURE

2° SERVICE

DATE: ______________________ OPERATOR: __________________________

SPARE PARTS: _____________________________________ NOTE: _____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

STAMP E SIGNATURE
3° SERVICE

DATE: ______________________ OPERATOR: __________________________

SPARE PARTS: _____________________________________ NOTE: _____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

STAMP E SIGNATURE

4° SERVICE

DATE: ______________________ OPERATOR: __________________________

SPARE PARTS: _____________________________________ NOTE: _____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

STAMP E SIGNATURE

5° SERVICE

DATE: ______________________ OPERATOR: __________________________

SPARE PARTS: _____________________________________ NOTE: _____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

______________________________________ ____________________________________

STAMP E SIGNATURE
 TECHNICAL SPECIFICATIONS

TORQUE FIGURES

ITEM TORQUE N-M LOCTITE

Shaft nut M10 x 1.0 14 (10.5 lbs-ft) None

Schrader Valve & hose fittings 4.5 (40 lbs-ins) Loctite 542 (Hydraulic sealant)

TOOLING SPECIFICATIONS

ITEM SIZE ET TOOL PART No.

Shaft Clamp Ø 14.0 TL0013A-014

Body Clamp Ø M48X2.0 TL0100A-48x2

Body Core Plunger Ø 40.0 TL0096A

Ø 35.0 (tech4) TL0095A

Cover tightening tool Ø 5.0 on 30.0 PCD TL0043+TL0046+TL0042

Piston seal resizing tool Ø 40.0 TL0038-040

Cover seals resizing tool Ø 14.0 TL0064-014

Reservoir piston puller TL0033

Reservoir cap puller Schrader thread TL0034

 EXTREME RACING SHOX
EXTREME BIOMEC SRL
VIA DEL PREGRESSO 23
36020 CASTEGNERO (VI)
P.IVA 03722710245
TEL. 0444/730636 – info@extremeshox.com
www.extremeshox.com