082311-XF-2012 owners manual.indd
Contents
1. e USON dm a E OWNERS MANULUAI Intro Congratulations on the purchase of your new X Fusion suspension X Fusion prides itself on manufacturing high end mountain bike suspension All of our products are made with the highest quality parts and backed by extensive R amp D and ride testing These products are derived from the passion we have for designing and riding the best bicycle suspension products available Before you go out to share our common passion please read this manual carefully It will provide you with important infor mation regarding installation use care 8 maintenance and the warranty for your new suspension Fork and Shock Controls The controls on X Fusion bicycle forks and rear shocks consist of the following Anodized red knobs REBOUND ADJUSTMENT Anodized blue knobs LOW SPEED COMPRESSION ADJUSTMENT Anodized blue knobs RL products LOCKOUT ADJUSTMENT Anodized gold knobs HIGH SPEED COMPRESSION ADJUSTMENT Dirt jumping Dirt jumping is a particularly extreme form of riding that involves jumping from one obstacle to another Because of the abusive nature of dirt jumping there is no fork that been proven to be impervious to the forces created by dirt jumping As a result using any suspension product for this form of riding requires the user to take extra precautions including but not limited to constant inspection of product for potential damage caused by this extreme use as well as frequent insp2. Fusion s Manufacturer Warranty Guarantee X Fusion provides a 24 month warranty on all suspension products to cover defects in materials and or workmanship This warranty only applies to the original owner and is not transferable To make a warranty claim you must provide proof of purchase within the 24 month warranty period The warranty period begins the date of purchase and will expire exactly 24 months later The acceptance of a warranty claim during the 24 month period is up to the discre tion of X Fusion or any Authorized Service Center acting on its behalf X Fusion or its agents will determine if the failure is due to workmanship defects in materials or product abuse The warranty guarantee will be void if the buyer does not inform the seller of the damage after its discovery within 60 days X Fusion and its agents reserve the right to all final warranty or non warranty claims To maintain valid the general guarantee conditions for all X Fusion shocks it is absolutely necessary that the buyer executes the periodical maintenance and that cleaning and maintenance are carried out according to the maintenance chart within the owners manual Limitations of Warranty General Exclusions from this warranty shall include but are not limited to any failures caused by Installation of parts or accessories that are not qualitatively equivalent to genuine X Fusion parts Abnormal strain neglect abuse and or misuse Accident or colli
3. TEL 41 34 422 47 11 FAX 41 34 422 47 12 info riders elements ch www riders elements ch Taiwan Iron Stable No 260 Kuang Cheng Lane Nei Tung Road Houli Shiang Taichung Country Taiwan TEL 04 25575422 FAX 04 25567528 contact ironstable com tw www ironstable com tw United Kingdom Upgrade Bikes LTD 23 Star Road Partridge Green West Sussex RH13 8RA United Kingdom TEL 44 0 1403 711 611 FAX 44 0 1403 710 753 Info Upgradebikes co uk http www upgradebikes co uk index html Ag SS WWW XFUISIONSHOX con
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5. Do not allow the cable to come in contact with the front wheel tire or other moving parts of the bicycle To confirm the cable is safely routed have a qualified bicycle technician inspect your bicycle Improper cable installation can result in SERIOUS INJURY OR DEATH Use the following procedure for installing the X Fusion Remote Lockout lever for X Fusion remote fork or rear shock products With a3 mm hex key wrench loosen the handlebar clamp bolt on the under side of the X Fusion Remote Lockout lever assembly Remove the left or right hand grip from the handlebar given which configuration you prefer Slide the assembly onto the handlebar Be sure 1 the lockout release button is facing inwards towards the rider and 2 the cable adjusting barrel is pointing towards the center of the bike above the hand brake lever assembly These setup criteria are true for either the left or right hand setup configuration Re install the handlebar grip Position the assembly so that it abuts the inner end of the grip Be sure the grip does not interfere with the normal operation of the lockout release button Push the actuation lever down to its locked out position Rotate the assembly into position so the actuation lever in its locked out position does not interfere with normal thumb operation of the rear derailleur shifter With a3 mm hex key wrench tighten the handlebar clamp bolt to seven 7 in Ib 0 80 Nm torque Press the release button
6. X Fusion fork onto your bicycle If you have any doubt whether or not you can properly install your fork then do not attempt it Improperly installed forks can fail causing the rider to lose control resulting in SERIOUS INJURY OR DEATH WARNING Never use more than 30 mm of height of steerer stem spacers under the steerer stem as this condition can cause the steerer tube to fail prematurely causing a loss of control resulting in SERIOUS INJURY OR DEATH Remove the original fork from the bicycle Measure the X Fusion fork steerer tube against the length of the original to confirm whether you need to cut the X Fusion fork steerer tube CAUTION Prior to any cutting consult your headset and stem manufacture s instructions to ensure that you have enough steerer tube length for clamping the steerer Do not notch cut mark or otherwise damage any part of the steerer tube below the cut area as this can cause the steeerer tube to fail causing SERIOUS INJURY OR DEATH Cutting Steerer Tubes Prior to cutting the steerer tube refer to your stem manufacture s instructions to ensure that you will have enough steerer tube length for clamping the steerer Mark the steerer tube accordingly and cut it to proper length WARNING If the steerer tube has any nicks or gouges the crown steerer tube assembly must be replaced A nick or gouge can cause the steerer tube to fail prematurely result ing in a loss of control of the bicycle and SERIOUS I
7. front wheel tire or other moving parts of the bicycle To confirm the cable is safely routed have a qualified bicycle technician inspect your bicycle Improper brake cable installation can result in SERIOUS INJURY OR DEATH Tighten the disc brake hose guide screw with a hex key wrench to 8 in Ib 0 90 Nm torque CAUTION Cable housing contacting the fork crown will cause abrasion damage to the crown over time If contact is unavoidable use vinyl tape or similar protection to cover the point of contact The X Fusion warranty does not cover abrasion damage to the X Fusion fork crown CAUTION If your fork loses oil tops or bottoms out excessively or makes unusual noises immediately contact X Fusion Shox or an Authorized X Fusion Shox Service Center for an inspection or repair service CAUTION Never use a power washer to clean your X Fusion fork 9 Installing X 15 and X 20 Axles Position your front wheel without the X 15 or X 20 axle into the dropouts of the lower fork leg Position the brake rotor between the brake pads of the disc caliper as you seat the hub shoulders squarely and firmly into the dropout counterbores WARNING As dirt and debris can accumulate between the fork axle openings always check and clean these areas before installing the wheel Improper hub and axle installa tion can result with SERIOUS INJURY OR DEATH Insert the X 15 or X 20 axle into the fork dropout and slide it all the way through th
8. tilts on or falls from a bicycle carrier do not ride it until it is examined by a qualified bicycle service technician Authorized Service Center or by X Fusion Shox A structurally damaged fork leg or a dropout failure can cause a loss of control resulting in SERIOUS INJURY OR DEATH WARNING When using a quick release mechanism to secure the front wheel into the X Fusion fork that is equipped with a disc brake system and open dropouts be sure that you adjust the quick release mechanism properly before closing it A maladjusted quick release mechanism can lead to the front wheel suddenly separating from the bicycle at any time including and especially when the front brake is applied Front wheel separation during a ride can result in SERIOUS INJURY OR DEATH Please follow the manufacturer s recommended instructions for installation of the wheel securing device WARNING Never attempt to pull apart open disassemble or service a X Fusion rear shock that is in a stuck down condition A stuck down condition results from a failure of the dynamic air seal located between the positive and negative air chambers within the shock air sleeve resulting with the negative chamber retaining a higher air pressure than the positive chamber To test whether the shock is in fact stuck down Remove the air cap and depress the Schrader valve to completely release air pressure from the positive air chamber of the shock If the shoc
9. to return the assembly to its unlocked state 11 Installing X Fusion Rear Shocks Air rear shock maximum air pressure 300 psi 20 68 bar Air rear shock minimum air pressure 60 psi 4 14 bar WARNING Rear shock setup and configuration varies greatly between different bicycle manu facturers Be sure to refer to the owner s manual for your bicycle It is extremely advisable to have a qualified bicycle service technician install your new X Fusion rear shock on your bicycle Improperly installed rear shocks can fail causing the rider to lose control resulting in SERIOUS INJURY OR DEATH CAUTION Before riding be sure the shock mount bolts on your X Fusion air or coil rear shocks are tightened to your bicycle manufacturer s torque specification CAUTION If your bike is outfitted with a X Fusion Vector or Vector Air model shock never ride with the rear shock reservoir air chamber with less than 180 psi or more than 300 psi of air pressure Doing so can damage your X Fusion Vector or Vector Air shock requiring repairs not covered by the warranty CAUTION If your X Fusion rear shock loses oil tops or bottoms out excessively or makes unusual noises immediately contact X Fusion Shox or an Authorized X Fusion Shox Service Center for an inspection or repair service CAUTION Never use a power washer to clean your X Fusion rear shock 12 Service Centers USA X Fusion Service Center 2400 Chanticleer Ave Suite F Santa
10. 603 33431050 yeann senaik com www senaik com New Zealand KRD Imports Unit 2 42 Maces Road Bromley Christchurch NZ TEL 64 3 3764060 FAX 64 3 3764064 x fusion krdimports co nz www krdimports co nz 13 Philippines Peregrine Marketing E O Perez St Subangdaku North Reclamatioin Mandaue City Cebu Philippine TEL 032 233 0352 sales peregrinebike com Poland Bikershop UL PUSZKARSKA 7 30 644 KRAKOW TEL 48 12 255 99 00 jacek bikershop pl Portugal Soc Comercial do Vouga Lda Joaquim Carvalho Rua Cabede e Lencastre 33 39 3750 177 AGUEDA PORTUGAL TEL 351234601500 FAX 351234601159 carvalho scvouga pt Russia Teammano Co 18 GSK Severniy Signalniy proezd TEL 89162431170 shop teammano ru Singapore Bike Labz Blk 3012 03 2018 Bedok Ind Park E 203 2018 Signapore 489978 TEL 65 64412426 sales bikelabz com www bikelabz com Slovakia Schindler spol s r o Slezska 101 112 747 27 Koberice Czech Republic TEL 606 426 855 FAX 553 657 809 info x fusion cz www x fusion cz South Africa De Wet Sports Prime Park Printers Way Montague Gardens 7441 South Africa TEL 27 21 551 5228 FAX 27 21 551 5229 cycles dewetsports co za www dewetsports co za Spain FunSport Express lt Llull 63 69 bajos 08005 Barcelona TEL 34 93 485 0006 info funsportexpress com www funsportexpress com Switzerland Rider s Elements Lyssachstrasse 108 3400 Burgdorf Schweiz Switzerland
11. Cruz CA 95062 TEL 831 221 5047 FAX 831 536 4731 usinfo x fusion shox com www xfusionshox com Argentina VOUGA S A Agustin de Vedia 3344 Capital Federal Buenos Aires TEL 541149180008 FAX 541149180008 felipe vouga com ar www vouga com ar Australia DIY MTB 20 BAY STREET CALLALA BAY NSW 2540 Australia TEL 61 2 4446 4636 FAX 61 2 4446 4731 dm diymtb com au www diymtb com au IMP COM E SERV LTDA Rua Carneiro Da Cunha 872 Sao Paulo SP 04144 001 TEL 11 5587 3662 FAX 11 5587 3662 Scitex scitex com br www scitex com br Bulgaria Velomania Ltd Gueshevo Street 83 1330 Sofia TEL 00359 2 812 70 60 FAX 00359 2 812 70 61 info velomania bg com www velomania bg com Canada Rendgade Cycle Solutions 765 Malone Rd Ladysmith BC V9G 1N1 TEL 250 483 6677 info r c s ca www r c S ca China ADURA BIKE No 7 Xiangyang 2nd Garden Feihu Rd Ludu Town Taicang City Jiangsu China TEL 86 512 5666 8333 0512 56668333 hill_xtvtk 163 com www adurabikes com Chile BIKEPLANET SL AV IV CENTENARIO 1015 LAS CONDES SANTIAGO TEL 56 9 92261093 FAX 56 2 2171767 rnuno bikeplanet cl Croatia Alan Prim dog Jandriceva 39 10000 Zagreb Croatia Europe TEL 38514673206 FAX 38514673206 alanprim gmail com Czech Republic Schindler spol s r o Slezska 101 112 747 27 Koberice Czech Republic TEL 606 426 855 FAX 553 657 809 info x fusion cz http
12. NJURY OR DEATH Always use a new threadless headset and follow the headset manufacture s instal lation instructions WARNING Never attempt to cut threads into the threadless steerers of X Fusion forks Cutting threads into a threadless steerer can cause the steerer tube to fail prematurely resulting in a loss of control of the bicycle and SERIOUS INJURY OR DEATH Use a 39 8 mm crown race for 1 1 2 steerer tubes and a 29 9 mm crown race for 1 1 8 steerer tubes Install the star nut into the steerer tube in accordance with the star nut manufacture s installation instructions WARNING Never attempt to remove or replace the steerer or upper tubes independently from the crown Modifying the integrated crown steerer or upper tubes can cause an assembly failure resulting in a loss of control of the bicycle and SERIOUS INJURY OR DEATH 8 For Single Crown Steerer X Fusion Forks Install the headset bearing parts and stem in accordance with the headset manufacture s instructions and adjust the headset preload accordingly until you feel no excessive play or bearing drag Tighten the stem clamping bolts to the stem manufacture s torque specifications at this time Install the brakes according to the brake manufacturer s instructions Route the front disc brake housing to the inside of the lower leg and through the supplied disc brake housing guide WARNING Do not allow disc brake cable to come in contact with the
13. dification voids all warranties and may cause failure of the fork or shock resulting in SERIOUS INJURY OR DEATH WARNING Make sure that your wheels and wheel axles are securely fastened before riding in accordance with the bicycle owner s manual instructions Wheels not properly secured to the bicycle may cause a crash and result in property damage SERIOUS INJURY OR DEATH WARNING Before riding verify that the brakes on your bicycle are installed and adjusted correctly in accordance with the brake manufacturer s instructions Improperly installed and adjusted brakes may cause a crash and result in property damage SERIOUS INJURY OR DEATH WARNING To avoid potential disc brake failure that could result in SERIOUS INJURY OR DEATH the disc brake caliper mounting bolts must 1 always have 10 12 mm of thread engagement with the fork and 2 be kept to the manufacturer s torque specifications In all cases the disc brake caliper mounting bolt tightening torque level must never be less than the manufacturer s torque specification or exceed 90 in Ib torque 3 WARNING If mounting the bicycle in a carrier designed to hold a fork by its dropouts avoid tilting the bicycle to either side to avoid causing structural damage to the fork Be sure your fork is fastened securely with the quick release the 9mm X15 and X20 axle with the bike carrier s thru axle mount and the rear wheel is properly secured If the bicycle ever
14. e hub until you contact the axle nut on the opposite side Thread the X 15 or X 20 axle through the hub and into the opposite fork leg until it becomes firmly snug Using hand strength only rotate the X 15 or X 20 lever to its fully secured position with the palm of your hand Do not use any kind of hand tool to increase leverage The minimum amount of torque to hold the axle in place is 70 inch pounds or 80 kg cm The maximum amount of torque is 100 inch pounds or 115 kg cm To set the X 15 or X20 lever in a safe location unscrew the hex key and place the lever in an non vulnerable position The lever should be positioned between one 1 and twenty 20 mm forward of the fork leg CAUTION Positioning the tightened X 15 or X 20 lever below the fork leg dropout may leave it vulnerable to hitting objects on the trail posing a potential risk of suddenly loosening the axle Position the tightened X 15 or X 20 lever in front of the fork leg as instructed to minimize this risk Remote Lockout Lever Installation WARNING Always use the remote cable holder assembly to secure the Remote fork cable housing to the fork crown Unsecured cable housing can snag and cause a crash resulting in SERIOUS INJURY OR DEATH 10 CAUTION Slightly decrease the tightening torque for carbon handlebars Consult the bicycle or handlebar manufacturer s documentation regarding the appropriate level of tightening torque for carbon handlebars WARNING
15. ections by a qualified bicycle mechanic or X Fusion authorized service center Failure to do so could result in product failure SERIOUS INJURY OR DEATH WARNING DO NOT use X Fusion bicycle suspension products on any motorized bicycle motorized cycle or motorized vehicle or on any vehicle carrying more than one operator or rider such as a tandem bicycle Any such misuse may overload the suspension and result in failure of the suspension Suspension failure may cause a crash and result in property damage SERIOUS INJURY OR DEATH Misuse of X Fusion suspension products voids all X Fusion warranties 2 WARNING X Fusion suspension products contain pressurized nitrogen air or both DO NOT puncture incinerate or crush any portion of aN X Fusion suspension product DO NOT attempt to disassemble any portion of a X Fusion suspension product unless expressly instructed to do so by the applicable X Fusion technical documentation and then ONLY while strictly adhering to all X Fusion instructions and warnings in that instance Failure to do so could result in SERIOUS INJURY OR DEATH WARNING Modification improper service or use of aftermarket replacement parts with X Fusion forks and shocks may cause the product to malfunction resulting in SERIOUS INJURY OR DEATH Do not modify any part of a fork or shock including the fork brace lower leg cross brace crown steerer upper and lower leg tubes or internal parts Any unauthorized mo
16. k body retracts into the air sleeve near bottom out after the air is released from the positive air cham ber attach a X Fusion Shox high pressure hand pump and pressurize the shock to 250 psi 17 bar If the shock does not fully extend it is in a stuck down condi tion WARNING Any improper servicing procedure with X Fusion air shocks in the stuck down condition can lead to SERIOUS INJURY OR DEATH Contact X Fusion Shox or an Authorized Service Center for repair Service Charts Forks Maintenance Clean dirt and debris from stanchion tubes Check air pressure air forks only Inspect upper tubes for scratches and gouges Lubricate dust seals and stanchion tubes Check torque on X Series Axle Clean or replace recommended remote lockout cable and housing Remove lowers clean inspect bushings and change oil bath if necessary Clean and lubricate air spring assembly Change oil in damping system Clean and lubricate coil spring assembly coil forks only Shocks Maintenance Clean dirt and debris from shock body Check air pressure and set sag Check torque on shock mounting bolts Lubricate shock body Remove air canister clean and lubricate Air sleeve maintenance replace seals Full damper system rebuild and oil change Interval Hours Every ride Every ride Every ride Every ride Every ride 25 25 50 100 100 Interval Hours Every ride Every ride Every ride 5 25 50 100 X
17. sion damage Modification or original parts Lack of proper maintenance see maintenance schedule Any attempt to disassemble damper assembly Shipping damages or loss purchase of full value insurance is recommended Damage to interior or exterior caused by improper cable routing seat post rocks crashes or improper installation Oil changes or service not performed by X Fusion Authorized Service Centers Coil bind excessive spring preload three turns maximum 6 Specific exclusions from this warranty include Parts replaced due to normal wear and tear and or routine maintenance Parts subject to normal wear and tear and or routine maintenance Bushings and reducers seals suspension fluids Vector shocks damaged by riding with less then 180psi in the reservoir X Fusion makes no other warranty of any kind expressed or implied All implied warranties of merchantability and fitness for a particular purpose that exceed the obligations and time limits stated in this warranty are hereby disclaimed by X Fusion and excluded from this warranty Installing your X Fusion fork Fork air spring maximum air pressures Velour Enix Slide Trace Velvet 150 PSI 10 34 bar Vengeance 200 PSI 13 78 bar Fork air spring minumum air pressures Velour Enix Slide Trace Velvet 50 PSI 3 4 bar Vengeance 40 PSI 2 75 bar WARNING It is extremely advisable to have a qualified bicycle service technician install your new
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