BOLANY Bike Air Fork Instruction Manual

1. Introduction

Thank you for choosing the BOLANY Bike Air Fork. This manual provides essential information for the proper installation, operation, and maintenance of your new suspension fork. Designed for mountain bikes, this air suspension fork features 120mm of travel, 32mm stanchions made from durable 7075 Aluminum Alloy, and a quick-release axle system. Its oil and gas damping system ensures a smooth and controlled ride across various terrains.

2. Specifications

3. Fork Components Overview

Understanding the main components of your BOLANY Air Fork is crucial for proper installation and maintenance. The fork features an integrated, non-removable structure for the steerer tube, crown, and damping inner tube.

Key Components:

• Steerer Tube: Connects the fork to the bicycle frame.
• Fork Crown: Connects the steerer tube to the stanchions.
• 7075 Suspension Inner Tube (Stanchions): The upper, sliding part of the fork, made from high-strength aluminum alloy.
• Fork Legs (Lower Legs): The lower part of the fork that houses the damping system and connects to the wheel axle.
• Damping Cartridge: Controls the compression and rebound of the fork.
• Piston & Oil Chamber Structure: Integral to the oil damping system.
• Air Valve Upper Cap & Air Valve Cap: Used for adjusting air pressure.
• Manual Adjustment Knob: For manual lockout control.
• Lower Leg Bolts: Secure the lower legs.
• Air Chamber Oil Seal: Prevents air and oil leakage.

4. Setup and Installation

4.1. Pre-Installation Check

• Ensure the fork's steerer tube size (Straight Tube 28.6mm) is compatible with your bicycle frame.
• Verify that your wheel's axle size (9x100mm Quick Release) matches the fork.
• Confirm brake compatibility (Disc Brake, default 160mm rotor; 180/203mm rotors require an adapter).
• Inspect the fork for any visible damage from shipping.

4.2. Installation Steps

1. Prepare the Frame: Remove your old fork. Clean the head tube and ensure it is free of debris.
2. Install Crown Race: Press the crown race onto the steerer tube until it seats firmly against the fork crown.
3. Insert Fork: Slide the steerer tube through the head tube of your bicycle frame.
4. Install Headset Components: Place the headset bearings, compression ring, and spacers onto the steerer tube.
5. Install Stem: Mount your stem onto the steerer tube. Ensure proper alignment.
6. Cut Steerer Tube (if necessary): Mark the steerer tube at the desired height (typically 2-3mm below the top of the stem or top spacer). Carefully cut the steerer tube using a hacksaw and a cutting guide. Deburr the edges.
7. Install Top Cap and Bolt: Place the top cap and insert the compression bolt. Tighten the bolt to remove play from the headset, then tighten the stem bolts to secure the fork.
8. Install Front Wheel: Insert the front wheel into the fork dropouts, ensuring the quick-release skewer is properly secured.
9. Install Brake Caliper: Mount your disc brake caliper to the fork's brake mounts. Ensure proper alignment and torque the bolts to manufacturer specifications.

4.3. Initial Air Pressure Adjustment

The air spring pressure needs to be set according to your weight and riding style. The maximum air pressure is approximately 120 PSI. Use a high-pressure shock pump (not included) to adjust the air pressure via the Adjustable Air Valve located on the top of one of the stanchions.

5. Operating Your BOLANY Air Fork

5.1. Air Damping System

The BOLANY Air Fork utilizes an air + oil damping system, providing smooth, controlled shock absorption on all terrains. This system is designed to deliver stable support, reduce frame vibration, and improve handling on both smooth roads and rough trails.

5.2. Lockout System

Your fork is equipped with a Crown Lockout system, allowing you to easily switch the fork mode to match the terrain. This is ideal for multiple riding scenarios:

• Open Mode: Provides full suspension travel for absorbing bumps and maintaining traction on rough trails.
• Locked Mode: Stiffens the fork, making it more efficient for climbing or riding on smooth surfaces by preventing energy loss from suspension movement.

Note: Some models may feature a Remote Lockout (RL) instead of a Manual Lockout (ML). Ensure you confirm your model before purchasing. The video below demonstrates the lockout function.

5.3. Cable Management

The fork includes a cable management clamp to keep brake and shift cables tidy, preventing shaking and friction during rides.

6. Maintenance

6.1. Cleaning

• After each ride, especially in wet or dusty conditions, wipe down the stanchions and seals with a clean, soft cloth.
• Use mild soap and water to clean the exterior of the fork. Avoid high-pressure washers directly on seals.
• Do not use harsh chemicals or solvents, as they can damage seals and finishes.

6.2. Inspection

• Regularly check for any signs of oil leakage around the seals.
• Inspect the stanchions for scratches or damage. The 7075 Aluminum Alloy stanchions are designed for high strength and scratch resistance.
• Ensure all bolts, especially those for the brake caliper and quick release, are tightened to the correct torque specifications.
• Check for any play in the headset or fork bushings.

6.3. Bushings

The fork uses Teflon + Sponge Bushings, which are designed to reduce friction, provide smoother performance, and improve sensitivity and stability. These bushings require minimal maintenance but should be inspected during regular service intervals.

6.4. Long-Term Durability

The BOLANY fork features 7075 Aluminum Alloy inner tubes, which offer superior strength, oxidation resistance, and color retention compared to standard 6061 aluminum. This material is scratch-resistant, impact-resistant, and has high hardness, ensuring long-lasting performance and appearance.

7. Troubleshooting

7.1. Fork Not Moving Smoothly

• Check Air Pressure: Ensure the air pressure is set correctly for your weight. Too low pressure can cause bottoming out, too high can make it stiff.
• Inspect Stanchions: Look for dirt, grime, or scratches on the stanchions. Clean thoroughly.
• Lubrication: Apply a small amount of suspension-specific lubricant to the stanchions and cycle the fork a few times.

7.2. Loss of Air Pressure

• Check Air Valve Cap: Ensure the air valve cap is securely tightened.
• Inspect Air Valve Core: The valve core might be loose or damaged. Tighten or replace if necessary.
• Seal Integrity: Persistent air loss may indicate a damaged air chamber oil seal. Professional service is recommended.

7.3. Lockout Not Engaging/Disengaging

• Check Knob Position: Ensure the lockout knob is fully turned to the 'LOCK' or 'OPEN' position.
• Internal Issue: If the mechanism feels loose or unresponsive, there might be an internal issue with the lockout cartridge. Seek professional assistance.

8. User Tips

No specific user tips from reviews or Q&A were provided for this product. However, general tips for air forks include:

• Regular Air Pressure Checks: Air pressure can fluctuate with temperature changes. Check your fork's air pressure before each ride for optimal performance.
• Sag Setting: Properly setting your sag (the amount the fork compresses under your body weight) is crucial for effective suspension. Aim for 15-25% sag for trail riding.
• Break-in Period: New forks may feel a bit stiff initially. A short break-in period (a few rides) will allow the seals and bushings to settle, improving smoothness.
• Clean Stanchions: Always keep the stanchions clean to prevent dirt from entering the seals, which can cause premature wear and performance issues.

9. Warranty and Support

For warranty information, technical support, or service inquiries, please contact the BOLANY Official Store or your authorized dealer. Keep your proof of purchase for any warranty claims. This product is manufactured in Mainland China.