BOLANY 700C 60mm Travel Air Suspension Fork User Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your BOLANY 700C 60mm Travel Air Suspension Fork. Designed for road bikes, this air fork features 60mm of travel, a manual lock, and a 12x100mm thru-axle system, offering enhanced shock absorption and control for various cycling conditions.

Figure 1: Illustration of the fork's arch design, engineered for improved stability during cycling.

2. Safety Information

Always prioritize safety when installing or maintaining bicycle components. Improper installation or adjustment can lead to serious injury or product damage.

• Ensure all bolts and fasteners are tightened to the manufacturer's recommended torque specifications.
• If you are unsure about any installation or maintenance step, consult a professional bicycle mechanic.
• Regularly inspect the fork for any signs of damage, wear, or loose components before each ride.
• Do not modify the fork's structure or components.

3. Specifications

Figure 2: Key dimensions of the BOLANY 700C Air Suspension Fork. This image illustrates the steerer tube diameter (28.6mm and 39.8mm tapered), steerer tube length (220mm), travel (60mm), axle type (12x100mm), and overall fork length (465mm).

Figure 3: Close-up view of the fork stanchion showing the 60mm travel markings. These markings assist in setting sag and monitoring travel usage.

Figure 4: Detail of the International Standard A-pillar disc brake mount, indicating a 70mm spacing for caliper attachment. This mount is compatible with 160mm disc rotors.

4. Setup and Installation

Proper installation is crucial for the performance and safety of your suspension fork. If you are not experienced with bicycle mechanics, it is recommended to seek professional assistance.

4.1 Pre-Installation Checks

• Verify that the fork's steerer tube length is compatible with your bicycle frame's head tube and stem setup. The steerer tube length is 220mm.
• Ensure your wheelset is 700C and uses a 12x100mm thru-axle.
• Confirm your brake system is an International Standard A-pillar disc brake, compatible with 160mm rotors.

4.2 Installation Steps

1. Prepare the Steerer Tube: Cut the steerer tube to the appropriate length for your frame and stem, leaving enough length for spacers and stem clamp. Deburr the edges.
2. Install Crown Race: Press the crown race onto the base of the steerer tube until it is fully seated against the fork crown.
3. Insert Fork into Frame: Carefully slide the steerer tube through the head tube of your bicycle frame, ensuring all headset bearings and components are correctly oriented.
4. Install Stem and Spacers: Place any necessary headset spacers and your stem onto the steerer tube.
5. Install Top Cap and Bolt: Install the top cap and tighten the compression bolt to preload the headset bearings.
6. Align and Tighten Stem: Align the stem with the front wheel and tighten the stem clamp bolts to the manufacturer's specified torque.
7. Install Front Wheel: Insert your 12x100mm thru-axle front wheel into the fork dropouts and secure the thru-axle firmly.
8. Install Brake Caliper: Mount your disc brake caliper to the A-pillar mounts on the fork leg. Ensure proper alignment with the disc rotor and tighten bolts to specifications.

4.3 Air Pressure Adjustment

The BOLANY fork is an air suspension fork, requiring air pressure adjustment to match rider weight and riding style. An air pump specifically designed for suspension forks is required.

Figure 5: Location of the air valve on the top of the fork leg. Unscrew the cap to access the valve for inflation or deflation. Always use a high-pressure shock pump.

1. Locate the air valve cap on the top of the fork leg (refer to Figure 5). Unscrew and remove the cap.
2. Attach a high-pressure shock pump to the valve.
3. Add or release air pressure gradually until the desired sag is achieved (typically 15-25% of total travel for road/gravel use). Consult your bike manufacturer's recommendations or personal preference.
4. Remove the pump and replace the valve cap to prevent dirt and moisture ingress.

Note: Do not operate the fork without sufficient air pressure. Refer to the fork manufacturer's recommended pressure ranges, usually printed on the fork leg or in supplementary documentation.

5. Operating Instructions

5.1 Manual Lockout Function

The BOLANY suspension fork features a manual lockout mechanism, allowing you to stiffen the fork for efficient climbing or riding on smooth surfaces.

Figure 6: Close-up of the manual lockout dial located on the top of the right fork leg. Rotate the dial to engage or disengage the lockout.

• To Lock the Fork: Rotate the lockout dial clockwise until it stops. This will significantly reduce or eliminate fork travel, providing a more rigid feel.
• To Unlock the Fork: Rotate the lockout dial counter-clockwise until it stops. This will restore full suspension travel.

Note: Avoid engaging or disengaging the lockout while actively riding over rough terrain, as this can damage the mechanism. It is best to adjust the lockout when stationary or on smooth ground.

6. Maintenance

Regular maintenance ensures optimal performance and extends the lifespan of your BOLANY suspension fork.

• Cleaning: After each ride, especially in wet or dusty conditions, clean the stanchions (upper tubes) and seals with a soft cloth and mild soap and water. Avoid high-pressure washing directly at the seals.
• Lubrication: Apply a small amount of suspension-specific lubricant to the stanchions periodically, then cycle the fork a few times to distribute it. Wipe off any excess.
• Inspection: Regularly check for any signs of oil leaks around the seals, scratches on the stanchions, or loose bolts. Inspect the thru-axle for proper tightness.
• Air Pressure Check: Check and adjust air pressure before each ride to ensure proper sag and performance.
• Service Intervals: For internal service (e.g., seal replacement, oil change), consult a professional bicycle mechanic. Service intervals depend on riding frequency and conditions but are typically recommended annually or every 100-200 hours of riding.

7. Troubleshooting

8. Warranty and Support

For warranty information or technical support, please contact BOLANY directly. Keep your proof of purchase for any warranty claims.

Manufacturer: BOLANY

For further assistance, visit the official BOLANY store: BOLANY Store on Amazon