2000 Model Formula Suspension

Parts List

Part #	Qty	Item	Part #	Qty	Item
1	2	Rockshox	18	6	5/16 AN Flat Washers
2	2	Upper A-Arms	19	6	¼ Lock nuts
3	2	Lower A-Arms	20	2	5/16 Lock nuts
4	6	Right Hand Rod Ends	21	2	#10 Aluminum Spacers
5	4	Nylon Washers	22	2	3/8 ID Needle Bearings
6	2	Push Rods	23	2	#10 ID Polished Rods
7	6	10-32 Allen Head Bolts	24	4	Rockers Plates
8	6	#10 Lock Washers	25	2	Needle Bearing Cases
9	6	#10 Flat Washers	26	4	Spherical Bearing Retaining rings
10	8	5/16 Spacers
12	24	¼ Spacers
13	14	¼-28 grade 5 Bolts
14	4	¼ ID Spherical Bearings
15	4	5/16 ID Spherical Bearings
16	2	Left Handed Rod ends
17	28	¼ AN Flat Washers

Table 1: 2000 Model Formula Suspension Parts List

Table 1 is a list of parts. The simple part number assignment can be used to order new parts from your local Formula Suspension dealer.

Required Tools

2 – 7/16 Box End Wrenches

1 – 5/16 Wrench

Inch-pound Torque Wrench (50-230 in-lb range)

1 – 5/16 Socket

2 – ½ Box End Wrenches

5/32 Allen Wrench

1 – 7/16 Socket for the Torque Wrench

1 – ½ Socket for Torque Wrench

Needle Nose Pliers

Flat Head Screw Driver

21mm Lug Wrench

Floor Jack

3/8 Wrench

Caring For Your Formula Suspension

Ride height adjustment

The ride height is adjusted using the pre-load adjusters on the Rock Shox spring/damper units. If the car’s weight is balanced laterally then each of the shocks must have the same pre-load. This means that you have to count the number of turns you make with the pre-load adjusters.

Steps for adjusting ride height:

1. With the intended driver in the car measure the height.

2. Jack up the front of the car until the wheels are just about off of the ground to unload the springs.

3. Tighten or loosen the adjusters both the same amount of turns on each shock.

4. Lower the jack then measure the height.

5. Repeat 1-4 until the height is correct.

Pre-load Adjustment

Maintenance

· The spherical and rod end mounts should be lubricated with lightweight oil prior to each drive. To lubricate them merely squirt the oil on the ball surface.

· Oil in the shocks should be changed manually. Take them to your local bicycle pro shop to get it changed.

· The nitrogen charge in the shocks needs to be check and or recharged annually also. Your local motorcycle shop or bicycle pro shop should do this.

· The bearings in the rockers should be removed cleaned and re-greased regularly.

· If the suspension is ever disassembled, the alignment needs to be checked and the camber needs to be reset.

Disassembly

1. Place the car on a flat, level surface.

2. Place a jack under the front of the car and carefully jack the front of the car up until the wheels are about a quarter of an inch off of the ground.

Bohbb the mechanic

3. Remove the lug nuts and slide the tire off of the car.

5/16 A-arm Bolt

4. Locate the 5/16 a-arm to upright mounting bolt on the underside of the upright.

5. Using a ½ inch wrench remove the 5/16 bolt. This will detach the lower a-arm from the upright. Care should be taken so that the upright doesn’t slide off and fall.

5/16 A-arm Bolt

6. Locate the 5/16 bolt on the top of the upright

7. Remove the 5/16 bolt and lay the upright to the side. Be careful not to bend any of the steering components or crease the brake line, as they will still be attached.

Push Rod

8. Locate the lower and upper push rod jam nuts.

9. Using a 7/16 wrench loosen both of these. Be aware that one of the two nuts will be left handed thread and thus it will have to be loosened the other way. Silver rod ends are right handed. Gold ones are left-handed.

10. Support the bottom A-arm with light pressure with your hand to prevent it from falling. Twist the push rod in the direction that makes it extend in length until the rod ends fall out of it.

11. Using a 5/16 and ½ wrench loosen and remove the bolt for the lower push rod, rod end. Be careful not to lose the spacers.

12. Also remover the bolt for the upper push rod, rod end. Again, keeping track of the spacers.

Rocker Mounting Bolt

13. Locate the rocker mounting bolt.

14. Remove the rocker mount bolt and pull the rocker assembly out of the mount.

Shock Mount bolt.

15. Locate the shock mount bolt.

16. Using a 5/32 Allan wrench and a 3/8 wrench. Loosen then remove the bolt and slide the shock out of the mount.

A-arm Mounting Bolts

17. Locate the A-arm mounting bolts.

Spacers

18. Using two 7/16 wrenches, loosen the mounting bolts, remove them then slide out the ends of the A-arms. Be careful not to lose the spacers.

Bearing Retainer

18. Support the outer A-arm with the outer spherical bearing open below and, using a socket and a hammer tap on the spherical bearing until the retainer ring falls out.

19. Continue to tap until the bearing falls out.

20. To remove the upper inner spherical bearings support the end of the A-arm so there is open space below the spherical bearing and lightly rap on the bearing with a socket until it falls out. It is important that the socket is applying pressure on the outer race of the bearing only.

Jam Nut

21. To remove the rod ends from the lower A-arm, loosen the jam nut and rotate the rod end.

21. Using the 5/32 Allan wrench and a 3/8 wrench remove the rocker plates securing bolt.

Nylon washers

22. Remove the nylon washers from the sides of the bearing case.

23. Remove the polished rod.

24. Then the rocker plates can be separated from the bearing housing.

Reassembly

To reassemble the suspension reverse the assembly process and adhere to the following assembly notes and torque charts:

Assembly Notes

· If the bearing in the rocker is fowled then a new bearing case, bearing and polished rod must be purchased as they are not serviceable and are precision sets.

· All of the bolts must be torqued according to the following torque chart.

· The lock nuts are not reusable. The must be replaced with each removal.

· Before inserting the polished rod into the rocker assembly, make sure to completely remove any dirt and debris from the inside the bearing and bearing case. Then lubricate the needle with standard EP grease.

· Be sure not to scratch the polished rod.

· Install the spherical bearings in the A-arms using a socket and a hammer or preferably a press. Then apply bearing and sleeve Loctite to the retainer and press it into the hole after the bearing. Make sure not to get it on the spherical bearing. Using a chisel and a hammer, peen the edge of the bearing housing just above the retainer to help prevent slipping during Loctite curing (see the following picture).

· Before installing the lower A-arm, the rod ends must be set in their proper positions. The length of each of extensions of the lower A-arm must be set at exactly 21 ¾ of an inch from the center of the spherical bearing and the center of the rod ends. Then the jam nuts must be tightened.

· Needle nose pliers will be needed to assist with installation of the spacers in the A-arm mounts and push rod mounts.

· When reinstalling the push rod, the length must be set. The push rod is not an adjustment. Its’ length must be set to 19.43 inches center of rod end to center of rod end.

· Only adjust the ride height using the pre-load adjustment on the shocks.

· If the suspension has been disassembled in any way then the front end must be realigned and the static camber must be reset.

· Lubricate all of the bearings before driving.

Torque Table

Bolt	Lubricated Torque (in-lbs)	Dry Torque (in-lbs)
Rocker to Shock Bolt	72	120
Rocker to Push Rod Bolt	72	120
Push Rod to A-arm Bolt	72	120
Outer Lower A-arm Bolt	144	230
Outer Upper A-arm Bolt	120	205
Inner A-Arm Bolts	72	120
Rocker to Frame Mount Bolt	35	45
Rocker Plate Retaining Bolt	35	45
Shock to Frame Mount Bolt	35	45

Note: Always use the torque wrench on the nut of a bolt-nut combonation.