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1. 4 On coil forks the preload adjuster on Manitou forks is located on the top left of the crown as you are looking at the fork from the rider s perspective Turning the knob clockwise increases spring preload and decreases sag while turning the knob counterclockwise decreases spring preload and increases sag 5 On air coil forks remove the air cap located on the top of the left leg and using a dedicated shock pump Manitou part 85 4069 inflate the fork with the desired pressure 75 of rider weight for 80 mm travel forks or 50 of rider weight for 100 mm and above Be aware that sometimes air systems lose a small amount of pressure when the pump is removed so you may want to check exactly how much your pump loses by reinstalling it after you have set and checked pressure 6 If adjusting the preload or air pressure does not provide the proper sag you may require a new ride kit Please see recommended ride kits below TABLE 3 SAG MEASUREMENT Fonte AB 1216 mm 1824 mm 2528 mm REBOUND DAMPING ADJUSTMENT Rebound adjusters on Manitou forks are located on the bottom of the right fork leg Turning the knob clockwise as you are looking at the fork from the bottom increases rebound damping while turning the knob counterclockwise decreases rebound damping RAPID TRAVEL WIND DOWN To change the travel with Rapid Travel Wind Down just turn the knob located at the top of the left leg from a rider s perspective clockwise f
2. ING YOUR BICYCLE YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF PREVIOUS RIDING OR ASSEMBLY DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING CRACKING CREAKING LEAKING OR IF IT IS MISSING ANY OF THE ORIGINALLY SUPPLIED COMPONENTS ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH FOLLOWING THESE INSTRUC TIONS CAN HELP YOU REDUCE THE RISK OF BEING INJURED IF YOU ARE A MOD ERATE OR AGGRESSIVE OFF ROAD RIDER OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN ANSWER RECOMMENDS RETURNING YOUR SUS PENSION FORK EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO ANSWER PRODUCTS OR YOU MAY CALL ANSWER TO HAVE YOUR FORK SHIPPED DIRECTLY AT 800 423 0273 IMPORTANT The Manitou fork is an off road fork and as such does not come with proper reflectors for on road use Have your dealer or mechanic install proper reflectors to meet the Consumer Product Safety Commission s C P S C Requirements for Bicycles if the fork is going to be used on public na m time If you have questions regarding C P S C Standards contact your dealer CONSUMER SAFETY INFORMATION Never remove or have the steerer tube or stanchions removed from the crown The steerer tube and stanchions inner legs are press fit at the factory Press fit inner legs have higher performance versus bolt in inner leg
3. SEE TABLE 1 FOR MINIMUM BRAKE ARCH CLEARANCE 2 MEASURE THE TIRE AT MAXIMUM WIDTH SEE FIGURE B SEE TABLE 1 FOR MAXIMUM TIRE WIDTH A TABLE 1 WHEEL CLEARANCE MINIMUM BRAKE ARCH CLEAR ANCE See Figure A See Figure B IMPORTANT Failure to properly route and securely attach the front brake cable to the fork can cause serious injury or death This fork should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replacement parts MAXIMUM TIRE WIDTH INITIAL SET UP MEASURING TRAVEL To determine which travel your fork is in simply measure the distance from the top of the seal area on the lowers or the bottom of the fork boot to the bottom of the crown See Table 2 to determine travel TABLE 2 TRAVEL MEASUREMENT Around T01 mm MEASURING SAG You ll need a tape measure a pencil a piece of paper and a helper 1 Measure the distance from the front axle s centerline to the bottom of the upper crown when no one s sitting on the bike and write this distance down Remember the exact locations of the two points because you ll need to use them later 2 Have the rider sit on the bike and measure the distance between the same two points as in step one It s important to be in the normal riding position weight centered with your feet on the pedals 3 Subtract the second measurement from the first The resulting measurement is the static sag See Table 3
4. 0 hours total riding time Prior to break in you may notice your fork feels tight and slight ly notchy Following the break in period your fork will feel much smoother and will react to bumps much better than when you first put it on your bike After 20 hours you may want to recheck adjustments where applicable to fine tune the fork completely FORK INSTALLATION 1 Remove the old fork from your bicycle 2 Measure and cut the steerer tube to fit your bicycle head tube see WARNING oe You can use your old fork as a guide for cutting the steerer tube ength 3 Remove the headset crown race from the old fork Install headset and fork per headset manufacturer s instructions 5 Install the handlebars and stem to the stem and handlebar manufacturer s instructions 6 Install the brakes per the brake manufacturer s instructions 7 To install the front wheel adjust the front wheel quick release to clear the sec ondary dropout safety tabs Secure wheel per quick release manufacturer s instructions 8 Install the brake cable per brake manufacturer instructions Ensure that the front brake cable is properly routed Make sure the brake line is not crimped or contacts the tire as the fork moves through its travel ANNO WHEN INSTALLING THE WHEEL WITH A PROPERLY INFLAT ED TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE 1 MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM OF THE BRAKE ARCH SEE FIGURE A
5. P N 042115 manitou 2004 OWNERS MANUAL Black Super Air Black Elite Black Comp Black Platinum 28209 Avenue Stanford Valencia California 91355 661 257 4411 fax 661 294 4179 vvvvvv ansvverproducts com MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE A 2004 MANITOU FORK This fork is fully assembled and ready to be installed onto your bicycle It comes equipped with a 1 s inch threadless steerer tube and may also be available in a disc brake only version A handlebar mounted reflector must be used for on road use which is not included with your fork 2004 MANITOU BLACK FORK LINE BLACK COMP 100 OR 120 MM TRAVEL COIL SPRING FLUID FLOW DAMPING SINGLE CROWN RA CASTING BLACK ELITE 100 OR 120 MM TRAVEL COIL SPRING FLUID FLOW ene REBOUND ADJUST SINGLE CROWN RA ASTIN BLACK SUPER AIR 80 100 OR 120 MM TRAVEL AIR SPRING FLUID FLOW DAMPING REBOUND ADJUST SINGLE CROWN RA CASTING BLACK PLATINUM 90 120 MM RAPID TRAVEL WIND DOWN re TPC LOCK OUT SINGLE CROWN RA You can also download this manual at www answerproducts com A ANA IA AN UNER BICYCLING IS A HAZARDOUS ACTIVITY THAT REQUIRES THAT THE RIDER STAY IN CONTROL OF HIS OR HER BICYCLE AT ALL TIMES READING THIS MANUAL ENTIRELY AND PROPERLY MAINTAINING YOUR BICYCLE AND SUSPENSION FORK WILL REDUCE THE POSSIBILITY OF INJURY OR POSSIBLE DEATH PRIOR TO RID
6. been subject to misuse or whose serial number has been altered defaced or removed This warranty does not cover paint damage Any modifications made by the user will render the warranty null and void This warranty is expressly in lieu of all other warranties and any implied are limited in duration to the same duration as the expressed warranty herein Answer Products Shall not be liable for any incidental or consequential damages If for any reason warranty work is necessary return the fork with original purchase receipt to the place of purchase At that time instructions for repair return or replacement shall be given Customers in countries other than USA should contact their dealer or local distributor INSTALLATION INSTRUCTIONS The steerer tube may need to be cut to length to fit your bicycle head tube If you are not familiar with this procedure or do not have the proper tools to cut the Steerer tube it is recommended that you seek a dealer with a qualified bicycle mechanic to perform installation A NIE THE STEERER TUBE AND STANCHIONS INNER LEGS ARE A ONE TIME PRECISION PRESS FIT AT THE FACTORY AND CANNOT BE REMOVED FROM THE CROWN REPLACEMENT OF THE ENTIRE CROWN STEERER ASSEMBLY MUST BE DONE TO INCREASE STEERER TUBE LENGTHS OR CHANGE DIAMETERS REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD BREAK IN Your new fork is designed to break in during your first few rides about 2
7. er Air 100 mm Rebound Damping Assembly BLACK Elite Super Air Platinum 120 mm Rebound Damping Assembly BLACK Super Air 80 mm Rebound Damping Assembly 04 BLACK Pre Load Adjuster Assembly 85 4837 BLACK Comp Elite Preload Adjuster Assembly 04 BLACK Air Cap Assemblies 85 5803 BLACK Super Air Air Cap Assembly 85 5304 BLACK Platinum Air Cap Assembly 04 BLACK Crown Steer Leg Assemblies 26 BLACK Comp Elite Crown Steer Assembly Steel 26 BLACK Super Air 80 mm Crown Steer Assembly Blk Alloy 26 BLACK Super Air 100 mm Crown Steer Assembly Blk Alloy BLACK Super Air 120 mm Crown Steer Assembly Blk Alloy BLACK Platinum Crown Steer Assembly Blk Alloy BLACK Comp Elite 100 mm Crown Steer Assembly Blk Alloy SPV BLACK Comp Elite Platinum 120 mm Crown Steer Assembly Blk Alloy SPV y acts Super Air 80 mm Crown Steer Assembly Blk Alloy SPV BLACK Super Air 100 mm Crown Steer Assembly Blk Alloy SPV i wi Super Air 120 mm Crown Steer Assembly Blk Alloy SPV Black Outer Leg Assembly Black Black Outer Leg Assembly Silver Black Outer Leg Assembly Red Normal Conditions Severe Conditions Disassemble fork per Service Manual clean out casting and replace Semi Bath oil every 6 months Service FFD TPC and SPV damping systems by chang ing the damper oil every year Grease spring stack as needed On air fork models check the oil level sitti
8. irm 100 mm IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight per quick release manufacturer s instructions NOTE Forks with standard dropouts are equipped with dropout safety tabs to retain the wheel in the fork in the event the quick release comes loose 2 Wipe the inner legs and clean the fork Check the entire fork for any obvious damage Do not use the fork if any parts are broken bent cracked or you suspect may be damaged 3 Check the headset for proper adjustment per headset manufacturer s instruc tions 4 Ensure that the front brake cable is properly routed and check brake adjust ment CHECKING OIL LEVEL IMPORTANT Setting the proper oil level in your damped suspension fork is critical The damping is located in the right leg of your fork Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel and may cause damage to the system and create an unsafe riding condition Finish reading this entire section prior to altering the oil level BLACK Super Air Ride Kit Firm 120 mm BLACK Platinum Ride Kit Firm BLACK Comp Elite Ride Kit X Firm 100 mm 190 lbs amp above BLACK Comp Elite Ride Kit X Firm 120 mm 190 lbs amp above BLACK Super Air Ride Kit X Firm 80 mm 190 Ibs amp above To check the oil level remove the compression assembly located in the top of the right leg as you are looking a
9. ng on top of the air piston every 2 months per directions found on web site Disassemble fork per Service Manual clean out casting and replace Semi Bath oil every 4 months Service FFD TPC and SPV damping systems by chang ing the damper oil every year Grease spring stack as needed On air fork models check the oil level sitting on top of the air piston every 6 weeks per directions found on web site Disassemble fork per Service Manual clean out casting and replace Semi Bath oil every 4 months Service FFD TPC and SPV damping systems by chang ing the damper oil every year Grease spring stack as needed On air fork models check the oil level sitting on top of the air piston every 6 weeks per directions found on web site Disassemble fork per Service Manual clean out casting and replace Semi Bath oil every 3 months Service FFD TPC and SPV damping systems by chang ing the damper oil every year Grease spring stack as needed On air fork models check the oil level sitting on top of the air piston every 4 weeks per directions found on web site Black Outer Leg Assembly White Black Outer Leg Assembly Black No Boss Black Outer Leg Assembly Silver No Boss Black Outer Leg Assembly Red No Boss Black Outer Leg Assembly White No Boss BLACK Comp Sticker Kit Silver BLACK Comp Sticker Kit Black BLACK Elite Sticker Kit Silver BLACK Elite Sticker Kit Black BLACK S
10. or shorter travel and counterclockwise for longer travel There is a dial indicator to determine the travel you are in The number that is right side up from the rider s perspective at the back of the fork crown indicates your current travel setting Do not attempt to activate this travel adjust feature while riding COMPRESSION DAMPING ADJUSTMENT TPC LOCKOUT For TPC with lockout forks a simple turn of the knob located on top of the right leg is all that is needed to add compression damping and activate the lockout Turning the knob clockwise as you are looking from a rider s position increases compression damping and activates the lockout while turning the knob counter clockwise decreases compression damping and deactivates the lockout The last 1 2 turn of the knob activates the lockout while the initial part of the knob s travel increases or decreases compression damping SPV DAMPING ADJUSTMENT With SPV damping your suspension s compression damping characteristics and position sensitivity can be set with an SPV pump Manitou part 85 4161 For proper function of your SPV damping system use the following procedure 1 Start by removing the red air cap located on the top of the right leg from the rider s perspective and using a dedicated SPV pump Manitou part 85 4161 inflate the fork to 50 psi 2 Check sag per procedure above 3 Adjust SPV pressure More pressure will create more compression damping hold
11. s but can not be pressed out Pressing them out will permanently damage the crown beyond repair and render it unsafe for any continued use Never attempt to thread a threadless Steerer tube Cutting threads will weaken the steerer tube and cause an unsafe condition The only safe thing to do is to obtain the proper crown steerer from your dealer or contact Answer Customer Service at 800 423 0273 Any other alteration or modification to your fork should be considered unsafe Contact Answer Customer Service prior to modifying your fork in any way for safety infor mation Do not use the fork if any parts are broken bent cracked or you suspect may be damaged Contact your dealer or Answer Products Customer Service at 800 423 0273 if you have any questions concerning the integrity or condition of your fork Answer Products recommends that you periodically inspect your fork for wear and damage Inspect the crown inner legs outer legs dropouts and brake arch areas for cracks or damage WARRANTY INFORMATION Any Answer Products fork found by the factory to be defective in materials and or workmanship within one year from the date of purchase or two years in EU coun tries will be repaired or replaced at the option of the manufacturer free of charge when received at the factory freight prepaid This warranty does not cover break age bending or damage that may result from crashes or falls This warranty does not cover any fork that has
12. t the fork from the rider s position Leave the left Side spring stack in place to keep the fork fully extended Use a tape measure or dip stick to measure from the top of the fork crown down to where the oil sits Figure C For the correct oil level see Table 4 BLACK Comp Elite Compression Rod Assembly 100 mm BLACK Comp Elite Compression Rod Assembly 120 mm BLACK Super Air Compression Rod Assembly 80 mm BLACK Super Air Compression Rod Assembly 100 mm BLACK Super Air Compression Rod Assembly 120 mm BLACK Platinum Compression Rod Assembly 90 120 mm WD BLACK Super Air Push Rod Assembly 80 mm BLACK Super Air Push Rod Assembly 100 mm BLACK Super Air Push Rod Assembly 120 mm TABLE 4 OIL LEVEL HEIGHT FORK MODEL OIL LEVEL 110 120 mm 4 33 4 72 BLACK NOTE Use SAE 5WT suspension fork oil only If you have any questions regarding your 2004 Manitou suspension fork in the U S contact the Answer Customer Service Department at 800 423 0273 For information outside of the U S contact your authorized Manitou dealer or distrib utor You can also log on to www answerproducts com and download this manual or see detailed instructions on how to service your suspension fork
13. the bike up more and pedal better Less pressure will create less com pression damping allow more sag and be more responsive and supple Do not run SPV pressure below 30 psi or above 100 psi 4 Adjust SPV volume With a 16 mm socket wrench or the SPV 16 mm volume adjust socket part 85 3007 you can adjust the air volume in your SPV Suspension The volume adjust hex is colored red and located on top of the right leg Turning the volume adjuster inwards will create a more progressive damping effect and make the suspension firmer from mid stroke to bottom out Turning the volume adjuster outwards will make the suspension more linear in compression damping and have a softer finish Refer to the website for specific tuning information about your SPV suspension MAINTENANCE Your fork requires periodic maintenance cleaning and inspection This is because moisture and contamination may build up inside the fork depending on the severity of riding conditions To maintain top performance it is recommended that the fork be periodically disassembled cleaned dried and re lubricated You can download service and tuning instructions on the web at www answerprod ucts com SUGGESTED SERVICE INTERVALS FOR BLACK FORKS 04 BLACK SERVICE PART KITS BLACK Comp Elite Super Air Compression Damping Assembly BLACK Platinum Compression Damping Assembly BLACK Comp 100 mm Rebound Damping Assembly BLACK Comp 120 mm Rebound Damping Assembly BLACK Elite Sup
14. uper Air Sticker Kit Silver BLACK Super Air Sticker Kit Black BLACK Platinum Sticker Kit Silver BLACK Platinum Sticker Kit Black BLACK Comp Elite Knob Kit BLACK Super Air Knob Kit BLACK Platinum Knob Kit BLACK Minute Seal Kit Air Piston Kit BLACK Bumper Kit BLACK O Ring Kit End Cap Assembly Left Leg BLACK Elite Super Air Platinum SPV Assembly 130 Ibs amp below 130 Ibs amp below 130 Ibs amp below 130 150 Ibs 130 150 Ibs 130 150 Ibs 130 150 Ibs 130 150 Ibs 130 150 Ibs 150 170 Ibs 150 170 Ibs 150 170 Ibs 150 170 Ibs 150 170 Ibs 150 170 Ibs 170 190 Ibs 170 190 Ibs 170 190 Ibs 170 190 Ibs 170 190 Ibs 170 190 Ibs BLACK Comp Elite Ride Kit X Soft 100 mm BLACK Comp Elite Ride Kit X Soft 120 mm BLACK Super Air Ride Kit X Soft 80 mm BLACK Comp Elite Ride Kit Soft 100 mm BLACK Comp Elite Ride Kit Soft 120 mm BLACK Super Air Ride Kit Soft 80 mm BLACK Super Air Ride Kit Soft 100 mm BLACK Super Air Ride Kit Soft 120 mm BLACK Platinum Ride Kit Soft BLACK Comp Elite Ride Kit Medium 100 mm BLACK Comp Elite Ride Kit Medium 120 mm BLACK Super Air Ride Rit Medium 80 mm BLACK Super Air Ride Kit Medium 100 mm BLACK Super Air Ride Kit Medium 120 mm BLACK Platinum Ride Kit Medium BLACK Comp Elite Ride Kit Firm 100 mm BLACK Comp Elite Ride Kit Firm 120 mm BLACK Super Air Ride Kit Firm 80 mm BLACK Super Air Ride Kit F

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