Manitou 2002 Mars Comp Coil, Elite Diva & Super Service Manual
Contents
1. ENGLISH MFIANNTA KR ALY E R 5S COMPCOIL ELITE DIVA SUPER e Betriebsanleitung Manual del usuario Manuel de l utilisateur e Manuale del proprietario e Handleiding Manual do propriet rio A A7 AV aF I E P N 042036 answerproducts 28209 Avenue Stanford Valencia California 91355 3984 661 257 4411 fax 661 294 4179 AMERICAN MADE MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE A 2002 MANITOU MARS FORK BUILT IN THE USA This MARS fork is fully assembled and is ready to be installed onto your bicycle It comes equipped with a 1 1 8 inch threadless steerer tube and is available with a V brake style hanger less arch or a disc brake only version 2002 MANITOU MARS FORK LINE MARS COMP COIL 80 MM TRAVEL COIL SPRING TPC DAMPING HOLLOW CROWN MARS ELITE eissa 80 MM TRAVEL AIR COIL SPRING TPC DAMPING HOLLOW CROWN MARS SUPER 80 MM TRAVEL AIR COIL SPRING LOCKOUT TPC DAMPING HOLLOW CROWN MARS DIVA eee 80 MM TRAVEL AIR COIL SPRING LOCKOUT TPC DAMPING HOLLOW CROWN You can also download this manual at www answerproducts com A eyo a2 VER VeININ eR 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 T2. 19 95 price Call Answer Products at 661 257 4411 to order or visit the website at www answerproducts com Boot Kit 85 4839
3. CANNOT BE REMOVED FROM THE CROWN REPLACEMENT OF THE ENTIRE CROWN STEERER ASSEMBLY MUST BE DONE TO CHANGE STEERER TUBE LENGTHS OR DIAMETERS REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE BREAK IN Your new fork is designed to break in during your first few rides about 20 hours total riding time Prior to break in you may notice your fork feels tight and slightly 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 your compression rebound and preload adjustments when applicable to fine tune the fork completely Between services on your Manitou fork all you must do is lubricate your fork as needed with Manitou Prep M part number 85 3810 for the lube and 85 3812 for the gun via the Microlube ports located on the back of the fork legs FORK INSTALLATION 1 Remove the old fork from your bicycle Measure and cut the steerer tube to fit your bicycle head tube You can use your old fork as a guide for cutting the steerer tube length Remove the headset crown race from the old fork and press onto the MARS steerer until the race is seated over the crown Clean and grease the headset bearings and races Install the lower bearings if applicable on fork crown race Insert the steerer tube into the head tube of the frame Install the
4. 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 To check the oil level on a Manitou MARS fork remove the compression assem bly located in the top of the right leg as you are looking at 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 see figure 2 The oil level for the Manitou MARS should be per following table FORK MODEL OIL LEVEL MARS Comp Coil 101 mm 127 mm 4 5 inches MARS Elite 95 mm 108 mm 3 75 4 25 inches MARS Super 89 mm 102 mm 3 5 4 inches MARS Diva 89 mm 102 mm 3 5 4 inches NOTE Use Maxima SAE 5WT fork oil suspension fluid only If you have any questions regarding your 2002 Manitou MARS suspension fork contact Answer Warranty Department at 661 257 4411 You can also log on to www answerproducts com and download this manual or see detailed instructions on how to service your suspension fork Thank you again for choosing a 2002 Manitou MARS suspension fork DEALER SERVICE ADDENDUM This section is designed to help a qualified bicycle mechanic tune and main tain your Manitou suspension fork MEASURING SAG You ll need a
5. see the top of the air piston and determine if there is a small amount of oil sitting on top of the air piston If this oil is no longer visi ble pour 3 cc of 20W 50 motor oil directly into the open fork leg After this reinstall the Schraeder valve and the air cap and pressurize MINI BOOT LUBRICATION 2000 MARS forks come with mini boots equipped with a foam lubricating ring inside the top bellow of the boot Occasionally you will need to relubricate this ring The best way to do this is turn your bicycle upside down pull the boots away from the seal and drip a small amount of 20W 50 motor oil down into the boot where the lubricating ring is situated It is only essential to moisten this ring so don t over do it COMPRESSION DAMPING ADJUSTMENT QUICK RANGE TPC For Quick Range TPC forks a simple turn of the knob located on top of the right leg is all that is needed Turning the knob clockwise as you are look ing from a rider s position increases compression damping while turning the knob counterclockwise decreases compression damping ADJUSTING COMPRESSION DAMPING WITH A LOCK OUT The Lock Out is simply an on off switch for your fork To adjust compression damp ing do the following Remove the compression assembly located in the right leg On the lower piston of the lockout assembly is a small set screw Turn this in or out to increase or decrease compression damping respectively Note a half turn makes a lot of difference so make
6. this fork without fork boots will require frequent service intervals to maintain performance and normal life of the fork 3 The warranty will be void if the fork is found to show that the boots were not in place and frequent service was not performed 20o NDIA w oe Your MARS 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 relubricated using the Microlube ports located on the back of each outer leg IMPORTANT When lubricating the fork through the Microlube ports it is important to note the lubricant is being forced between the upper and lower bushings If the area is overfilled the lubricant may force the upper bushing and dust seal out You should only insert lubricant to the level at which stiction is no longer felt IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs and clean and check the entire fork for any obvious damage 3 Check the headset for proper adjustment 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 TPC equipped fork is criti cal TPC is located in the right leg of your MARS fork Not
7. upper bearings stem spacers and stem Install the stem cap and bolt Tighten the bolt to headset manufacturer s specifications Install the handlebars to the desired height and the torque stem pinch screws or stem clamping system to manufacturer s specifications Install the brakes and adjust per the manufacturer s instructions Adjust the front wheel quick release to clear the 0 275 7 mm thick sec ondary catch dropout The quick release must be tightened after it is proper ly seated into the dropout counter bores to manufacturer s specifications Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock 12 Install the brake cable per manufacturer s instructions NOTE 2002 MARS forks are equipped with a secondary catch dropout to retain the wheel in the fork in the event the quick release comes loose AMI WHEN INSTALLING THE WHEEL OR A NEW TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM OF THE BRAKE ARCH THIS MEASUREMENT SHOULD BE AT LEAST 10 MM SEE 1 IMPORTANT The MARS fork should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replacement parts MAINTENANCE IMPORTANT Use of fork boots is recommended to keep your MARS fork performing at its optimum for extended service cycles and maintaining maximum life of the fork 2 Use of
8. O RIDING YOUR BICYCLE YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF RIDING DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING CRACKING 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 INSTRUCTIONS CAN HELP YOU REDUCE THE RISK OF BEING INJURED IF YOU ARE A MODERATE OR AGGRESSIVE OFF ROAD RIDER OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN ANSWER PRODUCTS RECOMMENDS RETURNING YOUR SUSPENSION 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 PRODUCTS TO HAVE YOUR FORK SHIPPED DIRECTLY AT 661 257 4411 IMPORTANT The MARS fork is an off road fork and as such does not come with proper reflectors for on road use CONSUMER SAFETY INFORMATION 1 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 a higher performance versus bolt in inner legs but cannot be pressed out Pressing them out will permanently damage the crown beyond repair and render it unsafe for any continued use 2 Never attempt to thread a threadless steerer tube Cutting threads will weaken the steerer tube and cause an unsafe condition The only safe thi
9. ORMAL CONDITIONS Short Infrequent Rides Lube fork as needed with Prep M via Microlube lubrication ports e Disassemble clean and lubricate fork every 4 5 months e Grease spring stack as needed e Service TPC by changing fork fluid every year NORMAL CONDITIONS Long Frequent Rides Lube fork as needed with Prep M via Microlube lubrication ports e Disassemble clean and lubricate fork every 10 14 weeks e Grease spring stack as needed e Service TPC by changing fork fluid every 6 months SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Short Infrequent Rides Lube fork as needed with Prep M via Microlube lubrication ports e Disassemble clean and lubricate fork every 6 8 weeks e Grease spring stack as needed e Service TPC by changing fork fluid every year SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Long Frequent Rides e Lube fork as needed with Prep M via Microlube lubrication ports e Disassemble clean and lubricate fork every 4 6 weeks e Grease spring stack as needed e Service TPC by changing fork fluid every 6 months SERVICE PARTS KITS MARS COMP COIL MARS SUPER Compression Damping Assembly 85 4875 A Compression Damping Assembly 85 4890 Rebound Damping Assembly 85 4876 Rebound Damping Assembly 85 4876 Crown Steerer Tube Assembly 85 4888 Crown Steerer Tube Assembly 85 4879 Outer Casting Assembly A B C Preload Adjuster Assemb
10. ants like Prep M Install the new spring 6 Reinstall the assembly into the left leg of the fork taking care not to cross thread the cap It should thread in by hand and should only be snug tight ened 7 Reinstall the lowers with the 11 mm and 8 mm bolts and tighten You may have trouble getting the 8 mm bolt to catch the threads If this occurs remove the lowers pull the rebound damping rod down again and reinstall the casting You should be able to now install the 8 mm bolt CHANGING AIR SPRING PRESSURE MARS ELITE MARS SUPER MARS DIVA ll you need to change the air pressure is a high pressure Manitou part 85 4069 or other shock pump Remove the air cap located on the top of the left leg and then inflate the fork with the desired pressure 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 on the fork after you have set and checked the pressure AIR PISTON LUBRICATION For proper function of your fork it is essen tial to have a small amount of lubricating oil on top of the air piston in your MARS Elite Super or Diva fork To check this remove the air cap on the left side of the fork as seen from the rider s perspective by simply unthreading it counterclockwise Release the air pressure from the fork and then use a 20 mm hex wrench to remove the aluminum Schraeder valve Once you have done this you can
11. ly 85 4877 D E Outer Casting Assembly Candy Red 85 4893 Candy Blue 85 4880 Sticker Kit 85 4881 Sticker Kit 85 4881 G Ride Kit Assembly Soft 85 9127 G Ride Kit Assembly Extra Soft Coil 85 4808 Medium 85 9128 Soft Coil 85 4878 Firm 85 9129 Extra Firm 85 9219 Medium Coil 85 4927 Firm Coil 85 9188 Knob Kit 85 4886 Knob Kit 85 4886 Boot Kit 85 4839 Boot Kit 85 4839 MARS ELITE MARS DIVA A Compression Damping Assembly 85 4875 Rebound Damping Assembly 85 4876 A Compression Damping Assembly 85 4890 Rebound Damping Assembly 85 4876 Crown Steerer Tube Assembly 85 4888 B D Crown Steerer Tube Assembly 85 4888 E Outer Casting Assembly Candy Chrome 85 4889 Outer Casting Assembly White 85 4894 Sticker Kit 85 4881 Sticker Kit 85 4897 Ride Kit Assembly Extra Soft Coil 85 4808 Ride Kit Assembly Extra Soft Coil 85 4808 Soft Coil 85 4878 Soft Coil 85 4878 Medium Coil 85 4927 Medium Coil 85 4927 Firm Coil 85 9188 Firm Coil 85 9188 Knob Kit 85 4886 Knob Kit 85 4886 Boot Kit 85 4839 SPECIAL OFFER Buy Prep M lubricant directly from Answer Products at a special introductory price for new purchasers of Manitou forks or Manitou equipped bikes Prep M Lubricant Gun amp Tube 19 95 International orders add a 15 handling charge credit card only Shipping and handling in the US included in the
12. mage that may result from crashes or falls This warranty does not cover any fork that has been subject to misuse or whose serial number has been altered defaced or removed This warranty does not cover paint dam age 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 limit ed 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 to the place of pur chase At that time instructions for repair return or replacement shall be given customers in countries other than USA should contact their dealer or local dis tributor Checking Oil Level Kontrolle des Olstandes Verificaci n del nivel de aceite V rification du niveau d huile Controllo del livello dell olio Oliepeil controleren Verifica o do n vel de leo ALNBOF IYI Ensure that the proper steerer tube has been delivered on your MARS first 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 per form installation A CUI THE STEERER TUBE AND STANCHIONS INNER LEGS ARE A ONE TIME PRECISION PRESS FIT AT THE FACTORY AND
13. ng to do is to obtain the proper crown steerer from your dealer or contact the Answer Warranty Department at 661 257 4411 3 Any other alteration or modification to your fork should be considered unsafe Contact Answer Warranty prior to modifying your fork in any way for safety information 4 Do not use the MARS fork if any parts are broken bent cracked or you sus pect may be damaged Contact your dealer or the Answer Warranty Department at 661 257 4411 if you have any questions concerning the integrity or condition of your fork 5 Answer Products recommends that you inspect your fork before every ride for wear and damage Inspect the crown inner legs outer legs dropout and brake arch areas for cracks or damage Tire clearance Reifenabstand Espacio libre de la cubierta Distance arceau pneu Spazio libero del pneu matico Bandspeling Folga do pneu BZIVPIYUSFIYRA Travel Measurement Messung der Auslenkung C mo medir el recorrido Mesure de la course Misurazione della corsa Meting van loop Medi o do curso KINVBOHE INSTALLATION INSTRUCTIONS 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 will be repaired or replaced at the option of the manufacturer free of charge when received at the factory with proof of purchase freight prepaid This warranty does not cover breakage bending or da
14. rks With the adjuster assembly removed the spring stack is now accessible Select the appropriate ride kit for the rider s weight and riding style refer to the above spring chart for recommended rates 4 Apply a liberal amount of grease to the outside surface of the new coil spring We recommend any thick grease not light lubricants like Prep M Install the new spring 5 Reinstall the preload adjuster assembly taking care not to cross thread the cap It should thread in by hand and does not need to be tightened with a wrench finger snug is recommended CHANGING COIL SPRINGS MARS ELITE MARS SUPER MARS DIVA 1 Start by unthreading the air cap on top of the left fork leg and removing he fork s air pressure via the Schraeder valve 2 Next from the bottom of the casting remove the 2 mm cap screws and caps the 11 mm open end bolt and 8 mm hex bolt turn to the right to oosen Once you do this you will be able to pull the lowers away from the uppers 3 On the left leg as seen from the rider s perspective remove the 15 16 inch cap from the bottom of the leg Remove the entire assembly by pulling he rod lightly At this point you will see the coil spring 4 Select the appropriate coil spring for the rider s weight and riding style refer to the above spring chart for recommended rates 5 Apply a liberal amount of grease to the outside surface of the new coil spring We recommend any thick grease not light lubric
15. small and incremental changes to the set screw REBOUND DAMPING ADJUSTMENT QUICK RANGE TPC 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 MICROLUBE All you need is a Microlube lubricant gun Part 85 3812 and Manitou s Prep M Part 85 3810 suspension fork lubricant Brush any dirt from the lubricant ports insert the lubricant gun into the small fitting located at the back of the fork and squeeze a few times Continue injecting lubricant and push the fork up and down until stiction is eliminated MAINTENANCE AND SERVICE When servicing the fork take the time to inspect all parts for excessive wear or damage There are basically four aspects of a fork that will require attention the stanchions inner legs the bushings in the outer legs the spring stack and the damping fluid In addi tion with the air spring forks you will also need to make sure a small amount of lubricating oil 3cc in sitting on top of the air piston see Air Piston Lubrication section Inspecting any of these parts requires disassembly of the fork Pay close attention to the bushings which can be damaged by contami nation in severe conditions Replace any worn or damaged parts that are dis covered SERVICE SCHEDULE Suggested Service for Manitou Forks N
16. tape measure a pencil and a piece of paper 1 Measure the distance from the front axle s centerline to the bottom of the upper crown when no one is 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 Have the rider sit on the bike and measure the distance between the same two points as in step one It is 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 measure ment is the static sag SAG MEASUREMENT CHART Fork Travel Sag 80 mm 12 16 mm RIDE KITS MARS COMP COIL Rider Weight Recommended Ride Kits Part 100 150 lbs Soft ride kit 85 9127 150 170 lbs Medium ride kit 85 9128 170 190 lbs Firm ride kit 85 9129 190 plus lbs Extra firm ride kit 85 9219 MARS ELITE SUPER DIVA Rider Weight Recommended Ride Kits Part 100 125 lbs X Soft ride kit 85 4808 125 150 lbs Soft ride kit 85 4878 150 190 lbs Medium ride kit 85 4927 190 plus lbs Firm ride kit 85 9188 Air pressure setting should equal 75 of body weight Maximum air pressure is 190 psi _ GING COIL SPRINGS MARS COMP COIL 1 Start by removing the preload adjuster by unscrewing the cap from the top of the crown leg assembly A 20 mm socket may be necessary Remember The springs are housed only in the left leg on 2002 Manitou suspension fo
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