Answer 2004 South Service Manual
Contents
1. act like springs when the elastomer is compressed No Boss The word used to describe an outer casting that has no brake posts for V brakes or cantilever brakes This casting is to be used for disk brakes only O Ring A soft flexible neoprene or Buna rubber ring with a round cross section which is used for sealing and retention Outer Casting see Slider Preload A condition of compressing a spring or elastomer before the operating loads are put on the suspension so that it provides a stiffer spring rate Rebound The phase of the suspension operation in which the wheel returns to its original position on the ground after compression 04 SOUTH SERVICE MANUAL Page 4 REV NC Reverse Arch Technology Also known as RA It is a system that is designed to move the arch of a fork to the backside of a fork rather than the conventional front position It was designed to provide greater rotational torque strength to an outer casting slider without adding additional weight to the fork SAG The amount a suspension fork compresses at rest with a normal load rider s weight Seal A part usually neoprene rubber or Buna that keeps contaminants out and or working fluids in Spring Rate The rate at which the resistance of a spring increases as it is compressed Slider Outer Casting The tube outer casting leg of the suspension fork that remains fixed to the wheel It slides up and down on the stanchion l2. and springs from inside the top cap 3 Unscrew the compression damping assembly using a 24mm socket Pour old oil out of the top of the fork then compress fork upside down over oil drain pan 3 5 times to get oil out from under rebound piston and discard appropriately Removal of Rebound Damping Assembly South Super 1 Unscrew Damper end cap from the bottom of the right leg and then pull out the rebound damper 04 SOUTH SERVICE MANUAL Page 6 REV NC Assembly Instructions Setting Travel Setting fork in short travel Thicker Clip in slot below flange 1 Follow Disassembly steps above 2 Using pliers pull thicker clip from top of rod and install it in slot just below flange Reassemble assembly and fork as directed below Bottom out clip removed for clarity Setting fork in longer travel Thicker Clip in slot above flange 1 Follow Disassembly steps above 2 Using pliers pull thicker clip from bottom of rod and install it in slot just above flange 3 Reassemble assembly and fork as directed below Assembly of Rebound Damping Assembly South Super Pile All leg caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death 1 Install rebound damper into bottom of right leg and tighten per the South Schematic and Torque Specification Table Slide the black rubber bottomout up the shaft until it contacts the damper cap Thi
3. can be pushed into the casting If you cannot 4 Remove crown steer inner leg assembly from the outer leg casting Bushing Removal amp Installation Please refer to section on Bushing Removal amp Installation Removal of Spring and Compression Rod Assembly AGAIN This fork uses a preloaded coil spring provide spring resistance The spring must be relieved of its preload prior to servicing Failure to do so could result in injury or possible death 1 Turn spring preload adjuster knob counter clockwise until it stops Remove 2mm hex screw on spring preload adjuster knob and remove knob on the top left side of the fork 2 Remove preload adjuster using 18mm socket 3 Compress fork and remove the spring preload MCU and spring assy 4 South Comp and Elite Remove top leg cap on right hand side using 27mm socket If you could not remove the right side compression rod externally reach down inside the inner leg with a 6mm hex the top of the compression rod has a recessed 6mm hex that a hex wrench will fit into The comp rod can be unscrewed counterclockwise at this point Remove crown steer inner leg assembly from the outer leg casting 5 Remove rubber bumper and clip on compression rods 6 Turn crown steer upside down to allow the comp rods to fall out of the inner legs Removal of Compression Damping Assembly South Super 1 Remove the 2mm fixing screw on top of the damper knob on top right side of the fork 2 Remove 2 balls
4. eg inner leg Stanchion Legs The suspension tube inner leg fixed to the fork crown It remains stationary during the operation of the suspension Steer Tube The long cylindrical tube that extends from the top of the fork crown Its function is to be inserted into the bicycle head tube and attach the suspension to the bicycle frame Top Out Bumper A rubber coil spring or elastomer device that absorbs the shock that occurs when the load is taken off a suspension so that it is allowed to rebound to its limits Travel The amount that a wheel moves between the most compressed and the most extended states of the suspension Wiper Seal A rubber material that is used as a seal to keep dirt and water out of the outer casting legs It is not designed to keep air pressure or extreme oil pressure in Manitou has the new Evil Genius wiper seals 04 SOUTH SERVICE MANUAL Page 5 REV NC 2004 South Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting 1 From the left leg dropout Left when sitting on the bike use a 4mm hex wrench to remove the compression rod screw 2 South Comp and Elite From the right leg dropout use a 6mm hex wrench to turn the compression rod clockwise until it can be pushed into the casting If you cannot unscrew the compression rod see step 5 below 3 South Super From the right leg dropout use a 8mm hex wrench to turn the compression rod clockwise until it
5. h forks Comp and Elite use two compression rods one in each leg Dampened south forks Super only use a compression rod in the left side 1 Drop the compression rod s into the crown steer assy Make sure that the comp rod that accepts the 4mm screw is installed in the left leg 2 Slide on the rubber bottomout bumper and clip onto the compression rod s 3 Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 4 Lightly grease the bushings on the inside of the outer leg casting and on the lower portion of the inner legs below the boots using a thick grease such as Motorex Bike Grease 2000 5 Grease spring heavily with Motorex Bike Grease 2000 Install the spring preload MCU and spring assy into the crown steer assy 6 Tighten preload adjuster using 18mm socket and tighten per the South Schematic and Torque Specification Table 7 Insert 2mm hex screw into spring preload adjuster knob and install knob on the top left side of the fork Press inner leg assembly into outer leg casting until comp rod contacts casting From the left leg dropout use a 4mm hex wrench to install the compression rod screw and tighten per the South Schematic and Torque Specification Table 04 SOUTH SERVICE MANUAL Page 8 REV NC to co 10 South Comp and Elite From the right leg dropout use a 6mm hex wrench to turn the compression rod counterclockwise until it screws into the casting You may have to apply
6. ion to its limit Bushings A cylindrical sleeve between a fork stanchion tube inner leg and a fork outer casting slider which facilitates the sliding movement between these two parts Coil Spring A coiled piece of metal that acts as a spring to help suspend a fork Compression The phase of the suspension operation in which the wheel travels up or travels closer to the frame The suspension forks reaction to a bump in the trail Convertible Travel A system used to alter the travel of a suspension fork It requires moving a travel clip on the compression rod to a different position This operation is accomplished by disassembling the fork and physically moving the travel clip on the compression rod Crown Steerer Assembly the stanchion legs inner legs the fork crown and the steer tube pressed together as one assembly This assembly is then finished by adding all of the fork internals and then outer casting slider Drop Out The end of an outer casting slider where the wheel attaches Dust Boot Usually a piece of rubber in the shape of a cylinder with baffles to allow it to compress as the fork compresses through its travel Its function is to help keep dirt and water from getting into the inner legs of the fork Fork Crown The component that joins the stanchion tubes inner legs to the steer tube of the fork MCU Micro Cellular Urethane Special urethane that is filled with tiny air cells that
7. mantou south 2004 SERVICE MANUAL South Super South Elite South Comp 28209 Avenue Stanford Valencia California 91355 661 257 4411 fax 661 294 4179 www answerprod ucts com Table of Contents Description Introduction Glossary of Terms Disassembly Instructions Assembly Instructions Troubleshooting Chart South Schematic and Torque Specifications South Service Kit Chart Contact Information Answer Products Customer Service Department 28209 Ave Stanford Valencia CA 91355 Toll Free 800 423 0273 Direct 661 257 4411 FAX 661 775 1798 E mail warranty answerproducts com tech answerproducts com Web site www answerproducts com 04 SOUTH SERVICE MANUAL Page 2 REV NC INTRODUCTION This manual is intended to guide the user through basic service of Manitou South front forks Service is supported by the identification of common parts and assemblies that have been assembled into Service Kits The purpose of this manual will be to describe conditions that may drive the need for service and to provide installation instructions for the kits Due to the time consuming nature suspension fork service at this time our primary focus is to offer service kits that minimize the amount of downtime and labor involved Important information is highlighted in this manual by the following notations Failure to follow WARNING instructions could result in severe injur
8. mp Elite Super Code D 410 D 420 D 430 Travel mm 60or75 60or75 60 or 75 Comp Damp A 85 5318 Rbnd Damp B 85 5319 Pre Load Adj Top Cap Cc 85 4810 Crn Str Leg D Steal S T 20 85 5325 85 5335 Steel S T 700C Steel Threaded 26 Steel Threaded 85 5329 85 5328 700c Outer Leg Assy E STD Black 26 85 5330 STD Black 700c 85 5331 STD Silver 26 85 5332 STD Silver 700c 85 5333 STD Red 26 85 5334 STD Red 700C 85 4458 STD Cobalt 85 5337 STD Orange 85 5338 STD Yellow 85 5339 STD Candy Chrome 85 5340 STD Candy Red 85 5341 STD Candy Blue 85 5342 No Boss Black 26 85 5343 No Boss Black 700c 85 5344 No Boss Silver 26 85 5345 No Boss Silver 700c 85 5346 No Boss Red 26 85 5347 No Boss Red 700C 85 5348 No Boss White 85 5349 No Boss Cobalt 85 5350 No Boss Orange 85 5351 No Boss Yellow 85 5352 No Boss Candy Chrome 85 5353 No Boss Candy Red 85 5354 No Boss Candy Blue 85 5355 Sticker Kit F Silver 85 5356 F Black 85 5357 Ride Kits G Soft 85 5358 Medium 85 5359 Firm 85 5360 04 SOUTH SERVICE MANUAL Page 12 REV NC South Service Kits Cont South Model Comp Elite Super Code D 410 D 420 D 430 Travel mm 60or75 60or75 60 or 75 Comp Rod H 60 or 75 85 5361 Knob Kit l 85 5362 Boot Kit J 85 5390 Seal Kit K 85 5391 Bumper Kit K 85 5363 O Ring Kit K 85 5555 04 SOUTH SERVICE MANUAL Page 13 REV NC
9. n place the ball bearings on top of the springs place a little dab of grease on spring to hold ball bearing in place 6 Place the adjuster knob onto the hex shaped aluminum shaft and seat it onto the top cap and ball bearing Position the adjuster cap so that the lever part of the cap is at the farthest point to the back of the crown 7 Insert 2mm fixing screw and tighten to secure the knob Twist the knob counter clockwise to activate the fork suspension Compress the fork several times to circulate the oil through the system and then activate the Lock out system by moving the lever clockwise to its stopping point at the back of the crown The fork should have approximately 5 mm of progressive travel before it locks out Note This system is a combination of adjustable compression damping that becomes a lock out It is fully active when the lever is facing all the way forward counter clockwise and locked out when the lever is facing all the way towards the back of the crown clockwise Installation of Spring Compression Rod Assembly and Outer Leg Casting Pile All top caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death AGAINNE When installing the outer Leg Casting to the Crown Steer Assy Compression Rod bolts and Damper Shafts must be properly tightened prior to use Failure to do so could result in injury or possible death Note Non dampened Sout
10. ng damaged Inspect and replace Top out spring if needed Fork Bottom out Damping oil volume not correct Too much SAG Check oil level Replace Rebound Damping assembly if needed Refer to SAG Set up in Tuning section of Owners Manual Bottom out Bumper damaged Inspect and replace Bottom out Bumper if needed Play in Fork Damping oil volume not correct Loose bushings Check oil level Replace Rebound Damping assembly if needed Replace outer leg Loose Compression Rod bolt Tighten bolt to specified torque Loose Rebound damping shaft Tighten Shaft to specified torque Loose press fit tolerances 04 SOUTH SERVICE MANUAL Call Answer Products Customer Service Page 10 REV NC South Fastener Torque and Setup Levels South Comp amp Elite South Super D H Model South Description Torque Value Torque Brake Post 90 110inlbs 10 2 12 4nm Leg Caps 25 35inlbs 2 8 4 0nm Torque Comp Rod Screw 10 30inlbs 1 1 3 4nm Torque Damper Screw South Super 10 30inlbs 1 1 3 4nm Adjuster caps Torque 35 50inlbs 4 0 5 7nm Damping Oil South Super 110 120mm 4 3 4 7 04 SOUTH SERVICE MANUAL Page 11 REV NC South Service Kits South Model Co
11. pressure from the top of the comp rod using a long 6mm hex to start screwing it in and tighten per the South Schematic and Torque Specification Table 11 South Super From the right leg dropout use a 8mm hex wrench to turn the compression damper counterclockwise until it screws into the casting and tighten per the South Schematic and Torque Specification Table 12 Slide fork boots down and snap over dust seal flange 13 Lubricate the inner legs through the Microlube ports using Prep M grease 04 SOUTH SERVICE MANUAL Page 9 REV NC Oil leaks from Wiper Seals Troubleshooting Chart Seal not seated properly Solution Remove Casting from Inner Legs reinstall or replace seals Service Manual Page Nicks or scratches on inner legs Replace Crown Steerer Inner Leg Assembly Oil leaks from bottom of Casting Wear Rebound damper shaft leaks Remove Casting from Inner Legs reinstall or replace seals Replace Rebound Damping assembly Rebound damper shaft O ring damaged Replace O ring on threaded end of Rebound Damping assembly Lack of Travel Tight Bushings Replace outer leg Hydraulic lock out Replace Rebound Damping assembly Damper oil volume Check oil level Replace Rebound Damping assembly if needed Fork Top out Fork alignment Loss of Rebound Damping Visually inspect fork call Answer Products Customer Service Replace Rebound Damping assembly Top out spri
12. s will assist later during assembly of the outer leg casting to the damper shaft Assembly of Compression Damping Assembly South Super Nite All top caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death 1 Fill right leg with 110 120mm 4 3 4 7in of 5wt Motorex fork oil Ref Answer Products PN 85 0023 Cover the opening at the top of the right leg of the crown steer with a rag and cycle the fork six times Recheck oil level and add drain to meet the level requirement 04 SOUTH SERVICE MANUAL Page 7 REV NC 2 Puta little bit of Prep M grease Ref Answer Products PN 85 0031 on the urethane or brown rubber o ring found on the lower piston of the Lock out assembly 3 Twist the Hex shaped aluminum shaft that sticks up from the top cap counter clockwise until it stops the system is completely open to oil flow at this point 4 Using a motion like screwing in a screw Twist the assy and apply a little pressure to insert the piston part of the mechanism past the threads at the top of the inner leg Then push the assy into the leg until the threads on the cap intersect the threads inside the inner leg screw the cap Tighten per the South Schematic and Torque Specification Table 5 Once the cap is tightened twist the Hex shaped shaft clockwise until it stops this is the locked out position Insert the springs into opposite holes in the top cap and the
13. y or death to the person inspecting or repairing the suspension fork or the user CAUTION A CAUTION a caution indicates special precautions that must be taken to avoid damage to the product NOTE A NOTE provides key information to make procedures easier or clearer Suspension forks by design can contain preloaded springs gases and fluids under extreme pressure and warnings contained in this manual must be observed to reduce the possibility of injury or possible death Following these instructions can help you reduce the risk of being injured Any questions in regards to the information in this manual should be directed to Answer Products Customer Service at 661 257 4411 AGAINN Suspension forks uses preloaded spring s to provide compression spring resistance This system must be relieved of preload prior to servicing Failure to relieve air pressure could result in injury or possible death CAUTION Suspension forks use precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage 04 SOUTH SERVICE MANUAL Page 3 REV NC GLOSSARY OF TERMS Arch A support that connects the two outer lower legs of the casting so as to keep them moving in unison Boss The word used to describe an outer casting that has brake posts for V brakes or cantilever brakes Bottom Out Bumper A rubber or elastomer device that absorbs the shock that occurs when a suspension is compress
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