2002 Six Deluxe Owners Manual
Contents
1. Disassemble clean and lubricate fork every 6 8 weeks Lubricate spring stack as needed SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Long Frequent Rides Lube fork as needed with Prep M lubricant via the Microlube ports Disassemble clean and lubricate fork every 4 6 weeks Lubricate spring stack as needed SERVICE PARTS KITS SIX DELUXE Compression Damping Assembly 85 3014 Rebound Damping Assembly 85 9268 Preload Adjuster Assembly 85 9073 Crown Steerer Tube Assembly Alloy 85 8209 Outer Casting Assembly Red 85 9196 Sticker Kit 85 4931 Ride Kit Assembly Soft Ride Kit Assembly Medium Ride Kit Assembly Firm Ride Kit Assembly Extra Firm 85 9127 85 9128 85 9129 85 9219 Knob Kit Boot Kit 85 4104 85 4839 SPECIAL OFFERS I Spring kits and Prep M lubricant directly from Answer Products I at a special introductory price for new purchasers I of Manitou forks or Manitou equipped bikes i Prep M Grease Gun amp Tube 19 95 l Spring Kits 12 95 l International orders add a 15 handling charge credit card only I Shipping and handling in the US included in the 19 95 price I Call Answer Products at 661 257 4411 to order I or visit the website at www answerproducts com l 12. 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 binds slightly and feels 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 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 injector gun via the Microlube grease ports located on the back of the fork legs 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 nivel de leo AINBOF IY FORK INSTALLATION 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 Manitou SIX DELUXE steerer tube until the race is seated over the crown Clean and grease the headset bearings and races Install the lower bearings if applicable on the fork crown race Insert the steerer tube into the head tube of the frame Install the uppe
3. 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 Tire Clearance Reifenabstand Espacio libre de la cubierta Distance arceau pneu Spazio libero del pneu matico Bandspeling Folga do pneu CqEUPTMEA INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your Manitou SIX DELUXE 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 WARNING THE STEERER TUBE AND STANCHIONS INNER LEGS ARE A ONE TIME PRECISION PRESS FIT AT THE FACTO RY AND 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
4. All you need is a Microlube lubricant gun Part 785 5818 and Manitou s Prep M Part 7785 5810 suspension fork lubri cant Brush any dirt from the grease ports insert the grease gun into the small fitting located at the back of the fork and squeeze a few times Continue injecting grease 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 Inspecting any of these parts requires disassembly of the fork Pay close atten tion to the bushings which can be damaged by contamination in severe condi tions Replace any worn or damaged parts that are discovered SERVICE SCHEDULE Suggested Service for Manitou Forks NORMAL CONDITIONS Short Infrequent Rides Lube fork as needed with Prep M lubricant via the Microlube ports Disassemble clean and lubricate fork every 4 5 months Lubricate spring stack as needed NORMAL CONDITIONS Long Frequent Rides Lube fork as needed with Prep M lubricant via the Microlube ports Disassemble clean and lubricate fork every 10 14 weeks Lubricate spring stack as needed SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Short Infrequent Rides Lube fork as needed with Prep M lubricant via the Microlube ports
5. GINALLY 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 AT 661 257 4411 TO HAVE YOUR FORK SHIPPED DIRECTLY IMPORTANT The SIX DELUXE 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 roads at any time If you have questions regarding C P S C Standards or would like to purchase a reflector bracket kit Part 85 3674 contact your dealer 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 higher performance versus bolt in inner legs but can not 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 tub
6. e 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 the Answer Products Warranty Department at 661 257 4411 3 Any other alteration or modification to your fork should be considered unsafe Contact the Answer Products Warranty Department prior to modifying your fork in any way for safety information 4 Do not use the SIX DELUXE fork if any parts are broken bent cracked or you suspect 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 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 damage 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
7. e first The resulting measure ment is the static sag or ride height SAG MEASUREMENT Fork Travel Sag 80 mm 12 16mm RECOMMENDED SPRINGS SIX DELUXE Rider Weight Recommended Spring Kit 100 150 lbs Soft ride kit Part 7485 9187 Standard Set up 150 170 Ibs Medium ride kit Part 7785 0128 170 190 Ibs Firm ride kit Part 7785 9129 190 pluslbs Extra Firm ride kit Part 7785 9219 CHANGING COIL SPRINGS Once you have checked sag you can either preload the spring via the cap on top of the left leg or even better make spring changes to accommodate for your riding style and weight 1 Start by removing the preload adjuster by unscrewing the cap from the top of the crown leg assembly A 1 1 16th inch or 27 mm socket will be neces sary with the SIX DELUXE Remember The springs are housed only in the left leg on 2008 Manitou suspension forks 8 With the adjuster assembly removed the spring stack is now accessible 3 Select the appropriate coil spring for your 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 greases like Prep M Install the new spring stack B 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 MICROLUBE
8. ife of the fork decrease the time between mainte nance intervals reduce the performance and void the warranty IMPORTANT When lubricating the fork with lubricant through the lubricant 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 stickiness when you compress the fork 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 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 Fluid Flow damped fork is critical Fluid Flow damping is located in the right leg of your Manitou SIX DELUXE 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 cre ate an unsafe riding condition Finish reading this entire section prior to alter ing the oil level To check the oil level on the Manitou SIX DELUXE remove the compression assembly 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 t
9. me ENGLISH e Betriebsanleitung Manual del usuario e Manuel de l utilisateur Manuale del proprietario e Handleiding Manual do propriet rio 27 AX v a 7L E P N 042037 answerproducts 28209 Avenue Stanford Valencia California 91355 3984 661 257 4411 fax 661 294 4179 MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING A 2002 MANITOU SIX DELUXE FORK This Manitou SIX DELUXE fork is fully assembled and ready to be installed onto your bicy cle It comes equipped with a 1 1 8 inch threadless steerer tube and is available with a V brake style hangerless arch or there s an optional attachable cable hanger which is available through your dealer SIX DELUXE forks are also available in a disc brake only version 2002 MANITOU SIX DELUXE FORK LINE SIX DELUXE 80 MM TRAVEL COIL SPRINGS TPC DAMPING SINGLE CROWN You can also download this manual at www answerproducts com A ej aay Ve Ved em 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 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 CREAKING LEAK ING OR IF IT IS MISSING ANY OF THE ORI
10. o 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 SIX DELUXE should be per following table Fork Model Oil Level Manitou SIX DELUXE 101 mm 4 inches NOTE Use Maxima SAE 5WT fork oil suspension fluid only If you have any questions regarding your 2002 Manitou SIX DELUXE suspension fork contact the Answer Products 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 SIX DELUXE suspension fork DEALER SERVICE ADDENDUM SIX DELUXE This section is designed to help a qualified bicycle mechanic tune and main tain your Manitou suspension fork MEASURING SAG To measure 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 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 8 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 the rider s feet on the pedals 3 Subtract the second measurement from th
11. r bearings stem spacers and stem Install the stem cap and bolt Tighten the bolt to headset manufacturer s specifications Install the handlebars to 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 For all SIX DELUXE forks adjust the front wheel quick release to clear the 0 275 7 mm thick secondary catch dropout The quick release must be tightened after it is properly seated into the dropout counter bores to manu facturer s specifications Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock NOTE 2002 Manitou SIX DELUXE forks are equipped with a secondary catch dropout to retain the wheel in the fork in the event the quick release comes loose A WARNING 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 10 MM SEE FIGURE 1 IMPORTANT The Manitou SIX DELUXE should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replace ment parts 0 ONDINA o N aa MAINTENANCE IMPORTANT Use of fork boots is required to keep your Manitou SIX DELUXE fork performing well and the warranty in effect Use of this fork with out boots will shorten the l
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