Manitou 1999 Spyder Service Manual
Contents
1. www answerproducts com Include on the site is down loadable manuals and e mail to technical support DESCRIPTION PART NUMBER 99 SPYDER BUSHING SEAL KIT 85 3826 99 SPYDER OUTER CASTING ASSEMBLY BRIGHT YELLOW W OUT STICKER 85 3830 99 SPYDER OUTER CASTING ASSEMBLY BALCK W OUT STICKER 85 3831 99 SPYDER OUTER CASTING ASSEMBLY DARK BLUE W OUT STICKER 85 3832 99 SPYDER OUTER CASTING ASSEMBLY BRIGHT RED W OUT STICKER 85 3833 98 99 SOFT RIDE KIT SPYDER 85 3844 98 99 MEDIUM RIDE KIT SPYDER 85 3845 98 99 FIRM RIDE KIT SPYDER 85 3846 98 99 ADJUSTER KIT SPYDER85 3847 98 99 CROWN STEER INNERLEG SPYDER ALUMINUM 85 3850 98 99 CROWN STEER INNERLEG SPYDER CROMOLY 85 3851 98 99 BUSHING REMOVAL TOOL 85 3892 98 99 BUSHING SIZER TOOL 85 3893 99 SPYDER YELLOW STICKER KIT 85 4015 99 SPYDER R MANGE STICKER KIT 85 4017 99 SPYDER R BLUE STICKER KIT 85 4018 99 SPYDER BLACK STICKER KIT 85 4046 page 3 Z9r v0 S3WOLSY13 ONNOA3M AINO S1300W T3AVuHl NWOZ SZZ90 YIIWAS x a NNOg33 WW Ol 8702790 92526 dO NOISSAYdNOIN 660170 ee DNINIS B10 x Z we LZZ170 we HOLIINNOI DNIMAS MIA od a 29000 NON Oda A a 971 _ Z9vItO YNO 1431 ZL LvO v Cay p qNn0832 NOW NOISSIAJANOO er 69r ro A8A3SSV yalsnrdy Lro ONIHSNG Hamo 77170 ONIHSNA 3dan 8 1 Ivo 1V3S 1SNQ M34331S NMOND YA W N ZI 0 INOYHOL SHT HONI OL O6 3N0Y01 126040 LSOd IMVAB Mo vrzLv0 1008 MY J WVLAG 1Y3S ONIHSNE OILVNSHOS 32. 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 contact your dealer 1 Never remove or have the steer tube or stanchions inner legs removed from the crown The steer tube and stanchions are press fit assembled at the factory Pressing them out will permanently damage the crown steer tube and stanchions beyond repair and render them unsafe for any continued use 2 Never attempt to thread a threadless steer tube Machining threads will weaken the steer tube and cause an unsafe condition The only safe thing to do is to obtain the proper crown steerer from your dealer 3 Any other alterations or modifications to your fork should be considered unsafe Contact Answer Products Technical Support prior to modifying your fork in any way for safety information 4 Do not use any Manitou Fork if any parts appear to be broken bent cracked or damaged Contact your dealer or Answer Products Technical Support 800 670 7446 if you have any questions concerning the integrity condition or safe operation of your fork 5 Answer Products recommends that you periodically inspect your fork for wear and damage Inspect the Crown Inner Legs and Outer Leg Dropout and Brake Arch areas for cracks or damage Before every ride check to ensure that the proper preload exists and that the positive rebound stop is installed to ensure that the fork can not over extend WARRANTY I
3. 04 YSAGAdS 66 F I4NI14 page 4 Z9v v0 GNNOBIY 3440 6rZZ2D AvD 931 L331 SSO1v0 1v35 110 a LLvIwA an s 01I v E x 9L 8 E k O 8 90Z790 LAVHS N 89970 8 2 x v E ININ 9 ODEZ90 DO6 X 442 IHS 262790 NO1SId INNOA3H BEZZIO ATANISSV 13VHS MMO 1 eS 96ZZ 9D AWA NOISS33d4N0O2 Moon Z s Y Z9r r0 ANNORBI L L910 Ava GLZ170 BONA m ne SR 2610 ALV1d 39V4 A 34 l ageLra Mass w PM 1331 yandi sy aan ONiddVL 4135 O yzgor0 087179 ues 931 Hd3NNI 732290 aNnagay NNO 562290 A19NaSSY nen a Ae ee SNIdNVG NOISS34 ADO q AN os Us ER BE OQ IT Co 12102 HOLDINNO ONS 4343115 NMOYI gt Y gZr v0 MN das _ zeZ170 NOLI3NNOD Cy Gzv1v0 NOW Das amp ZEZWO 301 93NNOD rvit SNIHSNEO uana gt 861170 12AY8l AOL 804 Y azviv0 mow day i gZF FO INIHSSNB Yadd SM 905170 ATONISSY YILENTON w N ZI 0 3MDYO1 HINI O1 06 3NO301 12600 150d 3MVYa rrZ 1960 TIVLIO Was 2 ONIHSNA G JANO JILVWAHOS 304 Y IAS 66 page 5 MAINTENANCE IMPORTANT Use of fork boots is required to keep your 99 SPYDER performing well and your warranty in effect Use of IMPORTANT The 99 SPYDER should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replacement parts this fork with the boots removed will shorten the life of the fork reduce the perform
4. 99 SPYDER SERVICE MANUAL P N 85 3665 MANITOU ANSWER PRODUCTS INC 28209 AVENUE STANFORD VALENCIA CA 91355 805 257 4411 www answerproducts com TABLE OF CONTENTS Consumer Safety amp Warranty Information Installation Instructions Spare Parts List Exploded View Maintenance amp Disassembly Inspection Re assemble l Inner Fork Leg Crown amp Brake Arch Adjusting the Ride Qualities Trouble Shooting O OO l N O Q IN ANSWER PRECISION SUSPENSION CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOWTAIN BIKE SUSPENSION FORK AVAILABLE THE 1999 SPYDER FORK MODELS HAVE STATE OF THE AR MCU SPRING COMPRESSION SYSTEMS THE SPYDER R IN THE SPYDER SERIES USES THE NEW TWIN PISTON CARTRIDGE SYSTEM TPC SPORT THAT SURPASS ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCEAND DURAEBILITY Your 99 SPYDER Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1 8 threadless steer tube 99 SPYDER s are available with the V Brake cable hangerless arch and have an optional attachable cable hanger kit P N 85 3644 which is available through your dealer CONSUMER SAFETY INFORMATION IMPORTANT The 99 SPYDER Fork is an off road fork and as such does not come with the reflectors for on road use installed Reflector bracket kit P N 85 3674 is available through your dealer Have your dealer or mechanic install the kit to meet the Consumer Product Safety Commission s C P S C
5. NFORMATION 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 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 modified 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 to the place of purchase In the USA dealers should call Answer Products for a return authorization number RAF 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 page 1 INSTALLATION INSTRUCTIONS Figures 1 2 amp 3 Insure that the proper steer tube has been delivered on your fork The steer 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
6. ance and void the warranty Your 99 SPYDER Fork requires periodic maintenance cleaning and inspection Moisture and contamination may build up inside the fork depending on the severity of riding conditions To maintain top performance it is recommended that thefork be periodically disassembled cleaned dried and re greased IMPORTANT When filling the fork with grease through the grease ports it is important to note the grease is being forced between the upper and lower bushing If the area is overfilled the force of the grease may force the upper bushing and dust seal out IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs clean lubricate and check entire fork for any obvious damage 3 Check headset adjustment 4 Insure that the front brake cable is properly seated in the cable retainer amp check brake adjustment FIGURE 6 LUBRICATING THE BUSHINGS IMPORTANT Maintaining the proper oil level in your TPC isvery important Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel and may cause damage to the system and an unsafe riding situation Finish reading this entire section prior to making any changes to the oil level To check the oil level remove only the compression damping assembly located in the top of the left leg Leave the right side compression stack adjuster MCU spring assembly in plac
7. e Replace if wear is excessive or damaged Check inner legs at the bottom of the crown for cracks or for flaking anodize Replace crown steer leg assembly if cracked or if gold anodize is beginning to flake Check the underside of the crown for cracks Replace if cracked A DROP ROD INTO INNER FORK LEG to get rod through B SLIDE ON EL STOMER OUTER LEG ASSEMBLY FIGURE 11 FIGURE 10 COMPRESSION ROD amp BOOTS 1 2 Install adjuster and elastomer stack into right leg Hand tight only For SPYDER R only Fill left leg with oil Refer to Figure 7 for For SPYEDR R only install compression valve assembly into left Slide Outer leg Arch assembly onto inner legs and fully compress Drop compression rod into the right side of SPYDER R and both sides of the SPYDER Use a 6mm Allen wrench to tighten compression rod to 10in lbs SPYDER R gt YA SPYDER er recommended oil level leg Hand tight only Slide fork boots down and snap over dust seal flange FIGURE 11 OUTER LEG ASSEMBLY Page 7 INNER FORK LEGS amp CROWN The inner fork legs and steer tube are press fit into the crown and may never be removed Removing them will make the fork unsafe to use If you see any slippage contact Answer Technical Staff immediately 800 670 7446 BRAKE ARCH NOTE The 99 SPYDER arch and outer leg assembly is a one piece unit Ifthe unit is damaged at all it must be replaced Using the fork with a damaged ou
8. e to keep the fork fully extended Use a tape measure or dip stick to determine the oil level Oil level should be between 3 5 89MM and 4 75 120MM below the crown where ee the damping assembly screws in The recommended level is 4 00 101MM MAR SEN FERN It is recommended that you replace your oil at least once during the season twice if it has been contaminated with dirt mud or other foreign substance MIN 4 75 120MM Use SAE 5WT Maxima fork oil or equivalent See Figure 7 GENERAL DISASSEMBLY FIGURE 7 TPC OIL LEVEL NOTE The Fork does not need to be removed from the bicycle for general disassembly assembly or cleaning It is also not necessary to disassemble the 99 Manitou Forks for compression Elastomer replacement Elastomer replacement is accomplished by removing the adjuster assembly per Figure 9 Removal of outer leg arch assembly Figure 8 Unscrew adjuster assembly from right leg and remove elastomer stack Unscrew adjuster assembly from left leg and remove compression valve assembly Pour oil out of the top of the fork and discard appropriately Use a 6mm Allen wrench to unscrew the compression rod from both sides Pull outer leg assembly down to remove from the inner legs and crown Remove fork boots Note It is not recommended to remove the dust seal every time the fork is disassembled The seal and bushings may be cleaned and re greased in place 7 Bushing replacement will re
9. e your Manitou right side up Ifthis condition causes you some problems please contact your Answer Products dealer or call our warranty tech department for prompt service CYCLE COMPUTER INSTALLATION INSTRUCTIONS Follow the instructions in your owner s manual with the following exceptions WARNING DO NOT DRILL A HOLE IN THE DROPOUT THIS MAY WEAKN THE DROPOUT WILL VOID THE WARRANTY AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INURY DO NOT USE THE TEMPLATE PROVIDED IN THE 95 OR 96 SERVICE MANUAL Page 8
10. h dropout The quick release must be tightened after it is properly seated into the dropout counter bores Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock due to the wide adjustment Install front wheel to bicycle per manufacturers specification 13 Install brake cable per manufacturers instructions Note The 99 SPYDER comes equipped with a hangerless arch Brake cable hangers that attach to the arch are available through your dealer See Figure WARNING When installing wheel or any new tire check the minimum tire clearance Measure from the highest point on the tire to the bottom of the crown The minimum clearance allowed for 70MM travel forks models is 2 875 73 0MM and 3 268 83 0MM for 80MM travel fork models Any less clearance can result in accident resulting in serious injury or death Figure 3 page 2 SLIP CROWN RACE OVER STEERER PRESS ONTO we RACE SEAT FIGURE 1 RACE INSTALLATION CABLE HANGER 85 3644 BRAKE ARCH FIGURE 2 BRAKE CABLE ROUTING A FIGURE 3 TIRE CLEARANCE SPARE PARTS Table 1 Spare parts can be ordered through your local dealer If you have any problems that you cannot resolve with your dealer you may call Answer Products Technical Warranty Service Department at 805 257 4411 8 00 AM to 5 00 PM Pacific Standard Monday through Friday In addition helpful information can be found on the Answer Products Web Site http
11. ional tuning tips we recommend that you obtain a copy of the MRD tuning Manual P N 85 3485 and check out the MRD Race Tuning kits available at your dealer TROUBLE SHOOTING Fork seems to top out or has a slight clunking feel when front wheel comes off the ground Excessive preload or insufficient rebound damping will result in a top out Select MCU s that better fit your weight and riding style having the preload adjuster set mid to low range and increase the rebound damping to eliminate top out The fork feels less active and is not getting the travel it used to when it was new Chances are that the fork is developing stiction Cleaning and applying light oil to the stanchions will help Outer legs feel loose on inner legs and bushings a knock or rock can be felt when pushed from side to side A very small knock is normal with the new 99 harder bushings Ifthe knock is excessive or you can feel the fork rocking then the bushings should be removed and replaced To do this you must have the Answer Products Bushing Removal and Replacement Tool Kit A small amount of oil seems to be leaking from top of the left leg at the adjuster cap If the 99 SPYDER R is stored upside down for a period of time a small amount of oil may leak through the adjuster cap knob assembly The cap area is not subjected to damping pressure A smallleak in that area will not affect the performance of the fork or cause any type of damage We recommend that you stor
12. quire the use of the bushing removal and installation tool available from Answer Products It is recommended that the bushings be left installed unless they absolute O O1 Q N page 6 FIGURE 8 OUTER LEG REMOVAL DAMPER INSPECTION 1 2 4 5 6 Check the shaft for scratches wear or other obvious damage Check the seal gland and end cap seal grooves for damage Check shims for permanent bends or damage Check all other parts for obvious damage replace if necessary Replace all seals that have been removed FORK INSPECTION O N N O Ol 9 COMPRESSION ROD amp BOOTS FIGURE 10 o rs Clean all parts thoroughly Grease compression rod lightly Drop compression rod down into inner legs Shake inner leg Slide on rebound elastomer Slide Boots onto inner leg Check the fork boots for obvious damage Check the dust seal for tears wear or damage Replace if needed Inspect the lower and upper bushing for damage to the Teflon coating Replace using the bushing removal and replacement kit of necessary Check all MCU amp springs for obvious damage Replace if necessary Check the preload adjuster and connectors Replace of damaged Check the outer leg arch assembly for nicks or deep gouges on outside and inside Replace of damaged Check the inner leg for deep gouges and other obvious damage Minor wear resulting in color change is not detrimental to the gold anodized surfac
13. ter leg unit is unsafe and could cause serious injury Contact Answer Products if you suspect that your outer leg arch unit is damaged ADJUSTING RIDE QUALITIES 99 SPYDER forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the MicroCellular Urethane MCU s Fine tune adjustments can be made using the preload adjusters located on top of the fork crown Softer blue and harder yellow MCU s are available from your Dealer NOTE Since 99 SPYDER R forks use a compression stack in the right leg only MCU s and Springs used in previous Manitou forks are NOT interchangeable with later versions of SPYDER model Forks COMPRESSION SPRING FINE TUNING FIGURE 12 Fine tuning adjustments to the spring rate are made by rotating the adjuster knobs located on top of the crown Note the 99 SPYDER uses compression spring systems in both right and left legs Both right and left knobs on top of the crown adjust preload The 99 SPYDER R use a compression spring system in the right leg only The right knob for this model is used to adjust preload Rotating the knobs clockwise will firm the ride adding preload to the compression stack Rotating the knobs counter clockwise will soften the ride Four full revolutions will take the adjuster from full soft to the extreme firm setting COMPRESSION DAMPING FINE TUNING FIGURE 12 PRELOAD The SPYDERR uses TPC sport for compression and is not adjustable For addit
14. tools to cut the steer tube it is recommended that you seek a dealer with a qualified bicycle mechanic to perform installation WARNING The steer 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 change steer tube lengths or diameters Removing and replacing the steer tube or stanchions will result in an unsafe condition and should never be done 1 Remove old fork from bicycle 2 Measure and cut the steer tube to fit your bicycle head tube 3 Remove crown race from old fork and press onto steer until seated on crown Figure 1 4 Clean and grease headset bearings and races of bicycle 5 Install lower bearings on fork crown race 6 Insert steer tube into head tube of frame 7 Install upper bearings spacers and stem 8 Install stem cap adjust and tighten headset per manufactures instructions 9 Install handlebars to desired height Torque stem handlebar pinch screw and stem clamping system to manufacturer s instructions 10 Install handlebars to desired height Torque stem handlebar pinch screws and stem clamping system to manufacturer s instruction s 11 Install cantilever breaks and adjust per manufacturers instructions Note All 99 SPYDER Forks are equipped with a secondary catch dropout 12 Adjust front wheel quick release to clear the 0 275 7mm thick secondary catc
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