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Manitou-Answer 2001 Mars Service Manual

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1. TITANIUM BRAKE POST 041396 TORQUE 90 110 INCH LBS TORQUE 10 12 N M Ag AIR PISTON ROD ASSY 063276 OUTER LEG ASSEMBLY 100 LBS COIL SPRING 3 LONG 063147 DAMPER DROPOUT NUT 041823 COMPRESSION ROD 062932 TOP OUT ELASTOMER 041475 a LEG CAP 062250 COMPRESSION ROD SCREW TORQUE 30 50 INCH LBS 060268 Fi TORQUE 3 5 5 6 N M TORQUE 10 30 INCL 35 WY BOTTOM OUT 063116 TORQUE 1 2 3 5 N m BOTTOM CLIP 040968 BUSHING amp SEAL DETAIL 2001 MARS ELITE FORK SCHEMATIC FORK BOOT 063249 DETENT BALL 040689 7 UPPER SHAFT 062997 O RING 5 32 x 9 32 041130 LOWER NEEDLE 062570 O RING 1 4 X 3 8 040690 SPIROLOX RETAINER 062393 TPC LOWER SHAFT ASSEMBLY TPC COMPRESSION DAMPING VALVE NUT 041483 13mm CLAMP SHIM 041157 REBOUND SHIM 20mm 041149 SUS JELLY BEAN 062578 REBOUND SHIM 21mm 041150 SELF TAPPING SCREW 041330 Paks TPC KNOB 062503 s TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m PISTON SEAT 062130 UPPER BUSHING 041473 pa O RING 5 32 X 9 32 1 16 041130 N wo DETENT SLEEVE 041527 LOWER BUSHING 041474 LOWER SHAFT 062970 O RING 040524 amp CLAMP SHIM 13MM 041157 a 041148 041149 2X 041150 LOC OUT ROD SEAL 062392 PISTON 062562 O END CAP 062422 SHIM 041139 062929 ASSEMBLY 063111 A PISTON 062562 SS 826 X 409 X 005 SHIM 041139
2. 2001 MARS SERVICE MANUAL I ANSWER PRECISION SUSPENSION THANK YOU FOR CHOOSING THE HIGHEST TECHNOLOGY MOUNTAIN BIKE SUSPENSION FORK AVAIL ABLE 2001 MARS FORK MODELS HAVE STATE OF THE ART AIR SPRING SYSTEMS THE MARS SERIES ALL USE THE TWIN PISTON CHAMBER SYSTEM TPC THAT SURPASS ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY Your 2001 MARS Fork is fully assembled and ready to for installation onto your bicycle and comes equipped with a 1 1 8 threadless steerer tube All MARS forks come in two versions standard No Boss The standard version has mounts for both V brakes and disc brakes The No Boss version has the cantilever brake boss removed and is for disk brake use only II CONSUMER SAFETY INFORMATION GENERAL WARNING 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 main taining 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 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 instruction can help you reduce the risk of being injured If you are a
3. 4 EG INCHES SEAL WIPER 062972 SPRING 041152 O RING 1 4 X 3 8 040690 ADJUSTER NEEDLE 062072 D3 O DETENT BALL 040689 1 COMPRESSION SHIM STACK TORQUE 30 50 INCH LBS oa SPRING 041152 TORQUE 3 5 5 6 N M at VALVE NUT 041483 BOTTOM OUT ELASTOMER 063116 y ae BOTTOM OUT WASHER 063181 ee 5 RETAINING RING 040679 ake LO DETENT SLEEVE 041527 N RIGHT LEG 062927 AIR SPRING CAP ASSEMBLY 061038 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 AIR SPRING PISTON ASSEMBLY 062478 LEFT LEG ASSEMBLY 062931 INCLUDING NEGATIVE SPRING Bes NOT REMOVABLE W TITANIUM BRAKE POST 041396 TORQUE 90 110 INCH LBS TORQUE 10 12 N M 7 AIR PISTON ROD ASSY 063276 OUTER LEG ASSEMBLY 100 LBS COIL SPRING 3 LONG 063147 COMPRESSION ROD 062932 DAMPER DROPOUT NUT 041822 AU O RING DROPOUT NUT 040688 REBOUND ELASTOMER 041475 LEG CAP 062250 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N M DAMPER ADJUSTER KNOB 041408 COMPRESSION ROD SCREW 060268 BOTTOM OUT 063116 TORQUE 10 30 INCH LBS TORQUE 1 2 3 5 N m ae BOTTOM CLIP 040968 BOSHING Sea DETAIL 2001 MARS SUPER FORK SCHEMATIC TPC LOWER SHAFT ASSEMBLY ANTI BOB FORK BOOT 063249 062929 TPC COMPRESSION DAMPING VALVE NUT 041483 ASSEMBLY 062500 13mm CLAMP SHIM 041157 REBOUND SHIM 20mm 041149 i JELLY BEAN 062585 REBOUND SHI
4. moderate or aggressive off road rider or ride at least three times a week over rough terrain Answer recommends returning your suspension fork every 2 years for a through 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 661 257 4411 IMPORTANT The 2001 MARS fork is for off road use only and as such does not come with the reflectors for on road use 1 Never remove have the steerer tube or stanchions inner legs removed from the crown The steerer tube and stanchions are press fit assembled at the factory Pressing them out will permanently damage the crown steerer tube and stanchions beyond repair and render them unsafe for any continued use 2 Never attempt to thread a threadless steerer tube Machining threads will weaken the steerer tube and create an unsafe condition The only safe thing to do is 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 part appears to be broken bent cracked or damaged Contact your dealer or Answer Products Technical Support 661 257 4411 if you have any questions concerning the integrity condition or safe operation of your fork 5 Answer Prod
5. of the shims and spacers REBOUND DAMPER INSPECTION 1 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 Clean shims using lint free rags or paper towels nou WN Check the shaft for scratches wear or other obvious damage MARS REBOUND DAMPER ASSEMBLY 1 7 3 4 Install all o rings and seals that you removed Grease all seals lightly with seal grease Insert into right leg and thread in end cap Torque 30 in lb 3 5N m max Install outer leg assembly see Figure 9 Add 5 WT Maxima or equivalent oil Do not over fill Check oil level see Figure 8 MARS ELITE AND MARS SUPER REBOUND DAMPER ASSEMBLY 1 Install all o rings and seals that you removed 7 3 Grease all seals lightly with seal grease Assemble shim stack and spacers onto the piston seat in exact order that they were removed Apply a small amount of blue Loc tite to piston seat threads install and hand tighten nut Be sure large blow off washer will slide over piston spacer and compress the small spring Torque 12 in lb 1 3 N m max over tightening will damage the piston Apply a small amount of blue Loc tite to piston seat threads Install piston seat into shaft Use wrench flats on piston seat to torque piston seat to 30 in lb 3 5 N m max Install lower needle ge
6. x SET SCREW 5 X 8 041423 ey O RING 3 4 7 8 050681 98 COMPRESSION VALVE NUT 021483 AY wey Oy SS RIGHT LEG 062927 AIR SPRING CAP ASSEMBLY 061038 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N M AIR SPRING PISTON ASSEMBLY 062478 LEFT LEG ASSEMBLY 062931 INCLUDING NEGATIVE SPRING NOT REMOVABLE TITANIUM BRAKE POST 041396 TORQUE 90 110 INCH LBS TORQUE 10 12 N M AIR PISTON ROD ASSY 063276 OUTER LEG ASSEMBLY 100 LBS COIL SPRING 3 LONG 063147 COMPRESSION ROD 062932 DAMPER DROPOUT NUT 041822 a REBOUND ELASTOMER 041475 O RING DROPOUT a LEG CAP 062250 NUT 040688 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N M DAMPER ADJUSTER COMPRESSION ROD SCREW 060268 KNOB 041408 TORQUE 10 30 INCH LBS BOTTOM OUT 063116 TORQUE 1 2 3 5 N m BOTTOM CLIP 040968
7. M 21mm 041150 lt ANTH BOB KNOB 062504 20 PISTON 062562 F O RING 1 4 X 3 8 063432 826 X 409 X 005 SHIM 041139 ANTI BOB NEEDLE 062618 SPRING 041152 O RING 1 4 X 3 8 063432 y O RING 1 4 X 3 8 063432 ZS SEAL WIPER 062972 PISTON SEAT 062130 6 22 O RING 21 6MM X 2 4MM 040524 UPPER BUSHING 041473 LOWER SHAFT 062970 i DETENT BALL 040689 ANTI BOB SHAFT 062617 LOWER BUSHING 041474 062583 RETAINING RING 040679 a WASHER 880 X 515 062342 SAFETY BLOW OFF SPRING 062341 Be SAFETY SPRING SEAT 062343 C DETENT SLEEVE 041657 SPRING SHIM 461 X 832 X 010 041354 2 DETENT PIN 040685 O RING 3 4 X 7 8 062594 SPRING SHIM 800 X 503 041058 ix SPRING 600 X 015 X 31 041381 N ANTI BOB PISTON SPACER 041380 PISTON SEAT 062227 AN Ta SPRING SHIM 8MM X 19MM X 1MM 041148 SPRING SHIM 8MM X 20MM X 1MM 041149 ay S ZA O RING 5 32 x 9 32 041130 LOWER NEEDLE 062570 O RING 1 4 X 3 8 040690 RETAINER 062393 ANTI BOB ROD SEAL 062392 END CAP 062422 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N M BOTTOM OUT ELASTOMER 063116 ANTI BOB PISTON 062303 BOTTOM OUT WASHER 063181 a 50 RETAINING RING 040679 50 SPRING SHIM 826 O D X 409 I D 041139 BETENT STEEVE OEN a SPRING 437 X 015 X 31 041152
8. MPING ASSEMBLY 85 4062 MARS MARS ELITE amp MARS SUPER AIR CAP PISTON ASSEMBLY 85 3033 MRD TUNING MANUAL 85 3696 MICROLUBE TUBE GREASE GUN 85 3810 FORK PUMP 85 4069 ANTI BOB KIT 85 4062 ANTI BOB SEAL KIT 85 3686 ansuverproducts neorporated 28209 AVENUE STANFORD VALENCIA 91355 661 257 4411 www answerproducts com 2001 MARS SERVICE MANUAL P N 85 3694 BUSHING amp SEAL DETAIL 2001 MARS FORK SCHEMATIC FORK BOOT 063249 TPC SPORT TPC SPORT COMPRESSION LOWER SHAFT ASSEMBLY DAMPING ASSEMBLY 062993 062934 TPC REBOUND PISTON 062670 JELLY BEAN 063186 SEAL WIPER 062972 372 X 900 X 005 SHIM 062300 SELF TAPPING SCREW 041330 Sa ADJUSTER KNOB 062503 UPPER BUSHING 041473 TPC LOWER SHAFT 062994 Lh TOP CAP 062583 7 TORQUE 30 50 INCH LBS LOWER BUSHING 041474 et TORQUE 3 5 5 6 N M 8 SPIROLOX RETAINER 062393 wee ADAPTER 062989 et LOC OUT ROD SEAL 062392 7 Q END CAP 062422 we ae a TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N M a O RING 21 6MM X 2 4MM 040524 gt A BOTTOM OUT 063116 a BOTTOM OUT WASHER 063181 RETAINING RING 040679 y BEN we RIGHT LEG 062927 O RING 3 4 x 7 8 040681 oF AIR SPRING CAP ASSEMBLY 061038 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N M AIR PISTON ASSEMBLY 062478 LEFT LEG ASSEMBLY 062931 INCLUDING NEGATIVE SPRING NOT REMOVABLE DAMPER SLEEVE 041574
9. bsite at www answerproducts com IV INSTALLATION INSTRUCTIONS Figures 1 amp 2 Ensure that the proper steerer tube length has been delivered on your fork 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 Never attempt to thread a threadless steerer tube Machining threads will weaken the steerer tube and cause an unsafe condition The only safe thing to do is obtain the proper crown steerer from your dealer FIG 2 Minimum Tire Clearance FIG 1 Race installation Einbau des Laufrings MINDESTABSTAND InstalacU del anillo ESPACIO LIBRE MINIMO s JUE MINIMUM Installation du jeu de direction spaziouseromINIMO 4 Montaggio dell anello della testa CROWN RACE a GABELBR CKEN LAUFRING ARANDELA DE LA DIRECCION CONE DE JEU DE DIRECTION ANELLO DELLIA TESTA MINIMUM CLEARANCE Fork model Minimum clearance brea i Mindestabstand lodelo de horquilla Espacio libre minimo ModEle de fourche Jeu minimum Modello di forcella Spazio libero minimo 80mm travel forks 3 26 83 mm WARNING The steerer tube and stanchions inner legs are a one time precision press fi
10. check O ring for tearing 3 If you think youve done everything right and the Anti Bob is still not functioning properly remove the compression assembly and recheck the oil height 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 661 257 4411 8 00 AM to 5 00 PM Pacific Standard Time Monday through Friday DESCRIPTION PART NUMBER MARS MARS ELITE amp MARS SUPER SOFT RIDE KIT 85 9187 MARS MARS ELITE amp MARS SUPER FIRM RIDE KIT 85 9188 MARS MARS ELITE amp MARS SUPER X FIRM RIDE KIT 85 9226 MARS MARS ELITE amp MARS SUPER BLACK OUTER ASSEMBLIE 85 9192 MARS MARS ELITE amp MARS SUPER YELLOW OUTER ASSEMBLIE 85 9195 MARS MARS ELITE amp MARS SUPER RED OUTER ASSEMBLIE 85 9203 MARS MARS ELITE amp MARS SUPER BLUE OUTER ASSEMBLIE 85 9204 MARS MARS ELITE amp MARS SUPER WHITE OUTER ASSEMBLIE 85 9205 MARS BLACK STICKER KIT 85 4128 MARS RED WHITE STICKER KIT 85 4129 MARS ELITE STICKER KIT 85 4130 MARS SUPER RED STICKER 85 4132 MARS MARS ELITE amp MARS SUPER STEER TUBE LEG ASSEMBLY 85 9213 MARS MARS ELITE amp MARS SUPER BUSHING SEAL KIT 85 4111 MARS REBOUND DAMPING ASSEMBLY 85 3016 MARS ELITE amp MARS SUPER REBOUND DAMPING ASSEMBLY 85 9268 MARS COMPRESSION DAMPING ASSEMBLY 85 3018 MARS ELITE COMPRESSION DAMPING ASSEMBLY 85 3014 MARS SUPER COMPRESSION DA
11. ched through the full travel of the fork 13 Check tire clearance with crown Figure 2 Note All 2001 MARS forks are equipped with a secondary catch dropout WARNING When installing the 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 clear ance allowed 3 26 83mm for 80mm travel fork models Any less clearance can result in accident resulting in serious injury or death See Figure 2 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 WEAKEN THE DROPOUT WILL VOID THE WARRANTY AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INJURY OR POSSIBLE DEATH V SUSPENSION SETUP e If the fork is new break it in with at least one hour of riding before making any changes e Make sure the fork is in good working condition and is properly serviced and lubricated e Make changes in small increments e Keep a record of all changes made for future reference ADJUSTING RIDE QUALITIES 2001 MARS forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the air pressure and spring rate Compression Spring Fine Tuning Fine tuning adjustments are made by adjusting the air pressure and changing the spring Use the chart below as a starting point for finding the proper air spring bas
12. e that the D bh My lube penetrates properly and the go ride Your 2001 MARS Fork requires periodic maintenance cleaning and inspection Moisture and con tamination 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 greased using Prep M grease See Figure 6 IMPORTANT When filling the fork with grease through the Microlube grease ports it is impor tant 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 TPC OIL LEVEL IMPORTANT Maintaining the proper oil level in your TPC is very important Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel and may cause damage to the sys RECOMMENDED LEVEL MAXIMUM 9 MINIMUM tem 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 right leg Leave the left side spring stack air spring in place to keep the fork fully extended Use a tape measure or dip stick to determine the oil level The recommended level is different for each model See Figure 7 It is recom
13. e the dust seal every time the fork is disassembled The seal and bushings should be cleaned and re greased in place INSPECTION 1 Check the dust seal for tears wear or damage Replace if needed 2 Inspect the lower and upper bushing for damage to the Teflon coating Replace by calling Answer Products or an authorized Manitou dealer 3 Check the outer leg arch assembly for nicks deep gouges on outside and inside Replace if damaged 4 Remove boots and check the inner legs for deep gouges and other damage Minor wear result ing in color change is not detrimental to the gold anodized surface Replace if wear is exces sive or if inner legs are damaged 5 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 6 Check the underside of the crown for cracks Replace if cracked OUTER LEG REASSEMBLY 1 Reinstall boots 2 Slide outer leg Arch assembly onto inner legs and fully compress 3 Install and torque 4mm compression rod screw and 8mm dropout nut to10 30 inch lb 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft 4 Grease o ring pop in damper adjuster knob O ring holds knob in place Slide skirt of fork boots onto the dust seal Be sure the lip snaps into the groove 6 Lubricate the fork using the MicroLube system and Prep M grease See page 4 Maintenance COMPRESSION STACK BOOTS a
14. ed on rider weight Recommended Spring Rates for 2001 MARS Forks Rider Weight Air Spring Coil Spring under 115 lbs 80 psi 5psi 1 3 blue 80 pound coil spring 115 145 lbs 100 psi 5psi 1 3 red 100 pound coil spring 145 175 lbs 120 psi 5psi 1 3 red 100 pound coil spring 175 205 lbs 140 psi 5psi 1 3 yellow 120 pound coil spring 205 230 lbs 160 psi 5 psi 1 3 yellow 120 pound coil spring 230 165 180 psi 5 psi 1 3 black 150 pound coil spring Air coil spring rate tuning All 2001 MARS forks use a combination of air and a coil spring The air spring is adjustable via a Schraeder valve located on top of the left leg See Figure 3 The positive coil spring can also be switched with stiffer or softer versions to accommodate for different rider styles and terrain There s also a coil negative spring but it is available in one rate only and is designed to be pre loaded automatically as the positive air spring pressure is increased in other words you dont need to do any thing to tune it Compression Damping Tuning To adjust the MARS Elite Figure 3 Simply rotate the compression damping knob located on top of the right leg and crown Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Excessive damping will give you a harsh ride over sharp bumps like rocky sections but will feel good in large hits like G outs Insufficient compression damp
15. ems to top out or has slight clunking feel when front wheel comes off the ground Excessive preload or insufficient rebound damping will result in atop out Select spring s that better fit your weight and riding style set the air pressure to a 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 Microlube and applying light oil to the stanchions should eliminate the problem Outer legs feel loose on inner legs and bushings a knock or rock can be felt when pushed from side to side A very minute knock is normal with the new harder bushings If the knock is excessive or you can feel the fork rocking then the bushings should be removed and replaced To do this contact Answer Products or an authorized Manitou Dealer A small amount of oil seems to be leaking from top of the right leg at the adjuster cap If you store the 2001 MARS Fork upside down for a extended 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 under normal use So you will not see any leakage with the fork right side up A small leak in that area will not affect the performance of the fork or cause any type of damage We rec ommend that you store your Manitou right side up If this condition causes any problems please contact your A
16. ing will bottom out in the large hit G outs and bob a little while climbing but feel plush on the sharp hits ROTATE DREHEN GIRAR TOURNER RUOTARE To adjust the MARS Super Figure 4 Remove the Anti Bob compression damping assembly from the top of the right leg Adjust the setscrew on the valve seat in to increase compression damping and out to reduce the compression damping Try adjusting one half turn at a time Note Compression and rebound damping on the MARS is factory pre set ADJUST SET SCREW Rebound Damping Fine Tuning Figure 5 To adjust the MARS Elite and MARS Super Simply rotate the rebound damping knob located on bot tom of the right leg Rotating the knob clockwise will increase the damping rotating the knob counter clock wise will reduce the damping Excessive rebound damp ing will give you a harsh ride over repetitive bumps like braking bumps because the fork will pack up Insufficient rebound damping will make the fork overac tive top out and slap back when landing from a jump CZ We suggest that you try adjusting your fork on the active side with minimum rebound Then try it over a variety of terrain and tune in more rebound from there For additional tuning tips we recommend that you obtain a copy of the MRD tuning Manual P N 85 3696 download from the web at www answerproducts com and check out the MRD Race Tuning kits available at your dealer VI TROUBLE SHOOTING Fork se
17. mended that you replace your oil at least once during the year twice if it has been contaminated with dirt mud or other foreign substance Use SAE 5WT Maxima fork oil or equivalent IMPORTANT Before every ride you should 1 Ensure that the quick release skewers are properly adjusted and tight 2 Check the entire fork for any obvious damage 3 Check headset adjustment 4 Ensure that the front brake cable is properly seated in the cable retainer amp check brake adjust ment NOTE The Fork does not need to be removed from the bicycle for general disassembly assembly or cleaning In addition coil spring replacement is accomplished by removal of outer leg arch assembly INNER FORK LEGS amp CROWN The inner fork legs and steerer 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 REMOVAL OF OUTER LEG ARCH ASSEMBLY 1 Use a 4MM Allen wrench to remove the lower compression rod screw from the left leg dropout Pop out the damping adjuster knob from the right dropout A small screwdriver may be help ful Use an 8MM allen wrench to remove the dropout nut Fully compress the fork if needed to prevent the compression rod and damper shaft from turning while removing screws 2 Pull the outer leg assembly down to remove from the inner legs and crown 3 Remove fork boots Note It is not recommended to remov
18. mp COMPRESSION ROD REMOVAL 1 Remove outer leg assembly Slide fork boots off of inner legs Press the bottom clip off the compression rod Slide off the bottom out elastomer from left leg compression rod Using a 15 16 wrench or socket unscrew the left inner leg cap Then remove the compression rod elastomer and push rod AWN AIR SPRING DISASSEMBLY 1 Remove compression rod 2 Let air out of air spring and remove top 3 Push piston out top of left leg with a 1 2 smaller rod Push through the center of the air piston stop Air piston stop is not removable COMPRESSION ROD amp AIR SPRING INSPECTION 1 Check the compression rod for obvious damage Check the fork boots for obvious damage Check all springs for obvious damage Replace if necessary Clean and inspect piston and seals replace if seals are worn nicked or torn Check all other parts for obvious damage replace if necessary Replace all seals that have been removed nuh COMPRESSION ROD amp BOOTS REASSEMBLY Clean all parts thoroughly Grease compression rod lightly Be sure rebound elastomer is installed onto compression rod Slide on end cap second stage elastomer and install bottom clip Install into left leg Torque to 10 20 in lbs 1 1 2 5 N m Slide boots onto inner leg WN AO AIR SPRING REASSEMBLY 1 Grease piston seals and threads in top of left leg 2 Push the piston into the leg wi
19. nswer Products dealer or call our warranty tech department for prompt service VII MAINTENANCE IMPORTANT The 2001 MARS should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replacement parts IMPORTANT Use of fork boots is recommended to keep your MARS fork performing at it s optimum for extended service cycles and maintaining maximum life of fork Use of this fork without fork boots will require frequent service intervals to maintain performance and normal life of fork Warranty will be void if fork is found to show that boots where not in place and frequent service was not performed MICROLUBE All 2001 Manitou forks come standard with the MicroLube lubrication system Located at the back of the fork is a small fitting that is the heart of the MicroLube system This is where you inject grease The major benefits of the MicroLube system are that it is lightweight and effective Only a small quantity of grease is needed to properly lubricate the fork and the fitting for injecting grease puts it just where it needs to be MicroLube also greatly decreases the time you have to spend servicing your fork because you can regrease the fork without disassembly With MicroLube you can simply grease your fork as needed and that s what we recommend If you feel any stiction developing with your fork give about 10 squirts with Prep M lube Push the fork up and down a few times to ensur
20. ntly into shaft thread until it stops then back off two turns for initial adjustment Slide shaft assembly through the plastic end cap slide on 2nd STG Elastomer cup washer and snap ring place detent ball in place and slide clear detent sleeve over it Insert into right leg and thread in end cap Torque 30 in lb 3 5N m max Install outer leg assembly see Figure 9 Add 5 WT Maxima or equivalent oil Do not over fill Check oil level see Figure 8 COMPRESSION DAMPER DISASSEMBLY MARS Elite 1 The compression damping assembly is almost identical to the lower shaft assembly Remove compression damping assembly from top of right leg 2 Unscrew the compression damping adjuster all the way until it stops The knob and the nee dle do not need to be removed The shaft also does not need to be removed from the cap The threads are bonded to prevent leaking 3 Do not remove piston assembly from shaft Remove the valve nut and disassemble damping stack make note of the exact order of the shims and spacers MARS Super 1 The Anti Bob compression damping shaft is assembled in a fixture at the factory to assure prop er alignment of the pistons and should not be disassembled COMPRESSION DAMPER INSPECTION 1 Check the cap o ring all models and piston o ring Anti Bob only for damage 2 Check shims for permanent bends or damage 3 Check all other parts for obvious damage replace if necessary 4 Replace all seals that have been remo
21. t at the factory and cannot be removed from the crown Replacement of the entire crown steerer assembly must be done to change steerer tube diameters or increase length of threaded steerer tubes Removing and replacing the steerer 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 steerer tube to fit your bicycle head tube 3 Remove crown race from old fork and press onto 2001 MARS steerer until seated on crown See Figure 1 4 Clean and grease headset bearing and crown races 5 Install lower bearings on fork crown race 6 Install steerer tube into head tube frame 7 Install upper bearing spacers and stem 8 Install handlebars Torque stem handlebar pinch screw and stem clamping system to manufac turer s instructions 9 Install stem cap adjust and tighten headset per manufacturer s instructions 10 Install brakes and adjust per manufacturer s instructions When installing disk brakes the caliper must fit or have an adapter to fit post style mounts with 74mm spacing 11 Adjust front wheel quick release to clear the 0 275 7MM thick secondary catch dropout The quick release must be tightened after it has adequate thread engagement 4 or more threads with the release adjusted to bicycle per manufacturer s specifications 12 Install brake cable per manufacturer s instructions Route disk brake lines so that they will not kink or be pin
22. th the smaller hole facing down Make certain piston is straight and gently rock it back and forth while pushing down until it is past threads Install compression rod as described above Install outer leg assembly as described in section 10 Pour 2 5 CC of 40 wt oil top of air piston 6 Install air cap pressurize system and install knob WARNING Do not fill air spring with more than 190 psi ok w REBOUND DAMPER DISASSEMBLY Note Disassembly of the damping stack is not required unless you want to change or replace the shim stack 1 Remove outer leg assembly 2 Remove the right compression damping assembly from the top of the right fork leg and pour the oil out of the top of the fork and discard appropriately 3 Using a 15 16 open end wrench or socket unscrew the plastic end cap and pull the lower shaft out of the inner leg Note Steps 4 8 apply to MARS Elite and MARS Super only 4 5 6 Remove the clear plastic detent sleeve and capture the 1 8 dia detent ball Adjuster needle may be unscrewed from the shaft Remove the retaining ring then slide off the cup washer amp bottom out bumper Do not remove the threaded plastic end cap at this time Sliding the seal over the retaining ring groove may damage the seal Clamp shaft in soft jaws or collet and remove piston as a complete unit slide end cap off of top of shaft Remove the valve nut and disassemble damping stack make note of the exact order
23. ucts recommends that you periodically inspect your fork for wear and damage Inspect the crown inner legs and outer leg dropout and break arch areas for cracks or damage Ill WARRANTY INFORMATION Any Answer Products Manitou fork found by the factory to be defective in materials and or work manship 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 at 661 257 4411 for a return authorization number RA Instructions for repair return or replacement shall be given at that time at Customers in countries other than USA should contact their dealer or local distributor For a list of international distributors visit our we
24. ved COMPRESSION DAMPER REASSEMBLY MARS Elite 1 Assemble shim stack and spacers onto the piston seat in exact order that they were removed Refer to Figure 15 Apply a small amount of blue Loc tite to piston seat threads Install and hand tighten valve nut Be sure large blow off washer will slide over piston spacer and com press the small spring Torque valve nut to 12 in lb 1 3 N m max over tightening will dam age the piston 2 Install compression damping assembly into the right leg The oil level should cover the com pression valve when the assembly is installed See figure 7 MARS Super 1 Lightly grease the o rings and threads on the Anti Bob With the Anti Bob open install the Anti Bob into the right side leg Be careful as you do this to avoid damaging the lower rubber o ring The fit should be tight so SLOWLY twist the Anti Bob as you slowly lower it in the leg Do not use the Anti Bob on off knob to turn the assembly when tightening 2 Once the Anti Bob assembly is firmly in place flip it to the closed position and while holding the front brake compress the fork It should only move a very small amount and the Anti Bob should feel firm Remember that there is a safety blow off which allows the fork to move under extreme bump forces when closed so if you push it very hard you will see more than a few millimeters of movement If at the end of installation the Anti Bob does not function properly remove the Anti Bob and

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