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Fork Service Manual

1. EES 55 2515 55 2515 n _ Pestee sco 2 PB AL Smeeni sey 1 83 2844 _ 83 2845 83 2846 AL SvTC26 SP RIT 83 2847 E LLL TexturedBlack Gray 2690 O Candy Blue Matte Black Textured Black Integrated Textured Grey Integrated Matte Silver Gloss Silver Textured Black Matte Black Black Textured Gray Silwer it Mate Silver Textured Black Integrated Textured Grey Integrate Mate Black Matte Silver Matte white Textured Black Tex Grey Tex Grey Intergrated F For Dark Colors For Light Colors 5 En J J e e a SEE Booster Soft 83 2802 Soft 83 2854 83 2859 83 2468 83 2855 83 2860 83 2864 Firm 83 2473 83 2865 M Firm 83 2857 Taps 83 2866 MERE 83 2863 as 2er0 pM EM 130 83 2870 00 130 RT Wind Down 15 145 RT Wind Down 20 150 RT Wind Down aS aa T Bottom Assy Ff 83 2888 Lower Spring End Cap Assy ddr o Loo S Y 11 130 127 83 283 pM 59 5964 63 2597 03 2013 25 5293 63 24856 m E m 4 93 2951 Hixon ccs tis rire rte Model Comp Flite Super Air Intrinsic
2. OE vus e cce8 2020 69 ea cc ea e acc es bocce z ae BE hee ac cae eal zz 8 10 0 104 4 L ES Aeg 103 3 FLEC ES a p B5BLc EB EE JAS 97 1 45819 eet E CV otiaesa usL V K oe X EB O RIEN FBLc eB FSbe ES 498d OL 2 vents OOOO Lc eae 00 Oo FOOT Ay ay dues 95195 g2 ASL LOH SHH 024 OF 1095 yng HH burgsng noumjog poy duin yen py arel priporg duin Suy apr WH 1943215 OQ ais ah OQ 215 OQ ais ah OQ 115 OQ JLS an Od OLS OQ JLS an OQ JLS ah 215 215 215 915 215 915 OLS Assy de gt jessy dez Assy de tajyenipy peo ald py duieg puqy sueag H A x MM Burgo 0 7 19942102 07 HAND s Wry 1942 0r 97342402 s H T Jenae oh WAND Assy 309m 2dl mwu 4201 034 duweg duin uni apo Model Travel mim Comp Damp FFO Lo
3. F irtTi Qu Qu 4 3 246 013 246 53 2466 53 2469 3 24 03 2411 3 24 2 24 3 24 a 2475 53 2476 E qi 00 Comp Rod Travel Adjust 83 253 ag 2483 15 145 RT wing Down T Bottom 4225 53 203 53 2480 Comp Rod Bottomout Spacer Air Push Rods 63 2455 ds ih m 2 2 3 1 q q E Ja c 53 2483 Bushing Kit LE 4 Thru Axel 8323987 Air Piston Kit EEE Knob Kit Dust Seal Kit o O Ring Kit 892488 IT O Ring Kit BR2487 Travel mim Comp Damp FFO Comp Damp Rbnd Damp Hon Adj Rbnd Damp Adj Spring Cap WO Adjuster Cap Assy CrnistrLeg Quter Leg Assy NB STD DO NB STD DO NB STD DO NB Hex Axel NB Hex Axel Sticker Kit Ride Kits Comp Rod Travel Adjust Comp Rod Bottomout Spacers Bushing Kit Thru Axel Thru Axel Quick Release Kit Knob Kit Dust Seal Kit 0 Ring Kit Stance 100 130 120 150 100 130 150 RAD 150 170 83 2886 83 2888 33 2887 832888 B 8328890 83 2890 83 2891 83 2890 83 2891 33 2894 33 2895 03 2032 03 2833 BEA HS SIT a DE Silver 257 P 05 5903 05 5962 05 9965 83 2371 183 2373 83 2375 s 83 2901 83 2302 83 2903 83 2903 83 2903 83 290
4. Check O ring tighten cap to proper BEEN Air Top Cap leaks Torque replace parts as needed Oil leaks from Remove Casting from Inner Legs reinstall Wiper Seals Seal not seated properly or replace seals Nicks or scratches on Replace Crown Steerer Inner Leg inner legs Assembly Follow instructions for removal and Too much Semi Bath oil installation of Outer Casting Remove Casting from Inner Legs reinstall Wear or replace seals Oil leaks from bottom of damper shaft Casting Replace Rebound Damping assembly Rebound damper shaft O Replace O ring on threaded end of NEN ring damaged Rebound Damping assembly Compression Rod Bolt Check O ring on bolt to see if it is EE leaks damaged and then reinstall Resize bushings or replace with new ones Lack of Travel Tight Bushings if damaged Hydraulic lock out Replace Rebound Damping assembly 7 77 Follow instructions for removal and MEN Semi Bath oil volume installation of Outer Casting Check oil level Replace Rebound Damper oil volume Damping assembly if needed Visually inspect fork call Answer Fork alignment Products Customer Service TROUBLESHOOTING CONT Service Manual Symptom Cause Page Fork Top out Damping Replace Rebound Damping assembly Inspect and replace Top out spring if Top out spring damaged needed Damping oil volume not Check oil level Replace Rebound correct Damping assembly if needed Fork Bottom Refer to SAG Set up in
5. Check for any cracks around the Axle bearing area on the Outer Casting If there are any found replace the casting Assembly Instructions Installation of Hex Thru Axle Insert the Clamp Nuts into the small hexagonal hole in each of the dropouts Insert a Spacer Washer 062876 in the slot of each dropout Start two clamp fixing bolts in each dropout Do not tighten these bolts down at this time Hold the wheel between the dropouts of the fork Insert Hex Thru Axle small hex first into the outside of the left drop out as you are facing fork and push it through the hub of the wheel and into the right drop out Thread the Thru Axle nut into the end of the axle that is in the right drop out Thread the Thru Axle Nut in about half way in do NOT tighten it down fully Set the end of the axle flush with the outside of the left drop out Tighten the 3mm clamp fixing bolts to specified torque value as called out in the Schematic and Technical Specification Chart at the end of manual Finish the installation by tightening axle nut to specified torque value and then tighten the clamp fixing bolts on the right drop out to the specified torque See Fig Quick Release Hex Thru Axle Removal of the QR Thru Axle A oe Ol Pull down on the QR lever on the right fork leg to relieve the tension on that fork leg Unscrew the QR Axle Bolt on the right hand side of the fork Pull down on the QR lever on the left fork leg to
6. 2006 Fork Service Manual Rev NC Table of Contents Description Page 3 Front Suspension Terminology r Section 1 Disassembly Assembly Instructions Damping Systems A B Kits Section 2 Disassembly Assembly Instructions Spring Systems C Kits Section 3 Disassembly Assembly Instructions Castings D E Kits Troubleshooting Chart Technical Information Oil Levels Torque Specs Ect 34 35 Service Kit Charts 36 45 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 INTRODUCTION This manual is intended to guide the user through basic service of Manitou Empire 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 of suspension fork service at this time our primary focus 15 to offer service kits that minimize the amount of downtime and labor involved Important information is highlighted in this manual by the following notations WARNING Failure to follow WARNING instructions could result in severe
7. into the right inner leg Fill leg about full Take a rag and cover the top of the right inner leg and then stroke the SPV damping assembly up and down about 5 times This will insure that oil gets below the piston and not create an air space Extend the damping assembly all the way out and then fill the inner leg to the specified oil level in the Fastener Torque and Setup Levels Chart at the end of the manual Insert the Volume control assembly into the top of the right inner leg and tighten it to specified torque value Be sure that you unscrew the red 16mm Hex shaped Volume control nut all of the way out counterclockwise until it is flush with the black outer surface of the cap after you tighten the entire assembly into the inner leg Assembly of SPV Damping System Cont 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 1 Turn completed crown steer leg assembly upside down so that the compression rod and damper shaft are facing you You will see a bottom out bumper on the damper shaft slide this bumper down towards the end cap that is threaded into the inner leg This will help in keeping the shaft extended as you install the outer casting You could also insert air into the damper leg through the Schrader valve on top of the right leg SPV models This extra pressure will h
8. usually neoprene rubber or Buna that keeps contaminants out and or working fluids in Semi Bath A lubrication system that uses a lubricating oil to keep the bushing surface and stanchion legs inner legs as friction free as possible during movement of the stanchion legs Spring Rate The rate at which the resistance of a spring increases as it is compressed SPV Stable Platform Valve new damping system that allows the rider to set the pedaling platform that he desires to pedal most efficiently in all situations It is dependent on the pressure that the SPV valve experiences from the movement of the wheel vs the terrain and the platform that is set by pressure introduced to other side of the SPV valve through changes of air pressure working on the damping oil SPV Evolve The latest version of SPV damping technology that has increased its performance with modifications to the original design Slider Outer Casting The tube outer casting leg of the suspension fork thatO remains fixed to the wheel It slides up and down on the stanchion leg inner leg Stanchion Clamps Double Triple Clamps the portions of the fork crown that clamp around the stanchion legs above and below the head tube of the bicycle frame on specific long travel applications 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
9. 2mm allen wrench Apply a drop of blue LocTite and tighten to 10 in Lbs Turn the fork upright install the detent springs and balls in to the top Install the compression adjusting knob and screw secure them using a p Coil Spring Service Instructions Removal Coil Spring Assembly E result in injury or possible death E Fig 1 For Forks with Pre Load adjuster assemblies coil spring systems To Change the Spring 1 Rotate the Pre Load adjuster knob all of the way counter clockwise to reduce the pre load on the spring Rotate adjuster on top left of fork crown counterclockwise until it stops This will relieve spring tension on the fork 2 Remove the adjuster knob from the top of the Pre Load adjuster assembly by unscrewing the 2mm Allen head screw See Fig 1 Use 20mm socket and unscrew the remainder of the assembly from the crown Pull the spring out of the fork See Fig 2 4 Generously grease the spring and insert it into the inner leg The spring needs to seat onto the top of the compression rod 5 Screw the preload assembly into the inner leg and tighten per the fastener torque guide at the end of this manual 6 Install the adjuster knob and 2mm hex screw For a complete teardown of the spring system including the compression rod 1 You must remove the outer casting from the inner legs a From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to rem
10. 95 5831 26 95 5832 95 5839 93 2298 5 50 54 85 3835 85 5835 85 5837 90 50858 95 5039 93 2502 83 23500 93 2424 Silk Blue Cobalt Orange Yellows Candy Chrome Candy Red Candy Blue Matte Black Matte Silver F For Dark Colors F For Light Colors 83 2278 AD Booster X Soft 83 2278 83 2284 83 2288 83 2278 83 2284 63 2288 Soft Medium 83 2281 83 2286 83 2291 83 2281 83 2286 83 2291 p 85 5577 85 4986 85 4989 Firm Firm 83 2283 83 2288 83 2283 183 2288 83 2274 0 83 2274 85 8857 5 24 83 2274 25 5280 83 2274 1 524 7 555860 0 100 RT Yina Down 12211 12221712 0 120 RT Wind Down LT 93 2321 95 5364 2 24222221 5 12E 85 5321 25 5567 IT Bottom 2 55 Y 95 2275 85 5266 85 59656 85 5965 05 5201 95 5202 95 2979 83 2980 93 2979 83 2990 85 2980 83 2990 63 2979 83 2980 a eae m Lh a 5 E m m e a T ia cA Model Travel mm Comp Damp Lock Out TPC Comp Damp Platform Plus Remote L O Assy Click It Remote L O Lever Left Click It Remote L O Cable Click It Remote L O Cable Guide Click It Remote L O O
11. Intrinsic Travel mm 145 ETAD 145 145 145 IT TPC Cartridge 83 2811 000 Rec i CID Cartridge Cantridge Damping Rebuild Parts Cartridge Rebound Assy AA 83 2813 Cartridge TPC Assy D 83 2814 Cartridge CID Assy 83 2815 Cartridge Body 83 2816 Cartridge End Cap ea 2817 Spring Cap ss24s0 WD Adjuster Cap Assy ccc NENNEN Air Cap 112 8532449 22 Assy 22 ss2446 IT Top Cable Guide 88 2818 _ IT HB Lever 63 2319 _ Crn Str Leg ee Steel S T 25 AL 1 5 SIT Outer Leg Assy MB STD DO Textured Black MB STD DO Textured Gray MB STD DO Black 26 MB STD DO MB STD DO Candy Blue MB STD DO Matte Black MB STD DO Matte Silver MHB STD Do Gloss Silver ag 2795 MA Hex Axel Textured Black 62 2826 Hex Axel Mate Black 2458 Hex Axel Black Hex Axel Textured Gray 63 2629 MA Axel Sher oo Axel it a3g 2798 Hex Axel Matte Silver 24 NE GR Hex Axel Matte Black 93 2823 MA GE Hex Axel Mate Silver 63 2624 GF Axel Matte hite o 2o02 GE Axel Textured Black Boa3a 282r7 MA 28 Hex Axel Grey 3 25 50 SCRE hae ee a olen 83 2831 23 2832 23 2833 83 2834 For Light Colors Ride Kits Booster
12. Reinstallation To reinstall the cartridge in the fork 1 2 3 Make sure that the rebound adjuster is screwed in clockwise fully Replace the o ring on the rebound shaft to match the one that was installed when you removed the assy either black or clear Slightly compress the fork and insert the Cartridge Damper System into the fork leg Turn the cartridge clockwise to engage the threads of the rebound assembly Release the fork so it extends to its full travel If you drained the Semibath oil previously add the proper weight and amount as listed in the table Using a 22mm socket screw the top cap into the fork and tighten it to in Ibs N M Invert the fork remove the Rebound Casting Plug Answer P N or rubber stopper from the lower casting Insert an 8mm Allen wrench into the end of the Rebound Shaft on the bottom of the right leg Turn the wrench in a Counterclockwise direction in order to tighten the damper shaft in the casting See Fig 15 You are turning the Damper Shaft in a way that causes it to thread out of the casting leg The end of the damper shaft should be flush with the end of the casting See Below First thread of rebound shaft even with the surface of the outer leg Thoroughly clean the area in the end of the rebound shaft of any trapped semi bath oil Otherwise it will give the appearance that the fork is leaking Install the rebound adjustment knob and secure it with the screw using a
13. SPV Volume Control Cap Red Hex Shaped Top Cap from top right of the crown with a 24mm Socket Turn fork upside down over drainage pan to empty Damping oil from the inner leg Stroke the Damper shaft on the bottom of the inner leg 3 5 times to purge the leg of oil that is caught below the Rebound piston Unscrew Damper end cap from the bottom of the right leg Fig 3 Pull the SPV Damping assembly out of inner leg To check the function of the SPV valve Visually inspect the gap between the SPV valve and the bottom of the damping piston It should have approximately 1mm of space Fig 4 The valve should spring back to its open rested position after compressing it with your fingers Fig 5 If the valve is not responsive or all the time closed it is bad and the assembly needs to be repaired or replaced Assembly of SPV Damping System 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 Install SPV damping assembly into bottom of other inner leg Be sure to check the function of the SPV valve and apply a thin layer of Prep M grease onto o ring that is around the piston at top of assembly Install the assembly and tighten end cap to specified torque value Fig 6 Turn Crown steer leg assembly right side up so that the crown of the assembly is facing you Extend the SPV damping assembly all the way out and then pour damping oil P N 85 0023
14. Tuning section of SO out Too much SAG Owners Manual Bottom out Bumper Inspect and replace Bottom out Bumper if damaged needed Damping oil volume not Check oil level Replace Rebound correct Damping assembly if needed Resize bushings or replace with new Play in Fork Loose bushings ones if damaged Loose Compression Rod bolt Tighten bolt to specified torque shaft Tighten Shaft to specified torque Loose press fit tolerances Call Answer Products Customer Service M e Problems Various See Air Assist Troubleshooting Guide NE 1 Problems Various See Lock Out Troubleshooting Hemote Lockout Problems Various See Remote Lockout Section Model Travel mm Comp Damp FFO Lock Out TPC Remote L O Assy Click It Remote L O Lever Left Click It Remote 1 0 Lever Right Click It Remote 1 0 Cable Click It Remote L O Cable Guide Click It Remote 1 0 O Ring Kit Click It Remote Lever Jelly Beans Rbnd Damp Hon Adj Rbnd Damp Adj Pre Load Adj Crn striLeg Outer Leg Assy STE STE STE STD Sticker Kit Ride Kits Comp Rod Comp Rod Bottomout Spacers Bushing Kit Knob Kit Boot Kit Dust Seal Kit O Ring Kit Click It L O Retro Kits HOT WARRANTY Air Cap Ride Kits Air Push Rods Air Piston Kit Trace Elite FFL super FFD R Platinum Lockout Platinum Lockout 80 or 100 pole 1 lo 85 5253 B 85 53
15. by depressing the Schrader valve Be sure to hold fork with the top of the crown facing upwards Note When the air is released there is a mixture of the oil and air inside the leg that maybe discharged 2 If you have not removed the Outer casting follow these instructions then proceed to next step a From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw b From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Screw the rebound all the way in clockwise remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork c Usea 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting see Fig 1 d Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting If the fork uses the Semibath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan 3 Unscrew the end cap on the bottom of the inner leg and remove compression rod assembly This will consist of a compression rod bottom and top out bumpers the end cap and should be followed by a coil spring and then another rod air push rod This spring is the one that would be changed if the fork s SAG needed to be changed beyond the capabilities of the air p
16. 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 No Tools SPV Volume Adjust A new system designed to work with SPV as a control of the compression ramp up rate of the fork It has a 4 position range of adjustments from linear to very progressive adjustment doesn t require a socket No Tools Hex Lock Axle Update of patented Hex Lock through axle provides simple and effective wheel removal system without requiring tools Features dual quick release to remove pinch pressure and the axle is tighten and lossened with hand turned side tension bolt Oil Damping A system that uses the resistance to oil flow through holes in a valve to provide a means to alter the rate of suspension compression or rebound Oil Level The level of damping oil needed for the optimal damping performance of a suspension It is measured as the air space distance between the top of the stanchion leg inner leg and the height of the oil inside of the leg The fork must be completely extended in order to get an accurate measurement O Ring A soft flexible neoprene or Buna rubber ring with a round cross section which is used for sealing and retention FRONT SUSPENSION TERMINOLOGY CONT Oil Weight A description of the relative viscosity of oil such as hydraulic oil Oil with low weight numbers 5wt or 7wt flows
17. inner leg The spring needs to seat onto the top of the compression rod See Fig 5 3 Screw the preload assembly into the inner leg and tighten per the fastener torque guide at the end of this manual 4 Install the adjuster knob and 2mm hex screw 5 For Grease Forks Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 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 Proceed to Step 6 6 For Semibath Forks Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil 7 Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting 8 Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten per the Schematic and Torque Specification Table for your fork 9 Install rebound adiuster knob if applicable 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 Air Assist
18. or open end wrench Syringe for Semi Bath Oil Air pump 32mm Leg Thru Axle and Quick Release Thru Axle Instructions Standard Hex Thru Axle Removal Instructions Removal of Hex Thru Axle 1 Loosen the two 3mm clamp fixing bolts on the right fork leg See Fig 1 2 Remove the Thru Axle nut from the right side of the Thru axle 3 Loosen the two 3mm clamp fixing bolts on the left fork leg 4 Push the Hex Thru Axle out of the dropouts from left to right and completely remove it and the front wheel from the fork Assembly Instructions Installation of Hex Thru Axle 1 Insert the Clamp Nuts See Fig 3 A into the small hexagonal hole in each of the dropouts 2 Insert 2 Spacer Washers p n 062876 See Fig 3 in the slot of each dropout See Fig 4 3 Start two clamp fixing bolts See Fig 3 C in each dropout Do not tighten these bolts down at this time 4 Hold the wheel between the dropouts of the fork 5 Insert Hex Thru Axle small hex first into the outside of the left drop out as you are facing fork and push it through the hub of the wheel and into the right drop out 6 Thread the Thru Axle nut into the end of the axle that is in the right drop out Thread the Thru Axle Nut in about half way in do NOT tighten it down fully 7 Setthe end of the axle flush with the outside of the left drop out Tighten the 3mm clamp fixing bolts to specified torque value as called out in the Schematic and Technical Specificati
19. 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 Thru Axle Hex lock A device used for mounting a thru axle hub to special outer legs that are not made for standard quick release hubs Manitou s Hex lock thru axle system is a special patented system utilizing a hex shaped end that increases the stiffness of the fork and reduces slippage in the joint between the axle clamps and the axle 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 TPC Twin Piston Chamber a patented damping system that has independent pistons for rebound and compression The system utilizes a mixture of air and oil in the damping leg of the fork to enhance the damping performance A variation of TPC that has added a floating piston to the compression damper to enhance the performance of the compression damping under the load of bigger hits Travel The amount that a wheel moves between the most compressed and the most extended states of the suspension Viscosity A description of how a liquid flows Liquids with higher viscosity are thicker flow less easily or quickly than liquids with low viscosity This has an affect on the damping speeds of rebound and compression Volume Control A new system designed to wo
20. the bow is in the travel of the shaft it will cause the Quad ring that it is passing through to distort Thus air transfers from one chamber to the other and the fork will extend by itself If this is the case you will need a new top assembly and an O ring kit Refer to Figure 6 Make sure that the valve core in the Schrader valve is tight and does not stick open or closed If this is faulty replace this valve core with a new one Any bicycle tube valve core Will work as well as any valve cores that we currently use on any of our other products Note Always replace all o rings and seals provided in the IT O ring kit each time you take the system apart this will insure that you receive maximum performance Installation of the IT Control Wire In order to change the inner control wire start by following IT disassembly steps 1 2 6 7 amp 8 Once you have the upper assembly out of the fork use the adjustable wrench and the 12mm Open End wrench to unscrew the top cap from the shaft of the assembly Refer to Figure 7 at the right As you unscrew the top cap you will feel a little tension created by a spring that is under the cap Separate the top cap from the shaft once you have completely unthreaded the two pieces Pull on the inner wire in order to remove the machined stopper with the cable end in it from the shaft You can now unhook the cable from the stopper and from the cable head end pull the cable through the spring the
21. through the valving with less resistance than higher weight numbers 100r 15 wt One Point Five Standard 1 5 inch interface standard for frame head tubes headset cups stem and steer tubes which allows for the lightest weight and strongest design in 170mm single crown forks This design greatly improves the control and steering precision of the fork It is used predominately on forks with longer travel and the intended use is for more hardcore extreme riding 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 Piston In front suspension the part of the damper that slides back and forth inside of the damping leg that houses the valves It can also refer to the air piston in the air spring assembly that slides back and forth compressing the air thus causing a change in the spring rate of the suspension Porosity The condition or property of having pores in a material that will allow gas or liquid to pass through it Platform Plus Damping A new damping system found on 2005 Rear shocks featured on Metel and Radium s This system will establish a pedaling efficiency platform similar to SPV but is done through unique valving that is not adjustable helps in bump control Rapid Travel Wind Down Systems that are used to control the travel of suspension forks Also known as a
22. to empty Damping oil from the inner leg otroke the Damper shaft on the bottom of the inner leg 3 5 times to purge the leg of oil that is caught below the Rebound piston Unscrew Damper end cap from the bottom of the right leg and then carefully pull the damping assembly out of inner leg See Fig 3 ooocp Assembly of FFD and TPC Damping System 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 10 Install the damping assembly into bottom of inner leg Be sure to apply a thin layer of Prep M grease onto piston ring that is around the piston at top of assembly Install the assembly and tighten end cap to specified torque value 11 Turn Crown steer leg assembly right side up so that the crown of the assembly is facing you Extend the the damping assembly all the way out and then pour damping oil P N 85 0023 into the right inner leg Fill leg about 1 4 full Take rag and cover the top of the right inner leg and then stroke the the damping assembly up and down about 5 times This will insure that oil gets below the piston and not create an air space 12 Extend the damping assembly all the way out and then fill the inner leg to the specified oil level in the Fastener Torque and Setup Levels Chart at the end of the manual All top caps for Damper and Spring sy
23. turn increments until full travel is reached Fi 8 Install the compression rod screw and tighten per the Black Schematic and ig 8 Torque Specification Table 9 Forforks with the Wind Down system follow steps 2 5 from the Wind Down Travel Adjust assembly instructions 10 Pressurize the SPV system to 50psi and check for proper damping function Use 8mm Allen wrench 2mm Allen wrench 11mm Nut Driver or open end wrench Syringe for Semi Bath Oil Air pump Fig 9 Fig 6 Cartridge Damping System Service All Cartridge Damping systems are serviced the same regardless of which forks they are used in the only difference between the different models is the length of the cartridge body compression assembly and or in some instances the length of the rebound assembly A chart of the dimensional differences is provided at the end of the section for your reference All Knobs o rings seals and end caps are the same One of the advantages to the system is the fact that you can service the system without having to remove the outer legs from the fork Cartridge Damper System Removal Remove the cartridge from the fork 1 Screw the rebound adjuster in clockwise fully so you are at the max rebound position Remove the rebound knob from the bottom of the fork by unscrewing the fixing bolt with a 2mm allen wrench Pull the knob out of the rebound assembly Remove the compression knob from the top of the fork using a 2mm all
24. 18 a 83 2407 A SIUShok _ 83 5568 A STDFork _ 83 2628 a MEN 83 2973 83 2183 83 2408 O 9036 83 2987 10 pack 83 2987 10 Pack 5 se 7112 0000005 85 4810 D Steel S T 26 000 esso 83 5561 83 5660 83 5561 83 5560 83 5961 82 5560 83 5561 _ BK ALS TQB STDISM 83 5562 83 5563 83 5562 83 5663 83 5662 83 5663 825562 83 5563 n 5 5 1 Black 26 Silver 26 24MM PMedum _ 82138 83 2139 832036 83 2133 EE 83 2800 832610 83 2611 83 250 83 2511 Hu EQ O O __ HM TED e 83 5578 83 5577 835578 83 5977 83 3578 83 5577 83 5578 _ EM eee _ t o mo wo 10 INNEN 925 I I I I I I I TB o E eS 5252 74 15 85 83 2583_ 013 5900 Model Travel mm Comp Damp FFD Lock Out TPC Remote 1 0 Assy Click It Remote 1 0 Lever Left Click It Remote 1 0 Lever Right Click It Remote 1 0 Cable Click It Remote 1 0 Cable Guide Click It Remote 1 0 O Ring Kit Click It Remote Lever Jelly Beans Rbnd Damp Hon Adj Rbnd Damp Adj Pre Load Adj CrnistriLeg Outer Leg Assy STD ST
25. 6 83 2906 83 2904 83 2905 amm 830395 83236 685980 ooo 0 1 1 0 LOK 0 2 Gold Label Jump Series Code Series 1 Series 2 Travel mm Po 1 80 100 80 100 Comp Damp A ee Rbnd Damp Adj B 8955128 Spring Cap Outer Leg Assy t MEN NB STD NB STD NB STD MB STD DO White NB STD NB STD NB STD NB STD NB Hex Axel NB Hex Axel NB Hex Axel NB Hex Axel NB Hex Axel Hex Axel White NB Hex Axel NB GR Hex Axel NB GR Hex Axel NB QR Hex Axel NB GR Hex Axel NB GR Hex Axel Sticker Kit Ride Kits O s eee TBD Comp Rod Travel Adjust 85 4494 7 0 83 2789 Bushing Kit E 89594 Thru Axel 83 238 Knob Kit 1 8328080 Dust Seal Kit 83 5293 O Ring Kit 83 2838 Grind Bolt X 854487 Model Travel mm TPC Cartridge CID Cartridge Cartridge Damping Rebuild Parts Cartridge Rebound Assy Cartridge Assy Cartridge CID Assy Cartridge Body Cartridge End Cap Spring Cap Crn StrLeg NB Hex Axel NB Hex Axel NB GR Hex Axel NB GR Hex Axel NB GR Hex Axel NB GR Hex Axel NB GR Hex Axel Sticker Kit Ride Kits Comp Rad Comp Rod Bottomout Spacers Bushing Kit Thru Axel Thru Axel Quick Release Kit Knob Kit Dust Seal Kit O Ring Kit Travis single Intrinsic Intrinsic Intrinsic Intrin
26. BLE 1 WHEEL CLEARANCE TORQUE SPECIFICATION 5 7 6 8 Mm 50 60 in Ibi 11 3 12 4 Nm 100 110 5 0 6 2 Mm 45 55 28 34 Nm 25 30 0 45 0 65 Nm 4 6 in Ibi 0 34 0 56 Nm 3 5 in lbi MINIMUM BRAKE ARCH MAXIMUM CLEARANCE TIRE WIDTH FORK MODEL See Figure Figure B LOLA 13 mm 47 mm EMPIRE 13 mm 47 mm TRACE 8 5 mm 60 mm AXEL 8 5 mm BO mm SPLICE 8 5 mm 60 mm BLACK 8 5 mm 60 mm RF 10 mm 60 mm MINUTE 8 5 mm amp 3 mm MIXON 17 mm BS mm GOLD LABEL 14 2 mm 65 mm STANCE 12 mm BS mm TRAVIS 11 4 mm mm TABLE 3 MEASUREMENT FORK TRAVEL SAG 60 mm 9 12 mm 75mm 12 15 mm 30 mm 12 16 mm 100 mm 15 20 mm 120 mm 18 30 mm 130 mm 26 33 mm 145 mm 29 37 mm 150 mm 30 45 mm 170 mm 34 50 mm 180 mm 36 54 mm 203 mm 40 60 mm TABLE 5 DUAL CROWN SIZING CUP TO CUP ME ASUREMENT DUAL CROWN SIZE STANCE 130 160 mm Small flat upper crown 155 185 mm Large drop upper crown TRAVIS 130 169 mm Small flat upper crown 150 185 mm Large drop upper crown GCup to cup measurement is the distance from the bottom of the lower headset cup to the top of the upper headset cup TROUBLESHOOTING Service Manual Symptom Cause Section Tighten Valve core replace bad parts as Air Loss Schrader Valve leaks needed Make sure O ring is seated properly Air Cap O ring leaks replace parts as needed Check oil volume on top of piston replace Air Piston leaks parts as needed
27. D STD SID STD NB STD DO NB STD DO NB STD DO NB STD DO NB STD DO NB STD DO Sticker Kit Ride Kits Comp Rod Comp Rod Bottomout Spacers Bushing Kit Air Piston Kit Knob kit Boot Kit Dust Seal Kit O Ring Kit Click It Retro Kits HOT WARRAH Air Cap Air Push Rods Axel am o O La wow m wi wisis ENS NN 85 5318 85 5318 EN 83 2407 83 5558 83 2529 832973 83 2183 83 2408 M 83 2987 10 Pack 83 2987 10 Pack 85 5255 85 4910 O D Steel SIT 067 Ee gem Black 26 53 2125 3213 83 2339 85 227 83 23 Black 25 03 21 2b silver 26 013 2122 03 2336 33 2333 33 23 33 23 a 83 2586 aaa 83 248 83 2141 83 2142 83 249 82243 ERN EE fo 85 432 sss 835570 825079 essers 88559 esser massa essea asss 83858 essers 33 25 33 2595 85 5390 O K 33 5583 O K 85 5555 E Axel Air Fork Specific Kits Elite Air FFD super Air FFD R Platinum Air Lockout Remate LIO 9 m j so w j so w m 53 2398 albc E8 Birce8 42 58 r sgc e8 LEGGO Ld COE L 00 1 Harag 15 OO pa Os ia HST Ue FLlbc EB ET 419 08 FLIbc EB
28. 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 Remove preload adjuster using 18mm socket Remove top leg cap on right hand side using 24mm socket Fig 1 Compress fork and remove the spring MCU and top cap assy If you need to make a spring rate change separate the individual pieces change to the required spring and reassemble 5 Invert fork and tap on work bench to remove plastic spacer from inside of left inner leg 6 Using a inch drive 4mm hex on an extension or Answer p n 85 3006 remove the comp rod screws from inside the bottom of both inner legs See Fig 2 and 3 7 Pull off outer leg from crown steer assy 8 remove compression rods remove the compression rod clips slotted washer if installed and the black rubber bottom out bumper Feed the compression rod up through the inner leg 9 The rubber fork boots can now be removed from the casting at this time and Fig 3 replaced if necessary prm Assembly Instructions 1 Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 2 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 3 Reinstall comp
29. Lever should be oriented so that in the closed position it points up to the top of the casting DO NOT tighten the bolt at this time Make sure that the bolt is inserted through the spacer washer in the slot in the drop out as they can slid around during assembly See Fig 8 Insert the Hex axle p n 069635 into the casting from left to right starting with the end that has the small hex first Apply Grease to threads of Axle Bolt p n 066471 and hand screw it into the Hex Axle but only screw it in a few threads do not tighten the Axle Bolt yet Make sure right lever is in closed position as shown The torque setting on the QR Lever Bolt is 30 40 Ib in 3 39 4 51 N m You want to use the lowest torque possible and still retain the axle properly a Start by first torquing the QR Lever Bolt to 30 3 39 N m b Open the lever and then close it check for smooth operation of the lever and if the axle is properly retained c fitis possible to move the axle side to side close the lever and increase the torque on the bolt by 2 5 in Ibs and retry the lever d Repeat the steps above until you achieve proper operation of the Quick Release Repeat 1 10 for the other side of the casting Remove the Axle Bolt and the Hex Axle Hold the wheel between the dropouts of the fork Insert Hex Thru Axle small hex first into the outside of the left drop out as you are facing fork and push it through the hub of the wheel
30. Ring Kit Click It Remote Lever Jelly Beans Rind Damp Adj SPY Snap Value Rebound Air Cap IT Top Assy IT Top Cable Guide IT HB Lever Crn Str Leg Outer Leg Assy STD STD STD STD STD STD STD STD STD STD STD STD STD NB STD DO MB STD DO MB STD DO MB STD DO NB STD DO NB STD DO MB STD DO NEA STO Do NB STD DO NB STD DO NB STD DO STD DO MB STD DO Sticker Kit Ride Kits Comp Rod Trauel Adjust Bushing Kit Air Piston Kit Knob Kit Dust Seal Kit IT O Ring Kit Ri comp Super atin _ 100 100 eo 100 A sor NENNEN BR2407 22 2 BEZIBS 20 28488 2 20 BR288T IDPack ____ B 802 o 2 Steal ST 26 83 2655 83 2655 12 AL 5 2695 83 2656 23 2659 P BK AL seze STD sM 63 2657 83 2660 83 2657 83 2560 Black 26 Red 26 White 83 2976 Candy Red aa 2Bb87 Candy Blue 95 2699 Matte Black 93 2683 O G 83 2696 83 2665 83 2696 e MegetiveSpring Ti 53 265 83 2697 m S0 83 2667 83 2667 83 2667 0 83 2668 83 2668 83 2668 ERE 35 2667 05 9221 68 Click It L O Re
31. System Service Instructions Removal of Air Assist Spring and Compression Rod Assembly This fork uses compressed air to supplement the spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death Fig 1 1 Remove all of the air pressure from the Schrader valve on top of the crown on the left side Black top cap by depressing the Schrader valve Be sure to hold fork with the top of the crown facing upwards Note When the air is released there is a mixture of the oil and air inside the leg 2 If you have not removed the Outer casting follow these instructions then proceed to next step a From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw b From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Screw the rebound all the way in clockwise remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork c Use an 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting See Fig 1 d Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting If the fork uses the Semi bath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this ov
32. all amount of oil that comes out of the inner leg when the assembly is pulled from the crown For forks with Adjustable compression damping Lock out a Twist the knob all the way counter clockwise to reduce the amount of compression damping on the system b Unscrew the 2mm Allen screw that holds the adjuster knob to the damping assembly c Remove the adjuster knob and unscrew the compression assembly from the crown using a 20mm socket It may be necessary to twist the assembly like you would be unscrewing a screw and gently pull upward to free the assembly from the crown Fig 2 Note there will be a small amount of oil that comes out of the inner leg when the assembly is pulled from the crown 7 Forforks with Remote Lock Out compression damping Make sure that the Lock out is in the off position Unscrew barrel adjuster in a counterclockwise direction until it stops Unscrew the set screw on the lever using a 2mm allen wrench Pull the cable out of the lever and remove the housing from the cable Unscrew the top cap of the Lock out assembly from the fork crown using Socket Answer p n 83 2503 or an adjustable wrench Pull Lock out assembly out of crown by twisting the assembly like unscrewing a screw and applying an upward pressure Slowly pull assembly out of crown and watch out for some excess damping oil to come out of inner leg as the piston at the end of the assembly comes out of crown Turn fork upside down over drainage pan
33. amount of blue Loctite to the threads on the cartridge body Insert the assy into the cartridge body being careful not to damage the piston rings as they enter the cartridge body Fig 8 Using a 22mm or adjustable wrench tighten the compression assy top in a clockwise direction to 50 in Ibs 5 65 CID Intrinsic Damper Rebuild Instructions Field service of the CID cartridge is not recommend as it is necessary to pull a slight vacuum on the CID Assy to make sure that the IFP is properly positioned To do this you must have vacuum tool Answer P N Also a clear plastic tube is used in these instructions for demonstration purposes actual cartridge is metal Disassembly Place Cartridge assembly in bicycle work stand or secure with Cartridge Clamp Blocks Answer P N with the cartridge in an inverted position 1 Using an adjustable wrench remove the rebound assembly from the cartridge by unscrewing it counterclockwise Fig 9 Once you have completely unscrewed the assembly carefully pull it out of the cartridge so that you don t damage the piston rings on the threads in the cartridge Pour out the oil in the cartridge and using a 22mm socket remove the CID Compression assembly by unscrewing it counterclockwise Once you have completely unscrewed the assembly pull the assy from the cartridge body Fig 10 Clean the cartridge body and check for scratch or imperfections in the inner walls of the tube Nex
34. and into the right drop out Thread the Axle Bolt into the end of the axle that is in the right drop out Thread the Axle Bolt about half way in DO NOT tighten it down fully Set the end of the axle flush with the outside of the left drop out Tighten the QR on the left fork leg Hand tighten the Axle bolt on the right side drop out Finish the installation by tightening the quick release on the right fork leg Manitou Fork Technical Information 2006 Oil Levels onte System pui System Travel Axel Trace FFD Lockout_ 80 100 or 120 Remote Lockout 80 100 or 120 L Pam wono 29 79 68 R7 TPcrockot woro 43 10 49 125 Gur Platforms 100 130 31 80 33 85 TPC Lockout 100430RTWD 35 90 37 95 10 10 30 175 31 80 SPV 130mmITTA 33 85 35 90 er Single Crown 150 3 7 95 3 9 100 Single Crown 180 4 3 110 4 5 115 Travis ere m oaa Crown 203 4 9 125 9 1 130 Eme am as n Crown 180 4 3 110 4 5 115 ore mu os be ar pa Crown 203 5 5 140 5 7 145 CID All Models 180 or 203 Consult the 2006 Service Manual Cartridge Damping Section for correct full damper bleed process TABLE 6 RECOMMENDED TORQUE SPECIFICATIONS TRAVIS INTEGRATED STEM DUAL CROWN CLAMPS HEX AXLE BOLTS 4 pieces HEX AXLE THRL BOLT REMOTE HANDLEBAR CLAMP ITEM LEVER cable clamp screw TA
35. as the leg is longer than the Comp Rod See Fig 3 10 For Reinstallation see Installation of Spring Assembly for E2 Air Spring Forks Assembly Instructions Installation of Spring Assembly for E2 Air Spring Forks Fig 2 All leg caps for Damper and Spring systems must be properly tightened orior to use Failure to do so could result in injury or possible death 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 1 Re install the air push rod positive spring that has been well greased and compression rod assembly The Air Push Rods are color coded to the fork travel a 120mm travel fork is red 100mm is white and 80mm is black See Fig 4 2 Apply a small amount of Prep M grease onto the threads at the top of the left inner leg with your finger 3 Apply a small amount of Prep M grease around the outside diameter of the new air piston 4 Insert the air piston larger cupped side down See photo below Piston shown top up into the inner leg through the threaded area at the top of the inner leg Use your fingers to push the piston past the threads into the leg See Fig 5 5 Using a long screwdriver or rod push the piston fully into leg sp that is in contact with the Compression Rod 6 Pour about 3cc of a 40 or greater automoti
36. astener torque guide at the end of this manual Install adjuster knob and 2mm hex screw Turn the knob counterclockwise until it stops This insures that the fork is in its longest travel position If the travel indicator arrow on the crown is not lined up with the maximum travel point on the indicator dial continue to turn the knob counterclockwise until the indicator points to maximum travel For Grease Forks Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 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 Proceed to Step 8 For Semibath Forks Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten per the Schematic and Torque Specification Table for your fork Install rebound adjuster knob if applicable Install the compression rod screw and tighten per the Schema
37. ble guide then feed the end of the inner wire through the hole in the black cable stop on the lever 9 The inner wire now feeds through the hole in bottom of the lever over the top of the lever and through the hole in the back of the lever 10 Pull the inner wire until there is no slack in the cable Be sure to set a 2mm gap between the front of the lever and the top of the cable stop to insure that you have not over tightened the cable before you tighten the 2mm Allen bolt on the front of the lever to cinch the inner wire Refer to Figure 12 11 The last step is to cut the inner wire that is left hanging on the backside of the lever and then installing the cable end to prevent it from fraying 12 Pressurize the system and check for proper function It is fastest if you have someone depress the control lever and hold it while you pump air into the system This way the system equalizes immediately If you do not have a second person to help just add air to the system and then periodically depress the lever to equalize the pressure Outer Casting Service There are two different ways that castings are retain on the fork legs one version is accessed through the top of the fork legs and the other is accessed on the bottom of the each casting leg Disassembly Instructions for Style 1 Fig 1 00 This fork uses a preloaded coil spring provide spring resistance The spring must be relieved of its preload prior to servicing
38. ck Out TPC SPV Volume Adj Remote L O Click It Remote L O Lever Left Click It Remote LO Lever Right gt Click It Remote L O Cable Click It Remote L O Cable Guide Click It Remote 1 0 O Ring Kit Click It Remote Lever Jelly Beans Rbnd Damp Hon Adj Rind Damp Adj SPV Rebound SPV Valve Pre Load Adj WO Adjuster Cap Assy Air Cap IT Top Assy IT Top Cable Guide IT Lever Crn stril eg Outer Leg Assy STD STD STD STD STD STD STD STD STO STD STD STD STD Do NB STD Dio NB STD Dio NB STD Dio NB STD Do NB STD Dio NB STD Dio NB STD DO NB STD Dio NB STD Do NB STD NB STD Dio NB STD Dio Sticker Kit Ride Kits Comp Rod Travel Adjust Comp Rod Bottomout Spacers Air Push Rods Bushing Kit Air Piston Kit Knob Kit Dust Seal Kit O Ring Kit Click It L O Retro Kits HOT WARRANTY ITEM Black 100 120 100 120 70 20 90 100 120 85 5800 85 5868 85 5871 83 2305 83 5558 83 2629 83 2973 83 2183 83 2410 83 2887 10 Pack 85 5306 STD Shock A STI Fork 85 5556 85 5306 85 5969 93 2746 85 5803 B3 2317 83 2518 93 2319 93 2616 Steel S T 267 Bik AL SIT 26 SPY ett 85 5806 85 5807 85 5808 85 5809 83 2297 85 5824 85 5825 85 5826 85 5827 85 5828 85 5829 83 2299 85 5830 silver 26
39. e bit of Prep M grease Ref Answer Products PN 85 0031 on the urethane or rubber o ring found on the lower piston of the Lock out assembly c 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 down using the cut out 22mm socket Tighten per the Axel Schematic and Torque Specification Table d With the lever in the released position Red Lever will be up install the Remote Lock Out cable by inserting it into the bottom of the clamp and up through the lever Pull the slack out of the cable and tighten down the 2mm anchor screw on the lever You should have approximately a 2mm between the lever and the housing when it is properly installed See Figure 3 e Run the cable of the top of the lever and then through the hole on the back of the lever f Bend the cable in towards the stem at a 90degree angle trim the cable so that it is the same length as the lever itself and then install the cable end crimp See figure 4 g Screw the barrel adjuster out in a clockwise direction until you just remove the slack in the cable If you tighten the cable to much the lock out will not release and the fork will not move Turn completed crown steer leg assembly upside down so that the compression rod and dam
40. e oil maybe substituted into the fork leg through the top of the crown 6 Torque the top cap to in Ibs using the slotted 22mm socket 7 Replace the Outer Casting if it has been removed as follows a Replace the o ring at the end of the rebound shaft if not you will risk having a leak in that area b Extend the rebound damper out from end cap as far as it will go and then slide bottom out bumper towards the end cap as far as it will go The bumper will help to hold the damper shaft in place as you are inserting the inner legs into the casting c Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil d Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting e Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting See fig 11 Tighten per the Schematic and Torque opecification Table for your fork f Install rebound adjuster knob if applicable g Install the compression rod screw and tighten per the Black Schematic and Torque Specification Table 8 Feedthe inner wire through the cable housing and secure one end of the of the housing into the gold ca
41. elp to keep the shaft from moving 2 Replace the o ring at the end of the rebound shaft Fig 7 if not you will risk having a leak in that area On the Nixon Minute and Stance Forks there are two different O rings which may have been used on your fork Use the same color o ring as the original when you replace it both styles will be included in your service kits Fig 8 3 Extend the rebound damper out from end cap as far as it will go and then slide bottom out bumper towards the end cap as far as it will go The bumper will help to hold the damper shaft in place as you are inserting the inner legs into the casting 4 Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil 5 Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting 6 Usean 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Fig 9 Tighten per the Schematic and Torque Specification Table for your fork 7 Install rebound adjuster knob if applicable Knob should turn uninhibited until the indicator is stopped by the casting if applicable If not remove knob and reinstall on hex shaft in 1 6
42. elper have them hold the IT lever on the handlebar down as you depress the valve core This will let all of the air out at one time 4 Now that all of the air is released Remove the casting a From the left leg dropout Left when sitting on the bike use a 12mm wrench to remove the compression rod nut b From the right leg dropout remove the rebound knob Screw the rebound all the way in clockwise remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork c Usea8mm hex wrench to turn the damper clockwise until it can be pushed into the casting see Fig 2 d Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting The fork uses a Semibath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan 5 Use an Adjustable Wrench and unscrew the black end cap that is threaded into the bottom of the left inner leg See Fig 3 6 Pull the lower IT assembly from the inner leg There may be a small amount of oil that comes out of the inner leg as you remove the lower IT assembly This is the lubricating oil used to allow the air piston on the lower shaft assembly to move freely 7 Now itis time to remove the IT upper assembly Release the IT control wire from the control lever if attached by unscrewing the fixing screw on the lev
43. emove it from the leg as the leg is longer than the Comp Rod 10 For Reinstallation see Installation of Spring Assembly for E2 Air Spring Forks a Ics pool e Assembly Instructions Installation of the Air Piston for R7 Forks 1 Apply a small amount of Prep M grease onto the threads at the top of the left inner leg with your finger 2 Apply a small amount of Prep M grease around the outside diameter of the new air piston 3 Insert the air piston larger cupped side up the end with the glide ring goes up See Fig 6 into the inner leg through the threaded area at the top of the inner leg Use your fingers to push the piston past the threads into the leg 4 Using a long screwdriver or rod push the piston fully into leg sp that is in contact with the Compression Rod 5 Pour about 3cc of a 40 or greater automotive oil into the top of the piston and then install the air cap assembly Tighten per the Fastener and Torque Values section Use a shock pump p n 85 4069 to fill the air system to the recommended levels as outlined in the R7 Fastener and Torque Values Chart in the back of this manual Installation of Air Piston and Compression Rod Assembly for R7 Forks 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 When installing the outer Leg Casting to the Crown Steer Assy Compression Rod bolts and Damper Shafts mus
44. en wrench Remove the detent balls and springs after pulling off knob See Fig 1 and 2 Red knob is for CID systems and Black is TPC systems Invert the fork and insert 8mm Allen wrench into the end of the Rebound Shaft on the bottom of the right leg Turn the wrench in a Clock Wise direction in order to loosen the damper shaft in the casting See Fig 3 You are turning the Damper Shaft in a way that causes it to disappear into the casting leg Screw in the Rebound Casting Plug Answer P N or a rubber stopper into the lower casting to keep the semi bath from leaking out Note if you suspect that the cartridge is leaking into the outer leg omit this step and drain the oil from the casting See fig 4 Turn the fork back upright and remove the cartridge from the fork using a 22mm socket by unscrewing it counterclockwise CTPC Damper Rebuild Instructions Disassembly Place Cartridge assembly in bicycle work stand or secure with Cartridge Clamp Blocks Answer P N with the cartridge in an upright position 1 Using a 22mm socket remove the TPC compression assembly from the cartridge by unscrewing it counterclockwise Once you have completely unscrewed the assembly pull it out of the cartridge Pour out the oil in the cartridge and using a mm or adjustable wrench remove the rebound assembly by unscrewing it counterclockwise Once you have completely unscrewed the assembly carefully pull it out of the cartridge so that y
45. er some type of catch pan e Unscrew the end cap on the bottom of the inner leg and remove compression rod assembly This will consist of a compression rod bottom and top out bumpers the end cap and should be followed by a coil spring See Fig 2 This spring is the one that would be changed if the fork s spring rate needed to be changed beyond the capabilities of the air pressure 3 Change the quad seal and inspect the finish of the interior of the inner leg If the seam in the leg is not smooth replace the Crown Steerer assy as this is why the system is failing Fig 3 Installation of the Air Assist Spring Svstem WENN 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 MENNA 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 Fig 2 1 Generously grease the spring and insert it into the inner leg The spring needs to seat onto the top cap Fig 4 2 Apply a small amount of Prep M grease onto the threads at the bottom of the left inner leg with your finger 3 Screw the Compression rod assembly into the inner leg and tighten the end cap per the fastener torque guide at the end of this manual See Fig 3 4 For Grease Forks Remove rubber fork boots from the casting and slide them o
46. er that holds the cable tight Use a 2mm Allen Wrench to unscrew this screw and then pull the cable out of the lever 8 To remove the upper IT assembly use a slotted 22mm 6 point socket P N 83 2503 a 22mm Open End wrench or an adjustable wrench Unscrew it by turning counter clockwise Note Be aware of the IT control Wire spinning around when unscrewing the top cap See Fig 4 9 Pull the upper assembly out of the inner leg Fig 2 Fig 3 Fig 5 Assembly Instructions Troubleshooting Tips f the fork starts to lose travel from an extended position to a shorter position by itself the damage is most likely centered on the Quad ring around the outside of the piston f the fork extends from a shorter travel to a longer travel by itself the failure can be involving the smaller Quad ring that is located under the piston on the inside diameter of it where the shaft of the upper assembly intersects the lower assembly and piston The shaft is sealed against leakage at this point to define the two different chambers Fig 5 Always check two things when you have the system apart Use a straight edge and lay it next to the inner shaft that is attached to the top cap of the upper assembly to insure that that shaft is not bowed at any point We found that in the assembly of these pieces the shaft is pressed into the top cap and occasionally if it is over pressed the shaft will bow This means that where
47. from the main spring grasp the flat end of the booster spring with a pair of needle nose pliers and twist it in a clockwise direction to unscrew it from the main spring 9 Toinstall a booster spring into a main spring catch the flat end of the booster spring under the flat end of the main spring and twist it counterclockwise into the main spring Make sure that the booster spring is threaded all of the way down into and contained by the main spring Before inserting it back into the inner leg Wind Down Travel Adjust Service Instructions Installation for Wind Down Travel Adjust Assembly 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 MENNA 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 If you removed the Outer casting 8 9 10 11 Reassemble the compression rod assembly and install in the fork leg Fig 6 Generously grease the spring and insert it into the inner leg The spring needs to seat onto the top of the compression rod Fig 7 Insert the wind down top cap assembly into the spring the D shaped portion of the adjuster assembly must fit into the D shaped end of the main spring Screw the assembly into the inner leg and tighten per the f
48. g New coating for steel stanchion legs that reduces stiction 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 compression 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 Cartridge Damping Provides better oil flow bump sensitivity and improved damping control in long travel applications Click It Remote A handle bar lever actuated system that controls the lock out function on front and rear suspension products It is activated by pressing the Red Lock button and unlocked by pressing the Green Release Lever Coil Spring A coiled piece of metal that acts as a spring to help suspend a fork Coil Spring Air Assist A new feature for 2005 that utilizes a full length coil spring and allows you to increase the spring rate of the fork by adding air as a booster to that coil spring 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 Compression Damping Restriction of the rate that the suspension compresses under load Convertible Travel A system used to alter the travel of a suspension fork It requires
49. he body with 5wt shock oil Fig 12 Pull the rebound assy out so that it is in the fully extended position the valve assembly is closest to the end cap from here slide the endcap back down the shaft 10mm It is easiest to measure from the nut to the flange on the endcap see Fig 13 Lightly grease the piston ring on the rebound shaft Carefully insert the assy into the cartridge body taking care that the piston ring isn t damaged by the threads of the body As you tighten the cap down oil and trapped air is going to bleed out of the small hole in the side of the cap This is supposed to happen to insure that there is no air in the system It is recommended to wrap a shop towel around the cartridge body below the end cap to catch this so it doesn t create a mess in the work area Stroke the rebound assembly several times to dislodge any air that is trapped in the CID Allow the cartridge to sit for a few minutes remove the rebound assy Remove the rebound assy fully refill the damper cartridge with shock oil Regrease the rebound piston lightly as before and apply a drop of Loctite to the threads of the endcap Carefully insert the assy into the cartridge body taking care that the piston ring isn t damaged by the threads of the body Again you will have a small amount of oil and air bleed out of the hole in the endcap and this is normal Tighten down the end cap in a clockwise direction to 50 in lbs 5 65 Cartridge Damper System
50. he lever and if the axle is properly retained c If itis possible to move the axle side to side close the lever and increase the torque on the bolt by 2 5 in lbs and retry the lever d Repeat the steps above until you achieve proper operation of the Quick Release Repeat 1 10 for the other side of the casting Remove the Axle Bolt and the Hex Axle Hold the wheel between the dropouts of the fork Insert Hex Thru Axle small hex first into the outside of the left drop out as you are facing fork and push it through the hub of the wheel and into the right drop out Thread the Axle Bolt into the end of the axle that is in the right drop out Thread the Axle Bolt in about half way do NOT tighten it down fully Set the end of the axle flush with the outside of the left drop out Tighten the QR on the left fork leg Hand tighten the Axle bolt on the right side drop out Finish the installation by tightening the quick release on the right fork leg Travis Thru Axle and Quick Release Thru Axle Instructions Standard Hex Thru Axle Removal Instructions Removal of Hex Thru Axle 1 2 4 5 Loosen the two clamp fixing bolts on the right fork leg Remove the Thru Axle nut from the right side of the Thru axle Loosen the two 3mm clamp fixing bolts on the left fork leg Push the Hex Thru Axle out of the dropouts from left to right and completely remove it and the front wheel from the fork
51. in a counterclockwise direction See Fig 8 Tighten per the Fastener and Torque Values section Use a shock pump p n 85 4069 to fill the air system to the recommended levels as outlined in the R7 Fastener and Torque Values Fig 8 7 IT Air System Service Instructions Removal of IT Air Spring and Travel Adjust Assembly This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could result Fig 1 in injury or possible death 1 Important You must remove all of the air from the left leg of the fork before disassembling the IT System It is advisable to to have the fork inverted and pointed away from your face as there may also be a discharge of a mixture of air and oil when you depress the Schrader valve core this is similar to the discharge when you depress the valve core on any of the Manitou Air or SPV forks 2 Onthe bottom of the left leg leg that has the Disk Brakes mounts on it there is a Schrader valve protruding from it Unscrew the valve cap and follow either of these two methods for releasing all of the air from the system See Fig 1 3 Depress the valve core and let all of the air out Now depress the IT lever on the bike s handlebar and release it Once again depress valve core in the Schrader valve to release any air in the leg Do this a couple of times until all of the air is released a If you have a h
52. injury 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 eS ee elites 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 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 FRONT SUSPENSION TERMINOLOGY Air Cap Top cap that threads into top of air spring leg this is the left leg of the fork as you are seated on the seat Forks may be controlled with an air spring or a coil spring The air cap contains the Schrader Valve which is used to control the spring rate or SAG of air forks Air Spring A mechanism that is used to control the SAG of an air fork Arch A support that connects the two outer lower legs of the casting so as to keep them moving in unison Black Nitrate Leg Coatin
53. leg See Fig 7 Place an adapter p n 066487 See Fig 6 D on top of spring the adapter is symmetrical so its orientation is not critical Place a shim p n 069647 See Fig 6 E on top of adapter see Fig 8 Install pivot cylinder p n 066479 See Fig 6 F into the bore of the QR Lever p n 066490 See Fig 6 G Install an M5x32 bolt p n 069638 See Fig 6 H through the hole in the pivot cylinder that you installed in the QR Lever The bolt head must sit in counter bore in the Pivot Cylinder Insert the M5x32 bolt through the shim adapter and the spacer washer and screw it into hexagonal nut in the drop out The QR Lever should be oriented so that in the closed position it points up to the top of the casting DO NOT tighten the bolt at this time Make sure that the bolt is inserted through the spacer washer in the slot in the drop out as they can slid around during assembly See Fig 9 Insert the Hex axle p n 064590 into the casting from left to right starting with the end that has the small hex first Apply Grease to threads of Axle Bolt p n 066471 and hand screw it into the Hex Axle but only screw it in a few threads do not tighten the Axle Bolt yet Make sure right lever is in closed position as shown below The torque setting on the QR Lever Bolt is 30 40 3 39 4 51 N m You want to use the lowest torque possible and still retain the axle properly b Open the lever and then close it check for smooth operation of t
54. leg and remove the Wind Down compression rod assembly and spring as a single unit through the bottom of the leg Fig 4 f You will find that on earlier production fork models that there is a nylon washer at the top of the compression rod assembly that is holding the spring in place Hold the spring in one hand and the compression rod assembly in your other hand and pull the apart from each other at a slight angle to each other Fig 4 g Once you have the two apart remove the Allen bolt on top of the compression rod with a 4mm Allen wrench and remove the nylon washer Re install the bolt without the washer it will not affect the operation of the Wind Down mechanism and insure that you will not have to take the whole fork apart in the future to change ride kit springs h Note the spring that you remove should have another spring booster spring intertwined within it 6 If you had to remove the outer casting reassemble the compression rod assembly and then follow instructions for Installation of Outer Casting 7 Optional Ride Kits If you need to adjust to overall ride characteristics either softer or Fig 5 firmer purchase and or install as follows Kit Part Numbers can be found in the Service Part section of this manual a Soft Remove the Booster Spring b Firm Purchase Firm Ride Kit and install the Booster Spring c Extra Firm Purchase Extra Firm Ride Kit and install the Booster Spring 8 Toremove the booster spring
55. ly away from the fork 3 Usea 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting see Fig 5 4 Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting If the fork uses the Semibath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan Assembly Instructions 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 Turn completed crown steer leg assembly upside down so that the compression rod and damper shaft are facing you You will see a bottom out bumper on the damper shaft slide this bumper down towards the end cap that is threaded into the inner leg This will help in keeping the shaft extended as you install the outer casting You could also insert air into the damper leg through the Schrader valve on top of the right leg SPV models This extra pressure will help to keep the shaft from moving See Fig 6 Replace the o ring at the end of the rebound shaft if not you will risk having an oil leak in that area See Fig 7 There are 2 styles of o ring which are used be sure to replace with a matching o ring See Fig 8 Extend the rebound damper out from end cap as far as it will go and then slide bott
56. 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 Damping A function that modifies the rate of suspension compression or rebound Detent An indentation that causes a rotating adjuster to stop at fixed increments 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 E2 Air System Lightweight alternative to coil springs for steel legged forks elimates the need for spring changes for various rider weights FRONT SUSPENSION TERMINOLOGY CONT FFD Fluid Flow Damping A Manitou patented low cost oil damping system The compression damping is non adjustable and the rebound damping may be non adjustable or adjustable damping Fork Crown The component that joins the stanchion tubes inner legs to the steer tube of the fork Hydraulic Fork Oil Oil used in suspension designs to provide damping It has special cha
57. n top of leg with 20mm socket Fig 1 Drain the oil off of the piston if it is present Insert Air Piston Removal Tool into the air piston and turn handle counter clockwise until tight to lock it in the air piston Fig 2 Demonstrates what you are trying to do 6 Pull out the tool and the Air Piston will come with it You may need to gently rock the piston back and forth to clear the threads in the top of the leg The Compression Rod and negative spring will remain in the fork Fig 3 7 For reinstallation see Air Piston see Installation of the Air Piston for R7 Air Spring Forks instructions on next page a a B Without this tool you will need to follow the procedures in the following section Remove air dust cap covering the Schrader valve Depress Schrader valve to release air pressure Remove air cap on top of Left leg with 20mm socket Remove rebound adjuster knob using a 2mm hex wrench From the right leg dropout use 8mm hex wrench to turn the damper shaft clockwise until it can be pushed into the casting Fig 4 Remove 11mm hex bolt Compression Rod bolt from bottom of Left leg Remove crown steer inner leg assembly from the outer leg casting Remove the end cap on the Left inner leg and remove Compression rod negative spring assembly Fig 5 9 Push the Air Piston out of the top of the leg by pushing on the Compression Rod You may need to use a screwdriver placed in the end of the Compression Rod to fully r
58. nd WD RTII is used for the specific purposes of controlling the travel in two conditions climbing and descending WD is an incremental travel adjustment between two set limits and does not affect the spring rate of the fork as severely as Quad Ring seal New seal that replaces standard o rings in designs that require more efficient air and oil sealing methods Rebound phase of the suspension operation in which the wheel returns to its original position on the ground after compression Rebound Damping Restriction of the rate that the suspension rebounds when the compression load is relived Remote Lock out system A handle bar lever actuated system that controls the lock out function on front and rear suspension products 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 Snap Valve SPV High platform low threshold SPV damping system that is resistant to pedaling induced movement but still offers bottoming resistance and small bump sensitivity Sag The amount a suspension fork compresses at rest with a normal load rider s weight Schrader Valve Valve used to introduce air into a chamber FRONT SUSPENSION TERMINOLOGY CONT Seal A part
59. ndicator is stopped by the casting if applicable If not remove knob and reinstall on hex shaft in 1 6 turn increments until full travel is reached Install the compression rod screw and tighten per the Black Schematic and Torque Specification Table For forks with the Wind Down system follow steps 2 5 from the Wind Down Travel Adjust assembly instructions Fig 1 SPV Damping System Service Disassembly Instructions for SPV Damping 5 The rebound knob needs to be removed Screw the rebound all the way in clockwise and then remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork Use an 8mm hex wrench to turn the damper shaft clockwise until it can be pushed into the casting see Fig 1 From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting The fork uses the Semibath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is and must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death 10 11 12 Remove Schrader valve dust cap from Red Hex Shaped Top Cap on the top right of the crown Release all air pressure from the Schrader valve Fig 2 Remove
60. nto the inner legs of the crown steer assy 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 Fig 5 such as Motorex Bike Grease 2000 Proceed to Step 6 5 For Semi bath Forks Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil 6 Press inner leg assembly into outer leg casting until damper shaft contacts casting 7 Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten per the Schematic and Torque Specification Table for your fork Fig 5 8 Install rebound adjuster knob if applicable 9 Screw in the comp rod bolt Tighten to the recommended torque listed in the Schematic and Torque Specification Table Wind Down Travel Adjust Service Instructions 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 Removal Wind Down Travel Adjust Assembly 1 Make sure that the Travel Adust is in its fully extended position Fig 1 Rotate adjuster on top left of fork crown counterclockwise until it st
61. o do so could result in injury or possible death 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 Fig 11 1 It is recommended that when reassembling the IT system that you start by installing the lower assembly into the bottom of the inner leg first Be sure to apply a small amount of Prep M grease to the Quad ring on the outside of the piston in the hole in the piston and onto the threads of the inner leg before inserting the assembly into leg 2 Twist the shaft assembly as you insert piston past the threads of inner leg Tighten end to 25 35inlbs 2 8 3 9Nm It might be necessary to use a socket and extension thru the top of the fork leg and engage the head on the top of the piston so that you can screw in the quad seal past the threads in the leg Puta small amount of Motorex grease on the end of the Upper Assembly shaft and then insert the assembly into the fork inner leg 4 soon as contact is made with the hole in the top of the air piston lower assembly twist the upper assembly like screwing in a screw to guide the upper assembly shaft into the hole without damaging the Quad ring seal in the shaft of the lower assembly 5 After reinserting the upper assembly into the fork but before screwing the top cap in pour about 8 10cc s of Air Piston Oil 40wt automotiv
62. om out bumper towards the end cap as far as it will go The bumper will help to hold the damper shaft in place as you are inserting the inner legs into the casting For Grease Forks Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 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 Proceed to Step 6 For Semibath Forks Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil See Fig 9 Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten per the Schematic and Torque Specification Table for your fork Install rebound adjuster knob if applicable Install the compression rod screw and tighten per the Black Schematic and Torque Specification Table For forks with the Wind Down system follow steps 2 5 from the Wind Down Travel Adjust assembly instructions Use 8mm Allen wrench 2mm Allen wrench 11mm Nut Driver
63. on Chart at the end of manual 8 Finish the installation by tightening axle nut to specified torque value and then tighten the clamp fixing bolts on the right drop out to the specified torque See Fig Quick Release Hex Thru Axle Removal of the QR Thru Axle 1 Pull down on the lever on the right fork leg to relieve the tension on that fork leg Fig 5 shows the QR Lever in the open position Unscrew the QR Axle Bolt on the right hand side of the fork Pull down on the QR lever on the left fork leg to relieve the tension on that fork leg Unless you need to replace a component of the QR system do not proceed further Remove the bolt in the center of the Pivot Cylinder of the QR Lever Remove the Pivot Cylinder from the Lever Remove the Shim Adapter spring and Hex Nut from each fork leg Inspect all parts for wear If any parts show signs of wear replace all components on the side as a system Mixing new and used parts will result in accelerated wear when the parts are reassembled puce Fig 7 3 16 17 2mm Leg Thru Axle and Quick Release Thru Axle Instructions Assembly Instructions Install a Spacer Washer p n 062876 See Fig 6 into the slot in the right drop out Install spring p n 069641 See Fig 6 C into counter bore of the right drop out of the casting Install a Hexagonal Nut p n 066484 See Fig 6 A into the small hexagonal hole in the drop out of the fork
64. ops This will relieve spring tension on the fork 2 Remove the adjuster knob from the top of the Wind Down adjuster assembly on the top of the crown on the left side of the fork by unscrewing the 2mm Allen head screw Remove the o ring that is located on the indicator dial Use 28mm socket and unscrew the remainder of the assembly from the crown Fig 1 The spring will be attached to the bottom of the assembly when you pull it from the inner leg Fig 3 4 Pullthe spring out of the Travel Adjust assembly 5 If spring will not come out you must take the outer casting off of inner legs a From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw b From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Screw the rebound all the way in clockwise remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork c Usea 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting see Fig 4 d Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting If the fork uses the Semibath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan e hen remove the end cap from the bottom of the left
65. ou don t damage the piston rings on the threads in the cartridge Clean the cartridge body and check for scratch or imperfections in the inner walls of the tube Reassembly Place Cartridge assembly in bicycle work stand or secure with Cartridge Clamp Blocks Answer P N with the cartridge upside down 5 Lightly coat the piston ring on the rebound assembly with Motorex grease Insert the assy into the cartridge body being careful not to damage the piston ring on the threads Also apply a small amount of blue Loctite to the threads of the end cap see Fig 6 Using a 22mm or adjustable wrench tighten the rebound assy end cap in a clockwise direction to 50 in lbs 5 65 6 i i 3 ro ET Dodd ad gt k Fig 10 Cartridge Damping System Service cont Reassembly Cont Turn the cartridge right side up and fill half way with Motorex 5w Shock oil Stroke the rebound assembly several times to remove any air that maybe trapped under the piston Pull the rebound assembly to the bottom of its stroke Finish filling the cartridge body to the correct level listed in table In order to determine the proper oil level measure from the top of the cartridge body to the top surface of the oil see Fig 7 or use Oil Level tool Lightly coat the piston rings on both pistons on the TPC compression assembly with Motorex grease Apply a small
66. ove the compression rod screw b From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Screw the rebound all the way in clockwise then remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork c Usean 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting See Fig 3 d Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting If the fork uses the Semi bath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan 2 Then remove the end cap from the bottom of the left leg and remove the compression rod assembly and spring through the bottom of the leg See Fig 4 3 Turn the fork over rotate the preload adjuster on top left of fork crown counterclockwise until it stops This will reset the preload in the lowest tension setting when you rebuild the fork 4 Remove the adjuster knob from the top of the Pre Load adjuster assembly on the top of the crown on the left side of the fork by unscrewing the 2mm Allen head screw 5 Unscrew the assembly from the crown and then pull it out of the inner leg Installing Coil Spring Assembly 1 Reassemble the compression rod assembly and install in the fork leg 2 Generously grease the spring and insert it into the
67. per shaft are facing you You will see a bottom out bumper on the damper shaft slide this bumper down towards the end cap that is threaded into the inner leg This will help in keeping the shaft extended as you install the outer casting You could also insert air into the damper leg through the Schrader valve on top of the right leg SPV models This extra pressure will help to keep the shaft from moving Replace the o ring at the end of the rebound shaft if not you will risk having a leak in that area Extend the rebound damper out from end cap as far as it will go and then slide bottom out bumper towards the end cap as far as it will go The bumper will help to hold the damper shaft in place as you are inserting the inner legs into the casting Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten per the Schematic and Torque Specification Table for your fork Install rebound adjuster knob if applicable Knob should turn uninhibited until the i
68. racteristics that determine how it reacts when exposed to compressed air how it changes viscosity when its temperature changes and how it moves through valves Hydraulic Lock Out a condition caused when the mixture of air and damping oil is out of balance It is caused when there is too little air space in a chamber not allowing the fork to compress through its travel IS2 Intergrated Stem System intergrates top triple clamp with bar mount eliminating the need for a stem Flip Flop mount allows for 45mm or 60mm stem measurements and spacers allow bar height adjustments Includes shims for both 31 8 and 25 4mm handlebars Infinite Travel System IT A handle bar mounted air travel adjust system that allows the rider to change the fork travel and ride height without a spring rate change The travel can be changed from full compression to full rebound and at any place in between Intrinsic Damping speed sensitive SPV based damping system for long travel applications Provides better sensitivity to small bumps and superior bottoming resistance Lock Out a special function that restricts the compression of the fork from moving It is generally controlled by an external knob that is activated when a rider does not want the fork to move thus eliminating extra energy needed to overcome the bobbing forces of the fork MCU Micro Cellular Urethane Special urethane that is filled with tiny air cells that act like springs when the
69. relieve the tension on that fork leg Unless you need to replace a component of the QR system do not proceed further Remove the bolt in the center of the Pivot Cylinder of the QR Lever Remove the Pivot Cylinder from the Lever Remove the Shim and Hex Nut from each fork leg Inspect all parts for wear If any parts show signs of wear replace all components on the side as a system Mixing new and used parts will result in accelerated wear when the parts are reassembled Inspect for any cracks around the Axle bearing area on the Outer Casting If there are any found replace the casting Fig 5 Fig 6 Fig 8 Travis Thru Axle and Quick Release Thru Axle Instructions 15 16 17 Assembly Instructions Install a Spacer Washer p n 062876 into the slot in the right drop out Install a Hexagonal Nut p n 066484 See Fig 5 A into the small hexagonal hole in the drop out of the right fork leg Place a shim p n 066488 See Fig 5 B on top of drop out in the semicircular area See Fig 6 Install pivot cylinder p n 066479 Fig 5 C into the bore of the QR Lever p n 066490 See Fig 5 D Install an M5x32 bolt p n 069638 See Fig 5 E through the hole in the pivot cylinder that you installed in the QR Lever The bolt head must sit in counter bore in the Pivot Cylinder See Fig 7 Insert the M5x32 bolt through the shim and the spacer washer and screw it into hexagonal nut in the drop out The QR
70. ression rods into the inner legs if necessary 4 Reinstall the bottomout bumpers and clips 5 Slide the outer leg onto the crown steer assy make sure the arch is facing to the rear 6 Using a inch drive 4mm hex on an extension or Answer p n 85 3006 tighten the comp rod screws from inside the bottom of both inner legs Torque per Fastener Torque and Setup Levels section ENNA When installing the outer Leg Casting to the Crown Steer Assy Compression rod bolts must be properly tightened prior to use Failure to do so could result in injury or possible death onap boots over dust seal of outer leg casting Install plastic spacer into left inner leg See Fig 4 for order Grease spring heavily with Motorex Bike Grease 2000 Extend fork and install the spring preload MCU and spring assy Tighten preload adjuster using 18mm socket to torque Listed in Fastener and Setup Levels section 12 Install preload adjuster knob using 2mm hex screw N LI LI Fig 5 Fig 6 Fig 8 Fig 10 Disassembly Instructions for Style 2 1 From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw 2 From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Screw the rebound all the way in clockwise remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gent
71. ressure Fig 3 E There are now two ways to remove the air piston from the inner leg A An Air Piston Removal tool has been developed that will enable you to remove the piston without having to take the fork apart P N 85 8062 Remove air dust cap covering the Schrader Valve Depress Schrader valve to release air pressure Remove air cap on top of leg with 20mm socket Drain the oil off of the piston if it is present Insert Air Piston Removal Tool into the air piston and turn handle counter clockwise until tight to lock it in the air piston Fig 2 for insertion example Pull out the tool and the Air Piston will come with it You may need to gently rock the piston back and forth to clear the threads in the top of the leg Fig 3 7 See Installation of the Air Piston for Air Spring Forks instructions on next page SN en B Without this tool you will need to follow the procedures in the following section 10 Remove air dust cap covering the Schrader valve 11 Depress Schrader valve to release air pressure 12 Remove air cap on top of Left leg with 20mm socket 13 Remove left leg end cap and compression rod assembly from inner left leg Then remove spring and Air piston rod 14 Use a long narrow rod approximately 18 458mm long and no greater than 4 7 in diameter and insert it into the left inner leg from the bottom of the leg Be sure to direct the rod through the center of the negative spring assembly that i
72. rk with SPV as a control of the compression ramp up rate of the fork It has a range of adjustments from linear to very progressive 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 Fig 1 FFD and TPC Damping System Service Disassembly Instructions for FFD and TPC Damping 1 First the rebound knob will need to be removed Screw the rebound all the way in clockwise and then remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork Use an 8mm hex wrench to turn the damper shaft clockwise until it can be pushed into the casting see Fig 1 From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting The fork uses the Semibath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan For forks with Non Adjustable compression damping a Using a 26mm socket unscrew the damping assembly top cap from the crown It may be necessary to twist the assembly like you would be unscrewing a screw and gently pull upward to free the assembly from the crown Fig 2 Note there will be a sm
73. s about halfway up the inner leg 15 Once the rod has contacted the air piston use a rubber mallet and tap the piston out through the top of the inner leg Caution Do not allow rod used for pushing piston out to contact the inside wall of inner leg during procedure the surface of the leg could be damaged 16 For Reinstallation see Installation of Assembly for Air Spring Forks E2 Air System Service Instructions Removal of Air Spring Assemblyssion Rod Assembly This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could result injury or possible death Remove air dust cap covering the Schrader valve Depress Schrader valve to release air pressure Remove air cap on top of Left leg with 20mm socket Remove rebound adjuster knob using a 2mm hex wrench From the right leg dropout use 8mm hex wrench to turn the damper shaft clockwise until it can be pushed into the casting See Fig 1 Remove 11mm hex bolt Compression Rod bolt from bottom of Left leg Remove crown steer inner leg assembly from the outer leg casting Remove the bottom out bumper washer and Spacer if applicable from the Compression rod See Fig 2 9 Push the Piston and Compression Rod out of the top of the leg by pushing on the Compression Rod You may need to use a screwdriver or long allen wrench placed in the end of the Compression Rod to fully remove it from the leg
74. sic single 180 Single 203 Triple 180 Triple 203 150 180 203 180 203 180 203 180 203 oe so 183 2912 83 2913 83 2914 83 2815 Po 83 2813 33 2817 83 2917 83 2918 83 2918 A 8328 83 29 83 2920 83 299 83 2920 83 2982 83 2082 TED ee eee EE eee 83 292 83 2383 83 2922 Steel S T 257 AL 5 7726 AL 5 26 LG 03 2926 03 2927 RIL Inner leg Forks TEDE TED TBDB B Al Top Clamp Large TBD 7 Al Top Clamp Small TBD 8 ee F For Dark Colors 03 2335 83 2936 aa S 33 2553 83 2562 O __ E 02 S3212 9 ODDD E BNENN
75. stems must be properly tightened prior to use Failure to do so could result in injury or possible death 13 For forks with Non Adjustable FFD a Puta little bit of Prep M grease Ref Answer Products PN 85 0031 on o ring found on the lower piston of the FFD assembly b Install the FFD Assy into the top right hand of the crown steer using a 27mm socket Tighten per the Axel Schematic and Torque Specification Table 14 For forks with Adjustable compression damping Lock out a Fill right leg with damping oil using 5wt Motorex fork oil Ref Answer Products PN 85 0023 to the height noted in the Axel Schematic and Torque Specification Table 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 b 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 c 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 d 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 Axel Schema
76. t be properly tightened prior to use Failure to do so could result in injury or possible death 1 Re install the Compression rod Negative spring that has been well greased and end cap Torque the end cap to 35 50 in lbs Fig 7 2 Apply a small amount of Prep M grease onto the threads at the top of the left inner leg with your finger 6 Apply a small amount of Prep M grease around the outside diameter of the new air piston Insert the air piston larger cupped side up the end with the glide ring goes up See Fig 6 into the inner leg through the threaded area at the top of the inner leg Use your fingers to push the piston past the threads into the leg 8 Using a long screwdriver or rod push the piston fully into leg so that is in contact with the Compression Rod 9 Pour about 3cc of a 40 or greater automotive oil into the top of the piston and then install the air cap assembly Tighten per the Fastener and Torque Values section 10 Fully extend the damper shaft and slide the rubber bumper and spacers against the inner leg end cap also slide the rubber bumper and spacers down to the end of the inner leg on the Compression Rod Lightly grease the bushings on the inside of the outer leg casting using a thick grease such as Motorex Bike Grease 2000 Insert the crown steer assembly into the outer legs to the upper bushing 11 Push the outer legs past the lower bushing and reinstall the 4mm bolt and tighten 8mm damper fitting
77. t examine the compression assy make sure that the CID valve body is free to move i e will open and close it is not necessary that it spring to the open position only that it has full travel Reassembly Place Cartridge assembly in bicycle work stand or secure with Cartridge Clamp Blocks Answer P N with the cartridge right side up 1 Lightly coat the piston ring and IFP on the CID compression assembly with Motorex grease and apply a small amount of blue Loctite to the threads of the cartridge body Insert the assy into the cartridge body being careful not to damage the piston ring and o ring as they enter the body Screw the top cap on about 6 turns DO NOT tighten the top cap down before you pull the vacuum on the IFP Insert the vacuum tool p n into the open end of cartridge body pull back fully on the plunger and hold for 60 seconds this creates a vacumm to make sure that the IFP is fully extended Fig 11 Using a 22mm socket wrench tighten the CID top cap in a clockwise direction to 50 in Ibs 5 65 Turn the cartridge upside down at 45 degree angle and fill half way with Motorex 5w Shock oil Lightly tap the side of the cartridge body several times to remove any air that maybe trapped between the IFP and the CID Piston Fig 15 Fig 11 Fig 12 10 Cartridge Damping System Service cont Reassembly Cont Turn the cartridge body so that it is fully upright and completely fill t
78. tic and Torque Specification Table If you only removed the Top Cap l 2 Generously grease the spring and insert it into the inner leg The spring needs seat onto the top of the compression rod Insert the wind down top cap assembly into the spring the D shaped portion of the adjuster assembly must fit into the D shaped end of the main spring Fig 8 Screw the assembly into the inner leg and tighten per the fastener torque guide at the end of this manual Install adjuster knob and 2mm hex screw Turn the knob counterclockwise until it stops This insures that the fork is in its longest travel position If the travel indicator arrow on the crown is not lined up with the maximum travel point on the indicator dial then the fork must be reclocked a Reclock the fork loosen the compression rod bolt on the bottom of the outer casting b Continue to turn the knob counterclockwise until the indicator points to maximum travel on the knob c Retighten the compression bolt per the fastener torque guide at the end of this manual Air Spring System Service Instructions Removal of Air Spring and Compression Rod Assembly This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death 1 Remove all of the air pressure from the Schrader valve on top of the crown on the left side Black top cap
79. tic and Torque Specification Table e 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 then place the ball bearings on top of the springs place a little dab of grease on spring to hold ball bearing in place f 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 g 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 Assembly of FFD and TPC Damping System Cont 15 16 17 18 19 20 21 22 23 24 For forks with Remote Lock Out compression damping a Fill right leg with damping oil using 5wt Motorex fork oil Ref Answer Products PN 85 0023 to the height noted in the Axel Schematic and Torque Specification Table 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 b Puta littl
80. top cap and the outer cable housing Refer to Figure 8 at the right Reverse the above steps to replace the cable Note The inner cable can be replaced with a standard bicycle derailleur cable It is recommended to replace the two O rings on the stopper each time that it is removed from the shaft in addition to the Black Buna O ring that is on the shaft below the threads Replacement of Piston Quad Rings l Refer to Figure 10 for wrench placement Hold the 12mm wrench in place on the flats that are on the piston seat and turn the piston with the adjustable wrench in a counter clockwise motion to unscrew the piston from the shaft Once the piston is off of the shaft you will see a small Black Quad ring inside the top of the shaft that you just unscrewed the piston from Replace this Quad ring with a new one from IT O ring kit Be sure that the new quad seal is seated in the shaft and rests flat against the shelf inside of the shaft Refer to Figure 9 Install the Air Piston back onto the shaft in the reverse of the way you removed it Tighten the piston to 15inlbs 1 7Nm onto the shaft Remove the large Quad ring on the outside of the piston Discard this Quad ring and replace it with a new one Be careful not to twist it in the groove that it rests in Assembly Instructions Installation of the IT Air Spring and Travel Adjust Assembly All leg caps for Damper and Spring systems must be properly tightened orior to use Failure t
81. tro Kits WARRANTY 83 2977 Model Travel mm Lock Out Comp Damp Platform Plus SPY Volume Adj Ho Tools Rind Damp Adj SPUY Rebound SPUY Valve WO Adjuster Cap assy Air IT Top Assy IT Top Cable Guide IT HE Lever rn Str Leg Outer Leg Assy ME STD Dc NWA STD Dc ME STD Dc STD Dc STD Dc ME STD Dc MHE STD Dc NA STD Dc ME STD Dc MHE STD Dc Axel Axel Hex Axel Axel Axel Hex Axel MA Axel Axel Axel MA GR Hex Axel GR Hex Axel GFE Hex Axel NMA GR Hex Axel GR Axel GFE Hex Axel Sticker Kit Hide Kits Comp Rod Travel Adjust Comp Rod Bottomout Spacers Sir Push Rods Bushing Kit Thru Axel Air Piston Kit Knob Kit Dust Seal Kit O Ring Kit IT O Ring Kit Check LO Retro Kits HOT WARRANTY ITEM Minute Textured Black Textured Gray o3 2525 Black C26 Baa3 2794 white aa z27u95 83 2431 Baa3 2457 aa 284a8 aa 2848 a3 2459 Baa3 2795 83 2826 aa3 245a8 aa 2797 BG3 2829 aa3 z27u98 aa z27989 o3 2460 B B 83 28923 aa z2824 aa3 2802 3 252 7 83 2830 83 2850 83 2852 63 2551 aG3 28025 X zo0 00 aoo ewe aao 100 150 100 130 130 20715 ME 000 sae qq 832448 83 2841
82. ve oil into the top of the piston and then install the air cap assembly Tighten per the Fastener and Torque Values section 7 Fully extend the damper shaft and slide the rubber bumper and spacers against the inner leg end cap also slide the rubber bumber and spacers down to the end of the inner leg on the Compression Rod Lightly grease the bushings on the inside of the outer leg casting using a thick grease such as Motorex Bike Grease 2000 Insert the crown steer assembly into the outer legs to the upper bushing 8 Push the outer legs past the lower bushing and reinstall the 4mm bolt and tighten amm damper fitting in a counterclockwise direction Tighten per the Fastener and Torque Values section Use a shock pump p n 85 4069 to fill the air system to the recommended levels as outlined in the Black Fastener and Torque Values R7 Air System Service Instructions Removal of Air Piston and Compression Rod Assembly WEN This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death There are now two ways to remove the air piston from the inner leg A An Air Piston Removal tool has been developed that will enable you to remove the piston without having to take the fork apart P N 85 8062 Remove air dust cap covering the Schrader Valve Depress Schrader valve to release air pressure Remove air cap o

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