Dorado Pro Service Manual
Contents
1. SEE FIGURE 100 110 100 026 FIGURE B This Is the poppet that is located inside the compression damper shaft Please see the service manual section that shows the dissasembly of the compression rod 101 350 150 NOTE O RINGS ARE NOT SCALE 26 Dorado SERVICE MANUAL COMPRESSION DAMPER O RING PLACEMENT 101 1250 200 K ZZ 08 29433 L026 100 023 NOTE O RINGS ARE NOT TO SCALE 27 Dorado SERVICE MANUAL TOP CAP amp COMPRESSION DAMPER KNOB O RING PLACEMENT 100 024 100 027 NOTE O RINGS ARE NOT TO SCALE 28 SERVICE MANUAL2. Put a small amount of Prep grease on the O ring on the rebound end of the damper car tridge assembly Install the assembly in the inner leg by sliding it into the bottom of the leg Use a 26mm socket to tighten it into the leg Tighten to 6 8 Nm 60 in Ibs FIG 3 10 Dorado SERVICE MANUAL 7 Insert the detent springs into opposite holes in the end cap and place the detent balls on top of the springs To hold the detent balls in place on the spring use a small dab of grease FIG 4 8 Install the high speed adjuster onto the end cap Be sure that O ring 100 025 below the adjuster is in place and greased FIG 5 Secure the adjuster with the c clip 9 Insert the springs into opposite holes on the TPC adjuster Knob and then place the detent balls in the corresponding holes of the high speed adjuster knob FIG 6 Place O ring 100 024 around the TPC knob and apply a small amount of grease to it FIG 7 10 Install the TPC adjuster knob onto the end cap and secure with the 2mm screw FIG 8 i i i il FIG 8 11 SERVICE MANUAL 11 Replace the oil and dust seals on the outer leg following the directions on pages 22 23 spect the inside of the outer leg and the outside of the inner leg and be sure they are free from debris and contaminants Lube the oil seal and dust wiper on the outer leg with a small amount of Prep M grease Slide the inner leg into the outer leg a
3. IVANVW JIIAGAS LdddXd Odd manitou Table of Contents Table of Contents Introduction and Required Tool List Damping Leg Service Disassembly Damping Leg Service Assembly Air Leg Service Disassembly Compression Rod Service Air Leg Service Assembly Dust and Oil Seal Replacement Exploded Diagram amp Parts List O Ring Placement Diagrams Contact Information Hayes Bicycle Group 5800 W Donges Bay Rd Mequon WI 53092 Toll Free 888 686 3472 Direct 262 242 4300 FAX 262 512 4219 E mail techsupport hayesbicycle com Web site www manitoumtb com 1 ado SERVICE MANUAL Page Number 1 2 3 4 9 10 12 13 14 15 19 20 21 22 23 24 25 28 INTRODUCTION This manual is intended to guide the user through basic service of Manitou Dorado Pro and Expert front forks We highly suggest the service on these forks be performed by an experienced suspension mechanic 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 is to offer service kits that minimize the amount of downtime and labor involved Please read through the manual carefully before beginning the service of your fork The Dorado fork
4. 20 23 19 _ Doraclo SERVICE MANUAL Air Spring Service Assembly 1 Inspect the inner leg inside and out be sure it is free from debris and contaminants 2 Lube the air piston on the Compression Rod Assembly with a small amount of Semi Bath oil 5 40wt Synthetic oil P N 85 0023 and slide it into the top of the inner leg FIG 1 3 Inject 10cc of Semi Bath oil 5 40wt Syn thetic oil P N 85 0023 into the inner leg on top of the air piston FIG 2 4 Use a 20mm crows foot to tighten the air spring end cap to the proper torque of 6 8 9 0 Nm 60 80 in Ibs FIG 3 5 Replace the oil and dust seals on the outer leg following the directions on pages 22 23 Inspect the inside of the outer leg and be sure it is free from debris and contaminants Lube the oil seal and dust wiper on the end of the outer leg with Prep M grease Ref Answer Products PN 85 0031 FIG 4 Slide the inner leg into the outer leg and clamp the top of the outer leg in the bike stand 4 I d Nn FIG 4 20 Doraco SERVICE MANUAL 6 Replace O ring 100 027 on the top cap FIG 5 7 Install the top cap onto the end of the com pression rod Use a 36mm wrench and a 13mm wrench to tighten to the proper torque of 6 8 9 0 Nm 60 80 in lbs FIG 6 8 Inject 30cc of Semi Bath oil 5 40wt Syn thetic oil P N 85 0023 into the outer leg on top of the inner leg FIG 7 9 Fully extend the inner le
5. service is considerably more involved than a standard fork service and having a basic understanding of the tasks you are about to perform will assist you greatly in the disassembly and re assembly of your fork Please read through the required tools page and be sure you have all of the items you will need for the service of your fork The guide is designed to be used with the Dorado Service kit which includes all O rings and seals to overhaul the fork The part number for the kit is 141 25995 For any assistance with the service of your Dorado please contact our Technical Service Department at 888 686 3472 and email them at techsupport hayesbicycle com CANA NA item 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 Manitou Customer Service at 888 686 3472 CAUTION Suspension forks use precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage 2 Dorado SERVICE MANUAL REQUIRED TOOLS Below is a list of tools that will be used in the complete service of a Dorado Pro Expert fork Dorado Clamp Blocks Manitou Part Number 172 25077 Dorado Seal Press Man
6. g and tighten down the top cap to the proper torque of 6 8 9 0 Nm 60 80 in Ibs FIG 8 10 Fill the fork to the desired air pressure 50 90psi FIG 5 21 SERVICE MANUAL FIG 8 Dust and Oil Seal Replacement 1 Using a pick or small blade screwdriver remove the wear ring from the outer leg FIG 1 2 Gently pry out the old dust seal from the outer leg A tool we have found that works well is a downhill tire lever using a flat blade screwdriver to remove the seal be careful the tip of the blade does not catch on the lip inside the outer leg FIG 2 3 Using a pick or small flat blade screwdriver remove the retaining ring on top of the oil seal FIG 3 4 Gently pry out the old oil seal from the outer leg FIG 4 5 Place the new oil seal into the outer leg Be sure the side with the lip and garter spring is facing upwards Use the smooth side of the Dorado Seal Press to press in the new oil seal until it stops FIG 5 amp 6 6 Place the retaining ring on top of the oil seal FIG 2 Ensure that it snaps completely into the groove on the inside of the leg FIG 7 7 Place the new dust seal into the leg and use the knurled end of the Dorado Seal Press to press it complete into the leg FIG 8 8 Install the wear ring back onto the outer leg 22 Doado SERVICE MANUAL FIG 7 FIG 4 FIG 8 FIG 5 FIG 6 23 Dorado SERVICE MANUAL V
7. ired to replace the O rings included in the service kit for the compres sion assembly FIG 19 Ail FIG 18 Dorado SERVICE MANUAL 18 Replace the following O rings on the com pression assembly top cap A O ring 08 29433 L026 This is the O ring that is around the outside of the compression as sembly top cap FIG 20 B O ring 100 023 This O ring is located in an inside groove in the top cap It is directly behind the two pins FIG 21 C O ring 101 1250 200 This O ring is located just below the top opening on the top cap where the adjuster slides through FIG 22 19 Press the top cap back onto the compression assembly FIG 23 FIG 21 9 Doraco SERVICE MANUAL FIG 22 Damping Leg Service Assembly 1 Inspect the inner and outer damper tubes and be sure they are free from debris and contaminants 2 Press the inner damper tube onto the rebound assembly 3 Clean the threads on the outer cartridge adapter with isopropyl alcohol and apply Blue Loctite to the threads Install the rebound damper assembly into the outer cartridge Only tighten to hand tight at this point 4 Clean the threads on the second outer cartridge adapter and apply blue Loctite to them Install the TPC compression assembly into the cartridge 5 Using a 26mm socket and 20mm wrench tighten both the compression assembly and rebound assembly to 6 8 Nm 60 in Ibs FIG 1 amp 2
8. itou Part Number 172 29862 Dorado Service Kit Includes all O rings and seals for service Part number 141 25995 M Prep Grease Manitou Part Number 85 0031 Semi bath Oil Manitou Part Number 85 0023 5wt Fork Oil Torque Wrench 36mm Wrench or Socket an adjustable wrench can be used instead but care must be taken to not damage the top caps 12mm Combination Wrench 13mm Combination Wrench 20mm Combination Wrench 20mm Crow s Foot 2mm Allen Wrench 2 5mm Allen Wrench 5mm Allen Wrench 6mm Allen Wrench 26mm Socket with ratchet Small Flat Blade Screwdriver Needle Nose Pliers Pick or similar tool for removing O rings Blue Loctite Safety Glasses Isopropyl Alcohol SERVICE MANUAL Damping Leg Service Disassembly 1 First step is to loosen the damping leg top cap using a 36mm wrench It helps if the leg is still clamped in the lower crown assembly while breaking the top cap loose be sure the upper crown is loosened you only want the lower tightened when breaking loose the top cap Only loosen the top cap at this point Do not remove it FIG 1 2 Loosen the pinch bolts on the lower crown and remove the damping leg from the fork You will need to remove the frame bumpers to do so Put them in a safe place so you do not misplace them 3 Clamp the upper sleeve of the fork in bike stand 4 Remove the top cap from the fork leg using a 36mm wrench The top cap 15 still attached to the rebound
9. nd clamp into the bike stand 12 Replace O ring 100 027 on the top cap FIG 9 13 Install the top cap onto the end of the re bound shaft Use a 36mm wrench and a 12mm wrench to tighten to the proper torque of 6 8 9 0 Nm 60 80 in Ibs 14 Install the rebound knob into the top cap by Snapping it into place Fully close the rebound by turning the knob clockwise 15 Fully extend the rebound shaft pulling the inner leg up into the outer leg 16 Pour damper oil 5wt fork oil into the leg Stroke the rebound shaft to bleed the system and release the air You want to stroke the re bound shaft a few times with the rebound fully closed then turn the rebound knob open two clicks counterclockwise Stroke the rebound shaft another 15 20 times and the system will be bled FIG 10 17 Once the system is bled you need to set the oil height in the leg The oil height is 110mm You measure this by measuring down from the top of the outer leg to the top of the oil You want the inner leg fully compressed into the outer leg when measuring FIG 11 18 After you have properly set the oil height fully extend the inner leg and tighten down the top cap using a 36mm wrench to the proper torque of 6 8 9 0 Nm 60 80 in lbs 19 Reinstall the damping leg into the fork crowns on the bike 12 Dorado SERVICE MANUAL FIG 9 Air Spring Leg Service Disassembly 1 First the air pressure needs to be released from the
10. rt 172 25077 clamp the compression rod in a vise Be sure to clamp the compression rod near the end or below the air piston Do not clamp in the middle of the shaft FIG 1 Do not clamp the rod in a vise without the clamp blocks Doing so will damage the rod rendering it unusable 2 Next you need to unthread the poppet from the valve shaft Insert a 2 5mm Allen wrench into the center hole of the air piston FIG 2 amp 3 You may have to turn and push lightly on the wrench until you feel it engage the Allen head inside the shaft Turn the wrench counter clockwise You will notice as you are turning the wrench the valve shaft is moving out of the valve housing on the other end of the compression rod FIG 4 Keep turning the wrench until the valve shaft stops moving out of the housing FIG 1 15 Dorado SERVICE MANUAL FIG 3 FIG 4 3 Using a 13mm wrench unthread the valve assembly off of the compression shaft and remove the air valve shaft from the compression rod shaft FIG 5 amp 6 4 Slide the travel spacer bottom out bumper and end cap off of the compression shaft FIG 7 5 Using a 6mm Allen wrench unthread the air piston off of the compression shaft FIG 8 Be careful when removing the piston as there is a small spring in the shaft under the piston FIG 9 FIG 8 FIG 6 16 Dorado SERVICE MANUAL Insert the valve shaft back into compression rod shaft and
11. shaft at this point 5 You will now remove the top cap from the re bound shaft Place a 12mm wrench on the flats of the rebound shaft and use a 36mm wrench to un thread the top cap from the shaft FIG 2 Once the top cap is unthreaded remove the rebound knob from the top cap 6 Remove the fork leg from the bike stand and pour the oil out of the leg FIG 3 Slide the inner leg out of the outer leg and leave the outer leg to drain in a drainage pan 7 Holding the inner leg over a drainage pan stroke the rebound shaft several times to drain the rest of the oil from the inner leg 4 Dorado SERVICE MANUAL 8 Wrap the inner leg in a rag and lightly clamp it into a bike stand with the rebound shaft pointing down towards the floor 9 Using a 2mm Allen wrench remove the TPC adjuster knob Remove O ring and be sure you capture the 2 detent balls and springs under the knob FIG 4 5 amp 6 10 Next you will remove the High Speed adjust er knob Remove the c clip that holds the knob on using a small flat blade screwdriver or similar tool FIG 7 Once the c clip is removed pull the knob up Be sure to capture the O ring 2 detent balls and springs under the knob FIG 8 FIG 4 FIG 5 9 Dorado SERVICE MANUAL FIG 7 11 Remove the damping cartridge from the in ner leg using a 26mm socket Pull the damping cartridge completely out of the inner leg FIG 9 810 12 You will notice
12. system Remove the air cap from the top of the fork leg and release the air pressure using a shock pump FIG 1 2 The air spring leg top cap needs to be loos ened Loosen the pinch bolt on the top crown and crack the top cap loose with a 36mm wrench FIG 2 3 Loosen the pinch bolts on the lower crown and remove the leg from the fork Be sure not to misplace the frame bumper that will need to come off the fork leg FIG 3 4 Lightly clamp the fork leg in a bike stand Remove the top cap from the leg with a 36mm wrench Remove the top cap from the compression rod with a 13mm wrench on the top of the compression rod and a 36mm wrench FIG 4 FIG 4 13 Dorado SERVICE MANUAL 5 Pour the fluid out of the leg and slide the inner leg out of the outer leg Remove the outer leg from the stand and let sit above a drainage pan FIG 5 Wrap the inner in a rag and clamp it lightly in the bike stand with the compression rod pointing towards the ceiling 7 Loosen the Compression Rod Assembly from the inner leg with a 20mm wrench FIG 6 8 Remove Compression Rod Assembly from the inner leg Note there will be a small amount of Semi bath oil on top of the piston FIG 7 FIG 6 14 Dorado SERVICE MANUAL Compression Rod Service This section covers the complete tear down and rebuild of the air spring compression rod in the air leg of the fork 1 Using the Dorado Clamp Blocks Pa
13. the damping cartridge has two larger diameter sections at the ends These are called the Outer Cartridge Adapters Using the Dorado Clamp Blocks Part 172 25077 clamp the outer cartridge adapter on the rebound end in a vise 13 Using a 20mm wrench remove the rebound damper from the cartridge The inner cartridge tube will come out with either the rebound as sembly or compression assembly If it comes out with the rebound pull the tube off of the assembly FIG 11 amp 12 6 Dorado SERVICE MANUAL 14 Replace the following O rings on the rebound damper assembly You can also refer to the Re bound Assembly Diagram on Page 23 to see the placement of the O rings on the assembly A O ring 064962 This is the O ring above the threads on the end of the damper assembly FIG 13 O ring 100 121 This is the larger O ring the bottom out end cap FIG 14 O ring 100 014 This is the smaller O ring on the bottom out end cap FIG 15 SERVICE MANUAL FIG 14 FIG 15 15 Clamp the outer cartridge adapter on the compression damper side using the Dorado Clamp Blocks FIG 16 16 Remove the TPC Compression assembly from the cartridge using a 26mm socket The inner cartridge tube will come out with either the rebound assembly or the compression assembly Pull the tube off of the assembly FIG 17 18 17 Remove the top cap and nylon washer from the assembly This is requ
14. use it to push the poppet out of the other end of the compression rod shaft FIG 10 amp 11 7 Replace O rings 101 350 150 on the poppet FIG 12 8 Replace O ring 100 214 on the air piston FIG 13 FIG 10 FIG 13 FIG 11 17 Dorado SERVICE MANUAL 9 Replace O rings 100 026 and 100 110 on the end cap See Page 26 FIG A Install the end cap bottom out bumper and the travel spacer back onto the compression rod shaft FIG 14 8 15 10 Apply a small amount too much Loctite will clog the air shaft assembly of red Loctite to the threads of the valve assembly FIG 16 Lightly grease valve shaft and insert both the valve shaft and valve assembly into compression rod Tighten to 45 55 in lbs 5 1 6 2 Nm FIG 17 18 FIG 16 FIG 14 18 Dorado SERVICE MANUAL 11 Replace O ring 064962 on the threaded end of the compression rod shaft FIG 19 12 Insert poppet into compression rod shaft FIG 20 13 Insert poppet spring into air piston and thread into compression rod shaft FIG 21 Tighten air piston to 45 55 in lbs 5 1 6 2 Nm 14 Insert a 2 5mm Allen wrench into the center of the air piston and push lightly until you feel it engage on the poppet FIG 22 Turn the poppet clockwise threading it onto the valve FIG 21 shaft Tighten it until the valve shaft protrudes from the valve housing 1mm FIG 23
15. vlad 338 900 60962 7 49696 7 199 S UMOIZ 19 AO mo 96692 7 G66SC LVL 2007 60962 7 986GC LVL 097 4auu 2007 60962 7 9869217 097 ya 8109811 8109817 ease ____ EA xy NUL ___ ET quessy SISPe18 JUNON 8481 JUNON 1504 5 MIEL eozein jedueq 2 E TN ETA peques Po Spiengbs7 6 004 086 Ma o pue q sped aBpueo ajejduoo E ajo 00690171 2009609621 96181 UMOID 8865Z 1p1 900M 6096Z L TL 0 LO8bz lyl LAVA LAVA NOILdIYISIA LAVA 1Y3dX3 OL Nj Nj ONIMV G 24 Dorado SERVICE MANUAL REBOUND DAMPER ASSEMBLY O RING PLACEMENT 064962 100 121 NOTE O RINGS ARE NOT TO SCALE 25 SERVICE MANUAL COMPRESSION ROD ASSEMBLY O RING PLACEMENT FIGURE A 100 214 y E A 2 _ Ey 7 S
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