Fork Service Manual
Contents
1. Oil Weight A description of the relative viscosity of oil such as hydraulic oil Oil with low weight numbers Swt or 7wt flows through the valving with less resistance than higher weight numbers 10or 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 Quad Ring seal New seal that replaces standard o rings in designs that require more efficient air and oil sealing methods Rebound The phase of the suspension operation in which the wheel returns to its original position on the ground af2. 2009 Fork Service Manual Rev 01 05 2011 Table of Contents Section 1 Disassembly Assembly Instructions Damping Systems 843 Section 2 Disassembiviassembi Instructions Spring Systems 1421 Section 3 Disassembly Assembly Instructions Castings 22 23 Troubleshooting Chart 21 22 Technical Information Oil Levels Torque Specs Fork Schematics 2329 Contact Information Hayes Bicycle Group 6750 W Florist Ave Milwaukee WI 53218 Toll Free 888 686 3472 Direct 262 242 4300 FAX 414 462 0214 E mail manitoutech hayesbicycle com Web site www manitoumtb com INTRODUCTION This manual is intended to guide the user through basic service of Manitou 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 is 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 injury or death to the person inspecting or repairing the suspension fork or the user CAUTION A CAUTION a caution indicates special precautions that
3. 19 20 21 For forks with Absolute and TPC compression damping a Puta little bit of Prep M grease Ref Answer Products PN 85 0031 on the glide ring or o ring found on the lower piston of the assembly b Push the assembly into the fork leg and tighten down the top cap c Once the cap is tightened 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 d Place the adjuster knob onto the hex shaped aluminum shaft and seat it onto the top cap and ball bearing e Insert 2mm fixing screw and tighten to secure the knob Compress the fork several times to circulate the oil through the system 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 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 injec
4. 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 Changing the Dust Seals To remove the dust seals first remove the seal tension springs otherwise they will get damaged then take a large flat bladed screwdriver and insert the tip between the bottom of the seal and the top of the foam wiper see Fig 2 Push down on the screwdriver This will pop the seal out of the casting Next remove the foam oil ring see Fig 3 Oil the foam rings new or after cleaning the old rings with a small amount of semi bath oil and place them in the top of the casting above the Upper Bushings see Fig 4 Install the dust seal into the leg use a large socket or piece of round tubing that is large enough in diameter to press on the outside shoulder of the seal rather than putting pressure on the sealing lip and spring so that they are not damaged Repeat steps 1 4 for the opposite fork leg See Fig 5 18 Fig 2 Fig 4 Assembiv Instructions VAGONE When installing the outer Leg Casting to the Crown Steer Assy Compression Rod bolts and Damper Shafts must be properly tightened orior 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 b
5. Kit Group 1 Compression Rod Coil 1 Compression Rod Air 2 Ride Kit Soft 80 100 2 Ride Kit Medium 80 100 2 Ride Kit Firm 80 100 2 Ride Kit Soft 120 2 Ride Kit Medium 120 2 Ride Kit Firm 120 2 Ride Kit Super Air 80 100 2 Ride Kit Super Air 120 3 Spring Cap Coil 3 Air Cap Super Air 4 4 5 5 5 6 7 8 9 9 9 9 1 Crown Steer Leg 80 100 Crown Steer Leg 120 Absolute Platform Damper TPC Compression Damper FFD Compression Damper Rebound Damper Seal amp Wiper Kit 32mm Bushing Kit Outer Casting QR NB Black Outer Casting QR NB White Outer Casting TA Black Outer Casting TA White 0 Knob Kit 141 23999 K002 141 23999 K004 141 23998 K001 141 23998 K004 141 23998 K007 141 23998 K002 141 23998 K006 141 23998 K008 141 23998 K010 141 23998 K012 141 23992 K001 141 23992 K002 141 23993 K004 141 23993 K005 83 3294 83 3143 141 23990 141 23991 K004 85 5293 85 5964 83 3302 141 23994 K031 83 3303 141 23994 K036 141 24000 mNiMlNlmxUPPPODOOODDODODOHODOTT Drake 29er Fork Schematic 28 Part Description Part Number Kit Group 0 1 Compression Rod 80mm 1 Compression Rod 100mm 2 Air Piston 3 Air Cap 4 Crown Steer Leg 80mm 4 Crown Steer Leg 100mm 5 Absolute Platform Damper 5 TPC Compression Damper 6 7 8 9 9 9 9 1 Rebound Damper Seal amp Wiper Kit 30mm Bushing Kit Outer
6. 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 5 15 Fig 7 Fig 8 Assembiv Instructions Troubleshooting Tips If 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 If 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 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
7. 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 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 7 Install rebound adjuster knob if applicable 8 Install the compression rod screw and tighten per the Schematic and Torque 10 MARS Air Spring Svstem Service Instructions Removal of Air Spring and Compression Rod Assembly LUNE 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 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
8. must be taken to avoid damage to the product NOTE A NOTE provides key information to make procedures easier or clearer eS ee eles 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 M M le 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 TERMINOLOGV Air Cap Top cap that threads into top of air spring leg this is the left leg of the fork as vou are seated on the seat Forks mav 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 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
9. 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 Coil Spring A coiled piece of metal that acts as a spring to help suspend a fork 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 Resiriction of the rate that the suspension compresses under load Crown Steer 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 FRONT SUSPENSION TERMINOLOGY CONT FFD Fl
10. through the center of the negative spring assembly that is about halfway up the inner leg Fig 3 6 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 ann R7 Air Svstem Service Instructions MATE 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 injurv or possible death Removal of Air Piston and Compression Rod Assembly 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 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 end cap on the Left inner leg and remove Compression rod negative spring assembly Fig 2 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 remove it from the leg as the leg is longer than th
11. 41 25698 83 3150 83 3299 83 3330 83 3331 141 26532 K008 83 3295 85 5293 85 5964 83 3302 141 23994 K031 83 3303 141 23994 K036 141 27177 K001 Minute 29er Fork Schematic Kit Group H nnnnn m x U gt O O O O 0 0000000000 26 Drake Fork Schematic Part Description Part Number Kit Group 1 Compression Rod Coil 141 23999 K001 1 Compression Rod Air 141 23999 K003 2 Ride Kit Soft 80 100 141 23998 K001 2 Ride Kit Medium 80 100 141 23998 K004 2 Ride Kit Firm 80 100 141 23998 K007 2 Ride Kit Soft 130 141 23998 K003 2 Ride Kit Medium 130 141 23998 K006 2 Ride Kit Firm 130 141 23998 K009 2 Ride Kit Super Air 80 100 141 23998 K010 2 Ride Kit Super Air 130 141 23998 K012 3 Spring Cap Coil 141 23992 K001 3 Air Cap Super Air 141 23992 K002 4 Crown Steer Leg 80 100 141 23993 K001 4 Crown Steer Leg 130 141 23993 K002 5 Absolute Platform Damper 83 3294 5 TPC Compression Damper 83 3143 5 FFD Compression Damper 141 23990 6 Rebound Damper 141 23991 K003 7 Seal amp Wiper Kit 32mm 85 5293 8 Bushing Kit 85 5964 9 Outer Casting QR STD Black 141 23994 K005 9 Outer Casting QR STD White 141 23994 K006 9 Outer Casting QR NB Black 141 23994 K015 9 Outer Casting QR NB White 141 23994 K016 9 Outer Casting TA Black 141 23994 K025 9 Outer Casting TA White 141 23994 K026 10 Knob Kit 141 24000 mnimmnimmm xU gt PPODOOOOOOOOOOTT 27 Part Description Part Number
12. 45 55 in Ib 14 IT Air Svstem Service Instructions Removal of IT Air Spring and Travel Adjust Assembly ZENI 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 Important You must remove all of the air from the left leg of the fork before disassembling the IT System It is advisable 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 On the 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 If you have a helper 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 Fig 2 4 Now that all of the air is released Remove the casting a From the left leg dropout Left when
13. 83 3173 G 2 Ride Kit Soft 120 83 3175 G 2 Ride Kit Medium 120 83 3176 G 2 Ride Kit Firm 120 83 3177 G 2 Ride Kit X Firm 120 141 26745 G 2 Ride Kit Soft 140 141 25683 K001 G 2 Ride Kit Medium 140 141 25683 K002 G 2 Ride Kit Firm 140 141 25683 K003 G 2 Ride Kit X Firm 140 141 25683 K004 G 3 Air Piston 83 3188 G 4 Air Cap 83 3150 C 5 Crown Steer Leg 100 83 3155 D 5 Crown Steer Leg 120 83 3156 D 5 Crown Steer Leg 140 83 3157 D 6 Absolute Damper 141 26532 K008 A 7 Rebound Damper 83 3341 B 8 Seal Wiper Kit 32mm 85 5293 K 9 Bushing Kit 85 5964 E E E E E E 25 Part Description Compression Rod Ride Kit Soft 80 Ride Kit Medium 80 Ride Kit Firm 80 Ride Kit X Firm 80 Ride Kit Medium 100 Ride Kit Firm 100 Ride Kit X Firm 100 Ride Kit Medium 120 Ride Kit Firm 120 Ride Kit X Firm 120 Air Piston Air Cap Crown Steer Leg 80 Crown Steer Leg 100 Crown Steer Leg 120 Absolute Damper Rebound Damper Assembly Seal Wiper Kit 32mm 9 Bushing Kit 10 Outer Casting QR Black 10 Outer Casting QR White 10 Outer Casting TA Black 10 Outer Casting TA White 11 Knob Kit Part Number 83 3312 141 25690 K002 141 25690 K003 141 25690 K004 141 25690 K005 141 26743 K001 141 26743 K002 141 26743 K003 141 26744 K001 141 26744 K002 141 26744 K003 1
14. Casting QR STD Black Outer Casting QR STD White Outer Casting QR NB Black Outer Casting QR NB White Knob Kit 83 3262 83 3263 83 2669 83 2654 83 2656 83 2659 83 3253 141 24675 83 3254 85 5281 85 5231 98 23561 98 23562 83 3258 98 23563 83 2670 R7 Fork Schematic 29
15. axle nut to specified torque value and then tighten the clamp fixing bolts on the right drop out to the specified torque Fig 2 Fig 3 20 TROUBLESHOOTING Service Manual mmm Cause Section Tighten Valve core replace bad parts as imam Air oman Schrader Valve leaks needed Make sure O ring is seated properly AW Air Cap O ring leaks replace parts as needed Check oil volume on top of piston replace Air Piston leaks parts as needed Check O ring tighten cap to proper a Air Top Cap leaks Torque and replace parts as needed Oil leaks from Remove Casting from Inner Legs reinstall Zn Wiper Seals Seal not seated properly or replace seals Da or scratches on inner legs Replace Crown Steer Inner Leg Assembly Follow instructions for removal and la Too much Semi Bath oil installation of Outer Casting Remove Casting from Inner Legs reinstall MW Wear or replace seals Oil leaks from bottom of oe damper shaft Casting Replace Rebound Damping assemb Rebound damper shaft O Replace O ring on threaded end of MI ring damaged Rebound Damping assembly Compression Rod Bolt Check O ring on bolt to see if it is oe leaks damaged and then reinstall Resize bushings or replace with new ones Lack of Travel Tight Bushings if damaged in Hydraulic lock out Replace Rebound Damping assembly poo l Follow instructions for removal and Semi Bath oil volume installation of Outer Casting Check oil level Replace Rebound Damper oil volume Da
16. cial 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 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 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 loosened 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
17. could result in injury or possible death 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 4 Apply a small amount of Prep M grease onto the threads at the top of the left inner leg with your finger 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 3 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 Using a long screwdriver or rod push the piston fully into leg so that is in contact with the Compression Rod Pour about 3cc of a 40wt 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 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 Push the outer legs past the lower bushing and reinstall the 4mm bolt and tighten 8mm damper fitting in a counterclockwise direction See Fig 5 Tighten per the Fastener and Torque Va
18. e Comp Rod oa to IM man Installation of the Air Piston for R7 Forks 7 Apply asmall amount of Prep M grease onto the threads at the top of the left inner leg with your finger 8 Apply asmall amount of Prep M grease around the outside diameter of the new air piston 9 Insert the air piston larger cupped side up the end with the glide ring goes up See Fig 3 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 10 Using a long screwdriver or rod push the piston fully into leg sp that is in contact with the Compression Rod 11 Pour about 3cc of a 40wt or greater automotive oil into the top of the piston and then install the air cap assembiv 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 a a 2 wer eher A a re m a TE f A Fig 5 Assembiv Instructions Installation of Air Piston and Compression Rod Assembiv for R7 Forks WAAIDE 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 Uu Uuihici 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
19. e 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 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 TPC 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 desc
20. e 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 6 Unscrew the end cap on the bottom of the inner leg and remove the compression rod assembly see Fig 3 Fig 2 Installing Air Spring and Compression Rod Assembly 9 Reassemble the compression rod assembly and install in the fork leg Tighten end cap to 9 0 11 3Nm 80 100 Ib in 10 Generously grease the spring and insert it through the top into the inner leg The spring needs to seat onto the top of the compression rod 11 Using a 20mm socket or wrench tighten the air cap onto the top left fork leg Tighten to 6 8 9 0 Nm 60 80 Ib in 12 Install the adjuster knob and 2mm hex screw 13 Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt Fig 3 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 14 Press inner leg assembly into outer leg casting until damper shaft contacts casting Adjuster hex shaft should protrude slightly from casting 15 Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten to 3 4 4 5 Nm 30 40 in Ib 16 Tighten Install rebound adjuster knob if applicable 17 Install the compression rod bolt and tighten to 5 1 6 2 Nm
21. e 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 10 Tighten per the Schematic and Torque Specification 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 Feed the inner wire through the cable housing and secure one end of the of the housing into the gold cable 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
22. e 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 1 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 16 Assembiv Instructions Installation of the IT Air Spring and Travel Adjust Assembly RUUJALC 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 VAGONE 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 c
23. ench to turn the damper clockwise until it can be pushed into the casting See Fig 2 c 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 d Then remove the end cap from the bottom of the left leg and remove the compression rod and spring through the bottom of the leg See Fig 3 2 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 3 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 4 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 inner leg The spring needs to seat onto the top of the compression rod See Fig 4 3 Install the adjuster knob and 2mm hex screw 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
24. 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 11 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 17 Section 3 Outer Casting Service From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw 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 Use a 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting see Fig 1 Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on
25. lues 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 13 ACT Air System Service Instructions MEME 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 Removal of Air Spring and Compression Rod Assembly 1 Remove dust cap from Schrader valve 2 Depress Schrader valve to release all the air pressure 3 Using a 20mm socket or wrench remove the air cap from the top of the left fork leg 4 Pull out the coil spring from the fork leg see Fig 1 5 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 a 8mm 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 If the fork uses the Semi bath Lubrication system use caution as th
26. mping assembiv if needed Visually inspect fork call Answer WW Fork alignment Products Customer Service Loss of Rebound AM 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 MW correct Damping assembiv if needed Fork Bottom Refer to SAG Set up in Tuning section of II out Too much SAG Owners Manual Bottom out Bumper Inspect and replace Bottom out Bumper if MMA damaged needed Damping oil volume not Check oil level Replace Rebound Pe correct Damping assembiv if needed 21 TROUBLESHOOTING CONT Service Manual o Cause Page Play in Fork Loose bushings ones if damaged bolt Tighten bolt to specified torgue shaft Tighten Shaft to specified torgue Loose press fit tolerances Call Answer Products Customer Service Problems Various See Lock Out Troubleshooting 22 Manitou Fork Technical Information 2009 OIL HEIGHTS Fork Torque Specifications 24 Minute Fork Schematic 141 23994 K015 141 23994 K016 10 Outer Casting QR Black 10 Outer Casting QR White 10 Outer Casting TA Black 141 23994 K025 10 Outer Casting TA White 141 23994 K026 11 Knob Kit 141 27177 KOO1 Part Description Part Number Kit Group 1 Compression Rod 83 3183 H 2 Ride Kit Soft 100 83 3170 G 2 Ride Kit Medium 100 83 3171 G 2 Ride Kit Firm 100 83 3172 G 2 Ride Kit X Firm 100
27. 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 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 th
28. orks with Absolute compression damping a Unscrew the 2mm Allen screw that holds the adjuster knob to the assembly Rane and remove the knob There are two ball bearings sitting on top of springs Fig 2 m underneath the adjuster cap Place those aside Using a 24mm socket unscrew the Absolute assembly from the crown Pull the assembly out of the fork leg 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 6 For forks with TPC compression damping 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 and remove the adjuster knob There are two ball bearings sitting on top of springs underneath Place those aside c Unscrew the compression assembiv from the crown using a 20mm socket lt may be necessary to twist the assembly like you would be unscrewing a screw and gently pull upward to free the assembiv 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 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 8 Unscrew Damper end cap from the bottom of the right leg and then carefully p
29. ottom 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 See Fig 2 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 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 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 semi bath oil into each outer leg See chart for correct amount It is recommended to use a syringe to inject oil See Fig 4 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 Schematic and Torque Specification Table Use 8mm Allen wrench 2mm Allen wrench 11mm Nut Driver or open end wrench Sy
30. ould result in injury or possible death 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 Fig 10 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 cap 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 3 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 As 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 automotive oil maybe substituted into the fork leg through the top of the crown 6 Torque the top cap to 60 80 in lbs using the slotted 22mm socket 7 Replace the Outer Casting if it has been removed as follows a Replac
31. 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 a 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 Fig 2 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 see Fig 2 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 the air push rod see Fig 3 This spring is the one that would be changed if the fork s SAG needed to be changed beyond the capabilities of the air pressure To remove the air piston from the inner leg 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 left leg end cap and compression rod assembly from inner left leg Then remove spring and Air piston rod 5 Use a long narrow rod approximately 18 458mm long and no greater than 4 7mm in diameter and insert it into the left inner leg from the bottom of the leg Be sure to direct the rod
32. ringe for Semi Bath Oil Air pump 19 32mm Leg Thru Axle Instructions 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 Fig 1 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 B in the slot of each dropout 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 Specification Chart at the end of manual 8 Finish the installation by tightening
33. ription 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 work 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 Section 1 Damping Systems Absolute and TPC Damping System Service Disassembly Instructions for Absolute 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 Fig 1 counter clockwise Remove the knob by pulling gently away from the fork 2 Use an 8mm hex wrench to turn the damper shaft clockwise until it can be pushed into the casting see Fig 1 3 From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw 4 Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting 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 5 For f
34. 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 Use a 8mm 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 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 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 it is 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 lever 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
35. t 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 to 3 4 4 5 Nm 30 40 in Ib Install rebound adjuster knob if applicable Knob should turn uninhibited until the indicator is stopped by the casting Fig 1 Fig 4 Section 2 Spring Svstems Coil Spring Service Instructions Removal Coil Spring Assembly 1 For Drake coil fork a Using a 20mm socket remove the top cap from the fork b Remove the spring from the fork Fig 1 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 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 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 wr
36. ter 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 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 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 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 th
37. uid 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 characteristics 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 Integrated Stem System integrates 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 spe
38. ull the damping assembly out of inner leg See Fig 3 Assembiv of Absolute and TPC Damping Svstem MAUAINA When installing the outer Leg Casting to the Crown Steer Assy Compression Rod bolts and Damper Shafts must be properly tightened orior to use Failure to do so could result in injury or possible death 9 10 11 Install the damping assembiv into bottom of inner leg Be sure to applv a thin laver 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 NOTE Proper torque of the damper cap to 92 115 Kg Cm 80 100inlbs is critical failure to tighten properly will result in system failure Turn Crown steer leg assembly right side up so that the crown of the assembly is facing you Extend the damping assembly all the way out and then pour damping oil P N 85 0023 into the right inner leg Fill leg about 4 full Take a rag and cover the top of the right inner leg and then stroke the 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 Oil Heights Chart at the end of the manual WAUA 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 12 19 16 17 18
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