Answer 2004 Axel Service Manual
Contents
1. 85 5189 30mm 85 5194 32mm 85 5192 Bushing Removal Tool Components Slide Hammer Threaded Handle Slide Threaded Shaft Removal Ring Moo Bushing Removal Tool Assembly 04 AXEL SERVICE MANUAL Page 12 REV NC Bushing Removal CONT Bushing Removal Instructions A Install 25 4mm Removal ring on the shiny smaller diameter threaded shaft Be sure to install the ring with the tapered chamfered end first followed by the long slide tube This tapered end leads the tool through the bushing B Start the procedure by removing the Dust Wiper seal with a screwdriver prying it out C Insert Removal tool past the upper bushing and then stop It is important to pull one bushing out at a time Push the slide on the threaded shaft down towards the removal ring Hold the casting with one hand and the slide hammer with your other hand Now move the slide hammer in a motion away from the casting and repeat this action until the bushing comes out D For all other leg diameters use the larger diameter dark colored threaded shaft and repeat steps A C Bushing Installation Note Sizer kits listed in above chart contain the sizers needed for each specific leg diameter 1 2 Bushing Installation Tool Components 1 Installation Mandrel pr 2 Threaded Rod w nuts 3 Sizer rings ss 4 Spacer 5 Washer OS9O0o00 6 Nut 3 4 3 5 6 04 AXEL SERVICE M2. 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 O Ring A soft flexible neoprene or Buna rubber ring with a round cross section which is used for sealing and retention 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 Rebound The phase of the suspension operation in which the wheel returns to its original position on the ground after compression 04 AXEL SERVICE MANUAL Page 4 REV NC 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 Seal A part usually neoprene rubber or Buna that keeps contaminants out and or working fluids in 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
3. facing all the way forward counter clockwise and locked out when the lever is facing all the way towards the back of the crown clockwise Installation of Spring Compression Rod Assembly and Outer Leg Casting Non Wind Down Forks AGAIN 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 AGAIN 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 Screw the compression rod assembly into the crown steer assy Make sure that the comp rod that accepts the 4mm screw is installed in the left leg Tighten per the Axel Schematic and Torque Specification Table 2 Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 3 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 4 Grease spring heavily with Motorex Bike Grease 2000 Install the spring preload and spring assy into the crown steer assy 5 Tighten preload adjuster using 18mm socket and tighten per the Axel Schematic and Torque Specification Table 6 Insert 2mm hex screw into spring preload adjuster knob and install knob on the top left side of the fork Press inner le
4. into the casting 4 Remove crown steer inner leg assembly from the outer leg casting Bushing Removal amp Installation Please refer to section on Bushing Removal amp Installation Removal of Spring and Compression Rod Assembly Non Wind Down Travel Adjust Forks AGAIN 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 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 Compress fork and remove the spring preload and spring assy Remove rubber bumper and clip on compression rod Turn crown steer upside down to allow the comp rods to fall out of the inner legs aPON Removal of Spring and Compression Rod Assembly Wind Down Travel Adjust Forks 1 Turn travel adjust knob clear plastic knob on top of the left side of the crown in a counterclockwise direction until it stops This insures that the fork is in its longest travel and reduces any spring preload on the fork 2 Remove the 2mm Allen screw from the knob Use a 28mm socket to unscrew the top cap assembly from the crown 3 Pull spring out of inner leg If spring will not come out you must take the outer casting off of inner legs refer to Removal of Outer Casting in
5. of bench with a rag under the end of the legs and insert installation tool with bushing into casting leg 04 AXEL SERVICE MANUAL Page 14 REV NC Bushing Installation CONT 4 Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet until proper depth is achieved If using depth gage slide gage onto rod before installing weighted handle and let it settle on of Mandrel Tap rod until appropriate line on gage is even with top of casting leg 5 Remove weighted handle and gage if applicable 6 For sizing of the lower bushing 7 Use slotted top cap from sizer kit and set it into the top of the casting leg straddling the threaded rod Spin the extra nut with washer down to the top cap and using a wrench socket or speeder wrench tighten the nut in a clockwise direction This will cause the Mandrel to be pulled through the bushing thus sizing it Keep turning the nut until the tool is all the way through the bushing and can be pulled out of the leg 8 To install top bushings repeat steps B E Note that the top bushing gets inserted until it stops against the step inside of the casting The extra sleeve that comes with the sizer kit is used to space the top cap off of the casting so that there is enough room to pull the sizers out of the casting without bottoming on the cap 9 If you find that the bushings are too tight after installing them use the sizer Mandrel that does not have a
6. oil flow at this point 4 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 Schematic and Torque Specification Table 04 AXEL SERVICE MANUAL Page 8 REV NC 5 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 6 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 7 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 Note This system is a combination of adjustable compression damping that becomes a lock out It is fully active when the lever is
7. stop on it to hold the bushing while installing it into the casting This is available in the 25 4mm leg kit 85 5191 to go back in and resize the bushings 10 To resize bushings Choose the next larger size rings and repeat the above process 11 When satisfied with the results reinstall Dust wiper seals and then reassemble fork 04 AXEL SERVICE MANUAL Page 15 REV NC Oil leaks from Wiper Seals Troubleshooting Chart Seal not seated properly Solution Remove Casting from Inner Legs reinstall or replace seals Nicks or scratches on inner legs Replace Crown Steerer Inner Leg Assembly Oil leaks from bottom of Casting Wear Rebound damper shaft leaks Remove Casting from Inner Legs reinstall or replace seals Replace Rebound Damping assembly Rebound damper shaft O ring damaged Replace O ring on threaded end of Rebound Damping assembly Lack of Travel Tight Bushings Replace outer leg Hydraulic lock out Replace Rebound Damping assembly Damper oil volume Check oil level Replace Rebound Damping assembly if needed Fork Top out Fork alignment Loss of Rebound Damping Visually inspect fork call Answer Products Customer Service Replace Rebound Damping assembly Top out spring damaged Inspect and replace Top out spring if needed Fork Bottom out Damping oil volume not correct Too much SAG Check oil level Replace Rebound Damping assembl
8. suspension fork that remains fixed to the wheel It slides up and down on the stanchion leg inner leg 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 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 Travel The amount that a wheel moves between the most compressed and the most extended states of the suspension 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 Manitou has the new Evil Genius wiper seals 04 AXEL SERVICE MANUAL Page 5 REV NC 2004 Axel Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting 1 From the left leg dropout Left when sitting on the bike use a 4mm hex 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 Remove the 2mm hex screw inside the knob and remove the knob 3 Use a 8mm hex wrench to turn the damper clockwise until it can be pushed
9. ANUAL Page 13 REV NC Bushing Installation CONT EE gt Bushing Installation Tool Assembly 4 With weighted handle When selecting sizer rings to install bushings choose the two rings that are in the middle of the size run to start with 1 Assemble installation tool as shown in picture above Each leg diameter kit has all of the needed pieces to remove and install bushings for forks with serviceable bushings Some of the kits come with gauges to tell you how far to drive in the lower bushings Upper bushings are driven in as far as the stop in the top of the casting will allow The general rule of thumb is that the lower bushings must not be driven any deeper than 5 into a casting leg If they do go deeper call Customer Service at Answer Products 800 423 0273 for a new outer casting 2 Always assemble Mandrel with the larger diameter sizer ring being placed on the mandrel first then the spacer the next largest sizer ring followed by the washer and the nut to hold it in place Be sure to lock the nut above the Mandrel and below the Mandrel against each other 3 Replace the lower bushing bushing with a thicker wall diameter first Place a small amount of Prep M grease onto the sizer rings to help the rings come through the bushings when pulling them out Slide bushing onto Mandrel until it stops Apply a bead of Red Loctite all the way around the outside of the bushing Hold casting on top
10. B 85 5254 85 5255 Pre Load Adj Top Cap Cc 85 4810 85 5396 Crn Str Leg D Steel S T 26 85 5393 BIk AL S T 26 STD SM 85 5394 Outer Leg Assy E STD Black 26 85 5228 STD Silver 26 85 5229 STD Red 26 85 5230 STD White 85 5274 STD Cobalt 85 5530 STD Orange 85 5531 STD Yellow 85 5532 STD Candy Chrome 85 5533 STD Candy Red 85 5534 STD Candy Blue 85 5273 No Boss Black 26 85 5236 No Boss Silver 26 85 5233 No Boss Red 26 85 5237 No Boss White 85 5537 No Boss Cobalt 85 5538 No Boss Orange 85 5539 No Boss Yellow 85 5540 No Boss Candy Chrome 85 5541 No Boss Candy Red 85 5542 No Boss Candy Blue 85 5543 Sticker Kit F Silver 85 5544 F Black 85 5545 Soft 85 5239 85 5546 Medium 85 5240 85 5550 Firm 85 5241 85 5551 Comp Rod H 80 or 100 85 5552 70 100 RT Wind Down 85 5553 Knob Kit l 85 5804 Boot Kit J 85 5390 Seal Kit 85 5391 Page 18 REV NC Axel Service Kits Cont Axel Model Comp Elite Super Code X 410 X 420 X 430 80 or 80 or 70to Travel mm 100 100 100 Bumper Kit K 85 5554 O Ring Kit K 85 5555 Bushing Kit E 85 5324 Options Damping e Lock Out A 85 5318 04 AXEL SERVICE MANUAL Page 19 REV NC 04 AXEL SERVICE MANUAL Page 20 REV NC
11. Grease 2000 4 Optional Ride Kits If you need to adjust to overall ride characteristics either softer or firmer purchase and or install as follows Kit Part Numbers can be found in the Service Part section of this manual e Soft Remove the Booster Spring e Firm Purchase Firm Ride Kit and install the Booster Spring e xtra Firm Purchase Extra Firm Ride Kit and install the Booster Spring 1 To remove the booster spring 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 2 To install 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 5 Generously grease the spring and insert it into the inner leg The end of the spring needs to seat onto the top of the compression rod 6 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 fastener torque guide at the end of this manual 7 Install adjuster knob and 2mm hex screw Holding the comp rod turn the knob counterclockwise until the knob stops This ins
12. g assembly into outer leg casting until comp rod contacts casting From the left leg dropout use a 4mm hex wrench to install the compression rod screw and tighten per the Axel Schematic and Torque Specification Table 9 From the right leg dropout use a 8mm hex wrench to turn the compression damper counterclockwise until it screws into the casting and tighten per the Axel Schematic and Torque Specification Table 10 Slide fork boots down and snap over dust seal flange 11 Lubricate the inner legs through the Microlube ports using Prep M grease oN 04 AXEL SERVICE MANUAL Page 9 REV NC Installation of Spring Compression Rod Assembly and Outer Leg Casting Wind Down Forks AGAIN 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 AGAINNE 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 Drop the compression rod into the crown steer assy Make sure that the comp rod accepts the 4mm screw is installed in the left leg 2 Remove rubber fork boots from the casting and slide them onto the inner legs of the crown steer assy 3 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
13. mantou 2004 SERVICE MANUAL Axel Super Axel Elite Axel Comp 28209 Avenue Stanford Valencia California 91355 661 257 4411 fax 661 294 4179 www answerproducts com Table of Contents Description Page Introduction Glossary of Terms Disassembly Instructions Assembly Instructions NIOJ B Bushing Removal and Installation Instructions _ _ Troubleshooting Chart Axel Schematic and Torque Specifications 16 Axel Service Kit Chart 17 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 04 AXEL SERVICE MANUAL Page 2 REV NC INTRODUCTION This manual is intended to guide the user through basic service of Manitou Axel 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 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
14. notations 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 must be taken to avoid damage to the product NOTE A NOTE provides key information to make procedures easier or clearer IDE ARAIN eH 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 AGAINN 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 CAUTION Suspension forks use precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage 04 AXEL SERVICE MANUAL Page 3 REVNC GLOSSARY OF TERMS 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
15. ntacts the damper cap This will assist later during assembly of the outer leg casting to the damper shaft Assembly of Compression Damping Assembly Non Adjustable FFD AGAIN 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 1 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 2 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 Assembly of Compression Damping Assembly Adjustable Compression Lockout AGAIN 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 1 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 2 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 3 Twist the Hex shaped aluminum shaft that sticks up from the top cap counter clockwise until it stops the system is completely open to
16. rom inside the top cap Unscrew the compression damping assembly using a 24mm socket Pour old oil out of the top of the fork then compress fork upside down over oil drain pan 3 5 times to get oil out from under rebound piston and discard appropriately Removal of Rebound Damping Assembly 1 Unscrew Damper end cap from the bottom of the right leg and then pull out the rebound damper Assembly Instructions Setting Travel Non Wind Down Forks Setting fork in short travel 1 Follow Disassembly steps above 2 Using pliers pull thicker clip from top of rod and install it in slot just below flange 3 Reassemble assembly and fork as directed below Thicker Clip in slot below flange Bottom out clip removed for clarity 04 AXEL SERVICE MANUAL Page 7 REV NC Setting fork in longer travel Thicker Clip in slot above flange 1 Follow Disassembly steps above 2 Using pliers pull thicker clip from bottom of rod and install it in slot just above flange 3 Reassemble assembly and fork as directed below o Tm bh i i Assembly of Rebound Damping Assembly AGAIN 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 1 Install rebound damper into bottom of right leg and tighten per the Axel Schematic and Torque Specification Table Slide the black rubber bottomout up the shaft until it co
17. 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 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 Convertible Travel A system used to alter the travel of a suspension fork It requires 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 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 Fork Crown The component that joins the stanchion tubes inner legs to the steer tube of the fork
18. structions Then remove the end cap from the bottom of the left leg and remove the Wind Down compression rod assembly and spring as a single unit through the bottom of the leg 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 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 Fig 2 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 Note the spring that you remove should have another spring booster spring intertwined within it 04 AXEL SERVICE MANUAL Page 6 REV NC Removal of Compression Damping Assembly Forks with FFD non adjustable Damping 1 Remove top leg cap FFD Assy on right hand side using 27mm socket 2 Pour old oil out of the top of the fork then compress fork upside down over oil drain pan 3 5 times to get oil out from under rebound piston and discard appropriately Forks with Adjustable Compression Lockout Damping ON Remove the 2mm fixing screw on top of the damper knob on top right side of the fork Remove 2 balls and springs f
19. ures 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 turn the knob counterclockwise until the indicator point to maximum travel Retighten the compression bolt per the fastener torque guide at the end of this manual Press inner leg assembly into outer leg casting until comp rod contacts casting From the left leg dropout use a 4mm hex wrench to install the compression rod screw and tighten per the Axel Schematic and Torque Specification Table 10 From the right leg dropout use a 8mm hex wrench to turn the compression damper counterclockwise until it screws into the casting and tighten per the Axel Schematic and Torque Specification Table 11 Slide fork boots down and snap over dust seal flange 12 Lubricate the inner legs through the Microlube ports using Prep M grease 8 9 04 AXEL SERVICE MANUAL Page 10 REV NC Wind Down Travel Adjust Assembly Top Cap Assembly amp Spring Travel adjust assembly amp End Cap Adjuster knob O ring knob amp 2mm screw Remove Nylon washer that rests on top of aluminum washer 4mm recessed Allen bolt 04 AXEL SERVICE MANUAL Page 11 REV NC Bushing Removal amp Installation Bushing Removal Note use appropriate removal ring that corresponds to the leg diameter of the fork being repaired Leg Diameter Answer Kit 25 4mm 1 85 5191 28 6mm 11 8
20. y if needed Refer to SAG Set up in Tuning section of Owners Manual Bottom out Bumper damaged Inspect and replace Bottom out Bumper if needed Play in Fork Damping oil volume not correct Loose bushings Check oil level Replace Rebound Damping assembly if needed Replace outer leg Loose Compression Rod bolt Tighten bolt to specified torque Loose Rebound damping shaft Tighten Shaft to specified torque Loose press fit tolerances 04 AXEL SERVICE MANUAL Call Answer Products Customer Service Page 16 REV NC Axel Fastener Torque and Setup Levels Axel Comp amp Elite Axel Super Model Axel Description Torque Value Bushing Depth Upper 8 9mm Min 35 Bushing Depth Lower 99 106 mm 3 9 4 2 Torque Brake Post 90 110inlbs 10 2 12 4nm Leg Caps 25 35inlbs 2 8 4 0nm Torque Comp Rod Screw 10 30inlb 1 1 3 4nm Torque Damper Screw Axel Super 10 30inIb 1 1 3 4nm Adjuster caps Torque 35 50inlbs 4 0 5 7nm Damping Oil 110 120mm 4 3 4 7 04 AXEL SERVICE MANUAL Page 17 REV NC Axel Service Kits 04 AXEL SERVICE MANUAL Axel Model Comp Elite Super Code X 410 X 420 X 430 80 or 80 or 70to Travel mm 100 100 100 Comp Damp A 85 5253 Rbnd Damp
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