2005 RADIUM/ METEL SHOCK SERVICE MANUAL
Contents
1. C Seal Kit DU Bushing Kit Q TIL 722 MANITOU MANITOU D Hardware F Sticker Kit H DU Bushing Tool 05 RADIUM METEL SHOCK SERVICE MANUAL Page 15 PN 042132 REV NC2. 6633 85 6639 85 85 85 85 200mm Eye to Eye 50mm Travel 6558 85 6562 6566 6631 6634 85 6640 85 85 85 200mm Eye to Eye 57mm Travel 6567 6632 6635 85 6641 85 215mm Eye to Eye 63mm Travel FP DENM 6636 85 6642 85 85 230mm Eye to Eye 70mm Travel 6645 6637 85 6643 C 85 85 240mm Eye to Eye 6mm Travel a 6646 6638 85 6644 L Lo bo Sa Seal Kit 83 2235 83 2236 IFP Chamber Refill Plug 85 5436 DU Bushing 85 6105 85 6105 Mounting Hardware Kits ID Contact Answer Products ee I T pL T I T 2005 RADIUM METEL SHOCK SERVICE KITS CONT 05 RADIUM METEL SHOCK SERVICE MANUAL Page 13 PN 042132 REV NC Radium Radium Radium R RL Metel RP Kit Description Ride Kits Springs for Coil Shocks e 85 6662 165 Eye to Eye x 38 Rate 700 85 6663 85 6669 j NENNEN Il K NENNEN NENNEN NENNEN NENNEN NN IL se a s Lo d Lo d it E _ j Lo d s Lo d NENNEN po L eee 190 200 Eye to Eye x 50 Rate 600 190 200 Eye to Eye x 50 Rate 650 190 200 Eye to Eye x 50 Rate 700 85 6673 190 200 Eye to Eye x 50 Rate 750 85 6674 Shock Pump Air Canister z o o o Je je ele je o Jo Je jo Jo jo jo o je o Jo jo lo jo Ja e 05 RADIUM METEL SHOCK SERVICE MANUAL Page 14 PN 042132 REV NC 2004 RADIUM METEL REAR SHOCK SERVICE KITS DESCRIPTION A Air Canister RADIUM METEL Shock No aiiis
3. the amount of downtime and labor involved As the program matures and we are able to gather feed back from our customers we may offer kits to a more detailed level GENERAL WARNING Rear shocks by design contain 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 CAUTION The RADIUM METEL Shocks use compressed air to provide fluid pressure in the damping system and spring resistance These systems must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death CAUTION The RADIUM METEL Shock uses precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage SECTION 2 SETUP TUNING PERIODIC MAINTENANCE Instructions for shock setup tuning and periodic rider maintenance is not covered in detail in this manual Please refer to the Manitou RADIUM METEL Rear Shock Owner s Manual for that information If you did not receive a manual you can download one at www answerproducts com or contact Answer Products Customer Service at 661 257 4411 05 RADIUM METEL SHOCK SERVICE MANUAL Page 3 PN 042132 REV NC SECTI
4. 2005 RADIUM METEL SHOCK SERVICE MANUAL PN 042132 REV NC 05 RADIUM METEL SHOCK SERVICE MANUAL Page 1 PN 042132 REV NC 2005 RADIUM METEL SHOCK SERVICE MANUAL INDEX mam remm Pe 3 Wmoumov 3 2 SETUP TUNING PERIODIC MAINTENANCE s 3 am 4 4 CompLeTe sHOcKLESSHAROWARE s 5 HAROWARE REMOVAL ANDINSTALLATION s 5 DUBUSHINGREMOVAL AND INSTALLATION 6 3 ARGWSER s ARCANSTERRENOVALANDSEALSERWGE sn neren mowesoomne mn H TABLET FASTENER TORQUE REQUIREMENTS n aa SHOCKSERVICEKMTS w 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 05 RADIUM METEL SHOCK SERVICE MANUAL Page 2 PN 042132 REV NC FANNIE ICO TL SECTION 1 INTRODUCTION This manual is intended to guide the user through basic service of Manitou RADIUM METEL rear shocks 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 rear shock service at this time our primary focus is to offer service kits that minimize
5. ON 3 GLOSSARY OF TERMS Air Canister Can that holds the air spring air in an air shock Bottom Out Point at which a shock reaches full compression Control Eyelet C End Eyelet that is on the rebound adjuster end of a shock The air canister is attached to this end on air shocks Damper Eyelet D End Eyelet that is on the damper body end of a shock Damper Body Section of shock that contains the damping system Damper Shaft Shaft attached to the damper piston that connects the two moving sections damping system and control eyelet of the shock together Damping System Controls compression and rebound rate speed DU Bushing Teflon guide bushing pressed into the eyelets Mounting hardware is inserted into the DU bushings and rotates within the bushing as need by the suspension design Eyelet Found on each end of the shock it is where the DU bushing and mounting hardware are and provides the connection between the shock and bicycle Internal Floating Piston IFP A floating piston that separates damping oil from the damping system air chamber Lockout Found on QRL shocks The Manitou lockout significantly increases the amount of load required to compress the shock The lockout does not prevent compression under load only increases the amount of load required to compress the shock Mounting Hardware Hardware that allows shocks to be mounted into the wide variety of suspension designs Schrader A
6. dequate air spring pressure kaka ee munem s a us spring and seals mer geen eee s 0T too low air pressure Damping Oil Leaks Oil leak at base of air Worn or damaged Replace shock 4 canister seals allowing oil to escape from damper chamber Oil comes out of the Damping oil has Replace shock 4 Air Spring Schrader leaked past the valve damper cap Damping System Performance knob has no effect work system Low IFP pressure Mounting Hardware Play in shock eyelets Worn DU bushing or Replace 5 6 when mounted in bike mounting hardware 05 RADIUM METEL SHOCK SERVICE MANUAL Page 12 PN 042132 REV NC SECTION 11 TABLE 1 FASTENER TORQUE REQUIREMENTS Torque Swinger Air Air Canister 15 24KgCm 13 21inlbs Schrader Valve Stem 5 10 KgCm 4 to 9 inlbs SECTION 12 2005 RADIUM METEL SHOCK SERVICE KITS Kit Description m Air Conter LL I j Regular Mount 32mmTreve 128 A s21 Regular Mount S mmTrave 9 1 89222 Regular Mount 50mm Travel 2 0 al aam j Regular Mount 56mm Travel 2 25 al 8322 j Schrader Valves Schrader Valves Radium amp Radium R Air Can Schrader Valve Assy Radium RL Air Can Schrader Valve Ass Complete Shock Without Hardware 85 152mm Eye to Eye 32mm Travel 6555 85 6559 85 85 85 85 165mm Eye to Eye 38mm Travel 6556 85 6560 6564 6649 6650 85 6651 85 85 85 85 190mm Eye to Eye 50mm Travel 6557 85 6561 6565 6630
7. e virtually an infinite number of hardware combinations in use on bikes today When ordering hardware from Answer Products It will be necessary to identify the overall eyelet width eyelet width and mounting hole diameter 05 RADIUM METEL SHOCK SERVICE MANUAL Page 5 PN 042132 REV NC HARDWARE REMOVAL AND INSTALLATION CONT 2 Measure hole size Current hardware are designed to accept a 6mm or 8mm fastener 1 Measure the overall eyelet width SECTION 6 DU BUSHING REMOVAL AND INSTALLATION DU bushings are press fit into the shock eyelets at each end of the shock The hardware fit into the bushings and will rotate slightly within the bushing during suspension compression DU Bushings like hardware may wear over time Removal and installation is accomplished using tool PN 85 6075 REMOVAL Remove hardware from the shock Insert unthreaded end of punch into the removal tool first and screw in about half a turn Punch 05 RADIUM METEL SHOCK SERVICE MANUAL Page 6 PN 042132 REV NC DU BUSHING REMOVAL AND INSTALLATION CONT Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch making sure that it is centered on the bushing This will press out the bushing INSTALLATION 1 Place a bushing onto the threaded end of the punch and into the removal tool screw in about half a turn Bushing Clamp removal tool in vise Insert eyelet into tool Use 6mm hex w
8. essure from air canister Air release Schrader valve Remove hardware as shown under HARDWARE REMOVAL AND INSTALLATION For leaks at the Schrader valves release all air pressure and replace the Schrader valve core or assembly as needed The core is removed using a standard core removal tool The assembly is removed by removing the core and unscrewing the assembly by inserting a 3mm hex into the center of the valve Place adjuster eyelet in a vise using soft jaws Using a rubber strap wrench to prevent damage loosen the air canister completely 05 RADIUM METEL SHOCK SERVICE MANUAL Page 9 PN 042132 REV NC AIR CANISTER REMOVAL AND SEAL SERVICE CONT 4 Slide air canister away from the canister Damper Cap DO NOT REMOVE eyelet and remove Do not remove the damper cap The damper system is under extreme pressure Removal of the damper cap without releasing damper system pressure will result in the possibility of injury or possible death 5 Replace o rings seals and wipers in the air canister and air piston Air Canister Kit A will have new seals installed as part of the kit Also replace the o ring inside the canister eyelet 6 Lightly grease the air piston damper body air canister seals and inside the air canister with a thick grease such as Motorex Bike Grease 2000 05 RADIUM METEL SHOCK SERVICE MANUAL Page 10 REV NC PN 042132 AIR CANISTER REMOVAL AND SEAL SERVICE CONT 7 Slide air cani
9. ir Black in color it is the valve for pressurizing the air canister in an air shock Seals O Rings Black synthetic rubber with a round cross section Primarily used for fluid sealing Seals Quad Seals Black synthetic rubber with an X cross section primarily used for sealing air Seals Wipers Teflon ring used for keeping debris out of quad seals guiding the damper piston and providing support Top Out Point at which a shock returns to its full extension 05 RADIUM METEL SHOCK SERVICE MANUAL Page 4 PN 042132 REV NC SECTION 4 COMPLETE SHOCK LESS MOUNTING HARDWARE The highest level kit offered will be a complete shock without mounting hardware These kits are offered as a fast replacement where all that is need is to change out the hardware or damping unit RADIUM METEL Shock Less Mounting Hardware SECTION 5 HARDWARE REMOVAL AND INSTALLATION Mounting hardware is used to mount shocks to the various frame configurations Over time hardware may wear between the mounting bolts or DU Bushing which will result in play in the connection Remove hardware using pliers as shown in Figure 1 DU Bushing Eyelet Figure 1 HARDWARE REPLACEMENT Hardware should have a slight press fit into the DU bushing and can be tapped in place with a rubber mallet or soft jaws in a vise Apply a small amount of thick grease such as Motorex Bike Grease 2000 PN 85 0033 to the hardware before installation There ar
10. rench to screw in punch making sure that it is centered on the bushing and that the bushing is centered to the eyelet This will press in the bushing 05 RADIUM METEL SHOCK SERVICE MANUAL 7 042132 REV NC SECTION 7 AIR CANISTER Manitou RADIUM Air Shocks use compressed air to provide resistance to compression in place of a coil spring You must be certain that the air canister is relieved of all pressure prior to servicing the air system Failure to relieve air pressure could result in injury or possible death Failure of an air shock to maintain air pressure is usually the result of defective or worn seals there is suspicion of an air leak the location can be isolated by spraying the air canister joints with a mild solution of dish soap and water Bubbles will form in from the area of leakage You can also immerse the shock in water to locate the leak Sealing of the shock is accomplished through a series if o rings quad seals and wipers When the air canister is removed these seals can be replaced from Seal Kit C Seal Descriptions O Rings Black synthetic rubber with a round cross section Used for fluid sealing Quad Seals Black synthetic rubber with an X cross section used for sealing air Wipers White Teflon used for keeping debris out of quad seals 1 For leaks at the adjuster eyelet or damper Adjuster Eyelet Schrader end of the air canister refer to the detailed disassembly instruc
11. ster over the damper body 8 Lightly grease the air canister threads and inside the canister Screw the air canister into the canister eyelet Due to pressure in the damping system it may be difficult to compress the shock enough to thread the canister onto its eyelet If necessary the shock test fixture can be used SECTION 9 DAMPING SYSTEM RADIUM METEL Shock damping system service requires special tooling and training that is unavailable at this time In cases where it is suspected that there is air in the damper or the damper body is leaking oil the shock should be replaced NOTICE Do not remove the Phillips screw and or the hex cap on the damper eyelet of the shock If either both are removed the pressure in the shock will be lost and the shock will have to be returned for service and or replaced 05 RADIUM METEL SHOCK SERVICE MANUAL Page 11 PN 042132 REV NC SECTION 10 RADIUM METEL SHOCK TROUBLESHOOTING CHART Symptom Cause Solution Service Section Air Spring Schrader valve Interference with Replace Confirm snapped off at base suspension linkage or clearance after other frame Schrader replacement components Air loss from air spring Air spring Schrader Tighten or replace valve leaks Schrader core or replace Schrader assembly anier Ar em Canister P e Piston Air shock does not Failure of negative Replace air canister return to full travel but spring and seals has a
12. tions below 2 For leaks at the Schrader valve release all air pressure and replace the Schrader valve core or assembly as needed 3 If when you pressurize the air canister the shock collapses to its shortest travel position the shock has an air piston leak into the negative chamber Place the shock in the shock tester and extend it to its full Shock in Shortest Travel Position travel Depress the adjuster eyelet Schrader while the shock is extended under load If it remains in the full travel position refer to the detailed disassembly instructions below for instructions on servicing the air canister and piston seals If the shock returns to the short travel position it is not serviceable and the entire shock must be replaced Extend to long travel and depress the air Attempting to service a canister Schrader Valve shock with this condition could result in injury or possible death 05 RADIUM METEL SHOCK SERVICE MANUAL Page 8 PN 042132 REV NC SECTION 8 AIR CANISTER REMOVAL AND SEAL SERVICE 1 Failure of an air shock to maintain air pressure is usually the result of defective or worn seals If there is suspicion of an air leak pressurize the air canister to 150psi from the adjuster eyelet Schrader Valve Locate the leak by spraying the air canister and Schrader joints with a mild solution of dish soap and water or submerge in a bucket of water Bubbles will form in the area of leakage 2 Release All air pr
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