Manitou 1999 SX Service Manual
Contents
1. NOLSId 68900 9 SB1 HONI 02 01 3n0301 TB 1N3130 QN 897090 ZG11v0 9NISdS A M332S 008 NOISS3HdWOO SrO rO Y3DWIS NOISId 6 1 LYO WIHS S00 X 60F x 9Z8 Rt A N3HSVM 1nOdONO SG v1 70 NOISId S Pd Sy 826070 353315 vv 110 ANG WIHS QNDnOH33 P S AIBNISSV LG 1160 WIHS dNV1d y 8v 1140 LAN 3NIVA HONv 931 J3ino W N ZL OL 3NDYOL SB1 HONI 011 06 3NDYOL 96 1v0 1SOd Svea NNINVLIL GW na NOLOH Pd Z v vO J g M3NOLSVI3 ANNOIN y 1 0Z90 AIBW3SSV LIVHS N3MO 41790 937 YANNI 1431 M Sy Pa EBY vO LON 3ATVA SS d ZG11v0 ONINdS SrO rO u3ovdS NOISId BELIYO WIHS S00 X 60v X ZZ9 9GvL v0 NOISIH LGILvO XZ OSILe0 6 140 OWLS WIHS ONNO938 LSLLvO WWE WIHS dNV1D 0 1290 LV3IS JAWA 01290 297170 YSWOLSV13 ONNOBSY 931 Y3NNI LHN 3383315 NMONO s P Y M LLg L0 MOLO3NNOO DNISAS v0LZ90 038 x20is MIN 275 10 33378 1N3130 0 110 91 1 Z 6 x Z2 9 ia 069010 8 X l ONIN O vzG0vO ONIN O L 888110 ATENISSV u31SnrOv 9r Z90 LivHS u3ddn 689070 TIV8 1N3130 LYLO SNIHSNG Y3MOT cv 1v0 ONIHSNG YIdAN ZL0Z90 31033N Y3LSNPQV ediro SENO S y1 0 dvd XS 6LZ1 0 BONA 96v1v0 31vid 32v3 02 1v0 MIYIS SNIddVl 4135 ONIGRO NOISS38dN0O n Mod 5805 OLVIN3HOS MYO4 NOSNVO XS 66 8 3Mfn9l3 o MM Page 9 MAINTENANCE IMPORTANT The2. OUT STICKERS 85 3894 99 SX OUTER ASSEMBLY BLACK WITH OUT STICKERS 85 3896 99 SX OUTER ASSEMBLY DARK BLUE WITH OUT STICKERS 85 3897 99 SX OUTER ASSEMBLY MANGO WITH OUT STICKERS 85 3898 99 SX OUTER ASSEMBLY BRIGHT RED WITH OUT STICKERS 85 3899 MICRO LUBE DEMO KIT 85 3900 99 SX OUTER ASSEMBLY JADE WITH OUT STICKERS 85 4004 99 SX C OUTER ASSEMBLY BRIGHT RED WITH OUT STICKERS 85 4005 99 SX E YELLOW STICKER KIT 85 4019 99 SX E BLACK STICKER KIT 85 4025 Page 3 SPARE PARTS Table 1 Continued DESCRIPTION 99 SX DARK BLUE STICKERT KIT 99 SX BRIGHT RED STICKER KIT 99 SX R MANGO STICKER KIT 99 SX R BLACK STICKER KIT 99 SX TI YELLOW STICKER KIT 99 SX TI DARK BLUE STICKER KIT 99 SX C BRIGHT RED STICKER KIT 99 SX E BRIGHT RED STICKER KIT 99 SX YELLOW STICKER KIT 99 SX TI JADE STICKER 99 SX E CROWN STEERER LEG KIT 99 SX CROWN STEERER LEG KIT 99 SX R amp SX TI CROWN STEERER LEG KIT 99 SX C CROWN STEERER LEG KIT Page 4 PART NUMBER 85 4027 85 4028 85 4029 85 4030 85 4031 85 4032 85 4033 85 4043 85 4044 85 4045 85 4047 85 4048 85 4049 85 4050 962290 JIYA NOISS3HdAOS 1890v0 Z S r0 dv3 ONIN O NOLSId 62Z 140 8ONM 267170 alyd 39V3 o 1v0 Mayos INIA VI 4735 vZG0v0 SNIN O dvd 662290 ATBNISSV ONIdANG NOISSIUANODO 619040 ONIN ONINIVLIM 4690v0 H3HSVM No FOVIS ANZ Z8v vO M3NOLSV13 QNnOS3H 199070 8 2 X v 2 ONIN O Z81 0 LAN INOJOYA MIHNVO evzz90 AVI ANA SS01bv0 v3S L
3. and may cause damage to the system and an unsafe riding situation Finish reading this entire section prior to making any changes to the oil level To check the oil level remove only the compression damping assembly located in the top of the left leg Leave the right side compression stack adjuster MCU spring assembly in place to keep the fork fully extended Use a tape measure or dip eee stick to determine the oil level Oil level should be between le EROM TOF OF CROWN 3 25 83MM and 4 5 114MM below the crown where the MAXIMUM damping assembly screws in The recommended level is RECOMMENDED i 4 0 102MM It is recommended that you replace your oil MUERE N at least once during the season twice if it has been contam B inated with dirt mud or other foreign substance Use SAE i 5WT Maxima fork oil or equivalent See Figure 10 FIGURE 10 TPC OIL LEVEL GENERAL DISASSEMBLY NOTE The Fork does not need to be removed from the bicycle for general disassembly assembly or cleaning Itis also not necessary to disassemble the 98 Manitou Forks for compression Elastomer replacement Elastomer replacement is accomplished by removing the adjuster assembly per Figure 12 Removal of outer leg arch assembly Figure 11 ANB LS CONRES AS 1 Use a 4MM allen wrench to remove the M6 lower compression rod screw from the right leg dropout Pop out the damping adjuster knob from the left dropout S
4. d at Sbv11 0 9 WHS dN 00832 SS I vv1170 wwe WiHS dN nORBR3H ZS 1iFO WIHS dAV 19 D S8v1v0 LAN 3A1VA PN 2 069070 9 2 X v ONIN O 4 ATSWSSSV L 6890v0 H24N 911 YUNG myg 1N313 vs vo ams G 1nOdONQ H3dAva W N zi 0L 300801 SE1 HONI 011 06 3MDIO1 Z60v0 150d 3NVYA R Q vZ0Z90 dd O31 1431 e 8960470 190790 p dr WOLLOd A TB8A3SSV L3VHS 3M07 Ce zavivo lt 2 ss ES u3WOISy 13 INNOS3H 62790 dv ONI _ SLv1v0 H3WOlSy13 INNOAIYA vGzz90 ATINO T3AV31 ANOZ X04 8 140 LAN 3ATVA a ZS11y0 SNIHdS 670170 YIDVAS NOISIH HA 821170 NIHS 9GY1Y0 3A1V NOISSIMANON vvz170 O8 AYOW 590790 doy NOISSIYANOD 1G11vO XZ OGLLYO 6vLLYO XOV15 WIHS NOISS3HdAO2 GSLIgO NIHS dAVTO EZvLvO M3N55 Las Y 8yg1v0 9N07 Z ONIMdS 13315 H106l Page 6 d LLE LYO BOLO3NNOO ONS d a rZvjvO 318 3014 LJOS 7 9Z71v0 NON MOTT3A szivo H0123NNO2 A gZr v0 now aay vLv1v0 ONIHSNE SES X LEZIO 30L93NNO2 bly IHSN n vOLZ90 TJAVYL WNOZ 304 ELF 17O ONIHSNA Hada ScvivO0 NOW 03 d sal ATEA3SSV HaLsnray zszz90 Was LSNA 1vS170 dv 6LZ1v0 8ONA L6v 110 a1V ld 39VW3 02210 M3HOS DNlddVL 4138 LrOZ90 A 18W3SS V S IdAVO NOISS 3HdWOO S vvZLv0 1008 u04 lIVLJd 1v3S SNIHSNE OILVWSHOS NHO4d XS 66 S AANA 4 S1v0 34331 1N
5. rotate the rebound damping knob located on bottom of the left leg Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Excessive rebound damping will give you a harsh ride over repetitive bumps like braking bumps because the fork will pack up Insufficient rebound damping will make the fork over active top out and slap back when landing from a jump We suggest that you try adjusting your fork on the very active side minimum rebound Then try it over a variety of terrain and tune in more rebound from there The SX E uses TPC FIGURE 19 REBOUND DAMPING Sport for Rebound damping and is not adjustable To adjust the rebound damping for the SX only the left legmust be disassembled as follows 1 Turn the entire fork upside down This will eliminate the need to drain the oil 2 Remove the dropout nut located at the bottom of the left leg and the M5 socket screw located at the bottom of the right leg Pull the outer leg casting off of the inner legs 3 Stroke the damper shaft several times to transfer the oil into the upper chamber Give the oil several minutes to drain off of the lower shaft assembly 4 Unscrew the damper end cap and pull out the lower shaft assembly 5 Adjust the set screw on the valve seat in to increase rebound damping and out to reduce the rebound damping Try adjusting one half full turn at a time 6 Re assemble Stroke the leg several times to bleed t
6. 0911 O 6 11F0 xovis WHS ONnoB3H 251170 WAEL WHS dAv32 011290 Sad IHI 9zv1v0 NIN MOTT3A ENI I W N S 2 3nDu01 S81 H3NI Of O1 INOYO1 gozaso uaa doy NOISS34dNO2 W N ZI 0L 3n0301 591 HINI DJ 06 IN0YQL SS 1z60 0 1SOd DYE O Zgv vO YINOLSVI2 ONNOBIY S vszzao AINO 7T3AVML WAOZ 303 ceozo0 doy NOISS3HdNO2 arbe ONO1 Z S DNS 11 B OvI X 10 YOLO3NNOD SNIHdS ZsSIir0 343318 1N3L30 0S 1170 91 72 6 X TE S ub O690v0 8 X 1 SNIN vZ50v0 ONBI Q E X ez 1 0 NOW 034 8851v0 ATaWaSSy NILSNPOY 9v1Z90 LIVHS N34dn Dunn mva LN313 Z 0Z90 31033N a1isnrav ESv1vO avo 6LZ1v0 BONA 96140 11Yld 39V4 0 140 M3495 ONiddVL 473S 040290 ATBNISSV ONIJAVO NOISSIYINOI SULVAJHOS Adua IL X5 66 Z 3efi9l3 vLvyvO ONIHSNG N3M01 Zv1v0 INIHSNQ 33ddn Z9ZZ9D Was 1sna vvZ v0 1008 X904 IV130 1v3S DNIHSn8 Page 8 Z81v0 3A331S 1N3130 629070 ONIN ONINIVL3H 169070 YIHSVM ANI 39VIS ONZ Zov vQ H3 O1SV13 UNNOB3Y 189070 B L X W E w 0SZZ90 avo UN 80v 70 gs0170 Was LavHS BON YILSNPOV N3dNVQ g90z90 31033N w3wo1 2890 0 ANN 1NOJOYO SNIN O GYEI LAN 10108030 33JAVO 069040 g g X v INY O oci1v0 Z 6 x zc c in P2 920Z90 LJVHS 33401 A E gt W N S Z INDIO 0 1Z90 1v3S
7. 3130 6290 0 SN SNINIVL33 169070 s3HSVM ANI 32V1S ANZ z9v 1v0 uaWoisvi3 INNOB3Y L90v0 91 4 X 91 GL SNIN O 092290 dyo UN SSOLv0 1V3S LIVHS B90Z90 31033N 33401 0zi1v0 Z 6 x Z S ON O 0690r0 8L0Z90 14VHS MOT 8 X r 9NRI O A 689090 Tyg 1N3130 05 1Z90 Ly3S NOLSId 231140 ONS UM cv01vO M30vdS NOLSId E 6 11v0 WIHS SOO X amp Ov X 9CH s SSrIr0 NOLSId NS S 12O 19 NIHS ONNOB3Y vv v0 wws WHS QNnOB3H Q CGsivO NHS dv To ac 9 9 8v1 0 LAN 3ATVA Q 90Z90 ATBNISSY LIVHS 33MO1 L61v0 343318 1nOdONQ N3dAVG vL0ZS90 531 1331 x 8v v0 INN BAVA a ZS11v0 INRIAS Gv0ivO N32VdS NOLSId B 11v0 WIHS S00 X 60v X 229 9Sr vO NOLSId LSLL O xz N OSLLbO SrllrO X2v1S WIHS QNnOB34 ZS11 0 WAS WIHS ANVIO 0 1280 1v3S 3ATVA ZSirO 343375 1N3130 ae 1170 91 1 ZE 6 x z sS 9Na 069070 B E X v L INIA rZG0vO SNIN O L 971790 13VHS Y3IddN 9Z 1 0 NOW 038 699070 11v8 1N3130 888140 ATBW3SSv Y3Lsnray w EGv1vO avo S 6Lziv0 BON 967170 31v 1d 35v 0t v0 M3N2S INIAAVL 4135 0L0290 A18N3SSV SNIdNVG NOISS3HdNOO HONV O31 H31nO Qe nt 3AQ01Sv 13 QNnOB3H _ I 9Zv 170 no MOTI Gszio YOLOINNOD GZ 1v0 NOW 038 L ZVvO YOLIINNO9 Y01Z90 T3AV31 WAOZ YOA OILVWAHOS MOJ M XS 66 9 340914 80v1v0 SON s3isnr v YIYI
8. 99 SX SERVICE MANUAL P N 85 3666 MANITOU ANSWER PRODUCTS INC 28209 AVENUE STANFORD VALENCIA CA 91355 805 257 4411 www answerproducts com TABLE OF CONTENTS Consumer Safety amp Warranty Information Installation Instructions Spare Parts List Exploded View Maintenance amp Disassembly Inspection Re assemble y i Inner Fork Leg Crown amp Brake Arch Adjusting the Ride Qualities Trouble Shooting OG Q O WD O ANSWER PRECISION SUSPENSION CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUITAIN BIKE SUSPENSION FORK AVAILABLE THE 1999 SX FORK MODELS HAVE STATE OF THE ART M SPRING COMPRESSION SYSTEMS THE SX SERIES ALL USE THE NEW TWIN PISTON CARTRIDGE SYSTEM TPC THAT SURPASS ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY Your 99 SX Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1 8 threadless steer tube 99 SX s are available with the V Brake cable hangerless arch and have an optional attachable cable hanger kit P N 85 3800 which is available through your dealer CONSUMER SAFETY INFORMATION IMPORTANT The 99 SX Fork is a off road fork and as such does come with the reflectors for on road use installed Reflector bracket kit P N 85 3674 is available through your dealer Have your dealer or mechanic install the kit to meet the Consumer Product Safety Commission s C P S C Requirements for Bicycles if t
9. 99 SX should not be used if any parts appea to be or are damaged Contact your local dealer or Answer Products for replacement parts IMPORTANT Use of fork boots is required to keep your 99 SX performing well and your warranty in effect Use of this fork with the boots removed will shorten the life of the fork reduce the performance and void the warranty Your 99 SX Fork requires periodic maintenance cleaning and inspection Moisture and contamination may build up inside the fork depending on the severity of riding conditions Tomaintain top performance it is recommended that the fork be periodically disassembled cleaned dried and re greased IMPORTANT When filling the fork with grease through the grease ports it is important to note the grease is being forced between the upper and lower bushing If the area is overfilled the force of the grease may force the upper bushing and dust seal out IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight 2 Whipe the inner legs clean lubricate and check entire fork for any obvious damage 3 Check headset adjustment 4 Insure that the front brake cable is properly seated in the cable retainer amp check brake adjustment FIGURE 9 LUBRICATING THE BUSHINGS IMPORTANT Maintaining the proper oil level in your TPC isvery important Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel
10. AVHS e uh oe 1 2 S81 H2NI 0 0 3no301 R g9zo90 M3HOS COX NOISS3HdAO2 560290 LJVHS A BN3SSV 00 790 006 X LLE WIHS H23V 931 M31nO L67790 NOISId QNnOQ33 h vZ91 0 343318 et 1nodosa YadWva 10 Z90 ATEWNaSSY L4VHS H3MD1 W N ZL OL 300801 S 1 HON 011 08 3nouoL Lz60v0 LSOd 3 veiB Z9v LLO M3JNOISV 3 QNDOS3M 6vZZ90 dvd QN3 E erm A HBR Page 5 S Zr 0 43A01SV13 ONNOBIY 7GZZ90 AINO T3AVHI WNOZ 304 vvz1v0 S1008 YAQA S90Z90 JOY NOISS3HdNO2 Een 8y61v0 SNOT Z ONINdS 13315 81061 LL WO0 H0193NNOO ANINdS 92v v0 NOW MOTIZA ZVv0 YOLDINNOI SZr r0 NOW 033 FZ1r0 YOLOANNOS vO1Z780 TAAVYL WWOZ 304 GZv vO NOW aay 898G O0 AMIN3SSV 3iisnrav vZvlvO SNIHSNS M3M01 Lv1 amp 0 ININSNG M3ddn D zezz9eo Iwas 1sna vvzivO 1008 X404 S INIHSNA AS EB ow E 0SZZ90 dvd aN3 S9070 IVIS L4VHS 226110 WINS LN3L30 169040 EN M 0011KO QONA eae z9vivO 43NOLSV13 INNOA3Y 189070 8 4 x v INIY O 889070 LON LnOdOMO DNIN O 278170 LAN LNOJOYA N3dAVQ E 890790 31033N 3MO1 W N S Z1 3NDYOL SBT HINI 02 0 3noa01 892090 Mayos dOX NOISSIYANOD O L1v0 2E E x ze 8 ERN 820790 14vHS PN O 1Z90 Lv3S NOLSId ZGh 170 9Nhids ES GvOLvO 3DVdS NOLSId b E 6 0 WIHS SOO X 60F X 978 A SSvIv0 NOISId
11. IUM RIDE KIT SX E SX SX R X VERT E 85 3752 99 FIRM RIDE KIT SX E SX SX R X VERT E 85 3753 99 ADJUSTER KIT SPYDER R SX X VERT E 85 3754 99 SX C BUSHING SEAL KIT 85 3758 99 LOC OUT ASSEMBLY KIT 70MM 85 3759 99 SX CROWN 1X5 5 CM 85 3787 99 SX CROWN 1X6 5 CM 85 3788 99 SX CROWN 1X7 5 CM 85 3789 99 SX CROWN 1X5 5 CM 85 3790 99 SX CROWN 1X8 5 CM 85 3791 99 SX CROWN 1X10 5 CM 85 3792 99 SX CROWN 1X12 5 CM 85 3793 99 SX CROWN 1 1 8 X5 5 CM 85 3794 99 SX CROWN 1 1 8 X6 5 CM 85 3795 99 SX CROWN 1 1 8 X7 5 CM 85 3796 99 SX CROWN 1 1 8 X8 5 CM 85 3797 99 SX CROWN 1 1 8 X10 5 CM 85 3798 99 SX CROWN 1 1 8 X12 THRDLS CM 85 3799 99 SX CROWN 1 1 8 X12 ALLOY 85 3800 99 SX BRAKE HANGER KIT 85 3801 99 SPYDER R amp SX E COMPRESSION DAMPING ASSEMBLY 85 3802 99 SX COMPRESSION DAMPING ASSEMBLY 85 3803 99 SX SX R amp SX TI LOWER SHAFT ASSEMBLY 85 3804 99 SX SX R amp SX TI COPMRESSION DAMPING ASSEMBLY 85 3805 99 SX E LOWER SHAFT ASSEMBLY 85 3806 99 SX C LOWER SHAFT ASSEMBLY 85 3807 MANITOU PREP M GREASE 6 OZ 85 3810 MICRO LUBE GREASE GUN HEAD 85 3812 MRD SUSPENSION FULID 5WT 80Z 85 3814 MAXIMA 7 5WT SUSPENSION FLUID 8 OZ 85 3820 MAXIMA 10WT SUSPENSION FLUID 8OZ 85 3822 99 SX BUSHING SEAL KIT 85 3827 98 99 SX TI SOFT RIDE KIT 85 3841 98 99 SX TI MEDIUM RIDE KIT 85 3842 98 99 SX TI FIRM RIDE KIT 85 3843 98 99 BUSHING REMOVAL TOOL 85 3892 98 99 BUSHING SIZING TOOL SPYDER amp SX 85 3893 99 SX OUTER ASSEMBLY BRIGHT YELLOW WITH
12. T 89070 INN LNOdONG ONB O s SB1 HONI O 0L INDHYOL 897090 N3YIS GON NOISS RIA NOD ATBN3SSY A W N ZL 01 300301 L SB1 HON 011 06 3nbU01 1Z60 0 1SOd 3 vuB z9vivO Z9v1v0 YINOLSV13 QNn08334 vGzZ90 AINO T3AV3L NNOZ 303 c90z90 GOY NOISS3MdAOO Y LLS1v0 JOLIINNOY ONIMAS v4v1vO 9NIHShB 43401 Lv1 0 INIHSNA u3dd zszz90 Was isnq Na vbZ1v0 1008 AYO4 IV130 Was ONIHSNE Page 7 ZSIrO0 3A331S 1N313 6L90v0 ONIN 9NINIVL33 1690v0 YIHSYM dno 39v1S ANZ 80c1c0 SON YALSMPOY sadAv z9vivO Y4INOLSV13 ONnOH3H 790v0 91 L X 91 21 INIJO H890v0 INN LNOJOMO ONIN O oszz90 dvo IN SSOIrO 1v3S L4vHS czaivo LAN 1nodO3d 890290 31033N yaMo7 OELLO TE 6 x ze s um 20Z90 LiyHS iin A 0 1z90 1y35 L se90vo ATANASSY ZG11 0 ONS Mya 1N3L3d H23v 931 33100 Sr01vO d30vds NOISId b 621 70 NiHS SOO x 60r x 928 F 0690 0 8 X v 9Nh 0 K amp EN P d v4Syv0 3A331S G SSr rO NOLSId LMOAONO M3aWva Gv1 v0 uxug WIHS QNnoS33 vb 170 ww WIHS INNO83y 251140 WIKS EN 8bv 10 LNN 3 TN Y A18W3SSY 13V HS W3MO1 vL0z90 an 1431 190790 896040 Ns WOLLOB zovyvO u3WorSvT3 ONnOH3M 810 INN JAVA ZSI1 0 SNS svO vO YIDVAS NOLSId nus S00 X 860v X 9 957170 NOLSId SILO XZ t
13. XR amp SX TI A smal screwdriver may be helpful Use a 8MM allen wrench to remove COMPRESSION ROD SCREW the dropout nut Fully compress the fork to prevent the AA compression rod and damper shaft from turning while removing screws pop our woe N PULL DOWN TO 2 Pull outer leg assembly down to remove from the inner legs and crown REMOVE NYT OSE FORK LEG UNIT 3 Remove fork boots FIGURE 12 COMPRESSION STACK Page 10 4 Bushing replacement will require the use of the bushing removal and installation tool available from Answer Products It is recom mended that the bushings be left installed unless they absolutely need replacement NN Note It is not recommended to remove the dust seal every time the fork is disassembled The seal and bushings may be cleaned and Y 6 INSPECT re greased In place A REMOVE 4 E Y Z NEE es BOTTOM Ww MUST BE BETWEEN C dE ion Rod R IE i5 Mr Par ALL MCU amp SERING mpr ion mov iqur S TIP FORK UPSID ompression Stack amp Compression Rod Removal Figure PLASTONER TIP FORK OPD e 1 Press the bottom clip off the compression rod COMPRESSION ROD 2 Slide off the rebound elastomer from right leg compression rod 3 Unscrew and remove the adjuster assembly by hand 4 Turn fork upside down to remove the compression rod If forks are installed on bicycle give the rod a quick upward thrust and catch it as it pops up above the crown FIGURE 12 COMPRESSION STACK Lower Shaft Disassembl
14. be it is recommended that you seek a dealer with a qualified bicycle mechanic to perform installation SLIP CROWN RACE OVER STEERER PRESS ONTO RACE SEAT WARNING The steer tube and stanchions inner legs are a one time precision press fit at the factory and cannot be removed from the crown Replacement of the entire crown steerer assembly must be done to change steer tube lengths or diameters Removing and replacing the steer tube or stanchions will result in an unsafe condition and should never be done FIGURE 1 RACE INSTALLATION Remove old forks from bicycle Measure and cut the steer tube to fit your bicycle head tube Remove crown race from old forks and press onto 99 SX Steer until seated on crown wo m 4 Clean and grease headset bearing and races of bicycle 5 Install lower bearings on fork crown race 6 Install steer tube into head tube frame REMOVABLE 7 Install upper bearing spacers and stem a 8 Install stem cap adjust and tighten headset per BRAKE ARCH manufacturer s instructions Install handlebars to desired height Torque stem handlebar pinch screw and stem clamping system to manufacturer s instructions 10 Install cantilever breaks and adjust to pre manufacturers instructions 11 Ajust fork whell quick release to clear the 0 275 7MM thick secondary catch dropout The quick release must be tightened after it is adequate thread engagement 4 or m
15. e STACK VALVE SEAT ay PRESSION Sa 041149 041150 amp 2X 041151 y i COMPRESSION VALVE 041456 sHiM 041128 ci SSION DAMPING CLAMP SHIM 13MM 041157 DH PISTON SPACER LY 062295 STACK SPRING 041152 VALVE NUT 041483 SPRING 041152 VALVE NUT 041483 FIGURE 14 TPC COMPRESSION DAMPING ASSEMLBY DAMPER INSPECTION 1 Check the shaft for scratches wear or other obvious damage 2 Check the seal gland and end cap seal grooves for damage 4 Check shims for permanent bends or damage 5 Check all other parts for obvious damage replace if necessary 6 Replace all seals that have been removed FORK INSPECTION 1 Check the fork boots for obvious damage 2 Check the dust seal for tears wear or damage Replace if needed 3 Inspect the lower and upper bushing for damage to the Teflon coating Replace using the bushing removal and replacement kits if necessary Check all MCU amp springs for obvious damage Replace if necessary Check the preload adjuster and connectors Replace if damaged Check the outer leg arch assembly for nicks or deep gouges on outside and inside Replace if damaged Check the inner leg for deep gouges and other damage Minor wear resulting in color change is not detrimental to the gold anodized surface Replace if wear is excessive or damaged 8 Check inner legs at the bottom of the crown for cracks or for flaking anodize Replace crown steer leg assembly if cracked or
16. fork or cause any type of damage We recommend that you store your Manitou right side up If this condition causes you some problems please contact your Answer Products dealer or call our warranty tech department for prompt service CYCLE COMPUTER INSTALLATION INSTRUCTIONS Follow the instructions in your owners manual with the following exceptions WARNING DO NOT DRILL A HOLE IN THE DROPOUT THIS MAY WEAKN THE DROPOUT WILL VOID THE WARRANTY AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INURY DO NOT USE THE TEMPLATE PROVIDED IN THE 95 OR 96 SERVICE MANUAL Page 15
17. g assembly into the left leg The oil level oN SLIDE ON should cover the compression valve when the assembly is installed FORK BOOTS B SLIDE on lt ELASTOMER 4 FIGURE 15 COMPRESSION ROD amp BOOT DROP COMPRESSION ROD INTO INNER FORK LEG Compression Rod amp Boots Figure 15 1 Clean all parts thoroughly 2 Grease compression rod lightly Be sure rebound Elastomer is installed onto compression rod 3 Drop compression rod down into inner legs Shake inner leg to get rod through inner leg plug 4 Slide on black second stage cup washer and orange 3rd stage Elastomer E INSTALL COMPRESSION STACK B HAND TIGHTEN ADJUSTER CAP 5 Slide Boots onto inner leg CONNECTORS co E BETWEEN ALL CU S amp SPRINGS S Outer Leg Assembly Figure 16 F SLIDE FORK BOOT DOWN TO SNAP INTO GROOVE OF OUTER LEG 1 Slide Outer leg Arch assembly onto inner legs and fully compress 2 Install and torque 5MM compression rod screw and dropout nut to 10 30 inch Ib 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft g INSTALE ensue e ON OUTER 3 Pop in damper adjuster knob O ring holds knob in place SX ROD SCREW IS FULLY COMPRESSED OR raids Tod 4 Slide skirt of fork boots onto the outer leg groove Be sure the lip NUT USE BMM ALLEN WRENCH snaps into the groove 5 Clean adjuster cap threads thoroughly Clean threads on inside FIGURE 16 OUTER LEG ASSEMBLY of inner leg 6 Assemb
18. he air out before checking the oil level For additional tuning tips we recommend that you obtain a copy of the MRD tuning Manual P N 85 3485 and check out the MRD Race Tuning kits available at your dealer Page 14 TROUBLE SHOOTING Fork seems to top out or has a slight clunking feel when front wheel comes off the ground Excessive preload or insufficient rebound damping will result in a top out Select MCU s that better fit your weight and riding style having the preload adjuster set mid to low range and increase the rebound damping to eliminate top out The fork feels less active and is not getting the travel it used to when it was new Chances are that the fork is developing stiction Cleaning and applying light oil to the stanchions will help Outer legs feel loose on inner legs and bushings a knock or rock can be felt when pushed from side to side A very small knock is normal with the new 99 harder bushings If the knock is excessive or you can feel the fork rocking then the bushings should be removed and replaced To do this you must have the Answer Products Bushing Removal and Replacement Tool Kit A small amount of oil seems to be leaking from top of the left leg at the adjuster cap If the 99 SX us store upside down for a period of time a small amount of oil may leak through the adjuster cap knob assembly The cap area is not subjected to damping pressure A small leak in that area will not affect the performance of the
19. he fork is going to be used on public roads at any time If you have questions regarding C P S C Standards contact your dealer 1 Never remove or have the steer tube or stanchions inner legs removed from the crown The steer tube and stanchions are press fit assembled at the factory Pressing them out will permanently damage the crown steer tube and stanchions beyond repair and render them unsafe for any continued use 2 Never attempt to threas a threadless steer tube Machining threads will weaken the steer tube and cause unsafe condition The only safe thing to do is obtain the proper crown steerer from your dealer 3 Any other alterations or modifications to your fork should be considered unsafe Contact Answer products Techinical Support prior to modifying your fork in any way for safety information 4 Do not use any Manitou Fork if any part appears to be be broken bent cracked or damaged Contact your dealer or Answer Products Technical Support 800 670 7446 if you have any questions concerning the integrity condition or safe operation of your fork 5 Answer Products recommends that you periodically inspect your fork for wear and damage Inspect the Crown Inner Legs and Outer Leg Dropout and Break Arch areas for cracks or damage Befor every ride check to ensure that the proper preload exists and that the positive rebound stop is in order to ensure that the fork can not over extend WARRANTY INFORMATION Any Answer Pr
20. if gold anodize is beginning to flake 9 Check the underside of the crown for cracks Replace if cracked NO RE ASSEMBLE Lower Shaft Figure 15 1 Install all o rings and seals removed 2 Grease all seals lightly with seal grease 3 Apply small amount of blue Locktite to piston seat threads 4 Assemble shim stack and spacers in exact order that they were removed For SX E thread on valve nut and torque 30 IN LB 3 5N m max For SX SX R SX TI and SX C hand tighten piston seat Be sure large blow off washer will slide over piston spacer and compress the small spring Clamp shaft in soft jaws or collet and line up slots in clamp ring with hole in piston seat using 1 8 or smaller pin Use a 5MM Allen wrench and tighten piston seat by turning Allen wrench and pin at same time Torque 30 IN LB 3 5 N m max Page12 5 SX SX R SX TI and SX C install lower needle gently into shaft thread until it stops then back off one turn for initial adjustment 6 Slide shaft assembly through the plastic end cap place detent ball in place and slide on 2nd STG Elastomer 7 Insert into left leg and thread in end cap Torque 30 IN LB 8 5N m max 8 Add approximately 100 CC of 5 WT Maxima or equivalent oil Do not over fill Check oil level see Figure 8 AL Compression Damping Assembly Figure 16 SS 1 Reassemble compression damping stack following the instructions above for the lower shaft assembly 5 2 Install compression dampin
21. is SHAFT SEAL 041055 yy LOWER NEEDLE 062068 END CAP 062250 O RING 15 16 x 1 1 16 040673 REBOUND ELASTOMER 041462 O RING 3 4 x 7 8 040681 2ND ST GE CUP WASHER 040691 RETAINING RING 040679 DETENT SLEEVE 041827 LOWER SHAFT 062076 RING 5 22 x 9 32 041130 DETENT SLEEVE 041527 FIGURE 13 LOWER TPC SHAFT ASSEMBLY Page 11 Compression Damping Disassembly Figure 14 1 The compression damping assembly is almost identical to the lower shaft assembly 2 Unscrew the compression damping adjuster all the way until it stops The knob and the needle do not need to be removed The shaft also does not need to be removed from the cap The threads are bonded to prevent leaking 3 Remove either the valve nut or the piston seat following the instructions above for the lower shaft assembly TPC SPORT COMPRESSION DAMPING COMPRESSION DAMPING ASSEMBLY COMPRESSION DAMPING ASSEMBLY SX 062041 N ASSEMBLY Sx E 062295 SX TI SX C amp SX R 062070 O RING 040824 O sur TAPPI So SEE M ary Gash SELF TAPPING SCREW 041330 rac REY 041330 KNOB 041279 I O RING 040824 S ie j CAP 041453 KNOB 041279 NG CAP 041547 UPPER SHAFT 062146 Ad ATE ADJUSTER NEEDLE 062072 2 No e e O RING 040524 xN COMPRESSION VALVE DETENT BALL 040689 ens j x 3 8 UPPER SH FT 062146 Mem ps x 9 32 1 16 DETENT SLEEVE 041527 N VALVE SEAT 041482 SET SCREW 041423 LAMP SHIM gsn con
22. le MCU s springs and connectors with thick grease 7 Install adjuster assembly into inner leg just hand tight INNER FORK LEGS amp CROWN The inner fork legs and steer tube are press fit into the crown and may never be removed Removing them will make the fork unsafe to use If you see any slippage contact Answer Technical Staff immediately 800 670 7446 BRAKE ARCH NOTE The 99 SX brake arch is permanently bonded to the outer legs and is not removable If the unit is damaged or if the bond is broken or separated it must be replaced Using the fork with a damaged brake arch bond is unsafe and could cause serious injury Contact Answer Products if you suspect that your brake arch bond is damaged Page13 ADJUSTING RIDE QUALITIES 98 SX TPC forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the MicroCellular Urethane MCU s Fine tune adjustments can be made using the preload adjusters located on top of the fork crown Softer blue and harder yellow MCU s are available from your Dealer NOTE Since 98 model forks use a compression stack in the right leg only MCU s and Springs used in previous Manitou forks are NOT interchangeable with later versions of SX model Forks Compression Spring Fine Tuning Figure 17 Fine tuning adjustments to the spring rate are made by rotating The adjuster knobs located on top of the crown Note the 99 SX E SX SX R SX TI and SX C uses compression
23. oducts fork found by the factory to be defective in materials and or workmanship within one year from the date of purchase will be repaired or replaced at the option of the manufacturer free of charge when received at the factory freight prepaid This warranty does not cover breakage bending or damage that may result from crashes or falls This warranty does not cover any fork that has been modified subject to misuse or whose serial number has been altered defaced or removed This warranty does not cover paint damage Any modifications made by the user will render the warranty null and void This warranty is expressly in lieu of all other warranties and any implied are limited in duration to the same duration as the expressed warranty herein Answer Products shall not be liable for any incidental or consequential damages If for any reason warranty work is necessary return the fork to the place of purchase In the USA dealers should call Answer Products for a return authorization number RA At that time instructions for repair return or replacement shall be given Customers in countries other than USA should contact their dealer or local distributor Page 1 INSTALLATION INSTRUCTIONS Figures 1 2 amp 3 Insure that the proper steer tube has been delivered on your fork The steer tube may need to be cut to length to fit your bicycle head tube If you are not familiar with this procedure or do not have the proper tools to cut the steer tu
24. ore threads with the release adjusted to bicycle per FIGURE 2 BRAKE CABLE ROUTING manufacturers specifications 12 Install brake cable per manufacturers instructions Note All 98 SX Forks are equipped with a secondary catch dropout Note The 98 SX comes equipped with a hangerless arch Brake cable hangers that attach to the arch are available through your dealer See Figure 2 73 0mm 83 0mm WARNING When installing wheel or any new tire check the minimum tire clearance Measure from the highest point on the tire to the bottom of the crown The minimum clearance allowed for 70MM travel fork models is 2 875 73 0MM and 3 268 83 0MM for 80MM travel fork modles Any less clearance can result in accident resulting in serious injury or death Figure 3 Page 2 age FIGURE 3 TIRE CLEARANCE SPARE PARTS Table 1 Spare parts can be ordered through your local dealer If you have any problems that you cannot resolve with your dealer you may call Answer Products Technical Warranty Service Department at 805 257 4411 8 00 AM to 5 00 PM Pacific Standard Monday through Friday In addition helpful information can be found on the Answer Products Web Site http Avww answerproducts com Include on the site is down loadable manuals and e mail to technical support DESCRIPTION PART NUMBER 99 SX TI MRD KIT 85 3566 99 LOC OUT ASSEMBLY KIT 80MM 85 3734 99 SOFT RIDE KIT SX E SX SX R X VERT E 85 3751 99 MED
25. spring systems in both right and left legs Both right and left knobs on top of the crown adjust preload The right knob for those models is used to adjust preload Rotating the knobs clockwise will firm the ride adding preload to the compression stack Rotating the knobs counter clockwise will soften the ride Four full revolutions will take the adjuster from full soft to the extreme firm setting Compression Damping Fine Tuning Figure 18 To adjust the SX R SX TI and SX C simply rotate the compression damping knob FIGURE 17 PRELOAD located on top of the left leg and crown Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Ex cessive damping will give you a harsh ride over sharp bumps like rocky sections but will feel good in large hits like G outs Insufficient compression damping will bottom out in the large hit G outs and bob a little while climbing but feel plush on the sharp hits A correctly adjusted fork will perform good in all conditions To adjust the compression dampling for the SX remove the compression damping assembly from the top of the left leg Adjust the set screw on the valve seat in to increase compression damping and out to reduce the compression damping Try adjusting one half full turn at a time The SX E uses TPC Sport for compression damping and is not adjustable Rebound Damping Fine Tuning Figure 19 To adjust the SX SX R SX TI and SX C simply
26. y Figure 13 Note Lower Shaft disassembly is best done with the fork removed from the bicycle Disassembly of the damping stack is not required unless you want to change or replace the shim stack 1 Remove the left cap compression damping assembly from the top of the fork leg and pour the oil out of the top of the fork and discard appropriately For complete disassembly continue Remove the plastic end cap and pull the lower shaft out of the inner leg Remove the clear plastic detent sleeve and capture the 1 8 dia Detent ball used on SX SX R SX TI and SX C SX SX R SX TI and SX C adjuster needle may be unscrewded from the shaft For SX SX R SX TI and SX C use 5MM allen wrench to remove piston seat Keep note of the exact order of the shims and spacers aR WP LOWER SHAFT ASSEMBLY LOWER SHAFT ASSEMBLY Sx E 062301 SX SX Ti de SX R 062067 LOWER SHAFT ASSEMBLY SX C 062037 A grr REBOUND PISTON 062297 YS p di SHIM 377 x 900 062300 9 ca Een 4 SHAF S calle Sd oris s 9 a REBOUND SHI 041144 PISTON 04 485 REBOUND ant 1 M cont A a 2 826 x 409 x 005 SHIM 041159 pais QUA ACER 041 SHAFT SEAL 041055 PESTON SPACER 041048 p 826 x A09 x 003 SHIM 041139 END CAP 062249 O RING 3 4 x 7 8 040681 REBOUND ELASTOMER 041462 2ND STAGE CUP WASHER 040691 RETAINING RING 040670 O RING 1 4 x 3 8 040690 O RING 5 22 9 32 041130 LOWER NEEDLE 062068
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