Manitou 2003 Black Service Manual
Contents
1. 27 BLACK SPORT COMP SUPER OWNERS MANUAL 042099 28209 Avenue Stanford Valencia California 91355 3984 661 257 4411 fax 661 294 4179 E 23 24 gt 26 BLACK SPORT 80 100 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Convertible Travel Knob Kit BLACK SPORT 100 120 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Steel Alloy Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Convertible Travel Knob Kit BLACK COMP 80 100 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Travel Adjust Knob Kit BLACK COMP 100 120 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Steel Alloy Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Travel Adjust Knob Kit 85 5135 85 5136 85 5137 85 5082 85 5165 85 4970 85 4971 85 4972 85 4973 85 4974 85 5052 85 5051 85 5138 85 5139 85 5140 85 5083 85 5085 85 5165 85 4975 85 4976 85 4977 85 4978 85 4979 85 5053 85 5051 85 4835 85 4836 85 4837 85 5082 85 5165 85 4970 85 4971 85 4972 85 4973 85 4974 85 5056 85 5051 85 4835 85 4850 85 4837 85 5083 85 5085 85 5165 85 4975 85 4972. 1 Start by unthreading the air cap on top of the left fork leg and remov ing the fork s air pressure via the Schraeder valve Figure 6 2 Next remove the 2 mm screws and knob and the 11 mm open end wrench and 8 mm hex wrench clockwise direction to loosen bolts from the bottom of the casting Once you do this you will be able to pull the lowers away from the uppers Figure 7 3 On the left leg as seen from the rider s perspective remove the 15 16 inch cap from the bottom of the leg Remove the entire assem bly by pulling the rod lightly As this point you will see the coil spring Figure 8 and 8 4 Select the appropriate coil spring for your weight and riding style refer to the above spring chart for recommended rates 5 Reinstall the assembly into the left leg of the fork taking care not to cross thread the cap It should thread in by hand and should only be snug tightened 6 Reinstall the lowers with the 8 mm and 11 mm bolts and tighten You may have trouble getting the 8 mm bolt to catch the threads If this occurs remove the lowers pull the rebound damping rod down again and reinstall the casting You should be able to now install the 8 mm bolt CHANGING AIR SPRING PRESSURE BLACK ELITE AIR BLACK SUPER AIR All you need to change the air pressure is a high pressure Manitou Part 385 4069 or other shock pump Remove the air cap located on the top of the left leg and then inflate the fork with the desired pre
3. Black Silver Red White Yellow Orange Blue Candy Red Candy Blue Candy Chrome Black N B Silver N B Red N B White N B Yellow N B Orange N B Blue N B Candy Red N B Candy Blue N B Candy Chrome N B Lockout for all BLACK forks except the BLACK ELITE AIR TPC for all Non AIR BLACK Forks TPC for BLACK Super Air 100 120 85 4855 85 4870 N A 85 5088 85 5165 85 4988 85 4989 85 4990 85 5063 85 5059 85 5141 85 5142 85 5143 85 5144 85 5145 85 5146 85 5147 85 5148 85 5149 85 5150 85 5151 85 5152 85 5153 85 5154 85 5155 85 5156 85 5157 85 5158 85 5159 85 5160 85 4869 85 4929 85 5065 AMERICAN MADE MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLO GY AVAILABLE A 2003 MANITOU BLACK BUILT IN THE USA This BLACK fork is fully assembled and ready to be installed onto your bicycle lt comes equipped with a 1 1 8 inch threadless steerer tube and R casting lt is also available in a disc brake only version A handlebar mounted reflector must be used for on road use which 15 not included with your fork 2003 MANITOU BLACK FORK LINE BLACK SPORT 80 100 80 100 MM CONVERTIBLE TRAVEL COIL SPRING FLUID FLOW DAMPING SIN GLE CROWN RA CASTING BLACK SPORT 100 120 100 120 MM CONVERTIBLE TRAVEL COIL SPRING FLUID FLOW DAMPING SIN GLE CROWN RA CASTING BLACK COMP 80 100 80 100 MM RAPID TRAVEL ADJUST COIL SPRING FLUID
4. HELP YOU REDUCE THE RISK OF BEING INJURED IF YOU ARE A MODERATE OR AGGRESSIVE OFF ROAD RIDER OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN ANSWER RECOMMENDS RETURNING YOUR SUSPENSION FORK EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO ANSWER PRODUCTS OR YOU MAY CALL ANSWER AT 661 257 4411 TO HAVE YOUR FORK SHIPPED DIRECTLY IMPORTANT The Manitou BLACK fork is an off road fork and as such does not come with proper reflectors for on road use Have your dealer or mechanic install proper reflectors to meet the Consumer Product Safety Commission s C P S C Requirements for Bicycles if the 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 CONSUMER SAFETY INFORMATION Never remove or have the steerer tube or stanchions removed from the crown The steerer tube and stanchions inner legs are press fit at the factory Press fit inner legs have higher performance versus bolt in inner legs but can not be pressed out Pressing them out will permanently damage the crown beyond repair and render it unsafe for any continued use Never attempt to thread a threadless steerer tube Cutting threads will weaken the steerer tube and cause an unsafe condition The only safe thing to do is to obtain the proper crown steerer from your dealer or contact Answer Customer Service at 661 257 44
5. Around 4 inches or 101 mm 100 mm Around 4 8 inches or 121 mm 120 mm Around 5 6 inches or 141 mm SPRING KITS BLACK SPORT 80 100 COMP 80 100 ELITE 80 100 Rider Weight Recommended Spring Kit 130 lbs amp below XS ride kit Part 385 4970 130 150 lbs Soft ride kit Part 85 4971 150 170 Ibs Medium ride kit Part 85 4972 170 190 Ibs Firm ride kit Part 85 4973 190 to 215 lbs Extra firm ride kit Part 85 4974 BLACK SPORT 100 120 COMP 100 120 ELITE 100 120 Rider Weight Recommended Spring Kit 130 150 lbs Soft ride kit Part 7285 4976 150 170 lbs Medium ride kit Part 85 4977 170 190 Ibs Firm ride kit Part 85 4978 190 to 215 Ibs Extra firm ride kit Part 85 4979 BLACK ELITE AIR Rider Weight Recommended Spring Kit 100 150 Ibs Soft DIVA coil spring Part 85 4980 150 190 lbs Stock ride kit Part 85 4981 190 to 215 Ibs Firm coil spring Part 85 4982 Air pressure setting should equal 75 of body weight BLACK SUPER AIR 80 100 Rider Weight Recommended Spring Kit 100 150 Ibs Soft coil spring Part 85 4985 150 190 lbs Medium ride kit Part 85 4986 190 to 215 lbs Firm coil spring Part 285 4087 BLACK SUPER AIR 100 120 Rider Weight Recommended Spring Kit 100 150 lbs Soft coil spring Part 85 4988 150 190 lbs Medium ride kit Part 285 4989 190 to 215 lbs Firm coil spring Part 2585 4090 Air pressure setting should equal 75 of body weight 80 to 100 mm travel forks Air pressure setting shou
6. any incidental or con sequential damages If for any reason warranty work is necessary return the fork with original pur chase receipt to the place of purchase 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 INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your BLACK fork first The steerer 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 steerer tube it is recommended that you seek a dealer with a qualified bicycle mechanic to perform installation THE STEERER TUBE AND STANCHIONS INNER LEGS ARE A ONE TIME PRECISION PRESS FIT AT THE FACTO RY AND CANNOT BE REMOVED FROM THE CROWN REPLACEMENT OF THE ENTIRE CROWN STEERER ASSEMBLY MUST BE DONE TO CHANGE STEERER TUBE LENGTHS OR DIAMETERS REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE BREAK IN Your new fork is designed to break in during your first few rides about 20 hours total riding time Prior to break in you may notice your fork feels tight and slightly notchy Following the break in period your fork will feel much smoother and will react to bumps much better than when you first put it on your bike After 20 hours you may want to recheck your compr
7. catch receptacle remove the 8 mm Allen and 11 mm socket bolts from the bottom Figure 11 Note With Rapid Travel Adjust forks you must remove the RTA knob with a mm Allen wrench to access the 11 mm socket bolt Clean the inside of the lowers thoroughly and wipe the inner legs until they are completely free of oil or debris Figure 12 Insert the crown steerer assembly back into the fork Reinstall the bolts snugging each tight and install the rebound adjuster knob Now insert grease into the fork via the Microlube grease ports Inject about 15 squirts into each side of the fork Make sure you use Microlube grease only Microlube lubricant gun part 785 5818 and Manitou s Prep part 85 3810 CHANGING THE OIL IN YOUR FORK Changing the oil in your damped fork is very easy to do of the damping systems FFD TPC and TPC Plus house the oil in the right leg 1 79 Remove the cap from the top of the right fork leg 20 mm socket Figure 13 Rock the compression damping assembly back and forth slightly as you pull up on it to remove Pour the old oil out of the fork Figure 14 Stroke the fork up and down to remove the oil that settles beneath the rebound piston Pour this oil out as well Figure 15 Add oil to the level shown in the Checking Oil Level section of this manual Cover the leg opening and stroke the fork up and down a few times before the final measurement is taken to e
8. the event the quick release comes loose A WHEN INSTALLING THE WHEEL OR A NEW TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOT TOM OF THE BRAKE ARCH THIS MEASUREMENT SHOULD BE AT LEAST 9 MM FOR ALL BLACK FORKS FIGURE 1 IMPORTANT The BLACK fork should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replace ment parts MAINTENANCE Your BLACK fork requires periodic maintenance cleaning and inspection This is because moisture and contamination may build up inside the fork depending on the severity of riding conditions To maintain top performance it is recom mended that the fork be periodically disassembled cleaned dried and relubri cated You can download service and tuning instructions on the web at www answerproducts com IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs and clean and check entire fork for any obvious dam age 3 Check the headset for proper adjustment 4 Ensure that the front brake cable is properly routed and check brake adjustment CHECKING OIL LEVEL IMPORTANT Setting the proper oil level in your TPC or FFD equipped fork is critical TPC or 15 located in the right leg of your BLACK fork Not enough oil will allow foaming and reduce the performance Too much oil will restri
9. 03 Manitou BLACK suspension fork contact the Answer Customer Service Department at 661 257 4411 You can also log on to www answerproducts com and download this manual or see detailed instructions on how to service your suspension fork Thank you again for choosing a 2003 Manitou BLACK suspension fork DEALER SERVICE ADDENDUM This section is designed to help a qualified bicycle mechanic tune and maintain your Manitou suspension fork MEASURING SAG You ll need a tape measure a pencil a piece of paper and a helper 1 Measure the distance from the front axle s centerline to the bottom of the upper crown when no one s sitting on the bike and write this dis tance down Remember the exact locations of the two points because you ll need to use them later amp Have the rider sit on the bike and measure the distance between the same two points as in step one It s important to be in the normal rid ing position weight centered with your feet on the pedals 3 Subtract the second measurement from the first The resulting meas urement is the static sag SAG MEASUREMENT CHART Fork Travel Sag 80 mm 12 16 mm 100 mm 18 24 mm 120 mm 25 28 mm TRAVEL MEASUREMENT To determine which travel your BLACK fork is in simply measure the distance from the top of the seal area on the lowers or the bottom of the fork boot to the bottom of the crown Figure 3 TRAVEL MEASUREMENT CHART Fork Travel Seal to Crown Measurement 80 mm
10. 11 Any other alteration or modification to your fork should be consid ered unsafe Contact Answer Customer Service prior to modifying your fork in any way for safety information Do not use the BLACK fork if any parts are broken bent cracked or you sus pect may be damaged Contact your dealer or Answer Products Customer Service at 661 257 4411 if you have any questions concerning the integrity or condition of your fork Answer Products recommends that you periodically inspect your fork for wear and damage Inspect the crown inner legs outer legs dropout and brake arch areas for cracks or damage WARRANTY INFORMATION Any Answer Products fork found by the factory to be defective in materials and or workmanship within one year from the date of purchase or two years in EU countries 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 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 war ranty 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
11. 6 85 4977 85 4978 85 4979 85 5057 85 5051 SERVICE PARTS KITS BLACK ELITE 80 100 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Travel Adjust Knob Kit BLACK ELITE 100 120 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Travel Adjust Knob Kit BLACK ELITE AIR Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Travel Adjust Knob Kit BLACK SUPER AIR 80 100 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm Travel Adjust Knob Kit 85 4855 85 4850 N A 85 5084 85 5165 85 4970 85 4971 85 4972 85 4973 85 4974 85 5058 85 5055 85 4855 85 4850 85 4837 85 5085 85 5165 85 4975 85 4976 85 4977 85 4978 85 4979 85 5061 85 5055 85 4855 85 4864 N A 85 5086 85 5165 85 5176 85 4980 85 4981 85 4982 85 5177 N A 85 5059 85 4855 85 4870 N A 85 5087 85 5165 85 4985 85 4986 85 4987 85 5062 85 5059 BLACK SUPER AIR 100 120 Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm Travel Adjust Knob Kit Outer Casting Assemblies
12. FLOW DAMPING SIN GLE CROWN RA CASTING BLACK COMP 100 120 100 120 MM RAPID TRAVEL ADJUST COIL SPRING FLUID FLOW DAMPING SIN GLE CROWN RA CASTING BLACK ELITE 80 100 80 100 MM RAPID TRAVEL II COIL SPRING ie DAMPING HOLLOW CROWN RA CAST IN BLACK ELITE 100 120 100 120 MM RAPID TRAVEL II COIL SPRING TPC DAMPING HOLLOW CROWN RA CAST ING BLACK ELITEAIR 80 MM TRAVEL AIR COIL SPRING TPC DAMP ING HOLLOW CROWN RA CASTING BLACK SUPER AIR 80 100 80 100 MM RAPID TRAVEL ADJUST AIR COIL SPRING TPC DAMPING HOLLOW CROWN RA CASTING BLACK SUPER AIR 100 120 100 120 MM RAPID TRAVEL ADJUST AIR COIL SPRING TPC DAMPING HOLLOW CROWN RA CASTING You can also download this manual at www answerproducts com A POSTEN BICYCLING IS A HAZARDOUS ACTIVITY THAT REQUIRES THAT THE RIDER STAY IN CONTROL OF HIS OR HER BICYCLE AT ALL TIMES READING THIS MANUAL ENTIRELY AND PROPERLY MAINTAINING YOUR BICYCLE AND SUSPENSION FORK WILL REDUCE THE POSSIBILITY OF INJURY OR POSSIBLE DEATH PRIOR TO RIDING YOUR BICYCLE YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF RIDING DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING CRACKING CREAKING LEAKING OR IF IT IS MISSING ANY OF THE ORIGINALLY SUPPLIED COMPONENTS ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH FOLLOWING THESE INSTRUCTIONS CAN
13. ck this remove the air cap on the left side of the fork as seen from the rider s perspective by simply unthreading it counterclockwise Release the air pressure from the fork and then use a 20 mm hex wrench to remove the aluminum Schraeder cap Figure 9 Once you have done this you can see the top of the air piston and determine if there is a small amount of oil sitting on top of the air piston If this oil is no longer visible pour 3cc of 20W 50 weight motor oil directly into the open fork leg After this reinstall the Schraeder cap and the valve cover MAINTENANCE AND SERVICE INTRODUCTION When servicing the fork take the time to inspect all parts for excessive wear or damage There are basically five aspects of a fork that will require attention the stanchions inner legs the bushings in the outer legs the spring stack lubricating oil and the damping fluid Inspecting any of these parts requires disassembly of the fork Pay close attention to the bushings which can be damaged by contamination in severe con ditions Replace any worn or damaged parts that are discovered MICROLUBE LUBRICATION MAINTENANCE Your 2003 Manitou BLACK fork is designed with the Microlube lubrica tion system This system requires periodic maintenance to ensure that your fork is working properly at all times 1 Remove the rebound damping knob with a 2 mm Allen wrench clock wise to loosen Figure 10 With the fork positioned over an oil
14. ct travel and may cause damage to the system and create an unsafe riding condition Finish reading this entire section prior to altering the oil evel To check the oil level remove the compression assembly located in the top of the right leg as you are looking at the fork from the riders position Leave the left side spring stack in place to keep the fork fully extended Use a tape meas ure or dip stick to measure from the top of the fork crown down to where the oil sits Figure 2 The oil level should be per the following table FORK MODEL OIL LEVEL BLACK SPORT 80 100 115 125 mm 4 5 4 9 in 100 mm travel BLACK SPORT 100 120 115 125 mm 4 5 4 9 in 120 mm travel BLACK SPORT W TPC 100 120 86 91 mm 3 4 3 6 in 120 mm travel BLACK COMP 80 100 115 125 mm 4 5 4 9 in 100 mm travel BLACK COMP 100 120 115 125 mm 4 5 4 9 120 mm travel BLACK COMP W TPC 100 120 86 91 mm 3 4 3 6 in 120 mm travel BLACK ELITE 80 100 115 125 mm 4 5 4 9 in 100 mm travel BLACK ELITE 100 120 BLACK ELITE W TPC 100 120 115 125 mm 4 5 4 9 in 120 mm travel 86 91 mm 3 4 3 6 in 120 mm travel BLACK ELITE AIR 115 125 mm 4 5 4 9 BLACK SUPER AIR 80 100 105 110 mm 4 1 4 3 in 100 mm travel BLACK SUPER AIR 100 120 105 110 mm 4 1 4 3 in 120 mm travel BLACK SUPER AIR W TPC 100 120 86 91 mm 3 4 3 6 in 120 mm travel NOTE Use SAE 5WT suspension fork oil only If you have any questions regarding your 20
15. e the travel with Rapid Travel II simply turn the knob located at the top of the fork s right leg to the 80 100 or 100 180 position as noted by the sticker on the fork Compressing the fork slightly is required to release or lock the fork in different travel positions RAPID TRAVEL ADJUST COMP AND SUPER AIR MODELS To change the travel with Rapid Travel Adjust just turn the knob locat ed at the bottom of the right leg to the 80 100 or 100 120 position as shown on the sticker Compressing the fork slightly is required to release or lock the fork into a different travel position CONVERTIBLE TRAVEL SPORT MODELS NOTE When changing travel you should also conduct a service on your lubrication system Please read this section thoroughly before begin ning this service section Changing the travel from 80 to 100 or 100 to 120 mm or vice versa requires the removal of the lower legs Unthread the 8 mm Allen bolt clockwise to loosen and 11 mm bolts on the bottom of the fork and pull the lowers free from the uppers Then unscrew the cap on the bottom of the right leg as seen from the rider s perspective Remove the clip and insert it into the upper position above the rod flange for 120 mm of travel or the lower position for 100 mm of travel AIR PISTON LUBRICATION For proper function of your fork it s essential to have a small amount of lubricating oil on top of the air pis ton in your BLACK ELITE AIR or BLACK SUPER AIR fork To che
16. ession rebound and preload adjustments when applicable to fine tune the fork completely FORK INSTALLATION 1 Remove the old fork from your bicycle 2 Measure and cut the steerer tube to fit your bicycle head tube You can use your old fork as a guide for cutting the steerer tube length 3 Remove the headset crown race from the old fork and press onto the BLACK fork steerer until the race is seated over the crown 4 Clean and grease the headset bearings and races Install the lower bearings if applicable on fork crown race 6 Insert the steerer tube into the head tube of the frame al 7 Install the upper bearings stem spacers and stem 8 Install the stem cap and bolt Tighten the bolt to headset manufacturer s specifications 9 Install the handlebars and the torque stem pinch screws or stem clamping system to manufacturer s specifications 10 Install the brakes and adjust per the manufacturer s instructions 11 For all BLACKS adjust the front wheel quick release to clear the 0 374 9 5 mm thick secondary catch dropout The quick release must be tightened after it is properly seated into the dropout counter bores to manufacturer s specifications Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock 12 Install the brake cable per manufacturer s instructions NOTE 2003 BLACK forks are equipped with a secondary catch dropout to retain the wheel in the fork in
17. ld equal 50 of body weight in 100 to 120 mm travel forks NOTE In forks with the Rapid Travel Adjust feature the preload should be adjusted when the fork is in the longer travel position for example 120 mm for the 100 120 mm fork CHANGING SPRINGS BLACK SPORT 80 100 BLACK SPORT 100 120 BLACK COMP 80 100 BLACK COMP 100 120 BLACK 80 100 BLACK ELITE 100 120 1 Start by removing the preload adjuster knob by unscrewing the 2 mm hex bolt from the top of the crown leg assembly Then remove the adjuster assembly A 20 mm socket may be necessary Remember The springs are housed only in the left leg on 2003 Manitou suspen sion forks as you are looking at the fork from the rider s perspec tive Figure 4 2 With the adjuster assembly removed the spring stack is now accessi ble Figure 5 3 Select the appropriate coil spring for your weight and riding style refer to the above spring chart for recommended rates 4 Reinstall the preload adjuster assembly then the knob taking care not to cross thread the cap on firm and x firm kits replace preload adjuster with aluminum preload cap It should thread in by hand and be snug tightened with a wrench CHANGING SPRINGS ON AIR FORKS BLACK ELITE AIR BLACK SUPER AIR NOTE When changing coil springs in air forks you should also conduct a service on your lubrication system Please read this section thorough ly before beginning the service section
18. nsure that oil has flowed beneath the rebound piston again Figure 16 uns SCHEDULE Suggested Service for Manitou orks NORMAL CONDITIONS Short Infrequent Rides Lube fork as needed with Prep lubricant via Microlube ports Disassemble clean and lubricate fork every 4 5 months e Lubricate spring stack as needed e Service FFD TPC or TPC Plus by changing damping fluid every year NORMAL CONDITIONS Long Frequent Rides Lube fork as needed with Prep lubricant via Microlube ports Disassemble clean and lubricate fork every 10 14 weeks e Lubricate spring stack as needed e Service FFD TPC or TPC Plus by changing damping fluid every 6 months SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Short Infrequent Rides Lube fork as needed with Prep lubricant via Microlube ports Disassemble clean and lubricate fork every 6 8 weeks e Lubricate spring stack as needed e Service FFD TPC or TPC Plus by changing damping fluid every year SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Long Frequent Rides Lube fork as needed with Prep lubricant via Microlube ports Disassemble clean and lubricate fork every 4 6 weeks e Lubricate spring stack as needed e Service FFD TPC or TPC Plus by changing damping fluid every 6 months
19. ssure Be aware that sometimes air systems lose a small amount of pressure when the pump is removed so you may want to check exactly how much your pump loses by reinstalling it after you have set and checked the pressure COMPRESSION DAMPING ADJUSTMENT QUICK RANGE TPC For Quick Range TPC forks a simple turn of the knob located on top of the right leg is all that is needed Turning the knob clockwise as you are looking from a rider s position increases compression damping while turning the knob counterclockwise decreas es compression damping BLACK ELITE 80 100 BLACK ELITE 100 120 and BLACK ELITE AIR only ADJUSTING COMPRESSION DAMPING WITH A LOCK OUT The Lock Out on the BLACK SUPER AIR is simply an on off switch for your fork To adjust compression damping do the following Remove the compression assembly located in the right leg On the lower piston of the lockout assembly is a small set screw Turn this in or out to increase or decrease compression damping respectively Note a half turn makes a lot of difference so make small and incremental changes to the set screw REBOUND DAMPING ADJUSTMENT QUICK RANGE TPC AND FLUID FLOW DAMPING FFD Rebound adjusters on Manitou forks are located on the bottom of the right fork leg Turning the knob clockwise as you are looking at the fork from the bottom increases rebound damping while turning it counterclockwise decreases rebound damping RAPID TRAVEL II ELITE MODELS To chang
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