Manitou 1998 X-Vert Fork Line Manual
Contents
1. CCMBRESSION RD SDREN 060268 TORQUE 10 20 INCH 85 12 3 N rmp DUER LEG ARLH ASSEMBLY bi OROPDUT NUT 0041 545 M RING OROPOUT NUT 449889 OAMPER AQUUSTER KNDH 4641 CONNECTOR D4l 237 RED MEU 44 425 041 445 CONNECTOR 041247 4 FORK SCHEMATIC ADJS TER ASSEMBLY 041888 RED MCU 041425 SELF TAPPING SCREW D4I 22D FACE PLATE 041447 KNdB 8241278 CAP 0415477 UPPER SHAFT 044 800 LN ge i SS 26 524 CROWN STEERER 1 E VALVE SEAT 27 A X SET amp amp REW 041422 CLAMP SHIM 041157 REBDUNG STACK PA 147 041148 U4T 4e 041150 d 041161 COMPRESSION VALVE D4 4565 BLOWOFF 5PADER D41165 HIM 0411 96 VALVE NUT 041483 More E X pd gt P4 md o NN d S Neuen SEAT P 2 041 457 7 REBOUND SHIM STADE lt P 041145 041146 N 2 PISTON 041457 X P N l BLONGEF SHIM 04139 PISTON SPACER D4 045 SPRING 041152 CLAMP SHIM 941170 CLAMP RING 241 1247 ic p gy UETENT BALL 440506 7 LOWER SHAFT 941464 RNG 8 32 X 4 327 1303 y LOWER NEEDLE D4 455 N su AFT SEAL 0 41 BRA ENO 041705 O RING 15 1 amp xi 1 15 040673 SHAFT SEAL MPER 0409944 SN STG ELASTOMER RANGE D4D8B82 T T UC gt FIGURE 3 BUSHING amp S FORK BOOT 04144 OUST SEAL2. MAINTENANCE IMPORTANT The 98 XVERT should not be used if any parts appear 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 XVERT 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 98 XVERT Fork requires periodic maintenance cleaning and inspection Moisture and contamination may build up inside the for depending the severity of riding conditions To maintain top performance it is recommended that the fork be periodically disassembl cleaned dried and re greased Note The best way to prevent sticktion is to lift the fork boots up and apply a light spray of lube to the stanchion area in and above i seals Be sure to use a lubricating oil not a penetrating fluid like WD 40 Stroke the fork several times adding more lube Wipe off excess lube from just the seal area while keeping the stanchions moist with lubricant Reposition the boots When cleaning the fork do not direct water spray at the seals Figure 7 IMPORTANT Before every ride you should Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs clean lubricate and check entire fork for any obvious damage 3 Check headset slack 4 Insure that the front brake cable is properly seated in the cable retainer amp check b
3. BRAKE ARCH 59 Note All 98 Manitou Forks Forks are equipped with a secondary catch dropout 11 Adjust front wheel quick release to clear the 0 275 7MM thick secondary catch dropout The quick release must be tightened after it is properly seated into the dropout counter bores Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock due to the wider adjustment Install front wheel to bicycle per manufacturers specification 12 Install brake cable per manufacturers instructions FIGURE 2 BRAKE CABLE ROUTING Note The XVERT comes equipped with a hangerless arch Brake cable hangers that attach to the arch are available through your dealer P N 85 3644 See Figure 2 Page 2 WARNING When installing wheel or any new tire check the minimum tir clearance Measure from the highest point on the tire to the bottom of the crown The minimum clearance allowed is as follows XVERT SC 3 2 81MM XVERTR 4 0 102MM XVERT TI 5 0 129MM Any less clearance can result in accident resulting in serious injury or death Figure 3 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 Warrant
4. 041445 UPPER BUSHING 2041504 REQ MCU 041425 CONNECTOR 041247 7 LOWER BUSHING 041504 RED MEU 04 425 SPRING GONN ELT R 0413771 140168 STEEL SPRING 61 27 LONG 941522 1405 STEEL SPRING FUMPRESSIUN ROD 1 2 LONG 941524 041 505 URITHANE REBIGUNDI 041 55D dw 2 CDMPRESSUN ROO BRAKE POST 040821 TORQUE 90 119 NCH LENS TORQUE 10 12 N m COMPRESSION ROD SCREW OBUZEB TORQUE 10 39 INCH LES TORQUE 1 2 3 5 ING DROPOUT NUT NX 040535 DAMPER ADJUSTER KNOB 041408 e ER DRGPDUT NUT 041348 R 40 CONNECTOR 041237 RED MOU 041427 CGNNEDTOR 041237 14018 STEEL SPRING 1 2 LONG 0041524 ai 2 041805 e D URITHANE REGGUNG CV 067850 Pd 2 dy COMPRESSION ROO SL yt 0415055 9 A md ES E URI THAN E REAGLND M e e 041550 2 E EOS oA ae Sh we 22 E 2 S 4 z Ns ES amp d A Ev 98 SMALL MEDIUM FORK SCHEMATIC AGJUSTER ASSEMBLY 241598 COMPRESSION STACK RDO LARGE 4841424 Vo CONNECTOR CONNECTOR 0412371 REO MOU 0414257 CQNNECTAR 041237 RED MEU 041425 N SRRING 4041377 0415773 Nj D SLEEVE 041 420 IVER t PLUG 047479 IND STAGE ELASTOM ER BLACK 040695 JND STAGE UP WASHER 040841 2ND STAGE ELAS TOMER DRA
5. The right knob 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 16 To adjust the compression damping for the XVERT and the XVERT R remove the compression damping assemble from the top of the left leg Adjust the set screw in the valve seat to increase compression damping and out to reduce the compression damping Try adjusting one full turn at a time To adjust XVERT TI models simply rotate the compression damping knob located on top of the left leg crown Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Excessive 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 condition Rebound Damping Fine Tuning Figure 17 To adjust the XVERT simply rotate the rebound damping knob located on the 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
6. 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 Stanchions may be removed from the upper and lower triple clamps 2 Never attempt to thread a threadless steer tube Machining threads will weaken the steer tube and cause an unsafe condition The only safe thing to do is to obtain the proper crown steerer from your dealer 3 Any other alterations or modifications to your fork should be considered unsafe Contact Answer Products Technical Support prior to modifying your fork in any way for safety information 4 Do not use any Manitou Fork if any parts appear to 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 or condition 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 Brake Arch areas for cracks or damage Before every ride check to ensure that the proper preload exists and that the positive rebound stop is in working order to ensure that the fork can not over extend 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
7. 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 turn in more rebound from there ROTATE FIGURE 15 PRELOAD XVERT TI XVERT amp XVERT R X ADJUST USING SET SCREW GLOGKWSE TO INCREASE GDMPRESSION DAMPING SDLUNTERCLDCKWISE DECREASE ROTATE STANUARD SETTING IS 4 5 TURNS BUT FIGURE 16 COMPRESSION DAMPING ROTATE FIGURE 17 REBOUND DAMPING 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 11 TROUBLE SHOOTING Fork seems to top out or has 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
8. that they were removed For XVERT amp XVERT R thread on valve nut and torque 30 IN LB 3 5 N m max For XVERT TI hand tighten piston seat Be sure large blow off washer will slide over piston spacer and compress the small 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 the same time Torque 30 IN LB 3 5N m max XVERT TI install lower needle gently into shaft thread until it stops then back off one turn for initial adjustment Slide shaft assembly through the plastic end cap place detent ball in place and slide 274 stg Elastomer Insert into left leg and thread in end cap Torque 30 IN LB 3 5N m max Add approximately 100CC of 5WT Maxima or equivalent oil Do not over fill Check oil level see Figure 8 GOSS ovis Compression Damping Assembly Figure 12 1 Reassemble compression damping stack following the instructions above for the lower shaft assembly 2 Install compression damping assembly into the leg The oil level should cover the compression valve when the assembly is installed Page 9 1 Clean all parts thouroughtly Compression Rod amp Boots Figure 13 2 Grease compression rod lightly Be sure rebound Elastomer is installed on to compression rod 3 Drop compression rod down into inner legs Shake inner leg to get rod through inner leg plug 4 Sl
9. 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 Page1 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 CROWN RACE have the proper tools to cut the steer tube it is recommended that PRESS ONTO you se
10. 41 547 NE TAPPING SCREW 041 350 FADE PLATE D41415 041179 9 141279 Sd 2 7 P 2 Scan 40414535 O RING 15 16 x 1 1 16 D RING 21 amp mm x 24mm 240675 040570 D RING 21 x 2 4mm Dans24 UPPER SHAFT 047480 ADJUSTER NEEDLE SIBASSEMBLY RING S 42 x 3 32 641156 SHAFT 1565 m On PU Neve SEAT D414 SET KREW 41423 CLAMP SHIM llmm 041157 mm x 18mm x mm SHIM 441147 mm x 19mm x mm SHIM 01441 43 Amm x Zimm xmm X ZITA XI DADA SHIM 0411 pS A 041 527 VALVE SEAT D41457 NS SET SGREW 1041471 gt lt G S CLAMP SHIM Iden 047187 5 nos xd imme i g m UPPER SHAFT 1541716 JU amm x Zimm xmm 241140 8 imm x 22mm x mim SHIM 041151 Emm x Hmm rimm SHIM 0411401 PU LAMP RING 46124 DMPRE amp SIIN VALVE D41455 ien Scat IM ABE UT SHIM 141157 G22 X 403 X ODS SHIM 041 138 AG M SPADER 044145 VALVE NUT COMPREGSIDN VALVE 341 4560 Emm x Bmm x mm SHIM 90411 47 fimm x Wmm mm SHIM 0411481 NO Emm x mm x1 mm eM 4941149 SUM SOS amm JZmm 1 SHIM 0411811 COMPRESSIIN VALVE 00414559 EZ X 08 X O05 SHIM 0411 58 SLOWOFF SPACER 0411659 622 X 409 X 0 041138 VALVE NUT 0416839 PISTAN SEAT 041457 DAMPER INSPECTION 1 Chec
11. CLAVE SHIM 0414 70 LEC ENO CAP SEN N FADE PLATE 041494 jotta PRU gh gro 627 P ER PISTAN 041407 GAP D4 453 2ND STAGE CUP HALL PLDWDOFF SHIM 0419 59 pETENT BALL Q RING 1 4 X 3 9 WASHER PISTON SPACER 041D485 0406895 D4D880 JRO STAGE ELASTDM ER SPRING 041152 SM UPPER NEEDLE UR ANGE 0405825 CLAMP RING 0411 595 041717 BRAKE POST d 24259215 e 22 O RING 9 32 x 8 32 TOROUE 90 10 INDH LBS EZ LOWER SHAFT 041718 0411505 TORQUE 15 12 N m f AXLE 041789 GRAKE PET SPACER p UPPER SHAFT 7041718 040942 RING amp 22 X 9 32 A 041150 PN Oh E ay 2 SLEEVE 0415 27 DLAMP RING 0411295 4 CLAMP SHIM D4157 J LOWER NOLE D4711 SHAFT SEAL DH 055 END 441705 O RING 1S5 1B X1 1 15 O4DB73 SHAFT WIPER 0400945 SND STS ELASTOMER ORANGE 040697 CONNECTAR 041247 X INNER LEG j 27 BMALL 0417441 SPRING BGNNEDTUR 041377 E d MEDIUM 41741 E LARGE 041742 lt 723 ah peg REBT Meo NER FORK SCHEMATIC GE TEER BE 041 701 J Bener 27 imm SPACER p 047730 FDRK BUMPER D4l 726 5 BOTTOM TRIPLE CLAMP D41700 s gt REEDLIND SHIM STACK Qy 01747 4140 1 1109 0415D amp 041151 PION VALNE 0414 38 SHIM 9411301 PISTUN SPACER 041045 piston SEAT OMA
12. ER FORK LEC SLIDE ON BLACK ZND STAGE CUP WASHER ORANGE 3RD STAGE FIGURE 13 COMPRESSION ROD amp BOOT A SLIDE ON OUTER LEGS UNTIL FORK IS FULLY COMPRESSED B INSTALL amp TORQUE COMPRESSION ROD SCREW 10 30 INCH LB 11 55 POP IN KNOG INSTALL amp TORQUE DROPUUT NUT USE SMM ALLEN WRENCH 10 50 IN H LB 0 1 35 5N m E INSTALL COMPRESSION ASSEMBLYS HAND TIGHTEN AGJUSTER CAPS SEE FIGURE 4 BE BETWEEN ALL MEUS amp SPRINGS gt CONNECTORS MUST F SLIDE FORK BHDOTS DOWN TO SNAP INTO GROOVE OUTER LES FIGURE 14 OUTER LEG ASSEMBLY ADJUSTING RIDE QUALITIES 98 XVERT forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the Micro Cellular Urethane MCU s Fine tune adjustments can be made using the preload adjuster 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 XVERT forks Compression Spring Fine Tuning Figure 15 Fine tuning adjustments to the spring rate are made by rotating the adjuster knobs located on top of the crown The 98 XVERT s use a compression spring system in the right leg only
13. MALL MEDIUM SARING CONNECTOR 041477 REO MOU D41425 SPRING CONN ESTO 4D 771 Lake S d SPRING CONNECTOR 0041577 v 74QLB 1 SPRING 8 1 24 eS o2 3 AE ONC clay spl NE avy 140L8 LONG 041501 AXEL NUT BERI TORQUE 10 30 INCH LBS TERQUE 1 2 35 RUP 041711 S EMP KR ON SLR 0404527 TERQUE 74 40 IN CH L 1 2 25 N m3 Q NCAXEL NUT DAMPER DROP 1047710 441 DAMAER DRODDUT NUT 041345 RING D REPO T 040822 DAMPER ADJUSTER KNOB D4 408 BPRING GONNEGTAR 4412779 SPRING amp BNNECTCR 4644377 RED Mta P4 A25 SPR Ine EZ FIGURE 6 98 TI BUSHING amp SEAL DETAIL FORK 0415441 ADIN STER ASSEMEBLY 1941 500 5 T NGU 1041427 CONNECTOR 041237 AY RED Meh 041425 oust sa CONNECTOR 041137 041445 RED WU 425 ADJUSTER ASSEMBLY 041588 SPRING CONNECTOR 0442777 4 LOWER BUSHING 041504 E REO MGU 041425 TARIE TE 54 2 GUNNEL TOR eH 251 N RED MCU 44414725 AGUURTER NW 5 TUM SPRING GONNEGTUR 041377 s 172 SPRING GONNEGTOR 41412779 RED MEU 4841425 5 SU R 2 BEN 2 p Tuc Pad LD SLEEVE PISTON SEAT 041457 Boxe d 041628 mi SELF TAPBING S REW 0412 35 S NN ind Sy
14. N INSTRUCTIONS Follow the instructions in your owners manual with the following exceptions WARNING DO NOT DRILL A HOLE IN THE DROPOUT THIS MAY WEAKEN THE DROPOUT WILL VOID THE WARRANTY AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INJURY DO NOT USE THE TEMPLATE PROVIDED IN THE 95 OR 96 SERVICE MANUAL 98 XVERT SERVICE MANUAL P N 85 3589 ANSWER PRODUCTS 28209 AVENUE STANFORD VALENCIA CA 91355 805 257 4411 WWW answerproducts com Page 12
15. NGE 945021 OAMPER ao SLEEVE COMPRESSICN SK ROD MEDIUM 041431 041237 lt RED NCL 0414275 QY REO Meh 041425 SPRING CONNES TOR ADJUSTER ASSEMELY 041558 COMPRESSION STAGK ROD SMALL 047422 CONNECTOR 041237 RED MEU 4041424 ee SU TOR TRIPLE CLAMP 041459 5 don pen 0471720 FORK BLIMFER 1941728 BOTTOM TRIPLE CLAMP 041440 2227 FDRK BOUT lt gt INNER LEG R SMALL 0414443 Pd MEDIUM B41594 d yee LARGE 4041624 P e s EN m ENO CAP 0417045 040674 SHAFT SEAL WIPER D40994 SRD 5TG ELASTOMER ORANGE 0406852 LN RINE 2 327 9 22 oer 30 7 LOWER NEEDLE 041466 SHAFT SEAL 041059 O RING 15 16 X1 1 16 SELF TAPPING SCREW 104330 FACE PLATE D41497 KNOB 041274 GAP 041547 UPPER SHAFT 041558 VALNE SEAT 04442 AS SET SCREW 041423 CLAMP SHIM 041157 REBOUND STACK 164147 041149 D411 4H DANSO d 0411515 DMPRESSIN VALVE 0414565 BLDOWOFF SPACER 9047165 SHIM 04146 VALVE NUT 1941 48 2 6 1 0 x 20 SOREW 5040455 X 5 PON Ed 15 af 2 PISTON SEAT 041457 REBOUND SHIM Nc 041144 PIS PISTON D41497 BLOWOFF SHIM 4411 59 di PISTEN GPAGER 9411046 SPRING 041152 poy rx LAMP SHIM 041172 CLAMP RING 641128 LOWER SHAFT 041485 9 o8eg S
16. TABLE OF CONTENTS Consumer Safety amp Warranty information Installation Instructions Spare Parts List Exploded View Maintenance amp Disassembly Inspection Inner Fork Leg Crown amp Break Arch Adjusting the Ride Qualities Trouble Shooting 9 NS an lt gt ANSWER PRECISION SUSPENSION CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK AVAILABLE THE 1998 XVERT FORK MODELS HAVE STATE OF THE ART MCU SPRING COMPRESSION SYSTEMS THE XVERT SERIES ALL USE THE NEW TWIN PISTON CARTRIDGE SYSTEM TPC THAT SURPASSES ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY Your 98 XVERT Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1 8 threadless steer tube 98 XVERT and XVERT R forks are available with the V Brake cable hangerless arch CONSUMER SAFETY INFORMATION IMPORTANT The 98 XVERT Fork is an off road fork and as such does not 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 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 1 Never remove or have the steer tube
17. ek a dealer with a qualified bicycle mechanic to perform p ASE SEAT installation MIN V TW MLA Il TW 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 FIGURE 1 RACE INSTALLATION stanchions will result in an unsafe condition and should never be done Remove old forks from bicycle Measure and cut the steer tube to fit your bicycle head tube 3 Remove crown race from old forks and press onto 98 XVERT Steerer until seated on crown Figure 1 Clean and grease headset bearings and races of bicycle Install lower bearings on fork crown race Insert steer tube into head tube of frame Install upper bearings spacers and stem Install stem cap and screw tighten until slack just disappears Install handlebars to desired height Torque stem handlebar pinch screws and stem clamping system to manufacturer s instructions 10 Install brakes and adjust per manufacturers instructions NOR CABLE HANGE 85 3644 PND
18. ide on black second stage cup washer and orange 3 stage Elastomer 5 Slide boots onto inner leg Outer Leg Assembly Figure 14 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 lb 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft 3 Pop in damper adjuster knob O ring holds knob in place XVERT amp XVERT R only 4 Slide skirt of fork boot onto the outer leg groove Be sure the lip snaps into the groove 5 Clean adjuster cap threads thoroughly Clean threads on inside of inner leg Assemble MCU s springs and connectors with thick grease Install adjuster assembly into inner leg just hand tight WARNING 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 WARNING BRAKE ARCH NOTE The 98 XVERT 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 is unsafe and could cause serious injury Contact Answer Products if you suspect that your brake arch bond is damaged Page 10 A SUDE ON REGUM DROP COMPRESSO ROD INTO INN
19. inner legs and bushings a knock or rock can be felt when pushed from side to side Avery small knock is normal with the new 98 harder bushings If the knock is excessive or you can feel the fork rocking then the bushing 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 the left leg at the adjuster cap If the 98 XVERT is stored 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 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 Fork is making a scraping noise that sounds as if the spring is binding There is a small seam around the outer diameter of the bushing connector This seam is probably rubbing on the inside diameter of the right inner leg To eliminate the scraping sound remove the right side adjuster assembly elastomer and spring File or sand the outside diameter of the clear bushing connector just enough to remove the seam Lubricate the spring elastomers and bushing spacers liberally with grease and re insert into fork Tighten the right adjuster cap CYCLE COMPUTER INSTALLATIO
20. ion 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 2 or 3 Stg Elastomer and capture the 1 8 Dia detent ball Adjuster needle must be unscrewed from the shaft Remove valve nut using end wrench and holding the shaft in soft jaws or collet to prevent damage Compression Damping Disassembly figure 12 REMOVE ADJUSTERS FULLY COMPRESS FREN TURNING REMOVE GDMPRESSICN RUD SCREW USE 4MM ALLEN WRENGH POP GUT K a gt a FORK LEGS TO KEEP COMPRESSION R amp D REMOVE NUT USING PULL DOWN TO BMM ALLEN WRENCH zd OUTER FORK LEG UNIT FIGURE 9 OUTER LEG REMOVAL 1 The compression damping assembly is almost identical to the lower shaft assembly 3 2 Unscrew the compression damping adjuster all the way until Se SH 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 FIGURE 10 COMPRESSION STACK 3 Remove either the valve nut of the piston seat following the instructions above fo
21. k the shaft for scratches wear or other obvious damage 2 Check the seal gland and end cap seal grooves for damage 3 Check shims for permanent bends or damage 4 Check all other parts for obvious damage replace if necessary 5 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 kit if necessary 4 Check all MCU amp springs for obvious damage Replace if necessary 5 Check the prelude adjuster and connectors Replace if damaged 6 Check the outer leg arch assembly for nicks or deep gouges on outside and inside Replace if damaged 7 Check the inner leg for deep gouges and other obvious damage Minor wear resulting in color change is not detrimental to the gold anodize 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 if gold anodize 1s beginning to flake 9 Check the underside of the crown for cracks Replace if cracked RE ASSEMBLY Lower Shaft Figure 11 1 Install all o rings and seals removed 2 Grease all seals lightly with a seal grease 3 Apply small amount of blue loctite to piston seat threads 4 Assemble shim stack and spacers inexact order
22. r leg arch assembly XVERT amp XVERT R Figure 9 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 A small screwdriver may be helpful Use a 8MM allen wrench to remove the dropout nut Fully compress the fork to prevent the compression rod and damper shaft from turning while removing screws 2 Pullouter leg assembly down to remove from the inner legs and crown 3 Remove fork boots Note It is not necessary to remove the dust seal every time the fork is disassembled The seal and bushings may be cleaned and re greased in place 4 Bushing replacement will require the use of the bushing removal and installation available from Answer Products It is recommended that the bushings be left installed unless they absolutely need replacement Page 7 Compression Stack amp Compression Rod Removal Figure 10 Slide off 2 and 3 stage Elastomer from right leg compression rod Unscrew and remove the adjuster assemblies by hand Turn fork upside down to remove the compression rod If forks are installed on the bicycle give the rod a quick thrust and catch it as it pops up above the crown Lower Shaft Disassembly Figure 11 Note Lower Shaft disassembly is best done with fork removed from the bicycle Disassembly of the damping stack is not required unless you want to change or replace the shim stack Se Remove the left cap compress
23. r the lower shaft assembly FIRGURE 11 LOWER TPC SHAFT ASSEMBLY LOWER SHAFT ASSEMBLY 041615 sd ete eh g REMOVE END GAP Bx PISTON SEAT 0414575 PISTON RING 6 0447489 N s wd ui aM Lae PISTAN SEAT 4841457 e mm x m x mrn Ko OMNEM v ru Y mm mm X Imm a 2d N 1 ED HAUT 1941138 X 17mm X Imm SHIM 141144 X PISTON SPACER D4 M5 i PISTON 941 4l S DETENT BALL SPRING 44112 1026 X 499 X 005 SHIM 1041128 Quee CLAMP RING 04 120 PISTON SPACER 041045 1 N SPRING 041152 LAWER SHAFT AHAS BALL CLAMP RINE D41 29 144650 1 V LOWER 8 004171 8 Na x 8 32 e LOWER NEEDLE ASSEMBLY EA ce RING 5 32 x 9 32 594 RN SHAFT SEAL 941061 a 041199 ENO 041714 LOWER NEEDLE 4441718 RING 15 15 X 1 15 949879 es SEAL goai oss WIBER END 6447855 E pepe vr e STG ELASTOMER GRANGE 040602 Page 8 INSPECT EN REBU UND CONNECTS ELASTOMER MUST GE TWEE AM ALL MCU amp SPRIN y amp SPRINGE RS TIP FORK WPSIDE DOWN 14 REMOVE COMPRESSION RDO FIGURE 12 TPC COMPRESSION DAMPING ASSEMBLY XVERT COMPRESSION DAME NG AI PAS SRL DN XVERT Tl COMPRESSI LUN 041592 5415845 DAMPING ASSEMBLY FN SELF TAPPING FOREW 0412201 SELF SERERE SE 041565 poe 041497 KNOB 041274 CAP 041547 O RING Ls FADE PLATE d414375 KNOB 941273 GAP 49
24. rake adjustment FIGURE 7 LUBRICATING THE BUSHINGS IMPORTANT Maintaining the proper oil level in your TPC is very important Not enough oil will allow foaming and reduce the performance Too much oil will restrict travle 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 TW assembly in place to keep the fork fully extended Use a tape measure or dip stick to determine the oil level Oil level should be between 3 5 89MM and 5 75 146MM below the crown where the damping assembly screws in The recommended level is 4 75 120MM Use SAE 5WT Maxima fork oil or equivalent Figure 8 MAXIMUM LEVEL MINIMUM LEVEL Minimum Maximum Recommended 4 5 114mm 3 76mm 3 75 95mm maw Xvert R 9 228mm 7 178mm 8 203mm Xvert TI 7 178mm 5 127mm 6 152mm FIGURE 8 TPC OIL LEVEL GENERAL DISSEMBLY NOTE The Fork does not need to be removed from the bicycle for general disassembly assembly or cleaning It is also not necessary to disassemble the 98 Manitou Forks for compression Elastomer replacement Elastomer replacement is accomplished by removing the adjuster assembly per Figure 10 Removal of oute
25. y Service Department at 805 257 4411 8 00 AM to 5 00PM Pacific Standard Monday through Friday In addition helpful information can be found on the Answer Products Web Site http www answerproducts com Included on the site is down loadable manuals and e mail technical support DESCRIPTION 5 WEIGHT FORK OIL 8 OZ BOTTLE 2 5 WEIGHT FORK OIL 8 OZ BOTTLE DH FORK CAR RACK ADAPTER 98 VERT STICKER SET 98 XVERT TI STICKER SET 98 XVERT R STICKER SET 11 8 TO 1 HEADSET XVERT INNER LEG PLUG REMOVAL KIT 100CC 5 WEIGHT FORK OIL 98 OEM REFLECTOR BRACKET KIT X VERT R HAYES BUSHING KIT 98 SOFT KIT SX SX R SX RR 98 MEDIUM KIT SX SX R SX RR 98 FIRM KIT SX SX R SX RR ADJUSTER KIT ALUMINUM SX amp XVERT Page 3 p Sed BUSHING amp SEAL DETAIL FIGURE 4 98 X VE RI FORK 4941544 ST LOWER BUSHING 041 504 DUST SEAL UPPER BUSHING 041503 RED MCU 40414241 SPRING DDNNEZTOR 041577 BDLE STEEL SPRING QD 2 1 1 LONG Ws amp MPREBSIUN ROD D4 REBGLIND SPAGER PS 441548 yas STAGE ELASTOMER 2 ORANGE 040642 RIY SLEEVE 041430 INNER LEG PLUG D41 479 IND STAGE ELASTSMER_ BLACK D40BR3 2ND STAGE CUP WASHER 040691 2 2NO STAGE ELASTOMER 3 ORANGE 041442 BRAKE POST P4421 Ex 5 STURQUE BO 110 INCH Las Sf L 7 AFT SLEEVE TORQUE 10 12 N m
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