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1. IMPORTANT Failure to properly route and securely attach the front brake cable to the fork can cause serious injury or death This fork should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replacement parts INITIAL SET UP MEASURING TRAVEL To determine which travel your 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 See Table 2 to determine travel TABLE 2 TRAVEL MEASUREMENT SEAL TO CROWN FORK TRAVEL MEASUREMENT 80 mm Around 110 mm 100 mm Around 130 mm 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 distance down Remember the exact locations of the two points because you ll need to use them later 2 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 riding position weight centered with your feet on the pedals 3 Subtract the second measurement from the first The resulting measurement is the static sag See Table 3 4 The preload adjuster on Manitou forks are located on the top left of the crown as you are looking at the fork from the rider s perspective Turning the knob clockwise incr
2. For information outside of the U S contact your authorized Manitou dealer or distrib utor You can also log on to www answerproducts com and download this manual or see detailed instructions on how to service your suspension fork 04 SIX SERVICE PART KITS 04 SIX Pre Load Adjuster Assemblies 85 4810 SIX SIX Sport Pre Load Adjuster Assembly 04 SIX Crown Steer Leg Assemblies 85 5366 26 SIX Crown Steer Assembly Steel 85 5367 26 SIX Crown Steer Assembly Alloy 04 SIX Outer Leg Assemblies 85 5250 26 SIX Outer Leg Assembly Black 85 5368 26 SIX Outer Leg Assembly Silver 85 5376 26 SIX Outer Leg Assembly Black No Boss 85 5377 26 SIX Outer Leg Assembly Silver No Boss 85 5228 26 SIX Sport Outer Leg Assembly Black 85 5229 26 SIX Sport Outer Leg Assembly Silver 85 5236 26 SIX Sport Outer Leg Assembly Black No Boss 85 5233 26 SIX Sport Outer Leg Assembly Silver No Boss 04 SIX Sticker Boot Knob Seal Bumper Kits 85 5313 SIX Sticker Kit Silver 85 5314 SIX Sticker Kit Black 85 5388 SIX Sport Sticker Kit Silver 85 5389 SIX Sport Sticker Kit Black 85 5390 SIX Boot Kit 85 5395 SIX Knob Kit 85 5391 SIX Seal Kit 85 5363 SIX Bumper Kit 04 SIX Ride Kits Rider Weight Range 85 5030 SIX Ride Kit Soft 130 150 Ibs 85 5031 SIX Ride Kit Medium 150 170 Ibs 85 5032 SIX Ride Kit Firm 170 Ibs amp above 04 SIX Co
3. LLY SUPPLIED COMPONENTS ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH FOLLOWING THESE INSTRUCTIONS CAN 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 TO HAVE YOUR FORK SHIPPED DIRECTLY AT 800 423 0273 IMPORTANT The Manitou 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 ae 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 thi
4. answerp oducts P N 042111 2004 OWNERS MANUAL Six Six Sport 28209 Avenue Stanford Valencia California 91355 O61 257 4411 fax 667 294 4175 WANA ar swerproducts com MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING A 2004 MANITOU FORK This fork is fully assembled and ready to be installed onto your bicycle It comes equipped with a 1 s inch threadless steerer tube and may be available in a disc brake only version A handlebar mounted reflector must be used for on road use which is not included with your fork 2004 MANITOU SIX FORK LINE SD E E 80 OR 100 MM TRAVEL COIL amp MCU SPRING SINGLE CROWN RA ALUMINUM CASTING SIX SPORT 80 OR 100 MM TRAVEL COIL amp MCU SPRING SINGLE CROWN RA MAGNESIUM CASTING Preset from the factory but changeable You can also download this manual at www answerproducts com A cix dir Vee bI 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 RID ING YOUR BICYCLE YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF PREVIOUS RIDING OR ASSEMBLY DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING CRACKING CREAKING LEAKING OR IF IT IS MISSING ANY OF THE ORIGINA
5. ay want to recheck adjustments where 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 see WARNING above 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 Install headset and fork per headset manufacturer s instructions 5 Install the handlebars and stem to the stem and handlebar manufacturer s instructions 6 Install the brakes per the brake manufacturer s instructions 7 To install the front wheel adjust the front wheel quick release to clear the sec ondary dropout safety tabs Secure wheel per quick release manufacturer s instructions 8 Install the brake cable per brake manufacturer instructions Ensure that the front brake cable is properly routed Make sure the brake line is not crimped or contacts the tire as the fork moves through its travel ANUS WHEN INSTALLING THE WHEEL WITH A PROPERLY INFLAT ED TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE 1 MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM OF THE BRAKE ARCH SEE FIGURE A SEE TABLE 1 FOR MINIMUM BRAKE ARCH CLEARANCE 2 MEASURE THE TIRE AT MAXIMUM WIDTH SEE FIGURE B SEE TABLE 1 FOR MAXIMUM TIRE WIDTH A TABLE 1 WHEEL CLEARANCE MINIMUM BRAKE ARCH CLEAR MAXIMUM ANCE TIRE WIDTH See Figure A See Figure B 5mm 55 mm
6. eases spring preload and decreases sag while turning the knob counterclockwise decreases spring preload and increases sag 5 If adjusting the preload does not provide the proper sag you may require a new ride kit Please see recommended ride kits below TABLE 3 SAG MEASUREMENT FORK TRAVEL SAG 80 mm 12 16 mm 100 mm 18 24 mm MAINTENANCE Your 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 recommended that the fork be periodically disassembled cleaned dried and re lubricated You can download service and tuning instructions on the web at www answerprod ucts com SUGGESTED SERVICE INTERVALS FOR SIX FORKS Short Sporadic Rides Long Frequent Rides Lube fork as needed Lube fork as needed with Prep M grease via Microlube lubrication ports 4 6 squirts every with Prep M grease via Microlube lubrication ports 4 6 squirts every fork per Service Manual Clean and grease every 6 8 weeks grease spring stack as needed Normal 15 rides Disassemble 10 rides Disassemble fork per Service Manual fork per Service Manual clean and grease every clean and grease every 5 6 months grease 4 5 months grease spring stack as needed spring stack as needed Lube fork as needed Lube fork as needed with Prep M grease via with P
7. mpression Rods 85 5315 SIX Compression Rod Assembly 60 or 75 mm
8. ng to do is to obtain the proper crown steerer from your dealer or contact Answer Customer Service at 800 423 0273 Any other alteration or modification to your fork should be considered unsafe Contact Answer Customer Service prior to modifying your fork in any way for safety infor mation Do not use the fork if any parts are broken bent cracked or you suspect may be damaged Contact your dealer or Answer Products Customer Service at 800 423 0273 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 dropouts 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 coun tries 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 break age 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 warranty null and void This warranty is expressly in lieu of all other warranties and any implied are limi
9. rep M grease via Microlube lubrication Microlube lubrication Severe ports 4 6 squirts every ports 4 6 squirts every Conditions 10 rides Disassemble 10 rides Disassemble fork per Service Manual clean and grease every 4 6 weeks grease spring stack as needed IMPORTANT When lubricating the fork with grease through the Microlube ports it is important to note that the grease is being forced between the upper and lower bushings If the area is overfilled the grease may force the upper bushing and dust seal out You should only insert grease to the level at which stiction stickiness when you compress the fork is no longer felt IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight per quick release manufacturer s instructions NOTE Forks with standard dropouts are equipped with dropout safety tabs to retain the wheel in the fork in the event the quick release comes loose 2 Wipe the inner legs and clean the fork Check the entire fork for any obvious damage Do not use the fork if any parts are broken bent cracked or you suspect may be damaged 3 Check the headset for proper adjustment per headset manufacturer s instruc tions 4 Ensure that the front brake cable is properly routed and check brake adjust ment If you have any questions regarding your 2004 Manitou suspension fork in the U S contact the Answer Customer Service Department at 800 423 0273
10. ted 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 with original purchase 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 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 A THE STEERER 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 INCREASE STEERER TUBE LENGTHS OR CHANGE 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 slight ly 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 m

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