Manitou 1998 SX Fork Line Manual
Contents
1. BRAKE ARC 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 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 FIGURE 1 RACE INSTALLATION Page 2 WARNING When installing wheel or any new tire check the 2 875 73 0MM Any less clearance can result in minimum tire clearance Measure from the highest point on the accident resulting in serious injury or death tire to the bottom of the crown The minimum clearance allowed is Figure 3 275 54 5MM 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 http2. lt VADE NUT 041483 5 7 ES AISTAN SEAT n SHN A3MM Z01197 REEQUNG SHIM STACK GIL Bit 45 e OCH PISTON SPACER 041045 s SPRING 041182 CLAMP SHIM 11MM 4041179 CLAMP RING 941128 LOWER SHAFT 041480 5 32 x8 se 04140 LOWER NEEDLE 041481 SHAFT SEAL 41055 040588 RAND 15 16 X 11 15 DAMPER ADJUSTER KNOB D40873 041406 41457 Page 4 FIGU RE BUSHING amp SEAL DETAIL e FORK BIDT D41244 DUST SEAL 4041 EL UPPER BUSHING 041 47 3 LOWER BUSHING 041474 N DAMPER SHAFT SLEEVE D40926 MCU STOK RED D41425 DAMPER SHAFT SLEEVE 0490923 MCU STOCK REO 04 425 SPRING CONNECTOR 441 377 SXRR_2ZBOLE STEEL SPRING R 2 1 2 LONG 4194 YO FORK BJDTS 041244 COMPRESSION ROO Ka REBOUND FLASTOME ege un STAGE ELASTONER BLACK 94lS9 3 EE ANNE LINERS BRAKE POST 0409 21 7 TORGUE 80 110 INSH LBS TORQUE 10 1Z N md PONP RESSION E RQD DCREW 060266 DAMPER OROPOUT TORQUE 10 30 NUT 041345 INCH LAS ORE i D Oso O RING DROPOUT NUT LOL DG BA DN ADJUSTER KNOB 414067 94 SX ADJLISTER ASSEMBLY 4041584 MEU STOCK RED 0414253 W ENO DAP 04133 DAAR 5AG X1 1 18 SHAFT SEAL WIPER fo4n994 INO 5TG ELASTOMER COMPRESSION DAMPING ASSEMBLY 041563 SELF TAPPING SCREW 0413303 FACE PLATE 141225 KNGB 541273 CAP 041453 GRING 1 4 X 3 8 9
3. www answerproducts com Include on the site is down loadable manuals and e mail to technical support DESCRIPTION PART NUMBER 98 SX TI MRD KIT 98 SOFT KIT PRO PRO LT SPY R 98 MEDIUM KIT PRO PRO LT SPY R 98 FIRM KIT PRO PRO LT SPY R 98 SOFT KIT SX SX R SX RR 98 MEDIUM KIT SX SX R SX RR 98 FIRM KIT SX SXR SX RR 98 TI SOFT RIDE KIT SX TI 98 TI MEDIUM RIDE KIT SX TI 98 TI FIRM RIDE KIT SX TI 98 ADJUSTER KIT ALUMINUM SX amp X VERT 98 ADJUSTER KIT SPYDER PRO PRO LT 98 SX TI RED CAST ASSEMBLY _ _ 98 BUSHING REMOVAL OO 98 SX TI RED CAST ASSEMBLY 85 3888 98 BUSHING REMOVAL TOOL 85 3892 Page 3 FIGURE 98 PRE Si BUSHING amp 5 EAL DETAIL BEER FELT WIPER 413188 UPPER BUSHING D41225 SPAGER BUSHING D4D4199 K LUWER BUSHING 940915 BRAKE PBST 04092 Herat HOI ING TORQUE 10 12 N M Sa ZND STAGE CUP WASHER 04069 1 K mall SPAC ER a 7 er ER aN GEN CLAMP Sas oe a 11MM 041170 REBOUND ELASTOMER 041415 y ars REBOUND ELASTOMER LEFT OUTER LEG 041475 TORQUE 12 35 N M SPRING END 041273 REGEN SEIN RK SCH 7 EMATIC cae ELASTUMER RED 1 2 041258 T amp SA ER SLEEVES 041247 COMPRESSION MEU ELASTOMERS BLUE D41952 OUTER LEG ROU COVPRERSIUN ROU SLEEVE SLEEVE C4 10689 S410 68 LASTONER SLEEVES a D41247 Le OF COMPRESSION MOU ELASTOMERS ge 9 RED 2 046
4. 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 16 FIGURE 16 PRELOAD Fine tuning adjustments to the spring rate are made by rotating The adjuster knobs located on top of the crown Note the 98 Pro uses compression spring systems in both right and left legs Both right and left knobs on top of the crown adjust preload The 98 SX SXR SXRS and SXTI use a compression spring system in the right leg only 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 17 To adjust the SXTI simply rotate the compression damping knob 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 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 f
5. 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 SLIP CROWN The steer tube may need to be cut to length to fit your bicycle ACE OVE head tube If you are not familiar with this procedure or do not STEERER have the proper tools to cut th
6. 40890 ADJUSTER NEEGLE 041159 GETENT BALL e E 2 FQ RK sC EMATIC FRONT SHAFT 014458 S Se RING 5 327 x 3 52 411307 S DETENT SLEEVE 041527 CLAMP SHIM 041167 EBQUNO SHIM STAGK F147 U41149 041149 GE E Ell ech A3 IW ARISTON SPACER 041 045 SPRING 04116Z E PISTON SEAT 1041457 Bo Sy LOWER SHAFT ASSEMELY amp 4 LEFT INNER LES PISTIN SEAT 041457 GLAMP SHIM 0411701 XZ REEGUNO SHIM STACK 041145 041145 NP BN UE 27 2 OS DETENT BALL 0406 Eg BLOWOFF SHIM PISTON SPACER 041045 SPRING 041182 J CLAMP RING 041129 LOWER SHAFT 041489 L RING 5 327x9 32 ENK deer LOWE W i 941 441 SHAFT SEAL 041055 3 ORANGE 040692 BUSHING amp SEAL DETAIL S FIGU RE FORK CSO 041244 ok LOWER BUSHING 041474 OUST SEAL 941245 UPPER BUSHING 041473 ADJUSTER ASSEMELY 04586 MCU STOCK REO D41495 SPRING CONNECTOR 1041577 140LB H SPRING 1 2 LONG 041501 OM PR ESSIN 644 49 gt REBGUNO ELASTONMER 3 041 462 ZNO STAGE ELASTOMER a FLACK C40603 Le 2ND STAGE CUP WASHER Lang 2NO STAGE ELASTOMER S k DRANGE 0405692 BRAKE FOBT 940921 AUTER LEG ARCH ASSEMBLY TORGUE D 11G INCH LBS TRRBUE 10 12 N m COMPRESSI ON ak y A SCREW 950268 SE TORQUE 19 30 INCH LBS DAMPER
7. 6525 De NCU SPRING CONECTOR Y S 044271 ZOMPRESEIBN ROD Ba ei SCREW OG Pipo wh F EN Z LONG TORQUE 10 49 NCH LBS Z ADJUSTER 122 GM 41 z CUMPRESSION ME RED M U 9414250 S SPRING GANNEGTOR 04127 D ae 260E SE SPRING 2 1 72 LONG a4 11 56 COM PRESSION ROD 0414995 E ELASTOMER 27 SSH E E Q4 475 z E PND BT th EEN s TETAS Sa O 2ND STAGE ELAS TOMER EFT INNER LEG ORANGE 0406902 BRAKE POST 040921 TORQUE 90 110 INCH Les TORQUE 10 12 N m i TAR DUE 10 39 INGH eee TORQUE 14 3 5 N m D CUTER LEG ARSH ASSEMBLY OETENT SALL 040689 4 v RING COMPRESSION ROO SCREW Ze EL Se PER DRUPUY T NUT 241345 O RING DROPOUT NUT ENO GAP O41133 SHAFT SEAL WFER 040994 ONO STG ELASTGMER ORANGE 040452 a U kr Sasha KOU O41027 BUSHING amp SEAL DETAIL rw FIGURE D SH SXR FORK SCHEMATIC FORK B 041244 COMPRESSION DAMPING ASSEMBLY 041562 SELF TAPRINS SCREW 041330 S FACE FLATE D21297 s ale ADJUSTER ASSEMBLY 041588 A UPPER BLISHING 041473 RED MGU 1041427 ee KNEB 0412795 LOWER BUSHING 041 474 TENNES n BAR Geel S RED MEU a41425 VALVE BEAT 041 4829 CONNECTOR 0412379 SET SCREW 0414 23 CLAMP SHIM D41157 COMPRESSION SHIM STALK 04147 041148 041149 D41150 amp O41451 D FRE EPI sN VALVE DU 456 SHIM 04138 lt BLOWORF SPACER 041166
8. AD JU BTER KNOB 0414061 PER DROPOUT NUT 041545 TORQUE 1 2 3 5 N GRI N DROPOUT NUT O40588 9S SXTI COMPRESSION DAMPING ASSEMBLY 04563 FO RK SCH EMATIC SELF TAPPING SCREW 041330 FAGE PLATE 4041496 KNOB 0412784 CAP 041454 O RING 1 4 X 3 5 0406301 ADIVSTER NEEDLE 041159 DETENT BALL GE 9 RING SALT daf O41 BOS FRONT SHAFT 041458 CLAMP RING ai 20 ETENT SLEEVE 041827 x LAMP SHIM 0411679 RCH OUND EN o M STACK DU4 47 amp N Asis AB 41148 54114 40 te U41151 We PISTON SFALER SPRING 0417152 7 ISTON SEAT 0414571 D44045 LOWER SHAFT ASSEMBLY 1941584 PISTON BEAT 041457 Si Alle I4 AS PISTO PISTON SPACER AS LAMP SHIM 041170 x25 REBOUN D_SHIM_ STACK O44 Ne N 044 465 Xa BLDWOFF SHIM to4 la Tee BETENT HAL SPRING 041153 Luauneg CLAMP RING 6471205 GOWER SHAFT 041 48a 3 e GE 5 22 x8 32 y 041130 Q LGWER NEEDLE 0414619 G NSHAFT SEAL 041085 ENG CAP 041134 FRING Sie xX 1S HAFT SEAL WPER t D40994 AND STO ELASTIPME R ARANGE 40872 Page 5 MAINTENANCE Your 98 SX Fork requires periodic maintenance cleaning and inspection 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 d
9. IN LB 3 5N m max Add approximately 100 CC of 5 WT Maxima or equivalent oil Do not over fill Check oil level see Figure 8 ompression Damping Assembly Figure 13 Reassemble compression damping stack following the instructions above for the lower shaft assembly installed Page 8 Compression Rod amp Boots Figure 14 2 Grease compression rod lightly Be sure 1 rebound Elastomer is installed onto Clean all parts thoroughly compression rod Drop compression rod down into inner legs Shake inner leg to get rod through inner leg plug Slide on black second stage cup washer and orange 3rd stage Elastomer Slide Boots onto inner leg Outer Leg Assembly Figure 15 1 2 ony Slide Outer leg Arch assembly onto inner legs and fully compress Install and torque SMM compression rod screw and dropout nut to10 30 inch lb 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft Pop in damper adjuster knob O ring holds knob in place SXR amp SX TI only Slide skirt of fork boots onto the outer leg groove Be sure the lip snaps into the groove 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 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 mak
10. NG 4047199 a Sp DETENT BALL 0404 BB ASSEMBLY LOWER SHAFT ASSEMBLY 041 584 PISTON SEAT 041497 CLAMP SHIM Timm CDA 79 Amm X 14mm X Imm SHIM D41143 PISTON SEAT 041457 Zenm CLAMP SHIM 0411579 REBOUND SHIM 0411445 Brim x mm x Jpm REAGUND_SHIM D4145 dmm x 16 Imm PISTEN O41 U411 39 gt 455 326 X DD X DOS SHIM N PISTUN SPACER 041045 SPRING 041152 Timm CLAMP SHIM 0471705 CLAMP RINGS 0411295 LOWER SHAFT 641460 SHAFT SEAL 041058 END CAP 041705 O RING 16 16 X1 1 16 940673 SHAFT SEAL WIPER 040894 JNO STS ELASTOMER ORANGE 0406921 Page 7 FIGURE 13 O RING 5 32 x 9 52 be LOWER NEEHLE 0414615 SHAFT SEAL 041945 END AP 0411331 G RING 15 16 x 1 1 1 67 4 D40874 SHAFT SEAL WIPER 040094 AND STG ELASTOMER IRANGE 040692 TPC COMPRESSION DAMPING ASSEMLBY CGMP RESSION DAMPING COMPRESSION DAMPING ASSEMBLY 041583 ASSEMBLY 041562 SELF TAPPING SCREW Pelee SELF TAPPING SGREW 0413305 FACE PLATE 041496 FAGE PLATE 041497 KNGB 641279 KNOB oe CAP G44455 CAP 41547 D RINS BMM 0 X 2 ZMN WIDE 041776 s GREEN DETENT BALL 04068 9 Pa WARNING STICKER 041278 J lt ADJUSTER NEEDLE y O RING ge k SS 15 16 x 1 1 18 XS 941139 lt D41672 lt O RING 5 32 x9 327 Ge D41131 S WARNING ST CKER 0413799 N UPPER SHAFT G41458 See SLEEVE m LU AND RING Meut
11. TABLE OF CONTENTS Consumer Safety amp Warranty Information Installation Instructions Spare Parts List Exploded View Maintenance amp Disassembly Inspection Re assemble Inner Fork Leg Crown amp Brake Arch Adjusting the Ride Qualities A Trouble Shooting xO G GO O S i ANSWER PRECISION SUSPENSION CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK AVAILABLE THE 1998 SX FORK MODELS HAVE STATE OF THE ART MCU 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 98 SX Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1 8 threadless steer tube 98 SX s are available with the V Brake cable hangerless arch and have an optional attachable cable hanger kit P N 85 3644 which is available through your dealer CONSUMER SAFETY INFORMATION IMPORTANT The 98 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 the fork is going to be used on public roads at any time If you have questions regarding C P S C Standards contact
12. cers Compression Damping Disassembly Figure 13 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 REMOVE ADJUSTERS AND FULLY COMPRESS FORK LEGS IQ KEEP KEEP COMPRESSION ROD FROM TURNING REMOVE COMPRESSION HDD SCREW USE SMM ALLEN WRENCH PULL DOWN TO REMOVE OUTER FORK LEG UNIT SX amp 5X TI REMOVE NUT USE AMM ALLEN WRENCH FIGURE 10 OUTER LEG REMOVAL UNSCREW_ SKEWER CAP ASSEMBLE BY HAND amp REMOVE FROM FORK LEG INSPEGT MCU amp SP CONNECTARS MUST BE BE ALL MCU A TIP FORK UPSIL OWN TO REMC COMPRESSION F CT REBOUND ONER SLIDE OFF 2NU U amp SRE Sa STAGE ELASTOMERS FIGURE 11 COMPRESSION STACK FIGURE 12 LOWER TPC SHAFT ASSEMBLY PISTEN INSTALL DETEN T N GE DN 2ND STG ELASTOMER OVER BALL REMOVE ENO CAP LL 7 LOWER SHAFT 04 718 D aff K BASS X 9 42 041130 LOWER NEEDLE 041719 LQWER SHAF 041731 Dron X 17mm X Imm SHIM O4114a PISTON 041414 see Ate X 409 g 005 A 0411355 N PISTON SPACER 041045 SPRING 4041152 CLAMP RI
13. e CLAMP SHIM 15 041187 REBDUND SHIM 041147 VALVE SEAT 041482 D ae SCREW 041423 CLAMP SHIM 13mm 041157 Bmm x 18mm xmm SHIM 941147 m x lmm x mm SHIN 041148 Raed DN i 41149 WI Smm x IMM x4mrn SHIM 941130 rr zw Ten SHIM 0240517 og REBOUND SHIM 047150 REBGUND SHIM D41141 PISTON D41456 ai Di E PIGTIN SPACER 041 045 CIMPRESSIUN VALVE 041490 622 X 4D9 X OOS SHIM GE os BLOWGFF SPACER 041165 G VALVE NUT 941482 SP RING Was PISTON SEAT 4041450 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 3 8 9 Check the dust seal for tears wear or damage Replace if needed 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 preload adjuster and connectors Replace if damaged 6 7 Check the inner leg for deep gouges and other obvious damage Minor wear resulting in color change is not detrimental to the Check the outer leg arch assembly for nicks or deep gouges on out
14. e steer tube it is recommended that PRESS UNTO you seek a dealer with a qualified bicycle mechanic to perform RACE SEAT installation E 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 1 Remove old forks from bicycle FIGURE 2 BRAKE CABLE ROUTING 2 Measure and cut the steer tube to fit your bicycle head tube 3 Remove crown race from old forks and press onto 98 SX 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 adjust and tighten headset per manufacturers instructions Install handlebars to desired height Torque stem handlebar pinch screws and stem clamping system to manufacturer s instructions 10 Install cantilever brakes and adjust per manufacturers instructions ON DAK S EMOVABLE RAKE TRIM CABLE CASING Note All 98 SX Forks are equipped with a secondary catch ZJ S V ETAINER USE METAL FERRULE dropout
15. e the fork unsafe to use If you see any slippage contact Answer Technical Staff immediately 800 670 7446 BRAKE ARCH NOTE The 98 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 Page 9 ADJUSTING RIDE QUALITIES SLIDE ON REBOUND ELASTQGMER B DROP CtMPRESSIGN ROO INTO INNER FDRK LEG a SLIDE ON FORK BOGTS SLE ON BLACK 2ND STAGE CUP WASHER a THEN ORANGE 2ND STAGE Es INSTALL COMPRESSION STACK HANDO TIGHTEN ADJUSTER CAPS SEE FIEGLRE 4 CONNECTORS MUST BE BETWEEN ALL MGW S amp SPRINGS F SLIDE FORK HBATS UDWN TO SNAP INTD GROOVE OF OUTER LEG A SLIDE UN OUTER LEGS UNTIL FORK D INSTALL amp TERUUE IS FULLY COMPRESSEO COMPRESSION ROG SCREW 10 40 INGH LB CG INSTALL amp ONE BROPOUT Q 1 3 5 N NUT USE SMM ALLEN WRENCH 0 30 INCH LB 1 1 4 5 N O o POP IN KNOB SX A SX TI FIGURE 15 OUTER LEG ASSEMBLY 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
16. e the oil level Oil level should be between 3 5 89MM and 5 75 146MM below i 475 the crown where the damping assembly screws in The recommended MAX 3 50 BIMM el NN level is 4 75 120MM It is recommended that you replace your oil at d least once during the season twice if it has been contaminated with Ee m dirt mud or other foreign substance Use SAE 5WT Maxima fork oil MIN 5 75 I 46MN tr or equivalent See Figure 9 FIGURE 9 TPC OIL LEVEL GENERAL DISASSEMBLY 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 11 Removal of outer leg arch assembly Figure 10 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 SXR amp SX TI 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 Pull outer leg assembly down to remove from the inner legs and crown 3 Remove fork boots Note It is not recommended to remove the dust seal every time the fork is disassembled The seal and bushings may be cleaned and re greas
17. ed 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 the air out before checking the oil level FIGURE 18 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 10 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 n
18. ed in place 4 Bushing replacement will require the use of the bushing removal and installation tool available from Answer Products It is recommended that the bushings be left installed unless they absolutely need replacement Page 6 Compression Stack amp Compression Rod Removal Figure 11 1 Slide off 2nd and 3rd stage Elastomer from right leg compression rod 2 Unscrew and remove the adjuster assemblies by hand 3 Turn fork upside down to remove the compression rod If forks are installed on the bicycle give the rod a quick upward thrust and catch it as it pops up above crown Lower Shaft Disassembly Figure 12 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 2 Remove the plastic end cap and pull the lower shaft out of the inner leg 3 Remove 2 or 3 Stg Elastomer and capture the 1 8 Dia detent ball used on SXR and SXTI 4 SXR and SXTI adjuster needle may be unscrewed from the shaft 5 For SX remove valve nut using end wrench and holding the shaft in soft jaws or collet to prevent damage For SXR and SXTI use 5MM allen wrench to remove piston seat Keep note of the exact order of the shims and spa
19. ork will perform good in all conditions The 98 Pro does not have adjustable compression damping To adjust the compression FIGURE 17 damping for the SX and SXR remove the compression damping assembly from the top of the COMPRESSION DAMPING 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 Rebound Damping Fine Tuning Figure 18 To adjust the SXR SXRR SXTI simply 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 98 Pro does not have adjustable rebound damping ROTATE D To adjust the rebound damping for the SX only the left leg must 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 locat
20. ormal with the new 98 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 98 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 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 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 SX SERVICE MANUAL P N 85 3490 ANSWER ANSWER PRODUCTS 28209 AVENUE STANFORD VALENCIA CA 91355 805 257 4411 www answerproducts com
21. ried and re greased Note The best way to prevent stiction is to lift the fork boots up and apply a light lube to the stanchion area in and above the 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 it is NOT RECOMMENDED to direct water spray at the seals See Figure 8 IMPORTANT Before every ride you should 1 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 adjustment 4 Insure that the front brake cable is properly seated in the cable retainer amp check brake adjustment FIGURE 8 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 travel 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 Az extended Use a tape measure or dip stick to determin
22. side and inside Replace if damaged gold anodized surface Replace if wear is excessive or damaged 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 is beginning to flake Check the underside of the crown for cracks Replace if cracked RE ASSEMBLE Lower Shaft Figure 12 1 2 3 4 ooy tA C 1 2 Install compression damping assembly into the left leg The oil level should cover the compression valve when the assembly is Install all o rings and seals removed Grease all seals lightly with a seal grease Apply small amount of blue Locktite to piston seat threads Assemble shim stack and spacers in exact order that they were removed For SX thread on valve nut and torque 30 IN LB 3 5N m max For SXR and SXTI 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 SXR and SXTI 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 on 2 STG Elastomer Insert into left leg and thread in end cap Torque 30
23. 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 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 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 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 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
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