2007 Manitou Rear Shock Service Guide
Contents
1. ep p j J Trunion 61mm Wide 44mm Travel RefOEPN85 17182 m p p j Trunion 61mm Wide 44mm Travel RefOEPN85 17183 1 mo p j J Radium Metel Shock IFP Chamber RefillPlug B e Fee NES FR Rebound Knob LL eem 833013 833013 8330033 83 3013 Swinger 4 6WReservoirAirVolumeAdjuser JB J T ERES ERR ERES E Swinger 4 6W Reservoir No Tools Volume Adjuster JB S S o T Comp Speed Adjuster Knob Needles Kit B ST ST HENNING EN GREEN Comp Speed Adjuster Knob Needles KitO Rings amp 8 J O n e LER SPVVave OB j 89305 HL Compression Assembly B p j p sang J Remote Lockout Cable HN WE NENNEN NEN SE Remote Lockout Conversion Kit Updated Cable Spool ENEMIES NES EE eS DEREN DR eee Remote Ready Conversion Kit Non Warranty jesse o esso Seal Kit epg 832708 832709 832707 Swinger 3WLRSSealkKit e p p p oo LLL LLL LL Swinger 6W Remote Reservoir Seal Kt c j p p p p p Heim Joint Mounting Hardware Swinger SWLRS DIU po perusing klen HemJont Swnger3WlRS Oe eere j Siero2. 07 MANITOU REAR SHOCK SERVICE GUIDE Page 29 REV NC 2007 COIL SPRING RIDE KITS Kit Description Swinger Coil Revox Revox Coil X3 Coil X4 Coil X6 Coil X3 Coil X4 Coil X6 SFS SFS SFS SPV SPV SPV ISX ISX QD o 2 Q o O o LD Se o O o Wu X co xw J 8 75 or 9 0 X 2 75 8 75 or 9 0 X 2 75 Rate 650 8 75 or 9 0 X 2 75 Rate 700 8 75 or 9 0 X 2 75 Rate 750 Rate 600 85 6679 85 6680 85 6681 85 6679 85 6680 WON KOAN Kee KOP d o o o 22 2 Ee bel bf fl El opo go fT a Oo o o o ajajaja O O OJO Oo o o o NINJA eg bg bg eg Oo o o o o o o o ALA LATA MTMITMI P CO CO CO ei Kei eil Ke rad Rad Ead gt lt I DNI DNI DN ei teil teil Ke CO C1 1 o o Co N 9 5 X 3 0 9 5 X 3 0 Rate 500 Rate 550 33 019S 85 6201 posbil99 85 6201 Kit Revox Revox W Shim BEN DJ Snim SPV pans LCS NE E ERR 6 5 X 1 5 Rate 250 G 85 6660 1 856660 85660 J J Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 300 1 G 85 6661 85 6600 est S Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 350 1 LD 85 6662 85 6662 55 6609 S Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 400 LD 85 6663 85 6669 85 6660 y Spring for Coil Shock 165
3. Schrader Valves o p D p P p prem EEUU NNI EPIS REA Radium RL Air Canister Schrader Valve Assy inc O Ring Black Al E ee NEN EE Swinger SPV Schrader Valve Assy inc O Ring Red FAP 90 Degree Schrader Air Valve Black AT _ ME mm as 360 Degree SPV Schrader Air Vave Red A J 360 Degree Air Can Schrader Air Valve Black AJ 82342 8932422 Complete Shock Body No Hardware or Spring T j Shock No Hardware 152mm Eye to Eye 32mm Travel B L 85 7100 LE Shock No Hardware 165mm Eye to Eye 38mm Travel B Shock No Hardware 190mm Eye to Eye 50mm Travel B 8571001 C es ee Shock No Hardware 200mm Eye to Eye 50mm Travel L Shock No Hardware 200mm Eye to Eye 57mm Trav B ep TBD 85 7167 857168 _ 85 7108 85 7162 8577115 Shock No Hardware 215mm Eye to Eye 68mm Travel BT Lo 85 7109 85 7168 85 7116 Shock No Hardware 222mm Eye to Eye 70mm Travel B po 85 7110 85 7164 857117 Shock No Hardware 230mm Eye to Eye 70mmTravel BYP 85 7111 85 7165 85 7118 Shock No Hardware 240mm Eye to Eye 76mm Travel SB S Jo S y 85 7112 85 7166 85 7119 Shock No Hardware 320mm Eye to Eye 63mm Travelwhiemjoint LRS J T Jena J j J Trunion 68mm Wide 44mm Travel RefCEPN85 17181
4. Replace rebound knob Bl Replace o ring REV NC SECTION 16 TABLE 1 FASTENER TORQUE REQUIREMENTS Fetue le Tore Ee WE Swinger Air S Type Radium Evolver SOS 15 24KgCm 13 21inlbs Air Piston to Damper 70 90 KgCm 61 to 78 inlbs Damper Shaft to Control Eyelet 70 90 KgCm 61 to 78 inlbs Damper Piston Bolt 70 90 KgCm 61 to 78 inlbs Schrader Valve Stem 5 10 KgCm 4 to 9 inlbs UU I Air Volume Adjuster Swinger Air 4 Way 70 90 KgCm 61 to 78 inlbs eS ae Swinger Coil Revox Metal E KENE 07 MANITOU REAR SHOCK SERVICE GUIDE Page 27 REV NC SECTION 17 2007 MANITOU REAR SHOCK SERVICE KITS 2007 SWINGER AIR S TYPE RADIUM SPLIT SERVICE KITS Kit Description 111 1 1 1 1 1 1 Kit Description 111 1 1 1 1 1 1 STye Evolver ISX 4 id En ie tif el fo Sv im SPV Shim Brei a i uL SS RE C BS dE BEES E Air Canister 200mm Eye to Eye 56mmTravel CA 83304 833060 Air Canister 215mm Eye to Eye 63mm Travel AT Lo BO Air Canister 222mm Eye to Eye 70mm Travel AT Lo 83308 Air Canister 230mm Eye to Eye 70mm Travel AJ oam O Air Canister 240mm Eye to Eye 76mm Travel AJ ST p qp p Jj 89310 Air Canister 320mm Eye to Eye 68mm Travel LRS Ja Tess p j pq p
5. Adjuster Eyelet SPV Ar Preload Air Spring Schrader For leaks in the air preload reservoir area 4W Swinger release all pressure replace the preload adjuster o ring Schrader valve core or Schrader assembly as needed If when you pressurize the air canister the shock collapses to its shortest travel position the shock has an air piston leak into the negative chamber Place the shock in the shock tester and extend it to its full travel Depress the adjuster eyelet Schrader while the shock is extended under load If it remains in the full travel position refer to the section on DAMPING SYSTEM BLEEDING Swinger Air for instructions on servicing the air canister and piston seals If the shock returns to the short travel position it is not serviceable and the entire shock must be replaced Attempting to service a shock with this condition could result in injury or possible death SECTION 5 COMPLETE SHOCK LESS MOUNTING HARDWARE AND COIL SPRING The highest level kit offered will be a complete shock without mounting hardware or coil springs for coil forks This kit is offered as a fast replacement where all that is need is to change out the hardware and spring and then reinstall the shock Swinger Air Less Mounting Hardware Swinger Coil Less Mounting Hardware and Coil SECTION 6 MOUNTING HARDWARE REMOVAL AND INSTALLATION Mounting hardware is used to mount shocks to the various frame configurations Over tim
6. rs ssze sw so kmsi T0 TED W2mso 059058 W209i Toots o SH p p p D po po Lo Lo LL Tool for adjusting Swinger Air Reservoir Volume JHU E EE Tool for locating Swinger IFP during bleed process FHT TP GENESIS DU Bushing Tool oS H Plunger for Removal of IFP Piston SwngerAr SH S S p Tool for Bleeding Swinger Air amp Coil Reservoir Shocks JH S p Fixture to Hold and Compress Shocks H Fixture for Clamping 10mm DamperShaft Un Fixture for Clamping 12 7mm Damper Shat JHU S Jp S p S Shock Pump Air Conte H Shock Pump SPV Reservoir O p p p Fixture for Clamping Reservoir and Damber Body Swinger Air and Coil OI High Pressure IFP Tod eg H 07 MANITOU REAR SHOCK SERVICE GUIDE Page 28 REV NC 2007 SWINGER COIL RREVOX METAL SERVICE KITS Kt Desoription S alleen CAN Dp Sica ees Sninger SPV Sdrader Vave Assy ic OR Ped TAL es ar 360 Degree SPV Schrader Ar Vave Red FATT i hs Complete Shock Body NoHardwereorSping p p P p p p pj S Stock NoFadae 165m Eye to Be S mmTrael B 867120 jazo jeer o7t76 Stock NoFadwae f mmEyetoEye Som Trad B 857121 85 7131 86 7145 857171 86 7177 a6 7188 Stock No Harcnere 200M Eye to De Som Trad B 857122 85 7132 85 7146 857172 86 7178 B7184 Shock NoHardware 215m Eeto Ee armTrad B
7. 857129 7138 7147 8 7178 7179 87185 Stock No Harcnere 222m Eeto Be mm Tad SBS 857134 86 7148 85 7180 857186 857155 Stock No Harcnere 230mm Eeto De Om Tad B Stock No Harcnere 40n Eyeto Be am Trad B Shack No Harcnere 287mm Eyeto Be Gm Tad B 856772 feo7zt5t Jee 87158 Sninger eW Pemate Resevoir Hosekt BE o EN omg SwWrgrOWPemgeFesevirHseF ngKt SB FP OO EE LEE Radium Metel Shock IFP Chamber Pefill Pug B Eck eboundKnob Bw 8392 SwngerdGWFeseworArVolume duser B ee be Swnger4GWFesewdrNoTodsVodureAduster B J F ES CompSpedAdusterKnmobeedesKt B NER EN PENNE Comp Speed Adjuster KnobNeedes Kt O Rings B NEN Swvde o SB p p p o HLOmpessn exmty BS 838014 8304 83 2707 Swinger 6WRemcteResavarSelKt EC ESSE El Z nn ellen Side ET 892247 89 2048 83 2040 83 2050 832058 83 2054 83 2252 83258 2A Spring Petention Collar GY Tes o A po p P p o b p P p b Tod for adjusting SningerAirResevoirVoume EHP are SES Tod for locating Swinger dg epes FHP S MEM TD TD Dison Pinger for Removal of IFP Piston SWrgerCol THY TodfoBeedngSWrgerAr amp Col Resevor Sods HO S J S Det ad Comes Sods LH Duer Qamping 127m Denper ge ul EE Damen Qanpi mDr gent e me SokPump SVRsevir TE Fixture for Qanping Reservoir and Darbar Body Singer Arando Tut Hgh Pressure IFP Tods o H
8. making sure that it is centered on the bushing This will press out the bushing INSTALLATION 1 Place a bushing onto the threaded end of the punch and into the removal tool screw in about half a turn Bushing Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch making sure that it is centered on the bushing and that the bushing is centered to the eyelet This will press in the bushing SECTION 8 RIDE KITS Ride kits Coil Swinger only consist of a replacement spring of a specific spring rate that is firmer or softer depending on the rider s preference Most manufacturers using Swinger Coil shocks vary the stock spring rate that is the standard offering based on frame size Larger frame sized have higher spring rates to accommodate bigger riders Due to the wide variety of frame geometry in use it is left to the rider to determine if they are satisfied with their stock spring rate opring rates and travel stroke are marked on the outside of each spring Example 300 X 2 75 Is a 300lb spring for a 2 75 Travel Shock To change out the coil spring Turn the spring preload adjustment ring to release any preload and back it away from the spring as far as possible Remove the retaining collar Slide spring over eyelet You may need to turn the rebound control knob in clockwise to its fully closed position NOTE Model year 2003 Swingers use a rebound knob that can be removed
9. 85 6192 85 6192 1 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 600 G 85 6675 85 6675 85 6675 J Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate enn amp G 85 6676 85 6676 85 66760 1 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 700 LD 856677 85 6678 O J Z JJ Ee ee ee eee ee eee eee 85 6193 Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 450 ee eee eee Spring for Coil Shock 230 X 70 8 75 or 9 0 X 2 75 Rate 400 Spring for Coil Shock 230 X 70 8 75 or 9 0 X 2 75 Rate 500 85 6679 85ST LD EE G 85 6681 boo Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 150 85 6711 Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 200 Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 250 Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 300 Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 400 GI 85 6199 85199 G 85 6201 P8520 SR oO o 22 2 2 Q uo Ojo A OO Oo o lo berg bg Oo o ojo AIT NIN AA ojo Xx M Oo o REV NC 2007 TI COIL SPRING RIDE KITS Kit Description Coil X3 Coil X4 Coil X6 Coil X3 Coil X4 Coil X6 L BO ECKE e ov isk le Pt Shim SPV Shim SPV CFs en
10. SPV shock install the SPV spring into the damper piston through the rebound adjustment shaft Screw the SPV valve assembly into the top of the damper piston and tighten to 80 inlbs 16 Push the Damper cap Air piston down the damper shaft so that the inside surface of the air piston is even with the hole in the damper shaft You don t want to cover the hole as it will prevent the air from bleeding out of the damper assembly Ze Damper Shaft Hole Air Piston Surface When the air piston is in the proper position relative to the hole your assembly will look similar to this 17 Insert the Damper piston in into the damper bogy It will be helpful to wrap a shop rag around the damper body to catch the overflow in the next couple of steps As you are installing the damper piston and damper cap you will have some air and oil coming up through the center of the rebound adjusting shaft this is normal Tighten down the Air Piston Damper cap to 85inlbs Push the damper shaft down into the damper body until the shaft extends from the top of the damper cap 8 75mm This is measured from the top of the piston to the top of the flange above the threads on the damper shaft This is critical to proper function of the shock but it is better to err on the short side if it is too long you will not get full travel Adjust the rebound adjusting needle until the flange on the needle is flush with the top of the damper shaft by screwi
11. Way Swinger Air Shock No Hardware la E B 3 Way Swinger Coil Shock No Hardware No Coil B 4 amp 6 Way Swinger Coil Shock No Hardware No Coil O O B Low and High Speed Adjuster Kit B Rebound Adjuster Knob Kit 07 MANITOU REAR SHOCK SERVICE GUIDE Page 32 REV NC Swinger Rear Shock Service Kits Description CONT B SPV Air Preload C Seal Kit D Hardware E DU Bushing Kit FFL ec SWINGER SWINGER SPV SPV F Sticker Kit G Ride Kits G Spring Collar G Bottomout Bumper 07 MANITOU REAR SHOCK SERVICE GUIDE Page 33 REV NC aD UAN 06 Swinger Rear Shock Service Kits Description CONT H Swinger Air Reservoir Volume Tool H Swinger Coil IFP Removal Tool H 6 Way Damper Body and Reservoir Clamp F H Rear Shock Compression Test Fixture l H 1 2 Soft Jaws 07 MANITOU REAR SHOCK SERVICE GUIDE Page 34 REV NC H 10mm Soft Jaws 07 MANITOU REAR SHOCK SERVICE GUIDE Page 35 REV NC
12. for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 500 G 85 670 4 85670 85 6705 J J Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 550 G 85 6700 685670 985 670 E Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 600 re 8570 859707 85277 J Spring for Coil Shock 200 x57mm 7875 X225 Rate 650 1 o 5859708 sem 856708 Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 700 c 85 6709 j 3J XS j XJJ J Jj Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 750 85 6710 1 ooo T Ll bL D po p p D p Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 250 85 6186 85 6186 amp 85 6186 Jo o Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 300 Pai 9 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 350 G 85 6188 85 6188 95 6188 1 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 400 G 85 6189 856189 amp X 85 6189 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 450 LD 85 6190 85 6190 55 6190 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 500 G 85 6191 X 85 6191 856191 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 550 amp G 85 6192
13. sure that it is functioning correctly The valve should look like the top picture with a space between the piston and the top plate and should spring open and closed when the two pieces are squeezed together If it has failed it will look like the second picture and when it is squeezed it will not spring back open Pull apart the two pieces of the SPV valve gently clean both the inside of the piston and the out side of the shim head to remove any oil or old grease that maybe on them Lightly grease the o ring with Wacker grease and reassemble the valve and recheck for proper function Set aside for reassembly Remove the SPV Adjustment spring that is inside the damper piston Set aside for reassembly Secure the Damper shaft using shaft clamps and a vice and remove the top cap by unscrewing it counter clockwise You can use an adjustable wrench to turn the cap Remove the Top out bumper and the SPV lockout adjustment needle by pulling it out of the damper shaft Screw the rebound adjustment shaft down so that the flange is just below the top of the damper shaft 13 Thoroughly clean all parts and replace all o rings and seals Reassembling the Swinger 3 Way 14 Lightly grease the seal on the IFP Insert the IFP into the damper body with the cupped side up towards the open end of the body Push the IFP all the way to the bottom of the damper body Fill damper body with 5wt Shock oil to the top of the bore If this is an
14. uses precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage SECTION 2 SETUP TUNING PERIODIC MAINTENANCE Instructions for shock setup tuning and periodic rider maintenance is not covered in detail in this manual Please refer to the Manitou Swinger Rear Shock Owner s Manual PN 042105 for that information If you did not receive a manual you can download one at www answerproducts com or contact Answer Products Customer Service at 661 257 4411 SECTION 3 GLOSSARY OF TERMS Air Canister Can that holds the air spring air in an air shock Air Preload Adjuster Located on the reservoir of SPV shocks It contains the red Schrader valve for setting the SPV pressure and a hex fitting for adjusting the air volume air preload Bottom Out Point at which a shock reaches full compression Control Eyelet C End Eyelet that is on the rebound adjuster end of a shock The air canister is attached to this end on air shocks and the spring retention collar is attached to this end on coil shocks Damper Eyelet D End Eyelet that is on the damper body end of a shock On SPV shocks this is the end that contains the SPV valve and reservoir if applicable Damper Body Section of shock that contains the damping system Damper Piston Piston in that controls the flow of oil during compression and rebound Damper Shaft Shaft attached to the damper piston th
15. 14 To Remove the SPV valve for service clamp the shaft in the vise using the proper size shaft clamps Using a mm wrench loosen the clamp bolt Remove the bolt shim stack piston and the SPV valve Be sure to keep all items in the proper order and orientation Pull apart the two pieces of the SPV valve gently clean both the inside of the piston and the out side of the shim head to remove any oil or old grease that maybe on them Lightly grease the quad seals with Silicone grease and reassemble the valve and recheck for proper function Set aside for reassembly Inspect air can pistons and damper body for excessive or abnormal wear Replace all o rings seals and glide rings Secure the shock eyelet in a vise with the mounting hole for the intrinsic damper up Fill the hole with oil and install the Intrinsic damping control unit If itis an adjustable unit for an X6 be sure that the adjusters are turned out to the lowest settings Turn the shock body so that the damper body is vertical Fill the damper about 3 4 full using the IFP removal tool push oil thru the Intrinsic damping unit into the Reservoir Do this until you no longer see bubbles coming through the port in the bottom of the reservoir Install the bleed bowl and fill the reservoir and bowl with 5wt shock fluid Install the IFP by lowering it into the fluid vertically so no air is trapped in the cavity if the piston Turn the piston 90 degrees and push it into the res
16. 2007 Manitou Rear Shock Service Guide REV NC 2007 Manitou Rear Shock Service Manual Index INTRODUCTION SETUP TUNING PERIODIC MAINTENANCE GLOSSARY AIR SPRING SYSTEM AND SPV AIR PRELOAD SWINGER AIR 05 COMPLETE SHOCK LESS HARDWARE COIL SPRING e HARDWARE REMOVAL AND INSTALLATION DU BUSHING REMOVAL AND INSTALLATION 7 14 1 BOTTOMOUT BUMPER REPLACEMENT SWINGER COIL REBOUND ADJUSTER KNOB REMOVAL AND INSTALLATION SWINGER COIL DAMPING SYSTEM DAMPING SYSTEM BLEEDING SWINGER X3 AIR S TYPE RADIUM SHOCKS DAMPING SYSTEM BLEEDING SWINGER X4 AIR EVOLVER ISX4 ISX6 SPLIT SHOCKS SHIM AND SPV DAMPING SYSTEM BLEEDING REVOX SWINGER X3 X4 X6 2 COIL METAL SHOCKS SHIM AND SPV 15 TROUBLESHOOTING 25 16 TABLE 1 FASTENER TORQUE REQUIREMENTS 27 SWINGER REAR SHOCK SERVICE KITS om Contact Information Answer Products Customer Service Department 28209 Ave Stanford Valencia CA 91355 Toll Free 800 423 0273 Direct 661 257 4411 FAX 661 775 1798 E mail warranty answerproducts com tech answerproducts com Web site www answerproducts com SECTION 1 INTRODUCTION This manual is intended to guide the user through basic service of Manitou Swinger rear shocks Service is supported by the identification of common parts and assemblies that have been assembled into Service Kits The purpose of this manual will be to describe conditions that may drive the need for service and to provide install
17. 6112 85 6112 956112 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 450 Te 85 6113 85 6113 95 6113 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 500 o DET is S 9 9 f Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 550 o RS ESS J v4 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 600 G 85 6671 85 6671 985 6671 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 650 LO ee 66 2 EEE ES SE G 9 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 700 G TP PD j mS Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 750 85 6674 1 Jf ee ee ee eee Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 250 85 6700 85 6700 85670 Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 300 G 85 6701 856701 85 6701 Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 350 G 55702 85702 8572 J Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 400 85 6703 85 6703 985 6708 J Jo Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 450 G 85 6704 85 6704 amp 85 6704 Spring
18. CK SERVICE GUIDE REV NC MANITOU REAR SHOCK TROUBLESHOOTING CHART CONT Section SWINGER AIR S TYPE RADIUM EVOLVER SPLIT Hard Bottomout Air spring pressure Increase air canister air pressure 4 too low Worn bottomout Replace bottomout bumper 14 15 bumper Hard top out Failure of negative Replace air canister and seals spring Air Volume adjuster on 4 Way Swinger has no affect on damping rate Oil leak at base of air canister Damaged adjuster piston o ring Worn or damaged seals allowing oil to escape from damper chamber Replace o ring 15 Replace seals and bleed damping 4 system SWINGER COIL REVOX METAL Spring System Hard bottomout Spring rate too low Replace with firmer spring a Worn bottomout Replace bottomout bumper bumper Hard top out Air in damping system Bleed damping system 12 13 Damping System Oil leak at high and low speed compression adjuster screws Oil leak at damper shaft Worn or damaged adjuster needles oil to escape Worn or damaged seals allowing oil to escape from damper chamber Broken rebound knob User attempted to on coil shocks remove knob during spring replacement Air Volume adjuster Damaged adjuster on 4 or 6 Way piston o ring Swinger has no affect on damping rate 07 MANITOU REAR SHOCK SERVICE GUIDE and or o ring allowing Replace adjuster needle and or o 13 rings Replace seals and bleed damping 12 13 system
19. N 13 INSTRUCTIONS FOR SWINGER X4 EVOLVER 4 6 WAY AND SPLIT REAR SHOCKS SPV AND SHIM STYLES Tools Needed 9mm 1 3mm 6mm Allen wrenches 39mm 10mm wrench 1 3mm Allen wrench 39mm wrench or suitable crescent wrench Release air in the main air spring and remove the Schrader valve Helease the air that is in the IFP chamber and remove this Schrader valve also Remove the air can using a 39mm wrench or a crescent wrench Once the can is free from the top cap slide the can down as far as possible to the damper eyelet Secure the damper shaft in the vise using the appropriate shaft clamps Unscrew the top cap counterclockwise After removing the top cap remove the bottom out bumper and the metal washer also Remove the damper cap using the special socket P N Pull out the damper shaft cap and damper piston as an assembly Pull firmly on the air can to remove it from the damper body The air piston will come off with the air can Remove the piston and top out bumper from the air can If this is a twin tube Evolver Remove the snap ring at the base of the can It is easiest to do this by inserting a small pick into the gap on the ring and lifting one end free of the groove and then just walk the rest of the ring out Once the ring is removed pull the outer can off of the inner can Remove the No Tools Volume adjust by unscrewing it counter clockwise There is no need to disassembly the assembly any further as th
20. OUBLESHOOTING CHART Section ALL SHOCKS Damping System Cannot set pedaling Air loss from SPV Tighten or replace Schrader core platform System SPV or replace Schrader assembly Schrader valve leaks SPV Valve failure Close rebound knob clockwise 12 15 If the shock brise fast after compression the SPV valve may be defective If the rebound is very slow the valve is probably OK Inspect and replace if necessary SPV Schrader valve Interference with Replace Confirm clearance after snapped off at base suspension linkage or Schrader replacement on 3 Way Air and Coil other frame Swingers components Adjusting rebound Air in damping system Bleed damping system 12 15 a has no effect comes out of the oil has o ring on the IFP and 15 SPV Schrader valve leaked past the IFP bleed the damping system Mounting Hardware Play in shock eyelets Worn DU bushing or Replace 6 7 when mounted in bike mounting hardware SWINGER AIR S TYPE RADIUM EVOLVER SPLIT valve leaks or replace S assembly Ee O a Canister a Se Piston Air shock does not Failure of negative Replace air canister and seals return to full travel but spring has adequate air spring pressure Oil comes out of the Damping oil has Replace seals on the damper cap 14 15 Air Spring Schrader leaked past the and bleed the damping system valve damper cap 07 MANITOU REAR SHO
21. The Swinger Air uses compressed air to provide resistance to compression in place of a coil spring You must be certain that the air canister is relieved of all pressure prior to servicing the air system Failure to relieve air pressure could result in injury or possible death Sealing of the shock is accomplished through a series of o rings quad seals and wipers When the air canister is removed these seals can be replaced from Seal Kit C Failure of an air shock to maintain air pressure is usually the result of defective or worn seals If there is suspicion of an air leak pressurize the air canister to 150psi from the adjuster eyelet Schrader Valve and the SPV Air Preload Schrader to 100psi Locate the leak by spraying the air canister and Schrader joints with a mild solution of dish soap and water or submerge in a bucket of water Bubbles will form in from the area of leakage For leaks at the adjuster eyelet or damper end of the air canister refer to the detailed disassembly instructions contained in the section on DAMPING SYSTEM BLEEDING Swinger Air This will guide you on how to replace the applicable o rings and seals For leaks at the Schrader valves release all air pressure and replace the Schrader valve core or assembly as needed The core is removed using a standard core removal tool The assembly is removed by removing the core and unscrewing the assembly by inserting a 3mm hex into the center of the valve
22. X 38 6 5 X 1 5 Rate 450 LD 85 6664 85 6604 85 6600 1 Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 500 1 LD 85 6665 85 6665 85 6666 Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 550 G 85 6666 85 6666 55 66606 S Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 600 amp G 85 6667 85 6667 85 6667 1 Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 650 amp G 85 6668 85 6668 85 6660 Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 700 LD 7856669 S 27 Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 750 cG 85ee70 S 1 1 y 1 o T Ll bL Lo po Dp p D p D Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 250 G 85 6185 85 6185 85 6185 1 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 300 G 85 5491 85554931 55491 l 1 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 350 Te 85 6111 856111 956111 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 400 Te 85
23. at connects the two moving sections damping system and control eyelet of the shock together Damping System Controls compression and rebound rate speed The system also provides the peddling platform unique to shocks with the SPV technology DU Bushing Teflon guide bushing pressed into the eyelets Mounting hardware is inserted into the DU bushings and rotates within the bushing as need by the suspension design Eyelet Found on each end of the shock it is where the DU bushing and mounting hardware are and provides the connection between the shock and bicycle Internal Floating Piston IFP A floating piston that separates damping oil from the SPV air chamber or reservoir Mounting Hardware Spacers that allow shocks to be mounted into the wide variety of suspension designs Schrader Air Black in color it is the valve for pressurizing the air canister in an air shock Schrader SPV Red in color it is the valve for pressurizing the SPV system Seals O Rings Black synthetic rubber with a round cross section Primarily used for fluid sealing Seals Quad Seals Black synthetic rubber with an X cross section primarily used for sealing air Seals Wipers Teflon ring used for keeping debris out of quad seals guiding the damper piston and providing support Top Out Point at which a shock returns to its full extension SECTION 4 AIR SPRING SYSTEM AND SPV AIR PRELOAD SWINGER AIR S Type uL VNbleR
24. ation instructions for the kits Due to the time consuming nature rear shock service at this time our primary focus is to offer service kits that minimize the amount of downtime and labor involved As the program matures and we are able to gather feed back from our customers we may offer kits to a more detailed level Important information is highlighted in this manual by the following notations WARNING Failure to follow WARNING instructions could result in severe injury or death to the person inspecting or repairing the shock absorber or the shock absorber operator CAUTION A CAUTION a caution indicates special precautions that must be taken to avoid damage to the shock absorber NOTE A NOTE provides key information to make procedures easier or clearer Rear shocks by design contain gases and fluids under extreme pressure and warnings contained in this manual must be observed to reduce the possibility of injury or possible death Following these instructions can help you reduce the risk of being injured Any questions in regards to the information in this manual should be directed to Answer Products Customer Service at 661 257 4411 WUER The Swinger Shock uses compressed air to provide fluid pressure in the damping system and spring resistance in Air models BOTH systems must be relieved of pressure prior to servicing these systems Failure to relieve air pressure could result in injury or possible death CAUTION The Swinger Shock
25. by taking out a hex screw Do not attempt to remove the 2004 2005 rebound knobs by unscrewing the E 3mm hex in the knob it will break Retaining Collar Slide the new spring over the eyelet Reinstall the spring collar so that it Spring Preload Adjustment Ring butts against the eyelet and the spring nests in the appropriate groove Turn the spring preload adjustment ring until it contacts the spring and then apply 2mm of preload SECTION 9 BOTTOMOUT BUMPER REPLACEMENT SWINGER COIL 1 Remove hardware as shown under HARDWARE REMOVAL and remove Spring as shown under RIDE KIT Section 2 Release reservoir pressure from the air preload SPV Air Reservoir 4 amp 6W Swinger Coil Extend and clamp damper shaft in a vise using 12 7mm 500 soft jaws Answer PN 85 5148 Remove eyelet using adjustable open end wrench Slip off old bumper Install new bumper Larger diameter face of the bumper should face the eyelet Clean damper shaft threads with alcohol and apply Blue Loctite Install damper shaft in vise using soft jaws as shown above and torque per Table 1 Add air to re pressurize the air preload reservoir per instructions in the Owner s Manual SECTION 10 REBOUND ADJUSTER KNOB REMOVAL AND INSTALLATION SWINGER COIL Instructions in the 2004 Swinger Shock Owners Manual were incorrect when it stated that the rebound knob had to be removed to replace shock springs Turning the knob to its full clock
26. dy Cover the Reservoir with a rag to catch the IFP and any oil which might be trapped to the reservoir Insert the IFP removal tool into the damper body Cover the hole in the tool with your finger and press the tool down firmly into the damper body This will push the piston out of the reservoir If you are servicing an ISX 6 remove the red and black knobs use caution as the detent balls and springs are VERY small Next remove the Intrinsic damping assembly by unscrewing it counter clock wise Pull the assembly out of the damper body Do not disassembly the Intrinsic damping unit as there are no serviceable parts inside and several of the parts are easily lost or damaged 22 6 If this is an ISX 4 use the special penta hex tool P N 83 3236 to remove the non adjustable Intrinsic damping assembly As with the ISX 6 other than the O rings on the out side of the assembly there are no serviceable parts inside the damping unit so do not attempt to disassemble the unit further If you are working on a shim style shock skip to step 10 if this is an SPV shock you need to make sure that the SPV valve is functioning correctly The valve should look like the top picture with a space between the piston and the top plate and should spring open and closed when the two pieces are squeezed together If it has failed it will probably look like the second picture and when it is squeezed it will not spring back open To Remove the SPV valv
27. e the hardware may wear between the mounting bolts or DU Bushing which will result in play in the connection Remove hardware using pliers as shown in Figure 1 DU Bushing Eyelet i d a 2d y Figure 1 Figure 2 MOUNTING HARDWARE REPLACEMENT Hardware should have a slight press fit into the DU bushing and can be tapped in place with a rubber mallet or soft jaws in a vise Apply a small amount of thick grease such as Motorex Bike Grease 2000 PN 85 0033 to the hardware before installation There are virtually an infinite number of hardware combinations in use on bikes today When ordering hardware from Answer Products It will be necessary to identify the eyelet width overall width and mounting hole diameter 1 Measure the hardware width Measure mounting hole size Current hardware is typically designed to accept a 6mm or 8mm fastener SECTION 7 DU BUSHING REMOVAL AND INSTALLATION DU bushings are press fit into the shock eyelets at each end of the shock The hardware fits into the bushings and will rotate slightly within the bushing during suspension compression DU Bushings like hardware may wear over time Removal and installation is accomplished using tool PN 85 6075 REMOVAL 1 Remove hardware from the shock 2 Insert unthreaded end of punch into the removal tool first and screw in about half a turn Punch Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch
28. e for service clamp the shaft in the vise using the proper size shaft clamps Using a mm wrench loosen the clamp bolt Hemove the bolt shim stack piston and the SPV valve Be sure to keep all items in the proper order and orientation for reassembly Pull apart the two pieces of the SPV valve gently clean both the inside of the piston and the out side of the shim head to remove any oil or old grease that maybe on them Check the quad seals for damage and replace if needed Lightly grease the quad seals with Silicone grease and reassemble the valve and recheck for proper function Set aside for reassembly For all shocks clamp the damper shaft in a vise using the shaft clamps Using an adjustable wrench remove the control eyelet by turning it counter clockwise Take care that you do not apply force to the rebound knows as the can be bent or broken After removing the eyelet remove the rebound needle Inspect damper body reservoir pistons and damper shaft for excessive or abnormal wear Replace all o rings seals and glide rings and any other parts that are showing excessive wear 12 Secure the shock eyelet in a vise with the mounting hole for the intrinsic damper up Fill the hole with oil and install the Intrinsic damping control unit If itis an adjustable unit for an X6 be sure that the adjusters are turned out to the lowest settings Turn the shock body so that the damper body is vertical Fill the damper about 3 4 full u
29. ere are no parts to wear in the no tools adjuster Pour out the oil in the damper body Cover the Reservoir with a rag to catch the IFP and any oil which might be trapped to the reservoir Insert the IFP removal tool into the damper body Cover the hole in the tool with your finger and press the tool down firmly into the damper body This will push the piston out of the reservoir If you are servicing an ISX 6 remove the red and black knobs use caution as the detent balls and springs are VERY small Next remove the Intrinsic damping assembly by unscrewing it counter clock wise Pull the assembly out of the damper body Do not disassembly the Intrinsic damping unit as there are no serviceable parts inside and several of the parts are easily lost or damaged If this is an ISX 4 use the special penta hex tool P N 83 3236 to remove the non adjustable Intrinsic damping assembly As with the ISX 6 other than the O rings on the out side of the assy There are no serviceable parts inside the damping unit so do not attempt to disassemble the unit further If this is an SPV shock you need to make sure that the SPV valve is functioning correctly The valve should look like the top picture with a space between the piston and the top plate and should spring open and closed when the two pieces are squeezed together If it has failed it will probably look like the second picture and when it is squeezed it will not spring back open
30. ervoir past the threads Remove the oil above the piston Remove the bleed bowl 17 18 Make sure that the IFP Positioning Tool is in its shortest position Screw it down into the reservoir pushing the IFP into the bore If you are servicing an Evolver with a twin tube grease the two o rings on the inner can with a small amount of silicone grease Reinstall the outer can by sliding it on the inner can be sure that is slid all the way to the end of the inner can Install the snap ring to retail the outer can by pressing it into the groove Makes sure that is firmly seated into the groove you will be able to that it completely seated as the ends of the snap ring will be almost touching Insert the air can installation tool into the damper body Slide the air can over the tool and on to the damper body Next install the top out bumper then remove the Installation tool Install the air piston into the air can and push it all the way down until it seats fully on to the top of the damper body There should be no space between the top of the damper body and the bottom of the air piston Reinstall piston shim stacks and the SPV valve on to the damper shaft tighten bolt to 80inlbs Line the damper cap up so that the inner end of the cap is lined up with the edge of the bleed hole in the damper shaft Fill the damper body with oil 26 Insert the damper piston shaft assembly into the damper body Screw down the t
31. inspect the SPV LEAKS If oil is found to be leaking from the shock the seals and or o rings that seal that suspect joint must be serviced Once the system has lost oil the faulty seals must be replaced and the shock bled to restore the shock to full performance LOOSE DAMPER OR RESEVOIR BODY All Swinger service can be performed without removing the damper or reservoir bodies where they are threaded into a machined casting This joint is bonded in place during final assembly at the factory If either becomes loose during service remove the body and thoroughly clean the threads on each part Apply green Loctite the threads and use the Answer reservoir clamp PN 85 6037 to tighten the bodies SECTION 12 DAMPING SYSTEM BLEEDING SWINGER X3 S TYPE RADIUM AIR SHOCKS WUER The Swinger Shock uses compressed air to provide fluid pressure in the damping system The damping system must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death Tools Needed Disassembling 1 Secure the shock in the vise by clamping the Top Cap eyelet in the jaws of the vise Remove the Schrader valve core form the air spring valve to relief all pressure in the air canister Remove the Air Can from the shock using a 39mm wrench or an adjustable wrench if it is an X3 if itis a Radium or S Type you will need to use a strap wrench to remove the air can It will unscrew in a counter clockw
32. ise direction Hemove MCU bottom out bumper from the Air Can Thoroughly clean out the interior of the can and MCU Replace the glide ring and seals in the end of the canister Set aside for reassembly If you are only solving an air spring leak you do not have to proceed any further go to step 4 Remove the Air pressure and Valve from the HP IFP system You will need to use P N A Remove the cap covering the Schrader assembly B Using the valve adapter and a shock pump release air pressure in the IFP C Remove the Schrader valve core 5 Remove the Damper Cap Air Piston Cap from the damper body Using an adjustable wrench or 14mm wrench Pull damper shaft assembly from the damper body Pour out the oil that is in the damper body 12 SPV Lock out Needle Rebound Adj Shaft Top Out Bumper Remove the IFP by threading in the valve adaptor and using a shock pump to slowly pressurize the chamber which will blow the Piston out of the bottom of the damper body NOTE Be sure to cover the end of the damper body with a shop rag so that the piston and any remaining oil don t shoot across the work area If this is an SPV equipped rear shock remove the SPV valve assembly from the damper piston using a pin wrench or an SPV valve tool P N You will want to insert the tool into the 3 slots in the piston DO NOT try to remove the SPV valve using the Phillips screw in the center of the assembly Check the SPV to make
33. nch torque the air can to 80 inlbs 9Nm If applicable install the detent springs balls and knobs on the Intrinsic Adjuster Make sure that the set screw on the high speed compression knob black knob is lined up with the pocket on the adjuster shaft before tightening it Next install the red lox speed compression knob Charge the air spring and check for proper function of the shock 20 SECTION 14 INSTRUCTIONS FOR REVOX SWINGER COIL METAL REAR SHOCKS WITH SPV OR SHIM DAMPING Tools Needed 9mm 1 3mm 6mm Allen wrenches 21 26mm 28mm or suitable adjustable wrench Manitou Rear Shock Service Tool Kit 1 Turn the Volume adjuster so that it is in position Release the air in the IFP chamber and remove the Schrader valve core Caution If you do not have the adjuster in the number 1 position you will not full discharge the IFP system and risk serious injury if you continue with the disassembly process 2 Remove the No Tools Volume adjust by unscrewing it counter clockwise There is no need to disassembly the assembly any further as there are no parts to wear in the no tools adjuster Make sure that the shock is full extended Clamp the shock in a vise by the damper eyelet Using a 28mm or an adjustable wrench remove the damper cap and shaft from the shock by turning it counter clockwise Drain out as much fluid as possible after pulling the damper assembly out of the shock Pour out the oil in the damper bo
34. ng it in or out 20 Insert the SPV adjusting needle fully into the rebound adjusting needle until the o rings have seated Screw on the Top Cap as snugly as possible Fully extend the damper shaft by pulling up on the Top Cap to the end of the travel Reinstall the high pressure Schrader valve into the IFP chamber port but DO NOT charge the IFP Remove the Top Cap Keep the damper shaft pointed straight up and clamp it in the vise with the clamp shafts Install bottom out bumper and reinstall the top cap using red Loctite Torque the top cap to 85 inlbs Note you may need to turn the Rebound counter clockwise a couple of turns as you are threading the top cap on as it will thread the adjusting needle in due to the detent plate Charge the IFP to 125psi using a standard shock pump Install the small threaded metal cover over the Schrader valve You will need to use components from the HP IFP tool kit for this Install the top out bumper into the air can Side the air can over the damper body Thread the top cap into the air can and tighten to approximately 100inlbs Note It may be helpful to secure the end of the damper eyelet in the vise so that you can pull up the air can up to meet the top cap Reinstall the Schrader core in the air can valve Charge the air spring to 100psi check to make sure that there are no air leaks Check the shock function for lack of rebound or compression damping and dead spots in the travel SECTIO
35. nn ls en EE Ti Spring Coil Shocks 222 or 230 X70 8 75 or 9 0 X 2 75 Rate 300 G Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 350 G Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 400 G Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 450 G Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 500_ Le Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 550 Te Ss SS SS E E E Ti Spring Coil Shocks 240 X76 9 5 X 3 0 Date 200 TG Ti Spring Coil Shocks 240 X76 9 5 X 3 0 Rate 350 TG Ti Spring Coil Shocks 240 X 76 9 5 X 3 0 Rate 400 TG Ti Spring Coil Shocks 240 X76 9 5 X 3 0 Rate 450 G Ti Spring Coil Shocks 240 X76 9 5 X 3 0 Rate 500 GI Ti Spring Coil Shocks 240 X76 9 5 X 3 0 Rate 550 GI Ti Spring for Coil Shock 267 X90 10 5 X 3 5 Rate 250 Jel j p p Ti Spring for Coil Shock 267 X90 105 X 3 5 Ratc300 TG j p pj J Ti Spring for Coil Shock 267 X90 10 5 X3 5 Rate350 e p p pj p p p Ti Spring for Coil Shock 267 X 90 10 5 X 3 5 Date 40 EGE p j p pq pj Ti Spring for Coil Shock 267 X90 105 X 3 5 Ratc400 G p ST 1L 1 1 07 MANITOU REAR SHOCK SERVICE GUIDE Page 31 REV NC Swinger Rear Shock Service Kits Description A Air Canister A Air Valve Assembly B 3 Way Swinger Air Shock No Hardware B 4
36. op cap and torque to 60 70inlbs 27 Insert the rebound preload spring and rebound needle into the damper shaft and then screw on the top cap Using the top cap fully extend the damper shaft Remove the top cap and the rebound needle Next using a 6mm Allen wrench screw the IFP Positioning tool down to the line matching the travel stroke of the shock you are servicing you want the line to just disappear below the top of the flange see the picture below You will have oil come out of the damper shaft as you do this This gives you the final bleed on the shock T E 29 Reinstall the rebound needle bottom out bumper and the bottom out washer Clean the tread of all oil residue ii Clamp the damper shaft in a vise using the 12 5mm shaft blocks Apply blue Loctite to the threads of the damper shaft Screw on the damper cap and to torque it to 110inlbs 12 Nm 19 31 Remove the IFP tool from the reservoir and install the Volume control assembly Torque the assembly to 100inlbs 11Nm Turn the control to the open position this is where the indicator is in the number 1 position this allows the entire volume control to be pressurized On Swinger X4 shocks charge the IFP to 125psi For the Evolver shocks the SPV version is charged to 120psi and the shim version to 150psi The charge pressure is 250psi on the Split shocks Pull the air can up and screw the top cap down Clamp the top cap in the vise and using a 39mm wre
37. sing the IFP removal tool push oil thru the Intrinsic damping unit into the Reservoir Do this until you no longer see bubbles coming through the port in the bottom of the reservoir Install the bleed bowl and fill the reservoir and bowl with 5wt shock fluid Install the IFP by lowering it into the fluid vertically so no air is trapped in the cavity if the piston Turn the piston 90 degrees and push it into the reservoir past the threads Remove the oil above the piston Remove the bleed bowl Make sure that the IFP Positioning Tool is in its shortest position Screw it down into the reservoir pushing the IFP into the bore If you are rebuilding a Revox shock be sure that you fit the IFP extension P N to the Positioning tool before installing it into the reservoir Reinstall piston shim stacks and the SPV valve on to the damper shaft tighten bolt to 80inlbs if it was removed earlier Line the damper cap up so that the inner end of the cap is lined up with the edge of the bleed hole in the damper shaft Fill the damper body with oil Insert the damper piston shaft assembly into the damper body Screw down the top cap and torque to 60 70inlbs Make sure that the shaft isn t moving out as you do this 23 Extend the damper shaft it might be necessary to screw on the top cap so you have something to grip to pull it out with Next using a 6mm Allen wrench screw the IFP Positioning tool down to the line matching the
38. travel stroke of the shock you are servicing you want the line to just disappear below the top of the flange You will have oil come out of the damper shaft as you do this This gives you the final bleed on the shock Reinstall the rebound needle and bottom out bumper Clean the tread of all oil residue Clamp the damper shaft in a vise using the 12mm shaft blocks Apply blue Loctite to the threads of the damper shaft Screw on the damper cap and to torque it to 110inlbs 12 Nm Remove the IFP tool from the reservoir and install the Volume control assembly Torque the assembly to 100inlbs 11Nm Turn the control to the open position this is where the indicator is in the number 1 position this allows the entire volume control to be pressurized On Swinger and Revox SPV shocks charge the IFP to 120psi For the shim versions of the Revox and Swinger coil the charge pressure is 150psi For the metal shocks the IFP charge pressure is 250psi If this is an X6 install the detent springs balls and knobs on the Intrinsic Adjuster Make sure that the set screw on the high speed compression knob black knob is lined up with the pocket on the adjuster shaft before tightening it Next install the red low speed compression knob use a small amount of blue Loctite on the fixing screw Test shock for proper rebound and compression characteristic 07 MANITOU REAR SHOCK SERVICE GUIDE Page 24 REV NC SECTION 15 MANITOU REAR SHOCK TR
39. wise setting is sufficient to provide clearance for removal Removal Hebound Knob 1 Remove control eyelet as shown under Bottom out Bumper Replacement Swinger Coll Remove 1 5mm hex set screw located under the control eyelet with the set screw pointed up Underneath the set screw is a spring and detent ball bearing Turn the eyelet over on a cloth rag and tap the eyelet to dislodge the spring and ball Unscrew the rebound knob from the eyelet Set Screw Installation Set Screw Spring 1 Installation is in reverse order Place a small amount of grease on the ball and rebound knob detents Screw in the knob and place the ball and spring in the set screw hole 2 Apply a small amount of blue Loctite to the set screw threads Screw in the set screw until it is flush with the eyelet Knob Detents Detent Ball SECTION 11 DAMPING SYSTEM The damping system controls compression and rebound rate speed The system also provides the peddling platform unique to shocks with the SPV technology The main conditions requiring service you may encounter in regards to the damping system are leaks a suspect SPV broken rebound adjuster knob or lose damper or reservoir body SPV VALVE INSPECTION If you are unable to achieve the pedaling platform after adjusting the shock per the Owner s Manual you will need to inspect the SPV Follow the instructions under the damping bleeding section for the shock in question in order to
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