Manitou-Answer 2001 X-Vert Service Manual
Contents
1. 21 5 041150 oy 2 16 5 041145 e gt a ELASTOMER 6 13 5 041157 041475 REBOUND PISTON 062562 2 22 041139 26 NY yo SPRING 041152 7 COMP VALVE 041483 7 Se SCREW 062566 Mi A eh en PINS 227 oor 7 a Sky ot 5 24 e 7 a 2 ae ESA 7 Sy a AXLE INSERT 062741 S4 au a gt AXLE 062738 5 18 5 5 030405 4 CARBON FIBER UPPER SHAFT 063092 b PISTON SEAT 062130 8 PAD ASSEMBLY 062628 PAD JELLY BEAN 062586 SELF TAPPING SCREW 041330 ADJUSTER KNOB 062503 TOP CAP 062583 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m No oe Q O RING 1 4 X 3 8 040690 UPPER NEEDLE 062072 O RING 5 32 X 9 32 041130 DETENT SLEEVE 041527 DETENT BALL 040689 AN Oo Q O RING 21 6MM X 2 4MM 040524 oe CROWN STEER LEG ASSEMBLY END CAP 062255 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m ADJUSTER ASSEMBLY 062540 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m RED MCU 041425 7 MCU CONNECTOR 041237 2 7 7 RED MCU 041425 DROP COVER 062626 2 HAND TIGHTEN EEE er SPRING CONNECTOR 041377 2 DROPOUT 061822 2 J Brie ap x 110 LB SPRING 5 875 O RING 0406732. COMPRESSION ROD 062610 COMPRESSION ROD SCREW 268 SN TORQU 269264 INCH LBS 4 TORQUE 1 2 3 5 N m COMP ROD PLUG 041713 perenne REBOUND 041475 2001 X VERT SUPERNOVA FORK 5 LOWER SHAFT ASSEMBLY 062613 BUSHING 8 SEAL DETAIL VALVE NUT 041483 2 1 01170 EXCLUDOR 063044 SPRING SHIM 15MM 041144 2 SPRING SHIM 17MM 041146 SPRING SHIM 18 041147 Q y UPPER BUSHING 0641503 2 X SPRING SHIM 19MM 041148 SPRING SHIM 21MM 041150 Y y REBOUND PISTON 041407 LOWER SEAL 062532 2 5 RING 041733 5 5 041045 2 SPRING 041152 Na PISTON SEAT 062130 LOWER SHAFT 062569 DETENT BALL 040689 N LOWER BUSHING 062145 13MM CLAMP SHIM 041157 16MM CLAMP SHIM 041145 19MM CLAMP SHIM 041149 21MM CLAMP SHIM 041150 15MM CLAMP SHIM 041144 a A ES REBOUND PISTON 062566 O RING 5 32 x 9 32 041130 N gt 5 041139 S LOWER NEEDLE 062570 SPRING 041152 O RING 1 4 3 8 040690 PISTON SLIDE SHAFT 062612 SPIROLOX RETAINER 062393 O RING 041130 2 5 SEAL 062392 SPRING 062600 A A 4 2 END 062580 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m O RING 040673 Y Y p SLIDING PISTON SEAT 062259 19MM SHIM 041148 N 9 Y a 2 2 2 2
3. 062130 LOWER NEEDLE 062570 ey LOWER NEEDLE 062570 X O RING 5 32 x 9 32 041 845 mae O RING O RING 040690 LOWER NEEDLE 062570 DETENT ane SPIROLOX RETAINER 062393 9 SPIROLOX RETAINER 062393 O RING 1 4 X 3 8 2 N 040689 WASHER 062413 WASHER 062413 7 doma SPIROLOX RETAINER 062393 O RING 5 32 x 9 32 041130 gt SHAFT SEAL 062392 END CAP 02560 WASHER LOWER NEEDLE 062133 END CAP 062580 A 6 sine ates SHAFT SEAL a O RING 1 4X 3 8 aa N O RING 040673 4 END ey SPIROLOX RETAINER 062393 REBOUND ELASTOMER 0 A REBOUND ELASTOMER 041462 O O RING 15 16 1 19 WASHER 06241 N Sy CUP WASHER 040691 N SY CUP WASHER 040691 ue SHAFT SEAL 062392 2 O A 5 REBOUND ELASTOMER REBOUND ELASTOMER END 062580 041462 041462 A O RING 040673 ELASTOMER 041462 DAMPER INSPECTION 1 anu RN F wn O uo 9 Inspect the shaft for scratches wear or other obvious damage Inspect the seal gland and end cap seal grooves for damage Inspect shims for permanent bends or damage Inspect all other parts for obvious damage and replace as necessary Replace all seals that have been removed RK INSPECTION Inspect the fork boots for obvious damage Inspect the dust seal for tears wear or damage Replace as needed Inspect the lower and upper bushing for damage to
4. 2 7 LONG 041890 2 ADJUSTER 24 041658 2 2 AXLE 062730 7 pr a DROP COVER 062627 E HAND TIGHTEN COMPRESSION ROD SCREW 060268 gen a COMPRESSION ROD 062568 TORQUE 10 30 INCH LBS TORQUE 1 2 3 5 N m BUSHING SEAL DETAIL FORK BOOT 041544 CC Y UPPER SEAL 062531 UPPER BUSHING 041503 LOWER BUSHING 041504 O RING 5 32 x 9 32 041 LOWER O RING RRN SPIROLOX RETAINER 062393 SHAFT SEAL 062392 END CAP 062580 TORQUE 30 50 INCH LBS 224 TORQUE 3 5 5 6 O RING 040673 REBOUND ELASTOMER 041462 CUP WASHER 040691 REBOUND ELASTOMER 041475 O LOWER SHAFT 062569 DETENT BALL 040689 TITANIUM POST 041396 TORQUE 90 110 INCH LBS TORQUE 10 12 N m DAMPER DROPOUT NUT 041822 O RING DROPOUT NUT ESTRA DAMPER ADJUSTER 041408 5 826 X 409 X 005 SHIM 041139 PISTON SPACER 041045 SPRING 0411 A 2 0621 2001 X VERT SUPER FORK SCHEMATIC DETENT SLEEVE 041527 O RING 1 4 3 8 040690 UPPER NEEDLE 062475 O RING 5 32 X 9 32 041 7 N DETENT BALL 040689 UPPER SHAFT 062474 PISTON SEAT 062130 11MM CLAMP SHIM 041170 15MM SPRING SHIM 041144 21MM SPRING SHIM 041150 REBOUND PISTON 062562 SPRING 041152 BLOW OFF SHIM 0411
5. pee 041730 SHAFT SEAL A SPRING 062600 FORK BUMPER 041726 oo SLIDING PISTON SEAT 062259 2 lt END 062580 y 17MM SHIM 041146 R TRIP AMP Dear TORQUE 30 50 INCH LBSA s 19MM SHIM 041148 Y 24 LOWE LE CLAMP 062522 Or TORQUE 3 5 5 6 y 2 6 1 0 20 SCREW 20MM SHIN 041149 y area O NENE Les ELASTOMER 22 o 041462 21MM SHIM 041150 124 TORQUE 6 7 o REBOUND PISTON 062562 men 2 Na RING 040673 041139 ye RIGHT INNER LEG Pi 54 ARE 27 SMALL Ze SPRING 041152 wet LARGE 062598 ead COMP VALVE 041483 24 see O RING 041130 226 SCREW o ad ADJUSTER ASSEMBLY 062540 2 TORQUE 30 50 INCH LBS 28 TORQUE 3 5 5 6 N m 9670 LEFT INNER LEG 7 Sur SMALL 22324 26 ea a LARGE 062599 7 2 COMPRESSION ROD AXLE 062542 SS 7 y SMALL 062587 LARGE 063011 CONNECTOR 062253 RED MCU 041425 5 X 18MM SHCS 030405 x4 S j END CAP 062255 SY TORQUE 30 50 INCH LBS gt TORQUE 3 5 5 6 REBOUND ELASTOMER E 041462 CONNECTOR 041377 FIBER s LEG ASSEMBLY N N Sy Sl pa COMP ROD FLANGE 041724 AXLE NUT 041710 DROP COVER 062536 DROP COVER 062534 DROPOUT NUT 12 0 DROPOUT NUT 040688 ES ADJUSTER KNOB 041408
6. TRAVEL COIL SPRING TPC PLUS DAMPING SINGLE MRD HOLLOW CROWN 20MM THRU AXLE X VERT CARBON 180MM TRAVEL COIL SPRING TPC PLUS DAMPING DUAL CROWN 20MM THRU AXLE X VERT DC 120MM TRAVEL COIL SPRING TPC PLUS DAMPING DUAL CROWN One last note If you lose this manual or want to take a look at the X Vert Service Manual or MRD Tuning Manual head straight for the web at www answerproducts com or call 661 257 4411 and ask for customer service GENERAL WARNING Bicycling is a hazardous activity that requires that the rider stay in control of his or her bicycle at all times Reading this manual entirely and properly maintaining your bicycle and suspension fork will reduce the possibility of injury or possible death Prior to riding your bicycle you should inspect your suspension fork to ensure that no damage has occurred during the course of riding Do not ride your bicycle if the fork shows any signs of bending cracking leaking or if it is missing any of the originally supplied components Any fall from your bicycle can result in serious injury or even death Following these instructions can 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 ship ment to Answer Products or you may call A
7. and torque the 5MM compression rod screw and dropout nut to between 10 30 inch lb 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft 3 Pop in the damper adjuster knob An O ring holds the knob in place 4 For all X VERT models except the X VERT Carbon slide the skirt of the fork boots over the flange on the upper seal Be sure the lip snaps into the groove 5 Clean the adjuster cap threads and the threads on the inside of the inner leg thoroughly 6 Assemble MCU s springs and connectors with thick grease 7 Install adjuster assembly into inner leg and torque to within 20 and 30 inch lb 2 3 3 5 N m INNER FORK LEGS amp CROWN The inner fork legs and steerer tube are press fitted into the crown and may never be removed Removing them will make the fork unsafe to use Should any slippage occur contact Answer Products Technical Staff immediately at 800 670 7446 NOTE 2001 X VERT outer leg arch is one piece Magnesium casting Thus if it is damaged it must be replaced Using the fork with damage to the outer leg arch casting is unsafe and could cause serious injury Please contact Answer Products if you suspect that your brake outer leg arch is damaged ADJUSTING RIDE QUALITIES All 2001 XVERT TPC forks offer a wide adjustment range to suit individual riding preference and rider weight Fine tuning adjustments can achieved by using the preload adjusters located on top of
8. do not use the cup washer and 2nd elastomer Therefore the first elastomer is used to retain the detent ball Insert into right leg and thread in end cap Torque 30 3 5N m max Compression Damping Assembly 1 2 3 Install all previously removed O rings Apply a small amount of blue Loktite to piston seat threads Reassemble shim stack spacers and pistons in exact order they were removed Next thread the valve nut onto the sliding piston assembly Likewise thread the sliding piston shaft onto the piston seat and torque them both to 12 IN LB 1 2 N M max Then install an O ring and the sliding piston spring onto the sliding piston shaft Slide the sliding piston assembly onto the shaft and then slide another O ring onto the shaft behind the sliding assembly Finally screw the button head cap screw with blue Loktite applied to it into the sliding piston shaft Install compression damping assembly into the right leg Refer to the oil level chart on page 10 to determine the proper oil height X VERT X VERT AIR amp X VERT SUPER X VERT SUPERNOVA COMPRESSION X VERT CARBON COMPRESSION COMPRESSION DAMPING ASSEMBLY 063210 DAMPING ASSEMBLY 062628 DAMPING ASSEMBLY 062611 ADJUSTER KNOB ASSEMBLY N ADJUSTER KNOBYSSEMBLY ADJUSTER ASSEMBLY A J UPPER NEEDLE ASSEMBLY 2 SN DETENT SLEEVE 041527 DEER NEEDEE DETEN TBALL 040089 DETENT SLEEVE 041527 UPPER SHAFT 062146 DETENT BALL 040689 PISTON SE
9. the adjuster cap If the 2001 XVERT is 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 answerproducts neorpeorated 28209 AVENUE STANFORD VALENCIA 91355 661 257 4411 e www answerproducts com 2001 X VERT SERVICE MANUAL P N 85 3693
10. 2001 X VERT SERVICE MANUAL AMERICAN MADE MANITOU SUSPENSION CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE 2001 X VERT FORKS USE MANITOUS PATENTED TPC PLUS TWIN PISTON CHAMBER SYSTEM THAT SURPASSES ALL OTHER TYPES OF OIL DAMPED SYSTEMS IN PERFORMANCE AND DURABILITY X VERT FORKS ALSO USE MANITOUS QUICK AND EASY MICROLUBE SYSTEM WHICH ALLOWS YOU TO LUBRICATE THE FORK VIA AN EXTERNAL FITTING ON THE BACK OF THE FORK ALL MANITOU FORKS COMES EQUIPPED WITH 74MM POST STYLE DISC BRAKE MOUNTS THE X VERT CARBON AND SUPERNOVA USE A 20MM OVERSIZE THROUGH AXLE WHICH 15 COMPATIBLE WITH STANDARD DH HUBS Your X Vert fork is fully assembled and ready to be installed onto your bicycle It comes equipped with a 1 1 8 inch threadless steerer tube is available with a V brake style hanger less arch or there s optional attachable cable hanger which is available through your dealer Manitou does not recommend retrofitting dual crown forks to older bicycle frames or frames not specially built for dual crown forks Dual crown forks may put greater stress on older frames so you should contact the frame manufacturer before installing this style of fork on your bike 2001 X VERT FORK LINE X VERT 105MM TRAVEL COIL SPRING TPC PLUS DAMPING SINGLE CROWN X VERT SUPER 105MM TRAVEL COIL SPRING TPC PLUS DAMPING SINGLE MRD HOLLOW CROWN X VERT AIR 105MM TRAVEL AIR COIL SPRING TPC PLUS DAMPLING SINGLE MRD HOLLOW CROWN X VERT SUPERNOVA 120MM
11. 2568 A ELASTOMER 041475 LEFT LEG END 062255 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m REBOUND ELASTOMER 041475 Nai WASHER 040691 REBOUND ELASTOMER 041475 BUSHING amp SEAL DETAIL 2001 CARBON SMALL amp LARGE PAD ASSEMBLY 062611 PAD JELLY BEAN AN SELF TAPPING SCREW a LOWER SHAFT ASSEMBLY ADJUSTER KNOB 062503 062509 TOP CAP 062583 TORQUE 30 50 INCH LBS VALVE NUT 041483 TORQUE 3 5 5 6 UPPER SEAL 062531 CLAMP SHIM 01170 09 O RING 1 4 X 3 8 RSS UPPER BUSHING 0641503 SPRING SHIM 14MM 041143 PPER N pe LOWER BUSHING 062145 2 X SPRING SHIM 19MM 041148 NE fyi Nene a Sea O y Y DETENT SLEEVE 041527 5 O RING 21 6 X 2 4MM 040524 REBOUND PISTON 062131 DETENT BALL 040689 PISTON RING 041733 UPPER SHAFT 062470 2 PISTON SPACER 062294 PISTON SEAT 62130 5 SPRING 041152 113MM CLAMP SHIM 04117 gt PISTON SEAT 062130 15MM CLAMP SHIM LOWER SHAFT Ea 21MM CLAMP SHIM a BALLA CLAMP SHIM 041144 ASG REBOUND PISTON Pa ae O RING 5 32 x 9 32 041130 2 LOWER NEEDLE 062133 Cay SPRING 7 TEER TUBE O RING 1 4 X 3 8 2 ie SHIM 041 5 er UPPER TRIPLE CLAMP 9 ae SPIROLOX RETAINER 952393 PISTON SLIDE SAS ane 24 gt mm WASHER eat O RING 041130
12. 39 PISTON SLIDE SHAFT 062262 O RING 041130 A SPRING 06241 D 2 Y NEEDLE LOWER SHAFT ASSEMBLY 062561 VALVE NUT 041483 CLAMP SHIM 01170 SHIM 16MM 041145 REBOUND PISTON 041407 DROPOUT SLEEVE 041574 END CAP 062255 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m REBOUND ELASTOMER 041475 CUP WASHER 040691 REBOUND ELASTOMER 041475 OUTER LEG ARCH ASSEMBLY GREASE FITTING 062036 COMPRESSION ROD SCREW 060268 TORQUE 10 30 INCH LBS TORQUE 1 2 3 5 N m REBOUND ELASTOMER 041475 RIGHT LEG 062597 PAD JELLY BEAN 062586 SELF TAPPING SCREW 041330 ADJUSTER KNOB 062503 TOP CAP 062583 7 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m PAD ASSEMBLY 063210 we O RING 21 6MM X 2 4MM 040524 ADJUSTER ASSEMBLY 062540 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m 17MM SHIM 041146 19MM SHIM 041148 SS 20MM SHIM 041149 227 21MM SHIM 041150 a RED MCU 041425 N A REBOUND PISTON 062562 11MM CLAMP SHIM 041170 SPRING 041152 2 COMP VALVE NUT 041483 MCU CONNECTOR 041237 RED MCU 041425 CAP SCREW 062566 CROWN STEER PS y SPRING CONNECTOR 041377 110 LB SPRING 5 875 LONG 041890 MAINTENANCE IMPORTANT Your X VERT fork should not be used if any parts appear to be damaged Please contact your local dealer or Answer Pr
13. 62580 TORQUE 30 50 INCH LBS LOWER SHAFT ASSEMBLY TORQUE 3 5 5 6 N m 063200 O RING 020673 VALVE NUT 041483 CLAMP SHIM 01170 REBOUND ELASTOMER 041475 CUR WASHER 00681 SHIM 15MM 041144 oa SHIM 18MM 041147 REBOUND ELASTOMER 5 21 041150 2 REBOUND PISTON 062562 826 X 409 X 005 SHIM 041139 SPRING 041152 2 5 5 062130 LOWER SHAFT 062569 DETENT BALL 040689 o DROPOUT SLEEVE 041574 BRAKE POST 040921 TORQUE 90 110 IN LBS TORQUE 10 12 N m END CAP 062255 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m REBOUND ELASTOMER 041475 X CUP WASHER 040691 REBOUND ELASTOMER 041475 OUTER LEG ARCH DAMPER DROPOUT NUT 041822 ASSEMBLY O RING DROPOUT NUT 040688 DAMPER ADJUSTER KNOB 2 N 041408 GREASE FITTING 062036 COMPRESSION ROD SCREW 060268 TORQUE 10 30 INCH LBS TORQUE 1 2 3 5 N m DETENT SLEEVE 041527 DETENT BALL 040689 UPPER SHAFT 062474 REBOUND ELASTOMER 041475 PAD JELLY BEAN 062586 SELF TAPPING SCREW 041330 ADJUSTER KNOB 062503 A PAD ASSEMBLY 063210 TOP CAP 062583 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m O RING 1 4 X 3 8 040690 UPPER NEEDLE 062475 O RING 5 32 X 9 32 041 mac SLIDING PISTON SEAT 062259 X 17MM SHIM 041146 19MM SHIM 041148 20MM SHIM 041149 A 21MM SH
14. ANIUM BRAKE POST 041396 TORQUE 90 110 INCH LBS TORQUE 10 12 NGE OUTER LEG ARCH DAMPER DROPOUT NUT 041822 ASSEMBLY O RING DROPOUT NUT DAMPER ADJUSTER 041408 2 Gee FITTING 062036 COMPRESSION ROD SCREW 060268 TORQUE 10 30 INCH LBS TORQUE 1 2 3 5 FORK SCH 11MM CLAMP SHIM RN get ee 15MM SPRING SHIM 04114 21 SPRING 5 Sit SPRING 041152 E Le COMP VALVE NUT EN amp yS EMATIC PAD JELLY BEAN 062586 SELF TAPPING SCREW 041330 ADJUSTER KNOB 062503 ASSEMBLY TOP CAP 062583 063210 TORQUE 30 50 INCH LBS O TORQUE 3 5 5 6 UPPER NEEDLE 062475 Q RY O RING 5 32 X 9 32 041150 N N DETENT SLEEVE a a E O RING 21 6MM X 2 4 040524 UPPER SHAFT 062998 OS O RING 1 4 X 3 8 pe DETENT BALL 940859 A SLIDING PISTON SEAT 062259 17MM SHIM 041146 a 19MM SHIM 041148 20MM SHIM 041149 WS ae 21MM SHIM 041150 1537 REBOUND PISTON 11 CLAMP SHIM 041170 SCREW 062566 062577 SPRING KNOB 062482 Ads RING 062912 ASSEMBLY 061038 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 A 4 AIR SPRING PISTON ASSEMBLY 062478 LEG ASSEMBLY 062663 INCLUDING NEGATIVE SPRING NOT REMOVABLE ar PISTON ROD A ASSEMBLY 063085 x SPRING 063147 COMPRESSION ROD 06
15. AT ASSEMBLY 51 DETENT SLEEVE 041527 DETENT BALL 040689 UPPER SHAFT 062146 PISTON SEAT ASSEMBLY UPPER SHAFT 062476 PISTON SEAT ASSEMBLY SPRING 062419 SPRING 062419 SLIDING HS TONASSEMBLY SLIDING PISTON ASSEMBLY NECE 15222 S ENE PNIU SLIDING PISTON ASSEMBLY AN CAP SCREW 062566 D CAE SEBEN 062566 O RING 041130 N CAP SCREW 062566 N A DROP COMPRESSION ROD INTO INNER FORK LEG FORK BOOTS B SLIDE ON ELASTOMER 8 Compression Rod amp Boots 1 Clean all parts thoroughly 2 Grease compression rod lightly Be sure rebound elastomer is installed onto compression rod 3 Insert the compression rod through the end 4 Slide on a bottom out bumper followed by the cup washer and then another bottom out bumper Note The X CERT DC amp X VERT Carbon do not use the cup washer and 2 elastomer 5 Slide Boots onto inner leg boots not used on the X VERT Carbon F SLIDE FORK BOOT DOWN TO SNAP INTO GROOVE OF OUTER LEG E INSTALL COMPRESSION STACK HAND TIGHTEN ADJUSTER CAP INSTALL amp TORQUE DROPOUT CONNECTORS MUST BETWEEN NUT USE 8MM ALLEN WRENCH Y ALL MCU S amp SPRINGS 10 30 IN LBS POP IN KNOB A SLIDE ON OUTER LEGS UNITL FORK 15 FULLY COMPRESSED INSTALL amp TORQUE 1 COMPRESSION ROD SCREW 10 30 IN LBS Outer Leg Assembly 1 Slide outer assembly onto inner legs and fully compress 2 Install
16. IM 041150 REBOUND PISTON 062562 BS SHIM 041139 ye SPRING 041152 COMP VALVE NUT 041483 CAP SCREW 062566 CROWN STEER INNER LEG 062560 INNER LEG 062560 EN a O RING 21 6 X 2 4MM 040524 ADJUSTER ASSEMBLY 062540 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 RED MCU 041425 MCU CONNECTOR 041237 RED MCU 041425 SPRING CONNECTOR 041377 BUSHING amp S AL D TAIL 2001 AIR FORK BOOT 041544 A UPPER SEAL 062531 UPPER BUSHING 041503 NS BUSHING 041504 REBOUND PISTON 062562 SPRING 2 BLOW OFF SHIM 041 139 PISTON SLIDE SHAFT O RING e aS SPRING 062419 O RING 5 32 x 9 32 LOWER NEEDLE 062570 O RING 040690 SPIROLOX RETAINER Ay SHAFT SEAL 062392 END 062580 ee TORQUE 50 50 INCH LBS pis TORQUE 5 5 5 6 O RING 040673 2 z A Y REBOUND ELASTOMER 041 Ex Y VALVE NUT 041483 CUP WASHER 040691 5 REBOUND E 2 S we CLAMP SHIM 01170 5 u L 2 041473 5 16 570 REBOUND 5 041407 27826 X 409 X 005 SHIM 041139 Pe PISTON SPACER 041045 SPRING 041152 x Ya ae PISTON SEAT 0621 WA LOWER 5 062569 Ss DETENT BALL 040689 LOWER 5 ASSEMBLY 062561 DROPOUT SLEEVE 041 574 TIT
17. MO MINIMUMSPELING Curso de 105 mm 105 mm Curso de 120 mm 120 mm Curso de 180 mm 180 mm N 2 7 Forcelle con corsa da 105 mm 105 mm Forcelle con corsa da 120 mm 120 mm Fork Installation 1 Remove the old fork from your bicycle 2 Measure and cut the steerer tube to fit your bicycle head tube You can use your old fork as a guide to how long you should cut the steerer tube 3 Remove the headset crown race from the old fork and press onto X VERT steerer until the race is seated over the crown Clean and grease the headset bearings and races Install the lower bearings if applicable on fork crown race Insert the steerer tube into the head tube of the frame Install the upper bearings stem spacers and stem Install the stem cap and bolt Tighten the bolt to headset manufacturer s specifications Install the handlebars and the torque stem pinch screws or stem clamping system to manufacturer s specifications 10 Install the brakes and adjust per the manufacturer s instructions 11 Position the X VERT CARBON dual crown fork steerering stop bumpers to prevent frame damage 12 For all X VERTS except X VERT CARBON and X VERT SUPERNOVA adjust the 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 to manufacturer s specificati
18. NG ASSEMBLY 85 9075 2001 X VERT CARBON REBOUND DAMPING ASSEMBLY 85 9074 2001 X VERT X VERT SUPER X VERT SUPERNOVA amp X VERT CARBON PRELOAD ADJUSTER ASSEMBLY 85 9073 2001 X VERT SUPERNOVA RED STICKER KIT 85 4139 2001 X VERT SUPER RED SITCKER KIT 85 4137 2001 X VERT AIR RED STICKER KIT 85 4136 2001 X VERT AIR BLUE BLACK STICKER KIT 85 4135 2001 X VERT RED STICKER KIT 85 4134 2001 X VERT BLACK STICKER KIT 85 4133 X VERT AIR FORK PUMP 85 4069 2001 X VERT SUPERNOVA amp X VERT CARBON BUSHING amp SEAL KIT 85 4057 2001 X VERT X VERT AIR amp X VERT SUPER BUSHING amp SEAL KIT 85 3828 2001 MRD TUNING MANUAL 85 3696 2001 X VERT AIR CAP PISTON KIT 85 3033 2001 X VERT SUPERNOVA COMPRESSION DAMPING ASSEMBLY 85 3031 2001 X VERT SUPERNOVA REBOUND DAMPING ASSEMBLY 85 3029 2001 X VERT REBOUND DAMPING ASSEMBLY 85 3026 2001 X VERT SUPERNOVA ALLOY STEERER LEG ASSEMBLY 85 3025 PREP M GREASE 85 3010 BUSHING amp SEAL DETAIL 2001 X VERT FORK SCHEMATIC FORK BOOT 041544 a Y UPPER SEAL 062531 UPPER BUSHING 041503 PISTON SEAT 062130 11MM CLAMP SHIM 041170 15MM SPRING SHIM 041144 21MM SPRING SHIM 041150 REBOUND PISTON 062562 SPRING 041152 BLOW OFF SHIM 041139 LOWER BUSHING 041504 PISTON SLIDE SHAFT 062262 O RING 041130 SPRING 062419 A 9 O RING 5 32 x 9 32 041 SIN LOWER NEEDLE 062570 O RING 040690 SPIROLOX RETAINER 062393 SHAFT SEAL 062392 END CAP 0
19. ROA BOULONS SERRAGE Instala o do canalete 2 DU COTE DROIT BULLONI DI SERRAGGIO DI DESTRA RECHTER KLEMBOUTEN PARAFUSOS DIREITOS on TN DE APERTO LEFT PINCH BOLTS BULLONI DI SERRAGGIO LINKE KLEMMSCHRAUBEN ISI PERNOS DE PRESION LINKER KLEMBOUTEN _ IZQUIERDOS PARAFUSOS ESQUERDOS BOULONS A SERRAGE DU DE COTE GAUCHE E FORK MODEL MINIMUM CLEARANCE GABELMODELL MINDESTABSTAND MODELO DE HORQUILLA ESPACIO LIBRE MINIMO Tire cl MODELE DE FOURCHE JEU MINIMUM VORKMODEL MINIMUMSPELING 9 Rei fenabstand MODELO DO GARFO FOLGA M NIMA Espacio libre de la cubierta Distance arceau pneu 105 mm travel forks 4 14 105 mm fe 120 mm travel forks 4 73 120 mm Spazio libero del pneumatico 180 mm travel forks 7 10 180 mm Bandspeling Gabel mit 105 mm Auslenkung 105 mm Folga do pneu Gabel mit 120 mm Auslenkung 120 mm 6 Gabel mit 180 mm Auslenkung 180 mm ATAN Horquillas con recorrido de 105 mm 105 mm Horquillas con recorrido de 120 mm 120 mm Horquillas con recorrido de 180 mm 180 mm N Fourches ayant une course de 105 mm 105 mm Fourches ayant une course de 120 mm 120 mm Fourches ayant une course de 180 mm 180 mm Forcelle con corsa da 180 mm 180 mm MINIMUM CLEARANCE MINDESTABSTAND Loop van 105 mm 105 mm ESPACIO LIBRE MINIMO Loop van 120 mm 120 mm JEU MINIMUM Loop van 180 mm 180 mm SPAZIO LIBERO MINI
20. e removed from the bicycle for general disassembly or cleaning Furthermore it is not necessary to disassemble your fork to service the spring stack or to change the oil height You may service the spring stack by removing the adjuster assembly as shown in Figure 12 Step 1 REMOVE ADJUSTERS AND FULLY COMPRESS FORK LEGS TO KEEP COMPRESSION RODS FROM TURNING POP OUT KNOB REMOVE NUT USE 8MM ALLEN WRENCH REMOVE COMPRESSION ROD SCREW USE 5MM ALLEN WRENCH PULL DOWN TO REMOVE OUTER FORK LEG UNIT Removal of outer leg Figure 11 1 Use a 4MM Allen wrench to remove the M5 lower compression rod screw from the left leg side 2 Pop out the damping adjuster knob from the right side a small screwdriver may be helpful Use an 8MM allen wrench to remove the dropout nut it may be helpful to compress the fork to prevent the compression rod and damper shaft from turning while removing these screws 3 Pull the outer leg assembly off the inner legs and crown assembly Remove the fork boots 5 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 Note It is not recommended to remove the dust arn seal every time the fork is disassembled The seal and bushings be cleaned and greased place 1 Unscrew and remove the spri
21. han USA should contact their dealer or local distributor INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your X VERT first The steerer tube may need to be cut to length to fit your bicycle head tube If you are not familiar with this procedure or do not have the proper tools to cut the steerer tube it is recommended that you seek a dealer with a qualified bicycle mechanic to perform installation WARNING 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 steererer assembly must be done to change steerer tube lengths or diameters Removing and replacing the steerer tube or stanchions will result in an unsafe condition and should never be done Axle and hub installation Montaggio dell assale Einbau der Achse und Nabe mozzo CROWN RACE Instalaci n del eje y Installatie van as en naaf Race Installation GABELBRUCKEN Installation de l axe et Instala o do eixo e do Einbau des Steversatzringes STEUERSATZRING du moyeu cubo Instalaci n del anill ANILLO DE RODADURA 8 e rodadura CONE DE JEU DE DIREC RIGHT PINCH BOLTS AXLE ASSALE nstallahon du eu de direction TION RECHTE ACHSE AS Montaggio dell anello della testa ANELLO DELLA TESTA 4 EIXO Installati loopri Ts KROONLOOPRING PRESI N DERECHOS whe 5 van CANALETE DA CO
22. ing the proper oil level in your TPC Plus equipped fork is critical TPC Plus is located in the right leg of your X VERT fork Se Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel and may cause damage to the system and one create an unsafe riding condition Finish reading this entire section FROM TOR OF ROVAN prior to altering the oil level le es A MAXIMUM L RECOMMENDED To check the oil level remove the compression damping assembly located in the top of the right leg Leave the left side spring stack in place to keep the fork fully extended Use a tape measure or dip stick to determine the oil level It is recommended that you replace your oil at least once during the season or twice if it has been contaminated with dirt mud or other substance Use SAE 5WT Maxima fork oil or equivalent Refer to Figure 10 for the recommended oil level or for a specific fork models refer to table 2 MINIMUM E OIL LEVEL TABLE 2 Fork Model Recommended Maximum Minimum X Vert 3 75 95 3 50 89mm 4 00 102mm X Vert Air 3 75 95 3 50 89mm 4 00 102mm X Vert Super 3 75 95 3 50 89mm 4 00 102mm X Vert Supernova 4 50 114mm 4 25 108mm 4 75 120mm X Vert DC 8 00 203mm 10 0 254mm 9 00 229mm X Vert Carbon 8 00 203mm 7 00 178mm 9 00 228mm GENERAL DISASSEMBLY NOTE Your fork does not need to b
23. ke 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 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 TROUBLE SHOOTING Fork seems to top out has slight clunking feel when front wheel comes off the ground Excessive preload or insufficient rebound damping will result in a top out Select MCU s that better fit your weight and riding style having the preload adjuster set mid to low range and increase the rebound damping to eliminate top out The fork feels less active and is not getting the travel it used to when it was new Chances are that the fork is developing stiction Clean and recharge your fork with Manitou prep M grease 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 normal on all 2001 Manitou forks 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
24. n addition helpful information can be found on the Answer Products website at www answerproducts com where you may download manuals and e mail us for technical support DESCRIPTION PART NUMBER 2001 X VERT CARBON X FIRM RIDE KIT 85 9236 2001 X VERT SUPERNOVA X FIRM RIDE KIT 85 9235 2001 X VERT SUPERNOVA BLACK OUTER ASSEMBLY 85 9234 2001 X VERT SUPERNOVA FIRM RIDE KIT 85 9229 2001 X VERT CARBON SOFT RIDE KIT 85 9228 2001 X VERT SUPERNOVA SOFT RIDE KIT 85 9227 2001 X VERT AIR X FIRM RIDE KIT 85 9226 2001 X VERT amp X VERT SUPER X FIRM RIDE KIT 85 9225 2001 X VERT AIR ALLOY STEERER LEG ASSEMBLY 85 9215 2001 X VERT SUPER ALLOY STEERER LEG ASSEMBLY 85 9214 2001 X VERT AIR FIRM RIDE KIT 85 9190 2001 X VERT AIR SOFT RIDE KIT 85 9189 2001 X VERT X VERT AIR amp X VERT SUPER RED OUTER ASSEMBLY 85 9144 2001 8 X VERT SUPER SOFT RIDE KIT 85 9100 2001 8 X VERT SUPER FIRM RIDE KIT 85 9099 2001 5 ASSEMBLY 85 9096 2001 X VERT X VERT AIR amp X VERT SUPER BLUE OUTER ASSEMBLY 85 9093 2001 X VERT X VERT AIR amp X VERT SUPER BLACK OUTER ASSEMBLY 85 9091 2001 AIR amp X VERT SUPER REBOUND DAMPING ASSEMBLY 85 9084 2001 X VERT X VERT AIR 8 X VERT SUPER COMPRESSION DAMPING ASSEMBLY 85 9084 2000 X VERT CARBON FIRM RIDE KIT 85 9080 2001 X VERT CARBON BLACK OUTER ASSEMBLY 85 9077 2001 X VERT CARBON 5 KIT 85 9076 2001 X VERT CARBON COMPRESSION DAMPI
25. ng adjuster assembly 2 Unscrew the end cap from the left inner leg and pull the compression rod out of the inner leg Lower Shaft Disassembly Figure 13 Note Lower Shaft removal disassembly is best done with the fork removed from the bicycle A REMOVE BOTTOM ELASTOMER Disassembly of the damping assembly is not ELASTOMER CUP WASHER AND ELASTOMER required unless you want to modify or replace the shim stack 1 Unscrew and remove the TPC compression damping assembly from the top of the right leg and discard the oil appropriately 2 Unscrew the end cap and pull the lower shaft assembly out of the inner leg Remove the bottom out elastomers and capture the 1 8 diameter detent ball The adjuster needle may be unscrewed and removed from the shaft However this is not recommended Remove the valve nut to change the shim stack It is recommended that you write down the order of the factory specified shim stack and spacers before you begin revalving Thus you will always be able to easily revert to the factory set up Unscrew the compression damping adjuster until it stops Do not remove the shaft from the cap because the threads are bonded to prevent leaking Unscrew the button head screw from the bottom of the assembly Remove the O ring floating piston assembly and spring You may disassemble the floating piston assembly to modify the shim stack However it is recommended that you use the precautions menti
26. nswer at 661 257 4411 to have your fork shipped directly IMPORTANT X VERT fork is an off road fork and as such does not come with proper reflec tors 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 you have questions regarding C P S C Standards or would like to purchase reflector bracket kit Part Number 85 3674 contact your dealer 1 Never remove or have the steerer tube or stanchions inner legs removed from the crown The steerer tube and stanchions are press fit into the crown at the factory Pressing them out will permanently damage the crown steerer tube and stanchions beyond repair and thus render them unsafe for any further use 2 Never attempt to thread a threadless steerer tube Machining threads will weaken the steerer tube and cause an unsafe condition The only safe alternative is to obtain the proper crown steererer from your dealer 3 Any other alterations or modifications to your fork should be considered unsafe Please contact Answer Products technical support at 661 257 4411 for safety information prior to modifying your fork in any way 4 Do not use your Manitou fork if any part appears to be broken bent cracked or damaged in any way Contact your dealer or Answer Products technical support 661 257 4411 if you have any q
27. oducts for replacement parts IMPORTANT Use of fork boots is required to keep your X VERT fork performing well and the warranty in effect Use of this fork without boots will shorten the life of the fork decrease the time between maintenance intervals reduce the performance and void the warranty The only exception is a fork that is sold by Answer from the factory without boots Your X VERT fork requires periodic maintenance cleaning and inspection This is because moisture and contaminants may build up inside the fork depending on the severity of the riding conditions To maintain top performance it is recommended that the fork be periodically disassembled cleaned dried and re greased using Microlube grease ports located on the back of each outer leg IMPORTANT When lubricating the fork with grease through the grease port it is important to note the grease is being forced between the upper and lower bushings If the area is overfilled the force of the grease may force the upper bushing and dust seal out You should only insert grease to the level at which stiction is no longer felt 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 the entire fork for any obvious damage 3 Check headset adjustment 4 Ensure the front brake cable is properly seated in the cable retainer amp verify proper brake adjustment IMPORTANT Maintain
28. oned in the instructions for disassembly of the lower shaft assembly 10 Remove either the floating piston shaft or the piston seat following the instructions above for the lower shaft assembly X VERT LOWER SHAFT ASSEMBLY X VERT SUPER 062563 LOWER SHAFT ASSEMBLY 062561 LOWER SHAFT ASSEMBLY 062506 X VERT CARBON Waive 0 489 LOWER SHAFT ASSEMBLY VAVE NIT w VALVE NUT 041483 062509 CLAMP SHIM 01170 CLAMP SHIM 011 5 15 041144 5 15 041144 REBOUND SHIM 17mm 041 VALVE NUT 041483 SHIM 18MM 041 ey oe 197 CEAME SHIM 01 ON CLAMP SHIM 01170 SHIM 20MM 041 SHIM 15MM 041 SHIM 21 041150 5 18 041147 REBOUND PISTON 062562 REBOUND PISTON 062562 Said spun OMITA yA PANE SAMIM OA tae 826 X 409 005 SHIM 9 826 X A09 X 005 SHIM y 1 21 041150 yY SPRING SHIM 18MM 041147 SPRING 041152 SPRING 041152 2 X SPRING SHIM 19MM 041 es PISTON SEAT 062130 PISTON SEAT 062180 PISTON SPACER CERNE 5 SPRING 0411 ae SPRING SHIM 21MM 041150 LOWER SHAFT 062569 LOWER SHAFT 062569 PISTON SEAT 062130 REBOUND PISTON 062131 DETENT BALL DH PISTON RING 041733 040689 040689 LOWER SHAFT ESN AN PISTON SPACER 062294 O RING 5 32 x 9 32 041130 N OFRING 1041 N aoee SPRING 041152 A Sd 9 32 5 5
29. ons Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock 13 For the X VERT CARBON and X VERT SUPERNOVA lightly pinch the thread axle sleeve in the left dropout Install the through axle and hub Tighten the axle until it bottoms 60 to 90 in lbs 6 8 5 6Nm Push the fork up and down to find the center position and torque the right dropout pinch bolts to 30 to 50 in lbs 3 4 5 6 NM 14 Install the brake cable per manufacturer s instructions ON DU RK Note 2001 X VERT X VERT AIR X VERT DC AND X VERT SUPER forks are equipped with a secondary catch dropout The X VERT CARBON and X VERT SUPERNOVA forks are equipped with a oversize 20mm through axles that are compatible with standard DH hubs WARNING When installing wheel or any new tire check the minimum tire clearance Measure from the highest point on the tire to the bottom of the crown The minimum clearance allowed for 105MM travel fork models is 4 25 108 0MM for 120MM travel fork models is 4 84 123MM and for 180MM travel fork models is 7 20 183MM Any less clearance can result in accident resulting in serious injury or death Figure 2 SPARE PARTS 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 661 257 4411 8 00 AM to 5 00 PM Pacific Standard time Monday through Friday I
30. the Teflon coating Replace using the bushing removal and replacement kits if necessary Inspect all MCU s amp springs for obvious damage Replace as necessary Inspect the preload adjuster and connectors Replace if damaged Check the outer legs for nicks or deep gouges on the outside and inside Replace if damaged Check the inner legs for deep gouges or any other obvious damage Slight wear resulting in a color change is not detrimental to the gold anodized surface Replace the crown leg assembly if wear is excessive or if it is damaged Check inner legs at the bottom of the crown for cracks or for flaking of the anodizing Replace crown leg assembly if cracked or if gold anodize is beginning to flake Check the crown for cracks Replace if cracked REASSEMBLY 1 hh 8 Install all previously removed O rings and seals Lightly grease all seals with seal grease Apply a small amount of blue Loktite to piston seat threads First reassemble shim stack spacers and piston in exact order they were removed Next thread the valve nut onto the piston seat and torque it to 12 IN LB 1 2 N M max 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 Slide an elastomer onto the shaft followed by the cup spacer Next place the detent ball in its hole and slide another elastomer over it Note X VERT DC 8 X VERT Carbon
31. the fork crown NOTE 98 and newer X VERT model forks use a spring stack in only leg the MCU s and springs used in previous Manitou forks are NOT interchangeable Spring Stack Fine Tuning Fine tuning adjustments to the spring rate are made by rotating the left adjuster knob located on top of the crown Rotating the knob clockwise will firm the ride by adding preload to the spring stack Likewise rotating the knob counter clockwise will soften the ride Compression Damping Fine Tuning Fine tuning adjustments to the compression damping are made by rotating the right adjuster knob located on top of the crown Rotating the knob clockwise will increase damping whereas rotating the knob counter clockwise will reduce damping Excessive compression damping will give you a harsh ride over high speed bumps but will feel good during slower speed fork compression Furthermore insufficient compression damping will allow the fork to bottom out in large hits and could cause the fork to bob a little while climbing but feel plush on the sharp hits A correctly adjusted fork will perform good in all conditions Rebound Damping Fine Tuning To adjust the rebound damping simply rotate the rebound damping knob located on bottom of the right leg Rotating the knob clockwise will increase the damping whereas rotating the knob counter clockwise will reduce the damping Excessive rebound damping will give you a harsh ride over repetitive bumps li
32. uestions 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 stanchions and outer leg dropout and brake arch areas for cracks or damage Before every ride check to ensure the proper preload exists 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 will be repaired or replaced at the option of the manufacturer free of charge when received at the factory freight prepaid This warranty does not cover breakage bending or damage that may result from crashes or falls This warranty does not cover any fork that has been subject to misuse or whose serial number has been altered defaced or removed This warranty does not cover paint damage Any modifications made by the user will render the 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 t
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