2004 SERVICE MANUAL Manitou Q shocks
Contents
1. 3 Insert eyelet into tool 4 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 04 Q SHOCK SERVICE MANUAL Page 7 PN 042132 REV NC SECTION 7 AIR CANISTER WANTS Manitou Q Air Shocks use 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 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 the location can be isolated by spraying the air canister joints with a mild solution of dish soap and water Bubbles will form in from the area of leakage You can also immerse the shock in water to locate the leak Sealing of the shock is accomplished through a series if o rings quad seals and wipers When the air canister is removed these seals can be replaced from Seal Kit C Seal Descriptions O Rings Black synthetic rubber with a round cross section Used for fluid sealing Quad Seals Black synthetic rubber with an X cross section used for sealing air Wipers White Teflon used for keeping debris out of quad seals 1 For leaks at the adjuster eyelet or damper Adjuster Eyelet Schrader end of the air canister refer to th2. Q QR QRL A 410 A 420 A 430 Air Canister Regular Mount 25mm Travel 1 00 85 4461 85 4462 Regular Mount 32mm Travel 1 25 A 85 6035 85 4463 Regular Mount 38mm Travel 1 5 A 85 6036 85 4464 Regular Mount 50mm Travel 2 0 A 85 6037 Schrader Valves Q amp QR Air Canister Schrader Valve Assy Black A 85 4400 QRL Air Canister Schrader Valve Assy Black A 85 4407 Complete Shock Without Hardware 152mm Eye to Eye 32mm Travel B 85 6128 85 6133 85 6140 165mm Eye to Eye 38mm Travel B 85 6129 85 6134 85 6143 190mm Eye to Eye 50mm Travel B 85 6131 85 6138 85 6144 200mm Eye to Eye 50mm Travel B 85 6132 85 6139 85 6145 Q Shock IFP Chamber Refill Plug B 85 5436 Seal Kit C 85 6054 Mounting Hardware Kits D Contact Answer Products Hardware Bushing Kit E DU Bushing 85 6105 Sticker Kit F Sticker Kit Q Shock F 85 4402 Sticker Kit QR Shock F 85 4403 Sticker Kit QRL F 85 4404 Sticker Kit Q QR QRL Trunion Shock F 85 4405 Tools H DU Bushing Tool H 85 6075 Fixture to Hold and Compress Shocks H 85 3008 Shock Pump Air Canister H 85 4069 04 Q SHOCK SERVICE MANUAL Page 14 PN 042132 REV NC 2004 Q REAR SHOCK SERVICE KITS DESCRIPTION A Air Canister B Q Shock No Hardware C Seal Kit D Hardware E DU Bushing Kit 04 Q SHOCK SERVICE MANUAL Page 15 PN 042132 REV NC F Sticker Kit H DU Bushing Tool 04 Q SHOCK SERVICE MANUAL Page 16 PN 042132 REV NC
3. Can that holds the air spring air in an air shock 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 Damper Eyelet D End Eyelet that is on the damper body end of a shock Damper Body Section of shock that contains the damping system Damper Shaft Shaft attached to the damper piston that connects the two moving sections damping system and control eyelet of the shock together Damping System Controls compression and rebound rate speed 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 damping system air chamber Lockout Found on QRL shocks The Manitou lockout significantly increases the amount of load required to compress the shock The lockout does not prevent compression under load only increases the amount of load required to compress the shock Mounting Hardware Hardware that allows shocks to be mounted into the wide variety of suspension designs Schrader Air Black in color it is the valve for p
4. UAL Page 10 PN 042132 REV NC AIR CANISTER REMOVAL AND SEAL SERVICE CONT 7 Slide air canister over the damper body 8 Lightly grease the air canister threads and inside the canister Screw the air canister into the canister eyelet Due to pressure in the damping system it may be difficult to compress the shock enough to thread the canister onto its eyelet If necessary the shock test fixture can be used SECTION 9 DAMPING SYSTEM CAUTION The Q Shock uses compressed air to provide fluid pressure in the damping system and spring resistance These systems must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death Q Shock damping system service requires special tooling and training that is unavailable at this time In cases where it is suspected that there is air in the damper or the damper body is leaking oil the shock should be replaced 04 Q SHOCK SERVICE MANUAL Page 11 PN 042132 REV NC SECTION 10 Q SHOCK TROUBLESHOOTING CHART Symptom Schrader valve snapped off at base Air loss from air spring Air shock does not return to full travel but has adequate air spring pressure Hard top out Hard Bottomout Damping Oil Leaks Oil leak at base of air canister Oil comes out of the Air Spring Schrader valve Damping System Performance Adjusting rebound knob has no effect Lockout does not work Mounting H
5. ardware Play in shock eyelets when mounted in bike 04 Q SHOCK SERVICE MANUAL Interference with suspension linkage or other frame components Air spring Schrader valve leaks Solution Replace Confirm clearance after Schrader replacement Tighten or replace Schrader core or replace Schrader assembly Service Section Seal failure on Air Canister Replace seal s Seal failure on Air Piston Failure of negative spring Failure of negative spring Air spring pressure too low Worn or damaged seals allowing oil to escape from damper chamber Damping oil has leaked past the damper cap Air in damping system Air in damping system Low IFP pressure Worn DU bushing or mounting hardware Replace seal s Replace air canister and seals Replace air canister and seals Increase air canister air pressure Replace shock Replace shock Replace shock Replace shock Replace Page 12 8 8 4 4 4 5 6 PN 042132 REV NC SECTION 11 TABLE 1 FASTENER TORQUE REQUIREMENTS Feature Torque Swinger Air Air Canister 15 24KgCm 13 21inlbs Schrader Valve Stem 5 10 KgCm 4 to 9 inlbs 04 Q SHOCK SERVICE MANUAL Page 13 PN 042132 REV NC SECTION 12 2004 Q SHOCK SERVICE KITS Kit Description Kit Q
6. e detailed disassembly instructions below 2 For leaks at the Schrader valve release all air pressure and replace the Schrader valve core or assembly as needed 3 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 Shock in Shortest Travel Position travel Depress the adjuster eyelet Schrader while the shock is extended under load If it remains in the full travel position refer to the detailed disassembly instructions below for instructions on servicing the air canister and piston seals 5 4 Ifthe shock returns to the short travel position it is not serviceable and the entire shock must be replaced Extend to long travel and depress the air WANNA Attempting to service a canister Schrader Valve shock with this condition could result in injury or possible death 04 Q SHOCK SERVICE MANUAL Page 8 PN 042132 REV NC SECTION 8 AIR CANISTER REMOVAL AND SEAL SERVICE 1 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 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 f
7. mantou 2004 SERVICE MANUAL Manitou Q shocks 28209 Avenue Stanford Valencia California 91355 661 257 4411 fax 661 294 4179 www answerproducts com 04 Q SHOCK SERVICE MANUAL INDEX Section Description Page 1 INTRODUCTION 3 2 SETUP TUNING PERIODIC MAINTENANCE 3 3 GLOSSARY 4 4 COMPLETE SHOCK LESS HARDWARE 5 5 HARDWARE REMOVAL AND INSTALLATION 5 6 DU BUSHING REMOVAL AND INSTALLATION 6 7 AIR CANISTER 8 8 AIR CANISTER REMOVAL AND SEAL SERVICE 9 9 DAMPING SYSTEM 11 10 TROUBLESHOOTING 12 11 TABLE 1 FASTENER TORQUE REQUIREMENTS 13 12 Q SHOCK SERVICE KITS 14 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 04 Q SHOCK SERVICE MANUAL Page 2 PN 042132 REV NC SECTION 1 INTRODUCTION This manual is intended to guide the user through basic service of Manitou Q 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 installation 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 minimi
8. ressurizing the air canister in an air shock 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 04 Q SHOCK SERVICE MANUAL Page 4 PN 042132 REV NC SECTION 4 COMPLETE SHOCK LESS MOUNTING HARDWARE The highest level kit offered will be a complete shock without mounting hardware These kits are offered as a fast replacement where all that is need is to change out the hardware or damping unit Q Shock Less Mounting Hardware SECTION 5 HARDWARE REMOVAL AND INSTALLATION Mounting hardware is used to mount shocks to the various frame configurations Over time 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 Figure 1 Figure 2 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 combina
9. rom the area of leakage 2 Release All air pressure from air canister Remove hardware as shown under HARDWARE REMOVAL AND INSTALLATION 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 Air release Schrader valve 3 Place adjuster eyelet in a vise using soft jaws Using a rubber strap wrench to prevent damage loosen the air canister completely 04 Q SHOCK SERVICE MANUAL Page 9 PN 042132 REV NC AIR CANISTER REMOVAL AND SEAL SERVICE CONT 4 Slide air canister away from the canister eyelet and remove Do not remove the damper cap The damper system is under extreme pressure Removal of the damper cap without releasing damper system pressure will result in the possibility of injury or possible death Damper Cap DO NOT REMOVE 5 Replace o rings seals and wipers in the air canister and air piston Air Canister Kit A will have new seals installed as part of the kit Also replace the o ring inside the canister eyelet O Ring Seal Wiper Locations 6 Lightly grease the air piston damper body air canister seals and inside the air canister with a thick grease such as Motorex Bike Grease 2000 04 Q SHOCK SERVICE MAN
10. tions in use on bikes today When ordering hardware from Answer Products It will be necessary to identify the overall eyelet width eyelet width and mounting hole diameter 04 Q SHOCK SERVICE MANUAL Page 5 PN 042132 REV NC HARDWARE REMOVAL AND INSTALLATION CONT 1 Measure the overall eyelet width 2 Measure hole size Current hardware are designed to accept a 6mm or 8mm fastener SECTION 6 DU BUSHING REMOVAL AND INSTALLATION DU bushings are press fit into the shock eyelets at each end of the shock The hardware fit 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 2 Remove hardware from the shock Insert unthreaded end of punch into the removal tool first and screw in about half a turn Punch gt ku EN 04 Q SHOCK SERVICE MANUAL Page 6 PN 042132 REV NC DU BUSHING REMOVAL AND INSTALLATION CONT 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 This will press out the bushing na INSTALLATION 1 Place a bushing onto the threaded end of the punch and into the removal tool screw in about half a turn Bushing L 4 U 2 Clamp removal tool in vise
11. ze 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 GENERAL WARNING 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 CAUTION The Q Shock uses compressed air to provide fluid pressure in the damping system and spring resistance These systems must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death CAUTION The Q Shock 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 Q Rear Shock Owner s Manual PN 042107 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 04 Q SHOCK SERVICE MANUAL Page 3 PN 042132 REV NC SECTION 3 GLOSSARY OF TERMS Air Canister
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