Manitou 2003 Luxe Service Manual
Contents
1. WILL RESULT IN AN UNSAFE CONDITION AND SHOULD 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 for cutting the steerer tube length 3 Remove the headset crown race from the old fork and press onto the LUXE steerer tube until the race is seated over the crown Clean and lubricate the headset bearings and races Install the lower bearings if applicable on the 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 9 Install the handlebars to desired height 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 For all LUXE forks adjust the front wheel quick release to clear the 0 275 7 mm thick secondary catch dropout The quick release must be tight ened after it is properly seated into the dropout counter bores to manufac turer s specifications Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock NOTE 2003 Manitou LUXE forks are equipped with a secondary catch dropout to retain the wheel in the fork in the event the quick release comes loose CON O O1 A A WHEN INSTALLING THE WH2. AS 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 AGGRES SIVE OFF ROAD RIDER OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN ANSWER RECOMMENDS RETURNING YOUR SUSPENSION FORK EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO ANSWER PRODUCTS OR YOU MAY CALL ANSWER AT 661 257 4411 TO HAVE YOUR FORK SHIPPED DIRECTLY IMPORTANT The LUXE fork is an off road fork and as such does not come with proper reflectors for on road use Have your dealer or mechanic install proper reflectors to meet the Consumer Product Safety Commission s C P S C Requirements for Bicycles if the fork is going to be used on public roads at any time If you have questions regarding C P S C Standards or would like to purchase a reflector bracket kit contact your deal er CONSUMER SAFETY INFORMATION 1 Never remove or have the steerer tube or stanchions removed from the crown The steerer tube and stanchions inner legs are press fit at the facto ry Press fit inner legs have higher performance versus bolt in inner legs but can not be pressed out Pressing them out will perm
3. EEL OR A NEW TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOT TOM OF THE BRAKE ARCH THIS MEASUREMENT SHOULD BE 5 MM FOR LUXE FORKS FIGURE 1 IMPORTANT A Manitou LUXE fork should not be used if any parts appear to be or are damaged Contact your local dealer or Answer Products for replacement parts MAINTENANCE IMPORTANT Use of fork boots is required to keep your LUXE fork per forming well and the warranty in effect Use of this fork without boots will shorten the life of the fork decrease the time between maintenance inter vals reduce the performance and void the warranty IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs and clean and check entire fork for any obvious dam age 3 Check the headset for proper adjustment 4 Ensure that the front brake cable is properly routed and check brake adjustment If you have any questions regarding your 2003 Manitou LUXE suspension fork contact the Answer Products Customer Service Department at 661 257 4411 You can also log on to www answerproducts com and download this manual or see detailed instructions on how to service your suspension fork Thank you again for choosing a 2003 Manitou LUXE suspension fork LUXE DEALER SERVICE ADDENDUM This section is designed to help you tune and maintain your Manitou suspension fo
4. JLJUS AS COMP ELITE SUPER OWNERS MANUAL P N 042095 28209 Avenue Stanford Valencia California 91355 3984 661 257 4411 fax 661 294 4179 MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING A 2003 MANITOU LUXE SUSPENSION FORK This Manitou fork is fully assembled and ready to be installed onto your bicycle It comes equipped with a 1 1 8 inch threadless steerer tube and is available with a V brake style hangerless arch The LUXE has Dynamo mounts for use with a lighting system A handlebar mounted reflector must be used for on road use which is not included with your fork 2003 MANITOU LUXE FORK LINE LUXE COMP aan 50 MM TRAVEL ALUMINUM CASTING COIL AND MCU SPRINGS SINGLE CROWN LUXE EVD 22202002 50 MM TRAVEL MAGNESIUM CASTING COIL AND MCU SPRINGS SINGLE CROWN LUXE SUPER ies 50 MM OR 75 MM TRAVEL MAGNESIUM CASTING COIL AND MCU SPRINGS SINGLE CROWN Preset from the factory but changeable See the Dealer Service Addendum section Convertible Travel LUXE Super You can also download this manual at www answerproducts com A POSTER NTE 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 H
5. al 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 dura tion 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 Customer Service for a return authorization number RA at 661 257 4411 At that time instructions for repair return or replacement shall be given Customers in countries other than USA should con tact their dealer or local distributor INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your LUXE fork 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 bicy cle mechanic to perform installation ANNO THE STEERER TUBE AND STANCHIONS INNER LEGS ARE A ONE TIME PRECISION PRESS FIT AT THE FACTO RY AND CAN NOT BE REMOVED FROM THE CROWN REPLACEMENT OF THE ENTIRE CROWN STEERER ASSEMBLY MUST BE DONE TO CHANGE STEERER TUBE LENGTHS OR DIAMETERS REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS
6. anently damage the crown beyond repair and render it unsafe for any use 2 Never attempt to thread a threadless steerer tube Cutting threads will weak en the steerer tube and cause an unsafe condition The only safe thing to do is to obtain the proper crown steerer from your dealer or contact Answer Warranty at 661 257 4411 3 Any other alteration or modification to your fork should be considered unsafe Contact Answer Customer Service prior to modifying your fork in any way for safety information 4 Do not use the LUXE fork if any parts are broken bent cracked or you sus pect may be damaged Contact your dealer or Answer Customer Service at 661 257 4411 if you have any questions concerning the integrity or condi tion of your fork 5 Answer Products recommends that you inspect your fork before every ride for wear and damage Inspect the crown inner legs outer legs dropout and brake arch areas for cracks or damage WARRANTY INFORMATION Any Answer Products fork found by the factory to be defective in materials and or workmanship within one year from the date of purchase or two years in EU countries will be repaired or replaced at the option of the manufacturer free of charge when received at the factory with proof of purchase 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 sub ject to misuse or whose seri
7. il Springs above 2 Next unthread the 4 mm bolts from the bottoms of both legs and pull the fork apart to expose the clip mechanism which allows for travel adjustment Figure 6 3 Remove the clip and insert it into the upper position above the rod flange for 75 millimeters of travel or the lower position below the rod flange for 50 millimeters of travel Figure 13 4 Reassemble the fork MAINTENANCE AND SERVICE When servicing the fork take the time to inspect all parts for excessive wear or damage There are basically three aspects of a fork that will require attention the stan chions inner legs the bushings in the outer legs and the spring stack Inspecting any of these parts requires disassembly of the fork Pay close attention to the bushings which can be damaged by contamination in severe conditions Replace any worn or damaged parts that are discov ered SERVICE SCHEDULE Suggested Service for Manitou forks NORMAL CONDITIONS Short Infrequent Rides Disassemble clean and grease fork every year Grease spring stack as needed NORMAL CONDITIONS Long Frequent Rides Disassemble clean and grease fork every 6 months Grease spring stack as needed SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Short Infrequent Rides Disassemble clean and grease fork every 6 months Grease spring stack as needed SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Long Frequent Rides Disassemble c
8. lean and grease fork every months Grease spring stack as needed
9. re 5 6 Reinstall the preload adjuster cap FORK DISASSEMBLY LUXE SUPER Disassembly of your LUXE Super fork is necessary to provide the proper service of your fork To do this 1 Remove the two 4 mm Allen bolts on the bottom of the fork Figure 6 8 Pull apart the fork removing the casting from crown steerer assem bly Figure 7 3 Wipe clean the inside of the fork casting stanchion tubes fork boots and crown At the same time you do this do a complete inspection on the fork Figure 8 4 Reassemble the fork and snug tighten the 4 mm bolts Figure 9 FORK DISASSEMBLY LUXE COMP amp ELITE Disassembly of your LUXE Comp and Elite fork is necessary to provide the proper service of your fork To do this 1 Remove the springs See Changing Coil Springs above 2 Insert a long 4 mm wrench into the fork and loosen the bolts that hold the casting to the crown steerer tube assembly Figure 10 Pull apart the fork removing the casting from crown steerer assem bly Figure 11 4 Wipe clean the inside of the fork casting stanchion tubes fork boots and crown At the same time you do this do a complete inspection on the fork Figure 12 5 Reassemble the fork and snug tighten the 4 mm bolts Figure 10 CONVERTIBLE TRAVEL LUXE SUPER Changing the travel from 50 to 75 millimeters or vice versa requires the removal of the lower legs 1 Start by removing the preload adjusters and spring see Changing Co
10. rk MEASURING SAG To measure sag you ll need a tape measure a pencil and a piece of paper 1 Measure the distance from the front axle s centerline to the bottom of the upper crown without anyone sitting on the bike and write this measurement down Remember the exact locations of the two points because you ll need to use them later 2 Have the rider sit on the bike and measure the distance between the same two points as in step one It s important to be in the normal rid ing position weight centered with the rider s feet on the pedals Subtract the second measurement from the first The resulting meas urement is the static sag or ride height SAG MEASUREMENT CHART Fork Travel Sag 50 mm 8 18 mm 75 mm 10 14 mm TRAVEL MEASUREMENT To determine which travel your LUXE fork is in simply measure the distance from the top of the seal area on the lowers or the bottom of the fork boot to the bottom of the crown TRAVEL MEASUREMENT CHART Seal to Crown Measurement Around 4 inches or 100 mm Fork Travel 50 mm 75 mm Around 5 inches or 125 mm RECOMMENDED COIL SPRINGS Once you have checked sag you can either preload the spring via the cap on top of the left hand leg or even better make spring changes to accommodate for your riding style and weight SPRING KITS LUXE COMP Rider Weight Recommended Spring Kit 100 150 lbs Soft ride kit Part 785 4990 Standard 5et u 150 170 lbs Medium ride kit Part 7785 4991 170 plus lb
11. s Firm ride kit Part 85 4992 LUXE ELITE Rider Weight Recommended Spring Kit 100 150 lbs Soft ride kit Part 85 4993 Standard 5et u 150 170 lbs Medium ride kit Part 7785 4994 170 plus lbs Firm ride kit Part 7785 4995 LUXE SUPER Rider Weight Recommended Spring Kit 100 150 lbs Soft ride kit Part 785 4996 Standard Set u 150 170 lbs Medium ride kit Part 7785 4997 170 plus lbs Firm ride kit Part 7785 4998 CHANGING COIL SPRINGS Once you have checked sag you can make spring changes to accommodate for your riding style and weight 1 Remove the preload adjusters by unscrewing the caps from the top of the crown leg assembly First you must remove the cap by unscrew ing the 2 mm fastening bolt Figure 2 An 18 mm socket will be nec essary with the LUXE to remove the preload adjuster assembly Remember The springs are housed in both legs of the LUXE forks 2 With the adjuster assembly removed the spring stack is now accessi ble Figure 3 Select the appropriate coil spring for your weight and riding style refer to the above spring chart for recommended rates 4 Apply a liberal amount of grease to the outside surface of the new coil spring and the spring couplers what holds the springs together Figure 4 We recommend any thick grease Install the new spring Stack 8 Reinstall the preload adjuster assembly taking care not to cross thread the cap It should thread in by hand and lightly snug tight ened Figu
Download Pdf Manuals
Related Search