DORADO OWNER`S MANUAL 2009
Contents
1. www manitoumtb com IMAGE 13 DAMPING OIL HEIGHT CHECK a EE i T Outer Leg W Top Cap Da 106 114mm 4 2 4 4in Oil Level Inner Leg Top Cap CHECKING DAMPING OIL LEVEL A MENNA SETTING THE PROPER OIL LEVEL IN YOUR SUSPENSION FORK IS CRITICAL THE DAMPING IS LOCATED IN THE RIGHT LEG OF YOUR FORK INSUFFICIENT OIL VOLUME WILL ALLOW FOAMING AND REDUCE PERFORMANCE EXCESS OIL WILL RESTRICT TRAVEL AND MAY CAUSE DAMAGE TO THE SYSTEM AND CREATE AN UNSAFE RIDING CONDITION FINISH READING THIS ENTIRE SECTION PRIOR TO ALTERING THE OIL LEVEL To check the oil level it is recommended that the right leg damping leg be completely removed from the rest of the fork for this operation Loosen the two pinch bolts right side damping side on the lower crown and the one pinch bolt on the right side damping side on the upper crown using a 5mm hex wrench Slide the right leg damping leg completely out from the upper and lower crowns Use a 36mm wrench to remove the top cap on the right outer leg damping leg It is not necessary to remove the rebound knob for this operation Slide the outer carbon leg all the way down the inner leg locating the oil height With the top cap and rebound shaft at full extension the oil level should cover the entire cartridge top cap Only the rebound shaft and inner leg top cap should be protruding above the oil surface If the cartridge top cap is visible add SAE 5WT suspension fork2. CONTACT YOUR DEALER OR MANITOU CUSTOMER SERVICE AT 888 686 3472 IF YOU HAVE ANY QUESTIONS CONCERNING THE FUNCTION INTEGRITY OR CONDITION OF YOUR FORK ANY MODIFICATIONS NOT AUTHORIZED IN THIS MANUAL SHOULD BE CONSIDERED UNSAFE IF YOU ARE AMODERATE OR AGGRESSIVE OFF ROAD RIDER OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN MANITOU RECOMMENDS RETURNING YOUR SUSPENSION FORK TO MANITOU EVERY 2 YEARS FORA THOR OUGH INSPECTION TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO MANITOU PHONE 888 686 3472 A MENNA REFLECTORS MANITOU FORKS ARE DESIGNED FOR OFF ROAD USE AND AS SUCH THEY DO 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 YOUR FORK IS GOING TO BE USED ON PUBLIC ROADS AT ANY TIME IF YOU HAVE QUESTIONS REGARDING C P S C REFLECTORS PLEASE CONTACT YOUR DEALER A MENNA IT IS CRITICAL THAT YOU SELECT AND USE THE SUSPENSION FORK THAT IS APPROPRIATE FOR YOUR ANTICIPATED RIDING STYLE THAT YOU USE THE FORK PROPERLY AND FOLLOW THE WARNINGS CONTAINED IN THE OWNER S MANUAL REGARDLESS OF THE RIDING STYLE FAILURE TO PROPERLY MATCH THE FORK TO YOUR FRAME OR RIDING STYLE COULD CAUSE THE FORK TO FAIL RESULTING INALOSS OF BICYCLE CONTROL AND POSSIBLY SERIOUS INJURY OR DEATH TO THE RIDER IN ADDITION AN IMPROPER COMBINATION OF FRAME AND FORK FOR THE
3. except as set forth herein Some states or countries do not allow limitation on how long an implied warranty lasts and some do not allow exclusions or limitations of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from location to location This warranty will be interpreted pursuant to the laws of the United States The original English language version meaning of this warranty controls over all translations and Manitou is not responsible for any errors in translation of this warranty or any product instructions This warranty is not intended to confer any additional legal jurisdictional or warranty rights to you other than those set forth herein or required by law If any portion of this warranty is held to be invalid or unenforceable for any reason such finding will not invalidate any other provision For products purchased in countries other than the United States please contact Manitou s authorized distributor or retailer in that respective country Warranty Service To obtain service under this warranty you must bring or send your Manitou product together with this warranty the retail seller s original receipt or other satisfactory proof of the date of purchase to the retailer where you purchased the item or another authorized Manitou retailer or authorized Manitou distributor Any po
4. fork in the USA contact the Manitou Customer Service Depart ment at 888 686 3472 or for information outside of the USA contact your authorized Manitou dealer or distributor You can also log on to www manitoumtb com and download this manual or see detailed instructions on how to service your suspension fork WORLDWIDE LIMITED WARRANTY Manitou producer manufacturer warrants to the original retail purchaser you that the Manitou product for which they received this warranty is free from defects in material and workmanship for ONE year two years in European Union countries from the date of original retail purchase This warranty is not transferable to a subsequent purchaser Manitou s sole obligation under this warranty is to repair or replace the product at Manitou s option Manitou must be notified in writing of any claim under this warranty within 60 days of any claimed lack of conformity of the product Warranty Limitations The duration of any implied warranty or condition of merchantability fitness for a particular purpose or otherwise on this product shall be limited to the duration of the express warranty set forth above In no event shall Manitou be liable for any loss inconvenience or damage whether direct incidental consequential or otherwise resulting from breach of any express or implied warranty or condition of merchantability fitness for a particular purpose or otherwise with respect to this product
5. tire pressure terrain style and riding style It is recommended that the fork is tested on easy terrain in various High Speed Adjuster and TPC Adjuster settings to both feel the range of adjustment and find the ideal setting for the course REBOUND DAMPING ADJUSTMENT Rebound damping controls the speed at which the fork returns to the un sprung or sagged position During a high speed short travel event it is desirable to have the fork return to un sprung position quickly to prevent pack up series of stutter bumps and the fork becomes low in the travel minimizing Pack up is when the fork does not return fast enough through a the available travel for additional high speed events Contrarily during high speed deep travel events it is desirable to have the fork return to the un sprung state more slowly to prevent loss of traction after the event It is the rider s responsibility to ensure their fork is tuned properly to account for rider weight spring rate tire pressure terrain style and riding style It is recommended that the fork be tested on easy terrain in various rebound settings to both feel the range of adjustment and find the ideal setting for the course The Rebound Adjuster is located on top of the right leg It is blue and is equipped with 18 detent positions Turning the Rebound Adjuster clockwise will make the suspension return slower Turning the Rebound Adjuster counter clockwise will make the susp
6. 12 to determine travel ADJUSTING MAIN SPRING AIR PRESSURE The Dorado s air spring is performance tuned to be high volume low pressure for quick linear break away and progressive bottoming ramp up The negative and positive air chambers are linked with a check valve the chambers auto equilibrate when set up properly INCREASING AIR PRESSURE Remove the Schrader valve cap from the top of the left leg spring leg Thread on pump s Schrader valve fitting snuggly If the fork already has pressure in it the pressure gauge will read a non zero pressure when the valve is engaged Pump up air spring until desired pressure is read on gauge If using a traditional shock pump minimize pressure loss by removing the pump s Schrader valve fitting quickly Replace Schrader valve cap IMAGE 7 BOTTOM SCHRADER VALVE RELIEF ONLY DECREASING AIR PRESSURE Remove the Schrader valve cap from the bottom of the left leg spring leg Thread on the pump s Schrader valve fitting snuggly Turning the fork upside down will minimize oil entering pump If the fork already has pressure in it the pressure gauge will read a non zero pressure when the valve is engaged Depress the pressure bleed valve until desired pressure is read on gauge If using a traditional shock pump minimize pressure loss by removing the pumps Schrader valve fitting quickly Replace Schrader valve cap MEASURING SAG The amount your suspension compresses due to the weight
7. 203mm is the position closest to the air piston 180mm is the position closest to the end cap Rethread the top out screw and bolt over the retaining ring torque to 3 4 N M 30 IN LB See Travel Adjustment Image 12 Coat the air piston with Splash Bath HBG P N 85 0023 Insert the air piston into the leg being sure to minimize contact between the threads and o ring Pour an additional 5cc of Splash Bath on top of the inserted piston Using a 20mm crow s foot torque wrench tighten the comp rod end cap to 6 8 9 0 N M 60 80 LB IN 13 Slide the outer carbon leg back onto the inner leg Using a 13mm open wrench hold the flats on the comp rod adapter Tighten the top cap with a 36mm torque wrench to 1 7 2 8 N M 15 25 LB IN Pour 30cc Splash Bath HBG P N 85 0023 into outer spring leg 14 With the leg fully extended thread the top cap into the spring leg hand tight being sure the o ring is engaged 15 Slide the left leg spring leg completely into the upper and lower crowns The top of the upper crown must be within 10 15mm below of the top of the tapered gold sleeve Tighten the two pinch bolts left side spring side on the lower crown and the one pinch bolt on the left side spring side on the upper crown using a 5mm hex torque wrench to 10 7 12 4 N M 95 110 LB IN 16 Using a 36mm wrench tighten the grey top cap to 8 9 0 N M 60 80 LB IN 17 Fill only the upper Schrader valve with desired air pressure Manitou r
8. Schrader cap for this operation Slide the outer carbon leg down the inner leg to have ample view into the leg A flashlight may aide in locating the oil height With the top cap and comp rod at full extension the oil level should cover the entire inner spring leg and top cap Only the comp rod and outer carbon leg should be protruding above the oil surface If the top cap is visible add Splash Bath HBG P N 85 0023 until the top cap is completely immersed in the damping oil Replace top cap and bleed the oil by stroking 10 20 times The leg may now be replaced into the crowns per required torque specs REPLACING SPLASH BATH OIL SPRING LEG ONLY Use a 36mm wrench to remove the top cap on the left leg spring leg It is not necessary to remove the Schrader cap for this operation Slide the outer carbon leg down the inner leg to allow oil to drain into an oil pan DO NOT REUSE OIL DISCARD OF PROPERLY WITH LOCAL OIL RECYCLER When fully drained pour 30cc of Splash Bath HBG P N 85 0023 into the outer leg With the top cap and comp rod at full extension the oil level should cover the entire inner spring leg and top cap Only the comp rod and outer carbon leg should be protruding above the oil surface If the top cap is visible add Splash Bath HBG P N 85 0023 until the top cap is completely immersed in the Splash Bath oil Replace top cap and circulate the oil by stroking 10 20 times The leg may now be replaced into the crowns per required
9. black High Speed Adjuster The TPC Adjuster when turned clockwise counter clockwise when reference from the handlebars will make the suspension firmer during high speed deep travel events Turning the TPC adjuster counter clockwise counter clockwise when reference from the handlebars will make the suspension plusher during high speed deep travel events The TPC Adjuster is equipped with 18 detent positions IMAGE 9 HIGH SPEED DEEP TRAVEL IMPACT Bicycle Direction of Travel Bicycle Direction of Travel Sprung Mass Chassis Movement During extreme High Speed events the rider s mass forces the fork deep into its travel more than 160mm 6in During these severe bottoming events the damper will engage the Hydraulic Bottom Out Resistance Circuit This dedicated circuit creates a cushion that is both position and shaft velocity dependent the faster and deeper the fork enters the Hydraulic Bottom Out the more force it generates to prevent the fork from bottoming The Hydraulic Bottom Out is factory tuned and is non adjustable A Low Speed event is characterized by a short travel less than 100mm 4in low shaft velocity as a result of changes to the bike s trail stance i e berms G outs pedaling amp braking The low speed characteristics of the fork will be dictated by the TPC adjuster It is the rider s responsibility to ensure their fork is tuned properly to account for rider weight spring rate
10. of your body when in a natural riding position To measure sag you ll need a tape measure a pencil a piece of paper and a helper 1 Measure the distance M from the top of the dropout to the dust seal when no one is sitting on the bike and write down this measurement 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 SAG1 between the same two points as in step one It is important to be in the normal riding position weight centered with your feet on the pedals 3 Repeat measurement after having rider jump on the bike returning to a neutral position SAG2 4 Subtract the second measurement from the first un weighted measure ment in each case Take the average of the two M SAG1 M SAG2 2 AVG SAG The resulting measurement is the average static sag see Table 3 on page 12 5 To increase air spring pressure remove the Schrader air cap located on the top of the left leg and using a dedicated shock pump Manitou part 85 4162 IMAGE 8 HIGH SPEED SHORT TRAVEL IMPACT Bicycle Direction af Travel Bicycle Direction of Travel gt Unsprung Mass Wheel Movement Rock Root etc Rock Root etc inflate the fork with the desired pressure Be aware that sometimes air systems lose a small amount of pressure when a standard shock pump is removed from the valve stem so yo
11. oil until the top cap is completely immersed in the damping oil This oil height should equate to 115 130mm 4 5 5 1in from the top of outer leg or gold sleeve Fully extend the outer carbon leg away from the dropout before replacing outer top cap Replace top cap and bleed the system by stroking 10 20 times with the rebound in full closed position The leg may now be replaced into the crowns per required torque specs NOTE Use SAE 5WT suspension fork oil from high quality manufacturers such as Motorex or Maxima REPLACING DAMPING OIL A EZENN SETTING THE PROPER OIL LEVEL IN YOUR SUSPENSION FORK IS CRITICAL THE DAMPING IS LOCATED IN THE RIGHT LEG OF YOUR FORK INSUFFICIENT OIL WILL ALLOW FOAMING AND REDUCE THE PERFORMANCE EXCESS OIL WILL RESTRICT TRAVEL AND MAY CAUSE DAMAGE TO THE SYSTEM AND CREATE AN UNSAFE RIDING CONDITION FINISH READING THIS ENTIRE SECTION PRIOR TO ALTERING THE OIL LEVEL To replace the damping oil it is recommended that the right leg damping leg be completely removed for this operation Loosen the two pinch bolts right side damping side on the lower crown and the one pinch bolt on the right side damping side on the upper crown using a 5mm hex wrench Slide the right leg damping leg completely out from the upper and lower crowns Use a 36mm wrench to remove the top cap on the right leg damping leg Slide the outer carbon leg down to access the rebound adapter Use a 12mm open wrench to hold the
12. D RACE OFFICIALS ON CONDI TIONS AND EQUIPMENT ADVISABLE AT THE SITE WHERE YOU PLAN TO RIDE DOWNHILL OR FREESTYLE SUSPENSION AND DISC BRAKES MAY INCREASE THE HANDLING CAPABILITIES AND COMFORT OF YOUR BICYCLE AND MAY ALLOW YOU TO RIDE FASTER BUT DO NOT CONFUSE THE ENHANCED CAPABILITIES OF A SUSPENSION BIKE WITH DISC BRAKES WITH YOUR OWN CAPA BILITIES INCREASING YOUR SKILL WILL TAKE TIME AND PRACTICE PROCEED CAREFULLY UNTIL YOU ARE SURE YOU ARE COMPETENT TO HANDLE THE FULL CAPABILITIES OF YOUR BIKE WHILE THE RUGGED APPEARANCE OF MOUNTAIN BIKES AND DISC BRAKES MIGHT SUGGEST THEY ARE INDESTRUCTIBLE THEY ARE NOT CERTAINLY THEY ARE TOUGH AND STURDY DOWNHILL OR FREESTYLE RIDING OR RACING PLACES EXTREME STRESS ON BICYCLES AND THEIR COMPONENTS LIKE IT DOES RIDERS REPEATED USE OF AFORK IN DOWNHILL RIDING MAY RESULT IN SUDDEN OR PREMATURE FAILURE OF A BICYCLE OR COMPONENT RESULTING IN SEVERE INJURIES IF YOU PARTICIPATE IN THESE TYPES OF EVENTS THE LIFETIME OF THE PRODUCT MAY BE SIGNIFICANTLY SHORTENED DEPENDING UPON THE LEVEL AND AMOUNT OF RACING THE NORMAL WEAR OF A COMPONENT MAY DIFFER GREATLY BETWEEN COMPETITIVE AND NON COMPETITIVE USES WHICH IS WHY PROFESSIONAL LEVEL RIDERS OFTEN USE NEW BIKES AND COMPONENTS EACH SEASON AS WELL AS HAVE THEIR BIKES SERVICED BY PROFESSIONAL MECHANICS A MAGI REDUCED FORK LIFE THE LIFE OF THIS FORK WILL BE REDUCED IF 1 YOU USE IT MORE THAN THE AVERAGE USER 2 YOU ARE HEAVIER THAN THE AVERAG
13. E RIDER 3 THE TERRAIN YOU RIDE ON IS ROUGHER THAN AVERAGE 4 YOU TEND TO BE HARDER ON COMPONENTS THAN THE AVERAGE RIDER 5 IT IS INSTALLED OR MAINTAINED IMPROP ERLY 6 IT MUST ENDURE MORE ADVERSE ENVIRONMENTAL CONDITIONS THAN THE AVERAGE FORK I E SWEAT CORROSIVE MUD SALTY BEACH AIR ETC AND OR 7 YOU DAMAGE IT INA CRASH JUMP OR THROUGH OTHER ABUSE THE MORE FACTORS YOU MEET THE MORE ITS LIFE WILL BE REDUCED HOWEVER IT IS IMPOSSIBLE TO SAY HOW MUCH A MENNA PRESS FIT CROWNS PRESS FIT CROWNS THE STEERER TUBE AND STANCHION DROP OUTS ARE PRESS FIT AT THE FACTORY AND SHOULD NEVER BE REMOVED FROM THE CROWN OR DROPOUTS RESPECTIVELY PRESSING THEM OUT WILL PERMANENTLY DAMAGE THE CROWN BEYOND REPAIR AND RENDER IT UNSAFE FOR ANY CONTINUED USE NEVER ATTEMPT TO THREAD A THREADLESS STEERER TUBE CUTTING THREADS WILL WEAKEN THE STEERER TUBE AND CAUSE AN UNSAFE CONDITION OBTAIN THE CORRECT CROWN STEERER FROM YOUR DEALER OR CONTACT MANITOU CUSTOMER SERVICE AT 888 686 3472 REPLACEMENT OF THE ENTIRE CROWN STEERER ASSEMBLY MUST BE DONE TO INCREASE STEERER TUBE LENGTH REMOVING AND REPLACING THE STEERER TUBE WILL RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your fork The steerer tube may need to be cut to length to fit your bicycle s head tube If you are not familiar with this procedure or do not have the proper tools to cut the
14. IDENTIFY YOUR RIDING STYLE It is critical that you select and use the suspension fork that is appropriate for your anticipated riding style that you use the fork properly and that you follow all warnings contained in this owner s manual regardless of riding style Visit our website at www manitoumtb com for more detailed information and guidance on fork selection for your riding style The Dorado is a downhill specific suspension fork This discipline is only for professional or highly skilled riders It includes use on relatively high jumps or drops and negotiating larger obstacles such as boulders fallen trees or holes These forks should be used only with disc brakes as well as frames wheels and other components specifically designed for this riding style A MENNA DOWNHILL FREESTYLE OR COMPETITIVE RIDING TO RIDE DOWNHILL AT HIGH SPEED OR IN COMPETITION IS TO VOLUNTARILY ASSUME A VERY HIGH RISK AND DOWNHILL OR FREESTYLE RIDING CAN LEAD TO SERIOUS ACCIDENTS DOWNHILLING SPEEDS CAN APPROACH THOSE SEEN ON MOTORCYCLES WITH SIMILAR HAZARDS AND RISKS WEAR APPROPRIATE SAFETY GEAR INCLUDING A FULL FACE HELMET FULL FINGER GLOVES AND BODY ARMOR HAVE YOUR BICYCLE INSPECTED BY A QUALIFIED MECHANIC BEFORE EVERY EVENT AND BE SURE IT IS INPERFECT WORKING CONDITION ROUTINE AND THOROUGH MAINTENANCE IS EVEN MORE CRITICAL THAN WITH A BIKE NOT USED FOR DOWNHILLING OR FREESTYLE RIDING CONSULT WITH EXPERT RIDERS AN
15. IGHT FROM WHICH YOU JUMP OR DROP EVERY SITUATION IS DIFFERENT FOR EVERY RIDER CONSULT WITH AN EXPERIENCED RIDER BEFORE ATTEMPTING ANY JUMP OR DROP FAILURE TO PROPERLY RIDE AROUND OBSTACLES ON THE TRAIL OR FAILURE TO PROPERLY LAND AFTER A JUMP OR DROP COULD CAUSE YOUR FORKS TO FAIL RESULTING INALOSS OF BICYCLE CONTROL AND POSSIBLY SERIOUS INJURY OR DEATH TO THE RIDER RIDE ONLY IN AREAS SPECIFICALLY DESIGNATED FOR YOUR RIDING STYLE DO NOT MISUSE OR ABUSE YOUR FORKS LEARN HOW TO RIDE AND ALWAYS RIDE WITHIN YOUR ABILITIES OUT OF CONTROL RIDING PUTS THE EQUIVALENT OF YEARS OF HARD USE ON YOUR FORKS AFTER ONLY A FEW RIDES SOMETIMES THE DAMAGE IS NOT OBVIOUS TO THE USER BUT COULD HAVE FAILED INTERNAL COMPONENTS OR DAMAGED THE LOAD CARRYING ABILITIES OF THE MATERIALS USED IN THE CONSTRUCTION OF THE FORK ALL SUSPENSION FORKS REQUIRE REGULAR MAINTENANCE AND REPAIR THE HARDER YOU RIDE THE MORE OFTEN YOU MUST INSPECT AND MAINTAIN YOUR FORK IF YOUR FORK STARTS MAKING ANY STRANGE NOISES CLUNKS CREAKS CLICKS OR FEEL LOOSE OR DIFFERENT IN ANY WAY IT SHOULD NOT CONTINUE BEING USED BUT IMMEDIATELY HAVE A CERTIFIED MANITOU SERVICE CENTER INSPECT AND REPAIR THE FORK BEFORE YOU RIDE AGAIN INSPECT YOUR FORK REGULARLY TO SEE THAT IT IS NOT BENT DEFORMED CRACKED OR CHIPPED IF ANY OF THESE CONDITIONS EXIST THE FORK SHOULD NOT BE USED A CERTIFIED MANITOU SERVICE CENTER SHOULD INSPECT AND REPAIR THE FORK BEFORE IT IS USED AGAIN
16. INTENDED CATEGORY WILL VOID THE FORK S WARRANTY VISIT OUR WEBSITE AT WWW MANITOUMTB COM FOR MORE DETAILED INFORMATION AND GUIDANCE ON FORK SELECTION FOR YOUR RIDING STYLE YOU SHOULD ONLY ATTACH DISC BRAKES AND ANY OTHER ACESSORIES TO THE DESIGNATED MOUNTING POINTS PROVIDED ON THE FORKS NEVER MAKE ANY MODIFICATION TO YOUR FORK TO ATTACH ANY EQUIPMENT THERE IS A HEIGHTENED LEVEL OF VOLUNTARY RISK ASSOCIATED WITH FREERIDING DIRT JUMPING AND DOWNHILLING LARGER STUNTS JUMPS MEAN MORE POTENTIAL FOR EQUIPMENT ISSUES OR PROBLEMS AND THE LIKELIHOOD OF SERIOUS INJURY IS GREATLY INCREASED LEARN HOW TO PROPERLY RIDE AROUND OBSTACLES ON THE TRAIL OR ROAD HITTING OBSTACLES SUCH AS CURBS ROCKS TREES ROOTS HOLES OR SIMILAR OBSTACLES STRAIGHT ON PUTS FORCES ON YOUR FORK IT WAS NOT DESIGNED TO ABSORB LANDING IMPROPERLY AFTER A JUMP OR DROP ALSO PUTS FORCES ON YOUR FORK IT WAS NOT DESIGNED TO ABSORB YOU SHOULD ONLY PERFORM JUMPS OR DROPS WHEN A TRANSITION OR DOWN RAMP IS AVAILABLE TO HELP YOUR BICYCLE AND FORK ABSORB THE IMPACT FORCES GENERATED DURING THE LANDING AND BOTH WHEELS SHOULD SMOOTHLY MAKE CONTACT WITH THE TRANSITION OR DOWN RAMP AT THE SAME TIME ANY OTHER TYPE OF LANDING IS DANGEROUS AS IT COULD OVERLOAD THE FRAME OR FORK AND RESULT INA COMPONENT PART FAILURE AND AN ACCIDENT OR COULD CAUSE YOU TO LOOSE CONTROL OF THE BICYCLE EVEN WITHOUT A COMPONENT PART FAILURE THE STEEPNESS AND LENGTH OF THE TRANSITION OR DOWN RAMP DEPENDS ON THE HE
17. UM KO K N N 7 bl CE e AA a i A dali 4 di inni DORADO OWNER S MANUAL 2009 ENGLISH MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY The Dorado is fully assembled and ready to be installed on your bicycle It comes equipped with a 1 1 8 inch steerer tube disc brake mount adapters and Hex Lock Thru Axle A handlebar mounted reflector must be used for on road use which is not included with your fork A WAR NIK Te GENERAL CONSUMER SAFETY INFORMATION BICYCLING IS AHAZARDOUS ACTIVITY THAT REQUIRES THAT THE RIDER STAY IN CONTROL OF HIS OR HER BICYCLE AT ALL TIMES ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH READING THIS MANUAL ENTIRELY AND PROPERLY MAINTAINING YOUR BICYCLE AND SUSPENSION FORK WILL REDUCE THE POSSIBILITY OF INJURY OR POSSIBLE DEATH PRIOR TO EVERY RIDE YOU SHOULD CLOSELY EXAMINE YOUR SUSPEN SION FORK AFTER CLEANING IN BRIGHT SUNLIGHT TO ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF RIDING TRANSPORTING OR AFTER A FALL PAY PARTICULAR ATTENTION TO THE CROWNS INNER LEGS OUTER LEGS DROP OUTS BRAKE MOUNT AREAS AND STRESS POINTS SUCH AS WELDS SEAMS HOLES AND POINTS OF CONTACT WITH OTHER PARTS ETC DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING LEAKING CRACKING CREAKING SQUEAKING CLUNKING OR ANY OTHER UNFAMILIAR NOISES OR IF IT IS MISSING ANY OF THE ORIGINALLY SUPPLIED COMPONENTS
18. adset manufacturer s instructions to tighten 5 Ensure that the front brake cable is properly routed and check brake adjustment Follow brake manufacturer s instructions SUGGESTED SERVICE INTERVALS FOR DORADO NORMAL CONDITIONS Short Infrequent Rides Long Frequent Rides Disassemble fork per Service Manual Clean outer leg and replace Splash Bath oil every 6 months Service damping systems by changing the damper oil every six months Check the oil level sitting on top of the air piston every 12 months per directions found on www manitoumtb com Disassemble fork per Service Manual Clean outer leg and replace Splash Bath oil every four months Service damping systems by changing the damper oil every four months Check the oil level sitting on top of the air piston every eight weeks per directions found on www manitoumtb com SEVERE CONDITIONS Short Infrequent Rides Long Frequent Rides Disassemble fork per Service Manual Clean outer leg and replace Splash Bath oil every three months Service damping systems by changing the damper oil every three months Check the oil level sitting on top of the air piston every six weeks per directions found on Disassemble fork per Service Manual Clean outer leg and replace Splash Bath oil every four months Service damping systems by changing the damper oil every four months Check the oil level sitting on top of the air piston every eight weeks per directions found on www manitoumtb com
19. al wear to the product e Any products for which the consumer does not follow the warranty procedures outlined above For the current version of this warranty please visit our website at www manitoumtb com FUTYES BICYCLE GROUP Hayes Bicycle Group 5800 W Donges Bay Rd Mequon WI 53092 1 888 MTN DISC 1 888 686 3472 Fax 262 512 4219 Email manitoutech manitoumtb com www manitoumtb com PN 141 23841
20. crown per the headset manufacturer s instructions 4 Clean and grease the headset bearings and races per the headset manufacturer s instructions 5 Install the lower bearings if applicable on fork crown race per the headset manufacturer s instructions 6 Insert the steerer tube into the head tube of the frame 7 Install the upper bearings stem spacers upper triple clamp and stem or integrated upper handlebar stem clamp 8 Install the stem cap and bolt Tighten the bolt to headset manufacturer s specifications 9 Install the handlebars and torque the stem pinch screws or stem clamping system to stem manufacturer s specifications 10 Install the brake levers and adjust per the brake manufacturer s instructions 11 Adjust stanchion legs in the upper and lower crowns The top of the lower clamp must be between 10mm 15mm below the top of the gold sleeve and should be even Both right and left outer carbon legs should be set at the same height 1mm Torque pinch bolts to specs found in Table 6 on Page 12 12 To install the hex axle simply slip the axle into the dropout small axle hex side first into the large dropout hex Thread the set bolt into the small hex side and snug slightly Push the fork up and down a few times to center the axle and hub and then tighten all pinch bolts to recommendations found in Table 6 NOTE The Dorado may only use a 110mm wide hub All other hub sizes are unsafe and will cause the for
21. ecommends using a pump equipped with a 2 stage valve relief system to prevent any pressure loss when disconnecting the pump from the valve stem Recommended air pressure is 50 90 PSI Replace the Schrader cap 18 Remount the wheel and Hex Axle and brake caliper per manufacturer s specifications First tighten the hex Axle to 3 4 4 5 N M 30 40 IN LB using a 6mm hex torque wrench Then tighten all four pinch bolts to 3 4 4 5 N M 30 40 IN LB using a 4mm hex torque wrench MAINTENANCE Your fork requires periodic maintenance cleaning and inspection This is because moisture and contamination may build up inside the fork depend ing on the severity of riding conditions To maintain top performance it is recommended that the fork be periodically disassembled cleaned dried and re lubricated You can download service and tuning instructions on the web at www manitoumtb com A ZEN BEFORE EVERY RIDE YOU SHOULD 1 Ensure that the Hex Axle is properly installed 2 Ensure that all bolts are tightened to the appropriate torque recommendations by the parts respective manufacturers 3 Wipe the inner legs and clean the fork Check the entire fork for any obvious damage 4 Check the headset for proper adjustment To check for a loose front headset apply the front brake with both wheels on level pavement and push the bike forwards and backwards rapidly to see if you hear the headset rattling If it is then it is too loose Follow he
22. ension return faster IMAGE 10 REBOUND DAMPING ADJUSTMENT Rebound Adjuster TRAVEL ADJUSTMENT The Dorado is capable of being internally adjusted from 203mm of travel to 180mm of travel This may be done with no change to the spring rate for a given spring air pressure The comp rod assembly must be removed for this operation If the fork is not yet installed on the bike skip to step four 1 Loosen the four drop out pinch bolts two per dropout using a 4mm hex wrench do not remove the pinch bolts from the dropouts 2 Remove the Hex Axle bolt using a 6mm hex wrench Slide the 20mm Hex Axle out of the drop outs and wheel hub 3 Remove brake caliper completely from left dropout along with brake cable from left leg guard 4 Remove the Schrader valve cap beneath the left dropout Relieve all air pressure from the positive air valve using a shock pump with a pressure relief valve and pressure gauge The pressure gauge should read 0 PSI before removing the pump Replace the Schrader valve cap 5 Remove the Schrader valve cap on top of the left leg spring leg Using a 36mm wrench loosen but do not remove the grey topcap on the gold sleeve on top of the left leg spring leg 6 It is recommended that the left leg spring leg be completely removed for this operation Loosen the two pinch bolts on the left side spring side of the lower crown and the one pinch bolt on the left side spring side of the upper crown using a 5
23. flats on the rebound while removing the top cap from the rebound adapter Pop out the rebound knob from the top cap by pressing on it from the underside of the top cap Drain the used damping oil into an oil pan by turning the leg upside down Allow to sit and drain until there is no longer a steady stream of oil from the leg The outer carbon tube may be removed at this point Holding the leg upright stroke the rebound shaft several times to move the oil from behind the rebound piston to further bleed the cartridge Turn upside down and allow oil to bleed out for several minutes DO NOT REUSE OIL DISCARD OF PROPERLY WITH LOCAL OIL RECYCLER When dry the outer carbon leg may be slid back on to the inner leg Retighten the top cap onto the rebound adapter Pour oil volume found in Table 4 of SAE 5WT suspension fork oil into the carbon leg below the top cap With the top cap and outer leg fully extended thread and tighten the top cap onto the gold sleeve of the outer leg Pop in the rebound knob by pressing it back in to the top cap Bleed the system by stroking 10 20 times or until rebound speed is slow throughout with the rebound in full closed position Reset rebound adjuster knob to desired setting NOTE Use SAE 5WT suspension fork oil from high quality manufacturers such as Motorex or Maxima CHECKING SPLASH BATH OIL SPRING LEG ONLY Use a 36mm wrench to remove the top cap on the left leg spring leg It is not necessary to remove the
24. k to fail and may lead to potential injury of rider See Image 2 on page 5 IMAGE 1 LOWER CROWN INSTALLATION Lower Sleeve IE D 0 39 0 59in 5 z Lower Crown IMAGE 2 AXLE INSTALLATION Hex Axle Hex Pinch son me IMAGES 3 amp 4 IS MOUNT BRAKE CALIPER ADAPTER INSTALLATION POST MOUNT BRAKE CALIPER ADAPTER INSTALLATION 068078 IS Mount Adapter 2x 064535 4mm Hex Torque to 9 0 11 3 N M t 80 100 Ib in Drop out Boss Spring Left Leg BRAKE CALIPER ADAPTER INSTALLATION Both post mount and IS disc brake caliper adapters are included with your fork HBG P N 141 23817 Identify the mounting standard of your disc brake caliper Post mount calipers have bolt holes parallel to the orientation of the rotor IS calipers have bolt holes perpendicular to the orientation of the rotor Consult your brake manufacturer s owner s manual for further information Only a 203mm 8in rotor may be used on the Dorado Once the proper adapter is identified install the adapter as shown Use the two bolts provided in the kit M6x1 20mm long Torque to 9 0 11 3 N M 80 100 Ib in BRAKE CABLE INSTALLATION A MENNA FAILURE TO PROPERLY ROUTE AND SECURELY ATTACH THE FRONT BRAKE CABLE TO THE FORK CAN CAUSE SERIOUS INJURY OR DEATH Included with your fork is a small black disc brake cable guide that can be attached to the lower crown to aid in routing the cables to disc brake calipers Also i
25. mm hex wrench Slide the left leg spring leg completely out from the upper and lower crowns IMAGE 11 COMPRESSION DAMPING ADJUSTMENTS Low Speed Adjuster High Speed Adjuster IMAGE 12 TRAVEL ADJUSTMENT Top Out Seated in 203mm Position Top Out Screw 20mm Top Out Nut Top Out Disassembled for Travel Adjustment Retaining Ring Retaining Ring 203mm Position 180mm Position Top Out Seated in 180mm Position 7 Holding the leg upright continue to remove the top cap from the sleeve on top of the leg Slide the outer carbon leg down 8 Using a 13mm open wrench hold the flats on the comp rod adapter it may be necessary to slide the bottom out spacer down to gain access and remove the top cap with a 36mm wrench Do this over an oil pan as some oil may spill 9 Turning the leg upside down allow the Splash Bath oil to drain into an oil pan DO NOT REUSE OIL DISCARD PROPERLY WITH LOCAL OIL RECYCLER When all oil has drained remove the outer leg by sliding it away from the dropout 10 Using a 20mm open end wrench loosen the comp rod end cap and remove the comp rod assembly form the leg Do this over an oil pan as some oil may spill 11 Locate the top out nut gold and screw black on the comp rod Loosen and unthread the nut from the screw then slide apart to reveal the retaining ring Splay the retaining ring to remove from grove and move to groove corresponding to the desired travel position
26. ncluded is a standard zip tie to secure the cable to the bash guard The preferred method is to route the cable so that it runs inside the spring leg secured to the bash guard then through the brake cable guide The cable should be loose through the lower crown cable guide so the cable is free to translate up and down Make sure the brake line is not crimped and does not touch the tire as the fork moves through its range of travel See Image 5 on page 6 068077 Post Mount Adapter 2x 064535 4mm Hex Torque to 9 0 11 3 N M 80 100 Ib in Drop out Boss Spring Left Leg IMAGE 5 BRAKE CABLE INSTALLATION IMAGE 6 TOP SCHRADER VALVE FILL ONLY A ZENNA WHEN INSTALLING THE WHEEL WITH A PROPERLY INFLATED TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE FAILURE TO CONFORM TO RECOMMENDED TIRE CLEARANCE SPECIFICATIONS MAY CAUSE THE TIRE TO STOP SUDDENLY DURING USE CAUSING PERSONAL INJURY OR DEATH Measure minimum tire clearance from any point on the profile of the tire upward to the bottom of the crown see Image 15 page 13 Compare to Table 1 on page 12 for minimum tire clearance Measure the tire at maximum width see Image 15 Compare with Table 1 for maximum tire width INITIAL SET UP MEASURING TRAVEL the total amount of up and down movement To determine how much travel your fork has simply measure the distance from the top of the droup out to the seal on the outer leg See Table 2 on page
27. stacle less than 100mm 4in i e stutter bumps rocks and roots See figure below Generally it is desirable for the fork to be plush minimal damping force when encountering a high speed event of this nature and should travel through the stroke with minimal movement translated to the rider This damping characteristic is set by High Speed Adjuster The High Speed Adjuster is located on the bottom of the right dropout It is black and encircles the red TPC adjuster The High Speed Adjuster when turned clockwise counter clockwise when reference from the handlebars will make the suspension firmer during short travel high speed events Turning the High Speed Adjuster counter clockwise clockwise when reference from the handlebars will make the suspension plusher during high speed events The High Speed Adjuster is equipped with 18 detent positions NOTE WHEN THE HIGH SPEED ADJUSTER OUTER KNOB IS TURNED THE TPC ADJUSTER INNER KNOB WILL FOLLOW THIS WILL NOT CHANGE THE SETTING OF THE TPC ADJUSTER THE TPC ADJUSTER SETTING WILL ONLY CHANGE IF TURNED INDEPENDENTLY OF THE HIGH SPEED ADJUSTER In the second case of high speed shaft velocity gravity forces the rider s mass downward deep into the fork s travel more than 100mm 4in from landing a jump or a drop See figure below This damping characteristic is set by the TPC Adjuster The TPC Adjuster is located on the bottom of the right dropout It is red and is encircled by the
28. stage insurance or other shipping costs incurred in sending your Manitou product for service is your responsibility Manitou will not be responsible for products lost or damaged in shipping For products purchased in countries other than the United States please contact Manitou s authorized distributor or retailer in the country where the product was purchased They can be found on our website at www manitoumtb com Warranty Exclusions Retailers and sellers of Manitou products are not authorized to modify this warranty in any way It is your responsibility to regularly examine the product to determine the need for normal service or replacement This warranty does not cover the following Products that have been modified neglected or poorly maintained used for commercial purposes misused or abused or involved in accidents Damage occurring during shipment of the products such claims must be presented directly to the shipper Products whose serial number has been altered defaced or removed Damage to products resulting from improper assembly or repair the use or installation of parts or accessories not compatible with the original intended use of the product or the failure to follow the product warnings and usage instructions Damage or deterioration to the surface finish paint aesthetics or appearance of the product The labor required to remove and or re fit and re adjust the item covered by this warranty e Norm
29. steerer tube it is recommended that you seek a dealer with a qualified bicycle mechanic to perform the installation When cutting a steerer tube of a fork make sure to measure twice before cutting forks cut too short during installation are NOT covered by the warranty BREAK IN Your new fork is designed to break in during your first few rides about 20 hours total riding time Prior to break in you may notice your fork feels tight and slightly notchy Following the break in period your fork will feel much smoother and will react to bumps much better than when you first put it on your bike After 20 hours you may want to recheck adjustments where applicable to fine tune the fork completely A MENNA WHENEVER YOU INSTALL ANY NEW COMPONENT ON YOUR BIKE MAKE SURE YOU THOROUGHLY TRY IT OUT CLOSE TO HOME WITH YOUR HELMET WHERE THERE ARE NO OBSTACLES TRAFFIC OR OVERLY CHALLENGING TERRAIN MAKE SURE EVERYTHING IS WORKING PROPERLY BEFORE GOING OFF ON A RIDE OR TO A RACE FORK INSTALLATION DUAL CROWN FORKS 1 Remove the old fork from your bicycle 2 Measure and cut the steerer tube to fit your bicycle s head tube see previous WARNING You can use your old fork as a guide for cutting the steerer tube length To determine which upper triple clamp your frame will need see Table 5 on page 12 3 Remove the headset crown race from the old fork and press onto the fork steerer until the race is seated snugly against the top of the
30. torque specs found in Table 6 CHECKING AIR PISTON LUBRICATION OIL Remove the Schrader valve cap from the left dropout and relieve all air pressure from the air spring Use a 36mm wrench to remove the top cap on the left leg spring leg Slide the outer carbon leg down the inner leg to the dropout Using a 13mm open wrench hold the flats on the comp rod adapter it may be necessary to slide the bottom out spacer down to gain access and remove the top cap with a 36mm wrench Do this over an oil pan some oil may spill Turning the leg upside down allow the Splash Bath oil to drain into an oil pan DO NOT REUSE OIL DISCARD PROPERLY WITH LOCAL OIL RECYCLER When all oil has drained remove the outer leg by sliding it away from the dropout Using a 20mm open end wrench loosen the comp rod end cap and remove the comp rod assembly form the leg Do this over an oil pan some oil may spill Allow oil to drain off of piston and out of inner leg Do not wipe oil from piston this may contaminate the seal and result in poor performance Dip the air piston in Splash Bath HBG P N 85 0023 Insert the air piston back into leg Be careful to insert the piston straight to avoid cutting the seal on the threads Pour an additional 5cc of Splash Bath HBG P N 85 0023 on top of the piston Replace the spring leg top cap and replace the outer carbon leg Pour 30cc of Splash Bath HBG P N 85 0023 into the outer carbon leg With the top cap and comp rod at full e
31. u may want to check exactly how much your pump loses by reinstalling it after you have set and checked the pressure 6 To decrease air spring pressure remove the Schrader air cap located on the bottom of the left leg and using a dedicated shock pump Manitou part 85 4162 depress the pressure bleed valve until the desired pressure is reached Be aware that sometimes air systems lose a small amount of pressure when a standard shock pump is removed from the valve stem so you may want to check exactly how much your pump loses by reinstalling it after you have set and checked the pressure DAMPING SYSTEM The Dorado is equipped with the following Damping technologies Externally Adjustable TPC Compression Damping Externally Adjustable High Speed Compression Damping Integrated Hydraulic Bottom Out Resistance Circuit and Externally Adjustable Rebound Damping All these technologies are contained in an open bath cartridge making it lightweight quick to bleed and easy to set up A MENNA THE DAMPING SYSTEM IS AN OPEN BATH SYSTEM OIL MAY INTERNALLY LEACH OUT OF THE DAMPING CARTRIDGE DURING SHIPPING OR IF YOUR BIKE IS STORED UPSIDE DOWN THE FORK SHOULD BE BLED PRIOR TO USE IF THE FORK IS NOT STORED UPRIGHT FAILURE TO DO SO MAY RESULT IN POOR PERFORMANCE To bleed the cartridge hold fork upright or as mounted on bike Turn rebound adjuster knob to Full Closed Position Stroke fork 10 20 times or until rebound speed is slow througho
32. ut travel of fork Reset rebound adjuster knob to desired setting The bleed process may be supplemented by also turning the TPC red compression adjusted to the full closed position COMPRESSION DAMPING ADJUSTMENT The Dorado is equipped with both an external TPC Compression damping adjustment and an external High Speed Compression damping adjustment as well as a dedicated independent hydraulic bottom out circuit These damping technologies allow greater adjustability for specific events encountered on terrain this allows the fork to be plush during stutter bumps and firm during bottoming while giving the rider the necessary adjustment to tune the Dorado to any riding conditions There are three distinct damping stages through the travel of the fork The first stage 0 100mm 0 4 in of travel is dedicated to high speed unsprung wheel movement and low speed rider trail movement The second stage 100 160mm 4 6in of travel is dedicated to high speed sprung weight movement of the rider and bike The third stage 160 203mm 6 8in of travel is dedicated to bottoming resistance Typically a high speed compression event is characterized by a high shaft velocity incident caused by either the unsprung wheel mass being forced towards bike chassis or the sprung rider mass being forced towards the ground In the first case the high shaft velocity is caused by the bike at high speeds coming in contact with a small ob
33. xtension the oil level should cover the entire inner spring leg and top cap Only the comp rod and outer carbon leg should be protruding above the oil surface If the top cap is visible add Splash Bath HBG P N 85 0023 until the top cap is completely immersed in the Splash Bath oil Replace top cap and circulate the oil by stroking 10 20 times The leg may now be replaced into the crowns per required torque specs found in Table 6 MINIMUM TIRE MAXIMUM TIRE MAXIMUM TIRE TABLE 2 TRAVEL MEASUREMENT SEAL TO DROPOUT MEASUREMENT FORK TRAVEL SETTING 185MM Image 14 208MM Image 14 TABLE 3 SAG MEASUREMENT FORK TRAVEL SETTING RECOMMENDED SAG 180MM 35 45MM Image 14 203MM 35 45MM Image 14 TABLE 4 VOLUME OIL VOLUME 160 CC TABLE 5 DUAL CROWN SIZING CUP TO CUP DUAL CROWN MEASUREMENT SIZE 131 159MM SMALL Flat Upper Crown 154 183mm LARGE Drop Upper Crown Cup to cup measurement is the distance from the bottom of the lower headset cup to the top of the upper headset cup See Image 1 TABLE 6 RECOMMENDED TORQUE SPECIFICATIONS ITEM TORQUE SPECIFICATIONS NM IN LBS DUAL CROWN CLAMPS 10 7 12 4 NM 95 110 IN LB HEX AXLE PINCH BOLTS 3 4 4 5 NM 30 40 IN LB HEX AXLE END SCREW 3 4 4 5 NM 30 40 IN LB IMAGE 14 Seal to Drop out IMAGE 15 Cup to Cup Minimum Tire Clearance Maximum Tire Diameter If you have any questions regarding your Manitou suspension
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