Manitou 2003 Skareb Service Manual
Contents
1. MAVEN RIT U CNY Skareb comp elite super OWNER S MANUAL P N 042098 28209 Avenue Stanford Valencia California 91355 3984 661 257 4411 e fax 661 294 4179 SERVICE PARTS KITS SKAREB COMP COIL Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm X Firm Knob Kit SKAREB ELITE Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Knob Kit SKAREB SUPER Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits X Soft Soft Medium Firm X Firm Knob Kit 89 4835 89 4876 89 4837 85 5081 85 5164 85 5041 85 5042 85 5043 85 5173 85 5050 89 4835 89 4876 N A 85 5081 89 9164 89 4808 89 4878 89 4927 85 9188 85 5174 85 5050 89 4856 89 4876 N A 85 5081 85 5164 89 4808 89 4878 89 4927 85 9188 85 5174 85 5050 Outer Casting Assemblies Black Silver Red White Yellow Orange Blue Candy Red Candy Blue Candy Chrome Black N B Silver N B Red N B White N B Yellow N B Orange N B Blue N B Candy Red N B Candy Blue N B Candy Chrome N B Lockout Assembly Will fit all SKAREB Forks 85 5100 85 5101 85 5102 85 5103 85 5104 85 5105 85 5106 85 5107 85 5108 85 5109 60 91 11 85 5112 85 5113 85 5114 85 5115 85 5116 85 5117 85 51182. bike and write this distance 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 riding position weight centered with your feet on the pedals 3 subtract the second measurement from the first The result ing measurement is the static sag SAG MEASUREMENT CHART Fork Travel Sag 80 mm 12 16 mm RIDE KITS SKAREB COMP COIL Rider Weight Recommended Ride Kits Part 100 150 lbs Soft ride kit 85 5041 150 170 lbs Medium ride kit 85 5042 170 190 Ibs Firm ride kit 85 5043 190 plus lbs Extra firm ride kit 85 5173 SKAREB ELITE SUPER DIVA Rider Weight Recommended Ride Kits Part 100 125 lbs X Soft ride kit 85 4808 125 150 lbs Soft ride kit 85 4878 150 190 lbs Medium ride kit 85 4927 190 plus lbs Firm ride kit 85 9188 Air pressure setting should equal 75 of body weight Maximum air pressure is 190 psi CHANGING COIL SPRINGS SKAREB COMP COIL 1 Start by removing the preload adjuster by removing the knob with a 2 mm hex wrench Figure 3 then unscrewing the assembly from the top of the crown leg assembly A 20 mm socket may be necessary Figure 4 Remember The springs are housed only in the left leg on 200 Manitou suspension forks With the adjuster assembly removed the spring stack is now accessible Figure 5 Select the appropriate ride ki
3. condition Finish reading this entire sec tion prior to altering the oil level To check the oil level on a Manitou SKAREB fork remove the compres sion assembly located in the top of the right leg as you are looking at the fork from the rider s position Leave the left side spring stack in place to keep the fork fully extended Use a tape measure or dip stick to measure from the top of the fork crown down to where the oil sits Figure 2 The oil level for the Manitou SKAREB should be per the fol lowing table FORK MODEL OIL LEVEL SKAREB COMP COIL 115 mm 125 mm 4 5 4 9 inches SKAREB ELITE 115 mm 125 mm 4 5 4 9 inches SKAREB SUPER 105 mm 110 mm 4 1 4 3 inches SKAREB DIVA 105 mm 110 mm 4 1 4 3 inches NOTE Use SAE 5WT fork oil suspension fluid only If you have any questions regarding your 2003 Manitou SKAREB sus pension fork contact Answer Customer Service 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 SKAREB suspension fork DEALER SERVICE ADDENDUM This section is designed to help a qualified bicycle mechanic tune and maintain your Manitou suspension fork MEASURING 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 when no one s sitting on the
4. oil and the damping fluid In addition with air spring forks you will also need to make sure a small amount of lubricating oil 8cc in sitting on top of the air piston see Air Piston Lubrication above Inspecting any of these parts requires disas sembly 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 discovered SEMIBATH LUBRICATION MAINTENANCE Your 2003 Manitou SKAREB fork is designed with a Semibath lubrication system This system requires periodic maintenance to ensure that your fork is working properly at all times To service the Semibath system do this 1 Remove the rebound damping knob with a 2 mm Allen wrench Figure 12 a With the fork positioned over an oil catch receptacle use an 8 mm Allen wrench to screw the rod located under the damp ing knob into the fork clockwise This will unthread the rod from the casting Next remove the 4 mm Allen bolt from the bottom of the fork Figure 8 You now may notice some oil draining out of the bottom of the fork 3 Pull the fork apart holding the fork away from you and let ting the oil drain out of the bottom of the fork Figure 9 4 Clean the inside of the lowers thoroughly and wipe the inner legs until they are completely free of oil or debris Figure 19 5 Pour lubricating oil into the fork before you reassemble it Pour 15cc of oil into each side of the lo
5. 85 5119 85 5120 85 4869 GA aapa pps 2 z z 26 agang AMERICAN MADE MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE A 2003 MANITOU SKAREB FORK BUILT IN THE USA This SKAREB fork is fully assembled and is ready to be installed onto your bicycle It comes equipped with a 1 1 8 inch thread less steerer tube RA casting and is available with a V brake style hangerless arch or a disc brake only version A handlebar mounted reflector must be used for on road use which is not included with your fork 2003 SKAREB FORK LINE SKAREB COMP COIL 80 MM TRAVEL COIL SPRING FLUID FLOW DAMPING SOLID CROWN RA CASTING SKAREB ELITE 80 MM TRAVEL AIR COIL SPRING TPC DAMPING HOLLOW CROWN RA CASTING SKAREB SUPER 80 MM TRAVEL AIR COIL SPRING LOCKOUT TPC DAMPING HOLLOW CROWN RA CASTING SKAREB DIVA 80 MM TRAVEL AIR COIL SPRING LOCKOUT TPC DAMPING HOLLOW CROWN RA CASTING You can also download this manual at www answerproducts com A CAN INTINTCH 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 MAINTAIN ING YOUR BICYCLE SUSPENSION FORK AND REAR SHOCK 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
6. HAS OCCURRED DURING THE COURSE OF RIDING DO NOT RIDE YOUR BICYCLE IF THE FORK OR SHOCK 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 SKAREB fork is an off road fork and as such does not come with proper reflectors for on road use 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 factory Press fit inner legs have a higher perform ance versus bolt in inner legs but cannot be pressed out Pressing them out will permanently damage the crown beyond repair and render it unsafe for any continued use 2 Never attempt to thread a threadless steerer tube Cutting threads will weaken 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 Ans
7. ble getting the 8 mm bolt to catch the threads If this occurs remove the lowers and pull the rebound damping rod again and reinstall the casting You should now be able to install the 8 mm bolt Reinstall the caps and 2 mm bolts Figure 8 and 12 CHANGING AIR SPRING PRESSURE SKAREB ELITE SKAREB SUPER SKAREB DIVA All you need to change the air pressure is a high pressure Manitou Manitou part 85 4069 or other shock pump Remove the air cap locat ed on the top of the left leg and then inflate the fork with the desired pressure Be aware that sometimes air systems lose a small amount of pressure when the pump is removed so you may want to check exactly how much your pump loses by rein stalling it on the fork after you have set and checked the pres sure ATR PISTON LUBRICATION For proper function of your fork it is essential to have a small amount of lubricating oil on top of the air piston in your SKAREB Elite Super or Diva fork To check this remove the air cap on the left side of the fork as seen from the rider s perspective by simply unthreading it counterclockwise Release the air pressure from the fork and then use a 20 mm hex wrench to remove the aluminum Schraeder cap Once you have done this you can see the top of the air piston and determine if there is a small amount of oil sit ting on top of the air piston If this oil is no longer visible pour 8cc of 20W 50 motor oil directly into the open fork leg Figure 13 A
8. ery 6 months SEVERE CONDITIONS Short Infrequent Rides e Disassemble clean and lubricate fork every 4 months e Service TPC or FFD by changing fork fluid every year SEVERE CONDITIONS Long Frequent Rides e Disassemble clean and lubricate fork every 2 months e Service TPC or FFD by changing fork fluid every 6 months
9. fter this reinstall the Schraeder cap and the air cap and pressurize COMPRESSION DAMPING ADJUSTMENT QUICK RANGE TPC For Quick Range TPC forks a simple turn of the knob located on top of the right leg is all that is need ed Turning the knob clockwise as you are looking from a rider s position increases compression damping while turning it coun terclockwise decreases compression damping ADJUSTING COMPRESSION DAMPING WITH A LOCK OUT The Lock Out is simply an on off switch for your fork To adjust compression damping do the following Remove the com pression assembly located in the right leg On the lower piston of the lockout assembly is a small setscrew Turn this in or out to increase or decrease compression damping respectively Note a half turn makes a lot of difference so make small and incremen tal changes to the setscrew REBOUND DAMPING ADJUSTMENT QUICK RANGE TPC amp FLUID FLOW Rebound adjusters on Manitou forks are located on the bottom of the right fork leg Turning the knob clockwise as you are looking at the fork from the bottom increases rebound damping while turning it counterclockwise decreases rebound damping MAINTENANCE AND SERVICE INTRODUCTION When servicing the fork take the time to inspect all parts for excessive wear or damage There are basically five aspects of a fork that will require attention the stanchions inner legs the bushings in the outer legs the spring stack the lubricating
10. out to retain the wheel in the fork in the event the quick release comes loose A EN WHEN INSTALLING THE WHEEL OR A NEW TIRE CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM OF THE BRAKE ARCH THIS MEA SUREMENT SHOULD BE AT LEAST 10 MM FIGURE 1 IMPORTANT The SKAREB 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 Your SKAREB fork requires periodic maintenance cleaning and inspec tion This is because moisture and contamination may build up inside the fork depending on the severity of riding conditions To maintain top performance it is recommended that the fork be periodically disassem bled cleaned dried and relubricated IMPORTANT Before every ride you should Ensure that quick release skewers are properly adjusted and tight Wipe the inner legs and clean and check the entire fork for any obvious damage Check the headset for proper adjustment Ensure that the front brake cable is properly routed and check brake adjustment NI Go CHECKING OIL LEVEL IMPORTANT Setting the proper oil level in your TPC equipped fork is critical TPC is located in the right leg of your SKAREB fork Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel and may cause damage to the system and create an unsafe riding
11. sed 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 At that time instructions for repair return or replacement shall be given Customers in countries other than USA should contact their dealer or local distributor INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your SKAREB 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 installa tion A WAGs 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 STEERER ASSEMBLY MUST BE DONE TO CHANGE STEERER TUBE LENGTHS OR DIAMETERS REMOV ING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE 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
12. t for the rider s weight and rid ing style refer to the above spring chart for recommended rates Reinstall the preload adjuster assembly and knob taking care not to cross thread the assembly It should thread in by hand and does not need to be tightened with a wrench finger snug is recommended CHANGING COIL SPRINGS SKAREB ELITE SKAREB SUPER SKAREB DIVA 1 Read section on Semibath Lubrication Maintenance first Unthread the air cap on top of the left fork leg and release the fork s air pressure via the Schraeder valve Figure 6 2 From the bottom of the casting remove the 2 mm cap screws and caps Figure 7 screw in the 8 mm rod turn clockwise to loosen and the 4 mm bolt from the bottom of the casting Figure 8 Once you do this you will be able to pull the lowers away from the uppers Figure 9 so 3 On the left leg as seen from the rider s perspective remove the 15 16 inch cap from the bottom of the leg Remove the entire assembly by pulling the rod lightly As this point you will see the coil spring Figure 10 4 Select the appropriate coil spring for the rider s weight and riding style refer to the above spring chart for recommended rates 5 Reinstall the assembly into the left leg of the fork taking care not to cross thread the cap It should thread in by hand and should only be snug tightened Figure 11 6 Reinstall the lowers with the 8 mm and 4 mm bolts and tight en You may have trou
13. to recheck your compression rebound and preload adjustments when applicable to fine tune the fork completely 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 SKAREB 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 manufac turer s specifications 9 Install the handlebars to the desired height and the torque stem pinch screws or stem clamping system to manufacturer s specifi cations 10 Install the brakes and adjust per the manufacturer s instructions 11 Adjust the front wheel quick release to clear the 0 335 8 5 mm thick secondary catch dropout The quick release must be tight ened after it is properly seated into the dropout counter bores to manufacturer s specifications Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock 12 Install the brake cable per manufacturer s instructions CON O CT A NOTE 2003 SKAREB forks are equipped with a secondary catch drop
14. wer Warranty at 661 257 4411 3 Any other alteration or modification to your fork should be consid ered unsafe Contact Answer Customer Service prior to modifying your fork in any way for safety information 4 Do not use the SKAREB fork if any parts are broken bent cracked or you suspect may be damaged Contact your dealer or Answer Customer Service at 661 257 4411 if you have any questions concerning the integrity or condition 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 mate rials 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 break age 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 war ranty 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 expres
15. wers while you hold the assembly horizontally A syringe is recommended for this Figure 14 6 Holding the fork horizontally insert the crown steerer assem bly back into the fork Reinstall the bolts to 10 30 in lbs and install the rebound adjuster knob Figure 8 CHANGING THE OIL IN YOUR FORK Changing the oil in your damped fork is very easy to do All of the damping systems FFD TPC and TPC Plus house the oil in the right leg 1 Remove the adjuster knob and loosen the assembly from the top of the right fork leg 20 mm socket Figure 15 Rock the compression damping assembly back and forth slightly as you pull up on it to remove it Figure 16 3 Pour the old oil out of the fork Figure 17 4 Stroke the fork up and down to remove the oil that settles beneath the rebound piston Pour this oil out as well 5 Add oil to the level shown in the Checking Oil Level section of this manual Figure 18 Make sure you stroke the fork up and down a few times before the final measurement is taken to ensure that oil has flowed beneath the rebound piston again Figure 2 SERVICE SCHEDULE Suggested Service for Manitou forks NORMAL CONDITIONS Short Infrequent Rides e Disassemble clean and lubricate fork every 6 months e Service TPC or FFD by changing fork fluid every year NORMAL CONDITIONS Long Frequent Rides e Disassemble clean and lubricate fork every 4 months e Service TPC or FFD by changing fork fluid ev
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