Manitou 2003 Sherman Service Manual
Contents
1. Outer Casting Assemblies Textured Black 85 5161 Textured Silver 89 5162 Textured Camo Grey85 5163 Textured Black N B 85 5130 Textured Silver N B 85 5131 Textured Camo Grey N B TPC for all SHERMAN models 05 S T for Ice and Flick 05 S T for Firefly 05 S T for Breakout OS S T for Slider Through Axle 89 5128 89 9126 N A 85 9093 85 5166 85 4956 85 4957 85 4958 85 4959 85 9076 85 9069 89 9129 85 5126 N A 85 5094 85 5166 85 5287 85 5288 85 5289 85 5290 N A 85 5069 AMERICAN MADE MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE A 2003 MANITOU SHERMAN BUILT IN THE USA This SHERMAN fork is fully assembled and ready to be installed onto your bicycle It comes equipped with a 1 1 8 inch or 1 1 2 inch threadless steerer tube and is available as a disc brake only version A handlebar mounted reflector must be used for on road use which is not included with your fork 2003 MANITOU SHERMAN FORK LINE SHERMAN ICE 110 130 MM CONVERTIBLE TRAVEL COIL SPRING FLUID FLOW DAMPING SINGLE CROWN RA CASTING SHERMAN FLICK 110 130 MM EXTERNALLY ADJUSTABLE RAPID TRAVEL II COIL SPRING TPC DAMPING SINGLE CROWN RA CASTING SHERMAN FIREFLY 110 130 MM EXTERNALLY ADJUSTABLE RAPID TRAVEL II COIL SPRING TPC DAMPING HOL LOW CROWN RA CASTING SHERMAN BREAKOUT 132 152 MM EXTERNALLY ADJUSTABLE RAPID TRAVE2. FORK INSTALLATION 1 Remove the old fork from your bicycle 2 Measure and cut the steerer tube to fit your bicycle head tube SEE IMPORTANT NOTE ABOVE 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 SHERMAN fork steerer until the race is seated over the crown 4 Clean and grease the headset bearings and races 5 Install the lower bearings if applicable on fork crown race 6 Insert the steerer tube into the head tube of the frame T Install the upper bearings stem spacers upper triple clamp on the Slider model and stem 8 Install the stem cap and bolt Tighten the bolt to headset manufac turer s specifications 9 Install the handlebars and the torque stem pinch screws or stem clamping system to manufacturer s specifications 10 Install the brakes and adjust per the manufacturer s instructions 11 For SHERMAN forks with standard dropouts adjust the front wheel quick release to clear the 0 275 7 mm thick secondary catch dropout The quick release must be tightened 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 For SHERMAN forks with the Hex Lock through axle system install small side of the through axle through the large opening and wheel Tighten down the hex l
3. fork crown down to where the oil sits Figure 2 The oil level should be per the following table FORK MODEL SHERMAN ICE SHERMAN FLICK SHERMAN FIREFLY SHERMAN BREAKOUT SHERMAN SLIDER SHERMAN W LOCKOUT OIL LEVEL 115 to 125 mm 4 5 to 4 9 78 to 83 mm 3 1 to 3 3 86 to 91 mm 3 4 to 3 6 86 to 91 mm 3 4 to 3 6 86 to 91 mm 3 4 to 3 6 101 to 106 mm 4 to 4 2 NOTE Use SAE 5WT suspension fork oil only If you have any questions regarding your 2003 Manitou SHERMAN Suspension fork in the U S contact the Answer Customer Service Department at 661 257 4411 For information outside of the U S contact your authorized Manitou dealer or distributor 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 SHERMAN 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 a piece of paper and a helper 1 Measure the distance from the front axle s centerline to the bottom of the upper crown when no one s sitting on the bike and write this distance down Remember the exact locations of the two points because you ll need to use them later Have the rider sit on the bike and measure the distance between the same two points as in step o
4. the fork depending on the severity of riding conditions To main tain top performance it is recommended that the fork be periodically disassembled cleaned dried and relubricated You can download serv ice and tuning instructions on the web at www answerproducts com IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight On Hex Lock through axle models ensure that the axle is fully inserted into the dropouts and the pinch bolts are tightened to 24 29 in Ibs 2 Wipe the inner legs and clean the fork Check the entire fork for any obvious damage 3 Check the headset for proper adjustment 4 Ensure that the front brake cable is properly routed and check brake adjustment CHECKING OIL LEVEL IMPORTANT Setting the proper oil level in your TPC TPC or FFD equipped fork is critical TPC TPC or FFD is located in the right leg of your SHERMAN 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 condi tion Finish reading this entire section prior to altering the oil level To check the oil level remove the compression assembly located in the top of the right leg as you are looking at the fork from the rider s posi tion 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
5. CD LMLANRYT COXU FLICK FIREFLY BREAKOUT SLIDER OW NER S MANUAL P N 040254 28209 Avenue Stanford Valencia California 91355 3984 661 257 4411 fax 661 294 4179 SERVICE PARTS KITS SHERMAN ICE Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm X Firm Convertible Travel Knob Kit SHERMAN FLICK Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly sticker Kit Ride Kits Soft Medium Firm X Firm Travel Adjust Knob Kit SHERMAN FIREFLY Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm X Firm Travel Adjust Knob Kit 85 5125 85 5126 N A 85 5091 85 5166 85 4966 85 4967 85 4968 85 4969 89 5067 85 5060 85 5127 85 9126 N A 85 5091 85 9166 85 9178 85 9179 85 5180 85 5181 85 5071 85 9069 85 9128 85 9126 N A 85 5092 85 9166 89 5178 85 5183 85 5184 89 5181 85 5186 85 5069 SHERMAN BREAKOUT Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm X Firm Travel Adjust Knob Kit SHERMAN SLIDER Compression Damping Assembly Rebound Damping Assembly Preload Crown Steer Tube Assembly Sticker Kit Ride Kits Soft Medium Firm X Firm Convertible Travel Knob Kit
6. L II COIL SPRING DAMPING HEX LOCK THROUGH AXLE onepointfive STEER ING SYSTEM RA CASTING SHERMAN SLIDER 152 MM TRAVEL COIL SPRING TPC DAMPING HEX LOCK THROUGH AXLE DOUBLE TRIPLE CLAMP RA CAST ING You can also download this manual at www answerproducts com A 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 AND SUSPENSION FORK WILL REDUCE THE POSSI BILITY OF INJURY OR POSSIBLE DEATH PRIOR TO RIDING YOUR BICY CLE YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF RIDING DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING CRACKING CREAKING LEAKING OR IF IT IS MISSING ANY OF THE ORIGINALLY SUPPLIED COMPONENTS ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH FOLLOWING THESE INSTRUCTIONS CAN HELP YOU REDUCE THE RISK OF BEING INJURED IF YOU ARE A MODERATE OR AGGRESSIVE OFF ROAD RIDER OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN ANSWER RECOMMENDS RETURNING YOUR SUSPENSION FORK EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO ANSWER PRODUCTS OR YOU MAY CALL ANSWER AT 661 257 4411 TO HAVE YOUR FORK SHIPPED DIRECTLY IMPORTANT The Manitou SHERMAN fork is an off road fork and as suc
7. RMAN ICE Changing the travel from 110 to 130 millimeters of vice versa requires the removal of the lower legs read the Semibath section first Unthread the 8 mm Allen bolt clockwise to loosen and 11 mm bolts on the bottom of the fork and pull the lowers free from the uppers Then unscrew the cap on the bottom of the left leg as seen from the rider s perspective Remove the upper clip and insert it into the upper position for 130 millimeters of travel or the lower position for 110 millimeters of travel 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 lubricating oil and the damping fluid 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 SHERMAN 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 6 With the fork positioned over an oil catch receptacle loosen clockwise to loo
8. ds that you periodically inspect your fork for wear and damage Inspect the crown inner legs outer legs dropouts 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 freight prepaid This warranty does not cover breakage bending or damage that may result from crashes or falls This warranty does not cover any fork that has been subject to misuse or whose serial number has been altered defaced or removed This warranty does not cover paint damage Any modifications made by the user will render the war ranty null and void This warranty is expressly in lieu of all other war ranties and any implied are limited in duration to the same duration as the expressed warranty herein Answer Products shall not be liable for any incidental or consequential damages If for any reason warranty work is necessary return the fork with origi nal purchase receipt to the place of purchase At that time instructions for repair return or replacement shall be given Customers in coun tries other than USA should contact their dealer or local distributor INSTALLATION INSTRUCTIONS Ensure that the proper steerer tube has been delivered on your SHER MAN fork first The s
9. h 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 contact your deal er CONSUMER SAFETY INFORMATION 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 Slider model excluded Press fit inner legs have higher per formance versus bolt in inner legs but can not be pressed out 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 The only safe thing to do is to obtain the proper crown steerer from your dealer on contact Answer Customer Service at 661 257 4411 Any other alteration or modifica tion to your fork should be considered unsafe Contact Answer Customer Service prior to modifying your fork in any way for safety information Do not use the SHERMAN fork if any parts are broken bent cracked or you suspect may be damaged Contact your dealer or Answer Products Customer Service at 661 257 4411 if you have any ques tions concerning the integrity or condition of your fork Answer Products recommen
10. ne 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 110 mm 22 to 27 mm 130 mm 26 to de mm 152 mm 30 to 58 mm SPRING KITS SHERMAN ICE SHERMAN FLICK 110 130 Rider Weight Recommended Spring Kit 130 150 lbs Soft ride kit Part 85 5178 150 170 lbs Medium ride kit Part 85 5179 170 190 lbs Firm ride kit Part 85 5180 190 215 lbs Extra firm ride kit Part 85 5181 SHERMAN FIREFLY 110 130 Rider Weight Recommended Spring Kit 130 150 lbs Soft ride kit Part 85 5178 150 170 lbs Medium ride kit Part 85 5183 170 190 lbs Firm ride kit Part 85 5184 190 215 lbs Extra firm ride kit Part 85 5181 SHERMAN BREAKOUT Rider Weight Recommended Spring Kit 130 150 lbs Soft ride kit Part 85 4956 150 170 lbs Medium ride kit Part 85 4957 170 190 Ibs Firm ride kit Part 85 4958 190 215 lbs Extra firm ride kit Part 85 4859 SHERMAN SLIDER Rider Weight Recommended Spring Kit 130 150 lbs Soft ride kit Part 85 5287 150 170 lbs Medium ride kit Part 85 5288 170 190 lbs Firm ride kit Part 85 5289 190 215 lbs Extra firm ride kit Part 85 5290 CHANGING COIL SPRINGS 1 Start by removing the spring cap by unscrewing the knob and cap from the top of the crown leg assembly Figure 3 Remember The springs are housed only in the left leg on 2003 Mani
11. nual Figure 17 Cover the leg opening and stroke the fork up and down a few times before the final measurement is taken to ensure that oil has flowed beneath the rebound pis ton again Figure 2 SERVICE SCHEDULE Suggested Service for Manitou forks NORMAL CONDITIONS Short Infrequent Rides Disassemble clean and lubricate fork every 6 months Service TPC TPC and FFD by changing fork fluid every year NORMAL CONDITIONS Long Frequent Rides Disassemble clean and lubricate fork every 4 months Service TPC TPC and FFD by changing fork fluid every 6 months SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Short Infrequent Rides Disassemble clean and lubricate fork every 4 months Service TPC TPC and FFD by changing fork fluid every year SEVERE CONDITIONS MUD RAIN SNOW EXTREME DUST Long Frequent Rides Disassemble clean and lubricate fork every 2 months Service TPC TPC and FFD by changing fork fluid every 6 months
12. ock end bolt until it is snug Then tighten the drop out pinch bolts to 24 29 in Ibs 2 7 3 3 Nm 13 Install the brake cable per manufacturer instructions NOTE 2003 SHERMAN forks with standard dropouts are equipped with a secondary catch dropout to retain the wheel in the fork in the event the quick release comes loose UPPER TRIPLE CLAMP SIZING SLIDER MODEL To fit a variety of bike head tube sizes there are two distinct upper triple clamps The flat upper triple clamp is the small size and fits head tubes between 125 and 145 mm in length The drop upper triple clamp is the large size and fits head tubes between 145 and 165 mm in length Both clamps must fully engage the aluminum bulges on the outer tubes without extending beyond the small taper line with the upper and lower clamps All triple clamp bolts must be torqued to 40 45 in Ibs 4 5 5 1 Nm 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 12 MM 0 47 FOR ALL SHERMAN FORKS FIGURE 1 IMPORTANT The SHERMAN 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 SHERMAN fork requires periodic maintenance cleaning and inspection This is because moisture and contamination may build up inside
13. sen the 8 mm Allen bolt Figure 7 and remove the 11 mm socket bolt from the bottom of the fork Figure 8 3 Pull the fork apart holding the fork away from you and let ting the oil drain out of the bottom of the forks 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 10 5 Reinstall lubricating oil into the fork before you reassemble it Pour about 16cc of oil into each side of the lowers while you hold the assembly horizontally A syringe works well for this It is best to keep the oil in between the bushings Figure 11 6 Holding the fork horizontally insert the crown steerer assem bly back into the fork Reinstall the bolts snugging each tight and install the rebound adjuster knob Figure 12 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 2 Remove the adjuster knob Figure 13 Loosen the assembly on top of the right fork leg with a 20 mm wrench Figure 14 Rock the compression damping assembly back and forth slightly as you pull up on it to remove Pour the old oil out of the fork Figure 15 otroke the fork up and down to remove the oil that settles beneath the rebound piston Pour this oil out as well Figure 16 Add oil to the level shown in the Checking Oil Level section of this ma
14. teerer 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 IMPORTANT NOTE SOME MODELS FEATURE THE NEW one pointfive STANDARD STEERER TUBE THE 1 1 2 INCH STEERER TUBE REQUIRES A SPECIFIC BICYCLE FRAME HEADSET AND STEM DO NOT ATTEMPT TO MODIFY ANY PARTS TO ADAPT FROM A 1 1 8 INCH SYSTEM TO THE 1 1 2 INCH SYSTEM FOR MORE INFORMA TION REFER TO WWW ONEPOINTFIVESTANDARD COM A WARNING THE STEERER TUBE AND STANCHIONS INNER LEGS ARE A ONE TIME PRECISION PRESS FIT AT THE FACTORY AND CANNOT BE REMOVED FROM THE CROWN SLID ER MODEL EXCLUDED REPLACEMENT OF THE ENTIRE CROWN STEER ER ASSEMBLY MUST BE DONE TO CHANGE STEERER TUBE LENGTHS OR DIAMETERS REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE 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 your compression rebound and preload adjustments when applicable to fine tune the fork completely
15. tou suspension forks as you are looking at the fork from the rider s perspective Figure 4 2 With the spring cap removed the spring stack is now accessi ble Figure 5 3 Select the appropriate coil spring for your weight and riding style refer to the above spring chart for recommended rates 4 Reinstall the spring cap taking care not to cross thread the cap It should be snug tightened with a wrench Figure 4 COMPRESSION DAMPING ADJUSTMENT QUICK RANGE TPC AND TPC For Quick Range TPC forks a simple turn of the knob located on top of the right leg is all that is needed Turning the knob clockwise as you are look ing from a rider s position increases compression damping while turning it counterclockwise decreases compression damping REBOUND DAMPING ADJUSTMENT UICK RANGE TPC TPC AND FLUID FLOW AMPING FFD 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 RAPID TRAVEL II SHERMAN FLICK SHERMAN FIREFLY SHERMAN BREAKOUT To change the travel with Rapid Travel II just turn the knob located at the top of the left leg Turn the knob forward for long travel backwards for short travel Compressing the fork slightly is required to release or lock the fork into a different travel position CONVERTIBLE TRAVEL SHE
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