Answer 2004 Sherman Service Manual
Contents
1. 85mm 125cc REV NC 04 SHERMAN SERVICE MANUAL Page 26 REV NC 2 8 4 1 1 3 Screw aere aer O SSS O 04 SHERMAN SERVICE MANUAL REV NC Model Sherman Breakout Breakout Leg Caps Not Cross Threaded Screw Torque TA Il Top Cap SPV Volume Control Assembly CI EEN 4 10 150mm Travel 04 SHERMAN SERVICE MANUAL REV NC 1 A ae co F N NED AAA kN l m m i PRP hk 4 Fred CEE 1 i i Le B H EZ GD Model Sherman Slider Torque Triple Clamp Bolts Leg Caps Not Cross Threaded 25 35inlbs 2 8 4 0nm Torque Comp Rod Screw 10 30inlbs 1 1 3 4nm Panao O 04 SHERMAN SERVICE MANUAL REV NC 1 To EE A Fa PP AL LLLOLA COLINA i i E A A PEE ES Ds Gs Sa v K E I ee C lt R Ll H 9 0 10 Damping ite 04 SHERMAN SERVICE MANUAL REV NC Sherman Service Kits Flick Flick 80 Firefly Breakout Breakout 85 5960 Slider 170 85 5129 85 5901 Travel mm Comp Damper Rebound Damper Pre Load Adj Top Cap Crn Str Leg Steel S T 26 BIk AL S T 26 STD SM BIk AL S T 26 LG PR Taner Teg TCSP AAA Outer Leg Assembly STD Textured Black 85 5161 STD Textured Gray 85 5162 T Camo 85 5163 No Boss Textured Black 85 5130 No Boss Textured Gray 85 5131 F Silver 85 5907 WD Booster TE 85 5902 85 5903 85 5962 85 59632. Check O ring tighten cap to proper MI Air Top Cap leaks Torque replace parts as needed Oil leaks from Remove Casting from Inner Legs reinstall Wiper Seals Seal not seated properly or replace seals MS E or scratches on Replace Crown Steerer Inner Leg inner legs Assembly Follow instructions for removal and Too much Semi Bath oil installation of Outer Casting Remove Casting from Inner Legs reinstall Wear or replace seals Oil leaks from bottom of Rebound damper shaft Casting leaks Replace Rebound Damping assembly Rebound damper shaft O Replace O ring on threaded end of ring damaged Rebound Damping assembly Compression Rod Bolt Check O ring on bolt to see if it is leaks damaged and then reinstall Resize bushings or replace with new ones Lack of Travel Tight Bushings if damaged N Hydraulic lock out Replace Rebound Damping assembly A Follow instructions for removal and Semi Bath oil volume installation of Outer Casting Check oil level Replace Rebound Damper oil volume Damping assembly if needed Visually inspect fork call Answer Fork alignment Products Customer Service Loss of SPV Inspect for damage check valve gap damping SPV valve not functioning replace assembly if needed Check oil level refer to Oil leaks from Damper oil volume bottom of Casting Rebound knob does not turn Replace Rebound Damping Assembly Refer to Air Loss Schrader valve leaks Loss of SPV air pressure and Air Cap O ring Leaks 04 SHERM
3. Lock Out a special function that restricts the compression of the fork from moving It is generally controlled by an external knob that is activated when a rider does not want the fork to move thus eliminating extra energy needed to overcome the bobbing forces of the fork MCU Micro Cellular Urethane Special urethane that is filled with tiny air cells that act like springs when the elastomer is compressed Micro Lube Lubrication system that is operated by injecting small quantities of grease directly into ports that are inserted into outer casting legs This enables the lubrication of the fork without having to disassemble it No Boss The word used to describe an outer casting that has no brake posts for V brakes or cantilever brakes This casting is to be used for disk brakes only Oil Damping A system that uses the resistance to oil flow through holes in a valve to provide a means to alter the rate of suspension compression or rebound Oil Level The level of damping oil needed for the optimal damping performance of a suspension It is measured as the air space distance between the top of the stanchion leg inner leg and the height of the oil inside of the leg The fork must be completely extended in order to get an accurate measurement O Ring A soft flexible neoprene or Buna rubber ring with a round cross section which is used for sealing and retention Oil Weight A description of the relative viscosity of
4. U Travel Adjust Comp Rod 152 170 90 130 110 150 130 170 85 5922 85 5924 85 5293 85 5925 85 5294 85 5964 85 5070 Bumper Kit Thru Axel Top Clamp LG Top Clamp SM 85 5965 85 5966 04 SHERMAN SERVICE MANUAL REV NC
5. at top of assembly Install the assembly and tighten end cap to specified torque value Be sure to put a dab of Blue Loctite on the end cap threads before installing cap into leg REV NC WACAN All leg caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death 4 Install compression rod assembly into bottom of left inner leg and tighten to specified torque value Be sure to put a dab of Blue Loctite on the end cap threads before installing cap into leg 5 Turn Crown steer leg assembly right side up so that the crown of the assembly is facing you Extend the SPV rebound damping assembly or TPC rebound damping assembly all the way out and then pour damping oil P N 85 0023 into the right inner leg Fill leg about _ of the way up Take a rag and cover the top of the right inner leg and then stroke the SPV damping assembly up and down about 5 times This will insure that oil gets below the piston and not create an air space Extend the damping assembly all the way out and then fill the inner leg to the specified oil level 6 Insert the Volume control assembly or TPC compression damping assembly into the top of the right inner leg and tighten it to specified torque value Be sure that you unscrew the red 16mm Hex shaped Volume control nut all of the way counterclockwise after you tighten the entire assembly into the inner leg Una Niel All top caps for Damper and Spri
6. cap into leg Pull out damper shaft as far as it will go Press inner legs into casting about half way and then inject Semi Bath oil 5 20wt synthetic oil into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16 cc s of oil into each outer leg It is recommended to use a syringe to inject oil Press inner leg assembly into outer leg casting until damper shaft contacts casting Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Torque to 20inlbs Install rebound adjuster knob Press inner leg assembly into outer leg casting until compression rod contacts casting Install Compression rod screw torque to 40 50inlbs Set travel adjust knob all the way clockwise compress fork and then release to verify that it is in longest travel Remove adjuster knob then remove top cap with 20mm socket Twist aluminum hex shaped shaft clockwise until you meet resistance release shaft and let it return naturally to wherever it stops Using a marking pen mark one side of the hex shaped shaft that is facing the front of the fork Remember where that colored side is in relation to the crown of the fork Install top cap and tighten to 35 50inlbs UI Niel All top caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death 15 Twist hex shaped shaft counterclockwise until i
7. of the way counterclockwise after you tighten the entire assembly into the inner leg Insert spring into the top of the left leg and follow procedure in Rapid Travel II service instructions for clocking the travel adjust Use 8 10 adjustable wrench Manitou Volume Control Adjuster P N 85 3007 24mm socket metric ruler Sherman Dual Crown forks 1 Removal of inner legs from Dual Clamps Loosen upper clamp fixing bolts with a 4mm Allen wrench and remove upper clamp from inner legs Loosen lower clamp fixing bolts with a 4mm Allen wrench and remove lower clamp from inner legs You may have to remove the frame bumpers first to remove the lower clamp 2 Installation of inner legs into Dual Clamps WACAN All Triple Clamp Pinch Bolts must be properly tightened prior to use Failure to do so could result in injury or possible death 04 SHERMAN SERVICE MANUAL Insert inner legs into lower clamp about 5 inches 125mm Install upper clamp onto the inner legs and steer tube so that the top of the upper clamp is flush with the top of the inner legs Do not tighten fixing bolts at this time because you will have to make adjustments to the distance between the clamps before you install the fork on your bike 3 Install SPV rebound damping assembly or TPC rebound damping assembly into bottom of right inner leg Be sure to check the function of the SPV valve and apply a thin layer of Prep M grease onto o ring that is around the piston
8. AN SERVICE MANUAL REV NC TROUBLESHOOTING CONT Symptom came cme Loss of Rebound Fork Top out Damping Replace Rebound Damping assembly Refer to Loss of SPV Damping SPV SPV Valve not functioning valve not functioning Inspect and replace Top out spring if Top out spring damaged needed Damping oil volume not Check oil level Replace Rebound correct Damping assembly if needed Fork Bottom Refer to SAG Set up in Tuning section of out Too much SAG Owners Manual Bottom out Bumper Inspect and replace Bottom out Bumper if damaged needed Damping oil volume not Check oil level Replace Rebound correct Damping assembly if needed Resize bushings or replace with new ones Play in Fork Loose bushings if damaged Loose Compression Rod bolt Tighten bolt to specified torque Loose Rebound damping shaft Tighten Shaft to specified torque MA Loose press fit tolerances Call Answer Products Customer Service 04 SHERMAN SERVICE MANUAL Page 24 REV NC Model Sherman Flick Torque Top Travel Adjust Comp Rod Screw Torque TA Il Top Cap Torque Comp Rod Screw Thru Axle Clamp Bolts Semi bath Oil Volume Damping Oil Level 90 130mm Travel 04 SHERMAN SERVICE MANUAL Torque Value 3 9 4 1in 99 104mm 3 4 3 6in 86 91mm 25 35inlbs 2 8 4 0nm 10 30inlbs 1 1 3 4nm 45 60inlbs 5 1 6 8nm 35 50inlbs 4 0 5 7nm 10 30inlbs 1 1 3 4nm 40 60inlbs 4 5 6 8nm 16cc per leg 3 3in
9. Reverse Arch Technology Also known as RA It is a system that is designed to move the arch of a fork to the backside of a fork rather than the conventional front position It was designed to provide greater rotational torque strength to an outer casting slider without adding additional weight to the fork SAG The amount a suspension fork compresses at rest with a normal load rider s weight Schrader Valve Valve used to introduce air into a chamber Seal A part usually neoprene rubber or Buna that keeps contaminants out and or working fluids in Semi Bath A lubrication system that uses a lubricating oil to keep the bushing surface and stanchion legs inner legs as friction free as possible during movement of the stanchion legs Spring Rate The rate at which the resistance of a spring increases as it is compressed SPV Stable Platform Valve new damping system that allows the rider to set the pedaling platform that he desires to pedal most efficiently in all situations It is dependent on the pressure that the SPV valve experiences from the movement of the wheel vs the terrain and the platform that is set by pressure introduced to other side of the SPV valve through changes of air pressure working on the damping oil Slider Outer Casting The tube outer casting leg of the suspension fork that remains fixed to the wheel It slides up and down on the stanchion leg inner leg Stanchion Clamps Double T
10. The bumper will help to hold the damper shaft in place as you are inserting the inner legs into the casting Use an 8mm hex 04 SHERMAN SERVICE MANUAL Page 17 REV NC wrench to turn the damper shaft counterclockwise threading it into the casting Tighten to specified torque values 4 Install rebound adjuster knob Knob should turn uninhibited until the indicator is stopped by the casting If not remove knob and reinstall on hex shaft in 1 6 turn increments until full travel is reached 5 Install the compression rod screw and tighten to specified torque values Use 8mm Allen wrench 2mm Allen wrench 11mm nut driver or open end wrench syringe for Semi Bath oil Adding Semi Bath oil to a casting with Syringe 04 SHERMAN SERVICE MANUAL Page 18 REV NC Bushing Removal amp Installation Bushing Removal Note use appropriate removal ring that corresponds to the leg diameter of the fork being repaired Leg Diameter Answer Kit 25 4mm 1 28 6mm 11 8 30mm 32mm Bushing Removal Tool Components Slide Hammer Threaded Handle Slide Threaded Shaft Removal Ring Bushing Removal Tool Assembly 04 SHERMAN SERVICE MANUAL Page 19 REV NC Bushing Removal CONT Bushing Removal Instructions A Install 25 4mm Removal ring on the shiny smaller diameter threaded shaft Be sure to install the ring with the tapered chamfered end first followed by the long slide tube This tapered end leads the to
11. h a 20mm socket The spring will be attached to the bottom of the assembly when you pull it from the inner leg 6 Pull the spring from the assembly and it can be substituted with a different rated spring if necessary 7 The compression rod assembly may be removed by unscrewing the end cap on the bottom of the left leg After unscrewing the end cap pull the assembly from the inner leg USE 24mm Open end wrench or 8 10 Adjustable wrench 2mm Allen wrench 20mm socket Note If you are going to change the spring without taking the entire fork apart you must first unscrew the compression rod on the bottom of the left fork leg Now you may unscrew the top cap and remove it and the spring It may be necessary to exert extra force when pulling the spring out of the leg Bushing Removal amp Installation Please refer to section on Bushing Removal amp Installation Rapid Travel Il Service Instructions Disassembly Una Niel This fork uses a preloaded coil spring provide spring resistance The spring must be relieved of its preload prior to servicing Failure to do so could result in injury or possible death 1 Make sure that fork is in long travel mode by turning T A knob clockwise until it stops then compress fork one time and release it into long travel Unscrew 2mm Allen Head from top of knob Unscrew top cap that is threaded into crown with 20mm socket Remove spring from inner leg From the right leg dropout use a 2mm Al
12. hits Travel The amount that a wheel moves between the most compressed and the most extended states of the suspension Viscosity A description of how a liquid flows Liquids with higher viscosity are thicker flow less easily or quickly than liquids with low viscosity This has an affect on the damping speeds of rebound and compression Volume Control A new system designed to work with SPV as a control of the compression ramp up rate of the fork It has a range of adjustments from linear to very progressive Wiper Seal A rubber material that is used as a seal to keep dirt and water out of the outer casting legs It is not designed to keep air pressure or extreme oil pressure in Manitou has the new Evil Genius wiper seals 04 SHERMAN SERVICE MANUAL REV NC 2004 Sherman Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting WACAN This fork uses a preloaded coil spring provide spring resistance The spring must be relieved of its preload prior to servicing Failure to do so could result in injury or possible death 1 On forks with Rapid Travel Adjust II Top Travel Adjust be sure to set travel to its longest setting Rotate knob on top left of fork leg clockwise towards the front of the fork and then push down on the fork to release its travel into the longest mode More complete instructions for servicing Travel Adjust systems may be found in the Travel Adjust section 2 T
13. ion and be aware that oil that is on top of the TPC pistons will come out with the assembly Have a rag handy Removal of SPV Compression Damping Assembly WAAI This fork uses compressed air as part of the SPV damping system and must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death 1 Remove Schrader valve dust cap from Red Hex Shaped Top Cap on the top right of the crown Release all air pressure from the Schrader valve 2 Remove SPV Volume Control Cap Red Hex Shaped Top Cap from top right of the crown with a 24mm Socket Turn fork upside down over drainage pan to empty Damping oil from the inner leg Stroke the Damper shaft on the bottom of the inner leg 3 5 times to purge the leg of oil that is caught below the oil piston USE 24mm Socket Valve core removal tool or small object that can be used to depress valve stem Removal of TPC and SPV Rebound Damping Assembly 1 Unscrew Damper end cap from the bottom of the right leg and then pull the TPC or SPV damping assembly out of inner leg Be aware that a small amount of damping oil will come out with the assembly This oil is the oil that is trapped under the piston 04 SHERMAN SERVICE MANUAL REV NC 2 Checking the function of the SPV valve a Visually inspect the gap between the SPV valve and the bottom of the damping piston It should have approximately 1mm of space The valve should also spring back t
14. is that the lower bushings must not be driven any deeper than 5 into a casting leg If they do go deeper call Customer Service at Answer Products 800 423 0273 for a new outer casting Always assemble Mandrel with the larger diameter sizer ring being placed on the mandrel first then the spacer the next largest sizer ring followed by the washer and the nut to hold it in place Be sure to lock the nut above the Mandrel and below the Mandrel against each other Replace the lower bushing bushing with a thicker wall diameter first Place a small amount of Prep M grease onto the sizer rings to help the rings come through the bushings when pulling them out Slide bushing onto Mandrel until it stops Apply a bead of Red Loctite all the way around the outside of the bushing Hold casting on top of bench with a rag under the end of the legs and insert installation tool with bushing into casting leg 04 SHERMAN SERVICE MANUAL Page 21 REV NC Bushing Installation CONT Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet until proper depth is achieved If using depth gage slide gage onto rod before installing weighted handle and let it settle on of Mandrel Tap rod until appropriate line on gage is even with top of casting leg Remove weighted handle and gage if applicable For sizing of the lower bushing Use slotted top cap from sizer kit and set it into the top of the casting
15. lamp fixing bolts on the right drop out to the specified torque see photo below Axle Nut Left Drop out Right Drop out Installation of Outer Casting WA ite When installing the outer Leg Casting to the Crown Steer Assembly Drop Out bolts and Damper Shafts must be properly tightened prior to use Failure to do so could result in injury or possible death 1 Turn completed crown steer leg assembly upside down so that the compression rod and SPV damper shaft are facing you You will see a bottom out bumper on the SPV or TPC damper shaft slide this bumper down towards the end cap that is threaded into the inner leg This will help in keeping the shaft extended as you install the outer casting On SPV equipped forks you could also insert air into the damper leg through the Schrader valve on top of the right leg This extra pressure will help to keep the shaft from moving 2 Press inner legs into casting about half way and then inject Semi Bath oil 5 40wt synthetic oil P N 85 0022 into outer casting holding fork at 45 degree angle to the ground with bottom of fork in the air drop outs up Inject 16cc s of oil into each outer leg It is recommended to use a syringe to inject oil Figure 1 3 Press inner leg assembly into outer leg casting until damper shaft contacts casting It is recommended to extend rebound damper out from end cap as far as it will go and then slide bottom out bumper towards the end cap as far as it will go
16. lation instructions for the kits Due to the time consuming nature suspension fork service at this time our primary focus is to offer service kits that minimize the amount of downtime and labor involved Important information is highlighted in this manual by the following notations Failure to follow WARNING instructions could result in severe injury or death to the person inspecting or repairing the suspension fork or the user CAUTION A CAUTION a caution indicates special precautions that must be taken to avoid damage to the product NOTE A NOTE provides key information to make procedures easier or clearer Suspension forks by design contain gases and fluids under extreme pressure and warnings contained in this manual must be observed to reduce the possibility of injury or possible death Following these instructions can help you reduce the risk of being injured Any questions in regards to the information in this manual should be directed to Answer Products Customer Service at 661 257 4411 MINA Ne The Sherman uses compressed air to provide fluid pressure in the damping system in some models This system must be relieved of pressure prior to servicing these systems Failure to relieve air pressure could result in injury or possible death 04 SHERMAN SERVICE MANUAL Page 3 REV NC GLOSSARY OF TERMS Air Cap Top cap that threads into top of air spring leg this is the left leg of the fork as you are seated on the seat Fork
17. leg straddling the threaded rod Spin the extra nut with washer down to the top cap and using a wrench socket or speeder wrench tighten the nut in a clockwise direction This will cause the Mandrel to be pulled through the bushing thus sizing it Keep turning the nut until the tool is all the way through the bushing and can be pulled out of the leg To install top bushings repeat steps B E Note that the top bushing gets inserted until it stops against the step inside of the casting The extra sleeve that comes with the sizer kit is used to space the top cap off of the casting so that there is enough room to pull the sizers out of the casting without bottoming on the cap If you find that the bushings are too tight after installing them use the sizer Mandrel that does not have a stop on it to hold the bushing while installing it into the casting This is available in the 25 4mm leg kit 85 5191 to go back in and resize the bushings 10 To resize bushings Choose the next larger size rings and repeat the above process 11 When satisfied with the results reinstall Dust wiper seals and then reassemble fork 04 SHERMAN SERVICE MANUAL Page 22 REV NC TROUBLESHOOTING Symptom cme cme g Tighten Valve core replace bad parts as Air Loss Schrader Valve leaks needed Make sure O ring is seated properly a Air Cap O ring leaks replace parts as needed Check oil volume on top of piston replace Air Piston leaks parts as needed
18. len wrench to remove rebound damper adjuster knob Use an 8mm Allen wrench and turn the damper shaft clockwise until it can be pushed into the casting 6 Remove Compression Rod bolt from the left leg dropout with a 7 16 socket or open end wrench 7 Remove crown steer inner leg assembly from the outer leg casting Be sure to drain all Semi Bath oil out of casting before re assembly of fork 8 Remove left leg end cap and compression rod assembly from inner leg Si PUN 04 SHERMAN SERVICE MANUAL REV NC Assembly See Photos on Next page WACAN When installing the outer Leg Casting to the Crown Steer Assembly Drop Out bolts and Damper Shafts must be properly tightened prior to use Failure to do so could result in injury or possible death 1 10 11 12 13 14 Install travel adjust compression rod assembly into inner left leg and torque end cap to 20inlbs Be sure to put a dab of Blue Loctite on the end cap threads before installing cap into leg Grease spring and insert into inner leg If spring does not go in all of the way twist it slightly and it will fall into place Do not force spring into leg Install top cap with 20mm socket and do not tighten it all of the way Be sure to put a dab of Blue Loctite on the end cap threads before installing cap into leg Install rebound assembly start threads by hand and then torque to 20inlbs Be sure to put a dab of Blue Loctite on the end cap threads before installing
19. manitou SHEnRNLAIN 2004 SERVICE MANUAL Sherman Slider Plus Sherman Slider Sherman Breakout Plus Sherman Breakout Sherman Firefly Sherman Flick 28209 Avenue Stanford Valencia California 91355 661 257 4411 fax 661 294 4179 www answerproducts com Table of Contents O Introduction Front Suspension Terminology Disassembly Instructions Travel Adjust Systems Rapid Travel Il Assembly Instructions Bushing Removal and Installation Instructions Troubleshooting Chart Sherman Flick Schematic and Torque Specifications Sherman Firefly Schematic and Torque Specifications Sherman Breakout Breakout Schematic and Torque Specifications Sherman Slider Schematic and Torque Specifications Sherman Slider Schematic and Torque Specifications Sherman Service Kit Chart Contact Information Answer Products Customer Service Department 28209 Ave Stanford Valencia CA 91355 Toll Free 800 423 0273 Direct 661 257 4411 FAX 661 775 1798 E mail warranty answerproducts com tech answerproducts com Web site www answerproducts com 04 SHERMAN SERVICE MANUAL REV NC INTRODUCTION This manual is intended to guide the user through basic service of Manitou Sherman front forks Service is supported by the identification of common parts and assemblies that have been assembled into Service Kits The purpose of this manual will be to describe conditions that may drive the need for service and to provide instal
20. nd the steer tube pressed together as one assembly This assembly is then finished by adding all of the fork internals and then outer casting slider Damping A function that modifies the rate of suspension compression or rebound Detent An indentation that causes a rotating adjuster to stop at fixed increments Drop Out The end of an outer casting slider where the wheel attaches Dust Boot Usually a piece of rubber in the shape of a cylinder with baffles to allow it to compress as the fork compresses through its travel Its function is to help keep dirt and water from getting into the inner legs of the fork FFD Fluid Flow Damping A Manitou patented low cost oil damping system The compression damping is non adjustable and the rebound damping may be non adjustable or adjustable damping 04 SHERMAN SERVICE MANUAL REV NC GLOSSARY OF TERMS CONT Fork Crown The component that joins the stanchion tubes inner legs to the steer tube of the fork Hydraulic Fork Oil Oil used in suspension designs to provide damping It has special characteristics that determine how it reacts when exposed to compressed air how it changes viscosity when its temperature changes and how it moves through valves Hydraulic Lock Out a condition caused when the mixture of air and damping oil is out of balance It is caused when there is too little air space in a chamber not allowing the fork to compress through its travel
21. ng systems must be properly tightened prior to use Failure to do so could result in injury or possible death 7 Insert spring into top of left leg followed by top cap Tighten top cap to specified torque value Setting Dual Crown Fork Ride Height 1 When setting the ride height for your fork make this calculation to determine the lowest point at which you can set the lower clamp without it interfering the casting s arch on full compression Travel of fork 20mm This is the distance that you are calculating 2 The number that you calculate will be measured from the top of the dust seal on the casting to the bottom of the lower clamp Warning Do not set the lower crown lower than the measurement that you calculated for fear of interference with brake arch Installation of Hex Thru Axle 1 Hold wheel between drop outs Insert Hex Thru Axle into the outside of the left 04 SHERMAN SERVICE MANUAL REV NC Drop out as you are facing fork and push it through the hub of the wheel into the right drop out 2 Thread Thru Axle nut into the end of the axle that is in the right drop out Thread in half Way 3 Set the end of the axle flush with the outside of the left drop out and tighten the 3mm clamp fixing bolts to specified torque value as called out in Slider Slider Fastener Torque and Set up Values at end of manual 4 Finish the installation by tightening axle nut to specified torque value and then tighten the c
22. o its open rested position after compressing it with your fingers If the valve is not responsive or all the time closed it is bad and the assembly needs to be replaced USE 24mm Open end wrench or 8 10 Adjustable wrench Check for 1mm gap between the blue SPV valve and the black piston Removal of Spring and Compression Rod Assembly ZUNE This fork uses a preloaded coil spring provide spring resistance The spring must be relieved of its preload prior to servicing Failure to do so could result in injury or possible death k 2 04 SHERMAN SERVICE MANUAL For Sherman Single Crown forks Rapid Travel ll Remove the adjuster knob from the top of the travel adjust assembly on the top of the crown on the left side of the fork by unscrewing the 2mm Allen head screw Use a 20mm socket and unscrew the remainder of the assembly from the crown The spring will be attached to the bottom of the assembly when you pull it from the inner leg Pull the spring from the assembly and it can be substituted with a different rated spring if necessary REV NC 3 The compression rod assembly may be removed by unscrewing the end cap on the bottom of the left leg After unscrewing the end cap pull the assembly from the inner leg 4 For more specific details on Rapid Travel Il refer to Travel Adjust section of this manual 5 For Sherman Dual Crown forks Remove the top cap from the top of the crown on the left side of the fork wit
23. oil such as hydraulic oil Oil with low weight numbers 5wt or 7wt flow through valves with less resistance than higher weight numbers 10or 15 wt Outer Casting see Slider Preload A condition of compressing a spring or elastomer before the operating loads are put on the suspension so that it provides a stiffer spring rate Piston In front suspension the part of the damper that slides back and forth inside of the damping leg that houses the valves It can also refer to the air piston in the air spring assembly that slides back and forth compressing the air thus causing a change in the spring rate of the suspension 04 SHERMAN SERVICE MANUAL REV NC GLOSSARY OF TERMS CONT Porosity The condition or property of having pores in a material that will allow gas or liquid to pass through it Rapid Travel Il Wind Down Systems that are used to control the travel of suspension forks Also known as RTI RTII and WD RTI and RTII are used for the specific purposes of controlling the travel in two conditions climbing and descending WD is an incremental travel adjustment between to set limits and does not affect the spring rate of the fork as severely as RTI and RTII Rebound The phase of the suspension operation in which the wheel returns to its original position on the ground after compression Rebound Damping Restriction of the rate that the suspension rebounds when the compression load is relived
24. ol through the bushing Start the procedure by removing the Dust Wiper seal with a screwdriver prying it out Insert Removal tool past the upper bushing and then stop It is important to pull one bushing out at a time Push the slide on the threaded shaft down towards the removal ring Hold the casting with one hand and the slide hammer with your other hand Now move the slide hammer in a motion away from the casting and repeat this action until the bushing comes out For all other leg diameters use the larger diameter dark colored threaded shaft and repeat steps A C Bushing Installation Note Sizer kits listed in above chart contain the sizers needed for each specific leg diameter Bushing Installation Tool Components Installation Mandrel Threaded Rod w nuts Sizer rings Spacer Washer Nut 04 SHERMAN SERVICE MANUAL REV NC Bushing Installation CONT Bushing Installation Tool Assembly With weighted handle When selecting sizer rings to install bushings choose the two rings that are in the middle of the size run to start with 1 Assemble installation tool as shown in picture above Each leg diameter kit has all of the needed pieces to remove and install bushings for forks with serviceable bushings Some of the kits come with gauges to tell you how far to drive in the lower bushings Upper bushings are driven in as far as the stop in the top of the casting will allow The general rule of thumb
25. result in injury or possible death 2 Now install SPV rebound damping assembly or TPC rebound damping assembly into bottom of other inner leg Be sure to check the function of the SPV valve and apply a thin layer of Prep M grease onto o ring that is around the piston at top of assembly Install the assembly and tighten end cap to specified torque value Check for 1mm gap between Blue SPV valve and Black piston If there is no gap assembly needs to be replaced 04 SHERMAN SERVICE MANUAL REV NC Turn Crown steer leg assembly right side up so that the crown of the assembly is facing you Extend the SPV rebound damping assembly or TPC rebound damping assembly all the way out and then pour damping oil P N 85 0023 into the right inner leg Fill leg about _ of the way up Take a rag and cover the top of the right inner leg and then stroke the SPV damping assembly up and down about 5 times This will insure that oil gets below the piston and not create an air space Extend the damping assembly all the way out and then fill the inner leg to the specified oil level WACON All top caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death 4 Insert the Volume control assembly or TPC compression damping assembly into the top of the right inner leg and tighten it to specified torque value Be sure that you unscrew the red 16mm Hex shaped Volume control nut all
26. riple Clamps the portions of the fork crown that clamp around the stanchion legs above and below the head tube of the bicycle frame on specific long travel applications Stanchion Legs The suspension tube inner leg fixed to the fork crown It remains stationary during the operation of the suspension Steer Tube The long cylindrical tube that extends from the top of the fork crown Its function is to be inserted into the bicycle head tube and attach the suspension to the bicycle frame 04 SHERMAN SERVICE MANUAL REV NC GLOSSARY OF TERMS CONT Thru Axle A device used for mounting a thru axle hub to special outer legs that are not made for standard quick release hubs Manitou s Thru Axle system is a special patented system utilizing a hex shaped end that increases the stiffness of the fork and reduces slippage in the joint between the axle clamps and the axle Top Out Bumper A rubber coil spring or elastomer device that absorbs the shock that occurs when the load is taken off a suspension so that it is allowed to rebound to its limits TPC Twin Piston Chamber a patented damping system that has independent pistons for rebound and compression The system utilizes a mixture of air and oil in the damping leg of the fork to enhance the damping performance TPC A variation of TPC that has added a floating piston to the compression damper to enhance the performance of the compression damping under the load of bigger
27. s may be controlled with an air spring or a coil spring The air cap contains the Schrader Valve which is used to control the spring rate or SAG of air forks Air Spring A mechanism that is used to control the SAG of an air fork Arch A support that connects the two outer lower legs of the casting so as to keep them moving in unison Boss The word used to describe an outer casting that has brake posts for V brakes or cantilever brakes Bottom Out Bumper A rubber or elastomer device that absorbs the shock that occurs when a suspension is compression to its limit Bushings A cylindrical sleeve between a fork stanchion tube inner leg and a fork outer casting slider which facilitates the sliding movement between these two parts Coil Spring A coiled piece of metal that acts as a spring to help suspend a fork Compression The phase of the suspension operation in which the wheel travels up or travels closer to the frame The suspension forks reaction to a bump in the trail Compression Damping Restriction of the rate that the suspension compresses under load Convertible Travel A system used to alter the travel of a suspension fork It requires moving a travel clip on the compression rod to a different position This operation is accomplished by disassembling the fork and physically moving the travel clip on the compression rod Crown Steerer Assembly the stanchion legs inner legs the fork crown a
28. t is in the same position that it was in 16 04 SHERMAN SERVICE MANUAL before you installed top cap Install adjuster Knob so that tang of knob is all the way clockwise and then tighten 2mm Allen screw until tight Compress fork and it should be in long travel and plush Twist Knob all the way in the other direction towards the arch of the fork and compress fork You should hear the Travel adjust mechanism engage and the travel will now be shorter REV NC Top Travel Adjust Components Compression Rod Bolt Removal amp Installation of Removal amp Installation Adjuster Knob of top cap 04 SHERMAN SERVICE MANUAL Page 13 REV NC Twisting Hex Shaft in order to clock assembly Assembly of Crown Steer Leg Assembly Sherman Single Crown forks Note Apply a small dab of Blue Loctite on all top cap and leg end cap threads before reinstalling them in fork 1 Make note of which is the right leg of the crown steer leg assembly fork serial is etched into the back of the right crown of the fork from the rider s perspective and which leg is the left one Turn the assembly upside down so that the bottoms of the inner legs are facing you In the left leg insert the Travel adjust compression rod assembly and tighten end cap into leg Tighten to torque values that are listed on fork schematic WACAN All leg caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could
29. urn the fork upside down and remove the fixing screw that attaches the Rebound Adjuster Knob Blue Set the knob and screw aside USE 2mm Allen wrench to unscrew fixing screw 3 Remove the 11mm Compression Rod bolt from the bottom of the left leg From the rider s perspective USE 11mm socket nut driver or open end wrench 4 Insert 8mm Allen wrench into the end of the Rebound Damper Shaft on the bottom of the right leg Turn the wrench in a Clock Wise direction in order to loosen the damper shaft in the casting See Figure below You are turning the Damper Shaft in a way that causes it to disappear into the casting leg USE 8mm Allen wrench 5 Working with the Semi Bath lubrication system A Position the bottom of the fork legs over a drain pan that is on the ground Pull the casting downward towards the pan allowing the Semi Bath oil in the casting to drip into the pan Pull the casting completely off of the inner legs and wipe any excess oil off of inner legs and inside of casting USE Drainage pan and extra rags 04 SHERMAN SERVICE MANUAL REV NC Removal of TPC Compression Damping Assembly 1 Be sure to twist adjuster knob all the way clockwise to decrease damping effect on fork Then unscrew 2mm Allen screw from top of TPC adjuster knob knob on top left stanchion leg 2 Remove adjuster knob and unscrew remaining assembly from stanchion leg with a 20mm socket 3 Pull assembly from leg in a twisting mot
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