Manitou 2001 Magnum Service Manual
Contents
1. Your 2001 SX Fork requires periodic maintenance clean ing and inspection Moisture and contamination may build up inside the fork depending on the severity of rid ing conditions To maintain top performance it is recom mended that the fork be periodically disassembled cleaned dried and re greased IMPORTANT When filling the fork with grease through the Microlube grease ports it is important to note the grease is being forced between the upper and lower bushing Figure 7 If the area is over filled the force of the grease may force the upper bushing and dust seal out IMPORTANT Before every ride you should 1 Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs clean lubricate and check entire fork for any obvious damage 3 Check headset adjustment 4 Ensure that the front brake cable is properly seated in the cable retainer amp check brake adjustment IMPORTANT Maintaining the proper oil level in your TPC is very important Not enough oil will allow foaming and reduce the performance Too much oil will restrict travel and may cause damage to the system and an unsafe riding situation Finish reading this entire section prior to making any changes to the oil level CHECKING OIL LEVEL FIGURE 8 To check the oil level remove only the compression damp ing assembly located in the top of the right leg Leave the left side compression stack adjuster MCU spring assem bl2. 2001 MAGNUM SERVICE MANUAL CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK AVAILABLE 2001 MANITOU MAGNUM FORK MODELS HAVE STATE OF THE ART MCU SPRING COMPRES SION SYSTEMS THE MAGNUM R IN THE MAGNUM SERIES USES THE NEW TWIN PISTON CARTRIDGE SYS TEM TPC SPORT THAT SURPASS ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY Your 2001 MAGNUM Fork is fully assembled and ready to be installed onto your bicycle It comes equipped with a 1 1 8 threadless steerer tube 2001 MAGNUM are sold with the V Brake cable hangerless arch but have an optional attachable cable hanger kit P N 85 4100 which is available through your dealer CONSUMER SAFETY INFORMATION GENERAL WARNING Bicycling is a hazardous activity that requires that the rider stay in control of his or her bicycle at all times Reading this manual entirely and properly maintaining your bicycle and suspension fork will reduce the possibility of injury or death Prior to riding your bicycle 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 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
3. 9 Torque stem handlebar pinch screw and stem clamping system to manufacturer s instructions 10 Install cantilever brakes and adjust per manufacturer s instructions Note All 2001 MAGNUM forks are equipped with a secondary catch dropout CON OUR WN Race Installation CROWN RACE Einbau des St GABELBRUCKEN inbau des Steversatzringes Instalaci n del anillo de rodadura 5 ANILLO DE RODADURA Installation du jeu de direction po CONE DE JEU DE DIRECTION nT 21 ANELLO DELLA TESTA Montaggio dell anello della testa LAE KROONIOOPRING Installatie van loopring CANALETE DA COROA Instala o do canalete D eA 2239y mie NG Tire clearance Reifenabstand Espacio libre de la cubierta Distance arceau pneu Spazio libero del pneumatico Bandspeling Folga do pneu BIVIZUSIYR MINIMUM CLEARANCE MINDESTABSTAND NI ESPACIO LIBRE MINIMO JEU MINIMUM M FOLGA MINIMA 2 FORK MODEL GABELMODELL MODELO DE HORQUILLA MODELE DE FOURCHE MODELLO DI FORCELLA VORKMODEL MODELO DO GARFO 74 2 MAGNUM 8 MAGNUM R 76 mm travel forks MAGNUM und MAGNUM R Gabel mit 76 mm Auslenkung Horquillas MAGNUM y MAGNUM R con recorrido de 76 mm Fourches MAGNUM et MAGNUM R ayant une course de 76 mm Forcelle MAGNUM e MAGNUM R con corsa da 76 mm MAGNUM amp MA
4. damping assembly is almost identical to the lower shaft assembly Unscrew the compression damping adjuster all the way until it stops The knob and the needle do not need to be removed The shaft also does not need to be removed from the cap The threads are bonded to prevent leaking Remove either the valve nut or the piston seat following the instructions above for the lower shaft assembly DAMPER INSPECTION nou ARN Check the shaft for scratches wear or other obvious damage Check the seal gland and end cap seal grooves for damage Check shims for permanent bends or damage Check all other parts for obvious damage replace if necessary Replace all seals that have been removed FORK INSPECTION 1 2 3 8 9 Check the fork boots for obvious damage Check the dust seal for tears wear or damage Replace if needed nspect the lower and upper bushing for damage to the Teflon coating Replace using the bush ing removal and replacement kits if necessary Check all MCU amp springs for obvious damage Replace if necessary Check the preload adjuster and connectors Replace if damaged Check the outer leg arch assembly for nicks or deep gouges on outside and inside Replace if damaged Check the inner leg for deep gouges and other damage Minor wear resulting in color change is not detrimental to the gold anodized surface Replace if wear is excessive or damaged Check inner legs at the bottom of the crown for c
5. 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 ship ment to Answer Products or you may call Answer at 661 257 4411 to have your fork shipped directly IMPORTANT 2001 MAGNUM Forks are off road forks and as such do not come with the reflectors installed for on road use Reflector bracket kit P N 85 3674 is available through your dealer Have your dealer or mechanic install the kit to meet the Consumer Product Safety Commission s 5 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 dealer 1 Never remove or have the steer tube or stanchions inner legs removed from the crown steer tube and stanchions are press fit assembled at the factory Pressing them out will perma nently damage the crown steer tube and stanchions beyond repair and render them unsafe for any continued use 2 Never attempt to thread a threadless steer tube Machining threads will weaken the steer tube and cause an unsafe condition The only safe thing to do is to obtain the proper crown steerer from your dealer 3 Any other alterations or modifications to your fork should be considered unsafe Contact Answer Products Technical Support at 661 257 4411 prior to modifying your fo
6. 41840 table 1 cont DESCRIPTION 2001 SX amp SX R SOFT RIDE KIT 2001 SX amp SX R FIRM RIDE KIT 2001 SX 100 SOFT RIDE KIT 2001 SX 100 FIRM RIDE KIT 2001 BLACK SX OUTER ASSEMBLY WITHOUT STICKERS 2001 YELLOW SX OUTER ASSEMBLY WITHOUT STICKERS 2001 RED SX OUTER ASSEMBLY WITHOUT STICKERS 2001 BLUE SX OUTER ASSEMBLY WITHOUT STICKERS 2001 FIREBALL SX OUTER ASSEMBLY WITHOUT STICKERS 2001 COBALT SX OUTER ASSEMBLY WITHOUT STICKERS 2001 WHITE SX OUTER ASSEMBLY WITHOUT STICKERS 2001 SX amp SX E STEER LEG ASSEMBLY 2001 SX 8 SX 100 STEER LEG ASSEMBLY 2001 SX R ALLOY STEER LEG ASSEMBLY 2001 SX E X FIRM RIDE KIT 2001 SX amp SX R X FIRM RIDE KIT 2001 SX 100 X FIRM RIDE KIT 2001 SX REBOUND DAMPING ASSEMBLY KIT 2001 SX 100 REBOUND DAMPING ASSEMBLY KIT 2001 SX R REBOUND DAMPING ASSEMBLY KIT 2001 SX amp SX 100 COMPRESSION DAMPING ASSEMBLY PART NUMBER 85 9127 85 9129 85 9184 85 9186 85 9191 85 9194 85 9196 85 9197 85 9198 85 9199 85 9202 85 920 85 9208 85 9209 85 9218 85 9219 85 9223 85 9266 85 9267 85 9268 85 9269 MAINTENANCE IMPORTANT 2001 SX forks should not be used if any parts appear to be are damaged Contact your local dealer or Answer Products for replacement parts IMPORTANT Use of fork boots is required to keep your 2001 SX performing well and your warranty in effect Use of this fork without boots will shorten the life of the fork reduce the performance and void the warranty
7. D tuning Manual P N 85 3485 and check out the MRD Race Tuning kits available at your dealer TROUBLE SHOOTING Fork seems to top out or has a slight clunking feel when front wheel comes off the ground Excessive preload or insufficient rebound damping will result top out Select MCU s that bet ter fit your weight and riding style having the preload adjuster set mid to low range and increase the rebound damping to eliminate top out The fork feels less active and is not getting the travel it used to when it was new Chances are that the fork is developing stiction Cleaning and applying light oil to the stanchions will help Outer legs feel loose on inner legs and bushings a knock or rock can be felt when pushed from side to side A very small knock is normal with the new harder bushings If the knock is excessive or you can feel the fork rocking then the bushings should be removed and replaced To do this you must have the Answer Products Bushing Removal and Replacement Tool Kit A small amount of oil seems to be leaking from top of the left leg at the adjuster cap If the 2001 SX us store upside down for a period of time a small amount of oil may leak through the adjuster cap knob assembly The cap area is not subjected to damping pressure A small leak in that area will not affect the performance of the fork or cause any type of damage We recommend that you store your Manitou left side up If this condition causes you some pr
8. GNUM R loop van 76 mm MAGNUM e MAGNUM R curso de 76 mm VIF LEVTFFLR 76 mm BF MINIMUM CLEARANCE MINDESTABSTAND ESPACIO LIBRE JEU MINIMUM SPAZIO LIBERO MINIMUMSPELING FOLGA MINIMA BRLIUTIVA 3 1 78 7 mm 78 7 mm 78 7 mm 78 7 mm 78 7 mm 78 7 mm 78 7 mm 78 7 mm 11 Adjust front wheel quick release to clear the 0 275 7mm thick secondary catch dropout The quick release must be tightened after it is properly seated into the dropout counter bores Ensure that there is adequate thread engagement 4 or more threads with the release adjusted to lock due to the wide adjustment Install front wheel to bicycle per manufacturer s specifi cation 12 Install brake cable per manufacturer s instructions Note 2001 MAGNUM forks come equipped with a hangerless arch Brake cable hangers that attach to the arch are available through your dealer WARNING When installing the wheel or any new tire check the minimum tire clearance Measure from the highest point on the tire to the bottom of the crown The minimum clearance allowed for 76MM travel forks models are 3 1 78 7MM dent with the possibility of serious injury or death Any less clearance can result in an acci BUSHING amp SEAL DETAIL FORK BOOT 041860 267 S DUST SEAL 041880 UPPER BUSHING 041861 LOWER BUSHING 041862 2001 MAGNUM FORK SC
9. HEMATIC TOP CAP 041867 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m N COMPRESSION ROD 062539 BRAKE POST 041927 TORQUE 90 110 INCH LBS TORQUE 10 12 N M SECOND STAGE CLIP 041841 X S 063116 SZ FO 2 041864 328 MN Spe END 9 041864 2 2 SECOND STAGE CLIP 041841 2 GREASE FITTING 24 062036 5 COMPRESSION ROD 062539 TOP OUT ELASTOMER 041840 ADJUSTER ASSEMBLY 041872 TORQUE 30 50 INCH LBS 55 TORQUE 3 5 5 6 N m MCU STOCK RED 041857 2001 MAGNUM FORK SCHEMATIC FORK BOOT 041860 041867 TORQUE 30 50 INCH LBS TORQUE 3 5 5 6 N m O RING 041866 NS REBOUND PISTON 063259 DUST SEAL 041880 750 SHIM 041838 UPPER BUSHING 041861 52 LOWER BUSHING 041862 LOWER SHAFT 041837 OIL SEAL 041836 END CAP 041864 O RING 041866 BOTTOM OUT ELASTOMER 063116 D SECOND STAGE CLIP 041841 END 041864 BRAKE POST 041927 N TORQUE 90 110 INCH LBS TORQUE 10 12 N M x ADJUSTER ASSEMBLY 041872 TORQUE 30 50 INCH LBS x TORQUE 3 5 5 6 N m A MCU STOCK RED 041857 be MCU CONNECTOR 041863 BOTTOM OUT ELASTOMER 063116 SECOND STAGE CLIP 041841 GREASE FITTING 062036 257 OUT ELASTOMER 0
10. hen the assembly is installed Compression Rod amp Boots 1 Clean all parts thoroughly Grease compression rod lightly Be sure rebound Elastomer is installed onto compression rod Drop compression rod down into inner legs Shake inner leg to get rod through inner leg plug Slide on black second stage cup washer and orange 3rd stage Elastomer Slide Boots onto inner leg ok wN Outer Leg Assembly 1 Slide Outer leg Arch assembly onto inner legs and fully compress 2 Install and torque 5MM compression rod screw and dropout nut to10 30 inch lb 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft Pop in damper adjuster knob O ring holds knob in place SXR Slide skirt of fork boots onto the outer leg groove Be sure the lip snaps into the groove Clean adjuster cap threads thoroughly Clean threads on inside of inner leg Assemble MCU s springs and connectors with thick grease In stall adjuster assembly into inner leg just hand tight NO oF hh INNER FORK LEGS amp CROWN The inner fork legs and steer tube are press fit into the crown and may never be removed Removing them will make the fork unsafe to use If you see any slippage contact Answer Technical Staff immediately 800 670 7446 ADJUSTING RIDE QUALITIES 2001 SX TPC forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the MicroCellular Urethane MCU s Fine tune adjustments can be
11. k does not need to be removed from the bicycle for general disassembly assembly or cleaning It is also not necessary to disassemble the 2001 Manitou Forks for compression elastomer replacement Elastomer replacement is accomplished by removing the adjuster assembly per Figure 10 Compression Stack amp Compression Rod 1 2 3 4 Press the bottom clip off the compression rod Slide off the rebound elastomer from left leg compression rod Unscrew and remove the adjuster assembly by hand Turn fork upside down to remove the compression rod If forks are installed on bicycle give the rod a quick upward thrust and catch it as it pops up above the crown Lower Shaft Disassembly Note Lower Shaft disassembly is best done with the fork removed from the bicycle Disassembly of the damping stack is not required unless you want to change or replace the shim stack 1 ok Remove the left cap compression damping assembly from the top of the fork leg and pour the oil out of the top of the fork and discard appropriately For complete disassembly continue Remove the plastic end cap and pull the lower shaft out of the inner leg Remove the clear plastic detent sleeve and capture the 1 8 dia Detent ball used on SX R only SX R adjuster needle may be unscrewed from the shaft For SX R use 5MM allen wrench to remove piston seat Keep note of the exact order of the shims and spacers Compression Damping Disassembly 1 2 The compression
12. made using the preload adjusters located on top of the fork crown Softer blue and harder yellow MCU s are available from your Dealer NOTE Since 2001 model forks use a compression stack in the left leg only MCU s and Springs used in previous Manitou forks are NOT interchangeable with later versions of SX model Forks Compression Spring Fine Tuning Fine tuning adjustments to the spring rate are made by rotating the adjuster knobs located on top of the crown Note the 2001 SX 100 SX and SX R uses compression spring systems in the left leg only Only the left knob on top of the crown adjusts preload Rotating the knob clockwise will firm the ride adding preload to the compression stack Rotating the knob counter clockwise will soften the ride Four full revolutions will take the adjuster from full soft to the extreme firm setting Compression Damping Fine Tuning To adjust the SX R simply rotate the compression damping knob located on top of the right leg and crown Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Excessive damping will give you a harsh ride over sharp bumps like rocky sections but will feel good in large hits like G outs Insufficient compression damping will bottom out in the large hit G outs and bob a little while climbing but feel plush on the sharp hits A cor rectly adjusted fork will perform good in all conditions The SX 100 and SX uses TPC Sport for c
13. n the fork to the place of purchase In the USA dealers should call Answer Products for a return authorization number RA At that time instruc tions 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 steer tube has been delivered on your fork The steer 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 steer tube it is recommended that you seek a dealer with a quali fied bicycle mechanic to perform installation WARNING The steer tube and stanchions inner legs are a one time precision press fit at the facto ry and cannot be removed from the crown Replacement of the entire crown steerer assembly must be done to change steer tube lengths or diameters Removing and replacing the steer tube or stan chions will result in an unsafe condition and should never be done 1 Remove old fork from bicycle Measure and cut the steer tube to the same length as the old fork Remove crown race from old fork and press onto steerer until seated on crown Figure 1 Clean and grease headset bearings and races of bicycle Install lower bearings on fork crown race Insert steer tube into head tube of frame Install upper bearings spacers and stem Install stem cap adjust and tighten headset per manufacture s instructions
14. oblems please contact your Answer Products dealer or call our warranty tech department for prompt service CYCLE COMPUTER INSTALLATION INSTRUCTIONS Follow the instructions in your owners manual with the following exceptions WARNING DO NOT DRILL A HOLE IN THE DROPOUT THIS MAY WEAKEN THE DROPOUT WILL VOID THE WARRANTY AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INJURY DO NOT USE THE TEMPLATE PROVIDED IN THE 95 OR 96 SERVICE MANUAL answerproducts neorporated 28209 AVENUE STANFORD VALENCIA 91355 661 257 4411 www answerproducts com 2001 SX SERVICE MANUAL P N 85 3692
15. om pression damping and is not adjustable Rebound Damping Fine Tuning To adjust the SX R simply rotate the rebound damping knob located on bottom of the right leg Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Excessive rebound damping will give you a harsh ride over repetitive bumps like braking bumps because the fork will pack up Insufficient rebound damping will make the fork over active top out and slap back when landing from a jump We suggest that you try adjusting your fork on the very active side minimum rebound Then try it over a variety of terrain and tune in more rebound from there The SX 100 and SX uses TPC Sport for Rebound damping and is not adjustable Lok Out System Kit P N 85 8989 Lok Outs are available for all SX models By turning the knob 1 4 turn CCW exposing the green sticker the front fork will have regular TPC suspension By turning the knob 1 4 turn CW exposing the red sticker the fork will be locked out A safety blow off valve will open under extreme condi tions to allow some movement To adjust the compression damping when not using the Lok Out Remove the compression damping assembly from the top of the right leg Adjust the setscrew located in the valve seat in to increase the damping and out to reduce the compression damping Try adjusting one 1 2 turn at a time For additional tuning tips we recommend that you obtain a copy of the MR
16. racks or for flaking anodize Replace crown steer leg assembly if cracked or if gold anodize is beginning to flake Check the underside of the crown for cracks Replace if cracked RE ASSEMBLE Lower Shaft 1 2 3 4 Install all o rings and seals removed Grease all seals lightly with seal grease Apply small amount of blue Locktite to piston seat threads Assemble shim stack and spacers in exact order that they were removed For SX R hand tighten piston seat Be sure large blow off washer will slide over piston spacer and compress the small spring Clamp shaft in soft jaws or collet and line up slots in clamp ring with hole in piston seat using 1 8 or smaller pin Use a 5MM Allen wrench and tighten piston seat by turning Allen wrench and pin at same time Torque 10 IN LB 3 5 N m max SX R install lower needle gently into shaft thread until it stops then back off one turn for ini tial adjustment Slide shaft assembly through the plastic end cap place detent ball in place and slide on 2nd STG Elastomer Insert into left leg and thread in end cap Torque 30 IN LB 3 5N m max Add approximately 90 CC of 5 WT Maxima or equivalent oil Do not over fill Check oil level see Figure 8 Compression Damping Assembly 1 2 Reassemble compression damping stack following the instructions above for the lower shaft assembly Install compression damping assembly into the left leg The oil level should cover the compres sion valve w
17. rk in any way for safety information 4 Do not use any Manitou fork if any parts appear to be broken bent cracked or damaged Contact your dealer or Answer Products Technical Support If you have any questions concern ing the integrity condition or safe operation of your fork 5 Answer Products recommends that you periodically inspect your fork for wear and damage Inspect the crown stanchions and outer leg dropout and brake arch areas for cracks or dam age Before every ride check to ensure that the proper preload exists WARRANTY INFORMATION Any Answer Products fork found by the factory to be defective in materials and or workmanship within one year from the date of purchase will be repaired or replaced at the option of the manu facturer 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 modified 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 warranty 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 retur
18. y in place to keep the fork fully extended Use a tape RECOMMENDED measure or dip stick to determine the oil level Oil level LEVEL should be between 3 75 95 2mm and 4 75 120 6mm below the crown where the damping assembly screws in see figure 8 The recommended level is 4 25 9 107 9mm It is recommended that you replace your oil at least once a year twice if it has been contaminated with dirt mud or other foreign substance Use SAE 5WT Maxima fork oil or equivalent MAXIMUM MINIMUM Removal of outer leg arch assembly 1 185 Use 4MM allen wrench to remove the M5 lower compression rod screw from the left leg dropout Pop out the damping adjuster knob from the right dropout SXR A small screwdriver may be helpful Use an 8MM Allen wrench to remove the dropout nut Fully compress the fork to prevent the compression rod and damper shaft from turning while removing screws Pull outer leg assembly down to remove from the inner legs and crown Remove fork boots Bushing replacement will require the use of the bushing removal and installation tool available from Answer Products It is recommended that the bushings be left installed unless they absolutely need replacement Note It is not recommended to remove the dust seal every time the fork is disassembled The seal and bushings may be cleaned and re greased in place GENERAL DISASSEMBLY NOTE The For
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