2005 Skareb Service Manual
Contents
1. 2005 Skareb Service Manual Rev NC 05 SKAREB SERVICE MANUAL REV NC Table of Contents Introduction Front Suspension Terminology Disassembly Assembly Instructions 8 Lock Out Troubleshooting 14 Remote Lockout Service Instructions Infinite Travel Adjustment System IT Instructions Bushing Removal and Installation Instructions 22 Troubleshooting Chart 26 Skareb Schematic and Technical Specifications 28 Skareb Service Kit Chart 29 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 05 SKAREB SERVICE MANUAL REV NC INTRODUCTION This manual is intended to guide the user through basic service of Manitou Skareb 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 installation instructions for the kits Due to the time consuming nature of 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 WARNING Failure to follow WARNING instructi2. created by a spring that is under the cap Separate the top cap from the shaft once you have completely unthreaded the two pieces Pull on the inner wire in order to remove the machined stopper with the cable end in it from the shaft You can now unhook the cable from the stopper and from the cable head end pull the cable through the spring the top cap and the outer cable housing Refer to Figure 6 at the right Reverse the above steps to replace the cable Note The inner cable can be replaced with a standard bicycle Derailleur cable It is recommended to replace the two O rings on the stopper each time that it is removed from the shaft in addition to the Black Buna O ring that is on the shaft below the threads Tighten top cap on the shaft to 25inlbs 2 85Nm Put a small amount of Motorex grease on the end of the Upper Assembly shaft and then insert the assembly into the fork inner leg As soon as contact is made with the hole in the top of the air piston lower assembly twist the upper assembly like screwing in a screw to guide the upper assembly shaft into the hole without damaging the Quad ring seal in the shaft of the lower assembly After reinserting the upper assembly into the fork but before screwing the top cap in pour about 6 8cc s of 40wt automotive oil into the fork leg through the top of the crown 05 SKAREB SERVICE MANUAL Page 19 REV NC Feed the inner wire through the cable housing and secure on
3. 85 85 85 85 Comp Rod 9264 9983 9983 5264 Lower Spring End Cap Assy IT Bottom Assy 85 85 Air Push Rods 4439 4474 Knob Kit oro 85 5584 DustSealkii kK 85 5265 Air Pistonkii G 85 5266 Bumperkt O k 85 5267 O Ringkt o _k ces Bushing Kit o eg 05 SKAREB SERVICE MANUAL REV NC
4. 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 Bushing Removal amp Installation Please refer to section on Bushing Removal amp Installation Removal of Compression Damping Assembly Forks with FFD non adjustable Damping 1 Remove top leg cap FFD Assy on right hand side using 27mm socket 2 Pour old oil out of the top of the fork then compress fork upside down over oil drain pan 3 5 times to get oil out from under rebound piston and discard appropriately Forks with Adjustable Compression Lockout Damping Remove the 2mm fixing screw on top of the damper knob on top right side of the fork Remove 2 balls and springs from inside the top cap Unscrew the compression damping assembly using a 24mm socket Pour old oil out of the top of the fork then compress fork upside down over oil drain pan 3 5 times to get oil out from under rebound piston and discard appropriately A Removal of SPV Compression Damping Assembly WAUN 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 If your fork has a red Schrader cap on the top right side of the fork it is equipped with SPV damping Remove Schrader valve dust cap from Red H
5. compression damping under the load of bigger 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 05 SKAREB SERVICE MANUAL REV NC 2004 Skareb Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting 1 From the left leg dropout Left when sitting on the bike use a 4mm hex wrench to remove the compression rod screw 2 From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Remove the 2mm hex screw inside the knob and remove the knob 3 Use a 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting 4 Remove crown steer inner leg assembly from the outer leg casting 5 Position the bottom of the fork legs over a drain pan that is on the ground
6. it Use an Adjustable Wrench and unscrew the black end cap that is threaded into the bottom of the left inner leg Pull the lower IT assembly from the inner leg There may be a very little amount of oil that comes out of the inner leg as you remove the lower IT assembly This is the lubricating oil used to allow the air piston on the lower shaft assembly to move freely 22mm slotted socket Adjustable Wrench 12mm Wrench 05 SKAREB SERVICE MANUAL Page 17 REV NC Disassembly Instructions continued Now it is time to remove the IT upper assembly Release the IT control wire from the control lever by unscrewing the fixing screw on the lever that holds the cable tight Use a 2mm Allen Wrench to unscrew this screw and then pull the cable out of the lever Go to Fig 2 for next step To remove the upper IT assembly use a slotted 22mm 6 point socket P N 83 2503 a 22mm Open End wrench or an adjustable wrench Note Be aware of the IT control Wire spinning around when unscrewing the top cap 12 Pull the upper assembly out of the inner leg Troubleshooting Tips 1 Here is a guide to help pinpoint fork travel issues If the fork starts to lose travel from an extended position to a shorter position by itself the damage is most likely centered on the Quad ring around the outside of the piston Tf the fork extends from a shorter travel to a longer travel by itself the failure can be involving the smaller Quad ring that is l
7. protruding from it Unscrew the valve cap and follow either of these two methods for releasing all of the air from the system A Depress the valve core and let all of the air out Now depress the IT lever on the bike s handlebar and release it Once again depress valve core in the amp P IT Lever Inner amp Outer Schrader valve to release any air in the Assembly IT control wire leg Do this a couple of times until all of the air is released IT System Components If you have a helper have them hold the IT lever on the handlebar down as you depress the valve core This will let all of the air out at one time Now that all of the air is released unscrew the 12mm nut that is threaded onto the Schrader valve It is recommended to either turn the fork upside down or hold it right side up over a drain pan to catch the Semi Bath lubrication oil that will come out of the bottom of the casting as you start the procedure of removing the casting see Fig 1 Move over to the bottom of the right leg and unscrew the 2mm Allen screw from the middle of the rebound adjuster knob Pull the knob away from the bottom of the casting leg exposing a recessed 8mm hex Use an 8mm Allen Wrench and turn it in a clockwise direction in order to unscrew the rebound damper shaft from the casting You can now remove the casting exposing the fork s inner legs Be aware that there may be some of the Semi Bath oil in the casting after you remove
8. 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 Black Nitrate Leg Coating New coating for steel stanchion legs that reduces stiction 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 Air Assist A new feature for 2005 that utilizes a full length coil spring and allows you to increase the spring rate of the fork by adding air as a booster to that coil spring 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 disass
9. the inner leg Use the Manitou Volume Control Adjuster P N 85 3007 to do this Installation of Outer Leg Casting WIN Ne When installing the outer Leg Casting to the Crown Steer Assy Compression Rod 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 damper shaft are facing you You will see a bottom out bumper on the 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 2 Pressurize the air spring to 100psi this will help keep the compression rod extended as you install the outer casting 3 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 4 Finish sliding inner leg assembly into outer leg casting until damper shaft contacts casting 5 Use an 8mm hex wrench to turn the damper shaft counterclockwise threading it into the casting Tighten per the Skareb Schematic and Torque Specification Table 6 Install rebound adjuster knob if applicable Knob should turn uninhibited until the indicator i
10. age 26 REV NC TROUBLESHOOTING CONT Service Manual Symptom Cause Page Fork Top out Damping Replace Rebound Damping assembl SPV Valve not functioning valve not functioning Top out spring damaged needed 12 Damping oil volume not Check oil level Replace Rebound correct Damping assembly if needed 12 Fork Bottoms Refer to SAG Set up in Tuning section of out Too much SAG Owners Manual NE Bottom out Bumper Inspect and replace Bottom out Bumper if damaged needed 11 a Damping oil volume not Check oil level Replace Rebound correct Damping assembly if needed 12 a A Resize bushings or replace with new ones Play in Fork Loose bushings if damaged Loose Rebound damping shaft Tighten Shaft to specified torgue bolt Tighten bolt to specified torgue 12 OH Loose press fit tolerances Call Answer Products Customer Service 2 RLO Problems See Remote Lock Out section Lock Out Problems Various See Lock Out Section 14 infinite Trave See IT Section 05 SKAREB SERVICE MANUAL Page 27 REV NC Skareb Schematic and Technical Specifications Torgue Brake Post 90 110inibs 10 2 12 4nm Air Preload Cap Torgue Comp Rod Screw 15 61KgCm 13 53inlbs foaming OH SSS CS 05 SKAREB SERVICE MANUAL REV NC AAA Service Kits ll Comp Elite Super Platinum Travel Ml ma LE Comp Damp FFD Damp FFD 85 5558 85 5559 2 Remote L O Lever Left a Z ett Remote L O Lever Rigt A 2d Re
11. and insert it into the left inner leg from the bottom of the leg Be sure to direct the rod through the center of the negative spring assembly that is about halfway up the inner leg Once the rod has contacted the air piston use a rubber mallet and tap the piston out through the top of the inner leg Tapping Piston out with lona rod Assembly Instructions Assembly of Air Piston and Compression Rod Assembly WAAI 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 1 Apply a small amount of Prep M grease onto the threads at the top of the left inner leg with your finger 2 Apply a small amount of Prep M grease around the outside diameter of the new air piston 3 Insert the air piston metal side up into the inner leg through the threaded area at the top of the inner leg Use your fingers to push the piston past the threads into the leg Air Piston is inserted into inner leg with metal side facina up 05 SKAREB SERVICE MANUAL REV NC 4 Re install the air push rod positive spring that has been well greased and compression rod assembly Tighten per the Fastener and Torgue Values section 5 Pour about 3cc of a 40wt or greater automotive oil into the top of the piston and then install the air cap assembly Tighten the air cap assembly 30 50in lbs Make sure to apply a thin layer of grease to inner threads and outside of piston be
12. b of grease on spring to hold ball bearing in place 6 Place the adjuster knob onto the hex shaped aluminum shaft and seat it onto the top cap and ball bearing Position the adjuster cap so that the lever part of the cap is at the farthest point to the back of the crown 7 Insert 2mm fixing screw and tighten to secure the knob Twist the knob counter clockwise to activate the fork suspension Compress the fork several times to circulate the oil through the system and then activate the Lock out system by moving the lever clockwise to its stopping point at the back of the crown The fork should have approximately 5 mm of progressive travel before it locks out Note This system is a combination of adjustable compression damping that becomes a lock out It is fully active when the lever is facing all the way forward counter clockwise and locked out when the lever is facing all the way towards the back of the crown clockwise Assembly of Compression Damping Assembly SPV WAI DN 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 1 Insert the Volume control assembly into the top of the right inner leg and tighten per the Skareb Schematic and Torque Specification Table Be sure that you unscrew the red 05 SKAREB SERVICE MANUAL Page 12 REV NC 16mm Hex shaped Volume control nut all of the way counterclockwise after you tighten the entire assembly into
13. comes ont of crown REV NC Steps of Cable Disassembly Cable Replacement Instructions Step 1 Lock out assembly should be out of fork at this point Step 2 Cable assembly should be out of Lever assembly Step 3 Look at tool placement in Figure A It is recommended to use the Adjustable Pliers to grasp the flange of the lower assembly right above the coil blow off spring Use a 10mm open end wrench on the flats of the upper assembly just below the top cap Hold the flange with the Pliers and turn the 10mm wrench in a counterclockwise direction in order to unscrew the upper and lower assemblies Separate the two assemblies and unhook the cable end from the eye hook as shown in Figure B Pull the cable out through the top cap and red cable guide There will also be a 75mm spring inside of Tool Placement to unscrew upper the upper shaft This spring provides the tension for shaft assembly from lower the cable when you move the Lock out lever from assembly Figure A the Lock position to Unlock position The inner cable runs through the center of the spring Cable Installation Instructions The inner cable is not removable from the cable assembly The entire cable assembly must be replaced Install the new cable assembly by reversing the Disassembly the instructions Slide the inner cable through the red cable guide the top cap and down through the spring Be sure to put a little bit of the Prep M grease on the spring before putting i
14. e end of the of the housing into the gold cable guide then feed the end of the inner wire through the hole in the black cable stop on the lever The inner wire now feeds through the hole in bottom of the lever over the top of the lever and through the hole in the back of the lever Pull the inner wire until there is no slack in the cable Be sure to set a 2mm gap between the front of the lever and the top of the cable stop to insure that you have not over tightened the cable before you tighten the 2mm Allen bolt on the front of the lever to cinch the inner wire Refer to Figure 7 The last step is to cut the inner wire that is left hanging on the backside of the lever and then installing the cable end to prevent it from fraying Replacement of Piston Ouad Rings In order to replace the Air piston Ouad rings you need a 12mm Open End wrench and an adjustable wrench Refer to Figure 8 for wrench placement Hold the 12mm wrench in place on the flats that are on the piston seat and turn the piston with the adjustable wrench in a counter clockwise motion to unscrew the piston from the shaft Once the piston is off of the shaft you will see a small Black Quad ring inside the top of the shaft that you just unscrewed the piston from Use a small diameter object to remove the Quad ring from the shaft Replace this Quad ring with a new one from your IT O ring kit Be sure that it is seated in the shaft and rests flat against the shelf i
15. eel It slides up and down on the stanchion leg inner leg Stanchion Clamps Double Triple 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 Thru Axle Hex lock A device used for mounting a thru axle hub to special outer legs that are not made for standard quick release hubs Manitou s Hex lock 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
16. embling the fork and physically moving the travel clip on the compression rod Crown Steerer Assembly the stanchion legs inner legs the fork crown and 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 Fork Crown The component that joins the stanchion tubes inner legs to the steer tube of the fork 05 SKAREB SERVICE MANUAL REV NC FRONT SUSPENSION TERMINOLOGY CONT 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 mi
17. ex 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 05 SKAREB SERVICE MANUAL REV NC Removal of Rebound Damping Assembly 1 Unscrew Damper end cap from the bottom of the right leg and then pull out the rebound damper Removal of SPV Rebound Damping Assembly 1 If your fork had a red Schrader cap on the top right side of the fork when removing the compression damper above it is eguipped with SPV damping and will have the companion SPV rebound assembly Unscrew damper end cap from the bottom of the right leg using a 24mm Open end wrench or 8 10 Adjustable wrench and then pull out the SPV rebound assembly 2 Checking the function of the SPV valve 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 to 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 rebound assembly needs to be replaced Check for 1mm gap between the blue SPV valve and the black piston Removal of Air Piston and Co
18. fore installation Pour 3 cc of oil into top of piston 6 Fully extend the damper shaft and slide the rubber bumper against the inner leg end cap Insert the crown steer assembly into the outer legs to the upper bushing Holding the fork horizontal inject 16cc of 5 40wt Semi bath oil into the hole at the bottom of each outer leg Figure 2 A syringe works well for this procedure 7 Push the outer legs past the lower bushing and reinstall the 4mm bolt and tighten 8mm damper fitting in a counterclockwise direction Tighten per the Fastener and Torque Values section 8 Use a shock pump p n 85 4069 to fill the air system to the recommended levels as outlined in the Fastener and Torque Values section Reassembly of Crown Steer Leg Assembly WAN 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 WAUA 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 1 Grease the outside of the air piston and then apply a thin film of grease to the threads at the top of the inner leg It is recommended to use Prep M grease P N 85 0031 Push the piston into the top of the left inner leg with the metallic side of the piston facing you using your thumb Push the piston past the threads and then pour approximately 3 4cc s of a 20 50wt oil P N 85 0022 into the top of the pist
19. hanism past the threads at the top of the inner leg Then push the assy into the leg until the threads on the cap intersect the threads inside the inner leg screw the cap in and do not use any tools to over tighten the cap Once the cap is tightened compression the fork several times to circulate the oil through the system and then activate the Lock out system by moving the lever to the other position The fork should have between 2 amp 5mm of progressive travel before it locks out l Troubleshooting 05 SKAREB SERVICE MANUAL If the Lock out does not lock out properly go back through the steps listed above If the o rings are damaged on the Lock out piston replace them with P N 062594 urethane 1998 2003 Mars SX amp Skareb Lock outs 065261 04 05 Skareb Lockouts and 02 03 Black 100 120mm Lock outs and 040315 Axel s If the oil level is low check to see if there is evidence of leaking at the Rebound Damper If so replace the Rebound Damper assembly and retry the Lock out The oil level may be low if you are upgrading a standard Compression Damping system with the Lock out system In this case make sure the oil level is at the correct level before trying it again If there are signs of oil leaking around the top of the Lock out system check the rubber o ring 040524 and replace if needed If the window does not open or close when the knob is moved replace the entire Lock out assembly REV NC Remote Lock out Service Ins
20. he ring with the tapered chamfered end first followed by the long slide tube This tapered end leads the tool 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 05 SKAREB 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 Uppe
21. ighten per the Skareb Schematic and Torque Specification Table Assembly of Compression Damping Assembly Adjustable Compression Lockout use Failure to do so could result in injury or possible death 1 Fill right leg with damping oil using 5wt Motorex fork oil Ref Answer Products PN 85 0023 to the height noted in the Skareb Schematic and Torque Specification Table Cover the opening at the top of the right leg of the crown steer with a rag and cycle the fork six times Recheck oil level and add drain to meet the level requirement 2 Puta little bit of Prep M grease Ref Answer Products PN 85 0031 on the urethane or brown rubber o ring found on the lower piston of the Lock out assembly 3 Twist the Hex shaped aluminum shaft that sticks up from the top cap counter clockwise until it stops the system is completely open to oil flow at this point 4 Using a motion like screwing in a screw Twist the assy and apply a little pressure to insert the piston part of the mechanism past the threads at the top of the inner leg Then push the assy into the leg until the threads on the cap intersect the threads inside the inner leg screw the cap Tighten per the Skareb Schematic and Torque Specification Table 5 Once the cap is tightened twist the Hex shaped shaft clockwise until it stops this is the locked out position Insert the springs into opposite holes in the top cap and then place the ball bearings on top of the springs place a little da
22. k 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 SPV Evolve The latest version of SPV damping technology that has increased its performance with modifications to the original design 05 SKAREB SERVICE MANUAL REV NC FRONT SUSPENSION TERMINOLOGY CONT Slider Outer Casting The tube outer casting leg of the suspension fork that0 remains fixed to the wh
23. le 6 For sizing of the lower bushing 7 Use slotted top cap from sizer kit and set it into the top of the casting leg straddling the threaded rod Spin the extra nut with washer down to the top cap and using a wrench socket or soeeder 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 8 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 9 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 05 SKAREB SERVICE MANUAL REV NC TROUBLESHOOTING Service Manual Symptom Cause Page Tighten Valve core replace bad parts as Air Loss Schrader Valve leaks needed 10 Air Cap O ring leaks replace part
24. mote L O Cover Left a ___ ___________ Baan O Remote L O Cover Rigt a J ________ OBa O RemoteLio LO Att Remote L O Cable __a ___ ___________ Ba O Remote L O Cable Guide A ett Remote LIO O Ringkit a nat Rbnd Damp Ad 4471 5308 4471 5308 4471 5308 85 5308 85 5587 85 4473 M Air Volume Adjust Cap C 85 5588 im IT Top Assy IT Top Cable Guide c ITHBLever J Crnistikeg Dp o URH o ds do lie ee le V Steel S T 26 9960 5561 5560 5561 5560 5561 NI EIA ale E Bik AL S T 26 SPV 4449 4455 4449 4455 4449 4455 83 2341 STD SM 9962 9963 9962 9963 9962 9963 83 2340 Quel E li Black 26 85 4470 Mm Silver 26 85 5101 E Red 26 85 5102 jena STD White 85 5103 nm Bike Blue 83 2293 A 85 5260 inu orange Y Y O 85 5565 85 5566 umi 85 5109 im 85 5107 uli Candy Blue 85 5108 una sm Matte Black 83 2295 05 SKAREB SERVICE MANUAL REV NC ten Service Kits Travel mm a A Outer Leg Assy con t NB STD DO Black TS 85 5111 83 2359 NB STD DO Silver 26 85 5112 83 2302 NB STD DO Red 26 85 5113 NB STD DO 85 5114 NB STD DO Bike Blue 83 2294 NB STD DO Cobalt 85 5568 85 5569 85 5570 NB STD DO Candy Chrome 85 5120 85 5118 A 85 5119 A 83 2296 a Sticker Kit PF ForDark Colors pF For Light Colors Ride kis G o soft 85 5573 a pO soft 85 5575 o Meri 85 5577 a er irm 85 5579 yo Travel Adjust oko V
25. mping 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 oil such as hydraulic oil Oil with low weight numbers 5wt or 7wt flows through the valving with less resistance than higher weight numbers 100r 15 wi One Point Five Standard 1 5 inch interface standard for frame head tubes headset cups stem and steer tubes which allows for the lightest weight and strongest design in 170mm single crown forks This design greatly improves the control and steering precision of the fork It is used predominately on forks with longer travel and the intended use is for more hardcore extreme riding 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 05 SKAREB SERVICE MANUAL REV NC FRONT SUSPENSION TERMINOLOGY CONT 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 co
26. mpressing the air thus causing a change in the spring rate of the Suspension Porosity The condition or property of having pores in a material that will allow gas or liquid to pass through it Platform Plus Damping A new damping system found on 2005 Rear shocks featured on Metel and Radium s This system will establish a pedaling efficiency platform similar to SPV but is done through unique valving that is not adjustable helps in bump control Rapid Travel Il Wind Down Systems that are used to control the travel of suspension forks Also known as RTII and WD RTII is 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 RTII Quad Ring seal New seal that replaces standard o rings in designs that require more efficient air and oil sealing methods Rebound he 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 Remote Lock out system A handle bar lever actuated system that controls the lock out function on front and rear suspension products 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 for
27. mpression Rod Assembly There are now two ways to remove the air piston from the inner leg 1 An Air Piston Removal tool has been developed that will enable you to remove the piston without having to take the fork apart P N 85 8062 2 Without this new tool you will need to follow the procedures in the following section WAAN This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death 1 Remove air dust cap covering the Schrader valves a Depress Schrader valve to release air pressure b Remove air cap on top of Left leg with 20mm socket 2 Remove rebound adjuster knob using a 2mm hex wrench 05 SKAREB SERVICE MANUAL REV NC 3 From the right leg dropout use 8mm hex wrench to turn the damper shaft clockwise until it can be pushed into the casting 4 Remove 11mm hex bolt Compression Rod bolt from bottom of Left leg 5 Remove crown steer inner leg assembly from the outer leg casting over a drain pan because Semi Bath oil will leak out of bottom of casting once you pull the inner legs from the outer casting legs 6 Be sure to drain all Semi Bath oil out of casting before re assembly of fork 7 Remove left leg end cap and compression rod assembly from inner left leg Then remove spring and Air piston rod 8 Use along narrow rod approximately 18 458mm long and no greater than 14 7mm in diameter
28. n the piston on one side of the piston only If this is a wear spot then this means that the hole in the bottom of the casting is slightly off center and the casting needs to be replaced with a new one Refer to Figure 4 Continued on next page 05 SKAREB SERVICE MANUAL Page 18 REV NC Troubleshooting Tips continued This condition causes the Lower shaft assembly to be side loaded inside of the inner leg and causes wearing of the piston that allows for a poor fit of the Ouad ring and thus an air leak C The last item to be concerned with is the casting When reassembling the fork be sure to visually inspect the position of the bottom of the lower assembly as it begins to come through the bottom hole in the casting before you secure it with the 12mm nut If that shaft is not guiding itself straight through that lower hole without any assistance you will eventually see the same issue as mentioned above Once again it is a casting issue Note Always replace all o rings and seals provided in the IT O ring kit each time you take the system apart IT Control Wire Change In order to change the inner control wire start by following IT disassembly steps 2 3 10 11 amp 12 Once you have the upper assembly out of the fork use the adjustable wrench and the 12mm Open End wrench to unscrew the top cap from the shaft of the assembly Refer to Figure 5 at the right As you unscrew the top cap you will feel a little tension
29. nside of the shaft Refer to Figure 9 Install the Air Piston back onto the shaft in the reverse of the way you removed it Tighten the piston to 15inlbs 1 7Nm onto the shaft To remove the large Quad ring on the outside of the piston grasp the piston at the Quad ring like you would pinch someone with your thumb and pointer finger Squeeze the Quad ring and you will see a section of the Quad ring move away from the piston Use the same tool that you used to remove the small Quad ring from the shaft and pry the Quad ring off of the piston being careful not to scar the surfaces of the piston Discard this Quad ring and replace it with a new one Be careful not to twist it in the seat that it rests in You are now ready to reassemble the IT system Note Always change all Quad rings and o rings when servicing the IT system 05 SKAREB SERVICE MANUAL Page 20 REV NC Reassembly of the IT System IT Service K its It is recommended that when reassembling the IT system that you start by installing the lower assembly into the bottom of the inner leg first Be sure to apply a small amount of Prep M grease to the Quad ring on the outside of the piston and onto the threads of the inner leg before inserting assembling into leg Twist shaft assembly as you insert piston past the threads of inner leg Tighten end cap to 25 35inlbs 2 8 3 9Nm Lever Kit Cable Refer to steps 8 9 and 10 above in the IT Assembly Guide Control Wi
30. ocated under the piston on the inside diameter of it where the shaft of the upper assembly intersects the lower assembly and piston The shaft is sealed against leakage at this point to define the two different chambers A Always check two things when you have the system apart Use a straight edge and lay it next to the inner shaft that is attached to the top cap of the upper assembly to insure that that shaft is not bowed at any point We found that on assembly of these pieces the shaft is pressed into the top cap and if it is over pressed the shaft will bow This means that at where the bow is in the travel of the shaft it will cause the Quad ring that it is passing OM through to distort Thus air transfers from one 1 TE A om chamber to the other and the fork will extend by Z 95700 mama STAINLESS STEEL RULES itself If this is the case you will need a new top assembly and an O ring kit Refer to Figure 3 Make sure that the valve core in the Schrader valve is tight and does not stick open or closed If this is faulty replace this valve core with a new one Any bicycle tube valve core will work as well as any valve cores that we currently use on any of our other products B On the lower assembly inspect the Ouad ring that is around the piston at the top of the lower assembly You are looking to see if it is seated properly and not torn or twisted Also inspect the piston to see if there are unusual wear marks o
31. on This oil needs to be checked about every 6 8 weeks of riding time It will dissipate over time and then you may experience some air leakage and increased stiction in the fork movement 2 Install the air cap and tighten it to value given on fork schematic 3 Turn crown steer leg assembly over so that the bottoms of the inner legs are facing you In the same leg that you just installed the air piston and air cap into insert the air push rod longer end in first then the positive spring this is your ride kit spring onto the short end of the push rod then install the compression rod assembly and tighten end cap into leg Tighten to torque values that are listed on fork schematic 4 Now install damping assembly into bottom of other inner leg If your fork uses SPV damping be sure to check the function of the SPV valve and apply a thin layer of Prep M grease onto 05 SKAREB SERVICE MANUAL REV NC o ring that is around the piston at top of assembly Install the assembly and tighten end cap to specified torque value Assembly of Compression Damping Assembly Non Adjustable FFD WAI 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 1 Puta little bit of Prep M grease Ref Answer Products PN 85 0031 on o ring found on the lower piston of the FFD assembly 2 Install the FFD Assy into the top right hand of the crown steer using a 27mm socket T
32. ons 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 WAUA Suspension forks use compressed air to provide fluid pressure in the damping system and spring resistance in Air models BOTH systems must be relieved of pressure prior to servicing these systems Failure to relieve air pressure could result in injury or possible death CAUTION The Skareb suspension fork uses precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage 05 SKAREB SERVICE MANUAL REV NC FRONT SUSPENSION TERMINOLOGY 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 Forks 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
33. r bushings are driven in as far as the stop in the top of the casting will allow The general rule of thumb 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 2 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 05 SKAREB SERVICE MANUAL REV NC Bushing Installation CONT 4 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 5 Remove weighted handle and gage if applicab
34. re Change for installation of the top assembly Once this assembly is installed the casting can be installed Semi Bath oil added and all fasteners secured When re inflating the IT system it is fastest if you have someone depress the control lever and hold it while you pump air into the system This way the system egualizes immediately If you do not have a second person to help just add air to the system and then periodically depress the lever to egualize the pressure This may have to be done a couple of times in order to reach the required air pressure It is recommended to initially set your fork up with an air pressure that is approximately 75 of your rider weight Then you can fine tune your ride by adding or deleting air as you need Top Assembly Lower Assembly 05 SKAREB SERVICE MANUAL Page 21 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 AnswerKit o oyoyoOoOoo 25 4mm 1 28 6mm 11 8 30mm 85 5194 85 5192 Bushing Removal Tool Components Slide Hammer Threaded Handle Slide Threaded Shaft Removal Ring Bushing Removal Tool Assembly 05 SKAREB SERVICE MANUAL Page 22 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 t
35. s as needed Air Piston leaks parts as needed Check O ring tighten cap to proper Air Top Cap leaks Torgue replace parts as needed Oil leaks from PA Remove Casting from Inner Legs reinstall Wiper Seals Seal not seated properly or replace seals Nicks 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 13 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 OO ring damaged Rebound Damping assembly NN Compression Rod Bolt Check O ring on bolt to see if it is OO leaks damaged and then reinstall Resize bushings or replace with new ones Lack of Travel Tight Bushings if damaged 22 MA Hydraulic lock out Replace Rebound Damping assembly 9 Follow instructions for removal and Semi Bath oil volume installation of Outer Casting 13 Damper oil volume Damping assembly if needed 12 Visually inspect fork call Answer Fork alignment Products Customer Service damping SPV valve not functioning replace assembly if needed bie Check oil level refer to Oil leaks from Damper oil volume bottom of Casting turn Replace Rebound Damping Assembly Refer to Air Loss Schrader valve leaks Loss of SPV air pressure and Air Cap O ring Leaks 05 SKAREB SERVICE MANUAL P
36. s stopped by the casting If not remove knob and reinstall on hex shaft in 1 6 turn increments until full travel is reached 7 Install the 4mm compression rod screw and tighten per the Skareb Schematic and Torque Specification Table 05 SKAREB SERVICE MANUAL REV NC Lock Out Troubleshooting Tips Installation of Lock out Compression Damping System Check the o ring that is installed around the lower piston on the damper shaft for tears or deformation Replace it if it is damaged This is the most common reason why the Lock out system will not function Check the level of oil in the inner leg The oil level may be a little high but never low The oil level must be high enough to cover the window that opens and closes on the damper shaft Make sure that the oil flow window on the lower portion of the damper shaft positioned right above the piston opens and closes when you move the lock out knob from open to close Inspect the rubber o ring that is around the threaded portion of the cap that screws into the inner leg of the fork This o ring should not have nicks or tears in it and should fit tightly around the cap Make sure that when installing the Lock out system into the fork leg that you follow this procedure Put a little bit of Prep M grease on the urethane o ring make sure that that the oil flow window is open using a motion like screwing in a screw Twist the assy and apply a little pressure to insert the piston part of the mec
37. t back into the upper shaft assembly Push the cable assembly together forcing the inner cable to stick through the spring and then out through the end of the upper shaft assembly See Figure C Hook the cable end into the eye hook and then pull on the cable assembly to pull the two shafts together Tighten them together snuggly Check oil level in fork leg refer to oil level heights in fork spec sheets Install Lock out assembly into the fork leg and tighten top cap to proper torque Re install the other cable end into the Lever assembly and then put the lever cover back on to the Lever assembly You may have to pull the cable assembly away from the housing of the lever assembly to expose the inner cable so that you can slide the cover into its proper position Cable hook up connection Figure B Figure C 05 SKAREB SERVICE MANUAL Page 16 REV NC Infinite Travel System IT IT System Disassembly Instructions Lower Air Piston Upper Top Cap amp Assembly Assembly Cable Guide Remove front wheel and brake set from fork Important you must remove all of the air from the left leg of the fork before disassembling the IT System There may also be a discharge of a white substance when you depress the Schrader valve core this is similar to the discharge when you depress the valve core on any of the Manitou Air or SPV forks On the bottom of the left leg leg that has the Disk Brakes mounts on it there is a Schrader valve
38. tructions Complete Remote Lock out Assembly Lever Kit and Lever cover Kit There are 5 Service kits available for each fork model that utilizes a Remote Lock out 1 Lever assembly 2 Lever Cover 3 Cable assembly 4 Cable guide 5 Lock out assembly Reference to these kits may be found in the Service Parts Matrix Instructions for removing assembly from fork Barrel Cable 1 Unscrew barrel adjuster ina 7 adjuster Assembly Lock out counterclockwise direction until it stops Assembly 2 Remove Lever cover by squeezing the two plastic prongs together on the under side of the lever and pulling the cover in an upwards direction from the lever assembly Pull on Black cable ferrule nearest to lever and pull cable assembly from the groove in the Lever assembly thus releasing cable from lever Unhook cable end from lever Tools needed to service assembly Adjustable Pliers Adjustable Wrench 22mm Socket W cut out 10mm open end wrench Socket Wrench Please continue to next page for more Service instructions 05 SKAREB SERVICE MANUAL Unscrew the top cap of the Lock out assembly from the fork crown using socket Answer p n 83 2503 or an adjustable wrench Pull Lock out assembly out of crown by twisting the assembly like unscrewing a screw and applying an upward pressure Slowly pull assembly out of crown and watch out for some excess damping oil to come out of inner leg as the piston at the end of the assemhlv
39. xture 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 Infinite Travel System IT A handle bar mounted air travel adjust system that allows the rider to change the fork travel and ride height without a spring rate change The travel can be changed from full compression to full rebound and at any place in between 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 da
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