Radium and Metal Shock Service Manual Rev NC
Contents
1. 126 a Regular Mount 38mm Travel 1 5 Regular Mount 50mm Travel 2 0 Regular Mount 56mm Travel 2 25 A 83 2228 Schrader Valves Radium 8 Radium R Air Can Schrader Valve Assy A Radium RL Air Can Schrader Valve Assy Complete Shock Without Hardware EN Eye to Eye smm res de So _____ 230mm Eye to Eye de S _ Eye TemmTravet e So HEP 6649 6650 85 6651 HAP 6630 6633 85 6639 ETE a 6631 6634 85 6640 EE 6632 6635 85 6641 Hamm 6636 85 6642 caras 6645 663 85 6643 Har 6646 6638 85 6644 Hardware Kits fT Lo D 8800356 83 2235 IFP Chamber Refill Plug B Sticker Kit CT 83 Sticker Kit Radium Shock 2244 83 2245 83 2236 85 5436 DU Bushing 85 6105 85 6105 Mounting Hardware Kits D Contact Answer Products 83 2246 T T 2005 RADIUM METEL SHOCK SERVICE KITS CONT 06 RADIUM METEL SPLIT S TYPE SRL SERVICE MANUAL Rev NC Radium Kit Description Radium Radium R RL Ride Kits Springs for Coil Shocks JL 165 Eye to Eye 38 Raie 250 Je F 85 6660 165 Eye to Eye Je F 85 6661 165 Eye to Eye 38 Rate 350 fa 85 6662 Metel R Metel RP 165 Eye to Eye x38 Rate 400 85 6663 c MEN EI 85 6664 165 Eye to Eye x38 Rate 500 T 85 6665 165 Eye to Eye x 38 Rate 550 G i 85 6666 165 Eye to 38 Rate 600 852. 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL SECTION 3 GLOSSARY OF TERMS Air Canister Can that holds the air spring air in an air shock Bottom Out Point at which a shock reaches full compression Control Eyelet C End Eyelet that is on the rebound adjuster end of a shock The air canister is attached to this end on air shocks Damper Eyelet D End Eyelet that is on the damper body end of a shock Damper Body Section of shock that contains the damping system Damper Shaft Shaft attached to the damper piston that connects the two moving sections damping system and control eyelet of the shock together Damping System Controls compression and rebound rate speed DU Bushing Teflon guide bushing pressed into the eyelets Mounting hardware is inserted into the DU bushings and rotates within the bushing as need by the suspension design Eyelet Found on each end of the shock it is where the DU bushing and mounting hardware are and provides the connection between the shock and bicycle Internal Floating Piston IFP A floating piston that separates damping oil from the damping system air chamber Lockout Found on QRL shocks The Manitou lockout significantly increases the amount of load required to compress the shock The lockout does not prevent compression under load only increases the amount of load required to compress the shock Mounting Hardware Hardware that allows shocks
3. 2006 RADIUM METEL SPLIT S TYPE SRL SHOCK SERVICE MANUAL REV NC 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL Page 1 2005 RADIUM METEL SPLIT S TYPE SRL SHOCK SERVICE MANUAL INDEX Section Description Page 1 INTRODUCTION 3 2 SETUP TUNING PERIODIC MAINTENANCE 3 GLOSSARY 4 COMPLETE SHOCK LESS HARDWARE 5 HARDWARE REMOVAL AND INSTALLATION 6 DU BUSHING REMOVAL AND INSTALLATION wem 8 MARCANSTERREMOVALANDSEALSERMCE o _ o pwPNGaSYSEM wW o 10 TROUBLESHOOTING Im TABLE 1 FASTENER TORQUE REQUIREMENTS mm 12 RADIUM METEL SHOCK SERVICE KITS BENT 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 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL SECTION 1 INTRODUCTION This manual is intended to guide the user through basic service of Manitou RADIUM METEL rear shocks 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 rear shoc
4. 667 165 Eye to Eye x38 Rato 650 lel T 85668 165 Eye to Eye 38 Rate 700 85669 165 Eye io Eye 38 Rate 750 ff seo ____ 190 200 Eye to Eye 50 Rate 600 taf essen ____ 190 200 Eye to Eye 50 Rate 650 taf 190 200 Eye to Eye 50 Rate 700 taf esee ____ 190 200 Eye to Eye 50 Rate 750 taf 215 Eye to Eye x 63 Rate 600 del T J 55665 ____ 215 Eye to Eye 63 Rate 650 del p J see o 215 Eye to Eye 63 Rate 700 jel T T J seem o 215 Eye x 63 Rate 780 6 T see ____ 222 230 Eye to Eye x 70 Rate 600 fat see ____ 222 230 Eye to Eye x 70 Rate 650 a see 222 230 Eye to Eye x 70 Rate 700 Jel J see ____ 222 230 Eye to Eye x 70 Rate 750 ef J see ____ 240 to 76 Rate 150 Je S osen 240 Eye to Eye x 76 Rate 200 Tools ll 85 6075 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL 2004 RADIUM METEL REAR SHOCK SERVICE KITS DESCRIPTION A Air Canister B RADIUM METEL Shock No Hardware C Seal Kit E DU Bushing Kit s 1 Z e e EE i fy P F EFFE F ail EZ Sie ee I MANITOU D Hardware F Sticker Kit 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL Page 15 H DU Bushing Tool 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL
5. PE SRL SERVICE MANUAL Page 10 Rev NC AIR CANISTER REMOVAL AND SEAL SERVICE CONT 7 Slide air canister over the damper body 8 Lightly grease the air canister threads and inside the canister Screw the air canister into the canister eyelet Due to pressure in the damping system it may be difficult to compress the shock enough to thread the canister onto its eyelet If necessary the shock test fixture can be used SECTION 9 DAMPING SYSTEM CAUTION The RADIUM METEL SPLIT S TYPE SRL shocks uses compressed air to provide fluid pressure in the damping system and spring resistance These systems must be relieved of pressure prior to servicing Failure to relieve air pressure could result in injury or possible death RADIUM 5 METEL SPLIT Shock damping system service requires special tooling and training that is unavailable at this time In cases where it is suspected that there is air in the damper or the damper body is leaking oil the shock should be replaced NOTICE Do not remove the the hex cap on the damper eyelet of the shock If it is removed the pressure in the shock will be lost and the shock will have to be returned for service and or replaced 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL SECTION 10 RADIUM METEL SHOCK TROUBLESHOOTING CHART Symptom Cause Solution Service Section Air Spring Schrader valve Interference with Replace Confirm Snapped of
6. Page 16
7. e Grease 2000 PN 85 0033 to the hardware before installation There are virtually an infinite number of hardware combinations in use on bikes today When ordering hardware from Answer Products It will be necessary to identify the overall eyelet width eyelet width and mounting hole diameter 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL HARDWARE REMOVAL AND INSTALLATION CONT 1 Measure the overall eyelet width 2 Measure hole size Current hardware are designed to accept a 6mm or 8mm P 29 fastener SECTION 6 DU BUSHING REMOVAL AND INSTALLATION DU bushings are press fit into the shock eyelets at each end of the shock The hardware fit into the bushings and will rotate slightly within the bushing during Suspension compression DU Bushings like hardware may wear over time Removal and installation is accomplished using tool PN 85 6075 REMOVAL 1 Remove hardware from the shock 2 Insert unthreaded end of punch into the removal tool first and screw in about half a turn Punch 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL DU BUSHING REMOVAL AND INSTALLATION CONT Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch making sure that it is centered on the bushing This will press out the bushing INSTALLATION 1 Place a bushing onto the threaded end of the punch and into the removal tool screw in about ha
8. f at base suspension linkage or clearance after other frame Schrader replacement components Air loss from air spring Air spring Schrader Tighten or replace valve leaks Schrader core or replace Schrader assembly Canister Seal failure on Air Replace seal s 8 Piston Air shock does not Failure of negative Replace air canister return to full travel but spring and seals has adequate air spring pressure pew ee eee spring and seals e too low air pressure Damping Oil Leaks Oil leak at base of air Worn or damaged Replace shock canister seals allowing oil to escape from damper chamber Oil comes out of the Damping oil has Replace shock Air Spring Schrader leaked past the valve damper cap Damping System Performance Adjusting rebound Air in damping system Replace shock 4 knob has no effect Lockout does not Air in damping Replace shock 4 work system Low IFP pressure Mounting Hardware Play in shock eyelets Worn DU bushing or Replace 5 6 when mounted in bike mounting hardware 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL Page 12 SECTION 11 TABLE 1 FASTENER TORQUE REQUIREMENTS Feature Torque 4 Swinger Air Air Canister 15 24KgCm 13 21inlbs Schrader Valve Stem 5 10 KgCm 4 to 9 inlbs SECTION 12 2005 RADIUM METEL SHOCK SERVICE KITS Radium Kit Description Radium R Air Canister __ Radium RL Metel RP Regular Mount 32mm
9. k service at this time our primary focus Is to offer service kits that minimize the amount of downtime and labor involved As the program matures and we are able to gather feed back from our customers we may offer kits to a more detailed level GENERAL WARNING Rear shocks 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 CAUTION The RADIUM METEL Shocks use compressed air to provide fluid pressure in the damping system and spring resistance These systems must be relieved of pressure orior to servicing Failure to relieve air pressure could result in injury or possible death CAUTION The RADIUM METEL Shock uses precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage SECTION 2 SETUP TUNING PERIODIC MAINTENANCE Instructions for shock setup tuning and periodic rider maintenance is not covered in detail in this manual Please refer to the Manitou RADIUM METEL Rear Shock Owner s Manual for that information If you did not receive a manual you can download one at www answerproducts com or contact Answer Products Customer Service at 661 257 4411
10. lf a turn Bushing Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch making sure that it is centered on the bushing and that the bushing is centered to the eyelet This will press in the bushing 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL SECTION 7 AIR CANISTER ities Manitou RADIUM Air Shocks use compressed air to provide resistance to compression in place of a coil spring You must be certain that the air canister is relieved of all pressure prior to servicing the air system Failure to relieve air pressure could result in injury or possible death Failure of an air shock to maintain air pressure is usually the result of defective or worn seals If there is suspicion of an air leak the location can be isolated by spraying the air canister joints with a mild solution of dish soap and water Bubbles will form in from the area of leakage You can also immerse the shock in water to locate the leak Sealing of the shock is accomplished through a series if o rings quad seals and wipers When the air canister is removed these seals can be replaced from Seal Kit C Seal Descriptions O Rings Black synthetic rubber with a round cross section Used for fluid sealing Quad Seals Black synthetic rubber with an X cross section used for sealing air Wipers White Teflon used for keeping debris out of quad seals 1 For leaks at the adjuster eyelet or damper Adju
11. ster Eyelet Schrader end of the air canister refer to the detailed disassembly instructions below 2 For leaks at the Schrader valve release all air pressure and replace the Schrader valve core or assembly as needed 3 If when you pressurize the air canister the shock collapses to its shortest travel position the shock has an air piston leak into the negative chamber Place the shock in the shock tester and extend it to its full Shock in Shortest Travel Position travel Depress the adjuster eyelet Schrader while the shock is extended under load If it remains in the full travel position refer to the detailed disassembly instructions below for instructions on servicing the air canister and piston seals If the shock returns to the short travel position it is not serviceable and the entire shock must be replaced MGI eH Attempting to service a Extend to long travel and depress the air shock with this condition could result in C2 Ster Schrader Valve injury or possible death 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL Page 8 SECTION 8 AIR CANISTER REMOVAL AND SEAL SERVICE 1 Failure of an air shock to maintain air pressure is usually the result of defective or worn seals If there is suspicion of an air leak pressurize the air canister to 150psi from the adjuster eyelet Schrader Valve Locate the leak by spraying the air canister and Schrader joints with a mild solution of dish soap and water or s
12. to be mounted into the wide variety of suspension designs Schrader Air Black in color it is the valve for pressurizing the air canister in an air shock Seals O Rings Black synthetic rubber with a round cross section Primarily used for fluid sealing Seals Quad Seals Black synthetic rubber with an X cross section primarily used for sealing air Seals Wipers Teflon ring used for keeping debris out of quad seals guiding the damper piston and providing support Top Out Point at which a shock returns to its full extension 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL SECTION 4 COMPLETE SHOCK LESS MOUNTING HARDWARE The highest level kit offered will be a complete shock without mounting hardware These kits are offered as a fast replacement where all that is need is to change out the hardware or damping unit RADIUM METEL Shock Less Mounting Hardware SECTION 5 HARDWARE REMOVAL AND INSTALLATION Mounting hardware is used to mount shocks to the various frame configurations Over time hardware may wear between the mounting bolts or DU Bushing which will result in play in the connection Remove hardware using pliers as shown in Figure 1 DU Bushing Eyelet Figure 1 HARDWARE REPLACEMENT Hardware should have a slight press fit into the DU bushing and can be tapped in place with a rubber mallet or soft jaws in a vise Apply a small amount of thick grease such as Motorex Bik
13. ubmerge in a bucket of water Bubbles will form in the area of leakage 2 Release All air pressure from air canister Air release Schrader valve Remove hardware as shown under HARDWARE REMOVAL AND INSTALLATION For leaks at the Schrader valves release all air pressure and replace the Schrader valve core or assembly as needed The core is removed using a standard core removal tool The assembly is removed by removing the core and unscrewing the assembly by inserting a 3mm hex into the center of the valve Place adjuster eyelet in a vise using soft jaws Using a rubber strap wrench to prevent damage loosen the air canister completely 06 RADIUM METEL SPLIT Rev NC S TYPE SRL SERVICE MANUAL Page 9 AIR CANISTER REMOVAL AND SEAL SERVICE CONT 4 Slide air canister away from the canister Damper Cap DO NOT REMOVE eyelet and remove Do not remove the damper cap The damper system is under extreme pressure Removal of the damper cap without releasing damper system pressure will result in the possibility of injury or possible death 5 Replace o rings seals and wipers in the air canister and air piston Air Canister Kit A will have new seals installed as part of the kit Also replace the o ring inside the canister eyelet 6 Lightly grease the air piston damper body air canister seals and inside the air canister with a thick grease such as Motorex Bike Grease 2000 06 RADIUM METEL SPLIT S TY
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