Q Shock Service Manual
Contents
1. Figure 1 SPACER REPLACEMENT Spacers 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 Bike Grease 2000 PN 85 0033 to the spacer before installation There are virtually an infinite number of spacer combinations in use on bikes today When ordering spacers from Answer Products It will be necessary to identify the eyelet width overall width and mounting hole diameter 03 Q SHOCK SERVICE MANUAL Page 4 PN 85 4420 REV NC 1 Measure the eyelet width 2 Measure hole size Current spacers are designed to accept a or 8mm fastener DU BUSHING REMOVAL AND INSTALLATION See Kit E DU bushings are press fit into the shock eyelets at each end of the shock The spacers fit into the bushings and will rotate slightly within the bushing during suspension compression DU Bushings like spacers may wear over time Removal and installation is accomplished using tool PN 85 6075 REMOVAL Remove spacers from the shock Insert unthreaded end of punch into the removal tool first and screw in about half a turn Punch 03 Q SHOCK SERVICE MANUAL Page 5 PN 85 4420 REV NC Clamp removal tool in vise Insert eyelet into tool mm hex wrench to screw in punch making sure that it is centered the bushing This will press out the bushing INSTALLATION 1 Place a bushing onto the threaded2. 03 Q Rear Shock Service Kits Description Air Canister Shock Spacers 7 B Q Shock Damper Body C Seal Kit D Spacers E DU Bushing Kit 03 Q SHOCK SERVICE MANUAL Page 12 PN 85 4420 REV NC 622 CD MANITOU MANITOU F Sticker Kit H DU Bushing Tool 03 Q SHOCK SERVICE MANUAL Page 13 PN 85 4420 REV NC 03 Q SHOCK SERVICE MANUAL Page 14 PN 85 4420 REV NC
3. Travel 45 Vale 8856000 Damper Body Q Shock 190mm Eye to Eye 50mm Travel 45 Valve 85 6041 Damper Body Shook 20mm Eye Eye Smm Travel 65 _ Damper Body GR Shock 152mm Eye Eye Samm Travel A Vaka o _ Damper Body OR Shock 165mm Eye to Eve 3mm Travel 45 Vale 8 85005 _ Damper Body GR Shock 70mm Eye to Eve nm Travel 5 Vee e eoe _ Damper Body GR Shack 290mm Eye to Eve Somm Travel 45 Vee 85 6047 _ Damper Body QL Shock 152mm Eye to Eye 32mm Travel 45 Valve 85 6049 Damper Body OL Shook 165mm Eye to Eye 38mm j eoo Damper Body OL Shook 165mm Eye to Eye 38mm Travel 30 Vave eo Damper Body QL Shock 190mm Eye to Eye 50mm Travel 45 Valve B 85 6052 Damper Body OL Shock 200mm Eve to Eye Som Treve 45 Vere 856053 _ Spacers Contact Arawar mounting hardware ee ee ees Sticker Kit Q 152mm Eye to COT Sticker Kit Q 165mm Eye to Eye 85600 Sticker Kit Q 190 200mm Eye to Eye FE 856 U U Sticker Kit QR 152mm Eye to Eye 856or8 Sticker Kit QR 165mm Eye to Eye 85608 Sticker Kit QR 190 200mm Eye to Eye O 85604 ___ Sticker Kit QL 152mm Eye to Eye 85 6079 Sticker Kit QL 165mm Eye to Eye 85 6082 Sticker Kit QL 190 200mm Eye to Eye 85 6085 Bushing Tool Air Shock Compression Fixture 85 6075 85 3008 03 Q SHOCK SERVICE MANUAL Page 11 PN 85 4420 REV NC
4. information in this manual should be directed to Answer Products Customer Service at 661 257 4411 CAUTION The Q Shock 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 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 Q Rear Shock Owner s Manual PN 042102 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 03 Q SHOCK SERVICE MANUAL Page 3 PN 85 4420 REV NC COMPLETE SHOCK LESS SPACERS See Kit B The highest level kit offered will be a complete shock without spacers mounting hardware or a Damper body without air canister Thes kits are offered as a fast replacements where all that is need is to change out the spacers or damping unit Shock Less Spacers Shock Damper Body SPACER REMOVAL AND INSTALLATION See Kit D Spacers sometimes called mounting hardware are used to mount shocks to the various frame configurations Over time spacers may wear between the mounting bolts or DU Bushing which will result in play in the connection Remove spacers using pliers as shown in Figure 1 DU Bushing Eyelet
5. 2003 SERVICE MANUAL MANITOU Q MANITOU MANITOU QL PN 85 4420 REV NC 03 SHOCK SERVICE MANUAL Page 1 PN 85 4420 REV NC 03 Q SHOCK SERVICE MANUAL INDEX INTRODUCTION SETUP TUNING PERIODIC MAINTENANCE COMPLETE SHOCK LESS SPACERS See Kit SPACER REMOVAL AND INSTALLATION See Kit D DU BUSHING REMOVAL AND INSTALLATION See Kit E AIR CANISTER See Kit A DAMPING SYSTEM BLEEDING Q SHOCK SERVICE KITS 03 Q SHOCK SERVICE MANUAL Page 2 PN 85 4420 REV NC M LAINNIKEOUJ INTRODUCTION This manual is intended to guide the user through basic service of Manitou 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 shock 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
6. away from the canister 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 03 Q SHOCK SERVICE MANUAL Page 8 PN 85 4420 REV NC AIR CANISTER REMOVAL AND SEAL SERVICE 4 Replace o rings seals and wipers in the air canister and air piston Air Canister Kit will have new seals installed as part of the kit Also replace the o ring inside the canister eyelet O Ring Seal Wiper Locations 9 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 6 Slide air canister over the damper body 7 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 03 Q SHOCK SERVICE MANUAL Page 9 PN 85 4420 REV NC DAMPING SYSTEM BLEEDING CAUTION The Q Shock 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 Air canister removal requires special tooling and
7. eals 1 For leaks at the adjuster eyelet or damper Adjuster 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 TIN Attempting to service Extend to long travel and depress the air shock with this condition could resultin canister Schrader Valve injury or possible death 03 Q SHOCK SERVICE MANUAL 7 85 4420 REV NC AIR CANISTER REMOVAL AND SEAL SERVICE 1 Release All air pressure from air canister Air release Schrader valve Remove spacers as shown under SPACER REMOVAL AND INSTALLATION 2 Place adjuster eyelet in a vise using soft jaws Using a rubber strap wrench to prevent damage loosen the air canister completely 3 Slide air canister
8. end of the punch and into the removal tool screw in about half a turn Bushing Clamp removal tool in vise Insert eyelet into tool Use hex wrench to screw in punch making sure that it is centered the bushing and that the bushing is centered to the eyelet This will press in the bushing 03 SHOCK SERVICE MANUAL Page 6 PN 85 4420 REV NC AIR CANISTER See Kit A The Swinger Air uses 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 s
9. training for service that is unavailable at this time In cases where is suspected that there is air in the damper or the damper body is leaking oil use the applicable Damper Body Kit to replace the suspect damper 03 Q SHOCK SERVICE MANUAL Page 10 PN 85 4420 REV NC 03 Q Rear Shock Service Kits Kit Description Detail Answer Kit Part Number Air Canister Regular Mount 32mm Travel 85 6035 Air Canister Regular Mount 38mm Travel 85 6036 Air Canister Regular Mount 50mm Travel Shack No Spacers Sarin Eye Eye aa Shock No Spacers TS Eye to Eye Br Travel Vane B sr _ Shock No Spacers oom Eye to Somm Travel Vane B asa Shock No Spacers 200mm Eye to Eye Sorin Travel s assa0 _ OR Shock No Spaces 182mm Eye Travel _ Shock No Spacers 165mm Eye wo Eye erm Travel 5550 _ OR Shock No Spacers 100mm Eye Eye Travel 45 Vane _ Shook No Spacers 200mm Eye Eye Somm Travel 45 Vawe e j ao _ OL Shock No Spacer 152mm Eye Eye mm Travel 8 aa _ Shock No Spacers 15mm Eye 0 Eye 3m Travel AS Vai 5550 _ OL Shock No Spacers Eye 0 Eye rim Travel 8550 _ QL Shock No Spacers 190mm Eye to Eye 50mm Travel 45 Valve 85 5411 QL Shock No Spacers 200mm Eye to Eye 50mm Travel 45 Valve B 85 5412 Damper Body Q Shock 152mm Eye to Eye 32mm Travel 45 Valve 85 6039 Damper Body Shook 165mm Eye 8
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