X-Vert Service Manual
Contents
1. OYHS unen X fern Vb 1N2138 T frase BE IAIIIG 143130 ferent ae x 8 0 AIIN uwelfT SEPALS WY Ge X WAL 557260 mic 2 LSP ABET toe aw five HIV ASHOS A304 a ses ke DOUG S 81913 252 80 04 d Pi LEUR SANA unda 6222 5 Nuus T d X WHS ub 26 8 x 28 9 ON B EES wi gu y mt 5 i 070 BEN NYD feo Oy GE LON 1 OOH ON D LAN ese 2 8 inbumi 6 1 9 ad erat e TIVE INAJ LIN HS X 574 ferdir 330149 NOLS te m 2 Stk X Ep Xx Sol 2i WO ENTERS uut A NIHE 9 4 SN CSL CSL I3 DNDEE3u E 2 h Pd XY X am lt ue D YIS CEECSO XO S Ni 2 110233N Iva N NIMS Os PG B sane e 2 PEGE firdiet 1068 Was SNInSNd FIGURE 5 2 Pas M 597 7 Qs obi d ES2. a secondary catch dropout AD SS BGM Note All 98 99 amp 2000 Xvert forks excluding the Xvert carbon are equipped with a hangerless arch A brake cable hanger kit that attaches to the arch is available through your dealer See Figure 2 WARNING When installing 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 105MM travel fork models is 3 4 252 108 0MM for 120MM travel fork models is 4 843 123 0MM and fo 2 180MM travel fork models is 7 205 183 0MM Any less clearance can result FIGURE 3 TIRE CLEARANCE in accident resulting in serious injury or death Figure 3 SPARE PARTS Table 1 Spare parts can be ordered through your local dealer If you have any problems that you cannot resolve with your dealer you may call Answer Products technical warranty service department at 661 257 4411 8 00 AM to 5 00 Pacific Standard time Monday through Friday In addition helpful information can be found on the Answer Products web site at http www answerproducts com where you may download manuals and e mail us for technical support 2000 X VERT DC FIRM RIDE KIT 2000 X VERT DC SOFT RIDE KIT 2000 X VERT CARBON SOFT RIDE KIT 2000 X VERT DC BLUE OUTER ASSEMBLY 2000 X VERT DC FIRM RIDE KIT 2000 X VERT DC SOFT RIDE KIT _ 2000 X VERT CARBON FIRM RIDE KIT 85 9080 2000 CARBON SOFT
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4. Xvert SUPER 3 50 89MM 4 0 102 3 75 95 Xvert CARBON 7 0 178MM 9 0 228 8 0 203 MAXIMUM ble REGBMME MINIMUM lt FIGURE 9 TPC OIL LEVEL GENERAL DISASSEMBLY NOTE Your fork does not need to be removed from the bicycle for general disassembly or cleaning Furthermore it is not necessary to disassemble your fork to service the spring stack or to change the oil height You may service the spring stack by removing the adjuster assembly as shown in Figure 11 Removal of outer leg Figure 10 1 2 Use 4MM Allen wrench to remove the lower compression rod screw from the left leg side Pop out the damping adjuster knob from the right side a small screwdriver may be helpful Use an 8MM allen wrench to remove the dropout nut it may be helpful to compress the fork to prevent the compression rod and damper shaft from turning while removing these screws Pull the outer leg assembly off assembly Remove the 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 the inner legs and crown 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 Spring Stack amp Compression Rod
5. LEG 6 INSTALL amp TERRE d NUT USE AMM ALLEN WRENEH TBR 13 66 E ER 4 A SLIDE QN OUTER LEGS WNITL FORK 15 FULLY amp INSTALL A GORE 1 IN LER FIGURE 15 OUTER LEG ASSEMBLY Outer Leg Assembly Figure 15 Slide outer assembly onto inner legs and fully compress 2 Install and torque the SMM compression rod screw and dropout nut to between 10 and 30 inch lb 1 1 3 5 N m Over torquing the dropout nut may damage the damper shaft 3 Pop in the damper adjuster knob An O ring holds the knob in place 4 For all Xvert models except the Xvert Carbon slide the skirt of the fork boots over the flange on the upper seal Be sure the lip snaps into the groove 11 5 Clean the adjuster cap threads and the threads on the inside of the inner leg thoroughly 6 Assemble MCU s springs and connectors with thick grease 7 Install adjuster assembly into inner leg and torque to within 20 and 30 inch Ib 2 3 3 5 N m INNER FORK LEGS amp CROWN The inner fork legs and steer tube are press fitted into the crown and may never be removed Removing them will make the fork unsafe to use Should any slippage occur contact Answer Products Technical Staff immediately at 800 670 7446 BRAKE ARCH NOTE The 2000 XVERT outer leg arch is a one piece Magnesium casting Thus if it is damaged it must be replaced Using the fork with damage to the o
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7. iN LL WHE dx OU LO INN L NHS EN uS EX aY mme vi uses teo PED rans me ON HITA uses 8 NNAL NAZE NIH ENIX INGE WIHS EN heit NS at i NHS d wv ASO 3139 lv wR 1 ATA acci va 800290 Ove AJBN3BEvV H3We 1 ISHV1 TIVAS NOHHVO LHd3 X 0002 defh9i4 19134 Was ONIHSTTG LOI yes FIGURE 7 MAINTENANCE IMPORTANT The fork boots are required to keep your 2000 Xvert excluding the Xvert Carbon performing well and your warranty in effect Use of this fork without the boots will shorten the life of the fork reduce the performance and void the warranty Your 2000 Xvert fork requires periodic maintenance cleaning and inspection Moisture and contamination may build up inside the fork depending upon the severity of riding conditions To maintain top performance it is recommended that the fork be periodically disassembled cleaned dried and re greased using the grease ports on the back of each leg Figure 8 IMPORTANT When filling the fork with grease through the Microlube ports it is important to note the grease is filling the space between the upper and lower bushings If this area is overfilled the force of the grease may force the upper bushings and dust seals out IM
8. resulting in a color change is not detrimental to the gold anodized surface Replace the crown leg assembly if wear is excessive or if they are damaged 8 Check inner legs at the bottom of the crown for cracks or for flaking of the anodizing Replace crown leg assembly if cracked or if gold anodize is beginning to flake 9 Check the crown for cracks Replace if cracked REASSEMBLY Lower Shaft Figure 12 Install all previously removed O rings and seals 1 Lightly grease all seals with seal grease 2 Apply a small amount of blue Loktite to piston seat threads 3 First reassemble shim stack spacers and piston in exact order they were removed Next thread the valve nut onto the piston seat and torque it to 12 IN LB 1 2 N M max 4 Install lower needle gently into shaft thread until it stops then back off one turn for initial adjustment 10 gt Slide assembly through the plastic end 6 Slide an elastomer onto the shaft followed by the cup spacer Next place the detent ball in its hole and slide another elastomer over it Note The Xvert DC amp Xvert Carbon do not use the cup washer and 2 elastomer Therefore the first elastomer is used to retain the detent ball 7 Insert into right leg and thread in end cap Torque 30 IN LB 3 5N m max Compression Damping Assembly Figure 13 1 Install all previously removed O rings 2 Apply a small amount of blue Loktite to piston seat threads 3 Reassemble shim stac
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10. A ALE BRAKE diameters Removing and replacing the steer tube or stanchions will result in an RETAINER unsafe condition and should never be done Remove old forks from bicycle Measure and cut the steer tube to fit your bicycle head tube Remove crown race from old forks and press it onto the steerer until it is seated on crown Clean and grease headset bearing and races of bicycle Install lower bearings on fork crown race if applicable Install steer tube into head tube frame Install upper bearing spacers and stem For the Xvert DC and Xvert carbon install the upper triple clamp before the stem Install stem cap adjust and tighten headset per manufacturer s instructions Install handlebars to desired height Torque stem handlebar pinch screw and stem clamping system to manufacturer s instructions 10 Install brakes and adjust per the manufacturers instructions 11 Adjust fork 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 Be sure to verify that there is adequate thread engagement 4 or more threads with the release adjusted lock due to the wider adjustment of the 2000 XVERT forks 12 Install brake cable per manufacturers instructions PONG 59 09 Note All 98 99 amp 2000 forks excluding the Xvert Carbon equipped with
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12. PORTANT Before every ride you should Ensure that quick release skewers are properly adjusted and tight 2 Wipe the inner legs clean lubricate and check the entire fork for any obvious damage 3 Check headset adjustment 4 Insure the front brake cable is properly seated in the cable retainer amp verify proper brake adjustment IMPORTANT Maintaining the proper oil level in your TPC damping system 15 very important Insufficient oil will allow foaming and reduce the damping performance Whereas too much oil will restrict travel and may cause damage to the system and an unsafe riding condition Finish reading this entire section prior to making any changes to the oil level To check the oil level remove the compression damping assembly located in the top of the right leg Leave the left side compression stack adjuster MCU spring assembly in FIGURE 8 place to keep the fork fully extended Use a tape measure or dip stick to determine LUBRICATING BUSHINGS oil level It is recommended that you replace your oil at least once during the season or twice if it has been contaminated with dirt mud or any other substance Use SAE 5WT Maxima fork oil or equivalent Refer to Figure 9 for the recommended oil level or for a specific fork models refer to table 2 OIL LEVEL TABLE 2 3 50 89 4 0 102MM 3 75 95MM Xvert DC 8 0 203MM 10 0 254MM 9 0 229MM MEASURE PIL LEVEL FROM OF GROAN
13. Removal Figure 11 1 2 Unscrew and remove the spring adjuster assembly Unscrew the end cap from the left inner leg and pull the compression rod out of the inner leg Lower Shaft Disassembly Figure 12 Note Lower Shaft removal disassembly is best done with the fork removed from the bicycle Disassembly of the damping assembly is not required unless you want to modify or replace the shim stack ID ELABTOME _ pesp we X VERT LGNER RHAFT ASSEM i Y vave doar taah ROG EEN WRENGH REMENE WER FORK LEG UNIT FIGURE 10 OUTER LEG REMOVAL BONNE TORE D MUST BE BETWEEN S ALL SPRING FORK GOWN Ta REMOVE A BOTTOM ELASTOMER ELASTOMER CUP WARHER AND ELASTOMER FIGURE 11 SPRING STACK amp COMPRESSION ROD MES AY X NERT xr LBWER Fase vave ieg BAIR SHIM DANA yim FONS Vave NUT par derra FENG parr 4 VALVE wot eat tun EN 472 READING CNN M EAM ENS ama AN Hiv aM e PSX EE NOM E U GE 15M ENT SRG HIM HAM eap gue n uv oae sig p ae ed Co ET JAMIU BIN aa SPRANG SHIM 47 AM om X ett I MN Es WM amp PRNG HM t S mE Qut M us AN AT inae Haec RAT ORNA am fed aea Ba W
14. T AREY EN IEAN AFAN GEAN leri rag TETN ird pu aa mF nie ZNN mu X DANERA EC MSN PAN EVM RAMM ons m Y fy ali e X SAMM DA tense bang 7 4 x EZ D NE X ANG 4 4 X 3 8 oig UPPER NEEDLE 77 arg aj x DETENT amp EEVE EINT tT RTT a ema y GENE ALL DORT UPAR 5 32 x B an mam CETENT 4 bh M MEI X 00074745 WER HAT QRRER HAT e karta BERN SEAT mn FIM E fh AN 1 ha eae A AMA 2 ers dra NN RESANO PN CORR FUTON UE t TMM LAMP Qe Es i us EST 0044 41 BAME HIM Riv ema ru E OF Henri REGEQND PE dci s ptit uc Am 2 a a DARING ONE wa wo eS NR uM SN gi omen HMM ev x IEN mun cat ed NN SHIM Quy RESIN TOM SHIM Pm a FANG MMM SHIM PANG A aen Ag SM WM NUT teense on 43M HIM my WEN a 89 o Pe 86421 m x pm ior COMP VALVE p44 e b mew ae FIGURE 13 TPC amp COMPRESSION DAMPING ASSEMBLY 1 Unscrew the compression damping adjuster until it
15. TABLE OF CONTENTS Consumer Safety amp Warranty Information Installation Instructions Spare Parts List Exploded View Maintenance amp Disassembly Inspection Reasemble Inner Fork Leg Crown amp Brake Arch Adjusting the Ride Qualities Trouble Shooting ANSWER PRECISION SUSPENSION Congratulations for choosing the latest state of the art mountain bike suspension fork available All 2000 Xvert fork models are sprung with a state of the art spring MCU compression system Likewise all Xvert suspension forks use the new advanced Twin Piston Chamber Plus damping system TPC that surpasses all other damping systems in performance reliability and durability Your 2000 X vert Fork is fully assembled and ready to be installed onto your bicycle Your fork is equipped with a 1 1 8 threadless steer tube and has been designed for use with V Brakes except the Xvert Carbon which can only use disc brakes However if your bicycle uses cantilever brakes a cable hanger kit P N 85 3800 is available through your dealer not compatible with the Xvert Carbon CONSUMER SAFETY INFORMATION GENERAL WARNING Bicycling is a hazardous activity that requires 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 bi
16. as been modified has been subject to misuse or whose serial number has been altered 1 defaced or removed This warranty does not cover paint damage Any modifications made by the user will render this warranty null and void This warranty is expressly in lieu of all other warranties 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 return the fork to the place of purchase In the USA dealers should call Answer Products for a return authorization number RA At that time instructions for repair return or replacement shall be given Customers in countries other than USA should contact their dealer or local distributor INSTALLATION INSTRUCTIONS Figures 1 2 amp 3 Insure 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 qualified bicycle mechanic to perform installation WARNING The steer tube and stanchions inner legs are a one time precision press fit at the factory and cannot be removed from the crown Replacement of the entire crown steerer assembly must be done to change steer tube lengths or REMGV
17. cycle 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 or shock 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 death Following these instruction can help you reduce the risk of being injured If you are a moderate or aggressive off road rider or ride at least three times a week over rough terrain Answer recommends returning your suspension fork every 2 years for a through inspection To do this you will need to take your fork to a Manitou authorized dealer who can arrange for shipment to Answer Products or you may call Answer to have your fork shipped directly at 661 257 4411 IMPORTANT All 2000 Xvert forks are off road forks and as such do not come with the reflectors for on road use installed However a reflector bracket kit P N 85 3674 is available through your dealer Your dealer or mechanic can install the kit to meet all Consumer Product Safety Commission s CPSC requirements If you have any questions regarding CPSC Standards please contact your dealer 1 Never remove or have the steer tube or stanchions inner legs removed from the crown The steer tube and stanchions press fitted into the crown at the factory Pressing them out will permanently damage the crown steer tube and stanchions beyond repair an
18. d thus render them unsafe for any further 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 alternative is to obtain the proper crown steerer from your dealer 3 Any other alterations or modifications to your fork should be considered unsafe Please contact Answer Products technical support for safety information prior to modifying your fork in any way 4 Do not use your Manitou fork if any part appears to be broken bent cracked or damaged in any way Contact your dealer or Answer Products technical support 800 670 7446 if you have any questions concerning 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 inner legs and outer leg dropout and brake arch areas for cracks or damage Before every ride check to ensure the proper spring preload exists WARRANTY INFORMATION PS SLF EROAN Any Answer Products fork found by the factory to be defective in materials and or R workmanship within one year from the date of purchase will be repaired or replaced PRESS BNTO at the option of the manufacturer free of charge when received at the factory freight RAGE SEAT prepaid This warranty does not cover breakage bending or damage that may result from crashes or falls Likewise this warranty does not cover any fork that h
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20. he fork is developing stiction Clean and recharge your fork with oil 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 on all 2000 Manitou forks 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 2000 XVERT is 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 right side up If this condition causes you some problems 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 2000 XVERT SERVICE MANUAL P N 85 3690 13 MANITOU ANSWER PRODU 5 IN
21. k spacers and pistons in exact order they were removed Next thread the valve nut onto the sliding piston assembly Likewise thread the sliding piston shaft onto the piston seat and torque them both to 12 IN LB 1 2 N M max Then install an O ring and the sliding piston spring onto the sliding piston shaft Slide the sliding piston assembly onto the shaft and then slide another O ring onto the shaft behind the sliding assembly Finally screw the button head cap screw with blue Loktite applied to it into the sliding piston shaft 4 Install compression damping assembly into the right leg Refer to the oil level chart on page 10 to determine the proper oil height Compression Rod amp Boots Figure 14 1 Clean all parts thoroughly 2 Grease compression rod lightly Be sure ENTS COM PRESS ON rebound Elastomer is installed onto ROD INNER compression rod 2 pw FORK LEG 3 Insert the compression rod through the T SLIDE ON end cap 4 Slide on a bottom out bumper followed by the a FORK BOOTS cup washer and then another bottom out B SLIDE ON e bumper Note The Xvert DC amp Xvert ELASTOMER Carbon do not use the cup washer and 2 FIGURE 14 COMPRESSION ROD amp BOOT elastomer 5 Slide Boots onto inner leg boots are not used on the Xvert Carbon E INSTALL NFREXREN STARK a HANG TIGHTEN F AY GREBVE SPRINGS BUTER
22. lush on the sharp hits A correctly adjusted fork will perform good in all conditions Rebound Damping Fine Tuning Figure 18 To adjust the rebound damping simply rotate the rebound damping knob located on bottom of the right leg Rotating the knob clockwise will increase the damping whereas 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 2 FIGURE 17 COMPRESSION DAMPING 12 For additional tuning tips we recommend that you obtain a copy of the MRD tuning Manual P N 85 3485 and check out the MRD Race Tuning kits available at your dealer FIGURE 18 REBOUND DAMPING 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 in a top out Select MCU s that better 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 t
23. stops Do not remove the shaft from the cap because the threads are bonded to prevent leaking Unscrew the button head screw from the bottom of the assembly Remove the O ring floating piston assembly and spring You may disassemble the floating piston assembly to modify the shim stack However it is recommended that you use the precautions mentioned in the instructions for disassembly of the lower shaft assembly 5 Remove either the floating piston shaft or the piston seat following the instructions above for the lower shaft assembly DAMPER INSPECTION Inspect the shaft for scratches wear or other obvious damage Inspect the seal gland and end cap seal grooves for damage Inspect shims for permanent bends or damage Inspect all other parts for obvious damage and replace as necessary Replace all seals that have been removed OEE ES FORK INSPECTION 1 Inspect the fork boots for obvious damage 2 Inspect the dust seal for tears wear or damage Replace as needed 3 Inspect the lower and upper bushing for damage to the Teflon coating Replace using the bushing removal and replacement kits if necessary 4 Inspect all MCU s amp springs for obvious damage Replace as necessary 5 Inspect the preload adjuster and connectors Replace if damaged 6 Check the outer legs for nicks or deep gouges on the outside and inside Replace if damaged 7 Check the inner legs for deep gouges or any other obvious damage Slight wear
24. uter leg arch casting is unsafe and could cause serious injury Please contact Answer Products if you suspect that your brake outer leg arch is damaged ADJUSTING RIDE QUALITIES 2000 XVERT TPC forks offer a wide adjustment range to suit individual riding preference and rider weight Fine tuning adjustments can achieved by using the preload adjusters located on top of the fork crown NOTE Since 98 and newer Xvert model forks use a spring stack in only one leg the MCU s and Springs used in previous Manitou forks are NOT interchangeable Compression Spring Stack Fine Tuning Figure 16 Fine tuning adjustments to the spring rate are made by rotating the left adjuster knob located on top of the crown Rotating the knob clockwise will firm the ride by adding preload to the spring stack Likewise rotating the knob counter clockwise will soften the ride Compression Damping Fine Tuning Figure 17 Fine tuning adjustments to the compression damping are made by rotating the right adjuster knob located on top of the crown Rotating the knob clockwise will increase damping whereas rotating the knob counter clockwise will reduce damping Excessive compression damping will give you a harsh ride over high speed bumps but will feel good during slower speed fork compression Furthermore insufficient compression damping will allow the fork to bottom out in FIGURE 16 PRE LOAD large hits and could cause the fork to bob a little while climbing but feel p
25. y Fang I note ie LEVER ie ae a APN RAT a 9 ELM er zi i m DH PLIN PNG b LIMER amp AER fe ids FADA ue di ad BNE B G cate FANE Gina Beran ELA omi LEVER Tm NG CL ET PTS ITI mox ee aN OP be Teg BO EAA AL REN CLAN TTKER eS SEAN DONI 5 9 cuu BEANS WORF XX HE LIMER FRIU TANER ENG REUS Eu ees TS eer ENG gl x qam RY pua s RETAINER meer pa et ob FIGURE 12 LOWER SHAFT ASSEMBLES Unscrew and remove the TPC compression damping assembly from the top of the right leg and discard the oil appropriately Unscrew the end cap and pull the lower shaft assembly out of the inner leg Remove the bottom out elastomers and capture the 1 8 dia detent ball The adjuster needle may be unscrew and removed from the shaft However this is not recommended X VERT CARERE LIMER SHAFT ABEEMELY 4 Remove the valve nut to change the shim stack It is recommended that you write down the order of the factory specified shim stack and spacers before you begin revalving Thus you will always be able to easily revert to the factory set up X VERT X VERT BALAERe X VERT FAN ASSEMBLY 2624633 FAN AREVA BA
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