Fork Service Manual
Contents
1. Firm 80 100 Ride Kit Soft 130 Ride Kit Medium 130 Ride Kit Firm 130 Air Preload Cap Crown Steer Leg 80 100 Blk Crwn 4 Crown Steer Leg 80 100 Wht Crwn 4 Crown Steer Leg 130 Blk Crwn 4 Crown Steer Leg 130 Wht Crwn 5 Absolute Damper 6 Rebound Damper 80 100 6 Rebound Damper 130 7 Seal Kit 8 Bushing Kit 9 9 9 9 4 Outer Casting QR NB Black Quter Casting QR NB White Outer Casting TA NB Black Outer Casting TA NB White 0 Knob Kit Part Number 141 23999 K003 141 23999 K003 141 23998 K001 141 23998 K004 141 23998 K007 141 23998 K003 141 23998 K006 141 23998 K009 141 23992 K002 141 27220 K006 141 27220 K007 141 27220 K008 141 27220 K009 141 26532 K007 141 27220 K002 141 27220 K003 85 5293 141 27181 KOO7 141 23994 K015 141 23994 K016 141 23994 K025 141 23994 K026 141 27177 K001 Circus Expert Fork Schematic Kit Group nnn n SUU gt 0O J J J OD oO OO TI Part Description Compression Rod Air Ride Kit Soft 80 100 Ride Kit Medium 80 100 Ride Kit Firm 80 100 Ride Kit Soft 120 Ride Kit Medium 120 Ride Kit Firm 120 Air Preload Cap Crown Steer Leg 80 100 Crown Steer Leg 120 Absolute Damper Rebound Damper Seal amp Wiper Kit 32mm Bushing Kit Outer Casting QR NB Black Outer Casting QR NB White Outer Casting TA Black Outer Casting TA2. CULO FORK SERVICE MANUAL INTRODUCTION This manual is intended to guide the user through basic service of Manitou 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 instructions could result in severe injurv 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 kev information to make procedures easier or clearer ALAN ites Suspension forks by design can contain preloaded springs 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 Manitou Customer Service at 888 686 3472 M M le Suspension forks uses preloaded spring s
3. to provide compression spring resistance This system must be relieved of preload prior to servicing Failure to relieve air pressure could result in injury or possible death This manual is divided up into different sections each one pertaining to a different part of the servicing of vour fork Below is a list of our fork models and which sections vou will use to service vour particular fork Circus Comp Match Forks Na IOs Section 1 Casting Removal Section 3 Dust Seal Replacement Section 4 Coil Spring Service Section 8 Absolute Service Section 10 Casting Installation Circus Expert Drake Drake 29er Forks 1 or PN Section 1 Casting Removal Section 3 Dust Seal Replacement Section 7 ACT Air Service Section 8 Absolute Service Section 10 Casting Installation Minute Minute 29er Forks Section 1 Casting Removal 2 Section 3 Dust Seal Replacement 3 Section 5 MARS Air Spring Service 4 Section 8 Absolute Service 5 Section 10 Casting Installation R7 Forks 1 Section 1 Casting Removal 2 Section 3 Dust Seal Replacement 3 Section 6 TS Air Service 4 Section 8 Absolute Service 5 Section 10 Casting Installation Minute MRD Forks QIS Ne R7 M i 2 3 4 5 Section 2 MRD Casting Removal Section 3 Dust Seal Replacement Section 5 MARS Air Spring Service Section 9 Absolute MRD Service Section 11 MRD Castin
4. 1 5mm Allen wrench Fig 4 FIG 2 FIG 4 MRD Casting Installation Slide the lower casting onto the upper stanchions You want to slide them on only about halfway at this point Inject 16cc s of semi bath oil into the lower legs using a syringe or similar tool Fig 1 Slide the casting all the way onto the upper stanchions Insert the compression rod bolt into the compression rod and tighten down using either a 10 or 11mm wrench depending on fork model Tighten to the torque specified in the back of the manual Fig 2 Using an 8mm Allen wrench thread the rebound damper assembly into the casting by turning it counter clockwise Tighten to 3 4 4 5 Nm 30 40 Ibf in Fig 3 Thread the detent housing on the rebound damper assembly threads using a green Park Tool pin spanner or similar tool Fig 4 Place springs and detent ball bearings into the detent housing Fig 5 Install rebound knob onto the rebound shaft using a 1 5mm Allen wrench Fig 6 FIG 6 FIG 4 OIL HEIGHT CHART In Leg Forks MRD Forks Oil Height Guide 1 Qil height is set with compression damper HEIGHT HEIGHT Absolute removed 2 Oil height is set with the fork fully extended ride height TRAVEL OIL HEIGHT mm Circus Comp Match somm 8B 80 85 Circus Comp Match O watch 30mm e3 aoas Circus Expert Drake 80mm 87 8590 Circus Expert Drake 100mm 87 8590 BO a ET e
5. result in injury or possible death 8 9 The casting needs to be removed prior to servicing the ACT Air system Refer to the Casting Removal section for instructions on how to do this Release all air from the system by depressing the valve core on the Schrader valve Using a 20mm socket or wrench remove the top air cap assembly from the fork Fig 1 Remove the spring from the fork Fig 2 Using a 22mm wrench unthread the compression rod assembly end cap and remove the assembly from the fork uppers Fig 3 Replace the air piston o ring on the compression rod assembly Fig 4 Apply a small amount of grease to the o ring and insert compression rod assembly back into the fork uppers Tighten the end cap down to 9 0 11 3 Nm 80 100 in Ibs Grease the spring and place it into the fork uppers from the top Install air cap Tighten down to 6 8 9 0 Nm 60 80 in Ibs 10 Using a shock pump fill fork to desired air pressure TRAVEL CONVERSION ON DRAKE 80 and 100mm ja FORKS The Drake 80 and 100mm forks can be converted to either travel bv moving a spacer on the compression rod assembiv Follow Steps 1 5 above to remove the compression rod assembiv The travel of the fork is determined by a plastic spacer The spacer being on the bottom of the air piston will cause the fork to have 80mm of travel The spacer being on top of the piston will cause the fork to have 100mm of travel Fig 5 on the n
6. you are ready to fill the fork with oil Pour oil into the stanchion leg until it is about a quarter of the way up Cover the hole in the stanchion with a rag and cycle the fork 7 10 times Failure to do this will Cause an incorrect oil height After cycling the fork continue filling the stanchion leg with oil to the oil height specified on the Oil Height Chart found in this manual for your fork model Install the Absolute damper into the stanchion and tighten down using a 24mm socket to 6 8 9 0 Nm 60 80 Ibf in Install detent springs and ball bearings into the holes on the top cap You want them placed in holes opposite of each other Install adjuster knob and using a 2mm Allen wrench tighten down to 0 5 0 7 Nm 4 6 Ibf in FIG 2 FIG 4 Absolute MRD Service Disassembly The casting will need to be removed prior to servicing the damping side of the fork Refer to the MRD Casting Removal Instructions Using a 2mm Allen wrench remove the adjuster knob from the top of the fork leg Fig 1 Be careful when removing the knob as there are two detent ball bearings below the knob Remove the detent springs from the top cap Remove the Absolute damper from the stanchion leg using a 24mm socket Fig 2 Pour the damping oil out of the fork leg Turn the fork upside down and using a 15mm open end wrench unthread the rebound damping assembly from the bottom of the stanchion Fig 3 The rebound assembly wil
7. 3994 K005 i IB 1 Outer Casting QR STD White 141 23994 K006 1 Outer Casting QR NB Black 141 23994 K015 E 1 Outer Casting QR NB White 141 23994 K016 2 Bushing Kit 141 27181 K007 E 4 Rebound Damper Assembly 14127181 K0 B 5 Absolute Damper 141 25404 K003 6 Crown SteerLeg 8000 1arerieikos DD 6 CrowniSteereg 130 14127181 K006 D 8 Ride Kit Medium 130 141 26686 K005 8 Ride Kit Firm 130 14126686K006 G O 0 I I 9 Compression Rod 130 141 27181 K004 Part Description Compression Rod Ride Kit Soft 80 Ride Kit Medium 80 Ride Kit Firm 80 Ride Kit X Firm 80 Ride Kit Medium 100 Ride Kit Firm 100 Ride Kit X Firm 100 Ride Kit Medium 120 Ride Kit Firm 120 Ride Kit X Firm 120 Air Piston Air Cap Crown Steer Leg 80 Crown Steer Leg 100 Crown Steer Leg 120 Absolute Damper Rebound Damper Assembly Seal Wiper Kit 32mm 9 Bushing Kit 10 Outer Casting QR Black 10 Outer Casting QR White 10 Outer Casting TA Black 10 Outer Casting TA White 11 Knob Kit Part Number 83 3312 141 25690 K002 141 25690 K003 141 25690 K004 141 25690 K005 141 26743 K001 141 26743 K002 141 26743 K003 141 26744 K001 141 26744 K002 141 26744 K003 141 25698 83 3150 83 3299 83 3330 83 3331 141 26532 K008 83 3295 85 5293 85 5964 83 3302 141 2
8. 3994 K031 83 3303 141 23994 K036 141 27177 K001 Minute 29er Fork Schematic Kit Group H nnnnn TS U gt u OITIUTo 9 a Da 2 DD DA DD DD Minute Fork Schematic Part Description Part Number Kit Group 1 Compression Rod 83 3183 H 2 Ride Kit Soft 100 83 3170 G 2 Ride Kit Medium 100 83 3171 G 2 Ride Kit Firm 100 83 3172 G 2 Ride Kit X Firm 100 83 3173 G 2 Ride Kit Soft 120 83 3175 G 2 Ride Kit Medium 120 83 3176 G 2 Ride Kit Firm 120 83 3177 G 2 Ride Kit X Firm 120 141 26745 G 2 Ride Kit Soft 140 141 25683 K001 G 2 Ride Kit Medium 140 141 25683 K002 G 2 Ride Kit Firm 140 141 25683 K003 G 2 Ride Kit X Firm 140 141 25683 K004 G 3 Air Piston 83 3188 G 4 Air Cap 83 3150 C 5 Crown Steer Leg 100 83 3155 D 5 Crown Steer Leg 120 83 3156 D 5 Crown Steer Leg 140 83 3157 D 6 Absolute Damper 141 26532 K008 A 7 Rebound Damper 83 3341 B 8 Seal Wiper Kit 32mm 85 5293 K 9 Bushing Kit 85 5964 E 10 Outer Casting QR Black 141 23994 K015 E 10 Outer Casting QR White 141 23994 K016 E 10 Outer Casting TA Black 141 23994 K025 E 10 Outer Casting TA White 141 23994 K026 E 11 Knob Kit 141 27177 K001 E Part Description O O O O N NOAH FPWNHNM NNN YN YN YN Compression Rod Assembly Ride Kit Soft 100mm Ride Kit Medium 100mm Ride Kit Firm 100mm Ride Kit X Firm 100mm Ride Kit Soft 130mm Ride Ki
9. White 0 Knob Kit Part Number 141 23999 K004 141 23998 K001 141 23998 K004 141 23998 K007 141 23998 K002 141 23998 K006 141 23998 K008 141 23992 K002 141 23993 K004 141 23993 K005 141 26532 K002 141 23991 K004 85 5293 85 5964 83 3302 141 23994 K031 83 3303 141 23994 K036 141 27177 K001 Kit Group mn n TR U gt TOT a9 ao oo Oo OT Drake 29er Fork Schematic Part Description 4 2 2 2 2 2 2 3 4 4 5 6 7 8 9 9 9 9 9 9 1 Compression Rod Assembly Ride Kit Soft 80 100 Ride Kit Medium 80 100 Ride Kit Firm 80 100 Ride Kit Soft 130 Ride Kit Medium 130 Ride Kit Firm 130 Air Preload Cap Crown Steer Leg 80 100 Crown Steer Leg 130 Absolute Damper Rebound Damper Seal amp Wiper Kit 32mm Bushing Kit Outer Casting QR STD Black Outer Casting QR STD White Outer Casting QR NB Black Outer Casting QR NB White Outer Casting TA Black Outer Casting TA White 0 Knob Kit Part Number 141 23999 K003 141 23998 K001 141 23998 K004 141 23998 K007 141 23998 KOO3 141 23998 KOO6 141 23998 K009 141 23992 K002 141 23993 K001 141 23993 K002 141 26532 K002 141 23991 K003 85 5293 85 5964 141 23994 K005 141 23994 K006 141 23994 K015 141 23994 K016 141 23994 K025 141 23994 K026 141 27177 K001 Drake Fork Schematic Match Exploded View Part Description Part Number Kit Group E 1 Outer Casting QR STD Black 141 2
10. e mm 777788 Minute Drake 29er 80mm 87 85 90 Drake 29er 100mm g _ 85 90 R7 Fork Schematic Part Description Part Number 1 Compression Rod Assembiv 80mm 83 3262 p 1 Compression Rod Assembly 100mm 83 3263 H 2 Air Piston 83 2669 G C 3 Air Cap 83 2654 MT 4 Crown Steer Leg 80mm 83 2656 D 4 Crown Steer Leg 100mm 83 2659 5 Absolute Damper 141 26532 K001 6 Rebound Damper Assembly 83 3254 a 7 Seal Kit 85 5281 OO K O 8 Bushing Kit 85 5321 CO g 9 Outer casting QR STD Black 98 2356 go l 9 Outer Casting QR STD White 98 23562 9 Outer Casting QR NB Black 141 27200 K001 m 9 Outer Casting QR NB White 141 27200 K002 10 Knob Kit 141 27177 K003 1 m Circus Comp Exploded View Part Description Part Number Kit Group 1 Outer Casting QR NB Black 141 23994 K015 E A Rebound DamparAssenbIV TAT2 20RMT B 6 Crown Steer Leg 80 100 Steel 141 27181 K005 D 6 Crown Steer Leg 80 100 Blk 141 27220 K004 Crwn 6 Crown Steer Leg 80 100 Wht 141 27220 K005 Crwn 7 Preload Adjuster 141 27181 K002 8 Ride Kit Soft 80 100 141 26686 K001 an 8 Ride Kit Medium 80 100 141 26686 K002 PG 8 Ride Kit Firm 80 100 141 26686 K003 9 Compression Rod 141 27181 K003 I Part Description RONMNNNND Compression Rod 80 100 Compression Rod 130 Ride Kit Soft 80 100 Ride Kit Medium 80 100 Ride Kit
11. er to the Casting Removal or MRD Casting Removal instructions depending on which model fork you have Toremove the dust seals first remove the seal tension springs otherwise they will get damaged then take a large flat bladed screwdriver and insert the tip between the bottom of the seal and the top of the foam wiper Fig 1 Push down on the screwdriver This will pop the seal out of the casting Next remove the foam oil ring Fig 2 Oil the foam rings new or after cleaning the old rings with a small amount of semi bath oil and place them in the top of the casting above the Upper Bushings Fig 3 Install the dust seal into the leg use a large socket or piece of round tubing that is large enough in diameter to press on the outside shoulder of the seal rather than putting pressure on the sealing lip and spring so that they are not damaged Fig 4 Repeat steps 1 4 for the opposite casting leg Coil Spring Service red ile 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 The casting needs to be removed prior to servicing the coil spring Refer to the Casting Removal Instructions first 2 Turn the preload knob counter clockwise until it stops to relieve the preload on the spring 3 Using a 2mm Allen wrench remove the knob from the preload adjuster Fig 1 4 Remove the preload adjuster from the fork using a 20mm
12. ext page shows the placement of the spacer for 80mm of travel Fig 6 on the next page shows the placement of the spacer for 100mm of travel FIG 1 FIG 2 FIG 4 FIG 5 FIG 6 Absolute Service Disassembly The casting needs to be removed prior to servicing the damping side of the fork Refer to the Casting Removal instructions Using a 2mm Allen wrench remove the adjuster knob from the top of the fork Be careful when removing the knob as there are two detent ball bearings under it Remove the detent ball bearings and springs Using a 24mm socket remove the Absolute damper from the stanchion leg Pour the damping oil out of the stanchion leg Turn the fork upside down and using a 22mm box end wrench remove the rebound damper assembly from the stanchion Check o rings on rebound and compression assemblies and replace any that are worn or damaged Assembly Install the rebound damper assembly into the bottom of the stanchion leg Using a 22mm box end wrench tighten down to 9 0 11 3 Nm 80 100 Ibf in The next step is to fill the fork with oil and install the compression damper To ensure proper oil height the casting must be installed prior to filling If you have other service to perform on the fork continue onto the appropriate section and finish that first If not refer to the Casting Installation instructions to install the casting back onto the fork Once the casting is installed
13. g Installation RD Forks Section 2 MRD Casting Removal Section 3 Dust Seal Replacement Section 6 TS Air Service Section 9 Absolute MRD Service Section 11 MRD Casting Installation Table of Contents Ti PageNumbar Section 1 Casting Removal Section 3 Dust Seal Replacement Section 4 Coil Spring Service Section 5 MARS Air Spring Service Section 6 TS Air Spring Service NIE BEE KE EEE 6 e BEE AH kanna EEE BEER EEE mene p zo Kenn EEE HERE 1 BEER ZU Tan Section 10 Casting Installation Section 11 MRD Casting Installation Oil Height Chart Fork Exploded Diagrams 17 26 Contact Information 7 4 Haves Bicvcle Group 6750 W Florist Ave Milwaukee WI 53218 Toll Free 888 686 3472 Direct 262 242 4300 FAX 414 462 0214 E mail manitoutech hayesbicycle com Web site www manitoumtb com Casting Removal From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw Fig 1 From the right leg dropout if the fork has adjustable rebound the knob will need to be removed Screw the rebound all the way in clockwise remove the 2mm hex screw inside the knob by turning it counter clockwise Remove the knob by pulling gently away from the fork Fig 2 Use an 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting Fig 3 Remove crown steer inner leg as
14. l Fig 5 The Spacer being on the bottom on the flange will cause the fork to have 80mm of travel Fig 6 FIG 4 FIG 5 FIG 6 MARS Air Spring Service 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 injurv or possible death VAN TE 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 Before servicing the Mars Air System you will need to remove the lower casting Refer to the Casting Removal or MRD Casting removal instructions depending on which fork model you have 2 Release the air from the fork by depressing the valve core on the Schrader valve 3 Remove the air cap from the fork using a 20mm socket 4 Using a 22mm wrench remove the compression rod assembly from the bottom of the stanchion Fig 1 5 Unthread the compression rod assembly from the bottom FIG 2 of the stanchion using a 22mm wrench and remove from fork Fig 2 6 Remove the spring from the stanchion Fig 3 7 Remove the air pushrod from the stanchion by pulling it out with needle nose pliers or by turning the fork upside down and letting it fall out Fig 4 8 The next step is to remove the air piston First look up into the stanchion leg from the bottom You will see an air shelf in the fork with a hole in the center of it You wil
15. l come out of the fork leg with the cartridge tube attached to it Fig 4 If you are replacing the tube or the damper pull the cartridge tube off the damper end cap The tube is tightly fit into the damper cap so it can be difficult to get off Check o rings on rebound damper end cap and ABS compression damper top cap and replace if damaged or worn Assembly IF you replaced the rebound damper cartridge or cartridge tube you will need to press the tube back onto the damper assembly end cap First slide the damper end cap all the way to the top of the assembly top is towards the piston head Next slide the tube over the piston head and press it into the end cap Install the rebound damper cartridge tube assembly into the bottom of the stanchion leg Using a 15mm open end wrench tighten the end cap down to 9 0 11 3 Nm 80 100 Ibf in The next step is to fill the fork with oil and install the compression damper To ensure proper oil height the casting must be installed prior to filling If you have other service to perform on the fork continue onto the appropriate section and finish that first If not refer to the MRD Casting Installation Instructions to install the casting back onto the fork FIG 2 4 Once the casting is installed you are ready to fill the fork with oil Insert a small funnel or similar device into the top of the cartridge tube Fig 5 Pour a small amount of oil 1Occ s into the cartridge tube Rem
16. l want to push the air piston out the top of the stanchion leg with a long Allen wrench or similar tool When inserting the tool into the stanchion leg you must be sure it goes through the center hole of the air shelf to push the piston out The air shelf should never be removed from the fork Doing so would damage the fork and require you to replace the crown steer assembly of the fork 9 Apply grease around the side of the new air piston We suggest using Manitou Prep M grease Fig 5 10 Install air piston into the top of the stanchion leg and push it past the threads Fig 6 11 Pour in 5cc s of semi bath oil on top of the air piston Fig 7 12 Install air cap onto the stanchion leg using a 20mm socket and tighten to 6 8 8 0 Nm 60 80 Ibf in 13 Turn the fork upside down and insert the air pushrod into the bottom of the stanchion The long end of the pushrod goes towards the top of the fork and must drop through the center hole of the air shelf discussed in Step 7 Drop the pushrod into the stanchion leg and maneuver it until vou feel it drop through the center hole 14 Lightly grease the spring and insert into the stanchion leg 15 Install compression rod assembiv into the stanchion leg using a 22mm wrench and tighten down to 6 8 8 0 Nm 60 80 Ibf in FIG 5 FIG 7 TS AIR SERVICE This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure t
17. o relieve air pressure could result in injurv or possible death Before servicing the TS Air system you will need to remove the lower casting Refer to the Casting Removal or MRD Casting removal instructions depending on which fork model you have Release all air from the system by depressing the valve core on the Schrader valve Using a 20mm socket remove the air cap from the fork Fig 1 Remove compression rod assembly from the bottom of the stanchion using a 22mm wrench Fig 2 amp 3 Using a long Allen wrench or similar tool push the air piston down and out the bottom of the stanchion leg Fig 4 Apply grease around the side of the new air piston We suggest using the Manitou Prep M grease Fig 5 Install air piston into the fork stanchion Install by pushing the piston in through the top of the stanchion and push it past the threads Fig 6 Install compression rod assembly into the bottom of the stanchion and tighten down the end cap using a 22mm wrench Tighten to 9 0 11 3 Nm 80 100 Ibf in 9 Pour in 5cc s of semi bath oil on top of the air piston 10 Install air cap onto the top of the stanchion and tighten down using a 20mm socket Tighten to 6 8 8 0 Nm 60 80 lof in LI Pa FIG 6 FIG 5 FIG 4 ACT Air Service WAONE This fork uses compressed air to provide spring resistance and must be relieved of pressure prior to servicing Failure to relieve air pressure could
18. oboKt 1100000000 denma 1 l
19. ove the funnel and cover the top of the tube with a rag Cycle the fork 7 10 times This is to ensure the oil gets under the rebound piston Failure to do this will cause your oil level to drop below the proper level After cycling the fork insert the funnel back into the cartridge tube and fill the fork to the specified oil height found on the Oil Height Chart in this manual Install the Absolute damper into the cartridge tube and using a 24mm socket tighten down to 6 8 9 0 Nm 60 80 lof in Fig 6 Install detent springs and ball bearings into the holes on the top cap You want to place them in holes opposite of each other Fig 7 Install adjuster knob onto the hex and using a 2mm Allen wrench tighten down to 0 5 0 7 Nm 4 6 Ibf in FIG 7 Casting Installation Slide the lower casting onto the upper stanchions You want to slide them on only about halfway at this point Inject 16cc s of semi bath oil into the lower legs using a syringe or similar tool Fig 1 Slide the casting all the way onto the upper stanchions Insert the compression rod bolt into the compression rod and tighten down using either a 10 or 11mm wrench depending on fork model Tighten 5 1 6 2 Nm 45 55 Ibf in Fig 2 Using an 8mm Allen wrench thread the rebound damper assembly into the casting by turning it counter clockwise Tighten to 3 4 4 5 Nm 30 40 Ibf in Fig 3 Install rebound knob onto the rebound shaft using a
20. sembly from the outer leg casting by pulling firmly on the casting If the fork uses the semi bath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan FIG 2 FIG 3 MRD Casting Removal From the left leg dropout Left when sitting on the bike use a 10 or 11mm wrench to remove the compression rod screw Fig 1 Remove the blue rebound knob on the bottom of the right leg with a 1 5mm Allen wrench Be cautious of the detent balls and springs under the knob as they are very small and easily lost Fig 2 Remove the detent balls and springs from the Detent Housing Fig 3 Remove the Detent housing by unscrewing it counter clockwise using a green Park Tool pin spanner or similar tool inserted into the holes that the springs and detent balls sit in Fig 4 Using a 7mm or 8mm Allen wrench turn the rebound assembly clockwise until it can be pushed into the casting Fig 5 Remove crown steer inner leg assembly from the outer leg casting by pulling firmly on the casting The fork uses the semi bath Lubrication system use caution as the oil that is in the casting will be released when the casting is removed it is best to do this over some type of catch pan FIG 1 FIG 2 FIG 4 Dust Seal Replacement Before replacing the dust seals you will need to remove the lower casting Ref
21. socket Fig 2 5 Pull the coil spring out of the stanchion leg 6 Remove travel spacer and bottom out bumper from the end of the compression rod assembly Fig 3 7 Remove the compression rod assembly from the stanchion leg The compression rod comes out from the top of the stanchion leg Turn the fork sideways or upside down to get the compression rod out of the leg Fig 4 FIG 2 8 Inspect compression rod and top out bumper If damaged replace 9 Install compression rod assembiv into the stanchion leg Insert through the top of the stanchion leg and maneuver the rod until it drops through the hole at the bottom of the stanchion leg 10 Lightiv grease the spring and install into stanchion leg 11 Install the preload adjuster into the fork leg Tighten down using a 20mm socket to 5 1 6 2 Nm 45 55 in Ibs 12 Using a 2mm Allen wrench install the preload knob onto the adjuster Tighten knob down to 0 5 0 7 Nm 4 6 in Ibs 13 Install bottom out bumper and travel spacer onto the end of the compression rod FIG 3 TRAVEL CONVERSION ON MATCH AND CIRCUS COMP 80 100MM FORKS 1 The Match Circus Comp 80 and 100mm forks can be converted to either travel by moving a spacer on the compression rod Follow steps 1 7 to remove the compression rod form the fork 2 The travel of the fork is determined by a plastic spacer The Spacer being on top of the flange on the compression rod will cause the fork to have 100mm of trave
22. t Medium 130mm Ride Kit Firm 130mm Ride Kit X Firm 130mm Air Piston Air Cap Crown Steer Leg 100mm Grown steer Leg 130mm Absolute Damper Cartridge Tube 100mm Cartridge Tube 130mm Cartridge Rebound Damper Assembly Outer Casting QR NB Black Outer Casting QR NB White Outer Casting TA NB Black 9 Outer Casting TA NB White 10 Seal Kit 11 Bushing Kit 12 Knob Kit Part Number 83 3183 83 3170 83 3171 83 3172 83 3173 141 25683 K001 141 25683 K002 141 25683 K003 141 25683 K004 83 3188 83 3150 141 25390 K001 141 25390 K002 141 26532 K005 83 3271 83 3285 83 3283 141 23994 K015 141 23994 K016 141 23994 K025 141 23994 K026 85 5293 85 5964 141 27177 K002 Minute MRD Schematic Kit Group na n n 1 gt gt gt gt DIT DD DD Do Do Do Oo DD I 11 R7 MRD Schematic Part Description Part Number Kit Group 1 Compression Rod Assembiv 80mm 83 3262 L d 1 Compression Rod Assembly 100mm 83 3263 H 83 2669 3 Air Cap 83 2654 4 Crown Steer Leg 80mm 141 25389 K00 1 D 4 Crown Steer Leg 100mm 141 25389 K002 mm 5 Absolute Cartridge Damper 141 26532 K004 A 6 Cartridge Tube 80mm 83 3270 6 Cartridge Tube 100mm 83 3271 7 Cartridge Rebound Damper 83 3267 10 Outer casting QR STD Black gas E 10 Outer Casting QR STD White 98 23562 E 10 Outer Casting QR NB White 141 27200 K002 E 11 Kn
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