MANITOU MINUTE 1:00® ENDURO FORK SEALS™
Contents
1. Extend the rods fully sliding the rubber bumpers down against the end caps Place the washers removed from the lower legs in Step 7 on top of the bum pers as pictured Lubricate the inside of the new seals and wipers with Super Slick Grease Lubricate the O ring and threads at the bottom of the damper rod 56 Start the lowers over the rods and down to the stanchion tubes Be sure the reverse arch is facing the right way When the wipers reach the end caps care fully work one wiper over the cap and just onto the stanchion then work the other wiper on to its stanchion 30 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 57 Slide the lowers down about half way onto the stanchions if you push them all the way on there will be no space to inject the semi bath oil into Reposition the fork horizontally with the end of the lower assembly angled slightly upward 58 Inject about 16cc of semi bath oil into each lower leg Manitou recommends Motorex Semi Bath 5 40w synthetic oil Other brands are available but can be difficult to find in this weight Maxima 15wt Fork Fluid seems to work very well this is not a recommen dation as it has not been tested in all condi tions 31 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 59 Cover the lower casting holes with a clean towel to pre vent oi2. be replace it 15 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 31 Apply a light coating of a suspension friendly grease such as Super Slick Grease or Prep M on the O ring or Teflon seal depending on whether you are using the SPV or the SPV Evolve cartridge 32 Likewise lightly coat the threads at the end of the right stanchion tube MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 33 CAREFULLY insert the SPV rebound damper assembly into the stanchion tube Don t try and shove the assembly past the threads or you will damage the seal Wind the damper assembly clockwise and thread the seal past the threads 34 Use good quality adjustable flat jawed pliers or a wrench to tighten the damper end cap The recommended torque for the plastic end caps is 25 35 inch pounds Unless you have a properly sized 24mm crows foot open end wrench attachment for your torque wrench just carefully snug the end cap 17 2005 EnduroForkSeals com Real World Cycling All rights reserved 35 Slowly add about 60cc of 5 wt synthetic suspension fluid into the top of the damper leg we like Maxima Fork Fluid After adding the fork fluid cover the top opening with a clean towel and work the damper rod up and down several times to be sure that suspension fluid ends up below the pisto
3. NOTE THIS WEB VERSION IS BEST VIEWED AT 75 IN YOUR ADOBE READER WINDOW PICTORIAL SERVICE INSTRUCTIONS for the 2005 EnduroForkSeals com Real World Cycling EnduroForkSeals com All rights reserved THESE INSTRUCTIONS ARE OPTIMIZED FOR RECOMMENDED PARTS FOR SERVICING THE MANITOU MINUTE 1 000 Plastic bucket drain pan 2mm and 8mm Allen wrenches 7 16 wrench Flat bladed screwdriver Pocket screwdriver 24mm 15 16 socket 16mm 5 8 socket Ratchet wrench Adjustable flat jawed wrench Torque wrench Clean lint free rags 5 wt fork fluid Heavy Synthetic Grease Super Slick Grease or PrepM Oil syringe or other measuring device Shock pump MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 1 Adjust the travel to its longest setting fully extended Note the indicator on the back of the fork crown 2 Remove the Schraeder valve cap from the SPV side and care fully relieve the air pressure Be prepared for a small amount of oil to spray out with the air MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 3 Adjust the rebound knob mid way and use the 2mm Allen wrench to remove the retaining screw Pull the rebound knob straight down to remove it 4 Invert the fork and use the 8mm Allen wrench to wind the damper rod CLOCK WISE into the lower leg Pl
4. a 24mm socket on the outer black hex of the SPV top cap 20 41 Pressurized the SPV air chamber to about 40 PSI This helps to keep the damper rod extend ed during re assembly You are now finished servicing the damp ing leg and are ready to service the spring stack if you are not planning to service the spring stack you may proceed to Step 55 42 Use a 2mm Allen wrench to loosen the adjuster knob set screw 21 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 43 Lift the adjuster knob straight up and off of the top cap assembly Be sure and put these small parts in a safe place laid out in the order in which they were removed 44 Remove the O ring from around the travel scale 22 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 45 Loosen the Travel Wind Down top cap using good quality adjustable flat jawed pliers or a wrench The factory manual recommends a 28mm socket but there is not really enough room for a socket to fit between the crown recess 46 Remove the top cap and coil spring The spring assembly usually comes out with the top cap even though it is just a friction fit The D shaped protrusion at the end of the top cap pushes into the D shaped end of the main spring If the spring wants to stay in the leg it may be due to the fact that some early produc
5. chamber 26 Pour the damping oil out of the chamber Slowly pumping the damping rod will help to get most of the oil out 27 Use good quality adjustable flat jawed pliers or a wrench to loosen the damper end cap It would be nice if thicker wrench flats were provided You will have to be careful to get a good grip so the wrench does not slip off 13 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 28 Remove the SPV rebound assembly from the stanchion The assembly picture on the left has the 2004 SPV valve as evidenced by the O ring The assembly pictured on the right is the 2005 SPV Evolve which has a flat Teflon seal in place of the O ring The new design requires less force to initiate movement the new seal has less stiction than the O ring Internally the previously solid check valve disc now has an orifice so that oil movement is never completely shut down 29 Verify a gap of approximately Imm between the blue SPV valve and the black piston 14 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 30 Test the responsiveness of the SPV valve Use your fingers to compress the blue SPV valve against the black damping piston The valve should spring back to the open position when you release it Check the condition of the O ring at the bottom of the rod If it is torn or deformed
6. e damping leg If you are not planning to service the damper leg you may proceed to step 41 23 This is the SPV top cap as sembly It s shown here with the red chamber volume adjuster nut backed all the way out meaning the chamber has maximum volume For ease of removal it is rec ommended to have the adjuster nut in this position 11 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 24 Use a 5 8 or 16mm socket on the red adjuster hex back out the entire SPV top cap Because the top cap is only tightened at 25 35 inch pounds you can use the adjust ing hex to back out the cap without being concerned about putting too much stress on it Using a 24mm socket on the larger black hex will work but the red hex tends to remain fixed with the rest of the top cap rotating around it This results in the vol ume adjuster being fully extended into the top cap body For some reason the top cap is more difficult to pull out with the vol ume adjuster wound in 25 Remove the SPV top cap Note that with the volume adjuster backed out for maximum volume in the chamber the lower O ring is just beyond the threads of the black top cap body 12 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved This is what the top cap assembly looks like with the adjuster hex wound all the way IN This is how volume is reduced in the air
7. ease note the inset and remember that the rod threads up INTO the lower casting Do not try and wind it out or damage will result MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 5 On the spring side rider s left use a 7 16 wrench to re move the bottom fixing bolt This bolt backs out CCW unlike the damper rod Manitou recommends an 11mm wrench but the bolt on this fork was slightly too big and required a 7 16 HAVE A BUCKET READY BEFORE THE NEXT STEP 6 OVER A BUCKET OR OIL PAN turn the fork back over drain the semi bath oil out of the lower assembly and pull the low er assembly off of the stanchions There are only 16cc s of oil in each lower leg so you can just pull the lowers off while the oil is draining if you wish MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 7 After draining the oil invert the lower assembly to remove the bottom washers You never know what you might find in Gm side your fork 8 Remove the garter springs from the top of the wipers Removal of the garter spring is not really necessary but if left in place it just ends up getting smashed and in the way MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 9 Insert a flat bladed screw driver under the back end of the seal wiper Note that the shaft of
8. er bottles etc Use a cable tie or similar means to see how far into the travel the bike set tles If you don t have enough sag pull the main spring back out of the left leg and remove the inner booster spring see Steps 42 54 Ifyou have too much sag you will need to order a Firm or Ex tra Firm spring and wind your existing booster spring into it Set the rebound knob to the half way point 5 a i 34 3 Aak n wie ARE EAr eae ep Hy E kia i pa Tf iy i ia p i hes QETAIEQF F PHOTO E BY DGE 2004 ALL RIGHTS RESERVED HEAD TO THE TRAIL FOR FURTHER ADJUSTMENTS TAKE YOUR SUSPEN SION PUMP WITH YOU Dial in the rebound If the fork is extend ing too harshly or you feel the fork is tending to pogo off of bumps increase the rebound damping If your fork is tending to pack up following a series of bumps your fork ends up too compressed to absorb subsequent impacts decrease the rebound damping Adjust the SPV pressure If you just want more of a platform want a bigger hit re quired to activate full travel you need to add air pressure at the SPV topcap This will take some experimentation and depends on per sonal preference It will be a trade off you can t have the perfect platform for hammer ing out of the saddle and still have supple small bump sensitivity when seated Adjust the SPV chamber volume If you find the damping too
9. l from being ejected and push the lower assembly all the way onto the stanchions Be sure the SPV Rebound damping rod is pressed against the bottom of the lower leg casting 60 Use the 8mm Allen wrench to wind the SPV Rebound damper rod back into the lower leg casting Turn counter clockwise as indicated in the inset picture Proper torque value is 10 30 inch pounds 32 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 61 Carefully line up the Re bound Adjuster Knob and push it up into the bottom of the damper rod 62 Insert and tighten the Re bound Knob set screw using a 2mm Allen wrench Hold the knob to keep it from rotating while tightening the screw 63 Insert and tighten the Com pression Rod Fixing Bolt Inspect the O ring and replace it if torn or distorted Lubricate the O ring and threads with Super Slick Grease or Prep M Recommended torque 10 30 inch pounds 33 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 64 Make initial pre ride adjust ments Start with the SPV volume adjuster red hex backed all the way out Pressurize the SPV chamber to 30 PSI This is the minimum Adjust the sag in this case probably 30 of travel Have someone support the bike while you sit on it in normal rid ing position wearing your full riding gear including hydraton pac wat
10. linear you blow through the travel and tend to bottom out presuming you have the sag spring rate set correctly you can turn the volume adjuster of the SPV valve inward to reduce the volume of the chamber This will cause the fork to be more progres sive or ramp up sooner and resist bottom ing out These are adjustment guidelines It will take time and experimentation to really dial in your fork 35 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved im E PROPER CARE OF YOUR Stanchion Lube by ee Finish Line For longevity it is important to Use a soft clean cloth to care keep the stanchion tubes and fully clean the stanchion tubes top edges of the wipers clean and wipers Note the dust ring on top of the wiper Drizzle some Stanchion Lube Compress the fork a few times onto the clean stanchion tubes Using a soft cloth work the and allow it so settle on the tops excess Stanchion Lube into of the wipers the upper legs Repeat until no residue remains 36
11. n 36 Repeat step 35 so that the total suspension fluid added is about 120cc 18 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 37 Verify the correct suspension fluid height A simple method for accomplishing this is to use an oil syringe and a piece of plastic tubing Since the longest travel setting of this fork is 130mm an oil height measurement of 84mm 3 3 inches is correct early versions of the factory PDF service manual said 3 9in 75mm bad math Starting from the bottom of the syringe body measure 84mm out onto the plastic tubing mark and cut Insert the syringe and tubing into the fork leg until the syringe body is resting against the crown Remove it and look for fluid on the end of the tubing If the tubing did not contact fluid add fluid until it is higher than the end of the tube Re insert the syringe with the plunger fully compressed into the syringe body Holding the syringe against the crown pull the plunger up removing the excess oil until only air is be ing pulled into the syringe You are now at a level of 84mm 19 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 38 Lightly lubricate the threads and both O rings on the SPV top cap Use Super Slick Grease or Prep M 39 Start the top cap into the top of the leg by hand 40 Torque the top cap to 35 50 inch pounds Use
12. now come out with the assembly It is recommended that you per form the following modification so that the main spring can be removed from the top during future service 1 Separate the compression rod from the spring by simultaneously pulling them apart while bending them at a slight angle to each other 2 Remove the Allen bolt from the top of the compression rod lift off the nylon washer and re install the Allen bolt 25 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 26 If you followed the directions and dis asssembled your fork with the travel in the longest setting then the Wind Down Compression Rod looks like this When the fork is assemble and you adjust the Travel Wind Down Knob the D shaped main spring end drives the black spacer up and down the Wind Down Com pression Rod 49 Re install the Wind Down Compression Rod and tighten the end cap Be sure everything above the end cap is clean and properly lubed with a heavy bod ied synthetic grease MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 50 Re install the main spring Be sure the main spring assembly is clean and well lubed with a heavy bodied syn thetic grease Slide the Wind Down Compression Rod up about half way into the stanchion tube and hold it there Slide the main spring down into the fork leg until it contacts the top
13. of the Com pression Rod assembly Slowly rotate the spring until the the D shaped spring end aligns with the D shaped top of the Compression Rod assembly you will feel the spring drop into place Continue to use the Compression Rod to hold the spring up 2 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 51 Re install the Wind Down top cap into the main spring Be sure the O ring and threads have a light coating of suspension grease on them Remember to line up the D shaped spring end with the D shaped protrusion on the bottom of the end cap Use the Compression rod to slowly lower the spring assembly into place and start the top cap threads by hand 52 Tighten the Wind Down top cap The recommended torque for the top cap is 35 50 inch pounds Unless you have a properly sized 28mm crows foot open end wrench attachment for your torque wrench just carefully snug the end cap 28 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 53 Replace the O ring around the travel scale 54 Replace the Adjuster Knob and use a 2mm Allen wrench to tighten the set screw 29 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 55 Prepare to put the upper and lower assemblies together Invert the Crown Steer Leg assembly
14. rease Prep M or other supsension compatible grease to lubricate the outside edge of the inner oil seal and the seal inser tion area of the lowers 18 Start the seal into the lower leg and use your thumbs to press it down evenly until flush with the top edge of the lower leg 19 Use a large inverted socket and extention to carefully seat the inner oil seals in each leg Push very lightly slowly increasing pres sure until the seal begins to move Once it starts sliding it takes very little pressure to seat it against the bushing MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 20 This is the Enduro Wiper Apply a thin coating of grease to the insertion area of the wiper 21 Start the wiper into the in sertion area of the lower leg It should be easy to start as the leading edge is slightly tapered If the wiper goes in easily enough you may seat it by hand and skip Step 22 If you can t start the wiper by hand try putting the wipers in a freezer for 10 min utes This will cause the inner metal band to contract thus slightly reducing the OD of the wiper insertion area 10 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 22 Use a piece of 1 1 4 PVC pipe to press the wipers in until no gap can be seen below the wiper lip You are now finished servicing the low ers and are ready to service th
15. the screwdriver is wrapped in tape to protect the finish of the fork 10 Apply downward pressure on the screwdriver handle until the wiper seal pops up and out Be careful not to scratch the metal at the back of the lowers while prying up the old wipers 11 Remove the foam ring from the seal insertion area The foam rings will not be re used They will be replaced with a special inner oil seal REPEAT STEPS 9 11 FOR THE OTHER SIDE Ww MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 12 If the lowers are particularly dirty it s time to move to the sink and use some biodegradable de greaser Sometimes the semi bath lube turns to jelly and needs to be cleaned out 13 Chase the degreaser with a mixture of hot water and dish soap and a little brushing if needed RINSE well with hot water Using hot water not only cuts the grease but heats up the lowers and causes them to dry quicker due to evaporations MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 14 Thoroughly dry the lower legs 15 This is the BOTTOM of the inner oil seal See the deep groove IT FACES DOWN 16 This is the TOP of the inner oil seal See the word ENDURO IT FACES UP MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 17 Use some Super Slick G
16. tion models had a spring retaining washer on top of the Wind Down Compression Rod assembly If this is the case with your fork the spring will come out when you remove the Wind Down Compression Rod 23 MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 24 This is the stock coil spring with the top cap still in the end of it Notice the smaller diameter spring interwined in the cen ter of the main spring This is called the Booster Spring The stock configuration is considered Medium For lighter weight riders wanting a Soft Ride Kit simply wind the Booster Spring out of the main spring and only re install the main spring in the fork The Firm and Extra Firm ride kits consist of stiffer main springs respectively The original Booster Spring is then wound into the new main spring The spring assembly requires lubrication with a heavy bodied grease such as Pedro s Syn Grease NOT Prep M MANITOU MINUTE 1 00 2005 EnduroForkSeals com Real World Cycling All rights reserved 47 Loosen the Wind Down Compression Rod End Cap Use good quality flat jawed adjustable pli ers or an adjustable wrench 48 Remove the Travel Wind Down Compression Rod assem bly from the stanchion tube If you have one of the early production forks that did not allow the main spring to be removed from the top of the leg the main spring will
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