2012 SERVICE MANUAL
Contents
1. d 2012 Fork Service Manual 5 d 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 ARNING Failure to follow WARNING instructions could result in severe injury 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 key information to make procedures easier or clearer DENVER 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 GYEH Suspension forks uses p2. oneulauosg 1103 Madi SNIA L00 22LZ2C V Vl 9c0 M v66 c Vv GCOM VE6EC L VL 9LOM VE66EC LVL GLOM VE6EC LVL 200 V8LZCc Vv EGCG G8 COOM O0 cLc lvl COOM O0 cLC LVL LOOM CESG9C LVL 600 0ccZc Vv V 800 0ccZc VvV 4005 0ccZc Vv 900 1 0ccZc Vv I c00 c66 c Vv 60051 866 c L VL 900M 866EC L VL COOM 866EC L VL LOOM 866EC L VL vOOM 866EC L VL LOOM 866Ec LVL COOM 666EC L VL COOM 666EC L VL JoquinwN Hed Wy qouy OL SHUM N VL Bunseo 18910 10819 GN V L Buse 19100 SHUM GN YO Bunseo 1ejno 10819 GN YO Bunseo 18910 jy Buiusng WY E9S og Jeduieq punoqey 001 08 Jodweq punogey Jeduueq e nNjosqy UMID JUM 08 6e7 499 S UMOID r UMID IG og 697 1299 S UMO019 UMIO JUM 001 08 687 489 S UMOID 7 UMID 119 001 08 6e7 489 S UMOID deo peojald JIM O L UA 15 9pre OE WNIP N 15 Sply OEL HOS JIM PI 001 08 WJIJ JIM SPIF 001 08 WNIP N 15 epis 001 08 HOS 159 SPla 0g poy uoissaJduio 001 08 po uolss iduuo uonduoseq Hed LO O O lt OD O gt O O Mm CN NN MSF 25 2012 SERVICE MANUAL 2012 SERVICE MANUAL 9 L0X 88647 40 RAI tV 9 GLOM LEL8Z L Ph uojstd JY H row 18181 44408 Aiquessy poy uoisse1du02 Q H CL0X LEL8C Lv 4400 Aiquessy poy uorsseJduo 0 3 60 98 JIM 1666 3 965 My Bu
3. 10819 GLS YO Bunseo 1ejno yy Bulysng JM 16836 Ajquiessy Jeduieq punogey Jadweq niosqv UJuu00 B5 7 199 S UAXO1O uJuipg 6e1 991S UMOIJ2 deo ly UO SId JIV uJulooL quu ssv poy uoiss iduuoo WWQ8 A quiessy poy uoiss iduuoo TA CN C s SF OO ON ooo O O Uuondi15s dq Hed 2012 SERVICE MANUAL 32 33 2012 SERVICE MANUAL LOOM ZZLL2 L bb JIM qouy OL J 9 0M P66ET L VL SHUM YL Bunseo 19100 6 J 6066 68 10819 VL Bunseo 19100 6 g LEOM V66ET L PL SHUM GN YO Bunseo 191NQ 6 J ZOEE E8 10819 GN HO Bunse 19100 6 3 1969 98 i Buiusng g M 6609 98 WLUZE JIM d dlAA 3 1666 Z g F001 L668Z Lr L Jadweq punogey 9 V ZOOM ZES9T L HL Jeduieq niosqv q S00 66 2 Lv I 071 597 199 S UMOJ0 y a vOOM 66E7 L VL 001 08 B5 1 1931S UAO01O y D ZOOM Z66ET L VL deo peojaid diy C 900 866 2 Lv I OZ 4414 3M OPIN Z C 900 866 2 Lv I OZ UInIpe N UM eprd Z C c00 866 2 LvL 001 YOS JIM eprd Z C 100 866 2 Lv 1 001 09 4414 3 epi Z C v00 866 2 Lv 001 09 WNIp N JIM eprd Z C LOOM 866EZ L VL 00L 08 HOS 13 OPIN Z H v00M 666E7 L 71 1IV poy UolssaJdWOD 90045 314 Jaquinn Hed uondii5s dq Hed DIJEWOUIS X103 19dx3 JOMOL OO O O O O O O O 0 00 ge aga lt m xX uU ul U ww Ll H 01045 HM ABEN AE E E E 4 GR VE ER E A BH HR AB NH L00 2Z2LZ2C Vv V 9 0 M vootc Lvl EOCE E8 LEOM VE6E
4. JOS 1M epis Oc y Ul4 X 1M 9pr Oc V WJ M Sply Oc y tunip l JIM PI 021 NOS 1M 2pid OO Ul4 X 1M 9prd OO 4414 Wy epreJ 00 uunipe N Y epre 001 YOS 1M 9preJ poy uoissaidwoy uondiiSs q ped N N N N ON N N N N NNO TH 10 10 2012 SERVICE MANUAL 30 COOM ZZLZIC LeL WM Gouy LL 31 2012 SERVICE MANUAL 3 200 00242 Lvl SIUM IN YO Bunse 19100 OL 3 L00M 00222 Lvl 10819 GN YO Bunse 19100 OL E ZOGET 86 SHUM ALS YO Bunseo 19100 OL 3 L9S 2 96 10819 GLS YO Bunseo 19100 OL M 909 98 JIM lees 6 E LZES 98 1 Bulysng 8 V LOTE E8 Jadweq punoqes e6puye Z V LLZ 8 uuo eqn eBpuped 9 V OLZE E8 wung eqn DpuueO 9 V vOOM ZES9T L HL Jadweq e6puue einjosqy G q ZOOM 68ESZ L VL WWQ0 Be14ee1s uwoJ p q LOOM 68EGT L 71 ug 687 189 S UMOID F 3 1990 68 deo ily 9 699Z 8 UO SId NW Z H E9ZE E8 WUIQ0 lqtuu ssv poy 4016684044103 H Q ZXZEL8 uJu0g A quiessy poy uoiss iduuoo dnog HM Jequinn ped uonduoseq Hed oneueu s qui Z3 SHEUISU5S 11034 Old ZY T Q O OQ OQ lt m SU ul ww Ll H danois HM COOM LLLLC L VL COOM 00CLC L VL LOOM O0CLC LVL CYGEC 86 LYGEC 86 LCEG G8 L8CG G8 VSCE E8 LOOM CES9C LVL 6S9C 8 9G9c 8 VS9C E8 699C E 8 9c 8 c9c 8 JequinN Wed WM qou OL SHUM 8N YO Bunseo 1810 10819 GN YO BunseoS 19100 SHUM ALS HO Bunseo 1810
5. 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 FIG 4 Z7 2012 SERVICE MANUAL 9 8 Apply grease around the side of the new air piston We suggest using Manitou Prep M grease Fig 5 9 Install air piston into the top of the stanchion leg and push it past the threads Fig 6 10 Pour in 5cc s of semi bath oil on top of the air pis ton Fig 7 11 Install air cap onto the stanchion leg using a 20mm socket and tighten to 6 8 8 0 Nm 60 80 Ibf in 12 Turn the fork upside down and insert the air push rod 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 you feel it drop through the center hole 13 Lightly grease the spring and insert into the stan chion leg 14 Install compression rod assembly into the stanchion leg using a 22mm wrench and tighten down to 6 8 8 0 Nm 60 80 Ibf in 10 22 2012 SERVICE MANUAL TS AIR SERVICE ANNE 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 injury or possible d
6. 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 3 Remove the Absolute damper from the stanchion leg using a 24mm socket Fig 2 4 Pour the damping oil out of the fork leg 5 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 will 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 6 Check o rings on rebound damper end cap and ABS compression damper top cap and replace if damaged or worn HE 2012 SERVICE MANUAL FIG 2 FIG 4 19 Assembly 1 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 2 Install the rebound damper cartridge tube assem bly 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 3 The next step is to fill the fork with oil and install the compression damper To ensu
7. 6L 09 998642 Lvl paepnjoul eijxe S HO JIU AA JN SEHO Bunseo 19100 g 3 0204 89642 Lvl pepnjoui axe gL HO MIRIT GN GLHO Dunseo 18100 g H 4 0 886 7 Vvl SHUM AN HO bused 1810 0 8 a 810 886 77 Vvl 10019 GN HO Dunseo ano 8 Sey g PZOXW 1E618Z LbI deopue 9 jiesul e4eMpJeH lXV SLHO 7 ANG 3 re SW GLUD 9 CHAO g KE8eeg A quiessy odweq punogey eDpuueo S c00M LEL8Z LYI WWOZ 1901S Jede 86001 eDpuge2 LOOM LELSZ LVL WWOO 1881S Jede aqn ebpiyed vV00M LE LS8Z LvL WWOZL 1891S 8 qn l eDpig1ieo p COOM LELSZ L vl uulgo 1991S 8 4 Eqn ebpuue2 v 600M 2 S9Z2 Ll Aiquassy Jodweq einjiosqy ebpuye2 6 LV0 X L L872 Lvl JIM qouy Z 0LOM LEL8Z Lv V UMIO UA WWOZ 199 S Jede Alqw ssy 199 S UMO10 ZLOM LELSZ L HL UM 119 WWOZ 199 S Jede Ajquassy 199 S UMOID 600M L L82 Lv Vy UMID UA WWOO 199 S Jede Ajqwassy l99 S UMOID q LLOM LELSc lvl UMID 119 WWOO Jeeis Jede Ajquassy i99 S UMOID SS QOOM LELSC 1LVI UMIO JUM WWOZ 1991S 8 14 Alquiessy 1e8e1S UMOJO 7 800X LEL8C LVL UM AIG 0601 1901S 8 Aqw ssy 199 S UMO010 S00 L L8c Vvl UMO1UM WWOO 1991S 8 4 AlQuassy i99 S UMOID L e LOOM LELSC 1LVI UM AIG WWOO 1991S 8 Alquessy jee1g uMOo12 00049 HY JequinwN Wied uondi120sog ed DEWOUIS JIo Old OMEN lt
8. C LVL COLE E8 v96S S8 6 S S9 G6CE E8 800M CESIC LVL LEEE E8 O 8 66c 8 OGLE E8 869Sc LYl 00 vvZ49c Lvl cOO0 vVZ49c Vvl LOOM YVZ9C Vv V COOM EVLIC LVL COOM EVLIC LVL LOOM EVL9C LVL S00M 069SC L VL vOOM 069SC L VL COOM 069SC L VL COOM 069SC L VL CLEC EB JoquinN Hed JIM qouy L L SHUM VL Bunseo 19100 OL 10819 VL Bunseo 19100 OL SHUM YO Bunseo 19100 OL 10819 YO BunseoS 19100 OL yy Buiusng 6 WWZE JIM Jediw ees 9 Ajquiessy Jeduie punogey Z Jeduieq einjosqy 9 071 5e1 ee1s uwo1J2 S 001 B 1 199 S uAO1O S 09 687 1991S UMOID G deo uv p UO SId II OZL 44134 X HY eprd Z OZ 14414 WY OPlY Z OZ uinip l 3M eprs Z 00 WIJIK 13M OPlY Z 00 14414 3M Ply Z 00L WNIPSNN 3M eprs Z 08 44114 X 3M epis Z 08 41114 3M 9prs Z 08 WNIp N 3M PIH Z 08 HOS 1IM OPlY Z poy uoisseJdulio2 uondii5s q ped 2012 SERVICE MANUAL 34
9. age shows the placement of the spacer for 80mm of travel Fig 6 on this page shows the placement of the spacer for 100mm of travel FIG 5 FIG 6 14 HE 2012 SERVICE MANUAL ISO Air Spring Service ile 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 injury or possible death LEV Alltop 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 Fig 1 4 Unthread the compression rod assembly from the bottom of the stanchion using a 22mm wrench and remove from fork Fig 2 amp 3 5 Remove the air piston from the stanchion leg There are two ways to do this You can use a long Allen wrench or dowel rod to push the air piston through and out the bottom of the stanchion leg Fig 4 You can alternatively use a 6mm bolt and thread it into the center of the piston and pull it out the top of the fork leg Fig 5 The second method is convenient when you are just servicing the air piston and do not want to dis
10. assemble the fork 6 Apply grease around the side of the new air piston We suggest using Manitou Prep M grease Fig 6 7 Install air piston into the top of the stanchion leg and push it past the threads 8 Pour in 5cc s of semi bath oil on top of the air piston Fig 7 9 Install air cap onto the stanchion leg using a 20mm socket and tighten to 6 8 8 0 Nm 60 80 Ibf in HE 2012 SERVICE MANUAL 15 16 22 2012 SERVICE MANUAL Absolute Service Disassembly 1 The casting needs to be removed prior to servic ing the damping side of the fork Refer to the Cast ing Removal instructions 2 Using a 2mm Allen wrench remove the adjuster knob from the top of the fork Fig 1 Be careful when removing the knob as there are two detent ball bearings under it Remove the detent ball bearings and springs 3 Using a 24mm socket remove the Absolute damper from the stanchion leg Fig 2 4 Pour the damping oil out of the stanchion leg 5 Turn the fork upside down and using a 22mm box end wrench remove the rebound damper assembly from the stanchion Fig 3 6 Check o rings on rebound and compression as semblies and replace any that are worn or damaged Assembly 1 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 2 The next step is to fill the fork with oil and install the compression damper T
11. ays or upside down to get the compression rod out of the leg Fig 4 FIG 2 6 Inspect compression rod and top out bumper If damaged replace 7 Install compression rod assembly into the stan chion 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 8 Lightly grease the spring and install into stan chion leg FIG 3 9 Install the preload adjuster into the fork leg Tighten down using a 20mm socket to 5 1 6 2 Nm 45 55 in Ibs 10 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 11 Install bottom out bumper and travel spacer onto the end of the compression rod HE 2042 SERVICE MANUAL 12 The casting needs to be removed prior to ser vicing the coil spring Refer to the Casting Removal Instructions first 13 Turn the preload knob counter clockwise until it stops to relieve the preload on the spring 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 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 travel Fig 5 The spacer being on the bottom on th
12. e flange will cause the fork to have 80mm of travel Fig 6 FIG 5 FIG 6 HE 2012 SERVICE MANUAL MARS Air Spring Service ile 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 injury or possible death Ute Alltop 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 Fig 1 4 Unthread the compression rod assembly from the bottom of the stanchion using a 22mm wrench and remove from fork Fig 2 o Remove the spring from the stanchion Fig 3 6 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 7 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 will 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
13. eath 1 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 2 Release all air from the system by depressing the valve core on the Schrader valve 3 Using a 20mm socket remove the air cap from the fork Fig 1 4 Remove compression rod assembly from the bottom of the stanchion using a 22mm wrench Fig 2 amp 3 5 Using a long Allen wrench or similar tool push the air piston down and out the bottom of the stanchion leg Fig 4 6 Apply grease around the side of the new air piston We suggest using the Manitou Prep M grease Fig 5 7 Install air piston into the fork stanchion Install by push ing the piston in through the top of the stanchion and push it past the threads Fig 6 8 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 HE 2012 SERVICE MANUAL 11 FIG 5 FIG 6 12 22 2012 SERVICE MANUAL ACT Air Service UNITS 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 injury or possible death 1 The casting needs to be removed prior to servicing the ACT Air system Re
14. ect 16cc s of semi bath oil into the lower legs using a syringe or similar tool Fig 1 3 Slide the casting all the way onto the upper stan chions 4 Insert the compression rod bolt into the compres sion 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 5 Using an 8mm Allen wrench thread the rebound damper assembly into the casting by turning it coun ter clockwise Tighten to 3 4 4 5 Nm 30 40 Ibf in Fig 3 6 Install rebound knob onto the rebound shaft using a 2mm Allen wrench Fig 4 HE 2012 SERVICE MANUAL 21 MRD Casting Installation 1 Slide the lower casting onto the upper stanchions You want to slide them on only about halfway at this point 2 Inject 16cc s of semi bath oil into the lower legs Using a syringe or similar tool Fig 1 3 Slide the casting all the way onto the upper stan chions 4 Insert the compression rod bolt into the compres sion 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 5 Using an 8mm Allen wrench thread the rebound damper assembly into the casting by turning it coun ter clockwise Tighten to 3 4 4 5 Nm 30 40 Ibf in Fig 3 6 Thread the detent housing on the rebound damp er assembly threads using a green Park Tool pin spanner or similar tool Fig 4 7 Place sprin
15. er to the Casting Removal or MRD Casting Removal instructions depending on which model fork you have 2 To remove 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 3 Push down on the screwdriver This will pop the seal out of the casting Next remove the foam oil ring Fig 2 4 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 5 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 put ting pressure on the sealing lip and spring so that they are not damaged Fig 4 Repeat steps 1 4 for the opposite casting leg HE 2012 SERVICE MANUAL Coil Spring Service 1 Using a 2mm Allen wrench remove the knob from the preload adjuster Fig 1 2 Remove the preload adjuster from the fork using a 20mm socket Fig 2 3 Pull the coil spring out of the stanchion leg 4 Remove travel spacer and bottom out bumper from the end of the compression rod assembly Fig 3 5 Remove the compression rod assembly from the stanchion leg The compression rod comes out from the top of the stanchion leg Turn the fork sidew
16. fer to the Casting Removal section for instructions on how to do this 2 Release all air from the system by depressing the valve core on the Schrader valve 3 Using a 20mm socket or wrench remove the top air Cap assembly from the fork Fig 1 4 R th ing f the fork Fig 2 emove the spring from the fork Fig 2 FIG 2 5 Using a 22mm wrench unthread the compression rod assembly end cap and remove the assembly from the fork uppers Fig 3 6 Replace the air piston o ring on the compression rod assembly Fig 4 7 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 8 Grease the spring and place it into the fork uppers from the top 9 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 pres sure F L 2012 SERVICE MANUAL 13 TRAVEL CONVERSION ON DRAKE CIRCUS EXPERT MINUTE EXPERT 80 and 100mm FORKS 1 The Drake 80 and 100mm forks can be converted to either travel by moving a spacer on the compression rod assembly Follow Steps 1 5 above to remove the compres sion rod assembly 2 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 this p
17. gs and detent ball bearings into the detent housing Fig 5 8 Install rebound knob onto the rebound shaft using a 1 5mm Allen wrench Fig 6 FIG 5 FIG 4 22 224 2012 SERVICE MANUAL OIL HEIGHT CHART In Leg Forks MRD Forks Oil Height Guide 1 Oil height is set with OIL compression damper HEIGHT HEIGHT Absolute removed 2 Oil height is set with the fork fully extended ride height FORK TRAVEL OIL HEIGHT mm Circus Comp Match 80 100mm 83 8085 a un Bm Expert s wa we v 8m Expert F L 2012 SERVICE MANUAL 23 00 X L8LZ2c lvl poy uoisseJduJo 6 00 9899c Lv V 001 08 WJ Hy PIA 8 c00 9899c Lv V 001 08 WNIP N 1M PIA 8 L00 79899c Vr 001 08 HOS JM 9plH 8 c00M L8LZC V vl Jejsn py peojeJg Z UMID GOOM 027LC L VL JUM 001 08 697 499 S UMOID 9 UMID V00 0ccZc Vvl MIT 001 08 597 499 S UMOID S00 L8LZC lV V 10816 001 08 697 199 S UMOID 900M CEGYC iil Jodweq 9 njosqy L0O0M 0ccZc Mv V quiessy Jodweq punogey JIM Je9S Z00 L91L2ZC Ltl JIM Buiusng 9c0 v66 c LV V SHUM GN VL Bunseo 18106 SCOM vY66 C Vil 10819 gN V L Buysed Jeino Q9LOM VE6EC LVL SHUM 8N YO Buysed 18106 3 GLOM VY66GEC IP 10819 GN HO Bunsed 1370 2012 SERVICE MANUAL MalA popojdxJ duio sn3112 24 2 N lt m m x L Lu Lu U U Ir oOo 000000 AQA a dnoJ5 314
18. gt lt H v009 L8V Z LL OE poy uolss iduuoO 6 LLI H 00F 8WJz 001 08 pow uoiss iduuoO 6 Q 2 9009 98992 Lvl OSL WIJI 1M epi 8 2 S00 9899z Ll OC WNIPON 1 OPIN 9 x j S r00 98997 LPL OEL YOS 4Y Opry 9 T 00 98992 Ltl 001 08 WI4 WY epr 8 e OO S 200 98992 Lvl 001 08 uinip NW Uy eprd g 100 99992 L l 001 08 YOS JM OPIN g pe S Z00X L8L Z Lvl jeysn py peojeud Z G 900M L8L 4 1 08 687 19816 40012 9 a GSO0Y I08 ZZ Lb 001 08 Be3 1ee15 UwoJ2 9 NE V 00M rPOPSZ LPL jedureq lniosqv 9 NG g FOOL SL ZZ E PL A quiessy aduwea punogey E L009 LLV4Z Ml JIM 1006 3 Z00 I8LZZ IPL JIM Bulysng 2 EUH 9L0w v66 2 Lvl SHUM AN HO Bunseo 18100 8 SIOfFr66ezl 10018 AN YO Bunseo 19100 38 900 rv66t7iv amp UM GIS YO BunseO i lnO L 38 SO0OFveeezivL 10009 GLS YO Punseo ano M9IA P Ppoldx3 YEN 28 29 lt gt lt LLI LOOM ZZLLZ L VL y qouy OL Q 3 920M v66 2 Lv I SHUM WL Bunseo 19100 6 gt 3 SCOM v66 7 LV I 10819 yL Bunse 19100 6 x 3 9L01 r66 Z LbL SUM gN YO Bunseo 19100 6 T 3 SL03M r66 Z LbL 10619 GN YO Bunseo 1100 6 3 9001 r66 Z LhL SHUM ALS HO Bunseo 19100 6 3 S00M v66 2 Lt I xoelg ALS YO Bunsed Jeino 6 e E r96S S8 JIM Buiusng g Q 6609 98 WWZE JIM d dlAA 9 16866 Z g 00 L66 2 Lvl Jedu
19. ieq punogey 9 NGE V COOM ZESG9T L VL 1 duieq ejniosqy Ni q ZOOM E66ET L VL 068 697 199 S UMOI0 v E q LOOM E66E7 L VL 001 08 627 1891S UMOJD v 3 ZOOM Z66ET L VL deo peojald liv 9 600 866 2 Lv L 06 44114 3M eprd Z 9 900 866 2 Lv OEL tunipeiN 3 9pid Z 9 003 966 2 Lvl OEL YOS 1IM epi Z 9 1003 966 2 Lt 001 08 4414 3M eprs Z 9 v003 966 2 Lvl 001 08 tunip N 3 Spy Z 9 LOOM 866E7 L VL 00L 08 HOS 1 epi Z H 003 666 2 Lv I quiessy poy uoisseJduio2 dnouJc Wy Joquuinw Hed uonduo seq Hed SIJeU19U5S 103 Mad ejnuily O00 COCO 00 0 0 0 00 00 aga aga0g lt m Y U U U U ul LI H 01015 JIM DJIJEWAUIS X104 Old nUllN LOOM LZLL2 L VL 9ZOM VE6EC LVL GCOM VE6EC LVL 9L 0 v66 c vl SLOM v66 c Vvl v96G G8 6609 99 LVEE E8 800 c S9c Vv LGLE 8 9GLE E8 GGLE E8 0S1 8 88 LE 8 V00 89SC Vv V 00 89SC Lv V c00 89SC Vv V L00 89Sc Lv L 9749 ILVE E8 9416 6868 GILE E8 ELLE E8 CLLE 8 LZLE E8 OLLE 8 E8LE E8 Jequinw Hed Wy gouy LL SHUM WL Bunse Jeino OL 10819 yL Buysed 19100 OL SHUM HO BunseO 19100 OL 10019 YO BunseO 19100 OL Wy Buiusng 6 WWZE Uy 1801 16866 8 Jeduieq punogey 7 Jedujeq n osqv 9 Op be7 189 S UMOID oz 6e7 489 S UMOID 00L 6e7 189 S UMOID deo IV UOJSId JIN OVL Ul4 X JM SPH OVL Wld JM aply OV tunip l JIM 9prs OVL
20. ing 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 HE 2012 SERVICE MANUAL MRD Casting Removal 1 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 2 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 FIG 1 3 Remove the detent balls and springs from the Detent Housing Fig 3 4 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 5 Using a mm or 8mm Allen wrench turn the rebound assembly clockwise until it can be pushed into the cast ing Fig 5 6 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 4 HE 2042 SERVICE MANUAL Dust Seal Replacement 1 Before replacing the dust seals you will need to remove the lower casting Ref
21. o 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 F L 2012 SERVICE MANUAL FIG 2 FIG 3 17 3 Once the casting is installed 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 Fig 4 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 4 Install the Absolute damper into the stanchion FIG 4 and tighten down using a 24mm socket to 6 8 9 0 Nm 60 80 Ibf in 9 Install detent springs and ball bearings into the holes on the top cap You want them placed in holes opposite of each other Fig 5 6 Install adjuster knob and using a 2mm Allen wrench tighten down to 0 5 0 7 Nm 4 6 Ibf in FIG 5 18 22 2012 SERVICE MANUAL Absolute MRD Service Disassembly 1 The casting will need to be removed prior to servicing the damping side of the fork Refer to the MRD Casting Removal Instructions 2 Using a 2mm Allen wrench remove the adjuster knob from the top of the fork
22. re proper oil height the casting must be installed prior to filling If you have other service to perform on the fork continue onto the appro priate section and finish that first If not refer to the MRD Casting Installation Instructions to install the casting 4 back onto the fork 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 10cc s into the cartridge tube Remove 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 9 Install the Absolute damper into the cartridge tube and using a 24mm socket tighten down to 6 8 9 0 Nm FIG 7 60 80 Ibf in Fig 6 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 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 20 224 2012 SERVICE MANUAL Casting Installation 1 Slide the lower casting onto the upper stanchions You want to slide them on only about halfway at this point 2 Inj
23. reloaded spring s 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 HE 2012 SERVICE MANUAL This manual is divided up into different sections each one pertaining to a different part of the servicing of your fork Below is a list of our fork models and which sections you will use to service your particular fork Circus Comp Match Tower Comp Forks Section 1 Casting Removal Section 3 Dust Seal Replacement Section 4 Coil Spring Service Section 8 Absolute Service Section 10 Casting Installation SN dct Circus Expert Minute Expert Tower Expert Forks Section 1 Casting Removal Section 3 Dust Seal Replacement Section 7 ACT Air Service Section 8 Absolute Service Section 10 Casting Installation SN dw et R7 MRD Forks e Section 2 MRD Casting Removal 2 Section 3 Dust Seal Replacement 3 Section 6 TS Air Service 4 Section 9 Absolute MRD Service 5 Section 11 MRD Casting Installation Marvel Pro Forks 1 Section 2 MRD Casting Removal 2 Section 3 Dust Seal Replacement 3 Section 8 ISO Air Service 4 Section 9 Absolute MRD Service 5 Section 11 MRD Casting Installation Minute Pro Tower Pro Forks SUD Des e ms o Doce 0 M 1 2 9 4 5 Section 1 Casting Removal Section 3 Dust Seal Replacement Sec
24. tion 5 MARS Air Spring Service Section 8 Absolute Service Section 10 Casting Installation 7 Forks Section 1 Casting Removal Section 3 Dust Seal Replacement Section 6 TS Air Service Section 8 Absolute Service Section 10 Casting Installation arvel Expert Forks Section 1 Casting Removal Section 3 Dust Seal Replacement Section 8 ISO Air Service Section 8 Absolute Service Section 10 Casting Installation 22 2012 SERVICE MANUAL Table of Contents Section 3 Dust Seal Replacement 6 Ce I 2 TU Contact Information Hayes Bicycle Group 6750 W Florist Ave Milwaukee W 53218 Toll Free 888 686 3472 Direct 262 242 4300 FAX 414 462 0214 E mail manitoutech hayesbicycle com Web site www manitoumtb com AME 2012 SERVICE MANUAL 3 Casting Removal 1 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 2 From the right leg dropout if the fork has adjustable re bound 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 3 Use an 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting Fig 3 4 Remove crown steer inner leg assembly from the outer leg casting by pull
25. ysng 8 3 1700 18181 deopue 9 m sul SIEMPIEH XV 91430 7 3 910 18182 L PI 9 XV GLUD 9 3 610 88622 1 rl pepniour ejxe GLYO eiu M GN GLYO buysed uano 9 3 02093 88647 1 papnjoul ejxe GLYO 49818 GN 9130 Ouse 1ejno 9 3 LbOM 88622 L 41 UM GN YO buyseg 19900 G 3 8 bOM 886L2 1 41 10018 GN YO bused 1ejno G QLOM LEL8Z L HL qwessy Jedweq punoq y y DA AS V 0LOX 28992 LP I Aiquassy Jedueq ejnjosqy NEG ZLOWLEL8SZ LPL JIM qouy Z da OLOXWLEL8SZ LYL UMIO UM 44021 23S Jade Aiquassy i99 S UMOID da ZOXWLELSZ LY UMIO yig WWOZ 1891S Jade A lquugssv 199 S UM019 da 600 16187 ltl UMID TUM WwW00 1991S ade A quu9ssy 199 S UA019 da LLOXWLEL8ZLYL umg yig WWOO a35 Jade lquu9ssy 199 S UM019 i 00 X QOOM LELSZ LHL UMID uA Uuogzi 1881S 8 1 Aiquessv 1ee g uMol2 Y 0 SOOM LELSZ LPL UMID 38 uu0Zl 189815 8 1 Alqwessy i99 S UMOID 0 GOOM LELSZ LPL 44014 0 44001 7080168 Alqwassy i99 S UMOID z q LOOW LELSZ LPL UMD yig uu00l 1991S 8 1 Alqwessy i99 S UMOID 26 SBPulU5S yio Mad OMEN 2 2012 SERVICE MANUAL 3 CLOM S86LZ L VL deo uv EL C SLOM LELSZ L vL UO SId IV ZL H vi0Mx I i87 V vl uWQZ Aiquessy pos uoisseJd uo YU H ELOWLEL8Z LYL WWOOL Aiquessy pos uoisseJduio M 629 99 JIM Iees OL 3 r96S S98 JIM Bulysng 6 J
Download Pdf Manuals
Related Search