Swinger Shock Service Manual
Contents
1. Spring for Shock 230 X 70 8 75 or 9 0 X 2 75 600 Le Spring for Coil Shock 230 X 70 Ges or 9 0 X 2 75 Rate 650 EN Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X275 Rate 300 Le Ti Spring Coil Shocks 222 230 X 70 8 75 or 9 0 X 2 75 Rate 350 Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 400 G Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 SC 450 Ti Spring Coil Shocks 222 or 230 X 70 8 75 or 9 0 X 2 75 Rate 500 Pig Gol ora ECR for Coil Shock 240 X 76 9 5 X 3 0 Rate 150 9 Spring for Coil Shock 240 X 76 95 X 3 0 Rate 250 5 Spring for Coil Shock 240 X 76 95 X 3 0 Rate 300 CG Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 350 CG Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 400 BON Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 450 E opring for Coil Shock 240 X 76 9 5 X 3 0 Rate 500 E Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 550 EON Spring for Coil Shock 240 X 76 9 5 X 3 0 Rate 600 E opring for Coil Shock 240 X 76 9 5 X 3 0 Rate 650 e d Coil Shocks 240 X 76 9 5 X 3 0 Rate 300 ER Ti Spring Coil Shocks 240 X 76 9 5 X 3 0 Rate 400 lol Ti Spring Coil Shocks 240 X 76 9 5 X 3 0 Rate 450 lol Ti Spring Coil Shocks 240 X 76 9 5 X 3 0 500 EE Spring Coil Shocks 240 X 76 9 5 X2. 15 If oil was leaking from one of the high or low speed compression adjusters on a 6 Way Swinger the adjusters should be replaced Do Not remove unless a leak was detected Remove the two 1 5mm set screws found on the backside of the reservoir forging Remove the adjuster needles using a 3mm hex Early Model Year 2004 or 2mm hex Late Model Year 2004 Pour a small amount of damping oil in each hole prior to replacing the needles Replace in reverse order As you screw in the needles use a 2mm hex to guide the needle o rings past the set screw openings to prevent damage Apply blue loctite 242 to the set screws prior to installation Tighten the set screw until it makes contact with the needle and then back off 1 4 turn NOTE Each adjuster needle is unique replace one at a time to avoid confusion 06 SWINGER SERVICE MANUAL 1 5mm Set Screws Low Speed Needle Red Xo High Speed Needle Black REV NC 11 Remove Eyelet as shown under the section on BOTTOMOUT BUMPER REPLACEMENT 12 Using pliers remove the rebound adjuster needle from end of the damper shaft VAS Damper Needle Note The following instructions will work Damper Cap Oil Return Port on all year model 4 and 6 way Swinger shocks 13 Slide damper cap on damper shaft assembly so that it is at the edge of the oil return port 06 SWINGER SERVICE MANUAL Page 20 REV NC e VLA DAMPING SYSTEM BLEEDING SWING
3. 21 Install eyelet as shown under the section on BOTTOMOUT BUMPER REPLACEMENT 22 Remove the IFP location tool Once the tool is removed DO NOT move the damper shaft 23 Apply blue Loctite to SPV air volume adjuster threads Install the air preload adjuster and tighten to 43KgCm 50 in Ibs 24 Add air to re pressurize the air preload reservoir per instructions in the Owner s Manual 25 Reinstall spring using the instructions under RIDE KITS 06 SWINGER SERVICE MANUAL Page 22 REV NC mD VLAN SECTION 14 DAMPING SYSTEM BLEEDING SWINGER 3 WAY AND S TYPE SPV SHOCKS 1 Release All air pressure from air canister Air Canister Schrader valve air spring and SPV chamber 2 Remove the SPV valve by removing valve core on the red SPV Schrader valve Insert a 3mm hex wrench inside the valve and unscrew to remove Valve Core Removal Schrader Removal Using 3mm Hex Wrench 3 Remove hardware as shown under HARDWARE REMOVAL Place adjuster eyelet in a vise using soft jaws Using a rubber strap wrench to prevent damage loosen the air canister completely Pull back the air canister and slide it off the damper body to expose the 10mm damper shaft Note If the only service necessary is to repair a leak from the adjuster end of the air canister replace the air canister o ring that is found inside the C eyelet Reassemble the shock as described at the end of this section 06 SWINGER SERVICE MANUAL Page 23 R
4. Ride Kits away 4Way 6 Way Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 250 EX Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 300 Ew Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 350 8 EEN ing for Coil Shock 165 X 38 5 X 1 ES Rate 450 EES Spring for Coil Shook 165 X 38 65 X 1 5 Rate 550_ Lp Spring for Coil Shock 165 X 38 X 1 5 Rate 600 Spring for Coil Shock 165 X 38 6 5 X 1 5 Rate 650 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 300 G Spring tor Coil Shook 190 or 200 X 50 7 5 or X 2 0 Rate 350 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 400 amc A Spring tor Coil Shook 190 or 200 X 50 7 5 or X 2 0 Rate S00 for Coil Shock 190 200 X 50 5 or 7 875 X 2 0 Rate 550 Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 600 ES Spring for Coil Shock 190 or 200 X 50 7 5 or 7 875 X 2 0 Rate 650 opring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 250 opring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 300 Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 350 Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 400 Spring for Coil Shock 200 x 57mm 7 875 X 2 25 Rate 450 G Spring for Coil Shock 200 x 57mm 7 875 X 2 25 500 G_ Spring for Coil Shock 200 x 57mm 7 875 X 2 25 550
5. 30 PSI 16 Clamp the adjuster eyelet in the soft jaw vise Grease the air canister threads and screw the canister on to the eyelet Tighten using strap wrench on canister to 13 21 in lbs or 15 24 Kg cm 17 Add air to re pressurize the SPV air preload per instructions in the Owner s Manual 18 Reinstall shock mounting hardware and install in bike per manufacturers instructions Add air to air canister per the setting instructions in the owner s manual 06 SWINGER SERVICE MANUAL Page 27 REV NC SECTION 15 DAMPING SYSTEM BLEEDING SWINGER 4 WAY AIR SHOCKS eines The Swinger Air uses compressed air to provide resistance to compression in place of a coil spring You must be certain that the air canister is relieved of all pressure prior to servicing the air system Failure to relieve air pressure could result in injury or possible death 1 Release All air pressure from air canister Air release Schrader valve and air preload reservoir Air Reservoir Schrader Valve 2 Remove hardware as shown under HARDWARE REMOVAL Place adjuster eyelet in a vise using soft jaws Using a rubber strap wrench to prevent damage loosen the air canister completely Pull back the air canister to expose the 10mm damper shaft Note If the only service necessary is to repair a leak from the adjuster end of the air canister replace the air canister o ring that is found inside the adjuster eyelet Heassemble the shock as describe
6. Out Point at which a shock returns to its full extension 06 SWINGER SERVICE MANUAL REV NC SECTION 4 AIR SPRING SYSTEM AND SPV AIR PRELOAD SWINGER AIR S Type The Swinger Air uses compressed air to provide resistance to compression in place of a coil spring You must be certain that the air canister is relieved of all pressure prior to servicing the air system Failure to relieve air pressure could result in injury or possible death Sealing of the shock is accomplished through a series of o rings quad seals and wipers When the air canister is removed these seals can be replaced from Seal Kit C 1 Failure of an air shock to maintain air pressure is usually the result of defective or worn seals If there is suspicion of an air leak pressurize the air canister to 150psi from the adjuster eyelet Schrader Valve and the SPV Air Preload Schrader to 100psi Locate the leak by spraying the air canister and Schrader joints with a mild solution of dish soap and water or submerge in a bucket of water Bubbles will form in from the area of leakage 2 For leaks at the adjuster eyelet or damper end of the air canister refer to the detailed disassembly instructions contained in the section on DAMPING SYSTEM BLEEDING Swinger Air This will guide you on how to replace the applicable o rings and seals 3 For leaks at the Schrader valves release all air pressure and replace the Schrader valve core or assembly as
7. canister 27 Add air to re pressurize the air preload reservoir per instructions in the Owner s Manual 28 Reinstall shock mounting hardware and install in bike per manufacturers instructions Add air to air canister per the Setting Sag instructions in the owner s manual 06 SWINGER SERVICE MANUAL Page 33 REV NC D VLAN SECTION 16 SWINGER SHOCK TROUBLESHOOTING CHART Section ALL SHOCKS Damping System Cannot set pedaling Air loss from SPV Tighten or replace Schrader core platform system SPV or replace Schrader assembly Schrader valve leaks SPV Valve failure Close rebound knob clockwise 12 15 If the shock pes fast after compression the SPV valve may be defective If the rebound is very slow the valve is probably OK Inspect and replace if necessary SPV Schrader valve Interference with Replace Confirm clearance after snapped off at base suspension linkage or Schrader replacement on 3 Way Air and Coil other frame Swingers components Adjusting rebound Air in damping system Bleed damping system 12 15 MESE has no effect comes out of the oil has o ring on the IFP and 15 SPV Schrader valve leaked past the IFP bleed the damping system Mounting Hardware Play in shock eyelets Worn DU bushing or Replace 6 7 when mounted in bike mounting hardware SWINGER AIR S TYPE SPV valve leaks or replace assembly quem os Canister SS n N
8. rate 06 SWINGER SERVICE MANUAL REV NC SECTION 17 TABLE 1 FASTENER TORQUE REQUIREMENTS Feaue Swinger Air S Type SPV p 15 24KgCm 13 21inlbs Air Piston to Damper 70 90 KgCm 61 to 78 inlbs Damper Piston Bolt 70 90 KgCm 61 to 78 inlbs Damper Shaft to Control Eyelet 70 90 KgCm 61 to 78 inlbs Schrader Valve Stem 5 10 KgCm 4 to 9 inlbs UU Air Volume Adjuster Swinger Air 4 Way 70 90 KgCm 61 to 78 inlbs _ Swinger Coil E KENE 06 SWINGER SERVICE MANUAL Page 36 REV NC SECTION 18 2006 SWINGER REAR SHOCK SERVICE KITS 2006 SWINGER AIR S TYPE SPV SHOCK SERVICE KITS KitDescription Swngr SType 4Way SRL sv Air jJ Air Canister 152mm Eye to Eye 32mm Travel Air Canister 165mm Eye to Eye 38mm Travel Air Canister 178mm Eye to Eye 40mm Travel Air Canister 190 200 210mm Eye to Eye 50mm Travel Air Canister 200mm Eye to Eye 56mm Travel LA _ _______ Schrader Valves Swinger SPV Schrader Valve Assy inc O Ring Red A 90 Degree Schrader Air Valve Black 360 Degree SPV Schrader Air Valve Red gt gt 83 2526 SEH LN Kasa Bulk Pack IFP Seal For 4 6wa 83 2719 EN Bulk Pack Air Can Wiper Seal 83 2720 Bulk Pack Air Can Glide Seal 83 2721 Bulk Pack Piston Damper Shaft Seal C 83 2722 Bulk Pack A
9. will rotate slightly within the bushing during Suspension compression DU Bushings like hardware may wear over time Removal and installation is accomplished using tool PN 85 6075 REMOVAL Remove hardware from the shock Insert unthreaded end of punch into the removal tool first and screw in about half a turn Punch Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch making sure that it is centered on the bushing This will press out the bushing 06 SWINGER SERVICE MANUAL Page 8 REV NC e VLAN INSTALLATION 1 Place a bushing onto the threaded end of the punch and into the removal tool screw in about half a turn Bushing Clamp removal tool in vise Insert eyelet into tool Use 6mm hex wrench to screw in punch making sure that it is centered on the bushing and that the bushing is centered to the eyelet This will press in the bushing SECTION 8 RIDE KITS Ride kits Coil Swinger only consist of a replacement spring of a specific spring rate that is firmer or softer depending on the rider s preference Most manufacturers using Swinger Coil shocks vary the stock spring rate that is the standard offering based on frame size Larger frame sized have higher spring rates to accommodate bigger riders Due to the wide variety of frame geometry in use it is left to the rider to determine if they are satisfied with their stock spring rate Spring rates and travel stroke
10. 3 0 Rate 550 _ Spring for Coil Shock 267 X 90 10 5 X 3 5 Rate250 amp Spring for Coil Shock 267 X 90 10 5 X 3 5 Rate 300 o G Spring for Coil Shock 267X90 10 5 X3 5 Rate350 G Spring for Coil Shock 267 X 90 10 5 3 5 Rate 400 o odel Spring for Coil Shock 267 X 90 0 5 X SH Rate 450 G RN O Ti Spring for Coil Shock 267 X 90 10 5 X 3 gt Rate 250 oE 65 6855 Ti Spring for Coil Shock 267 X 90 10 5 3 5 300 G 1 856856 Ti Spring for Coil Shock 267 X 90 10 5 X 3 5 De 9008 85 6857 Ti Spring for Coil Shock 267 X 90 0 5 X Rate 400 fa 85 6858 _ Ti Spring for Coil Shock 267 X 90 10 5 3 5 450 G 1 5 6859 06 SWINGER SERVICE MANUAL Page 41 REV NC Swinger Rear Shock Service Kits Description jn EE BEN AI A Air Canister A Air Valve Assembly B 3 Way Swinger Air Shock No Hardware 4 Way Swinger Air Shock No Hardware il 3 Way Swinger Coil Shock No Hardware No Coil 4 amp 6 Way Swinger Coil Shock No Hardware No Coil B Low and High Speed Adjuster Kit B Rebound Adjuster Knob Kit 06 SWINGER SERVICE MANUAL Page 42 REV NC Swinger Rear Shock Service Kits Description CONT B SPV Air Preload C Seal Kit D Hardware E DU Bushing Kit 772 777 SWINGER
11. CTION 13 DAMPING SYSTEM BLEEDING SWINGER 4 amp 6 WAY COIL SHOCKS NOTE Leaks from Low High Speed Adjusters on Swinger 6 Way Shocks The 6 Way adjuster knobs are adjusted using a 3mm Early 2004 Models or 2mm Late 2004 Models hex If too much force is applied then the knob is adjusted counterclockwise the adjuster needles may strip out and result in an oil leak If this occurs during adjustment and the shock has not been compressed the adjusters can be replaced without a complete teardown and bleeding of the shock Follow the instructions in Step 10 1 Remove hardware as shown under HARDWARE REMOVAL and remove opring as shown under RIDE KIT Section 2 Release reservoir pressure from the air preload 06 SWINGER SERVICE MANUAL Page 16 REV NC e VIAN 3 Unscrew air preload assembly and damper Air Preload Assembly shaft assembly using an adjustable open end wrench Damper Cap Damper Shaft Assembly 4 Inspect SPV valve there should be a 025 6mm gap as shown in the photograph adjacent to the damper piston If the gap 1 on the opposite side the valve is defective and will need to be serviced 5 If it is necessary to remove the valve clamp the damper shaft using soft jaws and loosen the damper piston bolt Grasp the damper bolt piston SPV and SPV backing plate and remove as a Set from the damper shaft 6 Remove the SPV backing plate and SPV It is best to replace a defective valve If a replacemen
12. E EE L H 2006 SWINGER S TYPE SERVICE MANUAL REV NC 06 SWINGER SERVICE MANUAL Page 1 REV NC 06 SWINGER and S TYPE SPV SERVICE MANUAL INDEX Seen Pm re 2 o SETUP TUNING PERIODIC MAINTENANCE 083 AIR SPRING SYSTEM AND SPV AIR PRELOAD SWINGER AIR 5 COMPLETE SHOCK LESS HARDWARE COIL SPRING 6 6 HARDWARE REMOVAL AND INSTALLATION 7 DU BUSHING REMOVAL AND INSTALLATION 9 BOTTOMOUT BUMPER REPLACEMENT SWINGER COIL q REBOUND ADJUSTER KNOB REMOVAL AND INSTALLATION SWINGER COIL DAMPING SYSTEM BLEEDING SWINGER 3 WAY COIL SHOCKS DAMPING SYSTEM BLEEDING SWINGER 4 amp 6 WAY COIL SHOCKS DAMPING SYSTEM BLEEDING SWINGER 3 WAY AIR S TYPE SPV SHOCKS 15 DAMPING SYSTEM BLEEDING SWINGER 4 WAY AIR 27 SHOCKS 16 TROUBLESHOOTING 33 17 TABLE 1 FASTENER TORQUE REQUIREMENTS 35 wm SWINGER REAR SHOCK SERVICE KITS 386 Contact Information Answer Products Customer Service Department 28209 Ave Stanford Valencia CA 91355 Toll Free 800 423 0273 Direct 661 257 4411 FAX 661 775 1798 E mail warranty answerproducts com tech answerproducts com Web site www answerproducts com 06 SWINGER SERVICE MANUAL REV NC SECTION 1 INTRODUCTION This manual is intended to guide the user through basic service of Manitou Swinger rear shocks Service is supported by the identification of common parts and assemblies that have been assembled into Service Kits The purpose of this
13. ER A amp 6 WAY COIL SHOCKS CONT 14 Fill body and reservoir with oil On the 6 way shocks open the H L circuits all the way Using the IFP Removal tool cycle the oil thru the damping circuits between the main body and the reservoir Top off the oil levels in the shock and the reservoir Push the damper shaft back into the main body tap the assembly to remove any air that maybe trapped in the ports of the piston Once the end cap touches the shock body screw it in and tighten it to 61 78in lbs or 70 90 Kg cm Fully extend the damper shaft 15 Top up the oil level in the reservoir In a small container of oil tap the IFP to get the air out from under the o ring insert the IFP into the reservoir starting at about a 45 degree so that you burp the air out of the piston cavity Push the IFP past the threads in the reservoir 16 Back the IFP tool out fully as pictured Using the IFP tool push the IFP piston fully into the reservoir Screw the tool in hand tight until the flange is flush with the air reservoir body Using a 6mm hex wrench adjust the IFP Locating Tool so that the indicated travel matches the shock travel Make sure that the travel indication line is flush to the top of the tool 17 Install rebound adjuster needle pointed end first Push until the needle and o ring seat firmly in the damper shaft 06 SWINGER SERVICE MANUAL Page 21 REV NC DAMPING SYSTEM BLEEDING SWINGER A amp 6 WAY COIL SHOCKS CONT
14. EV NC DAMPING SYSTEM BLEEDING SWINGER WAY AIR SHOCKS CONT 4 Using 10mm soft jaws clamp the damper shaft and remove the eyelet as shown 5 Clamp the damper body eyelet in a vise using soft jaws and remove the damper assembly by removing the air piston as shown Remove from vise and drain damper oil into a container and discard Air Piston 6 Remove IFP Internal Floating Piston using Shock pump Temporarily reinstall the SPV Schrader valve It is not necessary to reinstall the valve core Point the damper body away from you while the SPV Schrader vale is pressurized This action creates backpressure behind the IFP to eject it The reservoir body should not be pointed at anyone during this step 06 SWINGER SERVICE MANUAL Page 24 REV NC DAMPING SYSTEM BLEEDING SWINGER 3 WAY AIR SHOCKS CONT 7 Change out o rings and seals where indicated of o rings seals in each assembly noted in photo and grease with a thick grease such as Motorex Bike Grease 2000 1 1 inside and 1outside NOTE The Following bleed procedures will work on all model years of the Swinger Air Shocks and S Type SPV Shocks 8 Insert IFP into damper body make sure the flat side of the piston face is facing the bottom of the damper body Push the IFP to bottom of damper body Install the SPV Schrader valve Secure the damper body upright in a vise and fill it with 5wt Motorex shock oil 9 Slide the Air Piston so that
15. G Spring tor Col Shock 200 57mm 9752 26 Rats 600_ _ _ 7 for Coil Shock 200 x 57mm 7 875 X 2 zen Rate 650 Spring for Coil Shock 215 X 63 8 5 X 2 5 Rate 450 E Spring for Coil Shook 215 X 63 8 5 X 2 5 Rate 500 G Spring for Coil Shook 215 X 63 8 5 X 2 5 Rate 550 G Spring for Coil Shook 215 X 63 8 5 X 2 5 600 0_ Spring for Coil Shook 215 X 63 8 5 X 2 5 Rate 650 G Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 250 ET Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 300 8 Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 350 Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 400 Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 450 Spring for Coil Shock 222 X 70 8 75 or 9 0 X 2 75 Rate 500 Retention Collar 83 2882 06 SWINGER SERVICE MANUAL Page 40 REV NC 2006 SWINGER COIL RIDE KITS Cont Revox KtDescpion Kit Swinger Ride Kits ay away eme sx Spring for Shock 280 X 70 8 75 or 9 0 X 2 75 Rate 250 c FEI Spring for Coil Shock 230 X70 8 75 or 9 0 X 2 75 Rate 300 G Spring for Coil Shock 230 X 70 8 75 or 9 0 X 2 75 Rate 350 G Spring for Shock 280 X 70 8 75 9 0 2 75 400 LE Suing for Gol Shook 290 X 700 75 807 X276 Bate 80 e ing for Coil Shock 230 X 70 i 75 or 9 0 X 2 5 Rate 500 MM NINE EI MEE
16. N Piston Air shock does not Failure of negative Replace air canister and seals return to full travel but spring has adequate air spring pressure Oil comes out of the Damping oil has Replace seals on the damper cap 14 15 Air Spring Schrader leaked past the and bleed the damping system valve damper cap 06 SWINGER SERVICE MANUAL REV NC SWINGER SHOCK TROUBLESHOOTING CHART CONT Section SWINGER AIR S TYPE SPV too low bumper spring Air Volume adjuster Damaged adjuster Replace o ring 15 on 4 Way Swinger piston o ring has no affect on damping rate Oil leak at base of air Worn or damaged Replace seals and bleed damping 4 canister seals allowing oil to system escape from damper chamber SWINGER COIL Spring System Hard bottomout Spring rate too low Replace with firmer spring 8 Worn bottomout Replace bottomout bumper bumper Damping System Oil leak at high and Worn or damaged Replace adjuster needle and or o 13 low speed adjuster needles rings compression adjuster and or o ring allowing screws oil to escape Oil leak at damper Worn or damaged Replace seals and bleed damping 12 13 shaft seals allowing oil to system escape from damper chamber Broken rebound knob User attempted to Replace rebound knob on coil shocks remove knob during spring replacement Air Volume adjuster Damaged adjuster Replace o ring on 4 or 6 Way piston o ring Swinger has no affect on damping
17. SWINGER SPV SPV F Sticker Kit G Ride Kits G Spring Collar Bottomout Bumper 06 SWINGER SERVICE MANUAL Page 43 REV NC 06 Swinger Rear Shock Service Kits Description CONT H Swinger Air Reservoir Volume Tool H Swinger Coil IFP Removal Tool H 6 Way Damper Body and Reservoir Clamp F H Rear Shock Compression Test Fixture 1 2 Soft Jaws 06 SWINGER SERVICE MANUAL Page 44 REV NC H 10mm Soft Jaws 06 SWINGER SERVICE MANUAL Page 45 REV NC
18. are as shown under HARDWARE REMOVAL and remove Spring as shown under RIDE KIT Section 2 Release SPV pressure from the air preload SPV Air Preload 06 SWINGER SERVICE MANUAL REV NC DAMPING SYSTEM BLEEDING SWINGER 3 WAY COIL SHOCKS CONT 3 Unscrew control eyelet and damper shaft Control Eyelet Damper Shaft Assembly assembly using an adjustable open end wrench Pour out damping oil and discard 4 Using pliers remove the rebound adjuster needle from end of the damper shaft 5 Inspect SPV valve there should be a 025 6mm gap as shown in the photograph adjacent to the damper piston If the gap is on the opposite side the valve is defective and will need to be serviced See service instructions in the section on DAMPING SYSTEM BLEEDING Swinger Coil Shocks with Reservoirs Remove IFP Internal Floating Piston using a shock pump to pressurize the damper body Point the damper body away from you as you pressurize the body and expel the IFP This action creates backpressure behind the IFP to eject it The reservoir body should not be pointed at anyone during this step 06 SWINGER SERVICE MANUAL Page 14 REV NC DAMPING SYSTEM BLEEDING SWINGER 3 WAY COIL SHOCKS CONT 7 Replace external o rings on damper cap Damper Cap 2 and IFP Grease with a thick grease such as Motorex Bike Grease 2000 8 Remove valve core from the Schrader valve in the damper body Reinstall IFP into the damper body P
19. are marked on the outside of each spring Example 300 X 2 75 Is a 3001 spring for a 2 75 Travel Shock To change out the coil spring Turn the spring preload adjustment ring to release any preload and back it away from the spring as far as possible Remove the retaining collar Slide spring over eyelet You may 06 SWINGER SERVICE MANUAL Page 9 REV NC e need to turn the rebound control knob in clockwise to its fully closed position NOTE Model year 2003 Swingers use a rebound knob that can be removed by taking out a hex screw Do not attempt to remove the 2004 2005 rebound knobs by unscrewing the 3mm hex in the knob it will break Slide the new spring over the eyelet Reinstall the spring collar so that it butts against the eyelet and the spring nests in the appropriate groove Turn the spring preload adjustment ring until it contacts the spring and then apply 2mm of preload pply Retaining Collar Spring Preload Adjustment Ring SECTION 9 BOTTOMOUT BUMPER REPLACEMENT SWINGER COIL 1 Remove hardware as shown under HARDWARE REMOVAL and remove Spring as shown under RIDE KIT Section 2 Release reservoir pressure from the air preload SPV Air Reservoir 4 amp 6W Swinger 06 SWINGER SERVICE MANUAL Page 10 REV NC Extend and clamp damper shaft in a vise using 12 7mm 500 soft jaws Answer PN 85 5148 Remove eyelet using adjustable open end wrench Slip off old bump
20. ck No Hardware 240mm Eye to Eye 76mm Travel B Shock No Hardware 267mm Eye to Eye 90mm Travel B T Swinger 6W Remote ReservoirHoseKit BL Swinger 6W Remote Reservoir Hose Fitting Kit B Bebound Kap Swinger 4 6W Reservoir Air Volume Adjuster CSC Comp Speed Adjuster KnobiNecdieskit I B Comp Speed Adjuster KnobiNeedles KitO Rings p mas SPVVave dB HiLCompression Assembly Jpc 83 2878 SelKt 6 Swinger 6W Remote ReservoirSealkit L t i Bulk Pack Coil Damper Shaft Wiper i Bulk Coil Damper Cap Internal Omg 838 S Bulk Pack Coil Damper Cap External O ring Lol 8827155 Bulk Pack Coil Bottom Out Bumber C 83 2716 Bulk Pack Coil Damper Piston Glide Ring Lpl mmm Bulk Pack 6way Adjuster Knob O ring Z 83278 Bulk Pack IFP Seal For 4 6way Wa 83 2719 a Pack 3 way IFP Quad Seal 83 2724 pri LE F 83 2252 83 2253 83 2254 Tools MU Tool for adjusting Swinger Air Reservoir Volume Too for locating Swinger IFP during bleed process DUBusingTool LH x Plunger for Removal of IFP Piston SwingerCol Tool for Bleeding Swinger Air amp Coil Reservoir Shocks H Fixture for Clamping 14mm Damper Shaft Shock Pump SPV Reservoir i INN 06 SWINGER SERVICE MANUAL REV NC 2006 SWINGER COIL RIDE KITS
21. d at the end of this section 3 Unscrew air preload assembly 4 Using 10mm soft jaws clamp the damper shaft and remove the eyelet as shown 06 SWINGER SERVICE MANUAL Page 28 REV NC e DAMPING SYSTEM BLEEDING SWINGER 4 WAY AIR SHOCKS CONT 5 Clamp the damper body eyelet in a vise using soft jaws and remove the damper assembly by removing the air piston and damper assembly using the Air Shock Cap Socket p n 85 4418 as shown Remove from vise and drain damper oil into a container and discard Remove the air canister 7 Remove air piston from canister NOTE Apply grease to the open canister end prior to removing the air piston this will assist removal You can also use a hex socket and extension to help push out the piston 1 Select a socket with an outside diameter of 1 025 1 045 26 0 26 5mm and add an extension to make it longer than the air canister 2 Install into air canister 3 Hold air canister and lightly tap socket extension on a soft surface 06 SWINGER SERVICE MANUAL Page 29 REV NC D VLAN DAMPING SYSTEM BLEEDING SWINGER 4 WAY AIR SHOCKS CONT 8 Remove IFP Internal Floating Piston using IFP removal tool 85 4413 Insert the removal tool into the top of the damper body Cover hole in tool with your thumb Point the reservoir body away from you and push the tool to the bottom of the damper body This action creates backpressure behind the IFP to eject i
22. er Install new bumper Larger diameter face of the bumper should face the eyelet Clean damper shaft threads with alcohol and apply Blue Loctite Install damper shaft in vise using soft jaws as shown above and torque per Table 1 Add air to re pressurize the air preload reservoir per instructions in the Owner s Manual SECTION 10 REBOUND ADJUSTER KNOB REMOVAL AND INSTALLATION SWINGER COIL Instructions in the 2004 Swinger Shock Owners Manual were incorrect when it stated that the rebound knob had to be removed to replace shock springs Turning the knob to its full clockwise setting is sufficient to provide clearance for removal Removal Hebound Knob 1 Remove control eyelet as shown under Bottom out Bumper Replacement Swinger Coil Remove 1 5mm hex set screw located under the control eyelet with the set screw pointed up Underneath the set screw is a spring and detent ball bearing Turn the eyelet over on a cloth rag and tap the eyelet to dislodge the spring and ball Unscrew the rebound knob from the eyelet Set Screw 06 SWINGER SERVICE MANUAL REV NC Installation Set Screw Spring Detent Ball 1 Installation is in reverse order Place a small amount of grease on the ball and rebound knob detents Screw in the knob and place the ball and spring in the set screw hole 2 Apply a small amount of blue Loctite to the set screw threads Screw in the set screw until it is flush with the eyelet Kn
23. ir Can O ring 83 2723 m E EN Bulk Pack 3 way IFP Quad Seal 83 2724 EE 83 2724 Heim Joint Mounting Hardware Swinger 3W LRS D 83 2273 06 SWINGER SERVICE MANUAL REV NC 2006 SWINGER AIR S TYPE SPV SHOCK SERVICE KITS CONT KitDescription LEI Swinger S Type sas VnT DUBuhingKt S DUBwhingKt LE Heim Joint SwingersWLRS seme Sticker Kit E 83 2250 832251 TBD ae Tool for adjusting Swinger Air Reservoir Volume Tool for locating Swinger IFP during bleed process LH Plunger for Removal of IFP Piston Swinger r HL Tool for Bleeding Swinger Air amp Coil Reservoir Shocks a Fixture to Hold and Compress Shocks ER Fixture for Clamping 10mm Damper Shaft Shock Pump Air Canister Shock Pump SPV Reservoir Fixture for Clamping Reservoir and Damper Body Swinger Air and Coil P High Pressure IFP Tool set 06 SWINGER SERVICE MANUAL Page 38 REV NC 2006 SWINGER COIL SHOCK SERVICE KITS Kit Description LEI Swigercol Revox 4Way amp Way ISX _ Schrader Valves 360 Degree SPV Schrader Air Valve Red A Eeer s Shock No Hardware 190mm Eye to Eye 50mm Travel Deiere een 218mm Eye to Eye A Shock No Hardware 222mm Eye to Eye 63mm Travel pawaq ee Shock No Hardware 230mm Eye Eye 70mm Travel B Sho
24. iston Piston in that controls the flow of oil during compression and rebound Damper Shaft Shaft attached to the damper piston that connects the two moving sections damping system and control eyelet of the shock together Damping System Controls compression and rebound rate speed The system also provides the peddling platform unique to shocks with the SPV technology DU Bushing Teflon guide bushing pressed into the eyelets Mounting hardware is inserted into the DU bushings and rotates within the bushing as need by the suspension design Eyelet Found on each end of the shock it is where the DU bushing and mounting hardware are and provides the connection between the shock and bicycle Internal Floating Piston IFP A floating piston that separates damping oil from the SPV air chamber or reservoir Mounting Hardware Spacers that allow shocks to be mounted into the wide variety of suspension designs Schrader Air Black in color it is the valve for pressurizing the air canister in an air shock Schrader SPV Red in color it is the valve for pressurizing the SPV system Seals O Rings Black synthetic rubber with a round cross section Primarily used for fluid sealing Seals Quad Seals Black synthetic rubber with an X cross section primarily used for sealing air Seals Wipers Teflon ring used for keeping debris out of quad seals guiding the damper piston and providing support Top
25. it is at the edge of the oil return port Slowly insert the damper shaft assembly into the damper body Make sure there are no air bubbles stuck to the piston as it is submerged in the oil A paper can help to dislodge any stubborn bubbles Once the air piston contacts the damper body screw it down and tighten to 61 78 in Ibs or 70 90 Kg cm 06 SWINGER SERVICE MANUAL Page 25 REV NC DAMPING SYSTEM BLEEDING SWINGER 3 WAY AIR SHOCKS CONT 11 Depress the damper shaft until it protrudes 12 5mm from the top of the air piston to the top of the damper shaft 12 Insert the needle and o ring into the damper shaft until they are firmly seated Put on the bottom out bumper and then hand tighten the rebound damper eyelet 13 Remove the valve core from the Schrader valve and fully extend the damper shaft from the damper body This will set the level of the IFP Replace the valve core 06 SWINGER SERVICE MANUAL Page 26 REV NC DAMPING SYSTEM BLEEDING SWINGER 3 WAY AIR SHOCKS CONT 14 Clamp the damper shaft in the soft jaw vise and tighten the damper control cap to 61 78 in lbs 70 90 Kg cm Pressurize the SPV chamber to check for leaks 15 Release air pressure from the SPV chamber and remove the entire Schrader valve assembly DO NOT compress the Damper Shaft Slide the air canister over damper shaft Once the canister clears the eyelet replace the Schrader valve and pressurize the SPV chamber to
26. l the needle and o ring fully seat in the damper shaft 16 Remove the assembly from the oil keeping the open end of the damper shaft pointing up Using soft jaws to protect the eyelet clamp the reservoir eyelet and torque the air piston per Table 1 17 Top up the oil level in the reservoir In a small container of oil tap the IFP to get the air out from under the o ring Insert the IFP into the reservoir starting at about a 45 degree angle so that you burp the air out of the piston cavity Push the IFP past the threads in the reservoir Only press the piston in just beyond the reservoir threads 18 Back the IFP tool out fully as pictured Using the IFP tool push the IFP piston fully into the reservoir Screw the tool in hand tight until the flange is flush with the air reservoir body Using a 6mm hex wrench adjust the IFP Locating Tool so that the indicated travel matches the shock travel Make sure that the travel indication line is flush to the top of the tool 06 SWINGER SERVICE MANUAL Page 32 REV NC 24 Remove the IFP location tool Once the tool is removed DO NOT move the damper shaft 25 Clean the air preload threads with alcohol Apply blue loctite 242 to air preload adjuster threads and grease threads Install the air preload adjuster and torque per Table 1 26 Clamp adjuster eyelet in soft jaws Grease air canister threads and screw canister onto eyelet Tighten using strap wrench on
27. lure to relieve air pressure could result in injury or possible death CAUTION The Swinger Shock uses precision machined aluminum and other soft alloy components Using correct tools for assembly is essential to prevent damage SECTION 2 SETUP TUNING PERIODIC MAINTENANCE Instructions for shock setup tuning and periodic rider maintenance 1 not covered in detail in this manual Please refer to the Manitou Swinger Rear Shock Owner s Manual PN 042105 for that information If you did not receive a manual you can download one at www answerproducts com or contact Answer Products Customer Service at 661 257 4411 06 SWINGER SERVICE MANUAL REV NC SECTION 3 GLOSSARY OF TERMS Air Canister Can that holds the air spring air in an air shock Air Preload Adjuster Located on the reservoir of SPV shocks It contains the red Schrader valve for setting the SPV pressure and a hex fitting for adjusting the air volume air preload Bottom Out Point at which a shock reaches full compression Control Eyelet C End Eyelet that is on the rebound adjuster end of a shock The air canister is attached to this end on air shocks and the spring retention collar is attached to this end on coil shocks Damper Eyelet D End Eyelet that is on the damper body end of a shock On SPV shocks this is the end that contains the SPV valve and reservoir if applicable Damper Body Section of shock that contains the damping system Damper P
28. manual will be to describe conditions that may drive the need for service and to provide installation instructions for the kits Due to the time consuming nature rear shock service at this time our primary focus Is to offer service kits that minimize the amount of downtime and labor involved As the program matures and we are able to gather feed back from our customers we may offer kits to a more detailed level Important information is highlighted in this manual by the following notations WARNING Failure to follow WARNING instructions could result in severe injury or death to the person inspecting or repairing the shock absorber or the shock absorber operator CAUTION A CAUTION a caution indicates special precautions that must be taken to avoid damage to the shock absorber NOTE A NOTE provides key information to make procedures easier or clearer Rear shocks by design contain gases and fluids under extreme pressure and warnings contained in this manual must be observed to reduce the possibility of injury or possible death Following these instructions can help you reduce the risk of being injured Any questions in regards to the information in this manual should be directed to Answer Products Customer Service at 661 257 4411 The Swinger Shock uses compressed air to provide fluid pressure in the damping system and spring resistance in Air models BOTH systems must be relieved of pressure prior to servicing these systems Fai
29. needed The core is removed using a standard core removal tool The assembly is removed by removing the core and unscrewing the assembly by eo a 3mm hex into the center of the Adiuster Eyelet SPV Air Preload Air Spring Schrader 4 For leaks in the air preload reservoir area 4W Swinger release all pressure replace the preload adjuster o ring Schrader valve core or Schrader assembly as needed 06 SWINGER SERVICE MANUAL Page 5 REV NC AIR SPRING SYSTEM AND SPV AIR PRELOAD SWINGER AIR S TYPE SPV CONT 5 f when you pressurize the air canister the shock collapses to its shortest travel position the shock has an air piston leak into the negative chamber Place the shock in the shock tester and extend it to its full travel Depress the adjuster eyelet Schrader while the shock is extended under load If it remains in the full travel position refer to the section on DAMPING SYSTEM BLEEDING Swinger Air for instructions on servicing the air canister and piston seals If the shock returns to the short travel position it is not serviceable and the entire shock must be replaced Attempting to service a shock with this condition could result in injury or possible death SECTION 5 COMPLETE SHOCK LESS MOUNTING HARDWARE AND COIL SPRING The highest level kit offered will be a complete shock without mounting hardware or coil springs for coil forks This kit is offered as a fast replacement where all that i
30. ob Detents 06 SWINGER SERVICE MANUAL Page 12 REV NC SECTION 11 DAMPING SYSTEM The damping system controls compression and rebound rate speed The system also provides the peddling platform unique to shocks with the SPV technology The main conditions requiring service you may encounter in regards to the damping system are leaks a Suspect SPV broken rebound adjuster knob or lose damper or reservoir body SPV VALVE INSPECTION If you are unable to achieve the pedaling platform after adjusting the shock per the Owner s Manual you will need to inspect the SPV Follow the instructions under the damping bleeding section for the shock in question in order to inspect the SPV LEAKS If oil is found to be leaking from the shock the seals and or o rings that seal that suspect joint must be serviced Once the system has lost oil the faulty seals must be replaced and the shock bled to restore the shock to full performance LOOSE DAMPER OR RESEVOIR BODY All Swinger service can be performed without removing the damper or reservoir bodies where they are threaded into a machined casting This joint is bonded in place during final assembly at the factory If either becomes loose during service remove the body and thoroughly clean the threads on each part Apply green Loctite the threads and use the Answer reservoir clamp PN 85 6037 to tighten the bodies SECTION 12 DAMPING SYSTEM BLEEDING SWINGER 3 WAY COIL SHOCKS 1 Remove hardw
31. s need is to change out the hardware and spring and then reinstall the shock Swinger Air Less Mounting Hardware Swinger Coil Less Mounting Hardware and Coil 06 SWINGER SERVICE MANUAL REV NC SECTION 6 MOUNTING HARDWARE REMOVAL AND INSTALLATION Mounting hardware is used to mount shocks to the various frame configurations Over time the hardware may wear between the mounting bolts or DU Bushing which will result in play in the connection Remove hardware using pliers as shown in Figure 1 DU Bushing Eyelet e Sr Figure 1 Figure 2 MOUNTING HARDWARE REPLACEMENT Hardware should have a slight press fit into the DU bushing and can be tapped in place with a rubber mallet or soft jaws in a vise Apply a small amount of thick grease such as Motorex Bike Grease 2000 PN 85 0033 to the hardware before installation There are virtually an infinite number of hardware combinations in use on bikes today When ordering hardware from Answer Products It will be necessary to identify the eyelet width overall width and mounting hole diameter MOUNTING HARDWARE REPLACEMENT CONT 1 Measure the hardware width 2 Measure mounting hole size Current hardware is typically designed to haa accept a 6mm or 8mm fastener 06 SWINGER SERVICE MANUAL REV NC SECTION 7 DU BUSHING REMOVAL AND INSTALLATION DU bushings are press fit into the shock eyelets at each end of the shock The hardware fits into the bushings and
32. t The reservoir body should not be pointed at anyone during this step 9 Change out o rings and seals where indicated of o rings seals in each assembly noted in photo and grease with a thick grease such as Motorex Bike Grease 2000 Air Canister Seal Guide 10 Install Air Canister Seal Guide onto damper body Lightly grease damper body and slide air canister over body Remove guide 06 SWINGER SERVICE MANUAL Page 30 REV NC DAMPING SYSTEM BLEEDING SWINGER 4 WAY AIR SHOCKS CONT 11 Grease inside of air canister and install air canister as shown The seal end of the air piston is installed first 12 Slide air piston on damper shaft assembly Oil Return Port so that it is at the edge of the oil return port on the shaft NOTE The following bleed procedures will work on all model years of the Swinger 4 way Air shocks 13 Fill the damper body and reservoir with 5wt Motorex fork oil Using the IFP Removal tool cycle the oil thru the damping circuits between the main body and the reservoir Top up the oil level in both the damper and the reservoir 14 Push the damper shaft back into the main body tap the assembly to remove any air that maybe trapped in the ports of the piston 06 SWINGER SERVICE MANUAL Page 31 REV NC D VLAN DAMPING SYSTEM BLEEDING SWINGER 4 WAY AIR SHOCKS CONT 15 Hold the assembly over the oil container Install rebound adjuster needle pointed end first Push unti
33. t SPV is not immediately available you can attempt to service the defective one However since the valve has already failed once there is no guarantee how long a repaired valve will remain functional 06 SWINGER SERVICE MANUAL Page 17 REV NC Gen VIAN Separate the two halves as shown Inspect Inspect two seals for damage the two seals for signs of damage Grease seal surfaces and reassemble When reassembled the valve will trap air inside and keep the two haves from nesting completely A good valve when fully compressed to a flat condition will smoothly return to its original state 025 6mm offset when released 7 Remove the damper cap and replace the internal o ring Reinstall cap onto shaft and reassemble the SPV and damping piston stack in reverse order Apply Loctite to damper piston bolt and torque per Table 1 Remove IFP Internal Floating Piston using IFP removal tool Insert the removal tool into the top of the damper body Cover hole in tool with your thumb Point the reservoir body away from you and push the tool to the bottom of the damper body This action creates backpressure behind the IFP to eject it The reservoir body should not be pointed at anyone during this step IER Air Preload 2 9 Replace external o rings on damper cap IFP and air preload assembly as shown Grease with a thick grease such as Motorex Bike Grease 2000 Damper Cap 2 06 SWINGER SERVICE MANUAL Page 18 REV NC
34. ush IFP to the bottom of the body Replace the valve core in the Schrader valve Note The following bleed procedures will Damper Cap Oil Return Port work on all year models of Swinger shocks 9 Slide damper cap on damper shaft assembly so that it is at the edge of the oil return port Secure the damper body up right in a vise Fill the damper body with owt Motorex fork oil Slowly insert damper shaft assembly into the damper body Make sure there are no air bubbles stuck to the piston as it is submerged in the oil A paper clip can help to dislodge any stubborn bubbles Once the cap contacts the damper body screw it in and tighten it per to 61 78 in lbs or 70 90Kg cm Compress the damper shaft until it protrudes from the damper cap 8 5mm when measured from the top of the cap to the top of the shaft See Picture 06 SWINGER SERVICE MANUAL Page 15 REV NC DAMPING SYSTEM BLEEDING SWINGER 3 WAY COIL SHOCKS CONT 11 Remove the valve core from the damper body and then insert the needle valve until the o ring and the needle are fully seated Holding the needle in position fully extend the damper shaft Then reinstall the valve core in the damper body 12 The IFP is now set to the proper level Install bottom out bumper and control eyelet as shown under the bottom out bumper Replacement section 13 Install spring as shown under Ride Kits 14 Pressurize the SPV chamber per the Owners Manual Guidelines SE
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