2012 MANITOU FORK Service Manual

1 2012 SERVICE MANUAL Hayes Performance Systems 5800 W. Donges Bay Rd. Mequon, WI 53092 Tel: 888.686.3472 Email: techsupport@hayesbicycle.com Web: www.hayescomponents.com Hayes Components Europe Dirnismaning 20 a 85748 Garching (b. Munich) Germany ph: +49 (0)89 203237450 Email: techsupportEU@hayesbicycle.com Web: www.hayescomponents.com

2 2012 SERVICE MANUAL This manual is intended to guide the user through the steps necessary to fully service and maintain the Maitou suspension forks. Suspension forks by design can contain preloaded springs, gases and ﬂuids under extreme pressures. Warnings contained in this manual must be observed to avoid damage to fork, serious injury or even death. We highly recommend that service to this fork be performed by a certiﬁed bi- cycle mechanic. Failure to follow instructions presented in this manual could lead to serious injury or death. Any questions about the servicing of this fork or the manual itself should be directed to Manitou Customer Support at: Phone: 888-686-3472 Email: techsupport@hayesbicycle.com INTRODUCTION

3 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 1. Section 1 – Casting Removal 2. Section 3 – Dust Seal Replacement 3. Section 4 – Coil Spring Service 4. Section 8 – Absolute+ Service 5. Section 10 – Casting Installation Circus Expert/Minute Expert/Tower Expert Forks 1. Section 1 – Casting Removal 2. Section 3 – Dust Seal Replacement 3. Section 7 – ACT Air Service 4. Section 8 – Absolute+ Service 5. Section 10 – Casting Installation R7 MRD Forks 1. 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 1. Section 1 – Casting Removal 2. Section 3 – Dust Seal Replacement 3. Section 5 – MARS Air Spring Service 4. Section 8 - Absolute+ Service 5. Section 10 – Casting Installation R7 Forks 1. Section 1 – Casting Removal 2. Section 3 – Dust Seal Replacement 3. Section 6 – TS Air Service 4. Section 8 – Absolute+ Service 5. Section 10 - Casting Installation Marvel Expert Forks 1. Section 1 – Casting Removal 2. Section 3 – Dust Seal Replacement 3. Section 8 – ISO Air Service 4. Section 8 – Absolute+ Service 5. Section 10 – Casting Installation Fork models

4 2012 SERVICE MANUAL Section 1 - Casting Removal 4 Section 2 - MRD Casting Removal 5 Section 3 - Dust Seal Replacement 6 Section 4 - Coil Spring Service 7 - 8 Section 5 - MARS Air Spring Service 9 - 10 Section 6 - TS Air Spring Service 11 - 12 Section 7 - ACT Air Spring Service 13 - 14 Section 8 - ISO Air Spring Service 15 - 16 Section 9 - Absolute+ Service 17 - 18 Section 10 - Absolute+ MRD Service 19 - 20 Section 11 - Casting Installation 21 Section 12 - MRD Casting Installation 22 Oil Height Chart 23 Fork Exploded Diagrams 24 - 34 table of contents PAGE NUMBER SECTION

5 2012 SERVICE MANUAL FIG. 1 FIG. 2 FIG. 3 casting removal 1 2 3 4 From the left leg dropout (Left when sitting on the bike), use a 10 or 11mm wrench to remove the compression rod screw. (Fig. 1) From the right leg dropout, if the fork has ad- justable rebound, the knob will need to be removed. Screw the rebound all the way in (clockwise) remove the 2mm hex screw inside the knob by turning it counter clockwise. Remove the knob by pulling gently away from the fork. (Fig. 2) Use an 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting. (Fig. 3) 4. Remove crown/steer/inner leg assembly from the outer leg casting by pulling ﬁrmly on the casting. If the fork uses the Semi bath Lubri- cation 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.

6 2012 SERVICE MANUAL mrd casting removal FIG. 1 FIG. 2 FIG. 3 FIG. 4 1 2 3 4 5 6 From the left leg dropout (Left when sitting on the bike), use a 10 or 11mm wrench to remove the compression rod screw. (Fig. 1) Remove the blue rebound knob on the bottom of the right leg with a 1.5mm Allen wrench. Be cau- tious of the detent balls and springs under the knob as they are very small and easily lost. Remove the detent balls and springs from the De- tent Housing. (Fig. 2) 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. 3) Using a 7mm or 8mm Allen wrench, turn the rebound assembly clockwise until it can be pushed into the casting. (Fig. 4) 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.

7 2012 SERVICE MANUAL dust seal replacement FIG. 1 FIG. 2 FIG. 3 FIG. 4 1 2 3 4 5 Before replacing the dust seals you will need to remove the lower casting. Refer to the Casting Removal or MRD Casting Removal instructions depending on which model fork you have. 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) Push down on the screwdriver. This will pop the seal out of the casting. Next remove the foam oil ring. (Fig. 2) Oil the foam rings (new or after cleaning the old rings) with a small amount of semi-bath oil and place them in the top of the casting above the Upper Bushings. (Fig. 3) Install the dust seal into the leg, use a large socket or piece of round tubing that is large enough in diameter to press on the outside shoulder of the seal rather than putting pressure on the seal- ing lip and spring so that they are not damaged. (Fig. 4) Repeat steps 1-4 for the opposite casting leg.

8 2012 SERVICE MANUAL coil spring service FIG. 1 FIG. 2 FIG. 3 FIG. 4 1 2 3 4 5 9 6 10 11 12 13 7 8 Using a 2mm Allen wrench, remove the knob from the preload adjuster. (Fig. 1) Remove the preload adjuster from the fork using a 20mm socket. (Fig. 2) Pull the coil spring out of the stanchion leg. Remove travel spacer and bottom out bumper from the end of the compression rod assembly. (Fig. 3) Remove the compression rod assembly from the stanchion leg. The compression rod comes out from the top of the stanchion leg. Turn the fork sideways or upside down to get the compression rod out of the leg. (Fig. 4) Inspect compression rod and top-out bumper. If damaged replace. Install compression rod assembly into the stanchion leg. Insert through the top of the stanchion leg and maneuver the rod until it drops through the hole at the bottom of the stanchion leg. Lightly grease the spring and install into stanchion leg. Install the preload adjuster into the fork leg. Tight- en down using a 20mm socket to 5,1- 6,2 Nm (45- 55 in. lbs). Using a 2mm Allen wrench, install the preload knob onto the adjuster. Tighten knob down to 0,5-0,7 Nm (4-6 in. lbs). Install bottom-out bumper and travel spacer onto the end of the compression rod. The casting needs to be removed prior to servicing the coil spring. Refer to the Casting Removal In- structions ﬁrst. Turn the preload knob counter-clockwise until it stops to relieve the preload on the spring.

9 2012 SERVICE MANUAL circus comp travel change FIG. 1 FIG. 2 1 2 TRAVEL CONVERSION ON MATCH AND CIRCUS COMP 80/100MM FORKS The Match/Circus Comp 80 and 100mm forks can be converted to either travel by moving a spacer on the compression rod. Follow steps 1-7 to remove the compression rod form the fork. 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. 1). The spacer being on the bottom on the ﬂange will cause the fork to have 80mm of travel. (Fig. 2) 100 80

2012 MANITOU FORK Service Manual

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