Hayes markhor Service Guide

Hayes Performance Systems

5800 W. Donges Bay Rd.

Mequon, WI 53092

Tel: [phone]

Email: [e-mail]

Web: www.hayescomponents.com

Hayes Components Europe

Dirnismaning 20 a

85748 Garching (b. Munich)

Germany

ph: [phone]

Email: [e-mail]

Web: www.hayescomponents.com

2

MARKHOR SERVICE MANUAL

INTRODUCTION

This manual is intended to guide the user through the steps necessary to fully service and maintain
the Markhor suspension fork.

We highly recommend that service to this fork be performed by a certied

bicycle 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: [phone]
Email: [e-mail]

Suspension forks by design can contain preloaded springs, gases and uids under

extreme pressures. Warnings contained in this manual must be observed to avoid damage to fork,
serious injury or even death.

MARKHOR SERVICE MANUAL

3

TABLE OF CONTENTS

SECTI ON PAGE N UMBER

REQUIRED TOOLS 5
EXPLODED DIAGRAM 6–7
CASTING REMOVAL & SERVICE 9–11
AIR SPRING SERVICE 12–15
TRAVEL CHANGE 13
DAMPER SERVICE 16–19
CASTING INSTALLATION 20–22
COMPRESSION DAMPER INSTALL 23–26

4

MARKHOR SERVICE MANUAL

REQUIRED TOOLS

Below is a list of tools necessary for servicing the Markhor fork.

• Safety Glasses

• Nitrile Gloves

• Lint-Free Rags

• Torque Wrench

• Slickoleum Grease

• Semi-bath Oil, 5/40w Synthetic - Manitou part number 85-0022

• 5wt Maxima Fork oil - Manitou part number 85-0023

• Standard Cassette Spline Tool

• 8mm Hex Socket

• 2mm Hex Wrench

• 20mm Socket

• 24mm Socket

• 22mm Box end Wrench

• 12mm Box End Wrench

• 12mm Socket

• Ratchet

• 22mm Crow’s Foot

• Fork/Shock Pump

• Pick

• Adjustable Wrench

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MARKHOR SERVICE MANUAL

5

markhor 29 & 27.5 Exploded view

MArkhor 27.5 & 29 Exploded view

abs+ Dam per

10b

15mm Ro und ax le

11

5

6

4

ITEM

1

2 AIR CAP 83-2654

3 AIR PISTON 82-2669

4 COMPRESSION ROD 80/100/120, M26.5X1 141-31870-K009

5

6 KNOB KIT 141-27177-K003

7 BUSHING KIT 85-5321

8 SEAL KIT 85-5281

9

10A KWIK TOGGLE DAMPER (KNOB INCLUDED) 141-33385-K001

10B ABS+ DAMPER (OPTIONAL UPGRADE, REPLACES 10A) 141-26532-K001

MARKHOR 27.5 PART DESCRIPTION

100 & 110 MM AXLE

CSA, 100, 1-1/8 STRAIGHT STEER, 41 OS, BLK 141-333382-B711

CSA, 100, 1-1/2 TAPER STEER, 44 OS, BLK 141-333382-B721

CSA, 110, 1-1/8 STRAIGHT STEER, 44 OS, NAT 141-34004-K711

CSA, 110, 1-1/2 TAPER STEER, 44 OS, NAT 141-34004-K721

CSA, 110, 1-1/8 STRAIGHT STEER, 44 OS, BLK 141-34004-B711

CSA, 110, 1-1/2 TAPER STEER, 44 OS, BLK 141-34004-B721

OUTER CASTING (INCLUDES SEALS AND BUSHINGS) 100 141-27200-K012

OUTER CASTING (INCLUDES SEALS AND BUSHINGS) 110 141-34006-K012

REBOUND DAMPER ASSEMBLY, M26.5X1, 100 141-33456-K002

REBOUND DAMPER ASSEMBLY, M26.5X1, 110 141-31870-K008

DECAL KIT 141-34007-K001

REBUILD KIT 141-28528-K004

7

4

PART NUMBER

9

8

ITEM

1

2 AIR CAP 83-2654

3 AIR PISTON 82-2669

4 COMPRESSION ROD 80/100/120, M26.5X1 141-31870-K009

5

6 KNOB KIT 141-27177-K003

7 BUSHING KIT 85-5321

8 SEAL KIT 85-5281

9

10A KWIK TOGGLE DAMPER (KNOB INCLUDED) 141-33385-K001

10B ABS+ DAMPER (OPTIONAL UPGRADE, REPLACES 10A) 141-26532-K001

11 15MM ROUND AXLE, 110 141-34005-K001

10a

6

1

3

MARKHOR 29 PART DESCRIPTION

100 & 110 MM AXLE

CSA, 100, 1-1/8 STRAIGHT STEER, 48 OS, BLK 141-333382-B911

CSA, 100, 1-1/8 STRAIGHT STEER, 51 OS, BLK 141-333382-B912

CSA, 100, 1-1/2 TAPER STEER, 48 OS, BLK 141-333382-B921

CSA, 100, 1-1/2 TAPER STEER, 51 OS, BLK 141-333382-B922

CSA, 110, 1-1/8 STRAIGHT STEER, 51 OS, NAT 141-34004-K911

CSA, 110, 1-1/2 TAPER STEER, 51 OS, NAT 141-34004-K921

CSA, 110, 1-1/8 STRAIGHT STEER, 51 OS, BLK 141-34004-B911

CSA, 110, 1-1/2 TAPER STEER, 51 OS, BLACK 141-34004-B921

OUTER CASTING (INCLUDES SEALS AND BUSHINGS) 100 141-27200-K013

OUTER CASTING (INCLUDES SEALS AND BUSHINGS) 110 141-34006-K013

REBOUND DAMPER ASSEMBLY, M26.5X1, 100 141-33456-K003

REBOUND DAMPER ASSEMBLY, M26.5X1, 110 141-31870-K008

DECAL KIT 141-34007-K001

REBUILD KIT 141-28528-K004

2

PART NUMBER

6

MARKHOR SERVICE MANUAL

HAYES PERFORMANCE SYSTEMS WARRANTY

Limited Warranty:

HAYES warrants its products to be free from defects in materials or workmanship under
normal intended use for a period of one year (two years in European Union countries)
from the date of purchase, subject to normal wear and tear. Unless otherwise prohibited
by law, any such defective products will be repaired or replaced at the option of HAYES
when received with proof of purchase, freight prepaid. This warranty does not cover
breakage, bending, or damage that may result from crashes or falls. This warranty

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products or by normal wear, accidents, improper maintenance, damages caused by the

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of the product, application or uses other than those set forth in the HAYES instruction
manual or failure to follow the instructions contained in the applicable HAYES instruction
manual. Instruction manuals can be found on-line at www.hayescomponents.com. Any

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and void. This warranty does not apply when the serial number or production code has
been deliberately altered, defaced or removed from the product. The cost of normal
maintenance or replacement of service items, which are not defective, shall be the
BUYER’s responsibility. If permitted by local law, this warranty is expressly in lieu of all
other warranties (except as to title), express or implied, and in particular and without

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purpose If for any reason warranty work is necessary, return the component to the place
of purchase or contact your dealer or local HAYES distributor. In the USA, contact HAYES
for a return authorization number (RA#) at [phone]. At that time, instructions
for repair, return, or replacement shall be given. Customers in countries other than the
USA should contact their dealer or local HAYES distributor.

Limitation of Liability.

Unless required by mandatory law, HAYES shall not be liable for any incidental, indirect,
special or consequential damages.

This warranty does not apply to normal wear and tear. Wear and tear parts are subject to
damage through normal use, failure to service according to recommendations or riding in
conditions other than recommended. The cost of normal maintenance or replacement of service
items, which are not defective, shall be paid for by the original purchaser. Wear and tear parts
that will not be replaced under warranty include but are not limited to the following:

- Bushings

- Rear Shock
Mount Hardware

- Handlebar grips

- Tubeless Valves

- Dust Seals

- Fork and Shock air
Seals and/or O-rings

- Bearings

- Upper Stanchion Tubes

- Stripped or worn bolts

- Remote Lockout Cable

- Gloves

- Lower Stanchion
Tubes(Dorado)

MARKHOR SERVICE MANUAL

7

CASTING REMOVAL & SERVICE

Remove rebound knob using a

1

2

2mm hex wrench.

Insert an 8mm hex wrench into the
end of the rebound damper rod and
turn the rod clockwise until it is
disengaged from the casting and
can be pushed into the casting.

8

3

Use a 12mm wrench to remove the
compression rod bolt.

MARKHOR SERVICE MANUAL

4

5

Remove casting from fork. It is
recommended this be done over
a drain pan as the lower casting
contains semi-bath oil. Allow oil
in casting to drain out before
continuing to next step.

Using a downhill tire lever or similar
tool, gently pry the dust seals out
of the casting.

6

Remove old foam wiper rings. Apply

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wiper rings and install into fork
casting.

MARKHOR SERVICE MANUAL

9

CASTING REMOVAL & SERVICE

Remove springs from lip of dust seals.

7

Using the Manitou 30mm Seal Press
or large socket press in the dust seals.
Reinstall springs onto seals.

10

MARKHOR SERVICE MANUAL

AIR SPRING SERVICE

Release air from the fork. Depress

1

2

Schrader valve a few times to ensure all
air is released.

Remove air cap using a 20mm socket.

3

Invert the fork and use a 22mm box
end wrench to unthread the air spring
assembly from the stanchion.

MARKHOR SERVICE MANUAL

11

AIR SPRING SERVICE

Remove air spring assembly from

4

5

the stanchion. Clean spring and rod
assembly and re-grease.
TIP: Ensure grease is worked into the ID
of the rubber top-out bumper to improve
ride quality and topping feel.

Thread a piston removal tool (or a long
M6 bolt as seen in the bottom photo)
into the air piston and remove it from the
stanchion . Once the piston is removed
clean the inside of the stanchion with
isopropyl alcohol and a lint free towel.
Inspect the inside and outside of the
stanchion for scratches or other damage.

12

MARKHOR SERVICE MANUAL

markhor comp 27.5 110 axle

AIR SPRING SERVICE/travel change

Optional

To change fork travel to 80mm or 100mm add or remove spacers and compression rod extender as
seen below. This is the same for the 27.5 and 29 version of the fork.

80mm 100mm 120mm

Note*
The comp rod service kit for Markhor, Manitou part number 141-31870-K009, includes all the
necessary components to make any travel version for either 27.5 or 29.

MARKHOR SERVICE MANUAL

13

AIR SPRING SERVICE

Liberally grease the piston quad seal

6

7

and outer surface with Slickoleum™
grease.

Install greased air piston into the top of
the stanchion and push it down past the
threads.

14

Add 8cc’s of Slickoleum™ grease to the

8

top of the air piston.

MARKHOR SERVICE MANUAL

AIR SPRING SERVICE

Install air cap onto stanchion. Tighten to

9

10

60-80 in lb [6.8-9.0 N m].

Install air spring assembly into stanchion.
Using a 22mm crow’s foot, tighten
assembly end cap to 80-100 in lb
[9.0-11.3 N m].

MARKHOR SERVICE MANUAL

15

DAMPER SERVICE

The Markhor fork can have two

1

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ABS+ or Kwik Toggle. The following
instructions will work for both. Remove
ABS+ or Kwik Toggle knob using a
2mm hex wrench. If the fork has ABS+,
remove knob carefully as there are two
detent ball bearings on springs below
the knob.

KWIK TOGGLE

(Kwik Toggle compression damper
without knob)

16

ABS+

(ABS+ knob detent ball and springs.)

MARKHOR SERVICE MANUAL

DAMPER SERVICE

KWIK TOGGLE

2

Unthread the Kwik Toggle compression
damper from the fork. You will need to
use the cassette tool and 1” wrench or
socket to remove the damper.

ABS+

Unthread the ABS+ compression
damper form the fork using a 24mm
socket.

3

KWIK TOGGLE

Remove Kwik Toggle compression
damper assembly from the stanchion.

MARKHOR SERVICE MANUAL

17

DAMPER SERVICE

ABS+

Remove ABS+ compression damper
assembly from the stanchion.

Pour damper oil into a catch pan.

4

18

Using a 22mm box end wrench, unthread

5

the rebound damper assembly from the
fork stanchion.

MARKHOR SERVICE MANUAL

DAMPER SERVICE

Remove rebound damper assembly

6

7

from the fork. Once the damper
assembly is removed, clean the inside of
the stanchion with isopropyl alcohol and
a lint free towel. Inspect the inside and
outside of the stanchion for scratches
and other damage. Inspect rebound
damper for damage as well. Replace if
necessary.

Install rebound damper into stanchion.
Using a 22mm crow’s foot and torque
wrench, tighten the rebound damper
assembly end cap to 80-100 in lb
[9.0-11.3 N m].

MARKHOR SERVICE MANUAL

19

CASTING INSTALL

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1

2

installing the ABS+ compression damper,

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ensures correct oil level. First apply a
generous amount of grease to the oil
seal/dust seal area of the casting.

Fill the air chamber with a small amount
of air (30-50PSI). This will extend the
air spring assembly and make casting
installation easier.

20

Fully extend the rebound damper rod.

3

MARKHOR SERVICE MANUAL

CASTING INSTALL

Slide casting onto the stanchion

4

5

assembly. Only slide the casting down
about halfway at this point. Take care
that the seals do not get folded upon
installation.

Insert 15cc’s (15ml) of semi-bath into
each casting leg. Once the semi-bath is
in the legs slide the casting the rest of
the way onto the stanchion assembly.

6

Using an 8mm hex wrench tighten the
rebound damper rod and air spring
assembly to 35–40 in lb [3.95–4.5 N m]
by turning them counter-clockwise. Do
not overtighten, doing so can damage
the end of the rods.

MARKHOR SERVICE MANUAL

21

CASTING INSTALL

Install the rebound knob using a 2mm

7

8

hex wrench. Add a small drop of blue
Loctite to the screw before installation
to prevent the screw from backing out
during riding.

Install compression rod bolt. It helps to
have at least 50psi in the air chamber
when tightening down the bolt to the
proper torque. Use a 12mm socket and
torque wrench and tighten to 45 –55 in lb
[5.1–6.2 N m].

22

MARKHOR SERVICE MANUAL

COMPRESSION DAMPER INSTALL

Pour 5wt Maxima fork oil into the

1

2

damper leg. Fill it up ¾ of the way.

Place a lint-free towel over the opening
in the damper leg and compress the fork
10-15 times.

3

Pour additional 5wt fork oil into the
damper leg until the oil height (space
from the top of the damper leg to the top
of the oil) is set at the proper level. See
following page for the correct oil height
depending on compression damper type
and fork travel. An oil height setting tool
used for motorcycle forks similar to the
one pictured makes this job easier.

MARKHOR SERVICE MANUAL

23

oil height chart 2018

All forks listed us 5w synthetic Maxima oil, Manitou part number 85-0023.

COMPRESSION DAMPER INSTALL

fork model oil height

Mastadon pro
mastadon comp

markhor (80/100mm)
markhor (120mm)

mattoc pro
mattoc comp
machete (abs+)
machete (kwik toggle, 90-120mm)
machete (kwik toggle, 130-140mm)
circus comp/expert
circus sport (ffd)
R7 PRO

75mm
87mm
92mm
97mm

75mm
87mm

87mm
87mm

91mm
87mm

83mm
83mm

oil
height

(refers to the air
space between the top
of the oil and top of
the fork leg)

dorado (see dorado service guide)

180-190mm

note

1. oil height is set with compression damper
removed.

2. oil height is set with fork fully extended
and casting installed.

24

MARKHOR SERVICE MANUAL

COMPRESSION DAMPER INSTALL

Insert the Kwik Toggle or ABS+

4

5

compression damper into the damper
leg. Ensure the damper is set in the
unlocked position when installing.

If installing an ABS+ damper use a
24mm socket and torque wrench, tighten
the damper to 60–80 in lbs [6.8–9.0 NM].
If installing a Kwik Toggle damper use
a 1” socket or crow’s foot, the cassette
tool, and a torque wrench to tighten
down the damper to the same torque

VSHFL¿FDWLRQ

6

If the damper is an ABS+, install springs
and ball bearings into ABS+ top cap. A
small dab of grease on top of the spring
can help hold the ball bearings in place.

MARKHOR SERVICE MANUAL

25

COMPRESSION DAMPER INSTALL

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5800 W DONGES BAY ROAD MEQUON WI 53092

Using a 2mm hex wrench, install the

7

8

ABS+ or Kwik Toggle knob.

Clean fork and use a shock pump to
set to desired pressure. Pressure chart
below for reference.

26

MARKHOR SERVICE MANUAL

2.

Remote Knob Set-Up Guide, Kwik Toggle

1. Turn Kwik Toggle hex full counter-clockwise (Open Posit ion). This will
help set the knob f inal posit ion in Normal Open mode.

2. Install short tab of the spring into the cross-hole in underside of knob.
Red Arrow indicates the side to insert into.

3. Long leg of the spring goes into the slot indicated in the cable stop.

4. The thumb tab on the knob will overlap the ramping surface of the
cable stop unt il installed.

3.

www.manitoumtb.com

4.

tech support: [e-mail]

eu tech support: [e-mail]

Remote Knob Set-Up Guide, Kwik Toggle

5. Insert the cable stop into the splines of the Kwik-Toggle top cap. Allow
the knob to lif t away several mm unt il the splines of cable stop engage
to the top-cap. Be careful the long tab on the spring does not separate
from its home.

6. Rotate the knob clock-wise to engage the hex beyond the ramp edge.
Image 6 shows the approximate f inal orientat ion.

7. Seat the knob and cable stop fully. Install the knob screw in the center.

6.

7.

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tech support: [e-mail]

eu tech support: [e-mail]

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5800 W DONGES BAY ROAD MEQUON WI 53092