Manitou 2012 Service manual

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:

WARNING

Failure to follow WARNING instructions could result in severe injury or death
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

to the

GENERAL WARNING: 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.

WARNING: Suspension forks uses preloaded 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.

CAUTION: Suspension forks use precision machined aluminum and other soft alloy components.

Using correct tools for assembly is essential to prevent damage.

2012 SERVICE MANUAL

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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

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

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

2

2012 SERVICE MANUAL

Table of Contents

Section

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

Page Number

Contact Information
Hayes Bicycle Group

6750 W Florist Ave
Milwaukee, WI 53218

Toll Free: [phone]
Direct: [phone]
FAX: [phone]
E-mail: [e-mail]
Web site: www.manitoumtb.com

2012 SERVICE MANUAL

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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 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)

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 pulling rmly 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.

FIG. 1

FIG. 2

4

FIG. 3

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)

3. Remove the detent balls and springs from the Detent
Housing. (Fig. 3)

4. Remove the Detent housing by unscrewing it counter­clockwise 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 7mm or 8mm Allen wrench, turn the rebound
assembly clockwise until it can be pushed into the cast­ing. (Fig. 5)

6. Remove crown/steer/inner leg assembly from the outer

leg casting by pulling rmly 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. 1

FIG. 2

2012 SERVICE MANUAL

FIG. 3

FIG. 4FIG. 5

5

Dust Seal Replacement

1. 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.

2. To remove the dust seals, rst remove the seal tension

springs (otherwise they will get damaged), then take a

large at-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)

FIG. 1

FIG. 2

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 put­ting pressure on the sealing lip and spring so that they are
not damaged. (Fig. 4) Repeat steps 1-4 for the opposite
casting leg.

FIG. 3

6

2012 SERVICE MANUAL

FIG. 4

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
sideways or upside down to get the compression
rod out of the leg. (Fig. 4)

FIG 1

FIG 2

6. Inspect compression rod and top-out bumper. If
damaged replace.

7. 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.

8. Lightly grease the spring and install into stan­chion leg.

9. Install the preload adjuster into the fork leg.
Tighten down using a 20mm socket to 5,1- 6,2 Nm
(45-55 in. lbs).

10. Using a 2mm Allen wrench, install the preload
knob onto the adjuster. Tighten knob down to 0,5­0,7 Nm (4-6 in. lbs).

11. Install bottom-out bumper and travel spacer
onto the end of the compression rod.

FIG 3

FIG 4

2012 SERVICE MANUAL

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12. The casting needs to be removed prior to ser­vicing the coil spring. Refer to the Casting Removal

Instructions rst.

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 1-7 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 ange on

the compression rod will cause the fork to have
100mm of travel. (Fig. 5). The spacer being on the

bottom on the ange will cause the fork to have

80mm of travel. (Fig. 6)

100mm 80mm

FIG. 5 FIG. 6

8

2012 SERVICE MANUAL

MARS Air Spring Service

WARNING 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. 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)

FIG. 1

FIG. 2

5. 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
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. 3

FIG. 4

2012 SERVICE MANUAL

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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 pis­ton. (Fig. 7)

11. Install air cap onto the stanchion leg using a 20mm
socket and tighten to 6,8-8,0 Nm [60-80 lbf*in]

12. Turn the fork upside down and insert the air push­rod 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 stan­chion 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 lbf*in]

FIG. 5

FIG. 6

10

FIG. 7

2012 SERVICE MANUAL