Manitou Axel Super 2004, Axel Elite 2004, Axel Comp 2004 Service Manual

2004 SERVICE MANUAL

Axel Super
Axel Elite
Axel Comp

28209 Avenue Stanford, Valencia, California 91355
661 257-4411 | fax [phone] |

www.answerproducts.com

Table of Contents

Description Page

Introduction 3

Glossary of Terms 4

Disassembly Instructions 6

Assembly Instructions 7

Bushing Removal and Installation Instructions 11

Troubleshooting Chart 15

Axel Schematic and Torque Specifications 16

Axel Service Kit Chart 17

Contact Information

Answer Products Customer Service Department
28209 Ave. Stanford
Valencia, CA 91355

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

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INTRODUCTION

This manual is intended to guide the user through basic service of Manitou Axel 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 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 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

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 Answer Products Customer Service at
[phone].

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.

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GLOSSARY OF TERMS

Arch – A support that connects the two outer lower legs of the casting so as to keep them moving

in unison.

Boss – The word used to describe an outer casting that has brake posts for V-brakes or
cantilever brakes.

Bottom Out Bumper – A rubber or elastomer device that absorbs the shock that occurs when a
suspension is compression to its limit.

Bushings – A cylindrical sleeve between a fork stanchion tube (inner leg) and a fork outer
casting (slider), which facilitates the sliding movement between these two parts.

Coil Spring – A coiled piece of metal that acts as a spring to help suspend a fork.

Compression – The phase of the suspension operation in which the wheel travels up, or travels

closer to the frame. The suspension forks reaction to a bump in the trail.

Convertible Travel – A system used to alter the travel of a suspension fork. It requires moving a
travel clip on the compression rod to a different position. This operation is accomplished by
disassembling the fork and physically moving the travel clip on the compression rod.

Crown Steerer Assembly – the stanchion legs (inner legs), the fork crown, and the steer tube
pressed together as one assembly. This assembly is then finished by adding all of the fork
internals and then outer casting (slider).

Drop Out – The end of an outer casting (slider) where the wheel attaches.

Dust Boot – Usually a piece of rubber in the shape of a cylinder with baffles to allow it to

compress as the fork compresses through its travel. Its function is to help keep dirt and water
from getting into the inner legs of the fork.

Fork Crown – The component that joins the stanchion tubes (inner legs) to the steer tube of the
fork.

MCU – (Micro-Cellular Urethane) Special urethane that is filled with tiny air cells that act like
springs when the elastomer is compressed.

No Boss - The word used to describe an outer casting that has no brake posts for V-brakes or
cantilever brakes. This casting is to be used for disk brakes only.

O-Ring – A soft, flexible neoprene or Buna rubber ring with a round cross-section, which is used
for sealing and retention.

Outer Casting – (see Slider)

Preload – A condition of compressing a spring or elastomer before the operating loads are put on

the suspension, so that it provides a stiffer spring rate.

Rebound – The phase of the suspension operation in which the wheel returns to its original
position on the ground after compression.

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Reverse Arch Technology – Also known as RA. It is a system that is designed to move the arch
of a fork to the backside of a fork, rather than the conventional front position. It was designed to
provide greater rotational torque strength to an outer casting (slider), without adding additional
weight to the fork.

SAG – The amount a suspension fork compresses at rest with a normal load (rider’s weight).

Seal – A part, usually neoprene rubber or Buna, that keeps contaminants out and/or working

fluids in.

Spring Rate – The rate at which the resistance of a spring increases as it is compressed.

Slider/Outer Casting – The tube (outer casting leg) of the suspension fork that remains fixed to

the wheel. It slides up and down on the stanchion leg (inner leg).

Stanchion Legs – The suspension tube (inner leg) fixed to the fork crown. It remains stationary
during the operation of the suspension.

Steer Tube – The long cylindrical tube that extends from the top of the fork crown. Its function is
to be inserted into the bicycle head tube and attach the suspension to the bicycle frame.

Top Out Bumper – A rubber, coil spring, or elastomer device that absorbs the shock that occurs
when the load is taken off a suspension so that it is allowed to rebound to its limits

Travel – The amount that a wheel moves between the most compressed and the most extended
states of the suspension

Wiper Seal – A rubber material that is used as a seal to keep dirt and water out of the outer
casting legs. It is not designed to keep air pressure or extreme oil pressure in. Manitou has the
new Evil Genius wiper seals.

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2004 Axel Forks Disassembly and Rebuild Instructions

Disassembly Instructions

Removal of Outer Casting

1. From the left leg dropout (Left when sitting on the bike), use a 4mm hex wrench to
remove the compression rod screw.

2. From the right leg dropout, if the fork has adjustable rebound, the knob will need to be
removed. Remove the 2mm hex screw inside the knob and remove the knob.

3. Use a 8mm hex wrench to turn the damper clockwise until it can be pushed into the
casting.

4. Remove crown/steer/inner leg assembly from the outer leg casting.

Bushing Removal & Installation

Please refer to section on Bushing Removal & Installation.

Removal of Spring and Compression Rod Assembly - Non-Wind Down Travel
Adjust Forks

WARNING This fork uses a preloaded coil spring provide spring resistance. The spring

must be relieved of its preload prior to servicing. Failure to do so could result in injury or
possible death.

1. Turn spring preload adjuster knob counter clockwise until it stops. Remove 2mm hex
screw on spring preload adjuster knob and remove knob on the top left side of the fork.

2. Remove preload adjuster using 18mm socket.

3. Compress fork and remove the spring preload and spring assy.

4. Remove rubber bumper and clip on compression rod.

5. Turn crown/steer upside down to allow the comp rods to fall out of the inner legs.

Removal of Spring and Compression Rod Assembly - Wind Down Travel Adjust
Forks

1. Turn travel adjust knob (clear plastic knob on top of the left side of the crown) in a
counterclockwise direction until it stops. This insures that the fork is in its longest travel
and reduces any spring preload on the fork.

2. Remove the 2mm Allen screw from the knob. Use a 28mm socket to unscrew the top cap
assembly from the crown.

3. Pull spring out of inner leg. If spring will not come out, you must take the outer casting off
of inner legs (refer to Removal of Outer Casting instructions). Then remove the end cap
from the bottom of the left leg and remove the Wind Down compression rod assembly
and spring as a single unit through the bottom of the leg. You will find that on earlier
production fork models, that there is a nylon washer at the top of the compression rod
assembly that is holding the spring in place. Hold the spring in one hand and the
compression rod assembly in your other hand and pull the apart from each other at a
slight angle to each other. Once you have the two apart, remove the Allen bolt on top of
the compression rod with a 4mm Allen wrench and remove the nylon washer (Fig 2). Re­install the bolt without the washer, it will not affect the operation of the Wind Down
mechanism and insure that you will not have to take the whole fork apart in the future to
change ride kit springs. (Note: the spring that you remove should have another spring
(booster spring) intertwined within it)

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