Manitou Circus Expert Service Manual

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

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CIRCUS EXPERT SERVICE MANUAL

INTRODUCTION

This manual is intended to guide the user through the steps necessary to fully service and maintain
the Circus Expert 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.

CIRCUS EXPERT SERVICE MANUAL

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TABLE OF CONTENTS

SECTI ON PAGE N UMBER

REQUIRED TOOLS 5

EXPLODED DIAGRAM 6–8

CASTING REMOVAL & SERVICE 10–12

AIR SPRING SERVICE 13–17

TRAVEL CHANGE (OPTIONAL) 14-15

DAMPER SERVICE 18–19

CASTING INSTALLATION 20–22

COMPRESSION DAMPER INSTALL 23–26

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CIRCUS EXPERT SERVICE MANUAL

REQUIRED TOOLS

Below is a list of tools necessary for servicing the Circus Expert 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

• 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

• Downhill tire lever or at blade screwdriver

CIRCUS EXPERT SERVICE MANUAL

5

CIRCUS EXPERT Exploded view

6

CIRCUS EXPERT SERVICE MANUAL

CIRCUS comp Exploded view

CIRCUS EXPERT SERVICE MANUAL

7

CIRCUS sport Exploded view

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CIRCUS EXPERT 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

does not cover any defects or damage caused by alterations or modications of HAYES

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

use of HAYES products with parts of dierent manufacturers, improper use or abuse

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

modications made by the BUYER or any subsequent user will render the warranty null

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

limitation HAYES disclaims the implied warranties of merchantability or tness for

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)

CIRCUS EXPERT SERVICE MANUAL

9

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.

3

10

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

CIRCUS EXPERT SERVICE MANUAL

CASTING REMOVAL & SERVICE

Remove casting from fork. It is

4

5

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.

Remove old foam wiper rings. Apply

6

semi-bath uid to the new foam

wiper rings and install into fork
casting.

CIRCUS EXPERT SERVICE MANUAL

11

CASTING REMOVAL & SERVICE

Remove springs from lip of dust seals.

7

Using the Manitou 32mm Seal Press
(Manitou part number 172-31122) or
large socket press in the dust seals.
Reinstall springs onto seals.

12

CIRCUS EXPERT 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.

Remove the compression spring.

3

CIRCUS EXPERT SERVICE MANUAL

13

AIR SPRING SERVICE/TRAVEL CHANGE

Invert the fork and use a 22mm box end

4

5

wrench to unthread the compression rod
assembly from the stanchion.

Remove compression rod assembly from
the stanchion. Clean the assembly and
re-grease.

6

With the compression rod assembly
removed you can adjust the travel on the
aftermarket Circus Expert by adjusting
the spacer as shown.

14

CIRCUS EXPERT SERVICE MANUAL

Travel c hang e (optio nal)

AIR SPRING SERVICE/TRAVEL CHANGE

Travel c hang e (optio nal)

Liberally grease the piston seal and

7

outer surface with Slickoleum™ grease

Install air spring assembly into

8

stanchion. Using a 22mm crow’s foot,
tighten assembly end cap to 80-100 in
lbs [9.0-11.3 NM].

CIRCUS EXPERT SERVICE MANUAL

15

AIR SPRING SERVICE

Liberally grease the compression spring

9

10

outer surface with Slickoleum™ grease

Insert the compression spring and install
air cap onto stanchion. Tighten to 60-80
in lbs. [6.8-9.0 NM].

16

CIRCUS EXPERT SERVICE MANUAL

DAMPER SERVICE

Remove ABS+ knob using a 2mm hex

1

wrench. Remove knob carefully as there
are two detent ball bearings on springs
below the knob.

(ABS+ knob detent ball and springs.)

Unthread ABS+ compression damper

2

assembly from the stanchion using a
24mm socket and ratchet.

CIRCUS EXPERT SERVICE MANUAL

17

DAMPER SERVICE

Remove ABS+ compression damper

3

4

assembly from the stanchion.

Pour damper oil into a catch pan.

Using a 22mm box end wrench, unthread

5

18

the rebound damper assembly from the
fork stanchion.

CIRCUS EXPERT 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 lbs [9.0-

11.3 NM].

CIRCUS EXPERT SERVICE MANUAL

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CASTING INSTALL

Before lling the fork with fork oil and

1

2

installing the ABS+ compression damper,

the casting must rst be installed. This

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

Spread grease evenly along entire seal
inner diameter.

Fill the air chamber with a small amount

3

20

of air (30-50PSI). This will extend the
air spring assembly and make casting
installation easier.

CIRCUS EXPERT 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 over on
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.

Using an 8mm hex wrench tighten the

6

rebound damper rod and air spring
assembly to 35–40in lbs [3.95–4.5 Nm]
by turning them counter-clockwise. Do
not overtighten, doing so can damage
the end of the rods.

CIRCUS EXPERT 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 30-50PSI 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].

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CIRCUS EXPERT 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.

Pour additional 5wt fork oil into the

3

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.

CIRCUS EXPERT SERVICE MANUAL

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COMPRESSION DAMPER INSTALL

oil height chart 2017-2018

fork model oil height

Mastodon pro
mastodon 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.

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CIRCUS EXPERT SERVICE MANUAL

COMPRESSION DAMPER INSTALL

Insert the ABS+ compression damper

4

5

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

Install the ABS+ damper using a 24mm
socket and torque wrench, tighten the
damper to 60–80 in lbs [6.8–9.0 NM].

Install springs and ball bearings into

6

ABS+ top cap. A small dab of grease on
top of the spring can help hold the ball
bearings in place.

CIRCUS EXPERT SERVICE MANUAL

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COMPRESSION DAMPER INSTALL

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.

RIDER WEIGHT

LBS KGS
220 99.8 30-50 PSI [2.0-3.4 BAR]
200 90.7 20-35 PSI [1.4-2.4 BAR]
170 77.1 10-25 PSI [0.7-17 BAR]
140 63.5 5-15 PSI [0.3-1.0 BAR]
120 54.4 0-10 PSI [0-.07 BAR]

ACT AIR

MAX PRESSURE NOT TO EXCEED 50PSI (3.45 BAR)

MAX PRESSURE NOT TO EXCEED 50PSI (3.45 BAR)

SOFT SPRING FIRM SPRING

15 PSI [1.0 BAR]
10 PSI [0.7 BAR]

N/A
N/A

N/A

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CIRCUS EXPERT SERVICE MANUAL

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5800 W DONGES BAY ROAD MEQUON WI 53092