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

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CIRCUS EXPERT Exploded view

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CIRCUS EXPERT SERVICE MANUAL

CIRCUS comp Exploded view

CIRCUS EXPERT SERVICE MANUAL

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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

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