Manitou Mattoc Pro Service Manual

pro

2017

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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MATTOC PRO SERVICE MANUAL

INTRODUCTION

This manual is intended to guide the user through the steps necessary to fully service and maintain
the 2017 Mattoc Pro 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 pre-loaded 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.

MATTOC PRO SERVICE MANUAL

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TABLE OF CONTENTS

SECTI ON PAGE NUMB ER

REQUIRED TOOLS 5

EXPLODED DIAGRAM 6–10

CASTING REMOVAL & SERVICE 12–14

AIR SPRING SERVICE 15–19

DAMPER SERVICE 20–23

CASTING INSTALLATION 24–26

COMPRESSION DAMPER INSTALL 27–30

TRAVEL CHANGE (OPTIONAL) 31-33

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MATTOC PRO SERVICE MANUAL

REQUIRED TOOLS

Below is a list of tools necessary for servicing the 2017 Mattoc Pro 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

• Manitou Tool Kit - Manitou part number 172-31133
(This includes the Manitou Cassette Tool, 8mm thin wall socket, and at
ground 24mm socket)

• 8mm Hex Wrench

• 2mm Hex Wrench

• 20mm 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

MATTOC PRO SERVICE MANUAL

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MAttoc Pro 110 27.5 Exploded view

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MATTOC PRO SERVICE MANUAL

Magnum Pro 110 27.5+/29 Exploded view

MATTOC PRO SERVICE MANUAL

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MAttoc Pro 110 29+ Exploded view

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MATTOC PRO SERVICE MANUAL

MAttoc Pro 100 26 Exploded view

MATTOC PRO SERVICE MANUAL

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MAttoc Pro 100 27.5 Exploded view

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MATTOC PRO 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 Dust Seals Stripped or Worn Bolts

Rear Shock Fork/Shock Air Seals and/or O-rings Remote Lockout Cable

Mount Hardware Bearings Gloves

Handlebar grips Upper Stanchion Tubes Lower Stanchion Tubes(Dorado)

Tubeless Valves

MATTOC PRO SERVICE MANUAL

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