Manitou XVERT R, XVERT, XVERT TI, 98 XVERT User Manual

TABLE OF CONTENTS

Consumer Safety & Warranty information . . . 1

Installation Instructions . . . . . . . . . . 2

Spare Parts List . . . . . . . . . . . . . 3

Exploded View . . . . . . . . . . . . . 4

Maintenance & Disassembly . . . . . . . . 7

Inspection. . . . . . . . . . . . . . . . 8

Re-assemble . . . . . . . . . . . . . . . 8

Inner Fork Leg, Crown & Break Arch . . . . . 9

Adjusting the Ride Qualities. . . . . . . . . 10

Trouble Shooting . . . . . . . . . . . . . 11

ANSWER PRECISION SUSPENSION

CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK
AVAILABLE. THE 1998 XVERT FORK MODELS HAVE STATE OF THE ART MCU/SPRING COMPRESSION
SYSTEMS. THE XVERT SERIES ALL USE THE NEW TWIN PISTON CARTRIDGE SYSTEM (TPC) THAT
SURPASSES ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY.

Your 98 XVERT Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1/8Ó threadless
steer tube. 98 XVERT and XVERT R forks are available with the V-Brake cable hangerless arch.

CONSUMER SAFETY INFORMATION

IMPORTANT: The 98 XVERT Fork is an off road fork and as such, does not come with the reflectors for on road use installed.
Reflector bracket kit P/N 85-3674 is available through your dealer. Have your dealer or mechanic install the kit to meet the
Consumer Product Safety Commission's (C.P.S.C.) Requirements for Bicycles if the fork is going to be used on public roads at
any time. If you have questions regarding C.P.S.C. Standards contact your dealer.

1. Never remove or have the steer tube or stanchions (inner legs) removed from the crown. The steer tube and stanchions are press fit
assembled at the factory. Pressing them out will permanently damage the crown, steer tube, and stanchions beyond repair and render
them unsafe for any continued use. Stanchions may be removed from the upper and lower triple clamps.

2. Never attempt to thread a threadless steer tube. Machining threads will weaken the steer tube and cause an unsafe condition. The
only safe thing to do is to obtain the proper crown/steerer from your dealer.

3. Any other alterations or modifications to your fork should be considered unsafe. Contact Answer Products Technical Support
prior to modifying your fork in any way for safety information.

4. Do not use any Manitou Fork if any parts appear to be broken, bent, cracked, or damaged. Contact your dealer or Answer Products
Technical Support, [phone], if you have any questions concerning the integrity or condition of your fork.

5. Answer Products recommends that you periodically inspect your fork for wear and damage. Inspect the Crown, Inner Legs, and
Outer Leg Dropout and Brake Arch areas for cracks or damage. Before every ride check to ensure that the proper preload exists and
that the positive rebound stop is in working order to ensure that the fork can not over extend.

WARRANTY INFORMATION

Any Answer Products fork found by the factory to be defective in materials and/or workmanship within one year from the date of
purchase will be repaired or replaced at the option of the manufacturer, free of charge, when received at the factory, freight prepaid.
This warranty does not cover breakage, bending, or damage that may result from crashes or falls. This warranty does not cover any
fork that has been modified, subject to misuse or whose serial number has been altered, defaced or removed. This warranty does not
cover paint damage. Any modifications made by the user will render the warranty null and void. This warranty is expressly in lieu of
all other warranties, and any implied are limited in duration to the same duration as the expressed warranty herein. Answer Products
shall not be liable for any incidental or consequential damages.

If for any reason warranty work is necessary, return the fork to the place of purchase. In the USA, dealers should call Answer
Products for a return authorization number (RA#). At that time instructions for repair, return, or replacement shall be given.
Customers in countries other than USA should contact their dealer or local distributor.

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INSTALLATION INSTRUCTIONS

e

Figures 1,2, &3

Insure that the proper steer tube has been delivered on your fork.
The steer tube may need to be cut to length to fit your bicycle
head tube. If you are not familiar with this procedure or do not
have the proper tools to cut the steer tube it is recommended that
you seek a dealer with a qualified bicycle mechanic to perform
installation.

! WARNING

The steer tube and stanchions (inner legs) are a one time
precision press fit at the factory and cannot be removed from
the crown. Replacement of the entire crown/steerer
assembly must be done to change steer tube lengths or
diameters. Removing and replacing the steer tube or
stanchions will result in an unsafe condition and should
never be done.

1. Remove old forks from bicycle.

2. Measure and cut the steer tube to fit your bicycle head
tube.

3. Remove crown race from old forks and press onto 98
XVERT Steerer until seated on crown (Figure 1).

4. Clean and grease headset bearings and races of bicycle.

5 Install lower bearings on fork crown race.

6. Insert steer tube into head tube of frame.

7. Install upper bearings, spacers, and stem.

8. Install stem cap and screw, tighten until slack just

disappears.

9. Install handlebars to desired height. Torque stem handlebar

pinch screws and stem clamping system to manufacturerÕs
instructions.

10. Install brakes and adjust per manufacturers instructions.

FIGURE 1: RACE INSTALLATION

Note: All 98 Manitou Forks Forks are equipped with a
secondary catch dropout.

11. Adjust front wheel quick release to clear the 0.275"

(7MM) thick secondary catch dropout. The quick release
must be tightened after it is properly seated into the dropout
counter bores.
Ensure that there is adequate thread engagement (4 or more
threads with the release adjusted to lock) due to the wider
adjustment. Install front wheel to bicycle per manufacturers
specification.

12. Install brake cable per manufacturers instructions.

Note: The XVERT comes equipped with a hangerless arch.
Brake cable hangers that attach to the arch are available
through your dealer P/N 85-3644. See Figure 2

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! WARNING

FIGURE 2: BRAKE CABLE ROUTING

When installing wheel or any new tire check the minimum tir
clearance. Measure from the highest point on the tire to the

bottom of the crown. The minimum clearance allowed is as
follows: XVERT SC 3.2Ó (81MM)
XVERT R 4.0Ó (102MM)
XVERT TI 5.0Ó (129MM)
Any less clearance can result in accident resulting in serious
injury or death. Figure 3

FIGURE 3: TIRE CLEARANCE

SPARE PARTS: Table 1

Spare parts can be ordered through your local dealer. If you have any problems that you cannot resolve with your dealer, you may
call Answer Products Technical/Warranty Service Department at [phone], 8:00 AM to 5:00PM, Pacific Standard, Monday
through Friday, In addition helpful information can be found on the Answer Products Web Site, http://www.answerproducts.com.
Included on the site is down loadable manuals and e-mail technical support.

DESCRIPTION PART NUMBER

5 WEIGHT FORK OIL, 8 OZ BOTTLE 85-3470

2.5 WEIGHT FORK OIL, 8 OZ BOTTLE 85-3471
DH FORK CAR RACK ADAPTER 85-3534
98 VERT STICKER SET 85-3567
98 XVERT TI STICKER SET 85-3568
98 XVERT R STICKER SET 85-3569
1 1/8Ó TO 1 _Ó HEADSET KIT 85-3645
XVERT INNER LEG PLUG REMOVAL KIT 85-3654
100CC 5 WEIGHT FORK OIL 85-3656
98 OEM REFLECTOR BRACKET KIT 85-3674
X-VERT/R/HAYES BUSHING KIT 85-3733
98 SOFT KIT SX/SX R/SX RR 85-3538
98 MEDIUM KIT SX/SX R/SX RR 85-3839
98 FIRM KIT SX/SX R/SX RR 85-3840
ADJUSTER KIT ALUMINUM SX & XVERT 85-3848
98 CROWN STEER INNER LEG SET XVERT CROMOLY 85-3858
98 CROWN STEER INNER LEG SET XVERT ALUMINUM 85-3859
98 REBOUND DAMPER REBUILD KIT XVERT/R 85-3864
98 REBOUND DAMPER REBUILD KIT XVERT TI 85-3865
98 COMPRESSION DAMPING REBUILD KIT SX/R/XVERT 85-3866
98 COMPRESSION DAMPING KIT XVERT R 85-3868
98 COMPRESSION DAMPING REBUILD KIT XVERT TI 85-3869
98 SOFT RIDE KIT XVERT R 85-3871
98 MEDIUM RIDE KIT XVERT R 85-3872
98 FIRM RIDE KIT XVERT R 85-3873
98 CROWN STEER SET XVERT R ALUMINUM 85-3875
98 CROWN STEER SET XVERT TI ALUMINUM 85-3876
98 INNER LEG SMALL XVERT R 85-3877
98 INNER LEG LARGE XVERT R 85-3878
98 INNER LEG MEDIUM XVERT R 85-3879
98 INNER LEG SMALL XVERT TI 85-3880
98 INNER LEG LARGE XVERT TI 85-3881
98 INNER LEG MEDIUM XVERT TI 85-3882
98 XVERT RED CASTING ASSEMBLY 85-3890
98 XVERT/R MANGO CASTING ASSEMBLY 85-3891
98 BUSHING REMOVAL TOOL 85-3892
98 BUSHING SIZER TOOL 85-3893
98 XVERT HAYES MANGO CASTING ASSEMBLY 85-3895

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