Manitou Systems DORADOPRO - EXPERT Owner's Manual
D O R A D O P R O - E X P E R T O W N E R ’ S M A N U A L
WARNING!
GENERAL CONSUMER SAFETY INFORMATION
BICYCLING IS A HAZARDOUS ACTIVITY THAT REQUIRES
THAT THE RIDER STAY IN CONTROL OF HIS OR HER
BICYCLE AT ALL TIMES. ANY FALL FROM YOUR BICYCLE
CAN RESULT IN SERIOUS INJURY OR EVEN DEATH.
READING THIS MANUAL ENTIRELY, AND PROPERLY
MAINTAINING YOUR BICYCLE AND SUSPENSION FORK,
WILL REDUCE THE POSSIBILITY OF INJURY OR POSSIBLE DEATH. PRIOR TO EVERY RIDE, YOU SHOULD
CLOSELY EXAMINE YOUR SUSPENSION FORK (AFTER
CLEANING) IN BRIGHT SUNLIGHT TO ENSURE THAT NO
DAMAGE HAS OCCURRED DURING THE COURSE OF
RIDING, TRANSPORTING, OR AFTER A FALL. PAY PARTICULAR ATTENTION TO THE CROWNS, INNER LEGS,
OUTER LEGS, DROPOUTS, BRAKE MOUNT AREAS, AND
“STRESS POINTS” (SUCH AS WELDS, SEAMS, HOLES,
AND POINTS OF CONTACT WITH OTHER PARTS ETC.)
DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY
SIGNS OF BENDING, LEAKING, CRACKING, CREAKING,
SQUEAKING, CLUNKING, OR ANY OTHER UNFAMILIAR
NOISES, OR IF IT IS MISSING ANY OF THE ORIGINALLY
SUPPLIED COMPONENTS. CONTACT YOUR DEALER OR
MANITOU CUSTOMER SERVICE AT 888/686-3472 IF YOU
HAVE ANY QUESTIONS CONCERNING THE FUNCTION,
INTEGRITY OR CONDITION OF YOUR FORK. ANY MODIFICATIONS NOT AUTHORIZED IN THIS MANUAL SHOULD
BE CONSIDERED UNSAFE. IF YOU ARE A MODERATE
OR AGGRESSIVE OFF-ROAD RIDER, OR RIDE AT LEAST
THREE TIMES A WEEK OVER ROUGH TERRAIN, MANITOU RECOMMENDS RETURNING YOUR SUSPENSION
FORK TO MANITOU EVERY 2 YEARS FOR A THOROUGH
INSPECTION. TAKE YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT TO
THE NEAREST AUTHORIZED SERVICE CENTER.
WARNING!
REFLECTORS
MANITOU FORKS ARE DESIGNED FOR OFF-ROAD USE,
AND AS SUCH, THEY DO NOT COME WITH PROPER
REFLECTORS FOR ON-ROAD USE. HAVE YOUR DEALER
OR MECHANIC INSTALL PROPER REFLECTORS TO
MEET THE CONSUMER PRODUCT SAFETY COMMISSION’S (C.P.S.C.) REQUIREMENTS FOR BICYCLES IF
YOUR FORK IS GOING TO BE USED ON PUBLIC ROADS
AT ANY TIME. IF YOU HAVE QUESTIONS REGARDING
C.P.S.C. REFLECTORS, PLEASE CONTACT YOUR DEALER.
WARNING!
APPROPRIATE USE OF PRODUCT
IT IS CRITICAL THAT YOU SELECT AND USE THE SUSPENSION FORK THAT IS APPROPRIATE FOR YOUR
ANTICIPATED RIDING STYLE, THAT YOU USE THE FORK
PROPERLY, AND FOLLOW THE WARNINGS CONTAINED
IN THE OWNER’S MANUAL, REGARDLESS OF THE RIDING STYLE. FAILURE TO PROPERLY MATCH THE FORK
TO YOUR FRAME OR RIDING STYLE COULD CAUSE
THE FORK TO FAIL, RESULTING IN A LOSS OF BICYCLE
CONTROL AND POSSIBLY SERIOUS INJURY OR DEATH
TO THE RIDER. IN ADDITION, AN IMPROPER COMBINATION OF FRAME AND FORK FOR THE INTENDED CATEGORY WILL VOID THE FORK’S WARRANTY. VISIT OUR
WEBSITE AT WWW.MANITOUMTB.COM/ FOR MORE
DETAILED INFORMATION AND GUIDANCE ON FORK SELECTION FOR YOUR RIDING STYLE. YOU SHOULD ONLY
ATTACH DISC BRAKES AND ANY OTHER ACESSORIES
TO THE DESIGNATED MOUNTING POINTS PROVIDED
ON THE FORKS. NEVER MAKE ANY MODIFICATION TO
YOUR FORK TO ATTACH ANY EQUIPMENT. THERE IS A
HEIGHTENED LEVEL OF VOLUNTARY RISK ASSOCIATED
WITH FREERIDING, DIRT JUMPING AND DOWNHILLING.
LARGER STUNTS/JUMPS MEAN MORE POTENTIAL FOR
EQUIPMENT ISSUES OR PROBLEMS AND THE LIKELIHOOD OF SERIOUS INJURY IS GREATLY INCREASED.
LEARN HOW TO PROPERLY RIDE AROUND OBSTACLES
ON THE TRAIL OR ROAD. HITTING OBSTACLES SUCH AS
CURBS, ROCKS, TREES, ROOTS, HOLES, OR SIMILAR
OBSTACLES STRAIGHT ON PUTS FORCES ON YOUR
FORK IT WAS NOT DESIGNED TO ABSORB.
LANDING IMPROPERLY AFTER A JUMP OR DROP ALSO
PUTS FORCES ON YOUR FORK IT WAS NOT DESIGNED
TO ABSORB. YOU SHOULD ONLY PERFORM JUMPS OR
DROPS WHEN A TRANSITION OR DOWN RAMP IS AVAILABLE TO HELP YOUR BICYCLE AND FORK ABSORB THE
IMPACT FORCES GENERATED DURING THE LANDING,
AND BOTH WHEELS SHOULD SMOOTHLY MAKE CONTACT WITH THE TRANSITION OR DOWN RAMP AT THE
SAME TIME. ANY OTHER TYPE OF LANDING IS DANGEROUS, AS IT COULD OVERLOAD THE FRAME OR FORK
AND RESULT IN A COMPONENT PART FAILURE AND AN
ACCIDENT OR COULD CAUSE YOU TO LOOSE CONTROL
OF THE BICYCLE, EVEN WITHOUT A COMPONENT PART
FAILURE. THE STEEPNESS AND LENGTH OF THE TRANSITION OR DOWN RAMP DEPENDS ON THE HEIGHT
FROM WHICH YOU JUMP OR DROP. EVERY SITUATION
IS DIFFERENT FOR EVERY RIDER; CONSULT WITH AN
EXPERIENCED RIDER BEFORE ATTEMPTING ANY JUMP
OR DROP.
FAILURE TO PROPERLY RIDE AROUND OBSTACLES ON
THE TRAIL, OR FAILURE TO PROPERLY LAND AFTER A
JUMP OR DROP COULD CAUSE YOUR FORKS TO FAIL,
RESULTING IN A LOSS OF BICYCLE CONTROL AND,
POSSIBLY, SERIOUS INJURY OR DEATH TO THE RIDER.
RIDE ONLY IN AREAS SPECIFICALLY DESIGNATED FOR
YOUR RIDING STYLE. DO NOT MISUSE OR ABUSE YOUR
FORKS. LEARN HOW TO RIDE, AND ALWAYS RIDE WITHIN YOUR ABILITIES. OUT-OF-CONTROL RIDING PUTS
THE EQUIVALENT OF YEARS OF HARD USE ON YOUR
FORKS AFTER ONLY A FEW RIDES. SOMETIMES THE
DAMAGE IS NOT OBVIOUS TO THE USER, BUT COULD
HAVE FAILED INTERNAL COMPONENTS OR DAMAGED
THE LOAD CARRYING ABILITIES OF THE MATERIALS
USED IN THE CONSTRUCTION OF THE FORK.
ALL SUSPENSION FORKS REQUIRE REGULAR MAINTENANCE AND REPAIR. THE HARDER YOU RIDE, THE
MORE OFTEN YOU MUST INSPECT AND MAINTAIN YOUR
FORKS. IF YOUR FORKS START MAKING ANY STRANGE
NOISES, CLUNKS, CREAKS, CLICKS, OR FEEL “LOOSE”
OR DIFFERENT IN ANY WAY, THEY SHOULD NOT CONTINUE BEING USED, BUT IMMEDIATELY HAVE A CERTI-
FIED MANITOU SERVICE CENTER INSPECT AND REPAIR
THE FORKS BEFORE YOU RIDE AGAIN. INSPECT YOUR
FORKS REGULARLY TO SEE THAT THEY ARE NOT BENT,
DEFORMED, CRACKED, or CHIPPED. If any of these
conditions exist the fork SHOULD NOT BE USED. A CERTIFIED MANITOU SERVICE CENTER should INSPECT AND
REPAIR THE FORKS BEFORE they are USED AGAIN.
IDENTIFY YOUR RIDING STYLE
It is critical that you select and use the suspension fork that is
appropriate for your anticipated riding style, that you use the
fork properly, and that you follow all warnings contained in this
owner’s manual regardless of riding style. Visit our website at
www.manitoumtb.com for more detailed information and
guidance on fork selection for your riding style.
The Dorado is a downhill-specic suspension fork. This discipline is only for professional or highly-skilled riders. It includes
use on relatively high jumps (or “drops”) and negotiating larger
obstacles such as boulders, fallen trees or holes. These forks
should be used only with disc brakes, as well as frames,
wheels, and other components specically designed for this
riding style.
WARNING!
“DOWNHILL”, “FREESTYLE” OR COMPETITIVE RIDING
TO RIDE DOWNHILL AT HIGH SPEED OR IN COMPETITION
IS TO VOLUNTARILY ASSUME A VERY HIGH RISK, AND
DOWNHILL OR FREESTYLE RIDING CAN LEAD TO
SERIOUS ACCIDENTS. “DOWNHILLING” SPEEDS CAN
APPROACH THOSE SEEN ON MOTORCYCLES WITH
SIMILAR HAZARDS AND RISKS. WEAR APPROPRIATE
SAFETY GEAR, INCLUDING A FULL-FACE HELMET,
FULL- FINGER GLOVES, AND BODY ARMOR. HAVE
YOUR BICYCLE INSPECTED BY A QUALIFIED MECHANIC
BEFORE EVERY EVENT, AND BE SURE IT IS IN PERFECT
WORKING CONDITION. ROUTINE AND THOROUGH MAINTENANCE IS EVEN MORE CRITICAL THAN WITH A BIKE
NOT USED FOR DOWNHILLING OR FREESTYLE RIDING.
CONSULT WITH EXPERT RIDERS AND RACE OFFICIALS
ON CONDITIONS AND EQUIPMENT ADVISABLE AT THE
SITE WHERE YOU PLAN TO RIDE DOWNHILL OR FREE-
• ENGLISH
MANITOU SUSPENSION FORKS
CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY. The Dorado is fully assembled and
ready to be installed on your bicycle. It comes equipped with a 1 1/8-inch steerer tube, disc brake mount adapters, and Hex
Lock Thru Axle. A handlebar-mounted reector must be used for on-road use, which is not included with your fork.
3DORADO PRO - EXPERT OWNER’S MANUAL
STYLE. SUSPENSION AND DISC BRAKES MAY INCREASE
THE HANDLING CAPABILITIES AND COMFORT OF YOUR
BICYCLE AND MAY ALLOW YOU TO RIDE FASTER, BUT
DO NOT CONFUSE THE ENHANCED CAPABILITIES OF
A SUSPENSION BIKE WITH DISC BRAKES WITH YOUR
OWN CAPABILITIES. INCREASING YOUR SKILL WILL
TAKE TIME AND PRACTICE. PROCEED CAREFULLY UNTIL YOU ARE SURE YOU ARE COMPETENT TO HANDLE
THE FULL CAPABILITIES OF YOUR BIKE. WHILE THE
RUGGED APPEARANCE OF MOUNTAIN BIKES AND DISC
BRAKES MIGHT SUGGEST THEY ARE INDESTRUCTIBLE,
THEY ARE NOT. CERTAINLY THEY ARE TOUGH AND
STURDY. DOWNHILL OR FREESTYLE RIDING OR RACING
PLACES EXTREME STRESS ON BICYCLES AND THEIR
COMPONENTS (LIKE IT DOES RIDERS). REPEATED
USE OF A FORK IN DOWNHILL RIDING MAY RESULT IN
SUDDEN OR PREMATURE FAILURE OF A BICYCLE OR
COMPONENT RESULTING IN SEVERE INJURIES. IF YOU
PARTICIPATE IN THESE TYPES OF EVENTS, THE LIFETIME OF THE PRODUCT MAY BE SIGNIFICANTLY SHORTENED DEPENDING UPON THE LEVEL AND AMOUNT OF
RACING. THE “NORMAL WEAR” OF A COMPONENT MAY
DIFFER GREATLY BETWEEN COMPETITIVE AND NONCOMPETITIVE USES, WHICH IS WHY PROFESSIONAL
LEVEL RIDERS OFTEN USE NEW BIKES AND COMPONENTS EACH SEASON AS WELL AS HAVE THEIR BIKES
SERVICED BY PROFESSIONAL MECHANICS.
WARNING!
REDUCED FORK LIFE
THE LIFE OF THIS FORK WILL BE REDUCED IF (1) YOU
USE IT MORE THAN THE AVERAGE USER, (2) YOU ARE
HEAVIER THAN THE AVERAGE RIDER, (3) THE TERRAIN
YOU RIDE ON IS ROUGHER THAN AVERAGE, (4) YOU
TEND TO BE HARDER ON COMPONENTS THAN THE
AVERAGE RIDER, (5) IT IS INSTALLED OR MAINTAINED
IMPROPERLY, (6) IT MUST ENDURE MORE ADVERSE ENVIRONMENTAL CONDITIONS THAN THE AVERAGE FORK
(I.E. SWEAT, CORROSIVE MUD, SALTY BEACH AIR ETC.),
AND/OR (7) YOU DAMAGE IT IN A CRASH, JUMP, OR
THROUGH OTHER ABUSE. THE MORE FACTORS YOU
MEET, THE MORE ITS LIFE WILL BE REDUCED; HOWEVER IT IS IMPOSSIBLE TO SAY HOW MUCH.
WARNING!
PRESS FIT CROWNS
THE STEERER TUBE AND STANCHION DROPOUTS ARE
PRESS FIT AT THE FACTORY AND SHOULD NEVER BE
REMOVED FROM THE CROWN OR DROPOUTS RESPECTIVELY. PRESSING THEM OUT WILL PERMANENTLY
DAMAGE THE CROWN BEYOND REPAIR AND RENDER
IT UNSAFE FOR ANY CONTINUED USE. NEVER ATTEMPT
TO THREAD A THREADLESS STEERER TUBE. CUTTING
THREADS WILL WEAKEN THE STEERER TUBE AND
CAUSE AN UNSAFE CONDITION. OBTAIN THE CORRECT
CROWN/STEERER FROM YOUR DEALER, OR CONTACT
MANITOU CUSTOMER SERVICE AT 888/686-3472.
REPLACEMENT OF THE ENTIRE CROWN/STEERER ASSEMBLY MUST BE DONE TO INCREASE STEERER TUBE
LENGTH. REMOVING AND REPLACING THE STEERER
TUBE WILL RESULT IN AN UNSAFE CONDITION AND
SHOULD NEVER BE DONE.
CAUTION!
INSTALLATION INSTRUCTIONS
Ensure that the proper steerer tube has been delivered on
your fork. The steerer tube may need to be cut to length to t
your bicycle head tube. If you are not familiar with this procedure, or do not have the proper tools to cut the steerer tube, it
is recommended that you seek a dealer with a qualied bicycle
mechanic to perform the installation. When cutting a steering
column of a fork make sure to measure twice before cutting;
forks cut too short during installation are NOT covered by the
warranty.
BREAK-IN
Your new fork is designed to break-in during your rst few
rides (about 20 hours total riding time). Prior to break-in, you
may notice your fork feels tight and slightly notchy. Following
the break-in period, your fork will feel much smoother and will
react to bumps much better than when you rst put it on your
bike. After 20 hours, you may want to recheck adjustments
(where applicable) to ne-tune the fork completely.
WARNING!
WHENEVER YOU INSTALL ANY NEW COMPONENT ON
YOUR BIKE, MAKE SURE YOU THOROUGHLY TRY IT OUT
CLOSE TO HOME (WITH YOUR HELMET) WHERE THERE
ARE NO OBSTACLES, TRAFFIC OR OVERLY CHALLENGING TERRAIN. MAKE SURE EVERYTHING IS WORKING
PROPERLY BEFORE GOING OFF ON A RIDE OR TO A
RACE.
CAUTION!
USE RECOMMENDED TORQUES AT ALL TIMES! TORQUE
SPECS ARE OPTIMIZED FOR SAFETY AND LIFE OF
PRODUCT. THE DORADO FORK USES A SPACER IN THE
LOWER CROWN CLAMP JOINT TO OPTIMIZE CLAMP
FORCE. MAKE SURE THESE ARE IN PLACE! YOU
SHOULD SEE EITHER TWO WASHERS IN THE SLOT ON
EACH BOLT OR 1 RECTANGULAR PLATE SPANNING
BOTH BOLTS.
FORK INSTALLATION – DUAL CROWN FORKS
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to t your bicycle head
tube (see CAUTION above). You can use your old fork as a
guide for cutting the steerer tube length. To determine which
upper triple clamp your frame will need see Table 5, page 15.
3. Remove the headset crown race from the old fork and press
onto the fork steerer until the race is seated snugly against the
top of the crown per the headset manufacturer’s instructions.
4. Clean and grease the headset bearings and races per the
headset manufacturer’s instructions.
5. Install the lower bearings (if applicable) on fork crown race
per the headset manufacturer’s instructions.
6. Insert the steerer tube into the head tube of the frame.
7. Install the upper bearings, stem spacers, upper triple clamp
and stem or integrated upper handlebar stem clamp.
8. Install the stem cap and bolt. Tighten the bolt to headset
manufacturer’s specications.
9. Install the handlebars and torque the stem pinch screws or
stem clamping system to stem manufacturer’s specications.
10. Install the brake levers and adjust per the brake
manufacturer’s instructions.
11. Adjust stanchion legs in the upper and lower crowns.
Visually make sure the spacer(s) are present in the lower
crown clamp joint (pinch slot). There should be either 2 small
washers held in place by each bolt, or 1 rectangular spacer
held by both bolts. The top of the lower clamp must be between 0mm-15mm [0.00-0.59in] below the top of the clamp
diameter and should be even. Both right and left outer legs
should be set at the same height +/- 1mm. Torque pinch bolts
to specs found in Table 6, page 15. DO NOT TAKE THIS
STEP LIGHTLY! Proper tightening technique is to tighten bolts
uniformly by alternating back and forth between bolts so as to
bring them up to torque simultaneously. This ensures the best
alignment and uniform distribution of torque loads.
12. To install the hex axle, simply slip the axle into the dropout, small axle hex side rst into the large dropout hex. (See
Image 2, page 6.) Thread the set bolt into the small hex side
and snug slightly. Push the fork up and down a few times to
center the axle and hub and then tighten all pinch bolts to
recommendations found in Table 6, page 15. Proper tightening
technique is to tighten bolts uniformly by alternating back and
forth between bolts so as to bring them up to torque simultaneously. This ensures the best alignment and uniform distribution
of torque loads. NOTE: The axel is designed to use a 20mm
X110mm hub. All other hub sizes are unsafe and will cause
the fork to fail and may lead to potential injury of rider.
54 DORADO PRO - EXPERT OWNER’S MANUALDORADO PRO - EXPERT OWNER’S MANUAL
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