Answer Precision Suspension SX -E, SX, SX R, SX Ti, SX Carbon Ti suspension fork User manual

99 SX OWNERS MANUAL P/N:062167
TABLE OF CONTENTS
Consumer Safety Information
Warranty Information . . .
Installation Instructions . .
Maintenance .. . . . .
Adjusting the Ride Qualities.
Exploded Views .. . . .
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ANSWER PRECISION SUSPENSION
CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK
AVAILABLE. THE 1999 SX MODELS USE THE LATEST ONE PIECE OUTER LEG/ARCH TECHNOLOGY. BOTH
HAVE STATE OF THE ART MCU/SPRING COMPRESSION SYSTEMS. THE SX SERIES USE THE NEW TWIN
PISTON CARTRIDGE SYSTEM (TPC) THAT SURPASS ALL OTHER TYPES OF OIL DAMPED SYSTEM IN
PERFORMANCE AND DURABILITY.
Your SX Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1/8” threadless
steer tube. SX’s are available with the V-Brake cable hangerless arch, post style disk brake mounts, and have an optional
attachable cable hanger which is available through your dealer.
CONSUMER SAFETY INFORMATION
IMPORTANT: The SX Fork is a off road fork, and as such, does 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 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 removed from the crown. The steer tube and stanchions (inner legs)
are press fit assembled at the factory. Pressing them out will permanently damage the crown beyond repair and render it
unsafe for any continued use.
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 the SX Fork if any parts are broken, bent, cracked, or damaged. Contact your dealer or Answer Products
Technical Support, (805) 257-4411, 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 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 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.
INSTALATION INSTRUCTIONS
Insure that the proper steer tube has been delivered on your
SX. 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.
2.
Remove old forks from bicycle.
Measure and cut the steer tube to fit your bicycle head
tube.
3. Remove crown race from old forks and press onto SX
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
manufacturer’s instructions.
10. Install cantilever brakes and adjust per manufacturers
instructions.
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. Insure 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: All 99 SX Forks are equipped with a secondary catch
dropout.
Note: The SX comes equipped with a hangerless arch.
Brake cable hangers that attached to the arch are available
through your dealer. Part number 85-3800, 99 SX Brake
Cable Hanger Kit. See Figure 2
WARNING: When installing wheel or any new tire check
the minimum tire clearance. Measure from the highest
point on the tire to the bottom of the crown. The
minimum clearance allowed is:
2.75” (70mm) for 70mm travel forks
3.20” (80mm) for 80mm travel forks
Any less clearance can result in serious injury or death.
Figure 3
MAINTENANCE
IMPORTANT: The SX should not be used if any parts
appear to be or are damaged. Contact your local dealer or
Answer Products for replacement parts.
IMPORTANT: Use of fork boots is required to keep your
SX performing well and your warranty in effect. Use of
this fork with the boots removed will shorten the life,
reduce the performance and void the warranty.
Your SX Fork requires periodic maintenance, cleaning, and
inspection. Moisture and contamination may build up inside the
fork depending on the severity of riding conditions. To maintain
top performance it is recommended that the fork be periodically
disassembled, cleaned, dried and re-greased using the grease
ports located on the back of each outer leg. Figure 4
IMPORTANT: When filling the fork with grease through
the grease ports it is important to note the grease is being
forced between the upper and lower bushing. If the area is
overfilled the force of the grease may force the upper
bushing and dust seal out.
IMPORTANT: Before every ride you should:
1. Ensure that quick release skewers are properly
adjusted and tight.
2. Wipe the inner legs clean & check entire fork for any
obvious damage.
3. Check headset slack.
4. Insure that the front brake cable is properly seated in
the cable retainer & check brake adjustment
IMPORTANT: Maintaining the proper oil level in your
TPC is critical. Not enough oil will allow foaming and
reduce the performance. Too much oil will restrict travel
and may cause damage to the system and create and
unsafe riding condition. Finish reading this entire section
prior to making any changes to the oil level.
To check the oil level remove only the compression assembly
located in the top of the left leg. Leave the right side
compression stack (adjuster, MCU, spring assembly) in place
to keep the fork fully extended. Use a tape measure or “dip
stick” to determine the oil level. Oil level should be between
3.50” (90mm) and 5.75” (146mm) below the top of the crown
where the damping assembly screws in. For all SX models
with Lok-out the oil level should be between 3.75” (95mm)
and 4.25” (1.08mm). The recommended starting oil level is
4.00” (101mm). Use SAE 5WT for oil. (See Figure 5.)
ADJUSTING RIDE QUALITIES
SX TPC forks offer a wide adjustment range to suit individual
riding preference and rider weight by simply changing the
MicroCellular Elastomer (MCU’s). Fine tune adjustments can
be made using the preload adjusters located on top of the fork
crown. Softer blue Elastomer, and harder yellow Elastomer
are available from your Dealer.
NOTE: Since 98 and 99 SX model forks use a compression
stack in the right leg only, MCU’s and Springs used in
previous Manitou forks are NOT interchangeable with later
versions of SX model Forks.
Compression Spring Fine Tuning: Figure 6
Fine tuning adjustments to the spring rate are made by rotating
the adjuster knobs located on top of the crown. Note all 99
SX models use compression spring systems in the right leg
only. The right knob for all SX models is used to adjust
preload. Rotating the knob clockwise will firm the ride, adding
preload to the compression stack. Rotating the knob counter
clockwise will soften the ride. Four full revolutions will take
the adjuster from full soft to the extreme firm setting.
Compression Damping Fine Tuning: Figure 7
The 99 SX-E has TPC sport which is not adjustable. To adjust
the compression damping for the SX remove the compression
damping assembly from the top of the left leg. Adjust the set
screw (see exploded view), located in the valve seat, in to
increase compression damping and out to reduce the
compression damping. Try adjusting one full turn at a time.
To adjust the SX R, SX-Ti, and SX Carbon simply rotate the
compression damping knob located on top of the left leg and
crown. Rotating the knob clockwise will increase damping,
rotating the knob counter clockwise will reduce the damping.
Excessive damping will give you a harsh ride over sharp
bumps like rocky sections, but will feel good on large hits like
G-outs. Insufficient compression damping will bottom out in
the large hit G-outs and bob a little while climbing, but feel
plush on the sharp hits. A correctly adjusted fork will perform
good in all conditions.
Rebound Damping Fine Tuning: Figure 8
The 99 SX-E has TPC sport which is not adjustable. To
adjust the SX, SXR, SX Ti, and SX Carbon simply rotate the
rebound damping knob located on the bottom of the left leg.
Rotating the knob clockwise will increase the damping,
rotating the knob counter clockwise will reduce the damping.
Excessive damping will give you a harsh ride over repetitive
bumps (like breaking bumps) because the fork will pack up.
Insufficient rebound damping will make the fork over active
and top out. We suggest that you try adjusting your fork on
the very active side, or minimum rebound. Then try it over a
variety of terrain and tune in more rebound from there.
Figures 9, 10, 11, 12, 13 are schematics of the SX-E, SX.
SXR, SX Ti, and SX Carbon Ti fork models.
Lok-Out System Kit P/N 85-3734 Figure 14
Lok-Outs are available for all SX models. By turning the knob
_ turn CCW ,exposing the green sticker, the front fork will
have regular TPC suspension. By turning the knob _ turn CW,
exposing the red sticker, the fork will be locked out. A safety
blow off valve will open under extreme conditions to allow
some movement. To adjust the compression damping when
not using the Lok-Out. Remove the compression damping
assembly from the top of the left leg. Adjust the set screw (see
exploded view), located in the valve seat, in to increase the
damping and out to reduce the compression damping. Try
adjusting one _ turn at a time.
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