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AMERICAN MADE
MANITOU SUSPENSION FORKS
CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY
AVAILABLE, A 2004 MANITOU FORK. This fork
is fully assembled and ready to be installed onto your bicycle. It comes equipped
with a 11/8-inch threadless steerer tube and may also be available in a disc brake
only version. A handlebar-mounted reflector must be used for on-road use, which
is not included with your fork.
2004 MANITOU MINUTE FORK LINE
MINUTE ONE ............100-130 MM RAPID TRAVEL WIND-DOWN / COIL SPRING /
STABLE PLATFORM VALVE DAMPING / HOLLOW CROWN /
RA CASTING
MINUTE TWO ...........100 OR 130 MM TRAVEL / AIR-COIL SPRING / STABLE
PLATFORM VALVE DAMPING / HOLLOW CROWN / RA
CASTING
MINUTE THREE ........100/130 MM RAPID TRAVEL ADJUST / AIR-COIL SPRING /
STABLE PLATFORM VALVE DAMPING / HOLLOW CROWN /
RA CASTING
You can also download this manual at www.answerproducts.com.
BICYCLING IS A HAZARDOUS ACTIVITY
THAT REQUIRES THAT THE RIDER STAY IN
CONTROL OF HIS OR HER BICYCLE AT ALL TIMES. READING THIS MANUAL
ENTIRELY AND PROPERLY MAINTAINING YOUR BICYCLE AND SUSPENSION FORK
WILL REDUCE THE POSSIBILITY OF INJURY OR POSSIBLE DEATH. PRIOR TO RIDING YOUR BICYCLE, YOU SHOULD INSPECT YOUR SUSPENSION FORK TO ENSURE
THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF PREVIOUS RIDING OR
ASSEMBLY. DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF
BENDING, CRACKING, CREAKING, LEAKING, OR IF IT IS MISSING ANY OF THE
ORIGINALLY SUPPLIED COMPONENTS. ANY FALL FROM YOUR BICYCLE CAN
RESULT IN SERIOUS INJURY OR EVEN DEATH. FOLLOWING THESE INSTRUCTIONS
CAN HELP YOU REDUCE THE RISK OF BEING INJURED. IF YOU ARE A MODERATE
OR AGGRESSIVE OFF-ROAD RIDER, OR RIDE AT LEAST THREE TIMES A WEEK
OVER ROUGH TERRAIN, ANSWER RECOMMENDS RETURNING YOUR SUSPENSION
FORK EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE. TAKE YOUR
FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT
TO ANSWER PRODUCTS, OR YOU MAY CALL ANSWER TO HAVE YOUR FORK
SHIPPED DIRECTLY AT (800) 423-0273.
IMPORTANT: The Manitou fork is an 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.
CONSUMER SAFETY INFORMATION
Never remove or have the steerer tube or stanchions removed from the crown.
The steerer tube and stanchions (inner legs) are press fit at the factory. Press fit
inner legs have higher performance versus bolt-in inner legs, but can not be
pressed out. 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. The only safe thing to do is to obtain the proper crown/steerer from
your dealer, or contact Answer Customer Service at (800) 423-0273. Any other
alteration or modification to your fork should be considered unsafe. Contact
Answer Customer Service prior to modifying your fork in any way for safety information.
Do not use the fork if any parts are broken, bent, cracked, or you suspect may be
damaged. Contact your dealer or Answer Products Customer Service at (800) 4230273 if you have any questions concerning the integrity or condition of your fork.
Answer Products recommends that you periodically inspect your fork for wear and
damage. Inspect the crown, inner legs, outer legs, dropouts and brake arch areas
for cracks or damage.
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 (or two years in EU countries) 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 with original purchase
receipt to the place of purchase. 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.
INSTALLATION INSTRUCTIONS
The steerer 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
steerer tube, it is recommended that you seek a dealer with a qualified bicycle
mechanic to perform installation.
THE STEERER 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 INCREASE STEERER TUBE
LENGTHS OR CHANGE DIAMETERS. REMOVING AND REPLACING THE STEERER
TUBE OR STANCHIONS WILL RESULT IN AN UNSAFE CONDITION AND SHOULD
NEVER BE DONE.
BREAK-IN
Your new fork is designed to break in during your first 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 first put it on your bike. After 20
hours, you may want to recheck adjustments (where applicable) to fine tune the
fork completely.
FORK INSTALLATION
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube (see WARNING
above). You can use your old fork as a guide for cutting the steerer tube
length.
3. Remove the headset crown race from the old fork.
4. Install headset and fork per headset manufacturer’s instructions.
5. Install the handlebars and stem to the stem and handlebar manufacturer’s
instructions.
6. Install the brakes per the brake manufacturer’s instructions.
7. To install the front wheel adjust the front wheel quick release to clear the secondary dropout safety tabs. Secure wheel per quick release manufacturer’s
instructions.
8. Install the brake cable per brake manufacturer instructions. Ensure that the
front brake cable is properly routed. Make sure the brake line is not crimped
or contacts the tire as the fork moves through its travel.
WHEN INSTALLING THE WHEEL WITH A PROPERLY INFLATED TIRE, CHECK TO MAKE SURE THE FORK ACHIEVES
MINIMUM TIRE CLEARANCE.
1. MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM OF THE
BRAKE ARCH, SEE FIGURE A. SEE TABLE 1 FOR MINIMUM BRAKE ARCH
CLEARANCE.
2. MEASURE THE TIRE AT MAXIMUM WIDTH, SEE FIGURE B. SEE TABLE 1 FOR
MAXIMUM TIRE WIDTH.
TABLE 1: WHEEL CLEARANCE
MINIMUM BRAKE ARCH
CLEARANCE
(See Figure A)
MAXIMUM
TIRE WIDTH
(See Figure B)
8.5 mm
60 mm
IMPORTANT: Failure to properly route and securely attach the front brake
cable to the fork can cause serious injury or death. This fork should not be used
if any parts appear to be or are damaged. Contact your local dealer or Answer
Products for replacement parts.
A
B
INITIAL SET-UP
RAPID TRAVEL WIND DOWN: MINUTE ONE
MEASURING TRAVEL
To change the travel with Rapid Travel Wind Down, just turn the knob located at
the top of the left leg (from a rider’s perspective) clockwise for shorter travel and
counterclockwise for longer travel. There is a dial indicator to determine the travel
you are in. The number that is at the back of the crown indicates your current travel setting. Do not attempt to activate this travel adjust feature while riding.
To determine which travel your fork is in, simply measure the distance from the
top of the seal area on the lowers (or the bottom of the fork boot) to the bottom of
the crown. See Table 2 to determine travel.
MAINTENANCE
TABLE 2: TRAVEL MEASUREMENT
FORK TRAVEL
SEAL TO CROWN MEASUREMENT
100 mm
Around 112 mm
130 mm
Around 142 mm
Your fork requires periodic maintenance, cleaning and inspection. This
is because 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-lubricated. You
can download service and tuning instructions on the web at www.answerproducts.com.
MEASURING SAG
You’ll need a tape measure, a pencil, a piece of paper and a helper.
1. Start by removing the red air cap located on the top of the right leg (from the
rider’s perspective) and, using a dedicated SPV pump (Manitou Part #854161), inflate the fork to 50 psi.
2. Measure the distance from the front axle’s centerline to the bottom of the
upper crown when no one’s sitting on the bike and write this distance down.
(Remember the exact locations of the two points because you’ll need to use
them later.)
3. Have the rider sit on the bike and measure the distance between the same
two points as in step one. It’s important to be in the normal riding position
(weight centered) with your feet on the pedals.
4. Subtract the second measurement from the first. The resulting measurement
is the static sag (See Table 3).
5. On air-coil forks, remove the air cap located on the top of the left leg and,
using a dedicated shock pump (Manitou Part #85-4069), inflate the fork with
the desired pressure (75% of rider weight for 80 mm travel forks, or 50% of
rider weight for 100 mm and above). Be aware that sometimes air systems
lose a small amount of pressure when the pump is removed, so you may
want to check exactly how much your pump loses by reinstalling it after you
have set and checked pressure.
6. If adjusting the fork does not provide the proper sag you may require a new
ride kit. Please see recommended ride kits below.
TABLE 3: SAG MEASUREMENT
FORK TRAVEL
SAG
100 mm
18-24 mm
130 mm
27-30 mm
REBOUND DAMPING ADJUSTMENT
Blue rebound adjusters on Manitou forks are located on the bottom of the right
fork leg. Turning the knob clockwise (as you are looking at the fork from the bottom) increases rebound damping, while turning the knob counterclockwise
decreases rebound damping.
SPV DAMPING ADJUSTMENT
With SPV damping, your suspension’s compression damping characteristics and
position sensitivity can be set with an SPV pump (Manitou part #85-4161). For
proper function of your SPV damping system use the following procedure.
1. Start by removing the red air cap located on the top of the right leg (from the
rider’s perspective) and, using a dedicated SPV pump (Manitou part #854161), inflate the fork to 50 psi.
2. Check sag per procedure above.
3. Fine tune SPV pressure to preference. More pressure will create more compression damping, hold the bike up more and pedal better. Less pressure will
create less compression damping, allow more sag, and be more responsive
and supple. Do not run SPV pressure below 30 psi or above 100 psi.
4. Fine tune SPV volume to preference. With a 16 mm socket wrench or the SPV
16 mm volume adjust socket (part #85-3007), you can adjust the air volume
in your SPV suspension. The volume adjust hex is colored red and located on
top of the right leg. Turning the volume adjuster inwards will create a more
progressive damping effect and make the suspension firmer from mid-stroke
to bottom out. Turning the volume adjuster outwards will make the suspension more linear in compression damping and have a softer finish.
Refer to the website for additional information about your SPV suspension.
RAPID TRAVEL ADJUST: MINUTE THREE
To change the travel with Rapid Travel Adjust, just turn the knob located at the
bottom of the left leg (from a rider’s perspective) forward for the longer travel
position and rearward for the shorter travel position. Compressing the fork slightly
is required to release or lock the fork into a different travel position. Do not
attempt to activate this travel adjust feature while riding.
SUGGESTED SERVICE INTERVALS FOR MINUTE FORKS
Short, Sporadic Rides
Long, Frequent Rides
Normal Conditions
Disassemble fork per Service
Manual; clean out casting and
replace Semi Bath oil every 6
months. Service SPV damping systems by changing the damper
oil every year. Grease spring stack
as needed. On air fork models,
check the oil level sitting on top of
the air piston every 2 months per
directions found on web site.
Disassemble fork per Service
Manual; clean out casting and
replace Semi Bath oil every 4
months. Service SPV damping
systems by changing the damper
oil every year. Grease spring stack
as needed. On air fork models,
check the oil level sitting on top of
the air piston every 6 weeks per
directions found on web site.
Severe Conditions
Disassemble fork per Service
Manual; clean out casting and
replace Semi Bath oil every 4
months. Service SPV damping systems by changing the damper
oil every year. Grease spring stack
as needed. On air fork models,
check the oil level sitting on top of
the air piston every 6 weeks per
directions found on web site.
Disassemble fork per Service
Manual; clean out casting and
replace Semi Bath oil every 3
months. Service SPV damping
systems by changing the damper
oil every year. Grease spring stack
as needed. On air fork models,
check the oil level sitting on top of
the air piston every 4 weeks per
directions found on web site.
IMPORTANT: Before every ride you should:
1. Ensure that quick release skewers are properly adjusted and tight per quick
release manufacturer’s instructions.
NOTE: Forks with standard dropouts are equipped with dropout safety tabs to
retain the wheel in the fork in the event the quick release comes loose.
2. Wipe the inner legs and clean the fork. Check the entire fork for any obvious
damage. Do not use the fork if any parts are broken, bent, cracked, or you
suspect may be damaged.
3. Check the headset for proper adjustment per headset manufacturer’s instructions.
4. Ensure that the front brake cable is properly routed and check brake adjustment.
CHECKING OIL LEVEL
IMPORTANT: Setting the proper oil level in your damped suspension fork is
critical. The damping is located in the right leg of your fork. 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 an unsafe riding condition. Refer
to www.answerproducts.com for up to date information on checking and setting
oil levels.
NOTE: We recommend Motorex SAE 5WT suspension fork oil.
If you have any questions regarding your 2004 Manitou suspension fork in the
U.S., contact the Answer Customer Service Department at (800) 423-0273. For
information outside of the U.S., contact your authorized Manitou dealer or distributor.
You can also log on to www.answerproducts.com and download this manual or see
detailed instructions on how to service your suspension fork.
2004 MINUTE SERVICE PART KITS
04 MINUTE Damping Assemblies
85-5871
85-5872
MINUTE Compression Damping Assembly
MINUTE Rebound Damping Assembly
04 MINUTE Air Cap Assemblies
85-5873
MINUTE Two/Three Air Cap Assembly
04 MINUTE Crown Steer Leg Assemblies
85-5874
85-5875
26" MINUTE One/Two (130)/Three Crown/Steer Assembly –
Blk Alloy
26" MINUTE Two (100) Crown/Steer Assembly – Blk Alloy
04 MINUTE Outer Leg Assemblies
85-5876
85-5877
85-5878
85-5879
26" MINUTE Outer Leg Assembly – Matte Black
26" MINUTE Outer Leg Assembly – Matte Silver
26" MINUTE Outer Leg Assembly – Matte Black, No Boss
26" MINUTE Outer Leg Assembly – Matte Silver, No Boss
04 MINUTE Sticker/Knob/Seal/Bumper/Air Piston/O-Ring Kit
85-5861
85-5862
85-5893
85-5281
85-5266
85-5984
85-5895
MINUTE Sticker Kit – Silver
MINUTE Sticker Kit – Black
MINUTE Knob Kit
MINUTE/BLACK Seal Kit
Air Piston Kit
MINUTE Bumper Kit
MINUTE O-Ring Kit
04 MINUTE Ride Kits
85-5880
85-5881
85-5882
85-5883
85-5884
85-5885
85-5886
85-5887
85-5888
MINUTE One Ride Kit – X-Soft
MINUTE One Ride Kit – Soft
MINUTE Two (130)/MINUTE Three
Ride Kit – Soft
MINUTE Two (100) Ride Kit – Soft
MINUTE One Ride Kit – Medium
MINUTE Two (130)/MINUTE Three
Ride Kit – Medium
MINUTE One Ride Kit – Firm/
MINUTE Two (100) – Medium
MINUTE Two (130)/MINUTE Three
Ride Kit – Firm
MINUTE Two (100) Ride Kit – Firm
Rider Weight Range
130-150 lbs.
150-170 lbs.
150-170 lbs.
150-170 lbs.
170-190 lbs.
170-190 lbs.
170-190 lbs.
190 lbs. & above
190 lbs. & above
04 MINUTE Compression Rods
85-5889
85-5890
85-5891
85-5892
MINUTE Two (100) Compression Rod Assembly, 100 mm
MINUTE Two (130) Compression Rod Assembly, 130 mm
MINUTE Three Compression Rod Assembly, 100/130 mm
MINUTE One Compression Rod Assembly, 100-130 mm WD
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