2001 SX SERVICE MANUAL
2001 SX SERVICE MANUAL
ANSWER PRECISION SUSPENSION
CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK
AVAILABLE. THE 2001 SX FORK MODELS HAVE STATE OF THE ART MCU/SPRING COMPRESSION SYSTEMS. THE SX SERIES ALL USE THE NEW TWIN PISTON CARTRIDGE SYSTEM (TPC) THAT SURPASS ALL
OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY.
Your 2001 SX Fork is fully assembled and ready to be installed onto your bicycle and comes
equipped with a 1 1/8 threadless steer tube. 2001 SX’s are available with the V-Brake cable hangerless archs.
CONSUMER SAFETY INFORMATION
GENERAL WARNING: 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 death. Prior to riding your
bicycle, you should inspect your suspension fork to ensure that no damage has occurred during
the course of riding. Do not ride your bicycle if the fork shows any signs of bending, cracking,
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 at (661) 257-4411 to have your fork shipped
directly.
IMPORTANT: 2001 SX Forks are off road forks and as such, do not come with the reflectors installed
for on road use. 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.
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 at (661) 257-4411 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. If you have any questions concerning the integrity, condition, or safe operation of your fork.
5. Answer Products recommends that you periodically inspect your fork for wear and damage.
Inspect the crown, stanchions, and outer leg dropout, and brake arch areas for cracks or damage. Before every ride, check to ensure that the proper preload exists.
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.
INSTALLATION INSTRUCTIONS
Ensure 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
2
3
4
5
6
7
8
Remove old fork from bicycle.
Measure and cut the steer tube to the same length as the old fork.
Remove crown race from old fork and press onto steerer until seated on crown. Figure 1
Clean and grease headset bearings and races of bicycle.
Install lower bearings on fork crown race.
Insert steer tube into head tube of frame.
FIG 2:
Minimum Tire Clearance
Install upper bearings, spacers, and stem.
Install stem cap, adjust, and tighten headset
per manufacture’s instructions.
MINIMUM CLEARANCE
MINDESTABSTAND
ESPACIO LIBRE MINIMO
JUE MINIMUM
SPAZIO LIBERO MINIMO
FIG 1:
Race installation
Einbau des Laufrings
InstalacÛ del anillo
Installation du jeu de direction
Montaggio dell' anello della testa
CROWN RACE
GABELBR‹CKEN-LAUFRING
ARANDELA DE LA DIRECCION
CONE DE JEU DE DIRECTION
ANELLO DELLIA TESTA
Fork model
Gabelmodell
Modelo de horquilla
ModÈle de fourche
Modello di forcella
Minimum clearance
Mindestabstand
Espacio libre mÌnimo
Jeu minimum
Spazio libero minimo
80mm travel forks
3.26" (83 mm)
9 Torque stem handlebar pinch screw and stem clamping system to manufacturer’s instructions.
10 Install cantilever brakes and adjust per manufacturer’s instructions.
Note: All 2001 SX 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 wide adjustment. Install front wheel to bicycle per manufacturer’s specification.
12 Install brake cable per manufacturer’s instructions.
WARNING: When installing the 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 for 80mm travel fork models are 3.26(83mm) and for the 100mm travel fork model
4.05 (103mm). Any less clearance can result in an accident with the possibility of serious injury
or death. Figure 2
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
(805) 257-4411, 8:00 AM to 5:00 PM, 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 to technical support.
DESCRIPTION
PART NUMBER
2001 SX OWNERS MANUAL
042028
2001 SX R COMPRESSION DAMPING ASSEMBLY KIT
85-3014
2000/2001 ANTI-BOB SEAL KIT
85-3686
2001 MRD TUNING MANUAL
85-3696
MANITOU PREP M GREASE, 6 OZ.
85-3810
MICRO LUBE GREASE GUN HEAD
85-3812
MRD SUSPENSION FLUID, 5WT., 8OZ.
85-3814
MAXIMA 7.5WT SUSPENSION FLUID, 8 OZ.
85-3820
MAXIMA 10WT SUSPENSION FLUID, 8OZ.
85-3822
99/2001 BUSHING SIZE TOOL
85-3911
2000/2001 ANTI-BOB KIT
85-4062
SX BUSHING SEAL KIT
85-4111
2001 BLACK/SILVER STICKER KIT FOR YELLOW SX E
85-4117
2001 RED/SILVER STICKER KIT FOR BLACK SX E
85-4118
2001 YELLOW/SILVER STICKER KIT FOR RED SX E
85-4119
2001 BLUE/SILVER STICKER KIT FOR RED OR BLUE SX
85-4120
2001 RED/SILVER STICKER KIT FOR FIREBALL SX
85-4121
2001 RED/WHITE STICKER KIT FOR BLACK SX
85-4122
2001 BLUE/SILVER STICKER KIT FOR RED OR BLUE SX 100
85-4123
2001 RED/SILVER STICKER KIT FOR FIREBALL SX 100
85-4124
2001 RED/WHITE STICKER KIT FOR BLACK SX 100
85-4125
2001 RED/SILVER STICKER KIT FOR SX R
85-4126
2001 SILVER /WHIT STICKER KIT FOR COBALT OR BLACK SX R
85-4127
2001 ADJUSTER KIT SX R
85-9073
2000/2001 ADJUSTER KIT SX, SX E & SX 100MM
85-9105
table 1 (cont.)
DESCRIPTION
2001 SX & SX R SOFT RIDE KIT
2001 SX & SX R FIRM RIDE KIT
2001 SX 100 SOFT RIDE KIT
2001 SX 100 FIRM RIDE KIT
2001 BLACK SX OUTER ASSEMBLY WITHOUT STICKERS
2001 YELLOW SX OUTER ASSEMBLY WITHOUT STICKERS
2001 RED SX OUTER ASSEMBLY WITHOUT STICKERS
2001 BLUE SX OUTER ASSEMBLY WITHOUT STICKERS
2001 FIREBALL SX OUTER ASSEMBLY WITHOUT STICKERS
2001 COBALT SX OUTER ASSEMBLY WITHOUT STICKERS
2001 WHITE SX OUTER ASSEMBLY WITHOUT STICKERS
2001 SX & SX E STEER/LEG ASSEMBLY
2001 SX R & SX 100 STEER LEG ASSEMBLY
2001 SX R ALLOY STEER/LEG ASSEMBLY
2001 SX E X-FIRM RIDE KIT
2001 SX & SX R X-FIRM RIDE KIT
2001 SX 100 X-FIRM RIDE KIT
2001 SX REBOUND DAMPING ASSEMBLY KIT
2001 SX 100 REBOUND DAMPING ASSEMBLY KIT
2001 SX R REBOUND DAMPING ASSEMBLY KIT
2001 SX & SX 100 COMPRESSION DAMPING ASSEMBLY
PART NUMBER
85-9127
85-9129
85-9184
85-9186
85-9191
85-9194
85-9196
85-9197
85-9198
85-9199
85-9202
85-920
85-9208
85-9209
85-9218
85-9219
85-9223
85-9266
85-9267
85-9268
85-9269
BUSHING & SEAL DETAIL
2001 SX FORK SCHEMATIC
COMPRESSION DAMPING
ASSEMBLY (062496)
CAP 0-RING (040524)
FORK BOOT (041244)
TOP CAP (062507)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
REBOUND PISTON (062297)
UPPER SEAL (062972)
LOWER SHAFT
ASSEMBLY (063106)
COMPRESSION VALVE (062296)
PISTON O-RING (040681)
SHIM .377 X .900 (062300)
UPPER BUSHING (041473)
SHAFT (062994)
LOWER BUSHING (041474)
SPIROLOX RETAINER (062393)
LOC-OUT ROD SEAL (062392)
CROWN/STEERER
END CAP (062422)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
BOTTOM OUT ELASTOMER (063116)
INNER LEG
BOTTOM OUT WASHER (063181)
RETAINING RING (040679)
O-RING 3/4" x 7/8" (040681)
DAMPER DROPOUT SLEEVE (041574)
END CAP (062249)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
INNER LEG
BOTTOM OUT ELASTOMER (063116)
BRAKE POST 9MM HEX (041927)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
ADJUSTER ASSEMBLY (062529)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
BOTTOM CLIP (040968)
BLUE MCU (041424)
SPRING CONNECTOR (041377)
110LB STEEL SPRING
5 7/8" LONG (041890)
COMPRESSION ROD (063109)
DAMPER DROPOUT
NUT (041823)
OUTER CASTING
COMPRESSION ROD SCREW (060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
REBOUND ELASTOMER (041475)
BUSHING & SEAL DETAIL
2001 SX 100MM FORK SCHEMATIC
COMPRESSION DAMPING
ASSEMBLY (062496)
CAP 0-RING (040524)
FORK BOOT (062251)
TOP CAP (062507)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
LOWER SHAFT
ASSEMBLY (063251)
REBOUND PISTON (062297)
UPPER SEAL (062972)
COMPRESSION VALVE (062296)
PISTON O-RING (040681)
SHIM .377 X .900 (062300)
UPPER BUSHING (041473)
SHAFT (063752)
LOWER BUSHING (041474)
SPIROLOX RETAINER (062393)
LOC-OUT ROD SEAL (062392)
CROWN/STEERER
END CAP (062422)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
INNER LEG
BOTTOM OUT ELASTOMER (063116)
BOTTOM OUT WASHER (063181)
RETAINING RING (040679)
O-RING 3/4" x 7/8" (040681)
DAMPER DROPOUT SLEEVE (041574)
END CAP (062249)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
INNER LEG
ADJUSTER ASSEMBLY (062529)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
BOTTOM OUT ELASTOMER (063116)
BRAKE POST 9MM HEX (041927)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
BOTTOM CLIP (040968)
RED MCU (041428)
MCU CONNECTOR (041237)
BLUE MCU (041424)
SPRING CONNECTOR (041377)
110LB STEEL SPRING
5 7/8" LONG (041890)
COMPRESSION ROD (063250)
DAMPER DROPOUT
NUT (041823)
OUTTER CASTING
COMPRESSION ROD SCREW (060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
REBOUND ELASTOMER (041475)
BUSHING & SEAL DETAIL
2001 SX E FORK SCHEMATIC
FORK BOOT (041244)
TOP CAP (062507)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
UPPER SEAL (062972)
COMPRESSION ROD (063250)
UPPER BUSHING (041473)
LOWER BUSHING (041474)
CROWN/STEERER
INNER LEG
END CAP (062249)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
BOTTOM OUT ELASTOMER (063116)
BOTTOM CLIP (040968)
WASHER (041828)
INNER LEG
BRAKE POST 9MM HEX (041927)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
END CAP (062249)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
ADJUSTER ASSEMBLY (062529)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
RED MCU (063327)
BOTTOM OUT ELASTOMER (063116)
BOTTOM CLIP (040968)
MCU CONNECTOR (041237)
RED MCU (063327)
SPRING CONNECTOR (041377)
SPRING 4 1/4" (063162)
WASHER
(041828)
OUTTER CASTING
(2X) COMPRESSION ROD SCREW (060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
COMPRESSION ROD (063263)
REBOUND ELASTOMER (041475)
BUSHING & SEAL DETAIL
2001 SX R FORK SCHEMATIC
FORK BOOT (041244)
COMPRESSION DAMPING
ASSEMBLY (063111)
LOWER SHAFT ASSEMBLY
(062929)
JELLY BEAN (062578)
SELF TAPPING SCREW (041330)
TPC KNOB (062503)
TPC TOP CAP (062583)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
VALVE NUT (041483)
CLAMP SHIM (041157)
REBOUND SHIM 20mm (041149)
REBOUND SHIM 21mm (041150)
PISTON (062562)
O-RING 1/4 X 3/8 (040690)
.826 X .409 X .005 SHIM (041139)
UPPER SEAL (062972)
ADJUSTER NEEDLE (062072)
O-RING 5/32 X 9/32 1/16
(041130)
DETENT SLEEVE (041527)
SPRING (041152)
UPPER BUSHING (041473)
PISTON SEAT (062130)
DETENT BALL (040689)
LOWER BUSHING (041474)
LOWER SHAFT (062970)
UPPER SHAFT (062723)
DETENT BALL
(040689)
VALVE SEAT (062130)
CLAMP SHIM 13MM (041157)
O-RING 5/32" x 9/32" (041130)
LOWER NEEDLE (062570)
0-RING 1/4 X 3/8
(040690)
COMPRESSION SHIM STACK
(041148, 041149,
2X 041150)
SPIROLOX RETAINER (062393)
WASHER .737 X .550 (062413)
LOC-OUT ROD SEAL (062392)
PISTON (062562)
SHIM (041139)
END CAP (062422)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
SPRING (041152)
VALVE NUT (041483)
O-RING 3/4 X 7/8 (040681)
BOTTOM OUT ELASTOMER (063116)
BOTTOM OUT WASHER (063181)
RETAINING RING (040679)
CROWN/STEERER
DETENT SLEEVE (041527)
INNER LEG
DAMPER DROPOUT
SLEEVE (041574)
BRAKE POST 9MM HEX (041927)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
INNER LEG
END CAP (062249)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
BOTTOM OUT (063116)
ADJUSTER ASSEMBLY (062540)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
BOTTOM CLIP (040968)
DAMPER DROPOUT
NUT (041822)
BLUE MCU (041424)
O-RING, DROPOUT
NUT (040688)
DAMPER ADJUSTER
KNOB (041408)
SPRING CONNECTOR (041377)
OUTTER CASTING
110LB SPRING 5 7/8" LONG (041890)
COMPRESSION ROD SCREW
(060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
COMPRESSION ROD (063109)
REBOUND ELASTOMER (041475)
MAINTENANCE
IMPORTANT: 2001 SX forks 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
2001 SX performing well and your warranty in effect.
Use of this fork without boots will shorten the life of the
fork, reduce the performance and void the warranty.
Your 2001 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.
IMPORTANT: When filling the fork with grease through the Microlube grease ports it is important to
note the grease is being forced between the upper and lower bushing (Figure 7). 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, lubricate and check entire fork for any obvious damage.
3 Check headset adjustment.
4 Ensure 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 very important. Not enough oil will
allow foaming and reduce the performance. Too much oil will restrict travel and may cause
damage to the system and an unsafe riding situation. Finish reading this entire section prior to
making any changes to the oil level.
CHECKING OIL LEVEL FIGURE 8:
To check the oil level, remove only the compression damping assembly located in the top of the right leg. Leave the
left 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 3.75 (95.2mm) and 4.75 (120.6mm)
below the crown where the damping assembly screws in
(see figure 8). The recommended level is 4.25”
(107.9mm). It is recommended that you replace your oil at
least once a year, twice if it has been contaminated with
dirt, mud, or other foreign substance. Use SAE 5WT
Maxima fork oil or equivalent.
RECOMMENDED
LEVEL
MAXIMUM
MINIMUM
Removal of outer leg / arch assembly:
1 Use a 4MM allen wrench to remove the M5 lower compression rod screw from the left leg
dropout. Pop out the damping adjuster knob from the right dropout, SXR. A small screwdriver
may be helpful. Use an 8MM Allen wrench to remove the dropout nut. Fully compress the fork
to prevent the compression rod and damper shaft from turning while removing screws.
2 Pull outer leg assembly down to remove from the inner legs and crown.
3 Remove fork boots.
4 Bushing replacement will require the use of the bushing removal and installation tool available
from Answer Products. It is recommended that the bushings be left installed unless they
absolutely need replacement.
Note: It is not recommended to remove the dust seal every time the fork is disassembled. The seal
and bushings may be cleaned and re-greased in place.
GENERAL DISASSEMBLY
NOTE: The Fork does not need to be removed from the bicycle for general disassembly-assembly or
cleaning. It is also not necessary to disassemble the 2001 Manitou Forks for compression elastomer
replacement. Elastomer replacement is accomplished by removing the adjuster assembly per Figure 10.
Compression Stack & Compression Rod
1
2
3
4
Press the bottom clip off the compression rod.
Slide off the rebound elastomer from left leg compression rod.
Unscrew and remove the adjuster assembly by hand.
Turn fork upside down to remove the compression rod. If forks are installed on bicycle give the
rod a quick upward thrust and catch it as it pops up above the crown.
Lower Shaft Disassembly:
Note: Lower Shaft disassembly is best done with the fork removed from the bicycle. Disassembly of
the damping stack is not required unless you want to change or replace the shim stack.
1 Remove the left cap compression damping assembly from the top of the fork leg and pour the
oil out of the top of the fork and discard appropriately. For complete disassembly continue.
2 Remove the plastic end cap and pull the lower shaft out of the inner leg.
3 Remove the clear plastic detent sleeve and capture the 1/8 dia. Detent ball used on SX R only.
4 SX R adjuster needle may be unscrewed from the shaft.
5 For SX R use 5MM allen wrench to remove piston seat. Keep note of the exact order of the
shims and spacers.
Compression Damping Disassembly:
1 The compression damping assembly is almost identical to the lower shaft assembly.
2 Unscrew the compression damping adjuster all the way until it stops. The knob and the needle
do not need to be removed. The shaft also does not need to be removed from the cap. The
threads are bonded to prevent leaking.
3 Remove either the valve nut or the piston seat following the instructions above for the lower
shaft assembly.
DAMPER INSPECTION
1
2
4
5
6
Check the shaft for scratches, wear, or other obvious damage.
Check the seal gland and end cap seal grooves for damage.
Check shims for permanent bends or damage.
Check all other parts for obvious damage, replace if necessary.
Replace all seals that have been removed.
FORK INSPECTION
1 Check the fork boots for obvious damage.
2 Check the dust seal for tears, wear, or damage. Replace if needed.
3 nspect the lower and upper bushing for damage to the Teflon coating. Replace using the bushing removal and replacement kits if necessary.
4 Check all MCU & springs for obvious damage. Replace if necessary.
5 Check the preload adjuster and connectors. Replace if damaged.
6 Check the outer leg/arch assembly for nicks or deep gouges on outside and inside. Replace if
damaged.
7 Check the inner leg for deep gouges and other damage. Minor wear resulting in color change is
not detrimental to the gold anodized surface. Replace if wear is excessive or damaged.
8 Check inner legs at the bottom of the crown for cracks or for flaking anodize. Replace crown
steer leg assembly if cracked or if gold anodize is beginning to flake.
9 Check the underside of the crown for cracks. Replace if cracked.
RE-ASSEMBLE
Lower Shaft
1 Install all o-rings and seals removed.
2 Grease all seals lightly with seal grease.
3 Apply small amount of blue Locktite to piston seat threads.
4 Assemble shim stack and spacers in exact order that they were removed. For SX R hand tighten
piston seat. Be sure large blow off washer will slide over piston spacer and compress the small
spring. Clamp shaft in soft jaws or collet and line up slots in clamp ring with hole in piston
seat using 1/8 or smaller pin. Use a 5MM Allen wrench and tighten piston seat by turning
Allen wrench and pin at same time. Torque 10 IN-LB (3.5 N-m) max.
5 SX R install lower needle gently into shaft, thread until it stops then back off one turn for initial adjustment.
6 Slide shaft assembly through the plastic end cap, place detent ball in place and slide on 2nd
STG Elastomer.
7 Insert into left leg and thread in end cap. Torque 30 IN-LB (3.5N-m) max.
8 Add approximately 90 CC of 5 WT Maxima or equivalent oil. Do not over fill. Check oil level,
see Figure 8.
Compression Damping Assembly
1 Reassemble compression damping stack following the instructions above for the lower shaft
assembly.
2 Install compression damping assembly into the left leg. The oil level should cover the compression valve when the assembly is installed.
Compression Rod & Boots:
1
2
3
4
5
Clean all parts thoroughly.
Grease compression rod lightly. Be sure rebound Elastomer is installed onto compression rod.
Drop compression rod down into inner legs. Shake inner leg to get rod through inner leg plug.
Slide on black second stage, cup washer, and orange 3rd stage
Elastomer.
Slide Boots onto inner leg.
Outer Leg Assembly:
1 Slide Outer leg / Arch assembly onto inner legs and fully compress.
2 Install and torque 5MM compression rod screw and dropout nut to10-30 inch-lb. (1.1-3.5 N-m).
Over torquing the dropout nut may damage the damper shaft.
3 Pop in damper adjuster knob. O-ring holds knob in place(SXR).
4 Slide skirt of fork boots onto the outer leg groove. Be sure the lip snaps into the groove.
5 Clean adjuster cap threads thoroughly. Clean threads on inside of inner leg.
6 Assemble MCU’s, springs, and connectors with thick grease.
7 In stall adjuster assembly into inner leg just hand tight.
INNER FORK LEGS & CROWN
The inner fork legs and steer tube are press fit into the crown and may never be removed.
Removing them will make the fork unsafe to use. If you see any slippage contact Answer Technical
Staff immediately (800) 670-7446.
ADJUSTING RIDE QUALITIES
2001 SX TPC forks offer a wide adjustment range to suit individual riding preference and rider
weight by simply changing the MicroCellular Urethane (MCU’s). Fine tune adjustments can be made
using the preload adjusters located on top of the fork crown. Softer blue and harder yellow MCU’s
are available from your Dealer.
NOTE: Since 2001 model forks use a compression stack in the left 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:
Fine tuning adjustments to the spring rate are made by rotating the adjuster knobs located on top
of the crown. Note the 2001 SX 100, SX, and SX R uses compression spring systems in the left leg
only. Only the left knob on top of the crown adjusts 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:
To adjust the SX R simply rotate the compression damping knob located on top of the right leg and
crown. 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 sharp bumps like rocky
sections, but will feel good in 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. The SX 100 and SX uses TPC Sport for compression damping and is not adjustable.
Rebound Damping Fine Tuning:
To adjust the SX R simply rotate the rebound damping knob located on bottom of the right leg.
Rotating the knob clockwise will increase the damping, rotating the knob counter clockwise will
reduce the damping. Excessive rebound damping will give you a harsh ride over repetitive bumps
(like braking bumps) because the fork will pack up. Insufficient rebound damping will make the fork
over active, top out and slap back when landing from a jump. We suggest that you try adjusting
your fork on the very active side, minimum rebound. Then try it over a variety of terrain and tune
in more rebound from there. The SX 100 and SX uses TPC Sport for Rebound damping and is not
adjustable
Lok-Out System Kit P/N 85-8989
Lok-Outs are available for all SX models. By turning the knob 1/4 turn CCW, exposing the green
sticker; the front fork will have regular TPC suspension. By turning the knob 1/4 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 right leg. Adjust the setscrew,
located in the valve seat, in to increase the damping and out to reduce the compression damping.
Try adjusting one 1/2 turn at a time.
For additional tuning tips we recommend that you obtain a copy of the MRD tuning
Manual P/N 85-3485 and check out the MRD Race Tuning kits available at your dealer.
TROUBLE SHOOTING
Fork seems to top out or has a slight clunking feel when front wheel comes off the ground:
Excessive preload or insufficient rebound damping will result in a top out . Select MCU’s that better fit your weight and riding style, having the preload adjuster set mid to low range, and increase
the rebound damping to eliminate top out.
The fork feels less active and is not getting the travel it used to when it was new:
Chances are that the fork is developing stiction. Cleaning and applying light oil to the stanchions
will help.
Outer legs feel loose on inner legs and bushings,
a knock or rock can be felt when pushed from side to side:
A very small knock is normal with the new harder bushings. If the knock is excessive or you can feel
the fork rocking then the bushings should be removed and replaced. To do this you must have the
Answer Products Bushing Removal and Replacement Tool Kit.
A small amount of oil seems to be leaking from top of the left leg at the adjuster cap:
If the 2001 SX us store upside down for a period of time a small amount of oil may leak through the
adjuster cap / knob assembly. The cap area is not subjected to damping pressure. A small leak in
that area will not affect the performance of the fork or cause any type of damage. We recommend
that you store your Manitou left side up. If this condition causes you some problems please contact
your Answer Products dealer or call our warranty tech department for prompt service.
CYCLE COMPUTER INSTALLATION INSTRUCTIONS:
Follow the instructions in your owners manual with the following exceptions:
WARNING: DO NOT DRILL A HOLE IN THE DROPOUT. THIS MAY WEAKEN THE DROPOUT, WILL VOID
THE WARRANTY, AND MAY CAUSE AN UNSAFE CONDITION WITH RISK OF INJURY. DO NOT USE THE
TEMPLATE PROVIDED IN THE 95 OR 96 SERVICE MANUAL.
28209 AVENUE STANFORD • VALENCIA, CA 91355
(661) 257-4411 • www.answerproducts.com
2001 SX SERVICE MANUAL
P/N 85-3692
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