Manitou 2001 Mars Service Guide

P/N: 85-3694
answerproducts
28209 Avenue Stanford, Valencia, California 91355-3984 * Phone: 661.257.4411 * Sales Fax: 661 284.4179
TABLE OF CONTENTS
Consumer Safety & Warranty Information.
Installation Instructions.
Setup. . . . . . . .
Adjusting Ride Qualities. .
Trouble Shooting .
Maintenance. Ce ee
Inner Fork Leg, Crown & Arch. .
Disassembly.
Spare Parts List. aaa a e
Exploded views. . . . . . . . . . . + 10-14
GA ES 62 ВО во —
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I. ANSWER PRECISION SUSPENSION
THANK. YOU FOR CHOOSING THE HIGHEST TECHNOLOGY MOUNTAIN BIKE SUSPENSION FORK AVAILABLE. 2001 MARS
FORK MODELS HAVE STATE OF THE ART AIR SPRING SYSTEMS. THE MARS SERIES ALL USE THE TWIN PISTON
CHAMBER SYSTEM (TPC) THAT SURPASS ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND
DURABILITY.
Your 2001 MARS Fork is fully assembled and ready to for installation onto your bicycle and comes equipped with a 1 1/8” threadless
steerer tube. All MARS forks come in two versions: standard and No-Boss. The standard version has mounts for both V-brakes and
disc brakes. The No-Boss version has the cantilever brake boss removed and 1s for disk brake use only.
II. 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 possible
death. Prior to riding your bicycle, you should inspect your suspension fork to ensure that ne 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 instruction 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 through 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 (661) 257-4411.
| IMPORTANT: The 2001 MARS fork is for off road use only and as such, does come with the reflectors for on road use. ||
1. Never remove or have the steerer tube or stanchions (inner legs) removed from the crown. The steerer tube and stanchions are
press fit assembled at the factory. Pressing them out will permanently damage the crown, steerer tube, and stanchions beyond
repair and render them unsafe for any continued use.
2. Never attempt to thread a threadless steerer tube. Machining threads will weaken the steerer tube and create an unsafe condition.
The only safe thing to do is 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 part appears to be broken, bent, cracked, or damaged. Contact your dealer or Answer
Products Technical Support, (661) 257-4411, if you have any questions concerning the integrity, condition, or safe operation of
your fork. В
5. Answer Products recommends that you periodically inspect your fork for wear and damage. Inspect the crown, inner legs, and
outer leg dropout and break arch areas for cracks or damage.
UL WARRANTY INFORMATION ;
Any Answer Products Manitou 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 at (661) 257-4411 for a return anthorization number (RA#).
Instructions for repair, return, or replacement shall be given at that time at. Customers in countries other than USA should contact
their dealer or local distributor. For a list of international distributors, visit our website at www.answerproducts.com.
IV. INSTALLATION INSTRUCTIONS
Figures 1 & 2
SLIP CROWN
RACE OVER
STEERER
PRESS ONTO
RACE SEAT
Ensure that the proper steerer tube length has been delivered on your fork. 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.
Never attempt to thread a threadless steerer tube. Machining threads will weaken
the steerer tube and cause an unsafe condition. The only safe thing to do is obtain
the proper crown/steerer from your dealer. Figure 1: Race installation
WARNING: 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 change steerer tube diameters or
increase length of threaded steerer tubes. Removing and replacing the steerer tube or stanchions will result in an unsafe
condition and should never be done.
E
a
Remove old fork from bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube.
Remove crown race from old fork and press onto 2001 MARS steerer until
seated on crown. See Figure 1.
Clean and grease headset bearing and crown races.
Install lower bearings on fork crown race.
Install steerer tube into head tube frame.
Install upper bearing, spacers, and stem.
Install handlebars. Torque stem handlebar pinch screw and stem clamping
system to manufacturer’s instructions.
Install stem cap, adjust and tighten headset per manufacturer’s instructions.
10. Install brakes and adjust per manufacturer's instructions. When installing disk
brakes, the caliper must fit, or have an adapter to fit, post style mounts with
74mm spacing.
11. Adjust front wheel quick release to clear the 0.275” (TMM) thick secondary
catch dropout. The quick release must be tightened after it has adequate thread
engagement (4 or more threads with the release adjusted to bicycle per
manufacturer's specifications).
12. Install brake cable per manufacturer’s instructions. Route disk brake lines so that
they will not kink or be pinched through the full travel of the fork.
13. Check tire ciearance with crown. Figure 2.
Note: All 2001 MARS forks are equipped with a secondary catch dropout.
©
SIDA
©
Figure 2: Tire Clearance
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 3.26” (83mm) for §0mm travel fork models. Any less
clearance can result in accident resulting in serious injury or death. See Figure 2
CYCLE COMPUTER INSTALLATION INSTRUCTIONS:
Follow the instructions in your owner's 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 OR POSSIBLE DEATH.
Y. SUSPENSION SETUP:
If the fork is new, break it in with at least one hour of riding before making any changes.
Make sure the fork is in good working condition and is properly serviced and lubricated.
Make changes in small increments.
Keep a record of all changes made for future reference.
Y Y Y Y
ADJUSTING RIDE QUALITIES:
2001 MARS forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the air
pressure and spring rate.
Compression Spring Fine-Tuning
Fine tuning adjustments are made by adjusting the air pressure and changing the spring. Use the chart below as a starting point for
finding the proper air spring based on rider weight.
Recommended Spring Rates for 2001 MARS Forks
Rider Weight Air Spring Coil Spring
under 115 lbs. 80 psi +/-5psi (1) 3” blue 80 pound coil spring
115-145 155. 100 psi +/- Spsi (1) 3” red 100 pound coil spring
145-175 165. 120 psi +/- 5psi (1) 3” red 100 pound coil spring
175-205 165. 140 psi +/- 3psi (1) 3” yellow 120 pound coil spring
205-230 ibs. 160 psi +/- 5 psi (1) 3” yellow 120 pound coil spring
230 + lbs. 180 psi +/- 5 psi (1) 3” black 150 pound coil spring
Air/coil spring rate tuning
All 2001 MARS forks use a combination of air and a coil spring. The air spring 1s
adjustable via a Schraeder valve located on top of the left leg. See Figure 3. The
positive coil spring can also be switched with stiffer or softer versions to
accommodate for different rider styles and terrain. There’s also a coil negative
spring, but it is available in one rate only and is designed to be preloaded
automatically as the positive air spring pressure is increased (in other words, you
don’t need to do anything to tune it).
Compression Damping Tuning:
To adjust the MARS Elite: Figure 3
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.
To adjust the MARS Super: Figure 4
Remove the Anti-Bob compression damping assembly from the top of the right leg.
Adjust the setscrew on the valve seat in to increase compression damping and out
to reduce the compression damping. Try adjusting one half turn at a time.
Note: Compression and rebound damping on the MARS is factory pre set.
Rebound Damping Fine Tuning: Figure 5
To adjust the MARS Elite and MARS Super
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 overactive, top out and slap
back when landing from a jump. We suggest that you try adjusting your fork on the ~
active side with minimum rebound. Then try it over a variety of terrain and tune in
more rebound from there.
SCHRADER VALVE
UNDER KNOB
Figure 3: MARS Elite
compression damping
ADJUST SET SCREW
Figure 4:
MARS Super compression damping
Figure 5: Rebound Damping
For additional tuning tips we recommend that you obtain a copy of the MRD tuning Manual P/N 85-3696 (download from the web
at www.answerproducts.com) and check out the MRD Race Tuning kits available at your dealer.
VI. 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 spring’s that better fit your weight and riding style, set the air pressure to a 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 Microlube and applying light oil to the stanchions should eliminate the
problem.
Outer legs feel loose on inner legs and bushings, a knock or rock can be felt when pushed from side to side: A very minute knock 1s
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 contact Answer Products or an authorized Manitou Dealer.
A small amount of oil seems to be leaking from top of the right leg at the adjuster cap:
If you store the 2001 MARS Fork upside down for a extended 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 under normal use. So you will not see any leakage with the fork
right-side up.. 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 right side up. If this condition causes any problems please contact your Answer Products dealer or call our
warranty tech department for prompt service.
УП. MAINTENANCE
IMPORTANT: The 2001 MARS 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 recommended to keep your MARS fork performing at it’s optimum for extended service
cycles, and maintaining maximum life of fork. Use of this fork without fork boots will require frequent service intervals to
maintain performance and normal life of fork. Warranty will be void if fork is found to show that boots where not in place
and frequent service was not performed.
MICROLUBE
All 2001 Manitou forks come standard with the MicroLube lubrication system. Located at the
back of the fork is a small fitting that is the heart of the MicroLube system. This is where you
inject grease. The major benefits of the MicroLube system are that it is lightweight and
effective. Only a small quantity of grease is needed to properly lubricate the fork, and the fitting
for injecting grease puts it just where it needs to be. MicroLube also greatly decreases the time
you have to spend servicing your fork because you can regrease the fork without disassembly.
With MicroLube, you can simply grease your fork as needed, and that’s what we recommend. If
you feel any stiction developing with your fork, give about 10 squirts with Prep M lube. Push
the fork up and down a few times to ensure that the lube penetrates properly and the go ride.
Your 2001 MARS Fork requires periodic maintenance, cleaning, and inspection. Moisture and
contamination may build up inside the fork depending on the severity of riding conditions. To Figure 6:
maintain top performance, it is recommended that the fork be periodically disassembled, Lubricating The Bushings
cleaned, dried and re-greased using Prep-M grease. See Figure 6.
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. If the area is overfilled the force of the grease may force the upper bushing and
dust seal out.
TPC OIL LEVEL
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. MAXIMUM prt
|
RECOMMENDED LEVEL
MARS 4,50" (114mm)
MARS ELITE 4,00" (101mm)
MARS SUPER 3.75" (95mm)
MARS 4.00" (ore)
MARS ELITE 3.75" (95mm)
MARS SUPER 3.50” (89mm) E
To check the oil level: remove only the compression damping assembly located
in the top of the right leg. Leave the left side spring stack (air spring) in place to | vinmum : J
keep the fork fully extended. Use a tape measure or “dip stick” to determine the | Vars pie $ 20” Совет) |
oil level. The recommended level is different for each model See Figure 7. Itis | MARS SUPER 4007 (102m) Г!
recommended that you replace your oil at least once during the year, twice if it =
has been contaminated with dirt, mud, or other foreign substance. Use SAE | Figure 7: TPC Oil Level
SWT Maxima fork oil or equivalent. |
4
IMPORTANT: Before every ride you should:
|. Ensure that the quick release skewers are properly adjusted
and tight.
2, Check the entire fork for any obvious damage.
3. Check headset adjustment.
4. Ensure that the front brake cable 1s properly seated tn the
cable retainer & check brake adjustment.
NOTE: The Fork does not need to be removed from the
bicycle for general disassembly-assembly or cleaning. In
addition, coil spring replacement is accomplished by
removal of outer leg/arch assembly.
INNER FORK LEGS & CROWN
The inner fork legs and steerer 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.
REMOVAL OF OUTER LEG / ARCH ASSEMBLY
FIGURE 8:
Il. Use a 4MM Allen wrench to remove the lower compression
rod screw from the left leg dropout. Pop out the damping
adjuster knob from the right dropout. A small screwdriver
may be helpful. Use an 8MM allen wrench to remove the
dropout nut. Fully compress the fork if needed to prevent
the compression rod and damper shaft from turning while
removing screws.
2. Pull the outer leg assembly down to remove from the inner
legs and crown.
3. Remove fork boots.
Note: It is not recommended to remove the dust seal every
time the fork is disassembled. The seal and bushings should
be cleaned and re-greased in place.
INSPECTION
I. Check the dust seal for tears, wear, or damage. Replace if
needed.
2. Inspect the lower and upper bushing for damage to the
Teflon coating. Replace by calling Answer Products or an
authorized Manitou dealer.
3. Check the outer leg/arch assembly for nicks or deep
gouges on outside and inside. Replace if damaged.
REMOVE, ADJUSTERS
AND FULLY COMPR ss
FORK LEGS 10 KEEP
COMPRESSION RODS
FROM TURNING
REMOVE NUT USE
SMM ALLEN WRENCH
POF QUT KNOB
PULL DOWN TO
REMOVE OUTER
FORK LEG UNIT
ROD SCREW,
USE SMM
ALLEN WRENCH
Figure 8: Outer Leg Removal
E. SLIDE FORK BOOT
DOWN TO SNAP
INTO CROOVE
OF QUTER LEG
C. INSTALL & TORQUE DROPOUT
NUT, USE BMM ALLEN WRENCH \
10-30 IN-LBS
(1.1-3.5 N-M)
A. SUDE ON OUTER
LEGS UNTIL FORK
5 FULLY COMPRESSED
D. POP IH KNOB
B. INSTALL & TORQUE
COMPRESSION
ROD SCREW
1030 IN~LBS
(11-35 NM)
Figure 9: Outer Leg Assembly
C. UNSCREW LEFT
INNER LEG CAF
B. SLIDE OFF
ELASTOMER
A. REMOVE
BOTTOM CLIP
O. REMOVE COMPRESSION
ROD, SPRING AND
FUSH ROD.
Figure 10: Compression Stack
4. Remove boots and check the inner legs 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 if inner legs are damaged.
5. 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.
6. Check the underside of the crown for cracks. Replace if cracked.
OUTER LEG REASSEMBLY FIGURE 9:
i. Reinstall boots.
2. Slide outer leg / Arch assembly onto inner legs and fully compress.
3. Install and torque 4mm compression rod screw and 8mm dropout nut to10-30 inch-1b. (1.1-3.5 N-m).
Over torquing the dropout nut may damage the damper shaft.
4. Grease o-ring, pop in damper adjuster knob. O-ring holds knob in place.
wn
Slide skirt of fork boots onto the dust seal. Be sure the lip snaps into the groove.
6. Lubricate the fork using the MicroLube system and Prep M grease. See page 4 Maintenance.
COMPRESSION STACK, BOOTS, & COMPRESSION ROD REMOVAL
FIGURE 10:
E.
2.
3.
4
5.
Remove outer leg assembly.
Slide fork boots off of inner legs.
Press the bottom clip off the compression rod.
Slide off the bottom out elastomer from left leg compression
rod.
Using a 15/16” wrench or socket unscrew the left inner leg cap.
Than remove (he compression rod, elastomer and push rod.
AIR SPRING DISASSEMBLY
FIGURE 11:
|
2.
3.
Remove compression rod.
Let air out of air spring and remove top cap.
Push piston out top of left leg, with a 42” or smaller rod.
Push through the center of the air piston stop. (Air piston
stop is not removable).
COMPRESSION ROD & AIR SPRING INSPECTION
|.
2.
3.
4
6.
Check the compression rod for obvious damage.
Check the fork boots for obvious damage.
Check all springs for obvious damage. Replace if necessary
Clean and inspect piston and seals, replace if seals are worn,
nicked or torn.
Check all other parts for obvious damage, replace if necessary.
Replace all seals that have been removed.
COMPRESSION ROD & BOOTS REASSEMBLY FIGURE 12:
I.
2.
3.
4,
5.
Clean all parts thoroughly.
Grease compression rod lightly. Be sure rebound elastomer is
installed onto compression rod.
Slide on end cap, second stage elastomer, and install bottom clip.
Install into left leg. Torque to 10-20 in-1bs (1.1-2.5 N-m).
Slide boots onto inner leg.
AIR SPRING REASSEMBLY FIGURE 13:
В
2,
ow
Grease piston seals and threads in top of left leg.
Push the piston into the leg with the smaller hole facing down.
Make certain piston is straight and gently rock it back and forth
while pushing down until it is past threads,
Install compression rod as described above.
Install outer leg assembly as described in section 10.
Pour 2.5 CC of 40-wt oil on top of air piston.
Install air cap, pressurize system and install knob.
WARNING: Do not fill air spring with more than 190 psi.
REBOUND DAMPER DISASSEMBLY FIGURE 14:
Note: Disassembly of the damping stack is not required unless you want to change or replace the shim stack.
1.
2.
3.
4.
5.
6.
7.
Remove outer leg assembly.
Remove the right compression damping assembly from the top of the right fork leg and pour the oil out of the top of the fork and
discard appropriately.
8. LET AIR OUT OF
7 SERINC AND
E REMOVE CAP
C. PUSH PRISTON OUT
OF LEFT LEG
A, ROMOVE COMPRESSION
ROD, SPRING AND
PUSH ROD.
Figure 11: Air Spring Disassembly
B. INSTALL INTO LEG,
TORQUE TO
16-20 IN-LES
A. INSTALL REBOUND ON (1,1-2,3 H-m)
COMPRESSION ROD
SLIDE ON END CAP
SECOND STAGE ELASTOMER
& STALL BOTTOM CLIP
Figure 12: Lower Shaft
REINSTALL CAP
ve & PRESSURIZE
EN SYSTEM
Figure 13: Air Spring Reassembly
Using a 15/16” open end wrench or socket, unscrew the plastic end cap and pull the lower shaft out of the inner leg.
Note: Steps 4-8 apply to MARS Elite and MARS Super only.
Remove the clear plastic detent sleeve and capture the 1/8” dia. detent ball.
Adjuster needle may be unscrewed from the shaft,
Remove the retaining ring then slide off the cup washer, & bottom out bumper. Do not remove the threaded plastic end cap at this
time. Sliding the seal over the retaining ring groove may damage the seal.
Clamp shaft in soft jaws or collet and remove piston as a complete unit, slide end cap off of top of shaft.
Remove the valve nut and disassemble damping stack, make note of the exact order of the shims and spacers.
6
REBOUND DAMPER INSPECTION
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.
Replace all seals that have been removed.
Clean shims using lint free rags or paper towels.
Oh BLN
MARS REBOUND DAMPER ASSEMBLY
|. Install all o-rings and seals that you removed.
2. Grease all seals lightly with seal grease.
3.
4,
Check all other parts for obvious damage, replace 1f necessary.
Insert into right leg and thread in end cap. Torque 30 in-1b. (3.3N-m) max.
Install outer leg assembly, see Figure 9. Add 5 WT Maxima or equivalent oil. Do not over fill. Check oil level, see Figure 8.
MARS ELITE AND MARS SUPER REBOUND DAMPER ASSEMBLY FIGURE 14:
{. Install all o-rings and seals that you removed.
2. Grease all seals lightly with seal grease.
3. Assemble shim stack and spacers onto the piston seat in exact order that they were removed. Apply a small amount of blue Loc-
tite to piston seat threads install and hand tighten nut. Be sure large blow off washer will slide over piston spacer and compress
the small spring. Torque 12 in-Ib. (1.3 N-m) max, over tightening will damage the piston.
torque piston seat to 30 in-Ib. (3.5 N-m) max.
Apply a small amount of blue Loc-tite to piston seat threads. Install piston seat into shaft. Use wrench flats on piston seat to
5. Install lower needle gently into shaft; thread until it stops then back off two turns for initial adjustment.
and slide clear detent sleeve over it.
Slide shaft assembly through the plastic end cap, slide on 2" STG Elastomer, cup washer and snap ring, place detent ball in place
Insert into right leg and thread in end cap. Torque 30 in-Ib. (3.5N-m) max.
8. Install outer leg assembly ,see Figure 9.Add 5 WT Maxima or equivalent oil. Do not over fill. Check oil level, see Figure 8.
O-RING 5/32" x 9/32"
LOWER NEEDLE \
O-RING 1/4 X 3/8
SPIROLOY RETAINER
737 X .550 X 040 WASHER
LOC-OUT ROD SEAL
& BACK-UP RING
END CAP ih
OF
|
O 3
O-RING 3/4 X 7/8
1, INSTALL ALL O—RINGS AND SEALS.
2. GREASE: ALL SEALS WiTH SEAL GREASE
PISTON SUSASSEMBLY
LOWER SHAFT
DETENT x
NEEDLE SUBASSEMBLY
CAP SUBASSEMBLY
BOTTOM OUT ELASTOMER
ZN STAGE CUP WASHER
RETAINING RING
DETENT SLEEVE
4. INSTALL PISTON SEAT ASSEMBLY INTO LOWER SHAFT USE BLUE
LOC—TITE ON THREADS. TORQUE TO 30 IN-LBS (3.5 N-m) CHECK
SHIM ON SPRING SIDE TO MAKE CERTAIN IT MOVES FREELY.
5, INSTALL ADJUSTER NEEDLE (THREAD ALL THE WAY IN)
6. INSTALL ELASTOMER, CUP WASHER AND RETAINING RING.
INSTALL DETENT BALL AND SLEEVE,
Figureld4: Rebound Damping
.B26 X ‚409 X .005 SHIM
VALVE NUT
CLAMP SHIM
SHIM STACK
PISTON
SPRING
INSTALL SHIMS, PISTON, SPRING AS SHOWN ON TO THE
PISTON SEAT, TIGHTEN NUT 18-21 IN-LBS.
(2.0-2.4 N-m) USE BLUE LOC-TITE,
LOWER SHAFT
ASSEMBLY
7. INSTALL ASSEMBLY INTO RIGHT LEG AND THREAD IN END CAP
TORQUE TO 30 IN-LBS (3.5 N-m).
COMPRESSION DAMPER DISASSEMBLY FIGURE 15:
MARS Elite
|. The compression damping assembly is almost identical to the lower shaft assembly. Remove compression damping assembly from
top of right leg.
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. Do not remove piston assembly from shaft. Remove the valve nut and disassemble damping stack, make note of the exact order of
the shims and spacers.
COMPRESSION DAMPING ASSEMBLY
UPPER SHAFT
3 CLAMP SHIM 13MM
SPRING SHIM STACK
REBOUND PISTON
SPRING SHIM
SPRING
COMPRESSION VALVE NUT
i. REMOVE COMPRESSION DAMPING ASSEMBLY FROM TQP CF RIGHT LEG. 3. REMOVE THE PISTON ASSEMBLY FROM THE SHAFT, TG DO THIS
2. THE KNOB AND THE NEEDLE CO HOT NEED TO BE REMOVED FROM REMOVE THE VALVE NUT AND DISASSEMBLE DAMPING STACK.
THE SHAFT. DO NOT REMOVE THE SHAFT FROM THE CAP.
Figure 15: Compression Damping
MARS Super.
|. The Anti-Bob compression-damping shaft is assembled in a fixture at the factory to assure proper alignment of the pistons and
shouid not be disassembled.
COMPRESSION DAMPER INSPECTION
1. Check the cap o-ring, all models, and piston o-ring Anti-Bob only for damage.
2. Check shims for permanent bends or damage.
3. Check all other parts for obvious damage, replace if necessary.
4. Replace all seals that have been removed.
COMPRESSION DAMPER REASSEMBLY
MARS Elite
|. Assemble shim stack and spacers onto the piston seat in exact order that they were removed. Refer to Figure 15. Apply a small
amount of blue Loc-tite to piston seat threads. Install and hand tighten valve nut. Be sure large blow off washer will slide over
piston spacer and compress the small spring. Torque valve nut to 12 in-Ib. (1.3 N-m) max, over tightening will damage the piston.
2. Install compression damping assembly into the right leg. The oil level should cover the compression valve when the assembly is
installed. See figure 7.
MARS Super
I. Lightly grease the o-rings and threads on the Anti-Bob. With the Anti-Bob open, install the Anti-Bob into the right side leg ( Be
careful as you do this to avoid damaging the lower rubber o-ring. The fit should be tight, so SLOWLY twist the Anti-Bob as you
slowly lower it in the leg. Do not use the Anti-Bob on-off knob to turn the assembly when tightening.
2. Once the Anti-Bob assembly is firmly in place, flip it to the closed position and while holding the front brake, compress the fork.
It should only move a very small amount and the Anti-Bob should feel firm. Remember that there is a safety blow off which
allows the fork to move under extreme bump forces (when closed), so if you push it very hard, you will see more than a few
millimeters of movement. If at the end of installation, the Anti-Bob does not function properly, remove the Anti-Bob and check
O-ring for tearing.
3. If you think you've done everything right and the Anti-Bob is still not functioning properly, remove the compression assembly
and recheck the oil height.
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 (661) 257-4411, 8:00 AM to 5:00 PM, Pacific Standard Time, Monday
through Friday. In addition helpful information can be found on the Answer Products Web Site, http://www.answerproducts.com.
Included on the site are down loadable manuals and e-mail to technical support.
DESCRIPTION PART NUMBER
MARS, MARS ELITE & MARS SUPER SOFT RIDE KIT 85-9187
MARS, MARS ELITE & MARS SUPER FIRM RIDE KIT 85-9188
MARS, MARS ELITE & MARS SUPER X-FIRM RIDE KIT 85-9226
MARS, MARS ELITE & MARS SUPER BLACK OUTER ASSEMBLIE 85-9192
MARS, MARS ELITE & MARS SUPER YELLOW OUTER ASSEMBLIE 85-9195
MARS, MARS ELITE & MARS SUPER RED OUTER ASSEMBLIE 85-9203
MARS, MARS ELITE & MARS SUPER BLUE OUTER ASSEMBLIE 85-9204
MARS, MARS ELITE & MARS SUPER WHITE OUTER ASSEMBLIE 85-9205
MARS BLACK STICKER KIT 85-4128
MARS RED/WHITE STICKER KIT 85-4129
MARS ELITE STICKER KIT 85-4130
MARS SUPER RED STICKER KIT 85-4132
MARS, MARS ELITE & MARS SUPER STEER TUBE/LEG ASSEMBLY 85-9213
MARS, MARS ELITE & MARS SUPER BUSHING SEAL KIT 85-4111
MARS REBOUND DAMPING ASSEMBLY 85-3016
MARS ELITE & MARS SUPER REBOUND DAMPING ASSEMBLY 85-9268
MARS COMPRESSION DAMPING ASSEMBLY 85-3018
MARS ELITE COMPRESSION DAMPING ASSEMBLY 85-3014
MARS SUPER COMPRESSION DAMPING ASSEMBLY 85-4062
MARS, MARS ELITE & MARS SUPER AIR CAP/PISTON ASSEMBLY 85-3033
MRD TUNING MANUAL 85-3696
MICROLUBE TUBE/GREASE GUN 85-3810
FORK PUMP 85-4069
ANTI-BOB KIT 85-4062
ANTI-BOB SEAL KIT 85-3686
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2001 MARS SERVICE MANUAL
P/N 85-3694
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answerproducts
28209 AVENUE STANFORD,
VALENCIA, CA 91355
(661) 257-4411
www.answerproducts.com
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