2004 Minute Service Manual

2004 Minute Service Manual
2005 Stance Service Manual
Rev NC
05 STANCE SERVICE MANUAL
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Table of Contents
Description
Page
Introduction
3
Front Suspension Terminology
4
Disassembly/ Assembly Instructions
8
Travel Adjust Systems: Wind Down
12
Air Assist Troubleshooting Tips
14
Remote Lockout Service Instructions
15
Lockout Troubleshooting Tips
17
Bushing Removal and Installation Instructions
18
Troubleshooting Chart
27
Stance: Schematic and Torque Specifications
29
Stance Service Kit List
30
Contact Information
Answer Products Customer Service Department
28209 Ave. Stanford
Valencia, CA 91355
Toll Free:
Direct:
FAX:
E-mail:
Web site:
(800) 423-0273
(661) 257-4411
(661) 775-1798
[email protected]
[email protected]
www.answerproducts.com
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INTRODUCTION
This manual is intended to guide the user through basic service of Manitou Stance front forks.
Service is supported by the identification of common parts and assemblies that have been
assembled into Service Kits. The purpose of this manual will be to describe conditions that may
drive the need for service and to provide installation instructions for the kits.
Due to the time-consuming nature of suspension fork service, at this time our primary focus is to
offer service kits that minimize the amount of downtime and labor involved.
Important information is highlighted in this manual by the following notations:
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the
person inspecting or repairing the suspension fork or the user.
CAUTION
A CAUTION a caution indicates special precautions that must be taken to avoid damage to
the product.
NOTE
A NOTE provides key information to make procedures easier or clearer
GENERAL WARNING: Suspension forks by design contain gases and fluids under extreme
pressure and warnings contained in this manual must be observed to reduce the
possibility of injury or possible death. Following these instructions can help you reduce
the risk of being injured. Any questions in regards to the information in this manual
should be directed to Answer Products Customer Service at (661) 257-4411.
WARNING: The Stance uses compressed air to provide fluid pressure in the damping
system and spring resistance in Air models. BOTH systems must be relieved of pressure
prior to servicing these systems. Failure to relieve air pressure could result in injury or
possible death.
CAUTION: The Stance suspension fork uses precision machined aluminum and other soft alloy
components. Using correct tools for assembly is essential to prevent damage.
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FRONT SUSPENSION TERMINOLOGY
Air Cap – Top cap that threads into top of air/spring leg (this is the left leg of the fork as you are
seated on the seat). Forks may be controlled with an air/spring or a coil spring. The air cap
contains the Schrader Valve, which is used to control the spring rate or SAG of air forks.
Air Spring – A mechanism that is used to control the SAG of an air fork.
Arch – A support that connects the two outer lower legs of the casting so as to keep them moving
in unison.
Black Nitrate Leg Coating – New coating for steel stanchion legs that reduces stiction.
Boss – The word used to describe an outer casting that has brake posts for V-brakes or
cantilever brakes.
Bottom Out Bumper – A rubber or elastomer device that absorbs the shock that occurs when a
suspension is compression to its limit.
Bushings – A cylindrical sleeve between a fork stanchion tube (inner leg) and a fork outer
casting (slider), which facilitates the sliding movement between these two parts.
Coil Spring Air Assist – A new feature for 2005 that utilizes a full length coil spring and allows
you to increase the spring rate of the fork by adding air as a booster to that coil spring.
Coil Spring – A coiled piece of metal that acts as a spring to help suspend a fork.
Compression – The phase of the suspension operation in which the wheel travels up, or travels
closer to the frame. The suspension forks reaction to a bump in the trail.
Compression Damping – Restriction of the rate that the suspension compresses under load.
Convertible Travel – A system used to alter the travel of a suspension fork. It requires moving a
travel clip on the compression rod to a different position. This operation is accomplished by
disassembling the fork and physically moving the travel clip on the compression rod.
Crown Steerer Assembly – the stanchion legs (inner legs), the fork crown, and the steer tube
pressed together as one assembly. This assembly is then finished by adding all of the fork
internals and then outer casting (slider).
Damping – A function that modifies the rate of suspension compression or rebound.
Detent – An indentation that causes a rotating adjuster to stop at fixed increments.
Drop Out – The end of an outer casting (slider) where the wheel attaches.
Dust Boot – Usually a piece of rubber in the shape of a cylinder with baffles to allow it to
compress as the fork compresses through its travel. Its function is to help keep dirt and water
from getting into the inner legs of the fork.
FFD – Fluid Flow Damping. A Manitou patented low cost oil damping system. The compression
damping is non-adjustable and the rebound damping may be non-adjustable or adjustable
damping.
Fork Crown – The component that joins the stanchion tubes (inner legs) to the steer tube of the
fork.
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FRONT SUSPENSION TERMINOLOGY (CONT.)
Hydraulic Fork Oil – Oil used in suspension designs to provide damping. It has special
characteristics that determine how it reacts when exposed to compressed air, how it changes
viscosity when its temperature changes, and how it moves through valves.
Hydraulic Lock Out – a condition caused when the mixture of air and damping oil is out of
balance. It is caused when there is too little air space in a chamber, not allowing the fork to
compress through its travel.
Infinite Travel System (IT) – A handle-bar mounted air travel adjust system that allows the rider
to change the fork travel (and ride height) without a spring rate change. The travel can be
changed from full compression to full rebound and at any place in between.
Lock Out – a special function that restricts the compression of the fork from moving. It is
generally controlled by an external knob that is activated when a rider does not want the fork to
move, thus eliminating extra energy needed to overcome the bobbing forces of the fork.
MCU – (Micro-Cellular Urethane) Special urethane that is filled with tiny air cells that act like
springs when the elastomer is compressed.
Micro Lube – Lubrication system that is operated by injecting small quantities of grease directly
into ports that are inserted into outer casting legs. This enables the lubrication of the fork without
having to disassemble it.
No Boss - The word used to describe an outer casting that has no brake posts for V-brakes or
cantilever brakes. This casting is to be used for disk brakes only.
Oil Damping – A system that uses the resistance to oil flow through holes in a valve to provide a
means to alter the rate of suspension compression or rebound.
Oil Level – The level of damping oil needed for the optimal damping performance of a
suspension. It is measured as the air space distance between the top of the stanchion leg (inner
leg) and the height of the oil inside of the leg. The fork must be completely extended in order to
get an accurate measurement.
O-Ring – A soft, flexible neoprene or Buna rubber ring with a round cross-section, which is used
for sealing and retention.
Oil Weight – A description of the relative viscosity of oil, such as hydraulic oil. Oil with low weight
numbers (5wt or 7wt) flows through the valving with less resistance than higher weight numbers
(10or 15 wt).
One Point Five Standard - 1.5 inch interface standard for frame head tubes, headset, cups,
stem, and steer tubes which allows for the lightest weight and strongest design in 170mm single
crown forks. This design greatly improves the control and steering precision of the fork. It is used
predominately on forks with longer travel and the intended use is for more hardcore, extreme
riding.
Outer Casting – (see Slider)
Preload – A condition of compressing a spring or elastomer before the operating loads are put on
the suspension, so that it provides a stiffer spring rate.
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FRONT SUSPENSION TERMINOLOGY (CONT.)
Piston – In front suspension, the part of the damper that slides back and forth inside of the
damping leg that houses the valves. It can also refer to the air piston in the air/spring assembly
that slides back and forth compressing the air, thus causing a change in the spring rate of the
suspension.
Porosity – The condition or property of having pores in a material that will allow gas or liquid to
pass through it.
Platform Plus Damping – A new damping system found on 2005 Rear shocks (featured on
Metel and Radium’s). This system will establish a pedaling efficiency platform similar to SPV, but
is done through unique valving that is not adjustable (helps in bump control).
Rapid Travel II, Wind Down – Systems that are used to control the travel of suspension forks.
Also known as RTII, and WD. RTII is used for the specific purposes of controlling the travel in two
conditions: climbing and descending. WD is an incremental travel adjustment between to set
limits and does not affect the spring rate of the fork as severely as RTII.
Quad Ring seal – New seal that replaces standard o-rings in designs that require more efficient
air and oil sealing methods.
Rebound – The phase of the suspension operation in which the wheel returns to its original
position on the ground after compression.
Rebound Damping – Restriction of the rate that the suspension rebounds when the compression
load is relived.
Remote Lock out system – A handle-bar lever actuated system that controls the lock out
function on front and rear suspension products.
Reverse Arch Technology – Also known as RA. It is a system that is designed to move the arch
of a fork to the backside of a fork, rather than the conventional front position. It was designed to
provide greater rotational torque strength to an outer casting (slider), without adding additional
weight to the fork.
SAG – The amount a suspension fork compresses at rest with a normal load (rider’s weight).
Schrader Valve – Valve used to introduce air into a chamber.
Seal – A part, usually neoprene rubber or Buna, that keeps contaminants out and/or working
fluids in.
Semi Bath – A lubrication system that uses a lubricating oil to keep the bushing surface and
stanchion legs (inner legs) as friction free as possible during movement of the stanchion legs.
Spring Rate – The rate at which the resistance of a spring increases as it is compressed.
SPV – (Stable Platform Valve) new damping system that allows the rider to set the pedaling
platform that he desires to pedal most efficiently in all situations. It is dependent on the pressure
that the SPV valve experiences from the movement of the wheel vs. the terrain and the platform
that is set by pressure introduced to other side of the SPV valve through changes of air pressure
working on the damping oil.
SPV Evolve – The latest version of SPV damping technology that has increased its performance
with modifications to the original design.
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FRONT SUSPENSION TERMINOLOGY (CONT.)
Slider/Outer Casting – The tube (outer casting leg) of the suspension fork that0. remains fixed to
the wheel. It slides up and down on the stanchion leg (inner leg).
Stanchion Clamps - (Double-Triple Clamps) the portions of the fork crown that clamp around the
stanchion legs above and below the head tube of the bicycle frame on specific long travel
applications.
Stanchion Legs – The suspension tube (inner leg) fixed to the fork crown. It remains stationary
during the operation of the suspension.
Steer Tube – The long cylindrical tube that extends from the top of the fork crown. Its function is
to be inserted into the bicycle head tube and attach the suspension to the bicycle frame.
Thru Axle – (Hex-lock) A device used for mounting a thru axle hub to special outer legs that are
not made for standard quick release hubs. Manitou’s Hex-lock (thru axle) system is a special
patented system utilizing a hex shaped end that increases the stiffness of the fork and reduces
slippage in the joint between the axle clamps and the axle.
Top Out Bumper – A rubber, coil spring, or elastomer device that absorbs the shock that occurs
when the load is taken off a suspension so that it is allowed to rebound to its limits
TPC – (Twin Piston Chamber) a patented damping system that has independent pistons for
rebound and compression. The system utilizes a mixture of air and oil in the damping leg of the
fork to enhance the damping performance.
TPC+ - A variation of TPC that has added a floating piston to the compression damper to
enhance the performance of the compression damping under the load of bigger hits.
Travel – The amount that a wheel moves between the most compressed and the most extended
states of the suspension
Viscosity – A description of how a liquid flows. Liquids with higher viscosity are thicker flow less
easily or quickly than liquids with low viscosity. This has an affect on the damping speeds of
rebound and compression.
Volume Control – A new system designed to work with SPV as a control of the compression
ramp up rate of the fork. It has a range of adjustments from linear to very progressive.
Wiper Seal – A rubber material that is used as a seal to keep dirt and water out of the outer
casting legs. It is not designed to keep air pressure or extreme oil pressure in. Manitou has the
new Evil Genius wiper seals.
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2004 Stance Forks Disassembly and Rebuild Instructions
Disassembly Instructions
Removal of Outer Casting
1. On forks with the Wind Down travel adjust system, be sure to set travel to its longest setting.
For Wind Down, rotate adjuster on top left of fork crown counterclockwise until it stops. This
will relieve spring tension on the fork. More complete instructions for servicing Travel Adjust
systems may be found in the “Travel Adjust “section.
2. Turn the fork upside down and remove the fixing screws that attach the Rebound Adjuster
Knob (Blue) and/or the Rapid Travel 1, (Red) Travel Adjust knob. Set both knobs and screws
aside.
3. (Note: there will be three small pieces under the Red knob – wave washer, detent spring,
and a plastic detent plate.)
USE: 2mm Allen wrench to unscrew fixing screws.
4. Remove the 11mm Compression Rod bolt from the bottom of the left leg (From the rider's
perspective).
USE: 11mm socket, nut driver, or open-end wrench.
5. Insert 8mm Allen wrench into the end of the Rebound Damper Shaft on the bottom of the
right leg. Turn the wrench in a Clock Wise direction in order to loosen the damper shaft in
the casting (See Figure below). You are turning the Damper Shaft in a way that causes it to
disappear into the casting leg.
USE: 8mm Allen wrench
6. Working with the “Semi Bath” lubrication system:
A. Position the bottom of the fork legs over a drain pan that is on the ground. Pull the
casting downward towards the pan, allowing the Semi Bath oil in the casting to drip
into the pan. Pull the casting completely off of the inner legs and wipe any excess oil
off of inner legs and inside of casting.
USE: Drainage pan and extra rags
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Removal of Spring and Compression Rod Assembly
1. For Stance Air Assist forks (Air/spring systems as the spring): Remove all of the air
pressure from the Schrader valve on top of the crown on the left side (Black top cap), by
depressing the Schrader valve. Be sure to hold fork with the top of the crown facing upwards.
(Note: When the air is released, this is a mixture of the oil and air inside the leg).
2. If you have not removed the Outer casting, refer to the above section on Removal of Outer
Casting, then proceed to next step.
3. Unscrew the end cap on the bottom of the inner leg and remove compression rod assembly.
This will consist of a compression rod, bottom and top out bumpers, the end cap, and should
be followed by a coil spring and then another rod (air push rod). This spring is the one that
would be changed if the fork’s SAG needed to be changed beyond the capabilities of the air
pressure.
4. For Stance Coil Spring forks (Coil Springs only): Remove the adjuster knob from the top
of the Wind Down adjuster assembly on the top of the crown on the left side of the fork, by
unscrewing the 2mm Allen head screw. Use a 20mm socket and unscrew the remainder of
the assembly from the crown. The spring will be attached to the bottom of the assembly,
when you pull it form the inner leg.
5. Pull the spring from the assembly and it can be substituted with a different rated spring if
necessary.
6. The compression rod assembly on a Coil fork may be removed in the same
7. procedure as described above in the removal of an air spring.
a. USE: 24mm Open-end wrench or 8-10” Adjustable wrench,
2mm Allen wrench, 24mm socket
8. For more specific details on Wind Down, and Air Assist, refer to “Travel Adjust”
section of this manual.
Bushing Removal & Installation
Please refer to section on Bushing Removal & Installation.
Assembly Instructions
Reassembly of Crown Steer/Leg Assembly
For Air Assist Forks
WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.
1. Grease the outside of the air piston and then apply a thin film of grease to the threads at the
top of the inner leg. It is recommended to use Prep M grease (P/N: 85-0031). Push the piston
into the top of the left inner leg with the metallic side of the piston facing you, using your
thumb. Push the piston past the threads and then pour approximately 3-4cc’s of a 20-50wt oil
(P/N: 85-0022) into the top of the piston. This oil needs to be checked about every 6-8 weeks
of riding time. It will dissipate over time and then you may experience some air leakage and
increased stiction in the fork movement.
2. Install the air cap and tighten it to value given on fork schematic.
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3. Turn crown/steer/leg assembly over, so that the bottoms of the inner legs are facing you. In
the same leg that you just installed the air piston and air cap into; insert the air push rod
(longer end in first), then the positive spring (this is your ride kit spring) onto the short end of
the push rod, then install the compression rod assembly, and tighten end cap into leg.
Tighten to torque values that are listed on fork schematic.
4. Now, install damping assembly into bottom of other inner leg. Apply a thin layer of Prep M
grease onto o-ring that is around the piston at top of assembly. Install the assembly and
tighten end cap to specified torque value.
5. Turn Crown/steer/leg assembly right side up, so that the crown of the assembly is facing you.
Extend the damping assembly all the way out and then pour damping oil (P/N: 85-0023) into
the right inner leg. Fill leg about ¼ full. Take a rag and cover the top of the right inner leg and
then stroke the damping assembly up and down about 5 times. This will insure that oil gets
below the piston and not create an air space. Extend the damping assembly all the way out
and then fill the inner leg to the specified oil level.
6. Insert the Volume control assembly into the top of the right inner leg and tighten it to specified
torque value. Be sure that you unscrew the red 16mm Hex shaped Volume control nut all of
the way counterclockwise after you tighten the entire assembly into the inner leg.
7. The crown/steer/leg assembly is now complete.
8. Use: 8-10” adjustable wrench, 24mm socket, metric ruler.
WARNING All leg caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.
For Coil spring Forks :
1. Turn the crown/steer/leg assembly over so that the bottoms of the inner legs are facing you.
Install the compression rod assembly into the bottom of the left inner leg (the leg that was the
left side of the fork when you are sitting on the bicycle) and tighten the end cap to specified
torque value.
2. Refer to step 4 above, for installation of damping assembly.
3. Refer to step 5 & 6 above, for completing the installation of the components of the
damper leg.
4. Refer to Wind Down assembly service instructions for reassembly of Wind Down
assembly.
5. The crown/steer/leg assembly is now complete.
Installation of Outer Casting
For Stance :
When installing the outer Leg Casting to the Crown Steer Assy, Drop Out bolts and
Damper Shafts must be properly tightened prior to use. Failure to do so could result in
injury or possible death.
1. Turn completed crown/steer/leg assembly upside down, so that the compression rod and
damper shaft are facing you. You will see a bottom out bumper on the damper
2. Switch fork to longest travel setting.
3. Place the fork upside down (dropouts up) and slowly remove the travel adjust knob using a
2mm Allen wrench. Three parts are found underneath the knob: wave washer, detent clip,
and detent plate. Remove all parts to expose the 7/16 compression rod screw.
4. Use a 7/16 wrench to remove the compression rod screw.
5. Remove rebound adjuster knob if applicable using a 2mm Allen wrench.
6. From the right leg dropout, use an 8mm Allen wrench to turn the damper shaft clockwise
until it can be pushed into the casting.
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7. Remove crown/steer/inner leg assembly from the outer leg casting over a drain pan, due to
Semi Bath oil may leak out of the bottom of the casting. Set casting aside in drain pan to
allow all oil to drain from casting.
8. Remove left leg end cap and travel adjust assembly from inner leg.
Assembly:
1. Install travel adjust assembly into the left inner leg. Be sure that the adjuster dogs are
retracted into the shaft allowing the spring to ride at the top of the rod. Twist the hex shaft
(shaft where knob is attached) if necessary to retract the dogs, do not pull on the shaft. Start
threads by hand and then torque to 20inlbs.
2. Pull out damper shaft as far as it will go.
3. Lightly grease the bushings on the inside of the outer leg casting and on the lower portion of
the inner legs below the boots using a thick grease such as Motorex Bike Grease 2000.
4. Press inner leg assembly into outer leg casting until damper shaft contacts casting. (It is
recommended to extend rebound damper out from end cap as far as it will go and then slide
bottom out bumper towards the end cap as far as it will go. The bumper will help to hold the
damper shaft in place as you are inserting the inner legs into the casting). Adjuster hex shaft
should protrude slightly from casting.
5. Use an 8mm hex wrench to turn the damper shaft counterclockwise, threading it into the
casting. Torque to 20inlbs.
6. Install rebound adjuster knob if applicable. Knob should turn uninhibited until the indicator is
stopped by the casting. If not, remove knob and reinstall on hex shaft in 1/6 turn increments
until full travel is reached.
7. Install the compression rod screw and torque to 20inlbs.
8. Install detent plate and clip over the travel adjust screw so that the clip points to the center of
the fork. Your fork will have a raised area in the detent plate that locates in a keyway in the
casting. This features help prevent the plate from rotating. Place the wave washer on top of
the detent plate, using a small amount of grease to hold it in place.
9. Install knob on top of the detent plate and washer, with its indicator pointing to the longest
travel position. The underside of the knob has cutouts that the detent clip will nest in. Secure
knob onto assembly with 2mm fixing screw.
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STANCE DUAL CROWN FORKS
Clamp Fixing
Bolts
1. Removal of inner legs from Dual Clamps:
Loosen upper clamp fixing bolts with a 4mm Allen wrench and remove upper clamp from
inner legs.
Loosen lower clamp fixing bolts with a 4mm Allen wrench and remove lower clamp from
inner legs. You may have to remove the frame bumpers first to remove the lower clamp.
2. Installation of inner legs into Dual Clamps:
WARNING All Triple Clamp Pinch Bolts must be properly tightened prior to use. Failure to
do so could result in injury or possible death.
Insert inner legs into lower clamp about 5 inches (125mm).
Install upper clamp onto the inner legs and steer tube, so that the top of the upper clamp
is flush with the top of the inner legs. Do not tighten fixing bolts at this time, because you
will have to make adjustments to the distance between the clamps before you install the
fork on your bike.
3. Install SPV rebound damping assembly or TPC rebound damping assembly into bottom
of right inner leg. Be sure to check the function of the SPV valve and apply a thin layer
of Prep M grease onto o-ring that is around the piston at top of assembly. Install the
assembly and tighten end cap to specified torque value. Be sure to put a dab of Blue
Loctite on the end cap threads before installing cap into leg.
WARNING All leg caps for Damper and Spring systems must be properly tightened
prior to use. Failure to do so could result in injury or possible death.
4. Install compression rod assembly into bottom of left inner leg and tighten to specified
torque value. Be sure to put a dab of Blue Loctite on the end cap threads before
installing cap into leg.
5. Turn Crown/steer/leg assembly right side up, so that the crown of the assembly is
facing you. Extend the SPV rebound damping assembly or TPC rebound damping
assembly all the way out and then pour damping oil (P/N: 85-0023) into the right inner
leg. Fill leg about ¼ of the way up. Take a rag and cover the top of the right inner leg
and then stroke the SPV damping assembly up and down about 5 times. This will
insure that oil gets below the piston and not create an air space. Extend the damping
assembly all the way out and then fill the inner leg to the specified oil level.
6. Insert the Volume control assembly or TPC+ compression damping assembly into the
top of the right inner leg and tighten it to specified torque value. Be sure that you
unscrew the red 16mm Hex shaped Volume control nut all of the way counterclockwise
after you tighten the entire assembly into the inner leg.
WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.
7. Insert spring into top of left leg followed by top cap. Tighten top cap to specified torque
value.
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Setting Dual Crown Fork Ride Height
1. When setting the ride height for your fork, make this calculation to determine the lowest
point at which you can set the lower clamp without it interfering the casting’s arch on full
compression: Travel of fork + 20mm.
This is the
distance that
you are
calculating
2. The number that you calculate will be measured from the top of the dust seal on the
casting to the bottom of the lower clamp.
Warning: Do not set the lower crown lower than the measurement that you
calculated for fear of interference with brake arch.
Installation of Hex Thru Axle
1.
2.
3.
4.
Hold wheel between drop outs. Insert Hex Thru Axle into the outside of the left
Drop out (as you are facing fork) and push it through the hub of the wheel into the right
drop out.
Thread Thru Axle nut into the end of the axle that is in the right drop out. Thread in half
Way.
Set the end of the axle flush with the outside of the left drop out and tighten the 3mm
clamp fixing bolts to specified torque value as called out at end of manual.
Finish the installation by tightening axle nut to specified torque value and then tighten
the clamp fixing bolts on the right drop out to the specified torque.
(see photo below)
Axle Nut
Left Drop out
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Right Drop out
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Travel Adjust Systems: Wind Down
Wind Down Travel Adjust Service Instructions
Disassembly
1. Turn travel adjust knob (clear plastic knob on top of the left side of the crown) in a
counterclockwise direction until it stops. This insures that the fork is in its longest travel
and reduces any spring preload on the fork.
2. Remove the 2mm Allen screw from the knob. Use a 28mm socket to unscrew the top cap
assembly from the crown. (Refer to Figure 1)
3. Pull spring out of inner leg. If spring will not come out, you must take the outer casting off
of inner legs (refer to Removal of Outer Casting instructions). Then remove the end cap
from the bottom of the left leg and remove the Wind Down compression rod assembly
and spring as a single unit through the bottom of the leg. You will find that on earlier
production fork models, that there is a nylon washer at the top of the compression rod
assembly that is holding the spring in place. Hold the spring in one hand and the
compression rod assembly in your other hand and pull the apart from each other at a
slight angle to each other. Once you have the two apart, remove the Allen bolt on top of
the compression rod with a 4mm Allen wrench and remove the nylon washer (Fig 2). Reinstall the bolt without the washer, it will not affect the operation of the Wind Down
mechanism and insure that you will not have to take the whole fork apart in the future to
change ride kit springs. (Note: the spring that you remove should have another spring
(booster spring) intertwined within it)
Tools needed: 28mm socket, 2mm Allen wrench, 8 or 10” Adjustable wrench, 11mm nut
driver or open end wrench.
Assembly
1. If you had to remove the outer casting, reassemble the compression rod assembly and
then follow instructions for Installation of Outer Casting.
2. Optional Ride Kits - If you need to adjust to overall ride characteristics either softer or
firmer, purchase and/or install as follows (Kit Part Numbers can be found in the Service
Part section of this manual):
•
•
•
Soft - Remove the Booster Spring
Firm - Purchase Firm Ride Kit and install the Booster Spring
Extra Firm - Purchase Extra Firm Ride Kit and install the Booster Spring
1. To remove the booster spring from the main spring; grasp the flat end of the
booster spring with a pair of needle nose pliers and twist it in a clockwise
direction to unscrew it from the main spring.
2. To install a booster spring into a main spring, catch the flat end of the booster
spring under the flat end of the main spring and twist it counterclockwise into the
main spring. Make sure that the booster spring is threaded all of the way down
into and contained by the main spring. Before inserting it back into the inner leg.
3. Generously grease the spring and insert it into the inner leg. The spring needs to seat
onto the top of the compression rod.
4. Insert the wind down top cap assembly into the spring; the "D" shaped portion of the
adjuster assembly must fit into the "D" shaped end of the main spring. Screw the
assembly into the inner leg and tighten per the fastener torque guide at the end of this
manual.
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5. Install adjuster knob and 2mm hex screw. Turn the knob counterclockwise until it stops.
This insures that the fork is in its longest travel position. If the travel indicator arrow on
the crown is not lined up with the maximum travel point on the indicator dial, loosen the
compression rod bolt on the bottom of the outer casting and continue to turn the knob
counterclockwise until the indicator point to maximum travel. Retighten the compression
bolt per the fastener torque guide at the end of this manual.
Wind Down Travel Adjust Assembly
Top Cap Assembly & Spring
Travel adjust assembly & End Cap
Adjuster knob O-ring, knob, & 2mm screw
Figure 1
Remove Nylon washer that rests on top of aluminum washer
4mm recessed Allen bolt
Figure 2
05 STANCE SERVICE MANUAL
Page 15
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Air Assist Trouble Shooting Tips
The root cause of the air leaking from the left leg of the fork (the side with the Schrader valve on
top) is that the casting was drilled incorrectly on the hole in the bottom of the casting where the
compression rod bolt goes. It turns out that the Stance casting and the Nixon casting are the same
and have the same problem. This has caused inconsistency with the IT system and the Air Assist
system. Below are some steps to follow in order to trouble shoot this issue and potentially resolve
it.
1. Unlike trouble shooting the IT system, it is difficult to visually determine if the hole in
the bottom of the casting is drilled correctly. So you need to remove the casting and
check a couple of other areas.
2. Once the casting is off, try pumping up the left leg with about 50psi. If it blows out
immediately, this means that the seal around the compression rod piston is bad. This can
be changed out with a new Quad ring (p/n: 066398). Your assembly will probably have
an o-ring on it.
3. Just as with air pistons, you want to coat the threads of the inner leg with Prep M grease
and the Quad ring, and then twist the assembly as you put force on it to get it past the
threads of the inner leg. It is also important to add the air piston oil (20/50wt) (about 35cc’s) through the top of the inner leg prior to pumping it up.
4. If the air does not immediately pass from the inner leg, I recommend that you put that end
into a bucket of water and see if any air bubbles are produced. Once again, if the bubbles
are seen, check that seal.
5. If you get no bubbles, I would put some pressure on the compression rod in a side ways
manner to side load that shaft. If air is released, it points to the hole in the casting being
off center.
6. In this case, you need to change the casting. Remember: The Nixon casting is
interchangeable.
05 STANCE SERVICE MANUAL
Page 16
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Remote Lock out Service Instructions
Complete Remote Lock out Assembly
Lever Kit and
Lever cover
Kit
Cable Guide
There are (5) Service kits available for each fork
model that utilizes a Remote Lock out.
1. Lever assembly
2. Lever Cover
3. Cable assembly
4. Cable guide
5. Lock out assembly
*Reference to these kits may be found in the
Service Parts Matrix
Barrel
adjuster
Cable
Assembly
Lock out
Assembly
Instructions for removing assembly from fork
1.
2.
Tools needed
to service
assembly
3.
4.
5.
Unscrew barrel adjuster in a
counterclockwise direction until it stops.
Remove Lever cover by squeezing the two
plastic prongs together on the under side of
the lever and pulling the cover in an upwards
direction from the lever assembly.
Pull on Black cable ferrule nearest to lever
and pull cable assembly from the groove in
the Lever assembly, thus releasing cable
from lever. Unhook cable end from lever.
Unscrew the top cap of the Lock out
assembly from the fork crown using socket
(Answer p/n: 83-2503) or an adjustable
wrench.
Pull Lock out assembly out of crown by
twisting the assembly like unscrewing a
screw and applying an upward pressure.
Slowly pull assembly out of crown and watch
out for some excess damping oil to come out
of inner leg as the piston at the end of the
assembly comes out of crown.
Adjustable Pliers
Adjustable Wrench
Socket Wrench
22mm Socket
W/cut out
10mm open end wrench
05 STANCE SERVICE MANUAL
Page 17
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Steps For Cable Disassembly
1.
2.
3.
Step 3
Step 1
Step 2
4.
Tool Placement to unscrew upper
shaft assembly from lower
assembly (Figure A)
5.
1.
2.
Cable hook up connection
(Figure B)
3.
4.
5.
Cable Replacement Instructions
Step 1: Lock out assembly should be out of fork at
this point.
Step 2: Cable assembly should be out of Lever
assembly
Step 3: Look at tool placement in Figure A. It is
recommended to use the Adjustable Pliers to grasp
the flange of the lower assembly right above the coil
blow off spring. Use a 10mm open end wrench on
the flats of the upper assembly just below the top
cap. Hold the flange with the Pliers and turn the
10mm wrench in a counterclockwise direction in
order to unscrew the upper and lower assemblies.
Separate the two assemblies and unhook the cable
end from the eye hook as shown in Figure B.
Pull the cable out through the top cap and red cable
guide. There will also be a 75mm spring inside of
the upper shaft. This spring provides the tension for
the cable when you move the Lock out lever from
the Lock position to Unlock position. The inner
cable runs through the center of the spring.
Cable Installation Instructions
The inner cable is not removable from the cable
assembly. The entire cable assembly must be
replaced. Install the new cable assembly by
reversing the Disassembly the instructions.
Slide the inner cable through the red cable guide,
the top cap, and down through the spring. (Be sure to
put a little bit of the Prep M grease on the spring
before putting it back into the upper shaft assembly.)
Push the cable assembly together, forcing the inner
cable to stick through the spring and then out
through the end of the upper shaft assembly. (See
Figure C). Hook the cable end into the eye hook and
then pull on the cable assembly to pull the two shafts
together. Tighten them together snuggly.
Check oil level in fork leg (refer to oil level heights
in fork spec sheets). Install Lock out assembly into
the fork leg and tighten top cap to proper torque.
Re-install the other cable end into the Lever
assembly, and then put the lever cover back on to the
Lever assembly. You may have to pull the cable
assembly away from the housing of the lever
assembly to expose the inner cable, so that you can
slide the cover into its proper position.
Figure C
05 STANCE SERVICE MANUAL
Page 18
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Lock Out Troubleshooting Tips
1.
Installation of Lock out Compression Damping System
• Check the o-ring that is installed around the lower piston on the damper shaft for
tears or deformation. Replace it, if it is damaged. This is the most common reason
why the Lock out system will not function.
• Check the level of oil in the inner leg. The oil level may be a little high, but never
low. The oil level must be high enough to cover the window that opens and closes on
the damper shaft.
• Make sure that the oil flow window on the lower portion of the damper shaft,
positioned right above the piston, opens and closes when you move the lock out knob
from open to close.
• Inspect the rubber o-ring that is around the threaded portion of the cap that screws
into the inner leg of the fork. This o-ring should not have nicks or tears in it and
should fit tightly around the cap.
• Make sure that when installing the Lock out system into the fork leg that you follow
this procedure: Put a little bit of Prep M grease on the urethane o-ring, make sure that
that the oil flow window is open using a motion like screwing in a screw. Twist the
assy. and apply a little pressure to insert the piston part of the mechanism past the
threads at the top of the inner leg. Then push the assy. into the leg until the threads on
the cap intersect the threads inside the inner leg, screw the cap in and do not use any
tools to over tighten the cap. Once the cap is tightened, compression the fork several
times to circulate the oil through the system and then activate the Lock out system by
moving the lever to the other position. The fork should have between 2 & 5mm of
progressive travel before it locks out.
2.
Troubleshooting
• If the Lock out does not lock out properly, go back through the steps listed above.
• If the o-rings are damaged on the Lock out piston, replace them with P/N
062594(urethane 1998-2003 Mars, SX, & Skareb Lock outs), 065261 (04/05
Skareb Lockouts) and 02/03 Black 100/120mm Lock outs, and 040315 (Axel’s).
• If the oil level is low, check to see if there is evidence of leaking at the Rebound
Damper. If so, replace the Rebound Damper assembly and retry the Lock out. The oil
level may be low if you are upgrading a standard Compression Damping system with
the Lock out system. In this case, make sure the oil level is at the correct level before
trying it again. If there are signs of oil leaking around the top of the Lock out system,
check the rubber o-ring (040524) and replace if needed. If the window does not open
or close when the knob is moved, replace the entire Lock out assembly.
05 STANCE SERVICE MANUAL
Page 19
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Bushing Removal & Installation
Bushing Removal
(Note: use appropriate removal ring that corresponds to the leg diameter of the fork being
repaired)
Leg Diameter
25.4mm (1”)
28.6mm (11/8”)
30mm
32mm
Answer Kit #
85-5191
85-5189
85-5194
85-5192
Bushing Removal Tool Components
A. Slide Hammer
B. Threaded Handle
C. Slide
D. Threaded Shaft
E. Removal Ring
Bushing Removal Tool Assembly
05 STANCE SERVICE MANUAL
Page 20
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Bushing Removal (CONT.)
Bushing Removal Instructions
A. Install 25.4mm Removal ring on the
shiny, smaller diameter threaded shaft.
Be sure to install the ring with the
tapered, chamfered end first, followed by
the long slide tube. This tapered end
leads the tool through the bushing.
B. Start the procedure by removing the
Dust/Wiper seal with a screwdriver,
prying it out.
C. Insert Removal tool past the upper
bushing and then stop. It is important to
pull one bushing out at a time. Push the
slide on the threaded shaft down
towards the removal ring. Hold the
casting with one hand and the slide
hammer with your other hand. Now
move the slide hammer in a motion away
from the casting and repeat this action
until the bushing comes out.
D. For all other leg diameters: use the
larger diameter (dark colored) threaded
shaft and repeat steps A-C.
Bushing Installation
(Note: Sizer kits listed in above chart contain the sizers needed for each specific leg diameter.)
(1)
(2)
Bushing Installation Tool Components
1. Installation Mandrel
2. Threaded Rod w/nuts
3. Sizer rings
4. Spacer
5. Washer
6. Nut
(3)
05 STANCE SERVICE MANUAL
Page 21
(4) (3) (5)
(6)
REV NC
Bushing Installation (CONT.)
Bushing Installation Tool Assembly
With weighted handle
When selecting sizer rings to install bushings,
choose the two rings that are in the middle of
the size run to start with.
1. Assemble installation tool as shown in
picture above. Each leg diameter kit has all
of the needed pieces to remove and install
bushings for forks with serviceable
bushings. Some of the kits come with
gauges to tell you how far to drive in the
lower bushings. Upper bushings are driven
in as far as the stop in the top of the
casting will allow. The general rule of
thumb is that the lower bushings must not
be driven any deeper than 5” into a casting
leg. If they do go deeper, call Customer
Service at Answer Products – 800-4230273 for a new outer casting.
2. Always assemble Mandrel with the larger
diameter sizer ring being placed on the
mandrel first, then the spacer, the next
largest sizer ring, followed by the washer
and the nut to hold it in place. Be sure to
lock the nut above the Mandrel and below
the Mandrel against each other.
3. Replace the lower bushing (bushing with a
thicker wall diameter) first. Place a small
amount of Prep M grease onto the sizer
rings to help the rings come through the
bushings when pulling them out. Slide
bushing onto Mandrel until it stops. Apply
a bead of Red Loctite all the way around
the outside of the bushing. Hold casting on
top of bench with a rag under the end of
the legs and insert installation tool with
bushing into casting leg.
05 STANCE SERVICE MANUAL
Page 22
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Bushing Installation (CONT.)
4. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet
until proper depth is achieved. If using depth gage, slide gage onto rod before installing
weighted handle and let it settle on of Mandrel. Tap rod until appropriate line on gage is even
with top of casting leg.
5. Remove weighted handle and gage (if applicable).
6. For sizing of the lower bushing:
7. Use slotted top cap from sizer kit and set it into the top of the casting leg, straddling the
threaded rod. Spin the extra nut with washer down to the top cap and using a wrench,
socket, or speeder wrench, tighten the nut in a clockwise direction. This will cause the
Mandrel to be pulled through the bushing, thus sizing it. Keep turning the nut until the tool is
all the way through the bushing and can be pulled out of the leg.
8. To install top bushings, repeat steps B-E. Note that the top bushing gets inserted until it stops
against the step inside of the casting. The extra sleeve that comes with the sizer kit is used
to space the top cap off of the casting, so that there is enough room to pull the sizers out of
the casting without bottoming on the cap.
9. If you find that the bushings are too tight after installing them, use the sizer Mandrel that does
not have a stop on it to hold the bushing while installing it into the casting. This is available in
the 25.4mm leg kit (85-5191) to go back in and resize the bushings.
10. To resize bushings, Choose the next larger size rings and repeat the above process.
11. When satisfied with the results, reinstall Dust/wiper seals and then reassemble fork
05 STANCE SERVICE MANUAL
Page 23
REV NC
TROUBLESHOOTING
Symptom
Air Loss
Oil leaks from
Wiper Seals
Oil leaks from
bottom of
Casting
Lack of Travel
Cause
Solution
Service
Manual
Page
Schrader Valve leaks
Tighten Valve core, replace bad parts as
needed.
9
Air Cap O-ring leaks
Make sure O-ring is seated properly,
replace parts as needed.
9
Air Piston leaks
Check oil volume on top of piston, replace
parts as needed.
11
Air Top Cap leaks
Check O-ring, tighten cap to proper
Torque, replace parts as needed.
9
Seal not seated properly
Remove Casting from Inner Legs, reinstall
or replace seals
8
Nicks or scratches on
inner legs
Replace Crown/Steerer/Inner Leg
Assembly
13
Too much Semi Bath oil
Follow instructions for removal and
installation of Outer Casting
8
Wear
Remove Casting from Inner Legs, reinstall
or replace seals
8
Rebound damper shaft
leaks
Replace Rebound Damping assembly
8
Rebound damper shaft Oring damaged
Replace O-ring on threaded end of
Rebound Damping assembly
9
Compression Rod Bolt
leaks
Check O-ring on bolt to see if it is
damaged and then reinstall
8
Tight Bushings
Hydraulic lock out
Resize bushings or replace with new ones
if damaged
Replace Rebound Damping assembly
23
9
Semi Bath oil volume
Follow instructions for removal and
installation of Outer Casting
8
Damper oil volume
Check oil level, Replace Rebound
Damping assembly if needed
9
Fork alignment
Visually inspect fork, call Answer
Products Customer Service
2
05 STANCE SERVICE MANUAL
Page 24
REV NC
TROUBLESHOOTING (CONT.)
Symptom
Cause
Fork Top out
Loss of Rebound
Damping
Replace Rebound Damping assembly
9
Top out spring damaged
Inspect and replace Top out spring if
needed.
10
Damping oil volume not
correct
Check oil level, Replace Rebound
Damping assembly if needed
13
Too much SAG
Refer to SAG Set up in Tuning section of
Owners Manual
Bottom out Bumper
damaged
Inspect and replace Bottom out Bumper if
needed
13
Damping oil volume not
correct
Check oil level, Replace Rebound
Damping assembly if needed
13
Loose bushings
Resize bushings or replace with new
ones if damaged
23
Loose Compression Rod
bolt
Tighten bolt to specified torque
13
Loose Rebound damping
shaft
Tighten Shaft to specified torque
13
Loose press fit tolerances
Call Answer Products Customer Service
2
Various
See Air Assist Troubleshooting Guide
14
Various
See Lock Out Troubleshooting
17
Various
See Remote Lockout Section
15
Fork Bottom
out
Play in Fork
Air Assist
Problems
Lock Out
Problems
Remote
Lockout
Problems
05 STANCE SERVICE MANUAL
Solution
Service
Manual
Page
Page 25
REV NC
Stance: Fastener Torque and Setup Levels
A
C
G
E
D
B
H
Description
Model: Stance
Torque Values
Torque – Brake Post
90–110inlbs (10.2-12.4nm)
Bushing Depth Left Lower
4.25 – 4.50in (108-113mm)
Bushing Depth Right Lower
4.25 – 4.50 (108-113mm)
Leg Caps - Not Cross-Threaded
25–35inlbs (2.8-4.0nm)
Torque – Damper Screw
10-30inlb (1.1-3.4nm)
Torque - Comp Rod Screw
10-30inlb (1.1-3.4nm)
Adjuster caps & Top Caps
Torque
35-50inlbs (4.0-5.7nm)
Semi Bath Oil Volume
16cc per leg
Damping oil Level (100-130mm Travel)
3.9in, 75mm, 120cc
05 STANCE SERVICE MANUAL
Page 26
REV NC
Stance Kingpin: Fastener Torque and Setup Levels
F
A
C
D
E
G
B
Description
H
Model: Stance
Torque Values
Torque – Brake Post
90–110inlbs (10.2-12.4nm)
Bushing Depth Left Lower
4.25 – 4.50in (108-113mm)
Bushing Depth Right Lower
4.25 – 4.50 (108-113mm)
Leg Caps - Not Cross-Threaded
25–35inlbs (2.8-4.0nm)
Torque – Damper Screw
10-30inlb (1.1-3.4nm)
Torque - Comp Rod Screw
10-30inlb (1.1-3.4nm)
Adjuster caps & Top Caps
Torque
35-50inlbs (4.0-5.7nm)
Semi Bath Oil Volume
16cc per leg
Damping oil Level (100-130mm Travel)
8.7-8.9 in, 220-226mm
05 STANCE SERVICE MANUAL
Page 27
REV NC
Stance Service Kits
Model
Static
Travel (mm)
80
Comp Damp
Blunt
100
130
A
Rbnd Damp
B
Pre Load Adj/Top Cap
C
RTWD Travel Adjust Assy
C
Air Cap
C
Crn/Str/Leg
Std Stl Str
Flow
150
100/130
Kingpin
120/150
83-2342
83-2345
83-2347
83-2351
83-2352
832349
832350
832355
832357
83-2353
83-2354
832357
83-2355
85-5903
St Dbl Clamp - Large
Outer Leg Assy
170
83-2343
832348
St Dbl Clamp - Small
1.5 OS
150
85-5962
832358
83-2356
832356
832358
E
QR
Matte Silver
83-2427
QR
Matte Black
83-2361
QR
Charcoal
83-2360
TA
Matte Black
83-2363
TA
Sticker Kit
Charcoal
83-2362
Dark Forks
83-2364
Light Forks
83-2365
Ride Kits
G
832371
***WD Booster
***X-Soft
83-2366
83-2367
***Soft
83-2368
83-2369
***Medium
83-2374
83-2375
***Firm
83-2376
***X-Firm
Comp Rod
H
Knob Kit
I
Seal Kit
K
Bumper Kit
K
Bushing Kit
E
83-2380
83832382
2383
832373
83-2367
832370
832372
832378
832379
83-2377
832386
832387
83-2381
83832384
2388
83-2369
83-2375
83-2377
83-2381
83832384
2384
83-2391
83-2393
832394
83-2392
83832395
2396
83-2395
85-5964
Thru Axle Kit
83-2397
Top Clamp - LG
F
85-5965
Top Clamp - SM
F
85-5966
Options:
*****Lock Out
A
*****Internally Adj TPC +
A
*****FFD Rebound Damp
A
05 STANCE SERVICE MANUAL
85-5896
83-2344
83-2347
Page 28
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