p/n: 0629972
——_—] 5
answer pProducts
28208 Avenue Stanford, Valencia, California 91355-3984 * Phone: 861.257.4411 * Sales Fax: 661.294.4179
TABLE OF CONTENTS
Introduction..... ere KEG 1
Consumer Safety Information........ |
Warranty Information.................. 2
Installation Instructions................ 2
Maintenance.............——er__e-—.esve. 3
, Adjusting the Ride Qualities....... 4-5
Exploded Views. ...............ee... 6-9
AMERICAN MADE MANITOU SUSPENSIÓN
CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE, A 2001 MANITOU
MARS BUILT IN THE USA. WITH THIS FORK INSTALLED ON YOUR BIKE, YOU'LL BE ABLE TO RIDE FASTER
AND HAVE MORE FUN. SOME WORDS ON YOUR NEW MARS BEFORE WE BEGIN. 2001 MARS FORKS USE
MANITOU’S STATE OF THE ART AIR-COIL SPRING SYSTEM. THE MARS LINE USES THE PATENTED TPC (TWIN
PISTON CHAMBER) SYSTEM THAT SURPASSES ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE
AND DURABILITY. MARS FORKS ALSO USE MANITOU’S QUICK AND EASY MICROLUBE SYSTEM, WHICH
ALLOWS YOU TO LUBRICATE THE FORK VIA AN EXTERNAL FITTING ON THE BACK OF THE FORK. ALL MARS
FORKS COME EQUIPPED WITH 74MM POST-STYLE DISC BRAKE MOUNTS.
This MARS fork is fully assembled and ready to be instalied onto your bicycle. It comes equipped with a 1 1/8-inch threadless steerer
tube, is available with a V-brake-style hanger-less arch.
2001 MARS FORK LINE
MARS SOMM TRAVEL/AIR-COIL SPRING /TPC SPORT DAMPING/SINGLE HOLLOW CROWN
MARS ELITE › §0MM TRAVEL/AIR-COIL SPRING /TPC DAMPING/SINGLE HOLLOW CROWN
MARS SUPER 80MM TRAVEL/AIR-COIL SPRING /ANTI-BOB/TPC DAMPING/SINGLE HOLLOW CROWN
One last note. If you lose this manual, or want to take a look at the MARS Service Manual or MRD Tuning Manual, head
straight for the web at www.answerproducts.com or call (661) 257-4411 and ask for warranty service.
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 and rear shock will reduce the
possibility of injury or possible death. Prior to riding your bicycle, you should inspect your suspension fork to ensure that no
damage has occurred during the course of riding. Do not ride your bicycle if the fork or shock 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 to have your fork shipped directly at (661)
257-4411.
| IMPORTANT: The MARS fork is an off-road fork, and as such, does not come with proper reflectors for on road use.
CONSUMER SAFETY INFORMATION
1. Never remove or have the steerer tube or stanchions removed from the crown. The steerer tube and stanchions (inner legs) are press
fit at the factory. Press fit inner legs have a higher performance versus, bolt in inner legs, but cannot be pressed out. Pressing them
out will permanently damage the crown beyond repair and render it unsafe for any continued use.
2. Never attempt to thread a threadless steerer tube, Cutting threads will weaken the steerer tube and cause an unsafe condition. The
only safe thing to do is to obtain the proper crown/steerer from your dealer, on contact Answer warranty at (661) 257-4411.
3. Any other alteration or modification to your fork should be considered unsafe. Contact Answer Technical Support prior to
modifying your fork in any way for safety information.
4. Do not use the MARS fork if any parts are broken, bent, cracked, or you suspect may be damaged. Contact your dealer or Answer
Products Technical Support at (661) 257-4411 if you have any questions concerning the integrity or condition of your fork.
5. Answer Products recommends that you periodically inspect your fork for wear and damage. Inspect the crown, inner legs, outer legs
dropout and brake arch areas for cracks or damage. -
ep
© 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 with proof of
purchase, freight prepaid. This warranty does not cover breakage, bending, or damage that may result from crashes or falls. This
warranty does not cover any fork that has been subject to misuse or whose serial number has been altered, defaced or removed. This
warranty does not cover paint damage. Any modifications made by the user will render the warranty null and void. This warranty is
expressiy 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 (661) 257-4411 or (800) 423-0273. At that time, instructions for repair, return, or
replacement shall be given. Customers in countries other than USA should contact their dealer or loca! distributor.
INSTALLATION INSTRUCTIONS
Ensure that the proper steerer tube has been delivered on your MARS first. 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.
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 fo change
steerer tube lengths or diameters. Removing and replacing the steer tube
or stanchions will result in an unsafe condition and should never be done.
Fork Installation
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube, You can use
your old fork as a guide to how long you should cut the steerer tube to.
3. Remove the headset crown race from the old fork and press onto MARS
steer until the race is seated over the crown (Figure 1).
Clean and grease the headset bearings and races.
Install the lower bearings (if applicable) on fork crown race.
Insert the steer tube into the head tube of the frame.
Install the upper bearings, stem spacers, and stem.
Install the stem cap and bolt. Tighten the bolt to headset manufacturer's
specifications.
9. Install the handlebars to desired height and the torque stem pinch screws or
stem clamping system to manufacturer’s specifications.
10. Install the brakes and adjust per the manufacturer’s instructions.
11. Adjust the front wheel quick release to clear the 0.275 (TMM) thick
secondary catch dropout. The quick release must be tightened after it is
properly seated into the dropout counter bores to manufacturers
specifications. Insure that there is adequate thread engagement (4 or more
threads with the release adjusted to lock.
12. Install the brake cable per manufacturers instructions:
© Nh
Note: 2001 MARS forks are equipped with a secondary catch dropout. To
retain the wheel in the fork in the event the quick release comes loose.
WARNING: When installing the wheel or a new tire, check to make sure
the forks achieves minimum fire clearance. Measure from the highest point
on the tire to the bottom of the crown. The minimum clearance allowed is:
3.26” (83mm) for 80mm travel forks
Any clearance less than this can result in serious injury or death. Figure 2
IMPORTANT: The MARS should not be used if any parts appear to be
or are damaged. Contact your local dealer or Answer Products for
replacement parts.
MAINTENANCE
IMPORTANT:
1. 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.
2. Use of this fork without fork boots will require frequent service
_intervals to maintain performance and normal life of fork.
3. Warranty will be void if fork is found to show that boots where not in
place and frequent service was not performed.
Your MARS fork requires periodic maintenance, cleaning and inspection. This
is because moisture and contamination may build up inside the fork depending
on the severity of riding conditions. To maintain top performance, it is
recommended that the fork be periodically disassembled, cleaned, dried and re-
greased using the Microlube grease ports located on the back of each outer leg
(Figure 3). For information on how to properly service your fork, you will need
the 2001 MARS Service Manual P/N: 85-3694.
IMPORTANT: When lubricating the fork with Prep M grease through
the Microlube grease ports, it is important to note the grease is being
forced between the upper and lower bushings. If the area is overfilled the
force of the grease may force the upper bushing and dust seal out. You
should only insert grease to a maximum of 20 pumps.
IMPORTANT: Before every ride you should:
1. Ensure that quick release skewers are properly adjusted and tight.
2. Wipe the inner legs and clean and check the entire fork for any obvious
damage.
3. Check the headset for proper adjustment.
4. Ensure that the front brake cable is properly routed and check brake
adjustment.
CHECKING OIL LEVEL
IMPORTANT: Maintaining the proper oil level in your TPC-equipped
fork is critical. TPC is located in the right leg of your MARS fork. Not
enough oil will allow foaming and reduce the performance. Too much oil
will restrict travel and may cause damage to the system and create an
unsafe riding condition. Finish reading this entire section prior to altering
the oil level.
To check the oil level, remove the compression assembly located in the top of
the right leg. Leave the left side fully charged with air to keep the fork fully
extended. Use a tape measure or “dip stick” to determine the oil level. The oil
level should be per following table. (See Figure 4.)
OIL Level
Fork Model Recommended | Maximum Minimum
MARS 4.50”(114mm) | 4.00"(101mm) | 5.00"(127mm)
MARS Elite 4.00"(101mm) | 3.75"(95mm) | 4.25”(108mm)
MARS Super 3.75"(95mm) | 3.50"(89mm) | 4.00"(102mm)
NOTE: Use Maxima SAE SWT fork oil suspension fluid only.
AIR/COIL SPRING RATE TUNING
All 2001 MARS forks use a combination of air and a coil spring. The air spring
is adjustable via a Schraeder valve located on top of the left leg. 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 1s
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)
+ The air/coil system is both lightweight and produces a supple, but
progressive spring curve because of the use of two spring materials. The spring
system in action functions like this: When the fork compresses, the coil spring
compresses first. This is because the coil spring has a very low breakaway
threshold (it moves with just one pound of pressure applied) and thus provides
initial suppleness with the fork. The negative spring also helps provide initial
suppleness because it helps actuate the air spring (a negative spring works to
pull the fork together, where a positive spring 1s keeping the fork extended). In
the middle portion of the travel, the fork transitions from the coil spring to the
air spring. Near the end of the fork’s travel, the air spring’s progressive nature
provides resistance to bottoming. |
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 lbs. 100 psi +/- 5psi (1) 3” red 100 pound coil spring
145-175 165. 120 psi +/- 5psi (1) 3” red 100 pound coil spring
175-205 Ibs. 140 psi +/- Spsi (1) 3” yellow 120 pound coil spring
205-230 Ibs. 160 pst +/- 5 psi (1) 3” yellow 120 pound coil spring |
230 + lbs. 180 psi +/- 5 psi (1) 3” black 150 pound coil spring |
Spring rate fine tuning: Figure 5
NOTE: MCU’s and springs used in pre-2001 model Manitou forks are NOT
interchangeable with later versions of Manitou forks. Recommended spring
kits are available through your dealer.
ADJUSTING DAMPING FOR MARS ELITE AND SUPER
Compression Damping Fine Tuning For MARS Elite: Figure 6
To adjust the compression damping on your MARS Elite fork, simply rotate the
compression-damping knob located on top of the right leg. Rotating the knob
clockwise will increase damping, while rotating the knob counterclockwise will
reduce damping. Excessive damping (or an overly stiff spring rate) will give
you a harsh ride over sharp bumps like rocky sections, but will handle large hits
like G-outs well. Insufficient compression damping (or an overly soft spring
rate) will cause the fork to bottom out on large hit G-outs and bob a little while
climbing, but feel plush on the sharp hits. A correctly adjusted fork will
perform well in all conditions.
Compression Damping Fine Tuning For MARS Super : Figure 7
To adjust the compression damping for the Mars Super. Remove the Anti-Bob
compression damping assembly from the top of the right leg. Adjust the set
screw on the valve seat in to increase compression damping and out to reduce
the compression damping. Try adjusting one half turn at a time.
Rebound Damping Fine Tuning Mars Elite and MARS Super: Figure 8
To adjust the rebound damping on your MARS Elite and Super fork, simply
rotate the rebound-damping knob located on the bottom of the right leg.
Rotating the knob clockwise will increase the damping, while rotating the knob
counterclockwise will reduce the damping. Excessive damping (or an overly
soft spring rate) will give you a harsh ride over repetitive bumps (like braking
bumps) because the fork will pack up and sit too deep in the travel under
normal riding conditions. Insufficient rebound damping will make the fork
overly active and may even cause the fork to top out (a slight thumping noise
when the fork extends completely. We suggest that you try adjusting your fork
on the very active side, with minimum rebound damping. Then try it over a
variety of terrain and tune in more rebound from there.
>
Tuning TPC Sport
The TPC Sport damping found on the MARS model is not adjustable
externally, but that doesn’t mean you can’t vary the feel of the fork; changing
the fork oil weight in your TPC Sport-equipped fork will significantly alter the
damping character of the fork. The standard fork fluid for Manitou forks is 5-
weight Maxima, but 2.5-weight oil will decrease damping control, while 7.5-
weight will increase damping in the TPC sport system.
One thing to remember when changing fork fluid from stock is that the
increased or decreased oil weight will affect both compression and rebound
damping equally, This means that while you may be slowing rebound down by
say, adding heavier fork oil, you also may be adding compression damping to
the point of the fork feeling harsh. The best thing to do is to experiment with
different oil weights until you find that perfect setting for you.
Note: Since TPC Sport uses orifices (or holes) in the compression and rebound
pistons to meter the flow of oil (and thus create damping), changing the orifice
sizing may seem an obvious method to tuning TPC Sport. While doing this will
produce significant changes in the damping of the fork, it is not recommended.
Changing the size of the damping ports risks damaging the pistons, will void the
warranty on the fork and will most likely compromise the performance of the
fork as well.
Figures 9, 10 & 11 are schematics of the MARS, MARS Elite & MARS Super
fork models.
Anti-Bob System
Anti-Bobs are available for all MARS models and is stock on the MARS Super.
By turning the knob ¥ turn CCW, the front fork will have regular TPC
suspension. By turning the knob % turn CW, the fork will have extreme
damping. Partial Anti-Bob can be used by turning the knob between the on and
off positions. A safety blow off valve will open under extreme conditions to
allow some movement.
FIG 1:
- Race installation
‘Einbau des Laufrings
Instoigcé del cnillo
Installation du jeu de direction
Montaggio del?
anelio della testa
CROWN RACE
GABELBRUCKEN~LAUFRING
ARANDELA DE LA DIRECCION
CONE DE JU DE DIRECTION
ANELLO DEELIA TESTA
FIG 2:
Minimum Trie Clearance
Fork model
Gabelmodell
Modelo de horquilla
Modéle de fourche
Modello di forcelta
Minimum cleoronce
Mindestabstand
Espacio libra mínimo
Jeu minimum
Spazio libero minimo
BOmm travet forks
3.26" (B3 mm)
FIG 5:
Fine tuning air/coil sprin
Feinabstimmung der Bruc feder
Ajustes de precislón al resorte da compresión
Réglages fins des ressorts de compression
Messa a punto delle mola di compressions
SCHRADER VALVE
UNDER KNOB
FIG 6:
Fine tuning compression damping MARS Elite
ROLE
REHEN
GIRAR
TOURNER
RUOTARE
РСЗ
Grease Port
FIG 7:
Fine tuning compression domping MARS Super
ADJUST SET SCREW
FIG 4:
Qil level
Olstand
Nivel del aceite
Niveau d'huile
Livello dell'olio
| |
-
MAXIMUM я
|
|
$ |
;
MINIMUM | |
| |
A
RECOMMENDED LEVEL
EMPFOHLENE ANFANGSULSTAND
NIVEL RECOMENDADO
NIVEAU RECOMMANDE
LIVELLO RACCOMANDATO
FIG 8:
Fine tuning rebound damping MARS Elite & MARS Super only
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