Manitou 2003 Skareb Service Manual

Manitou 2003 Skareb Service Manual
SERVICE PARTS KITS
SKAREB COMP COIL
Compression Damping Assembly
Rebound Damping Assembly
Preload
Crown/Steer Tube Assembly
Sticker Kit
Ride Kits - Soft
Medium
Firm
X-Firm
Knob Kit
SKAREB ELITE
Compression Damping Assembly
Rebound Damping Assembly
Preload
Crown/Steer Tube Assembly
Sticker Kit
Ride Kits - X-Soft
Soft
Medium
Firm
X-Firm
Knob Kit
SKAREB SUPER
Compression Damping Assembly
Rebound Damping Assembly
Preload
Crown/Steer Tube Assembly
Sticker Kit
Ride Kits - X-Soft
Soft
Medium
Firm
X-Firm
Knob Kit
85-4835
85-4876
85-4837
85-5081
85-5164
85-5041
85-5042
85-5043
85-5173
85-5050
85-4835
85-4876
N/A
85-5081
85-5164
85-4808
85-4878
85-4927
85-9188
85-5174
85-5050
85-4856
85-4876
N/A
85-5081
85-5164
85-4808
85-4878
85-4927
85-9188
85-5174
85-5050
Outer Casting Assemblies
Black
Silver
Red
White
Yellow
Orange
Blue
Candy Red
Candy Blue
Candy Chrome
Black N/B
Silver N/B
Red N/B
White N/B
Yellow N/B
Orange N/B
Blue N/B
Candy Red N/B
Candy Blue N/B
Candy Chrome N/B
* Lockout Assembly
Will fit all SKAREB Forks
85-5100
85-5101
85-5102
85-5103
85-5104
85-5105
85-5106
85-5107
85-5108
85-5109
85-5111
85-5112
85-5113
85-5114
85-5115
85-5116
85-5117
85-5118
85-5119
85-5120
85-4869
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AMERICAN MADE MANITOU
SUSPENSION FORKS
CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION
TECHNOLOGY AVAILABLE, A 2003 MANITOU SKAREB FORK BUILT IN
THE USA. This SKAREB fork is fully assembled and is ready to be
installed onto your bicycle. It comes equipped with a 1 1/8-inch threadless steerer tube, RA casting, and is available with a V-brake-style
hangerless arch or a disc brake only version. A handlebar-mounted
reflector must be used for on-road use, which is not included with your
fork.
2003 SKAREB FORK LINE
SKAREB COMP COIL . . . . . . . 80 MM TRAVEL / COIL SPRING /
FLUID FLOW DAMPING / SOLID
CROWN / RA CASTING
SKAREB ELITE. . . . . . . . . . . . 80 MM TRAVEL/ AIR-COIL SPRING /
TPC DAMPING / HOLLOW CROWN /
RA CASTING
SKAREB SUPER . . . . . . . . . . 80 MM TRAVEL / AIR-COIL SPRING /
LOCKOUT / TPC DAMPING /
HOLLOW CROWN / RA CASTING
SKAREB DIVA . . . . . . . . . . . . 80 MM TRAVEL / AIR COIL SPRING /
LOCKOUT / TPC DAMPING /
HOLLOW CROWN / RA CASTING
You can also download this manual at www.answerproducts.com.
BICYCLING IS A HAZARDOUS
ACTIVITY THAT REQUIRES
THAT THE RIDER STAY IN CONTROL OF HIS OR HER BICYCLE AT ALL
TIMES. READING THIS MANUAL ENTIRELY AND PROPERLY MAINTAINING YOUR BICYCLE, 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 AT (661) 257-4411 TO HAVE YOUR FORK SHIPPED
DIRECTLY.
IMPORTANT: The SKAREB 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, or contact Answer Warranty at (661) 257-4411.
3. Any other alteration or modification to your fork should be considered unsafe. Contact Answer Customer Service prior to modifying
your fork in any way for safety information.
4. Do not use the SKAREB fork if any parts are broken, bent,
cracked, or you suspect may be damaged. Contact your dealer or
Answer Customer Service at (661) 257-4411 if you have any
questions concerning the integrity or condition of your fork.
5. Answer Products recommends that you inspect your fork before
every ride for wear and damage. Inspect the crown, inner legs,
outer legs, dropout and brake arch areas for cracks or damage.
WARRANTY INFORMATION
Any Answer Products fork found by the factory to be defective in materials and/or workmanship within one year from the date of purchase
(or two years in EU countries) will be repaired or replaced at the option
of the manufacturer, free of charge, when received at the factory 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 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. At that time, instructions for repair, return, or
replacement shall be given. Customers in countries other than USA
should contact their dealer or local distributor.
INSTALLATION INSTRUCTIONS
Ensure that the proper steerer tube has been delivered on your
SKAREB 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.
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 LENGTHS OR DIAMETERS. REMOVING AND REPLACING THE STEERER TUBE OR STANCHIONS WILL
RESULT IN AN UNSAFE CONDITION AND SHOULD NEVER BE DONE.
BREAK-IN
Your new fork is designed to break in during your first few rides (about
20 hours total riding time). Prior to break-in, you may notice your fork
feels tight and slightly notchy. Following the break-in period, your fork
will feel much smoother and will react to bumps much better than
when you first put it on your bike. After 20 hours, you may want to
recheck your compression, rebound and preload adjustments (when
applicable) to fine tune the fork completely.
FORK INSTALLATION
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube. You
can use your old fork as a guide for cutting the steerer tube
length.
3. Remove the headset crown race from the old fork and press onto
the SKAREB steerer until the race is seated over the crown.
4. Clean and grease the headset bearings and races.
5. Install the lower bearings (if applicable) on fork crown race.
6. Insert the steerer tube into the head tube of the frame.
7. Install the upper bearings, stem spacers, and stem.
8. Install the stem cap and bolt. Tighten the bolt to headset manufacturer’s specifications.
9. Install the handlebars to the 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 0.335” (8.5 mm)
thick secondary catch dropout. The quick release must be tightened after it is properly seated into the dropout counter bores to
manufacturer’s specifications. Ensure that there is adequate thread
engagement (4 or more threads with the release adjusted to lock).
12. Install the brake cable per manufacturer’s instructions.
NOTE: 2003 SKAREB forks are equipped with a secondary catch
dropout to retain the wheel in the fork in the event the quick release
comes loose.
WHEN INSTALLING THE WHEEL OR A NEW
TIRE, CHECK TO MAKE SURE THE FORK
ACHIEVES MINIMUM TIRE CLEARANCE. MEASURE FROM THE HIGHEST
POINT ON THE TIRE TO THE BOTTOM OF THE BRAKE ARCH. THIS MEASUREMENT SHOULD BE AT LEAST 10 MM. (FIGURE 1)
IMPORTANT: The SKAREB fork should not be used if any parts
appear to be or are damaged. Contact your local dealer or Answer
Products for replacement parts.
MAINTENANCE
Your SKAREB 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 relubricated.
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: Setting the proper oil level in your TPC-equipped
fork is critical. TPC is located in the right leg of your SKAREB 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 on a Manitou SKAREB fork, remove the compression assembly located in the top of the right leg (as you are looking at
the fork from the rider’s position). Leave the left side spring stack in
place to keep the fork fully extended. Use a tape measure or “dip stick”
to measure from the top of the fork crown down to where the oil sits
(Figure 2). The oil level for the Manitou SKAREB should be per the following table.
FORK MODEL
OIL LEVEL
SKAREB COMP COIL
115 mm - 125 mm (4.5-4.9 inches)
SKAREB ELITE
115 mm - 125 mm (4.5-4.9 inches)
SKAREB SUPER
105 mm - 110 mm (4.1-4.3 inches)
SKAREB DIVA
105 mm - 110 mm (4.1-4.3 inches)
NOTE: Use SAE 5WT fork oil suspension fluid only.
If you have any questions regarding your 2003 Manitou SKAREB suspension fork, contact Answer Customer Service at (661) 257-4411.
You can also log on to www.answerproducts.com and download this
manual or see detailed instructions on how to service your
suspension fork.
Thank you again for choosing a 2003 Manitou SKAREB suspension
fork.
DEALER SERVICE ADDENDUM
This section is designed to help a qualified bicycle mechanic tune
and maintain your Manitou suspension fork.
MEASURING SAG You’ll need a tape measure, a pencil and
a piece of paper.
1. Measure the distance from the front axle’s centerline to the
bottom of the upper crown when no one’s sitting on the bike
and write this distance down. (Remember the exact locations
of the two points because you’ll need to use them later.)
2. Have the rider sit on the bike and measure the distance
between the same two points as in step one. It’s important to
be in the normal riding position (weight centered) with your
feet on the pedals.
3. Subtract the second measurement from the first. The resulting measurement is the static sag.
SAG MEASUREMENT CHART
Fork Travel
80 mm
Sag
12-16 mm
RIDE KITS
SKAREB COMP COIL
Rider Weight
Recommended Ride Kits
100-150 lbs.
Soft ride kit
150-170 lbs.
Medium ride kit
170-190 lbs.
Firm ride kit
190 plus lbs.
Extra firm ride kit
SKAREB ELITE/SUPER/DIVA
Rider Weight
Recommended Ride Kits
100-125 lbs.
X-Soft ride kit
125-150 lbs.
Soft ride kit
150-190 lbs.
Medium ride kit
190 plus lbs.
Firm ride kit
* Air pressure setting should equal 75% of body weight.
* Maximum air pressure is 190 psi.
Part #
85-5041
85-5042
85-5043
85-5173
Part #
85-4808
85-4878
85-4927
85-9188
CHANGING COIL SPRINGS – SKAREB COMP COIL
1. Start by removing the preload adjuster by removing the knob
with a 2 mm hex wrench (Figure 3), then unscrewing the
assembly from the top of the crown/leg assembly. A 20 mm
socket may be necessary (Figure 4). Remember: The springs
are housed only in the left leg on 2003 Manitou suspension
forks.
2. With the adjuster assembly removed, the spring stack is now
accessible. (Figure 5)
3. Select the appropriate ride kit for the rider’s weight and riding style (refer to the above spring chart for recommended
rates).
4. Reinstall the preload adjuster assembly and knob, taking care
not to cross-thread the assembly. It should thread in by hand
and does not need to be tightened with a wrench (finger-snug
is recommended).
CHANGING COIL SPRINGS – SKAREB ELITE,
SKAREB SUPER, SKAREB DIVA
1. Read section on Semibath Lubrication Maintenance first.
Unthread the air cap on top of the left fork leg and release the
fork’s air pressure via the Schraeder valve. (Figure 6)
2. From the bottom of the casting remove the 2 mm cap screws
and caps (Figure 7), screw in the 8 mm rod (turn clockwise to
loosen) and the 4 mm bolt from the bottom of the casting
(Figure 8). Once you do this, you will be able to pull the lowers
away from the uppers. (Figure 9)
3. On the left leg (as seen from the rider’s perspective), remove
the 15/16-inch cap from the bottom of the leg. Remove the
entire assembly by pulling the rod lightly. As this point, you
will see the coil spring. (Figure 10)
4. Select the appropriate coil spring for the rider’s weight and
riding style (refer to the above spring chart for recommended
rates).
5. Reinstall the assembly into the left leg of the fork, taking care
not to cross-thread the cap. It should thread in by hand and
should only be snug tightened. (Figure 11)
6. Reinstall the lowers with the 8 mm and 4 mm bolts and tighten. You may have trouble getting the 8 mm bolt to catch the
threads. If this occurs, remove the lowers and pull the
rebound damping rod again, and reinstall the casting. You
should now be able to install the 8 mm bolt. Reinstall the
caps and 2 mm bolts. (Figure 8 and 12)
CHANGING AIR SPRING PRESSURE – SKAREB
ELITE, SKAREB SUPER, SKAREB DIVA All you need
to change the air pressure is a high-pressure Manitou (Manitou
part #85-4069) or other shock pump. Remove the air cap located on the top of the left leg, and then inflate the fork with the
desired pressure. Be aware that sometimes air systems lose a
small amount of pressure when the pump is removed, so you
may want to check exactly how much your pump loses by reinstalling it on the fork after you have set and checked the pressure.
AIR PISTON LUBRICATION For proper function of your
fork, it is essential to have a small amount of lubricating oil on
top of the air piston in your SKAREB Elite, Super or Diva fork. To
check this, remove the air cap on the left side of the fork (as
seen from the rider’s perspective) by simply unthreading it
counterclockwise. Release the air pressure from the fork and
then use a 20 mm hex wrench to remove the aluminum
Schraeder cap. Once you have done this, you can see the top of
the air piston and determine if there is a small amount of oil sitting on top of the air piston. If this oil is no longer visible, pour
8cc of 20W-50 motor oil directly into the open fork leg (Figure
13). After this, reinstall the Schraeder cap and the air cap, and
pressurize.
COMPRESSION DAMPING ADJUSTMENT –
QUICK RANGE TPC For Quick Range TPC forks, a simple
turn of the knob located on top of the right leg is all that is needed. Turning the knob clockwise (as you are looking from a rider’s
position) increases compression damping, while turning it counterclockwise decreases compression damping.
ADJUSTING COMPRESSION DAMPING WITH A LOCK
OUT The Lock Out is simply an on-off switch for your fork. To
adjust compression damping, do the following: Remove the compression assembly located in the right leg. On the lower piston of
the lockout assembly is a small setscrew. Turn this in or out to
increase or decrease compression damping respectively. Note: a
half turn makes a lot of difference, so make small and incremental changes to the setscrew.
REBOUND DAMPING ADJUSTMENT – QUICK RANGE
TPC & FLUID FLOW Rebound adjusters on Manitou forks
are located on the bottom of the right fork leg. Turning the knob
clockwise (as you are looking at the fork from the bottom)
increases rebound damping, while turning it counterclockwise
decreases rebound damping.
MAINTENANCE AND SERVICE – INTRODUCTION
When servicing the fork, take the time to inspect all parts for
excessive wear or damage. There are basically five aspects of a
fork that will require attention: the stanchions (inner legs), the
bushings in the outer legs, the spring stack, the lubricating oil,
and the damping fluid. In addition, with air spring forks, you
will also need to make sure a small amount of lubricating oil
(8cc) in sitting on top of the air piston (see Air Piston
Lubrication above). Inspecting any of these parts requires disassembly of the fork. Pay close attention to the bushings, which
can be damaged by contamination in severe conditions. Replace
any worn or damaged parts that are discovered.
SEMIBATH LUBRICATION MAINTENANCE
Your 2003 Manitou SKAREB fork is designed with a Semibath
lubrication system. This system requires periodic maintenance
to ensure that your fork is working properly at all times. To
service the Semibath system, do this:
1. Remove the rebound damping knob with a 2 mm Allen
wrench. (Figure 12)
2. With the fork positioned over an oil catch receptacle, use an
8 mm Allen wrench to screw the rod located under the damping knob into the fork (clockwise). This will unthread the rod
from the casting. Next, remove the 4 mm Allen bolt from the
bottom of the fork (Figure 8). You now may notice some oil
draining out of the bottom of the fork.
3. Pull the fork apart, holding the fork away from you and letting the oil drain out of the bottom of the fork. (Figure 9)
4. Clean the inside of the lowers thoroughly and wipe the inner
legs until they are completely free of oil or debris. (Figure 19)
5. Pour lubricating oil into the fork before you reassemble it.
Pour 15cc of oil into each side of the lowers while you hold the
assembly horizontally. A syringe is recommended for this.
(Figure 14)
6. Holding the fork horizontally, insert the crown/steerer assembly back into the fork. Reinstall the bolts to
10 - 30 in-lbs., and install the rebound adjuster knob.
(Figure 8)
CHANGING THE OIL IN YOUR FORK Changing the oil in
your damped fork is very easy to do. All of the damping systems,
FFD, TPC and TPC Plus, house the oil in the right leg.
1. Remove the adjuster knob and loosen the assembly from the
top of the right fork leg (20 mm socket). (Figure 15)
2. Rock the compression damping assembly back and forth
slightly as you pull up on it to remove it. (Figure 16)
3. Pour the old oil out of the fork. (Figure 17)
4. Stroke the fork up and down to remove the oil that settles
beneath the rebound piston. Pour this oil out as well.
5. Add oil to the level shown in the Checking Oil Level section of
this manual (Figure 18). Make sure you stroke the fork up
and down a few times before the final measurement is taken
to ensure that oil has flowed beneath the rebound piston
again. (Figure 2)
SERVICE SCHEDULE – Suggested Service for
Manitou forks
NORMAL CONDITIONS – Short/Infrequent Rides
• Disassemble, clean and lubricate fork every 6 months.
• Service TPC or FFD by changing fork fluid every year.
NORMAL CONDITIONS – Long/Frequent Rides
• Disassemble, clean and lubricate fork every 4 months.
• Service TPC or FFD by changing fork fluid every 6 months.
SEVERE CONDITIONS – Short/Infrequent Rides
• Disassemble, clean and lubricate fork every 4 months.
• Service TPC or FFD by changing fork fluid every year.
SEVERE CONDITIONS – Long/Frequent Rides
• Disassemble, clean and lubricate fork every 2 months.
• Service TPC or FFD by changing fork fluid every 6 months.
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