Manitou 2003 Luxe Service Manual

Manitou 2003 Luxe Service Manual
P/N 042095
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MANITOU SUSPENSION FORKS
WARRANTY INFORMATION
CONGRATULATIONS ON CHOOSING A 2003 MANITOU LUXE SUSPENSION
FORK. This Manitou fork is fully assembled and ready to be installed onto your
bicycle. It comes equipped with a 1 1/8-inch threadless steerer tube and is
available with a V-brake-style hangerless arch. The LUXE has Dynamo mounts
for use with a lighting system. A handlebar-mounted reflector must be used for
on-road use, which is not included with your fork.
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. In the USA, dealers should
call Answer Products Customer Service for a return authorization number
(RA#) at (661) 257-4411. 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.
2003 MANITOU LUXE FORK LINE
LUXE COMP ..............50 MM TRAVEL / ALUMINUM CASTING / COIL AND MCU
SPRINGS / SINGLE CROWN
LUXE ELITE ...............50 MM TRAVEL / MAGNESIUM CASTING / COIL AND
MCU SPRINGS / SINGLE CROWN
LUXE SUPER.............50 MM OR 75 MM TRAVEL*/ MAGNESIUM CASTING /
COIL AND MCU SPRINGS / SINGLE CROWN
*Preset from the factory, but changeable. See the Dealer Service Addendum
section “Convertible Travel – LUXE Super”.
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 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 NO DAMAGE HAS OCCURRED DURING THE COURSE OF RIDING.
DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY SIGNS OF BENDING,
CRACKING, LEAKING, OR IF IT IS MISSING ANY OF THE ORIGINALLY SUPPLIED
COMPONENTS. ANY FALL FROM YOUR BICYCLE CAN RESULT IN SERIOUS
INJURY OR EVEN DEATH. FOLLOWING THESE INSTRUCTIONS CAN HELP YOU
REDUCE THE RISK OF BEING INJURED. IF YOU ARE A MODERATE OR AGGRESSIVE OFF-ROAD RIDER, OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH
TERRAIN, ANSWER RECOMMENDS RETURNING YOUR SUSPENSION FORK
EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE. TAKE YOUR
FORK TO A MANITOU AUTHORIZED DEALER WHO CAN ARRANGE FOR SHIPMENT
TO ANSWER PRODUCTS, OR YOU MAY CALL ANSWER AT (661) 257-4411 TO
HAVE YOUR FORK SHIPPED DIRECTLY.
IMPORTANT: The LUXE fork is an off-road fork, and as such, does
not come with proper reflectors for on road use. Have your dealer or
mechanic install proper reflectors to meet the Consumer Product Safety
Commission’s (C.P.S.C.) Requirements for Bicycles if the fork is going to be
used on public roads at any time. If you have questions regarding C.P.S.C.
Standards or would like to purchase a reflector bracket kit contact your dealer.
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 higher performance versus bolt-in inner legs, but
can not be pressed out. Pressing them out will permanently damage the
crown beyond repair and render it unsafe for any 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 LUXE 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.
INSTALLATION INSTRUCTIONS
Ensure that the proper steerer tube has been delivered on your LUXE fork 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 CAN NOT 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.
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
LUXE steerer tube until the race is seated over the crown.
4. Clean and lubricate the headset bearings and races.
5. Install the lower bearings (if applicable) on the 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 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. For all LUXE forks, adjust the front wheel quick release to clear the 0.275"
(7 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).
NOTE: 2003 Manitou LUXE 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 5 MM FOR LUXE
FORKS. (FIGURE 1)
IMPORTANT: A Manitou LUXE 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
IMPORTANT: Use of fork boots is required to keep your LUXE fork performing well and the warranty in effect. Use of this fork without boots will
shorten the life of the fork, decrease the time between maintenance intervals, reduce the performance and void the warranty.
If you have any questions regarding your 2003 Manitou LUXE suspension fork,
contact the Answer Products Customer Service Department 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 LUXE suspension fork.
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 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.
LUXE DEALER
SERVICE ADDENDUM
MEASURING SAG To measure 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 without anyone sitting on the bike and write this
measurement 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 the rider’s feet on the pedals.
3. Subtract the second measurement from the first. The resulting measurement is the static sag or ride height.
1. Remove the preload adjusters by unscrewing the caps from the top of
the crown/leg assembly. First, you must remove the cap by unscrewing the 2 mm fastening bolt (Figure 2). An 18 mm socket will be necessary with the LUXE to remove the preload adjuster assembly.
Remember: The springs are housed in both legs of the LUXE forks.
2. With the adjuster assembly removed, the spring stack is now accessible (Figure 3).
3. Select the appropriate coil spring for your weight and riding style
(refer to the above spring chart for recommended rates).
4. Apply a liberal amount of grease to the outside surface of the new coil
spring and the spring couplers (what holds the springs together)
(Figure 4). We recommend any thick grease. Install the new spring
stack.
5. Reinstall the preload adjuster assembly, taking care not to crossthread the cap. It should thread in by hand and lightly snug tightened (Figure 5).
6. Reinstall the preload adjuster cap.
SAG MEASUREMENT CHART
FORK DISASSEMBLY – LUXE SUPER
This section is designed to help you tune and maintain your Manitou
suspension fork.
Fork Travel
50 mm
75 mm
Sag
8-12 mm
10-14 mm
TRAVEL MEASUREMENT To determine which travel your LUXE
fork is in, simply measure the distance from the top of the seal area on
the lowers (or the bottom of the fork boot) to the bottom of the crown.
TRAVEL MEASUREMENT CHART
Fork Travel
50 mm
75 mm
Seal to Crown Measurement
Around 4 inches or 100 mm
Around 5 inches or 125 mm
RECOMMENDED COIL SPRINGS Once you have checked sag,
you can either preload the spring via the cap on top of the left hand leg,
or even better, make spring changes to accommodate for your riding
style and weight.
SPRING KITS
LUXE COMP
Standard Set-up
LUXE ELITE
Standard Set-up
LUXE SUPER
Standard Set-up
Rider Weight
100-150 lbs.
150-170 lbs.
170 plus lbs.
Rider Weight
100-150 lbs.
150-170 lbs.
170 plus lbs.
Rider Weight
100-150 lbs.
150-170 lbs.
170 plus lbs.
Recommended Spring Kit
Soft ride kit (Part #85-4990)
Medium ride kit (Part #85-4991)
Firm ride kit (Part #85-4992)
Recommended Spring Kit
Soft ride kit (Part #85-4993)
Medium ride kit (Part #85-4994)
Firm ride kit (Part #85-4995)
Recommended Spring Kit
Soft ride kit (Part #85-4996)
Medium ride kit (Part #85-4997)
Firm ride kit (Part #85-4998)
CHANGING COIL SPRINGS Once you have checked sag, you can
make spring changes to accommodate for your riding style and weight.
Disassembly of your
LUXE Super fork is necessary to provide the proper service of your fork.
To do this:
1. Remove the two 4 mm Allen bolts on the bottom of the fork (Figure
6).
2. Pull apart the fork, removing the casting from crown/steerer assembly (Figure 7).
3. Wipe clean the inside of the fork casting, stanchion tubes, fork boots,
and crown. At the same time you do this, do a complete inspection on
the fork (Figure 8).
4. Reassemble the fork and snug tighten the 4 mm bolts (Figure 9).
FORK DISASSEMBLY – LUXE COMP & ELITE Disassembly
of your LUXE Comp and Elite fork is necessary to provide the proper
service of your fork. To do this:
1. Remove the springs (See Changing Coil Springs above).
2. Insert a long 4 mm wrench into the fork and loosen the bolts that hold
the casting to the crown/steerer tube assembly (Figure 10).
3. Pull apart the fork, removing the casting from crown/steerer assembly (Figure 11).
4. Wipe clean the inside of the fork casting, stanchion tubes, fork boots,
and crown. At the same time you do this, do a complete inspection on
the fork (Figure 12).
5. Reassemble the fork and snug tighten the 4 mm bolts (Figure 10).
CONVERTIBLE TRAVEL – LUXE SUPER Changing the travel
from 50 to 75 millimeters or vice-versa requires the removal of the
lower legs.
1. Start by removing the preload adjusters and spring (see Changing Coil
Springs above).
2. Next, unthread the 4 mm bolts from the bottoms of both legs and pull
the fork apart to expose the clip mechanism which allows for travel
adjustment (Figure 6).
3. Remove the clip and insert it into the upper position (above the rod
flange) for 75 millimeters of travel or the lower position (below the
rod flange) for 50 millimeters of travel (Figure 13).
4. Reassemble the fork.
MAINTENANCE AND SERVICE When servicing the fork, take
the time to inspect all parts for excessive wear or damage. There are
basically three aspects of a fork that will require attention: the stanchions (inner legs), the bushings in the outer legs, and the spring stack.
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.
SERVICE SCHEDULE –
Suggested Service for Manitou forks
NORMAL CONDITIONS – Short/Infrequent Rides
• Disassemble, clean and grease fork every year.
• Grease spring stack as needed.
NORMAL CONDITIONS – Long/Frequent Rides
• Disassemble, clean and grease fork every 6 months.
• Grease spring stack as needed.
SEVERE CONDITIONS (MUD, RAIN, SNOW, EXTREME DUST) –
Short/Infrequent Rides
• Disassemble, clean and grease fork every 6 months.
• Grease spring stack as needed.
SEVERE CONDITIONS (MUD, RAIN, SNOW, EXTREME DUST) –
Long/Frequent Rides
• Disassemble, clean and grease fork every 3 months.
• Grease spring stack as needed.
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