Manitou MARS ELITE, SUPER suspension fork Owner's manual

062992
2001 OWNER’S MANUAL
MARS, MARS ELITE, MARS SUPER
28209 Avenue Stanford, Valencia, California 91355-3984 • 661 257.4411 • Sales fax 661 294.4179
Race Installation
Montaggio dell’anello della
testa
Einbau des
Steuersatzringes
Installatie van loopring
Instalación del anillo de
Instalação do canalete
rodadura
Installation du jeu de direction
.1.
CROWN RACE
GABELBRÜCKEN-STEUERSATZRING
ANILLO DE RODADURA
CONE DE JEU DE DIRECTION
ANELLO DELLA TESTA
KROONLOOPRING
CANALETE DA COROA
Tire clearance
Reifenabstand
Espacio libre de la cubierta
Distance arceau/pneu
.2.
FORK MODEL
GABELMODELL
MODELO DE HORQUILLA
MODÈLE DE FOURCHE
MODELLO DI FORCELLA
VORKMODEL
MODELO DO GARFO
Spazio libero del pneumatico
Bandspeling
Folga do pneu
MINIMUM CLEARANCE
MINDESTABSTAND
ESPACIO LIBRE MÍNIMO
JEU MINIMUM
SPAZIO LIBERO MINIMO
MINIMUMSPELING
FOLGA MÍNIMA
80 mm travel forks
Gabel mit 80 mm Auslenkung
Horquillas con recorrido de 80 mm
Fourches ayant une course de 80 mm
Forcelle con corsa da 80 mm
Loop van 80 mm
Curso de 80 mm
3.26" (83 mm)
83 mm
83 mm
83 mm
83 mm
83 mm
83 mm
.3.
Grease port
Schmieröffnung
Orificio de engrasado
Graisseur
Apertura per l’ingrassaggio
Smeergat
Orifício de lubrificação
.4.
Oil level
Ölstand
Nivel del aceite
Niveau d’huile
Livello dell’olio
Oliepeil
Nível do óleo
MAX.
RECOMMENDED LEVEL
EMPFOHLENER ÖLSTAND
NIVEL RECOMENDADO
NIVEAU RECOMMANDÉ
LIVELLO RACCOMANDATO
AANBEVOLEN PEIL
NÍVEL RECOMENDADO
MIN.
.5.
Fine tuning air/coil spring rate
Feinabstimmung der Luft-/
Schraubenfederrate
Ajuste de precisión de la
capacidad de resortes
neumáticos y helicoidales
Réglage du taux de raideur des
ressorts pneumatique/à bobine
SCHRAEDER VALVE UNDER KNOB.
Messa a punto pneumatica/
DAS VENTIL (SCHRAEDER VENTIL)
della molla di compressione
BEFINDET SICH UNTER DEM
Fijnafstelling van lucht-/springveer LADREHKNOPF.
VÁLVULA SCHRAEDER SE
DEBAJO DEL REGUAjuste de precisão da taxa de com- ENCUENTRA
LADOR.
pressão da mola
LA VALVE SCHRAEDER EST SITUÉE
SOUS LE BOUTON.
pneumática/helicoidal
LA VALVOLA SCHRAEDER VALVE È
SITUATA SOTTO LA MANOPOLA.
SCHRAEDER-KLEP BEVINDT ZICH
ONDER DE KNOP.
A VÁLVULA SCHRAEDER ESTÁ
LOCALIZADA EM BAIXO DO
BOTÃO.
.6.
Fine tuning compression damping – MARS Elite
Feinabstimmung der Druckstufendämpfung –
MARS Elite
Ajuste de precisión para el sistema de
amortiguación de compresión –
MARS Elite
Réglages fins de l’amortissement de la compression –
MARS Elite
Messa a punto del
gruppo compressione
di smorzamento –
MARS Elite
Fijnafstelling van drukdemping –
MARS Elite
ROTATE
RUOTARE
Ajuste de precisão do amortecimento
DREHEN
DRAAIEN
de compressão – MARS Elite
GIRAR
GIRAR
TOURNER
Fine tuning compression damping – MARS Super
Feinabstimmung der Druckstufendämpfung –
MARS Super
Ajuste de precisión de amortiguación de compresión –
MARS Super
Réglages fins de l’amortissement de la compression – MARS Super
Messa a punto del gruppo compressione
di smorzamento – MARS Super
Fijnafstelling van drukdemping
– MARS Super
Ajuste de precisão do
amortecimento de
ADJUST SET SCREW
compressão –
EINSTELLEN DER
MARS Super
STELLSCHRAUBE
.7.
GIRE EL TORNILLO DE AJUSTE
TOURNER LA VIS DE RÉGLAGE
REGOLARE LA VITE DI FERMO
STELSCHROEF BIJSTELLEN
REGULE O PARAFUSO
DE AJUSTAGEM
.8.
Fine tuning rebound damping – MARS Elite and
MARS Super only
Feinabstimmung der Zugstufendämpfung – nur für
MARS Elite und MARS Super
Ajuste de precisión para la amortiguación de rebote –
MARS Elite y MARS Super solamente
Réglages fins de l’amortissement de la détente – MARS Elite
et MARS Super uniquement
Messa a punto dello smorzamento all’estensione –
MARS Elite e MARS Super
Fijnafstelling van terugveringdemping – uitsluitend MARS
Elite en MARS Super
Ajuste de precisão do ressalto de amortecimento do
– somente para o MARS Elite e MARS Super
ROTATE
DREHEN
GIRAR
TOURNER
RUOTARE
DRAAIEN
GIRAR
• ENGLISH
AMERICAN MADE MANITOU SUSPENSION
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 SYSTEMS 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 74 MM POSTSTYLE DISC BRAKE MOUNTS.
This MARS 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 Vbrake-style hangerless arch.
2001 MARS FORK LINE
MARS ..........................80 MM TRAVEL / AIR-COIL SPRING / TPC SPORT DAMPING /
SINGLE HOLLOW CROWN
MARS ELITE ................80 MM TRAVEL / AIR-COIL SPRING / TPC DAMPING / SINGLE
HOLLOW CROWN
MARS SUPER .............80 MM 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.
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, or 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 Warranty 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.
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 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 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 Manitou dealer or local 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 the 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 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.
3. Remove the headset crown race from the old fork and press onto the MARS
steerer until the race is seated over the crown (Figure 1).
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 stem/handlebar assembly 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 (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. Insure 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: 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.
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
CROWN. THE MINIMUM CLEARANCE ALLOWED IS:
3.26" (83 MM) FOR 80 MM 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 its 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 were 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: 853694.
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 criti-
cal. 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 the following
table. (See Figure 4.)
Fork Model
MARS
MARS Elite
MARS Super
Recommended
4.50" (114 mm)
4.00" (101 mm)
3.75" (95 mm)
OIL LEVEL
Maximum
4.00" (101 mm)
3.75" (95 mm)
3.50" (89 mm)
Minimum
5.00" (127 mm)
4.25" (108 mm)
4.00" (102 mm)
NOTE: Use Maxima SAE 5WT 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 is available in one rate only
and is designed to be preloaded automatically as the positive air spring pressure is
increased (in other words, you don’t need to do anything to tune it).
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 is 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 +/-5 psi
(1) 3" blue 80 pound coil spring
(5.5 bar +/- 0.3 bar)
115-145 lbs.
100 psi +/- 5 psi
(1) 3" red 100 pound coil spring
(6.9 bar +/- 0.3 bar)
145-175 lbs.
120 psi +/- 5 psi
(1) 3" red 100 pound coil spring
(8.3 bar +/- 0.3 bar)
175-205 lbs.
140 psi +/- 5 psi
(1) 3" yellow 120 pound coil spring
(9.7 bar +/- 0.3 bar)
205-230 lbs.
160 psi +/- 5 psi
(1) 3" yellow 120 pound coil spring
(11.0 bar +/- 0.3 bar)
230 + lbs.
180 psi +/- 5 psi
(1) 3" black 150 pound coil spring
(12.4 bar +/- 0.3 bar)
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 standard fork fluid 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 1/4 turn counterclockwise, the front fork will have regular TPC suspension.
By turning the knob 1/4 turn clockwise, the fork will have extreme damping. Partial AntiBob can be used by turning the knob between the on and off positions. A safety blowoff valve will open under extreme conditions to allow some movement. n
2001 MARS FORK SCHEMATIC
BUSHING & SEAL DETAIL
FORK BOOT (063249)
TPC SPORT
LOWER SHAFT ASSEMBLY
(062993)
TPC SPORT COMPRESSION
DAMPING ASSEMBLY
(062934)
TPC REBOUND PISTON (062670)
SEAL/WIPER (062972)
JELLY BEAN (063186)
SELF TAPPING SCREW (041330)
.372 X .900 X .005 SHIM (062300)
ADJUSTER KNOB (062503)
UPPER BUSHING (041473)
TOP CAP (062583)
TPC LOWER SHAFT (062994)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
LOWER BUSHING (041474)
SPIROLOX RETAINER (062393)
ADAPTER (062989)
LOC-OUT ROD SEAL (062392)
END CAP (062422)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
COMPRESSION VALVE (062296)
O-RING 21.6MM X 2.4MM (040524)
BOTTOM OUT (063116)
BOTTOM OUT WASHER (063181)
RETAINING RING (040679)
RIGHT LEG (062927)
O-RING 3/4 x 7/8 (040681)
AIR SPRING KNOB ASSEMBLY (062902)
AIR SPRING CAP ASSEMBLY (061038)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
AIR PISTON ASSEMBLY (062478)
LEFT LEG ASSEMBLY (062931)
INCLUDING NEGATIVE SPRING
(NOT REMOVABLE)
DAMPER SLEEVE (041574)
TITANIUM BRAKE POST (041396)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
AIR PISTON ROD ASSY (063276)
OUTER LEG ASSEMBLY
100 LBS COIL SPRING 3" LONG (063147)
DAMPER DROPOUT
NUT (041823)
COMPRESSION ROD (062932)
TOP OUT ELASTOMER (041475)
COMPRESSION ROD SCREW
(060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
LEG CAP (062250)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
BOTTOM OUT (063116)
BOTTOM CLIP (040968)
BUSHING & SEAL DETAIL
2001 MARS ELITE FORK SCHEMATIC
FORK BOOT (063249)
TPC LOWER SHAFT ASSEMBLY
(062929)
TPC COMPRESSION DAMPING
ASSEMBLY (063111)
VALVE NUT (041483)
13mm CLAMP SHIM (041157)
REBOUND SHIM 20mm (041149)
JELLY BEAN (062578)
SELF TAPPING SCREW (041330)
TPC KNOB (062503)
TPC TOP CAP (062583)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-m)
REBOUND SHIM 21mm (041150)
PISTON (062562)
.826 X .409 X .005 SHIM (041139)
SEAL/WIPER (062972)
SPRING (041152)
O-RING 1/4 X 3/8 (040690)
ADJUSTER NEEDLE (062072)
O-RING 5/32 X 9/32 1/16 (041130)
PISTON SEAT (062130)
UPPER BUSHING (041473)
DETENT SLEEVE (041527)
LOWER SHAFT (062970)
LOWER BUSHING (041474)
O-RING (040524)
DETENT BALL (040689)
DETENT BALL (040689)
UPPER SHAFT (062997)
O-RING 5/32" x 9/32" (041130)
LOWER NEEDLE (062570)
CLAMP SHIM 13MM (041157)
COMPRESSION SHIM STACK
(041148, 041149, 2X 041150)
0-RING 1/4 X 3/8 (040690)
SPIROLOX RETAINER (062393)
PISTON (062562)
LOC-OUT ROD SEAL (062392)
END CAP (062422)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
SHIM (041139)
SPRING (041152)
VALVE NUT (041483)
BOTTOM OUT ELASTOMER (063116)
BOTTOM OUT WASHER (063181)
RETAINING RING (040679)
RIGHT LEG (062927)
DETENT SLEEVE (041527)
AIR SPRING KNOB ASSEMBLY (062902)
O-RING 3/4 X 7/8 (040681)
AIR SPRING CAP ASSEMBLY (061038)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
AIR SPRING PISTON ASSEMBLY (062478)
LEFT LEG ASSEMBLY (062931)
INCLUDING NEGATIVE SPRING
(NOT REMOVABLE)
DAMPER SLEEVE (041574)
TITANIUM BRAKE POST (041396)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
AIR PISTON ROD ASSY (063276)
OUTER LEG ASSEMBLY
100 LBS COIL SPRING 3" LONG (063147)
COMPRESSION ROD (062932)
DAMPER DROPOUT
NUT (041822)
REBOUND ELASTOMER (041475)
O-RING, DROPOUT
NUT (040688)
DAMPER ADJUSTER KNOB (041408)
LEG CAP (062250)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
COMPRESSION ROD SCREW (060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
BOTTOM OUT (063116)
BOTTOM CLIP (040968)
2001 MARS SUPER FORK SCHEMATIC
BUSHING & SEAL DETAIL
TPC LOWER SHAFT ASSEMBLY
(062929)
FORK BOOT (063249)
ANTI-BOB
TPC COMPRESSION DAMPING
ASSEMBLY (062500)
VALVE NUT (041483)
13mm CLAMP SHIM (041157)
REBOUND SHIM 20mm (041149)
JELLY BEAN (062585)
SELF TAPPING SCREW (041330)
ANTI-BOB KNOB (062504)
O-RING 1/4" X 3/8" (063432)
REBOUND SHIM 21mm (041150)
PISTON (062562)
.826 X .409 X .005 SHIM (041139)
ANTI-BOB NEEDLE (062618)
O-RING 1/4" X 3/8" (063432)
O-RING 1/4" X 3/8" (063432)
SPRING (041152)
SEAL/WIPER (062972)
PISTON SEAT (062130)
O-RING 21.6MM X 2.4MM (040524)
UPPER BUSHING (041473)
LOWER SHAFT (062970)
ANTI-BOB SHAFT (062617)
RETAINING RING (040679)
WASHER .880 X .515 (062342)
SAFETY BLOW OFF SPRING (062341)
SAFETY SPRING SEAT (062343)
SPRING SHIM .461 X .832 X .010 (041354)
O-RING 3/4" X 7/8" (062594)
DETENT BALL (040689)
LOWER BUSHING (041474)
O-RING 5/32" x 9/32" (041130)
LOWER NEEDLE (062570)
0-RING 1/4 X 3/8 (040690)
ANTI-BOB CAP (062583)
DETENT SLEEVE (041657)
DETENT PIN (040685)
SPRING SHIM .800 X .503 (041058)
SPRING .600 X .015 X .31 (041381)
ANTI-BOB PISTON SPACER (041380)
PISTON SEAT (062227)
SPIROLOX RETAINER (062393)
ANTI-BOB ROD SEAL (062392)
END CAP (062422)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
SPRING SHIM 8MM X 19MM X .1MM (041148)
SPRING SHIM 8MM X 20MM X .1MM (041149)
SPRING SHIM 8MM X 21MM X .1MM (041150)
PISTON (062562)
SPRING SHIM .826 O.D. X .409 I.D (041139)
SPRING .437 X .015 X .31 (041152)
CLAMP SHIM 13MM (041157)
98 COMPRESSION VALVE NUT (041483)
BOTTOM OUT ELASTOMER (063116)
BOTTOM OUT WASHER (063181)
RETAINING RING (040679)
DETENT SLEEVE (041527)
O-RING 3/4 X 7/8 (040681)
ANTI-BOB PISTON (062303)
SET SCREW M5 X .8 (041423)
RIGHT LEG (062927)
AIR SPRING KNOB ASSEMBLY (062902)
AIR SPRING CAP ASSEMBLY (061038)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
AIR SPRING PISTON ASSEMBLY (062478)
LEFT LEG ASSEMBLY (062931)
INCLUDING NEGATIVE SPRING
(NOT REMOVABLE)
DAMPER SLEEVE (041574)
TITANIUM BRAKE POST (041396)
(TORQUE 90-110 INCH-LBS)
(TORQUE 10-12 N-M)
AIR PISTON ROD ASSY (063276)
OUTER LEG ASSEMBLY
100 LBS COIL SPRING 3" LONG (063147)
COMPRESSION ROD (062932)
DAMPER DROPOUT
NUT (041822)
REBOUND ELASTOMER (041475)
O-RING, DROPOUT
NUT (040688)
DAMPER ADJUSTER
KNOB (041408)
LEG CAP (062250)
(TORQUE 30-50 INCH-LBS)
(TORQUE 3.5-5.6 N-M)
COMPRESSION ROD SCREW (060268)
(TORQUE 10-30 INCH-LBS)
(TORQUE 1.2-3.5 N-m)
BOTTOM OUT (063116)
BOTTOM CLIP (040968)
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