Manitou 2002 Mars Comp Coil, Elite Diva & Super Service Manual

Manitou 2002 Mars Comp Coil, Elite Diva & Super Service Manual
• ENGLISH
AMERICAN MADE MANITOU SUSPENSION FORKS
CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE, A 2002 MANITOU MARS FORK BUILT IN THE USA. This MARS 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, and is available with a V-brake-style hangerless arch or a disc brake only version.
2002 MANITOU MARS FORK LINE
MARS COMP COIL........80 MM TRAVEL / COIL SPRING / TPC DAMPING / HOLLOW CROWN
MARS ELITE .................80 MM TRAVEL / AIR-COIL SPRING / TPC DAMPING / HOLLOW CROWN
MARS SUPER ..............80 MM TRAVEL / AIR-COIL SPRING / LOCKOUT / TPC DAMPING / HOLLOW CROWN
MARS DIVA ..................80 MM TRAVEL / AIR-COIL SPRING / LOCKOUT / TPC DAMPING / HOLLOW CROWN
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 PRODUCTS 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 PRODUCTS 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
WARRANTY 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 the Answer
Warranty Department at (661) 257-4411.
3. Any other alteration or modification to your fork should be considered unsafe.
Contact Answer Warranty 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 the Answer Warranty
Department 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.
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. 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.
.1.
.2.
Tire clearance
Reifenabstand
Espacio libre de
la cubierta
Distance arceau/pneu
Spazio libero del pneumatico
Bandspeling
Folga do pneu
Checking Oil Level
Kontrolle des Ölstandes
Verificación del nivel de
aceite
Vérification du niveau
d’huile
Controllo del livello dell’olio
Oliepeil controleren
Verificação do nível de óleo
.3.
Travel Measurement
Messung der Auslenkung
Cómo medir el recorrido
Mesure de la course
Misurazione della corsa
Meting van loop
Medição do curso
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.
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. Between services on your Manitou fork, all
you must do is lubricate your fork as needed with Manitou Prep M (part number 85-3810 for the lube and 85-3812 for the gun) via the Microlube ports located on the
back of the fork legs.
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 MARS
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 0.275” (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).
12. Install the brake cable per manufacturer’s instructions.
NOTE: 2002 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 BRAKE ARCH. THIS MEASUREMENT SHOULD BE AT LEAST 10 MM (SEE
FIGURE 1).
IMPORTANT: The MARS fork should not be used if any parts appear to be
or are damaged. Contact your local dealer or Answer Products for replacement
parts.
If you have any questions regarding your 2002 Manitou MARS suspension fork,
contact Answer Warranty 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 2002 Manitou MARS 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 is 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 is 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
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 relubricated using
the Microlube ports located on the back of each outer leg.
MARS 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
MARS 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.
IMPORTANT: When lubricating the fork through the Microlube ports, it is
CHANGING COIL SPRINGS – MARS COMP COIL
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 the fork.
2. Use of this fork without fork boots will require frequent service intervals to
maintain performance and normal life of the fork.
3. The warranty will be void if the fork is found to show that the boots were not
in place and frequent service was not performed.
important to note the lubricant is being forced between the upper and lower
bushings. If the area is overfilled, the lubricant may force the upper bushing
and dust seal out. You should only insert lubricant to the level at which stiction
is no longer felt.
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 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 on a Manitou MARS 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 (see figure 2). The oil level for the Manitou
MARS should be per following table.
FORK MODEL
MARS Comp Coil
MARS Elite
MARS Super
MARS Diva
OIL LEVEL
101 mm – 127 mm (4 - 5 inches)
95 mm – 108 mm (3.75 - 4.25 inches)
89 mm – 102 mm (3.5 - 4 inches)
89 mm – 102 mm (3.5 - 4 inches)
NOTE: Use Maxima SAE 5WT fork oil suspension fluid only.
Part #
85-9127
85-9128
85-9129
85-9219
Part #
85-4808
85-4878
85-4927
85-9188
1. Start by removing the preload adjuster by unscrewing the cap from the top
of the crown/leg assembly. A 20 mm socket may be necessary. Remember:
The springs are housed only in the left leg on 2002 Manitou suspension
forks.
2. With the adjuster assembly removed, the spring stack is now accessible.
3. Select the appropriate ride kit for the rider’s 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. We recommend any thick grease (not light lubricants like Prep M).
Install the new spring.
5. Reinstall the preload adjuster assembly, taking care not to cross-thread the
cap. It should thread in by hand and does not need to be tightened with a
wrench (finger-snug is recommended).
CHANGING COIL SPRINGS – MARS ELITE, MARS SUPER,
MARS DIVA
1. Start by unthreading the air cap on top of the left fork leg and removing
the fork’s air pressure via the Schraeder valve.
2. Next, from the bottom of the casting remove the 2 mm cap screws and
caps, the 11 mm open end bolt and 8 mm hex bolt (turn to the right to
loosen). Once you do this, you will be able to pull the lowers away from the
uppers.
3. On the left leg (as seen from the rider’s perspective), remove the 15/16inch cap from the bottom of the leg. Remove the entire assembly by pulling
the rod lightly. At this point, you will see the coil spring.
4. Select the appropriate coil spring for the rider’s weight and riding style
(refer to the above spring chart for recommended rates).
5. Apply a liberal amount of grease to the outside surface of the new
coil spring. We recommend any thick grease (not light lubricants like
Prep M). Install the new spring.
6. Reinstall the assembly into the left leg of the fork, taking care not to crossthread the cap. It should thread in by hand and should only be snug tightened.
7. Reinstall the lowers with the 11 mm and 8 mm bolts and tighten. You may
have trouble getting the 8 mm bolt to catch the threads. If this occurs,
remove the lowers, pull the rebound damping rod down again, and reinstall
the casting. You should be able to now install the 8 mm bolt.
CHANGING AIR SPRING PRESSURE – MARS ELITE,
MARS SUPER, MARS DIVA All you need to change the air pressure is
a high-pressure 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
MARS 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 valve. 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 3 cc of 20W-50 motor oil directly into the open fork leg. After this,
reinstall the Schraeder valve and the air cap and pressurize.
MINI BOOT LUBRICATION 2000 MARS forks come with mini boots
equipped with a foam lubricating ring inside the top bellow of the boot.
Occasionally you will need to relubricate this ring. The best way to do this is
turn your bicycle upside down, pull the boots away from the seal and drip a
small amount of 20W-50 motor oil down into the boot where the lubricating
ring is situated. It is only essential to moisten this ring, so don’t over do it.
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 the
knob 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 set screw. 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 set screw.
REBOUND DAMPING ADJUSTMENT – QUICK RANGE TPC
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 the knob counterclockwise
decreases rebound damping.
MICROLUBE
All you need is a Microlube lubricant gun (Part #85-3812)
and Manitou’s Prep M (Part #85-3810) suspension fork lubricant. Brush any
dirt from the lubricant ports, insert the lubricant gun into the small fitting
located at the back of the fork and squeeze a few times. Continue injecting
lubricant and push the fork up and down until stiction is eliminated.
MAINTENANCE AND SERVICE
When servicing the fork, take the
time to inspect all parts for excessive wear or damage. There are basically
four aspects of a fork that will require attention: the stanchions (inner legs),
the bushings in the outer legs, the spring stack and the damping fluid. In addition, with the air spring forks, you will also need to make sure a small amount
of lubricating oil (3cc) in sitting on top of the air piston (see Air Piston
Lubrication section). 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
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 4-5 months.
• Grease spring stack as needed.
• Service TPC by changing fork fluid every year.
NORMAL CONDITIONS – Long/Frequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 10-14 weeks.
• Grease spring stack as needed.
• Service TPC by changing fork fluid every 6 months.
SEVERE CONDITIONS (MUD, RAIN, SNOW, EXTREME DUST) –
Short/Infrequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 6-8 weeks.
• Grease spring stack as needed.
• Service TPC by changing fork fluid every year.
SEVERE CONDITIONS (MUD, RAIN, SNOW, EXTREME DUST) –
Long/Frequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 4-6 weeks.
• Grease spring stack as needed.
• Service TPC by changing fork fluid every 6 months.
SERVICE PARTS KITS
MARS COMP COIL
A
B
C
D
E
F
G
I
J
Compression Damping Assembly
Rebound Damping Assembly
Preload Adjuster Assembly
Crown/Steerer Tube Assembly
Outer Casting Assembly,
Candy Blue
Sticker Kit
Ride Kit Assembly, Soft
Medium
Firm
Extra-Firm
Knob Kit
Boot Kit
MARS SUPER
85-4875
85-4876
85-4877
85-4879
A
B
D
E
85-4880
85-4881
85-9127
85-9128
85-9129
85-9219
85-4886
85-4839
F
G
MARS ELITE
A
B
D
E
F
G
I
J
Compression Damping Assembly
Rebound Damping Assembly
Crown/Steerer Tube Assembly
Outer Casting Assembly,
Candy Chrome
Sticker Kit
Ride Kit Assembly,
Extra Soft Coil
Soft Coil
Medium Coil
Firm Coil
Knob Kit
Boot Kit
I
J
Compression Damping Assembly
Rebound Damping Assembly
Crown/Steerer Tube Assembly
Outer Casting Assembly,
Candy Red
Sticker Kit
Ride Kit Assembly,
Extra Soft Coil
Soft Coil
Medium Coil
Firm Coil
Knob Kit
Boot Kit
85-4890
85-4876
85-4888
85-4893
85-4881
85-4808
85-4878
85-4927
85-9188
85-4886
85-4839
MARS DIVA
85-4875
85-4876
85-4888
85-4889
85-4881
85-4808
85-4878
85-4927
85-9188
85-4886
85-4839
SPECIAL OFFER
Buy Prep M lubricant directly from Answer Products at a special
introductory price for new purchasers of Manitou forks
or Manitou equipped bikes.
Prep M Lubricant Gun & Tube: $19.95
International orders add a $15 handling charge, credit card only.
Shipping and handling in the US included in the $19.95 price.
Call Answer Products at 661-257-4411 to order
or visit the website at www.answerproducts.com.
A
B
D
E
F
G
I
J
Compression Damping Assembly
Rebound Damping Assembly
Crown/Steerer Tube Assembly
Outer Casting Assembly,
White
Sticker Kit
Ride Kit Assembly,
Extra Soft Coil
Soft Coil
Medium Coil
Firm Coil
Knob Kit
Boot Kit
85-4890
85-4876
85-4888
85-4894
85-4897
85-4808
85-4878
85-4927
85-9188
85-4886
85-4839
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