Manitou Circus Expert Service Manual
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Manitou Circus Expert Service Manual

Suspension fork
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  • Page 2 Hayes Performance Systems 5800 W. Donges Bay Rd. Mequon, WI 53092 Tel: 888.686.3472 Email: techsupport@hayesbicycle.com Web: www.hayescomponents.com Hayes Components Europe Dirnismaning 20 a 85748 Garching (b. Munich) Germany ph: +49 (0)89 203237450 Email: techsupportEU@hayesbicycle.com Web: www.hayescomponents.com CIRCUS EXPERT SERVICE MANUAL...
  • Page 3 INTRODUCTION This manual is intended to guide the user through the steps necessary to fully service and maintain the Circus Expert suspension fork. We highly recommend that service to this fork be performed by a certified bicycle mechanic. Failure to follow instructions presented in this manual could lead to serious injury or death.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION PAGE NUMBER REQUIRED TOOLS EXPLODED DIAGRAM 6–8 CASTING REMOVAL & SERVICE 10–12 AIR SPRING SERVICE 13–17 TRAVEL CHANGE (OPTIONAL) 14-15 DAMPER SERVICE 18–19 CASTING INSTALLATION 20–22 COMPRESSION DAMPER INSTALL 23–26 CIRCUS EXPERT SERVICE MANUAL...

  • Page 5: Required Tools

    REQUIRED TOOLS Below is a list of tools necessary for servicing the Circus Expert fork. • Safety Glasses • Nitrile Gloves • Lint-Free Rags • Torque Wrench • Slickoleum Grease • Semi-bath Oil, 5/40w Synthetic - Manitou part number 85-0022 •...
  • Page 6 CIRCUS EXPERT Exploded view CIRCUS EXPERT SERVICE MANUAL...
  • Page 7 CIRCUS comp Exploded view CIRCUS EXPERT SERVICE MANUAL...
  • Page 8 CIRCUS sport Exploded view CIRCUS EXPERT SERVICE MANUAL...

  • Page 9: Limited Warranty

    Dust Seals - Rear Shock - Remote Lockout Cable - Fork and Shock air Mount Hardware - Gloves Seals and/or O-rings - Handlebar grips - Lower Stanchion - Bearings - Tubeless Valves Tubes(Dorado) - Upper Stanchion Tubes CIRCUS EXPERT SERVICE MANUAL...

  • Page 10: Casting Removal & Service

    Insert an 8mm hex wrench into the end of the rebound damper rod and turn the rod clockwise until it is disengaged from the casting and can be pushed into the casting. Use a 12mm wrench to remove the compression rod bolt. CIRCUS EXPERT SERVICE MANUAL...
  • Page 11 Using a downhill tire lever or similar tool, gently pry the dust seals out of the casting. Remove old foam wiper rings. Apply semi-bath fluid to the new foam wiper rings and install into fork casting. CIRCUS EXPERT SERVICE MANUAL...

  • Page 12: Casting Removal & Service

    CASTING REMOVAL & SERVICE Remove springs from lip of dust seals. Using the Manitou 32mm Seal Press (Manitou part number 172-31122) or large socket press in the dust seals. Reinstall springs onto seals. CIRCUS EXPERT SERVICE MANUAL...

  • Page 13: Air Spring Service

    AIR SPRING SERVICE Release air from the fork. Depress Schrader valve a few times to ensure all air is released. Remove air cap using a 20mm socket. Remove the compression spring. CIRCUS EXPERT SERVICE MANUAL...
  • Page 14 Remove compression rod assembly from the stanchion. Clean the assembly and re-grease. Travel change (optional) With the compression rod assembly removed you can adjust the travel on the aftermarket Circus Expert by adjusting the spacer as shown. CIRCUS EXPERT SERVICE MANUAL...

  • Page 15: Travel Change (Optional)

    AIR SPRING SERVICE/TRAVEL CHANGE Travel change (optional) Liberally grease the piston seal and outer surface with Slickoleum™ grease Install air spring assembly into stanchion. Using a 22mm crow’s foot, tighten assembly end cap to 80-100 in lbs [9.0-11.3 NM]. CIRCUS EXPERT SERVICE MANUAL...
  • Page 16 AIR SPRING SERVICE Liberally grease the compression spring outer surface with Slickoleum™ grease Insert the compression spring and install air cap onto stanchion. Tighten to 60-80 in lbs. [6.8-9.0 NM]. CIRCUS EXPERT SERVICE MANUAL...

  • Page 17: Damper Service

    Remove knob carefully as there are two detent ball bearings on springs below the knob. (ABS+ knob detent ball and springs.) Unthread ABS+ compression damper assembly from the stanchion using a 24mm socket and ratchet. CIRCUS EXPERT SERVICE MANUAL...
  • Page 18 DAMPER SERVICE Remove ABS+ compression damper assembly from the stanchion. Pour damper oil into a catch pan. Using a 22mm box end wrench, unthread the rebound damper assembly from the fork stanchion. CIRCUS EXPERT SERVICE MANUAL...
  • Page 19 Inspect rebound damper for damage as well. Replace if necessary. Install rebound damper into stanchion. Using a 22mm crow’s foot and torque wrench, tighten the rebound damper assembly end cap to 80-100 in lbs [9.0- 11.3 NM]. CIRCUS EXPERT SERVICE MANUAL...

  • Page 20: Casting Installation

    Spread grease evenly along entire seal inner diameter. Fill the air chamber with a small amount of air (30-50PSI). This will extend the air spring assembly and make casting installation easier. CIRCUS EXPERT SERVICE MANUAL...
  • Page 21 Using an 8mm hex wrench tighten the rebound damper rod and air spring assembly to 35–40in lbs [3.95–4.5 Nm] by turning them counter-clockwise. Do not overtighten, doing so can damage the end of the rods. CIRCUS EXPERT SERVICE MANUAL...
  • Page 22 Install compression rod bolt. It helps to have at least 30-50PSI in the air chamber when tightening down the bolt to the proper torque. Use a 12mm socket and torque wrench and tighten to 45 –55 in lb [5.1–6.2 N m]. CIRCUS EXPERT SERVICE MANUAL...

  • Page 23: Compression Damper Install

    See following page for the correct oil height depending on compression damper type and fork travel. An oil height setting tool used for motorcycle forks similar to the one pictured makes this job easier. CIRCUS EXPERT SERVICE MANUAL...
  • Page 24 2. oil height is set with fork fully extended and casting installed. All forks listed us 5w synthetic oil for the damer, Manitou part number 85-0023. CIRCUS EXPERT SERVICE MANUAL All forks listed us 5w40 synthetic oil for the lowers, Manitou part number 85-0024.
  • Page 25 60–80 in lbs [6.8–9.0 NM]. Install springs and ball bearings into ABS+ top cap. A small dab of grease on top of the spring can help hold the ball bearings in place. CIRCUS EXPERT SERVICE MANUAL...
  • Page 26 10 PSI [0.7 BAR] 77. 1 10-25 PSI [0.7-17 BAR] 63.5 5-15 PSI [0.3-1.0 BAR] 54.4 0-10 PSI [0-.07 BAR] MAX PRESSURE NOT TO EXCEED 50PSI (3.45 BAR) MAX PRESSURE NOT TO EXCEED 50PSI (3.45 BAR) CIRCUS EXPERT SERVICE MANUAL...
  • Page 27 WWW. MANITOUMTB.COM WWW.HAYESCOMPONENTS.COM 5800 W DONGES BAY ROAD MEQUON WI 53092...

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