Related Manuals for Manitou Axel Super 2004
Summary of Contents for Manitou Axel Super 2004
- Page 1 2004 SERVICE MANUAL Axel Super Axel Elite Axel Comp 28209 Avenue Stanford, Valencia, California 91355 www.answerproducts.com 661 257-4411 | fax 661 294-4179 |...
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Page 2: Table Of Contents
Table of Contents Description Page Introduction Glossary of Terms Disassembly Instructions Assembly Instructions Bushing Removal and Installation Instructions Troubleshooting Chart Axel Schematic and Torque Specifications Axel Service Kit Chart Contact Information Answer Products Customer Service Department 28209 Ave. Stanford Valencia, CA 91355 Toll Free: (800) 423-0273 Direct: (661) 257-4411... -
Page 3: Introduction
INTRODUCTION This manual is intended to guide the user through basic service of Manitou Axel front forks. Service is supported by the identification of common parts and assemblies that have been assembled into Service Kits. The purpose of this manual will be to describe conditions that may drive the need for service and to provide installation instructions for the kits. -
Page 4: Glossary Of Terms
GLOSSARY OF TERMS Arch – A support that connects the two outer lower legs of the casting so as to keep them moving in unison. Boss – The word used to describe an outer casting that has brake posts for V-brakes or cantilever brakes. - Page 5 Wiper Seal – A rubber material that is used as a seal to keep dirt and water out of the outer casting legs. It is not designed to keep air pressure or extreme oil pressure in. Manitou has the new Evil Genius wiper seals.
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Page 6: Disassembly Instructions
2004 Axel Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting 1. From the left leg dropout (Left when sitting on the bike), use a 4mm hex wrench to remove the compression rod screw. 2. From the right leg dropout, if the fork has adjustable rebound, the knob will need to be removed. -
Page 7: Assembly Instructions
Removal of Compression Damping Assembly Forks with FFD (non-adjustable) Damping 1. Remove top leg cap (FFD Assy) on right hand side using 27mm socket. 2. Pour old oil out of the top of the fork, then compress fork upside down over oil drain pan 3-5 times to get oil out from under rebound piston and discard appropriately. - Page 8 Setting fork in longer travel: Thicker Clip in slot above flange Follow Disassembly steps above. 2. Using pliers, pull thicker clip from bottom of rod and install it in slot just above flange. 3. Reassemble assembly and fork as directed below Assembly of Rebound Damping Assembly WARNING All leg caps for Damper and Spring systems must be properly tightened prior to...
- Page 9 5. Once the cap is tightened, twist the Hex shaped shaft clockwise until it stops (this is the locked out position). Insert the springs into opposite holes in the top cap and then place the ball bearings on top of the springs (place a little dab of grease on spring to hold ball bearing in place).
- Page 10 Installation of Spring, Compression Rod Assembly, and Outer Leg Casting - Wind Down Forks WARNING All top caps for Damper and Spring systems must be properly tightened prior to use. Failure to do so could result in injury or possible death. WARNING When installing the outer Leg Casting to the Crown Steer Assy, Compression Rod bolts and Damper Shafts must be properly tightened prior to use.
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Page 11: Bushing Removal And Installation Instructions
Wind Down Travel Adjust Assembly Top Cap Assembly & Spring Travel adjust assembly & End Cap Adjuster knob O-ring, knob, & 2mm screw Remove Nylon washer that rests on top of aluminum washer 4mm recessed Allen bolt 04 AXEL SERVICE MANUAL Page 11 REV NC... - Page 12 Bushing Removal & Installation Bushing Removal (Note: use appropriate removal ring that corresponds to the leg diameter of the fork being repaired) Leg Diameter Answer Kit # 25.4mm (1”) 85-5191 28.6mm (11/8”) 85-5189 30mm 85-5194 32mm 85-5192 Bushing Removal Tool Components A.
- Page 13 Bushing Removal (CONT.) Bushing Removal Instructions A. Install 25.4mm Removal ring on the shiny, smaller diameter threaded shaft. Be sure to install the ring with the tapered, chamfered end first, followed by the long slide tube. This tapered end leads the tool through the bushing. B.
- Page 14 Bushing Installation (CONT.) Bushing Installation Tool Assembly With weighted handle When selecting sizer rings to install bushings, choose the two rings that are in the middle of the size run to start with. 1. Assemble installation tool as shown in picture above.
- Page 15 Bushing Installation (CONT.) 4. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet until proper depth is achieved. If using depth gage, slide gage onto rod before installing weighted handle and let it settle on of Mandrel. Tap rod until appropriate line on gage is even with top of casting leg.
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Page 16: Troubleshooting Chart
Troubleshooting Chart Service Manual Symptom Cause Solution Page Oil leaks from Remove Casting from Inner Legs, reinstall Wiper Seals Seal not seated properly or replace seals Nicks or scratches on Replace Crown/Steerer/Inner Leg inner legs Assembly Remove Casting from Inner Legs, reinstall Wear or replace seals Oil leaks from... -
Page 17: Axel Service Kit Chart
Axel: Fastener Torque and Setup Levels Axel Comp & Elite Axel Super Model: Axel Description Torque Value Bushing Depth - Upper *8.9mm Min. (.35”) Bushing Depth - Lower *99 – 106 mm (3.9 - 4.2”) Torque – Brake Post 90–110inlbs (10.2-12.4nm) Leg Caps 25–35inlbs (2.8-4.0nm) Torque - Comp Rod Screw... - Page 18 Axel Service Kits Axel Model Comp Elite Super Code X-410 X-420 X-430 80 or 80 or 70 to Travel (mm) Comp Damp 85-5253 Rbnd Damp 85-5254 85-5255 Pre Load Adj/Top Cap 85-4810 85-5396 Crn/Str/Leg ***Steel S/T (26") 85-5393 ***Blk AL S/T(26") STD/SM 85-5394 Outer Leg Assy...
- Page 19 Axel Service Kits (Cont.) Axel Model Comp Elite Super Code X-410 X-420 X-430 80 or 80 or 70 to Travel (mm) Bumper Kit 85-5554 O-Ring Kit 85-5555 Bushing Kit 85-5324 Options: ***Damping *****Lock Out 85-5318 04 AXEL SERVICE MANUAL Page 19 REV NC...
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