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Hayes Manitou MARKHOR 29 Service Manual

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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 MARKHOR SERVICE MANUAL...
  • Page 3 INTRODUCTION This manual is intended to guide the user through the steps necessary to fully service and maintain the Markhor suspension fork. We highly recommend that service to this fork be performed by a certi ed bicycle mechanic. Failure to follow instructions presented in this manual could lead to serious injury or death.
  • Page 4 TABLE OF CONTENTS SECTION PAGE NUMBER REQUIRED TOOLS EXPLODED DIAGRAM 6–7 CASTING REMOVAL & SERVICE 9–11 AIR SPRING SERVICE 12–15 TRAVEL CHANGE DAMPER SERVICE 16–19 CASTING INSTALLATION 20–22 COMPRESSION DAMPER INSTALL 23–26 MARKHOR SERVICE MANUAL...
  • Page 5 REQUIRED TOOLS Below is a list of tools necessary for servicing the Markhor fork. • Safety Glasses • Nitrile Gloves • Lint-Free Rags • Torque Wrench • Slickoleum Grease • Semi-bath Oil, 5/40w Synthetic - Manitou part number 85-0022 • 5wt Maxima Fork oil - Manitou part number 85-0023 •...
  • Page 6 markhor 29 & 27.5 Exploded view MArkhor 27.5 & 29 Exploded view abs+ Damper 15mm Round axle MARKHOR 27.5 PART DESCRIPTION MARKHOR 29 PART DESCRIPTION ITEM PART NUMBER ITEM PART NUMBER 100 & 110 MM AXLE 100 & 110 MM AXLE CSA, 100, 1-1/8 STRAIGHT STEER, 41 OS, BLK 141-333382-B711 CSA, 100, 1-1/8 STRAIGHT STEER, 48 OS, BLK...
  • Page 7 Unless otherwise prohibited by law, any such defective products will be repaired or replaced at the option of HAYES when received with proof of purchase, freight prepaid. This warranty does not cover breakage, bending, or damage that may result from crashes or falls.
  • Page 8 CASTING REMOVAL & SERVICE Remove rebound knob using a 2mm hex wrench. 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.
  • Page 9 Remove casting from fork. It is recommended this be done over a drain pan as the lower casting contains semi-bath oil. Allow oil in casting to drain out before continuing to next step. Using a downhill tire lever or similar tool, gently pry the dust seals out of the casting.
  • Page 10 CASTING REMOVAL & SERVICE Remove springs from lip of dust seals. Using the Manitou 30mm Seal Press or large socket press in the dust seals. Reinstall springs onto seals. MARKHOR SERVICE MANUAL...
  • Page 11 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. Invert the fork and use a 22mm box end wrench to unthread the air spring assembly from the stanchion.
  • Page 12 AIR SPRING SERVICE Remove air spring assembly from the stanchion. Clean spring and rod assembly and re-grease. TIP: Ensure grease is worked into the ID of the rubber top-out bumper to improve ride quality and topping feel. Thread a piston removal tool (or a long M6 bolt as seen in the bottom photo) into the air piston and remove it from the stanchion .
  • Page 13 AIR SPRING SERVICE/travel change Optional To change fork travel to 80mm or 100mm add or remove spacers and compression rod extender as seen below. This is the same for the 27.5 and 29 version of the fork. Note* The comp rod service kit for Markhor, Manitou part number 141-31870-K009, includes all the necessary components to make any travel version for either 27.5 or 29.
  • Page 14 AIR SPRING SERVICE Liberally grease the piston quad seal and outer surface with Slickoleum™ grease. Install greased air piston into the top of the stanchion and push it down past the threads. Add 8cc’s of Slickoleum™ grease to the top of the air piston. MARKHOR SERVICE MANUAL...
  • Page 15 AIR SPRING SERVICE Install air cap onto stanchion. Tighten to 60-80 in lb [6.8-9.0 N m]. Install air spring assembly into stanchion. Using a 22mm crow’s foot, tighten assembly end cap to 80-100 in lb [9.0-11.3 N m]. MARKHOR SERVICE MANUAL...
  • Page 16 DAMPER SERVICE The Markhor fork can have two ABS+ or Kwik Toggle. The following instructions will work for both. Remove ABS+ or Kwik Toggle knob using a 2mm hex wrench. If the fork has ABS+, remove knob carefully as there are two detent ball bearings on springs below the knob.
  • Page 17 DAMPER SERVICE KWIK TOGGLE Unthread the Kwik Toggle compression damper from the fork. You will need to use the cassette tool and 1” wrench or socket to remove the damper. ABS+ Unthread the ABS+ compression damper form the fork using a 24mm socket.
  • Page 18 DAMPER SERVICE ABS+ 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. MARKHOR SERVICE MANUAL...
  • Page 19 DAMPER SERVICE Remove rebound damper assembly from the fork. Once the damper assembly is removed, clean the inside of the stanchion with isopropyl alcohol and a lint free towel. Inspect the inside and outside of the stanchion for scratches and other damage. Inspect rebound damper for damage as well.
  • Page 20 CASTING INSTALL installing the ABS+ compression damper, ensures correct oil level. First apply a generous amount of grease to the oil seal/dust seal area of the casting. Fill the air chamber with a small amount of air (30-50PSI). This will extend the air spring assembly and make casting installation easier.
  • Page 21 CASTING INSTALL Slide casting onto the stanchion assembly. Only slide the casting down about halfway at this point. Take care that the seals do not get folded upon installation. Insert 15cc’s (15ml) of semi-bath into each casting leg. Once the semi-bath is in the legs slide the casting the rest of the way onto the stanchion assembly.
  • Page 22 CASTING INSTALL Install the rebound knob using a 2mm hex wrench. Add a small drop of blue Loctite to the screw before installation to prevent the screw from backing out during riding. Install compression rod bolt. It helps to have at least 50psi in the air chamber when tightening down the bolt to the proper torque.
  • Page 23 COMPRESSION DAMPER INSTALL Pour 5wt Maxima fork oil into the damper leg. Fill it up ¾ of the way. Place a lint-free towel over the opening in the damper leg and compress the fork 10-15 times. Pour additional 5wt fork oil into the damper leg until the oil height (space from the top of the damper leg to the top of the oil) is set at the proper level.
  • Page 24 COMPRESSION DAMPER INSTALL oil height chart 2018 fork model oil height Mastadon pro 75mm mastadon comp 87mm height markhor (80/100mm) 92mm (refers to the air space between the top markhor (120mm) 97mm of the oil and top of mattoc pro 75mm the fork leg) mattoc comp...
  • Page 25 COMPRESSION DAMPER INSTALL Insert the Kwik Toggle or ABS+ compression damper into the damper leg. Ensure the damper is set in the unlocked position when installing. If installing an ABS+ damper use a 24mm socket and torque wrench, tighten the damper to 60–80 in lbs [6.8–9.0 NM]. If installing a Kwik Toggle damper use a 1”...
  • Page 26 COMPRESSION DAMPER INSTALL Using a 2mm hex wrench, install the ABS+ or Kwik Toggle knob. Clean fork and use a shock pump to set to desired pressure. Pressure chart below for reference. MARKHOR SERVICE MANUAL...
  • Page 27 Remote Knob Set-Up Guide, Kwik Toggle 1. Turn Kwik Toggle hex full counter-clockwise (Open Posit i o n). This will help set the knob f i n al posit i o n in Normal Open mode. 2. Install short tab of the spring into the cross-hole in underside of knob. Red Arrow indicates the side to insert into.
  • Page 28 Remote Knob Set-Up Guide, Kwik Toggle 5. Insert the cable stop into the splines of the Kwik-Toggle top cap. Allow the knob to lif t away several mm unt i l the splines of cable stop engage to the top-cap. Be careful the long tab on the spring does not separate from its home.
  • Page 29 WWW. MANITOUMTB.COM WWW.HAYESCOMPONENTS.COM 5800 W DONGES BAY ROAD MEQUON WI 53092...

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Manitou markhor 27.5

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