Manitou R7 EXPERT Service Manual
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Manitou R7 EXPERT Service Manual

Manitou R7 EXPERT Service Manual

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R7 EXPERT / PRO | SERVICE & TRAVEL GUIDE

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Summary of Contents for Manitou R7 EXPERT

  • Page 1 R7 EXPERT / PRO | SERVICE & TRAVEL GUIDE...
  • Page 2 MANITOU 5800 W Donges Bay Rd Mequon, WI 53092 manitoumtb.com 888.686.3472 Support: manitoumtb.com/support Warranty: For full warranty information please visit hayesbicycle.com/warranty Revised June 12, 2020...
  • Page 3 INTRODUCTION This manual is intended to provide the information necessary to service the Manitou R7 Expert and Pro Suspension fork. We highly recommend any service or installation be performed by a qualified mechanic. These instructions can be downloaded from the Hayes Bicycle Group website at www.hayesbicycle.com...

  • Page 4: Table Of Contents

    SECTION PAGE NUMBER Tools And Materials Casting Removal & Service 6–8 Air Spring Service 9–11 Damper Service 12–15 Casting Install 16–18 Compression Damper Install 19–21 Recommended Starting Pressure Travel Change Exploded Views 24–31 R7 EXPERT / PRO SERVICE GUIDE...

  • Page 5: Tools And Materials

    • 32mm Seal Press Manitou Part Number 172-31122 • 32mm Rebuild Kit Manitou Part Number 141-28528-K010 • Manitou Tool Kit – Manitou Part Number 172-31133 (Includes The 3 Tools Below) Manitou Slotted Cassette Tool Manitou Thin Walled 8mm Socket Manitou 24mm Flat Ground Socket •...

  • Page 6: Casting Removal & Service

    Unscrew air cap and depress Schrader valve a few times to ensure all air is released. CAUTION Do not proceed to next step without completely depressurizing air spring R7 EXPERT / PRO SERVICE GUIDE...
  • Page 7 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. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 8 Apply semi-bath fluid to the new foam wiper rings and install into fork casting. Remove springs from lip of dust seals. Using the Manitou 32mm Seal Press or large socket, press in the dust seals. Reinstall springs onto seals. R7 EXPERT / PRO SERVICE GUIDE...

  • Page 9: Air Spring Service

    Remove air spring assembly. Clean assembly with isopropyl alcohol and a lint-free towel. Inspect air spring shaft, bumpers, and air piston seal for wear/damage and replace if necessary. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 10 Slickoleum™ grease. Also add 3cc’s of Slickoleum™ grease to the top of the air piston. Add Slickoleum™ grease to the stanchion threads before inserting the air spring assembly. Spread grease across entire thread surface. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 11 80-100 in lb [9.0-11.3 N m]. Install air spring top cap into stanchion. Torque to 60-80 in lbs [6.8-9.0 N m]. NOTICE Make sure to apply top down force on the tool to prevent slipping. R7 EXPERT / PRO SERVICE GUIDE...

  • Page 12: Damper Service

    NOTICE For Expert, skip to step 2. *Expert Model* Using a 2mm hex wrench, rotate counter-clockwise and remove knob screw when threads completely disengage from the damper. NOTICE For Pro, skip to step 3. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 13 NOTICE Non-standard spanners may damage the damper’s splined interface. Only use a standard cassette lockring tool and apply a top-down force while loosening to prevent slipping. Remove compression damper assembly from the stanchion. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 14 NOTICE For Expert, skip to step 7B *EXPERT MODEL* Using a 22mm wrench, rotate the damper end cap counter-clockwise until threads completely disengage from the stanchion. NOTICE For Pro, skip to step 8 R7 EXPERT / PRO SERVICE GUIDE...
  • Page 15 Manitou slotted cassette tool, and torque wrench to tighten to 60-80 in lbs [6.8-9.0 N m]. *EXPERT MODEL* Use a 22mm crow’s foot and torque wrench to tighten to 80-100 in lbs [9.0-11.3 N m]. R7 EXPERT / PRO SERVICE GUIDE...

  • Page 16: Casting Install

    Remove the shock pump. This process will ease casting installation. Lightly pull the rebound damper rod to full extension. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 17 Using an 8mm Hex wrench and torque wrench, tighten the rebound damper rod to 30–40 in lb [3.4–4.5 N m] by turning them counter- clockwise. Do not overtighten, as doing so can damage the end of the rods. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 18 Using the Manitou 8mm Thin Wall Socket and torque wrench, turn the compression rod counter- clockwise. Torque to 30-40 in lbs [3,4-4,5 N m]. Do not overtighten, as doing so can damage the end of the rods. R7 EXPERT / PRO SERVICE GUIDE...

  • Page 19: Compression Damper Install

    87mm. An oil height setting tool used for motorcycle forks similar to the one 87mm pictured makes this job easier. R7 EXPERT / PRO SERVICE GUIDE...
  • Page 20 Holding the knob steady, use an 11mm socket and torque wrench to assemble the knob lock nut (rotating clockwise) and tighten to 0.5-0.7 in lbs [4-6 N NOTICE For Expert, skip to step 7 R7 EXPERT / PRO SERVICE GUIDE...
  • Page 21 Remove the shock pump and clean the fork with isopropyl alcohol. NOTICE Lightly pulling the casting away from the CSA during air fill ensures full extension of the fork and proper air spring performance. R7 EXPERT / PRO SERVICE GUIDE...

  • Page 22: Recommended Starting Pressure

    MAX PRESSURE NOT TO EXCEED 120 PSI [8.3 BAR] 120mm Travel Rider Weight Air Pressure [BAR] >220 >100 99-110 [6.8-7.6] 85-100 [5.9-6.9] 73-85 [5-5.9] 59-73 [4-5] 51-59 [3.5-4] ! WARNING ! MAX PRESSURE NOT TO EXCEED 120 PSI [8.3 BAR] R7 EXPERT / PRO SERVICE GUIDE...

  • Page 23: Travel Change

    9. Once the rod is removed, arrange the travel spacers into the desired amount of travel using the following charts. Picture shows 100mm travel configuration. Diagram and travel chart apply to both Pro and Expert. R7 Spacer Diagram R7 EXPERT / PRO SERVICE GUIDE...

  • Page 24: Exploded Views

    R7 Expert 27.5" exploded view R7 EXPERT / PRO SERVICE GUIDE...
  • Page 25 12B KIT, FENDER, MY20 MEZZER & KIDS FORK (INCL. 12A) 141-36103-K001 KIT, ASSY, MILO AL W/CABLE & HOUSING 193-24931-C017 KIT, ASSY, MILO REMOTE LOCKOUT, LEVER & CABLE 141-31975-K003 KIT, DECAL, MY21 R7 141-38117-K021 KIT, REBUILD 32MM 141-28528-K010 R7 EXPERT / PRO SERVICE GUIDE...
  • Page 26 R7 expert 27.5+/29" exploded view R7 EXPERT / PRO SERVICE GUIDE...
  • Page 27 12B KIT, FENDER, MY20 MEZZER & KIDS FORK (INCL. 12A) 141-36103-K001 KIT, ASSY, MILO AL W/CABLE & HOUSING 193-24931-C017 KIT, ASSY, MILO REMOTE LOCKOUT, LEVER & CABLE 141-31975-K003 KIT, DECAL, MY21 R7 141-38117-K021 KIT, REBUILD 32MM 141-28528-K010 R7 EXPERT / PRO SERVICE GUIDE...
  • Page 28 R7 PRO 27.5" exploded view R7 EXPERT / PRO SERVICE GUIDE...
  • Page 29 12B KIT, FENDER, MY20 MEZZER & KIDS FORK (INCL. 12A) 141-36103-K001 KIT, ASSY, MILO AL W/CABLE & HOUSING 193-24931-C017 KIT, ASSY, MILO REMOTE LOCKOUT, LEVER & CABLE 141-31975-K003 KIT, DECAL, MY21 R7 141-38117-K021 KIT, REBUILD 32MM 141-28528-K010 R7 EXPERT / PRO SERVICE GUIDE...
  • Page 30 R7 PRO 27.5+/29" exploded view R7 EXPERT / PRO SERVICE GUIDE...
  • Page 31 193-24931-C017 KIT, ASSY, MILO REMOTE LOCKOUT, LEVER & CABLE 141-31975-K003 KIT, DECAL, MY21 R7 141-38117-K021 KIT, REBUILD 32MM 141-28528-K010 KIT, MATTOC SERVICE TOOL (8MM THIN-WALL SOCKET, 24MM FLAT SOCKET, & END 172-31133 CAP SOCKET) R7 EXPERT / PRO SERVICE GUIDE...
  • Page 32 GLOBAL HEADQUARTERS & HAYES BICYCLE GROUP USA 5800 W. Donges Bay Rd. Mequon, WI 53092 HAYES BICYCLE GROUP EU Dirnismaning 20 a 85748 Garching (b. Munich) Germany HAYES BICYCLE GROUP ASIA 16F, No. 37, Sec. 3 16F, No. 37, Sec. 3 Mincyuan E.

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