.B. .A. .C. MANITOU SUSPENSION FORKS CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION TECHNOLOGY AVAILABLE, A 2005 MANITOU FORK. This fork is fully assembled and ready to be installed onto your bicycle. It comes equipped with a 11/8-inch or 11/2-inch (onepointfive) threadless steerer tube and may also be available in a disc brake only version. A handlebar-mounted reflector must be used for on-road use, which is not included with your fork. This manual is designed as a comprehensive guide for all 2005 Manitou fork models, including LUXE, SOUTH, SIX, AXEL, SPLICE, BLACK, SKAREB, MINUTE, NIXON, STANCE, SHERMAN and DORADO. All figures and tables are located at the front of this manual. This manual can be downloaded from the www.answerproducts.com website. 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, CREAKING, 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 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 TO HAVE YOUR FORK SHIPPED DIRECTLY AT (800) 423-0273. WARRANTY INFORMATION Any Answer Products fork found by the factory to be defective in materials and/or workmanship within one year from the date of purchase (or two years in EU countries) will be repaired or replaced at the option of the manufacturer, free of charge, when received at the factory, 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 with original purchase receipt 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. INSTALLATION INSTRUCTIONS IMPORTANT: Ensure that the proper steerer tube has been delivered on your fork 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 the installation. REPLACEMENT OF THE ENTIRE CROWN/STEERER ASSEMBLY MUST BE DONE TO INCREASE STEERER TUBE LENGTHS OR CHANGE DIAMETERS. REMOVING AND REPLACING THE STEERER TUBE 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 adjustments (where applicable) to fine-tune the fork completely. IMPORTANT: Manitou forks are designed for off-road use, and as such, they do not come with proper reflectors for on-road use. Have your dealer or mechanic install proper reflectors to meet the Consumer Product Safety Commission's (C.P.S.C.) Requirements for Bicycles if your fork is going to be used on public roads at any time. If you have questions regarding C.P.S.C. Standards, please contact your dealer. CONSUMER SAFETY INFORMATION Answer Products recommends that you periodically inspect your crown, inner legs, outer legs, dropouts and brake arch areas for cracks or damage. Do not use the fork if any parts are broken, bent, cracked, or you suspect may be damaged. Contact your dealer or Answer Products Customer Service at (800) 423-0273 if you have any questions concerning the integrity or condition of your fork. Any modifications not authorized by Answer Products should be considered unsafe. FORK INSTALLATION ­ SINGLE CROWN FORKS 1. Remove the old fork from your bicycle. 2. Measure and cut the steerer tube to fit your bicycle head tube (SEE IMPORTANT NOTE ABOVE). 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 fork 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 and torque the stem pinch screws or stem clamping system to manufacturer's specifications. 10. Install the brakes and adjust per the manufacturer's instructions. 11. For forks with standard dropouts (non through axle), 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. To install the hex axle, simply slip the axle into the dropout, small axle hex side first into the large dropout hex. Thread in the set bolt into the small hex side and snug slightly. Push the fork up and down a few times to center the axle and hub and then tighten all pinch bolts to recommendations found in Table 6. 13. Install the brake cable per manufacturer's instructions. SINGLE CROWN FORKS THE STEERER TUBE AND STANCHIONS (INNER LEGS) ARE PRESS FIT AT THE FACTORY AND SHOULD NEVER BE REMOVED FROM THE CROWN. PRESSING THEM OUT WILL PERMANENTLY DAMAGE THE CROWN BEYOND REPAIR AND RENDER IT UNSAFE FOR ANY CONTINUED USE. NEVER ATTEMPT TO THREAD A THREADLESS STEERER TUBE. CUTTING THREADS WILL WEAKEN THE STEERER TUBE AND CAUSE AN UNSAFE CONDITION. OBTAIN THE CORRECT CROWN/STEERER FROM YOUR DEALER, OR CONTACT ANSWER CUSTOMER SERVICE AT (800) 423-0273. DUAL CROWN FORKS THE STEERER TUBE IS PRESS FIT AT THE FACTORY AND SHOULD NEVER BE REMOVED FROM THE CROWN. NEVER ATTEMPT TO THREAD A THREADLESS STEERER TUBE. CUTTING THREADS WILL WEAKEN THE STEERER TUBE AND CAUSE AN UNSAFE CONDITION. OBTAIN THE CORRECT CROWN/STEERER FROM YOUR DEALER, OR CONTACT ANSWER CUSTOMER SERVICE AT (800) 423-0273. FORK INSTALLATION ­ DUAL CROWN FORKS 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. To determine which upper triple clamp your frame will need see Table 5. 3. Remove the headset crown race from the old fork and press onto the fork 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 the fork crown race. 6. Insert the steerer tube into the head tube of the frame. 7. Install the upper bearings, stem spacers, upper triple clamp and stem or integrated upper handlebar stem clamp. 8. Install the stem cap and bolt. Tighten the bolt to headset manufacturer's specifications. 9. Install the handlebars and torque the stem pinch screws or stem clamping system to manufacturer's specifications. Triple clamp, steerer tube, and handlebar bolts (integrated crown/stem models only) should be tightened to recommendations found in Table 6. 10. Install the brakes and adjust per manufacturer's instructions. 11. To install the hex axle, simply slip the axle into the dropout, small axle hex side first into the large dropout hex. Thread in the set bolt into the small hex side and snug slightly. Push the fork up and down a few times to center the axle and hub and then tighten all pinch bolts to recommendations found in Table 6. 12. Install the brake cable per manufacturer's instructions (see WARNING below.) 4. On coil forks with preload adjusters, turning the knob clockwise increases spring preload and decreases sag, while turning the knob counterclockwise decreases spring preload and increases sag. 5. On air forks, remove the Schrader air cap located on the top or on the bottom of the left leg and, using a dedicated shock pump (Manitou part #85-4069), 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 after you have set and checked the pressure. When setting sag on forks featuring IT technology, see "ADJUSTING MAIN SPRING AIR PRESSURE" below. 6. If adjusting the preload or air pressure does not provide the proper sag, you may require a new ride kit. DAMPING ADJUSTMENT ­ SPV EVOLVE With SPV Evolve damping, your suspension's compression damping characteristics and position sensitivity can be set with an SPV pump (Manitou part #85-4161). For proper function of your SPV damping system follow this procedure: 1. Start by removing the red SPV air cap located on the top of the right fork leg, as you are looking at the fork from the rider's position. (DORADO MRD X-Works forks have this adjustment at the bottom of the right fork leg). Using a dedicated SPV pump (Manitou part #85-4161), inflate the fork to the pressure recommended in Table 7. 2. Check sag per procedure above. 3. Adjust SPV pressure. More pressure will create more compression damping, hold the bike up more and pedal better. Less pressure will create less compression damping, allow more sag, and be more responsive and supple. Do not run SPV pressure below 30 psi. 4. Adjust SPV volume. With a 16 mm socket wrench or the SPV 16 mm volume adjust socket (part #85-3007), you can adjust the air volume in your SPV Evolve suspension. The volume adjust hex is colored red and is located on top of the right leg. Turning the volume adjuster inwards will create a more progressive damping effect and make the suspension firmer from mid-stroke to bottom-out. Turning the volume adjuster outwards will make the suspension more linear in compression damping and have a softer finish. Refer to the Answer Products website for specific tuning information about your SPV suspension. BRAKE CABLE INSTALLATION FAILURE TO PROPERLY ROUTE AND SECURELY ATTACH THE BRAKE CABLE TO THE FORK CAN CAUSE SERIOUS INJURY OR DEATH. Included with the fork is a small black cable guide that can be attached to the fork. The best method we've found is to attach the cable so that it runs down the outside of the left fork leg. Make sure the brake line is not crimped and does not touch the tire as the fork moves through its travel. NOTE: 2005 forks with standard dropouts 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 WITH A PROPERLY INFLATED TIRE, CHECK TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE CLEARANCE. 1. Measure from the highest point on the tire to the bottom of the brake arch (see Figure A). See Table 1 for minimum brake arch clearance. All figures and tables are located at the front of this manual. 2. Measure the tire at maximum width (see Figure B). See Table 1 for maximum tire width. COMPRESSION DAMPING ADJUSTMENT ­ TWIN PISTON CHAMBER (TPC) and TPC+ For forks equipped with TPC and TPC+, a simple turn of the knob located on top of the right leg is all that is needed to add compression damping. Turning the knob clockwise (as you are looking at the fork from the rider's position) increases compression damping, while turning the knob counterclockwise decreases compression damping. DORADOS featuring TPC+ damping will have this same compression adjustment at the bottom of the right fork leg. Some forks featuring TPC+ may not have external compression adjustments. Please consult the service manual (located at www.answerproducts.com) for further instructio ...