MAINTENANCE
IMPORTANT: The 98 XVERT should not be used if any parts appear to be or are damaged. Contact your local dealer or Answer
Products for replacement parts.
IMPORTANT: Use of fork boots is required to keep your XVERT performing well and your warranty in effect. Use of this fork with
the boots removed will shorten the life of the fork, reduce the performance and void the warranty.
Your 98 XVERT Fork requires periodic maintenance, cleaning, and inspection. Moisture and contamination may build up inside the fork
depending on the severity of riding conditions. To maintain top performance it is recommended that the fork be periodically disassemble
cleaned, dried and re-greased.
Note: The best way to prevent sticktion is to lift the fork boots up and apply a light spray of lube to the stanchion area in and above t
seals. Be sure to use a lubricating oil, not a penetrating fluid like WD 40. Stroke the fork several times adding more lube. Wipe off
excess lube from just the seal area while keeping the stanchions moist with lubricant. Reposition the boots.
When cleaning the fork do not direct water spray at the seals. Figure 7
IMPORTANT: Before every ride you should:
1. Ensure that quick release skewers are properly adjusted
and tight.
2. Wipe the inner legs clean, lubricate and check entire fork for any
obvious damage.
3. Check headset slack.
4. Insure that the front brake cable is properly seated in the
cable retainer & check brake adjustment
FIGURE 7: LUBRICATING THE BUSHINGS
IMPORTANT: Maintaining the proper oil level in your TPC is very important. Not enough oil will allow foaming and
reduce the performance. Too much oil will restrict travle and may cause damage to the system and an unsafe riding
situation, Finish reading this entire section prior to making any changes to the oil level.
To check the oil level remove only the compression
damping assembly located in the top of the left leg. Leave
the right side compression stack (adjuster, MCU, spring
assembly) in place to keep the fork fully extended. Use a
tape measure or Òdip stickÓ to determine the oil level. Oil
level should be between 3.5Ó (89MM) and 5.75Ó
(146MM) below the crown where the damping assembly
screws in. The recommended level is 4.75Ó (120MM).
Use SAE 5WT Maxima fork oil or equivalent. Figure 8
Model
Minimum
Maximum
Recommended
Xvert
4.5Ó (114mm) 3Ó (76mm) 3.75Ó (95mm)
Xvert R
9Ó (228mm) 7Ó (178mm) 8Ó (203mm)
Xvert TI 7Ó (178mm) 5Ó (127mm) 6Ó (152mm)
FIGURE 8: TPC OIL LEVEL
GENERAL DISSEMBLY
NOTE: The Fork does not need to be removed from the bicycle for general disassembly-assembly or cleaning. It is also not
necessary to disassemble the 98 Manitou Forks for compression Elastomer replacement. Elastomer replacement is
accomplished by removing the adjuster assembly per Figure 10.
Removal of outer leg / arch assembly XVERT & XVERT R Figure 9:
1.
Use a 4MM allen wrench to remove the M6 lower compression rod screw from the right leg dropout. Pop out the
damping adjuster knob from the left dropout. A small screwdriver may be helpful. Use a 8MM allen wrench to remove
the dropout nut. Fully compress the fork to prevent the compression rod and damper shaft from turning while removing
screws.
2.
Pull outer leg assembly down to remove from the inner legs and crown.
3.
Remove fork boots.
Note: It is not necessary to remove the dust seal every time the fork is disassembled. The seal and bushings may be
cleaned and re-greased in place.
4. Bushing replacement will require the use of the bushing removal and installation available from Answer Products. It is
recommended that the bushings be left installed unless they absolutely need replacement.
Page 7
Compression Stack & Compression Rod Removal Figure 10:
