CHANGING COIL SPRINGS – BLACK COMP 80/100,
BLACK ELITE 80/100, BLACK ELITE 100/120
1.
Start by removing the preload adjuster by unscrewing the cap from the top
of the crown/leg assembly. A 1-1/16” socket may be necessary. Remember:
The springs are housed only in the left leg on 2002 Manitou suspension
forks (as you are looking at the fork from the rider’s perspective).
2.
With the adjuster assembly removed, the spring stack is now accessible.
3.
Select the appropriate coil spring for your weight and riding style (refer to
the above spring chart for recommended rates).
4.
Apply a liberal amount of grease to the outside surface of the new coil
spring. We recommend any thick grease (not light lubricants like Prep M).
Install the new spring stack.
5.
Reinstall the preload adjuster assembly, taking care not to cross-thread the
cap. It should thread in by hand and does not need to be tightened with a
wrench (finger-snug is recommended).
CHANGING COIL SPRINGS – AIR FORKS
BLACK ELITE AIR, BLACK SUPER AIR
1.
Start by unthreading the air cap on top of the left fork leg and removing
the fork’s air pressure via the Schraeder valve.
2.
Next, from the bottom of the casting remove the 2 mm cap screws and
caps, the 11 mm open end bolt and 8 mm hex bolt (turn to the right to
loosen). Once you do this, you will be able to pull the lowers away from the
uppers.
3.
On the left leg (as seen from the rider’s perspective), remove the 15/16-inch
cap from the bottom of the leg. Remove the entire assembly by pulling the
rod lightly. At this point, you will see the coil spring.
4.
Select the appropriate coil spring for your weight and riding style (refer to
the above spring chart for recommended rates).
5.
Apply a liberal amount of grease to the outside surface of the new coil
spring. We recommend any thick grease (not light lubricants like Prep M).
Install the new spring.
6.
Reinstall the assembly into the left leg of the fork, taking care not to cross-
thread the cap. It should thread in by hand and should only be snug tight-
ened.
7.
Reinstall the lowers with the 11 mm and 8 mm bolts and tighten. You may
have trouble getting the 8 mm bolt to catch the threads. If this occurs,
remove the lowers, pull the rebound damping rod down again, and reinstall
the casting. You should be able to now install the 8 mm bolt.
CHANGING AIR SPRING PRESSURE – BLACK ELITE AIR,
BLACK SUPER AIR
All you need to change the air pressure is a high-
pressure Manitou (Part #85-4069) or other shock pump. Remove the air cap
located on the top of the left leg and then inflate the fork with the desired
pressure. Be aware that sometimes air systems lose a small amount of pres-
sure 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 pres-
sure.
COMPRESSION DAMPING ADJUSTMENT – QUICK RANGE
TPC
For Quick Range TPC forks, a simple turn of the knob located on top of
the right leg is all that is needed. Turning the knob clockwise (as you are look-
ing from a rider’s position) increases compression damping, while turning the
counterclockwise decreases compression damping.
Black Elite 80/100, Black Elite 100/120 and Black Elite Air only.
ADJUSTING COMPRESSION DAMPING WITH A LOCK OUT
The
Lock Out on the Black Super Air is simply an on-off switch for your fork. To
adjust compression damping, do the following: Remove the compression
assembly located in the right leg. On the lower piston of the lockout assembly
is a small set screw. Turn this in or out to increase or decrease compression
damping respectively. Note: a half turn makes a lot of difference, so make small
and incremental changes to the set screw.
Black Super Air only.
REBOUND DAMPING ADJUSTMENT – QUICK RANGE TPC
and FLUID FLOW DAMPING (FFD)
Rebound adjusters on Manitou
forks are located on the bottom of the right fork leg. Turning the knob clock-
wise (as you are looking at the fork from the bottom) increases rebound damp-
ing, while turning the knob counterclockwise decreases rebound damping.
Fluid Flow Damping: Black Comp 80/100
Quick Range TPC: Black Elite 80/100, Black Elite 100/120, Black Elite Air, and
Black Super Air
RAPID TRAVEL ADJUST
To change the travel with Rapid Travel
Adjust, just turn the knob located at the bottom of the left leg to the 80/100 or
100/120 position as shown on the sticker. Compressing the fork slightly is
required to release or lock the fork into a different travel position.
Black Comp 80/100, Black Elite 80/100 and Black Elite 100/120 only.
AIR PISTON LUBRICATION
For proper function of your fork, it’s essen-
tial to have a small amount of lubricating oil on top of the air piston in your
Black Elite Air or Black Super Air fork. To check this, remove the air cap on
the left side of the fork (as seen from the rider’s perspective) by simply
unthreading it counterclockwise. Release the air pressure from the fork and
then use a 20 mm hex wrench to remove the aluminum Schraeder valve. Once
you have done this, you can see the top of the air piston and determine if
there is a small amount of oil sitting on top of the air piston. If this oil is no
longer visible, pour 3cc of 20W-50 weight motor oil directly into the open fork
leg, After this, reinstall the Schraeder valve and the valve cover.
TRAVEL ADJUST KITS FOR BLACK SUPER AIR
Travel
Adjustment Kits for Black Super Air 100/120 are available free from Answer
Products. There is a shipping charge of $6 in the US and $15 for International
orders.
Travel Adjust Assembly 100 to 120 Part #85-4922
Travel Adjust Assembly 120 to 100 Part #85-4923
MICROLUBE
All you need is a Microlube lubricant gun (Part #85-3812)
and Manitou’s Prep M (Part #85-3810) suspension fork lubricant. Brush any
dirt from the lubrication ports, insert the gun into the small fitting located at
the back of the fork and squeeze a few times. Continue injecting Prep M and
push the fork up and down until stiction is eliminated.
MINI BOOT LUBRICATION
2002 Black forks come equipped with mini
boots equipped with a foam lubricating ring inside the top bellow of the boot.
Occasionally you will need to relubricate this ring. The best way to do this is
turn your bicycle upside down, pull the boots away from the seal and drip a
small amount of 20W-50 motor oil down into the boot where the lubricating
ring is situated. It’s only essential to moisten this ring, so don’t over do it.
MAINTENANCE AND SERVICE
When servicing the fork, take the
time to inspect all parts for excessive wear or damage. There are basically
four aspects of a fork that will require attention: the stanchions (inner legs),
the bushings in the outer legs, the spring stack and the damping fluid.
Inspecting any of these parts requires disassembly of the fork. Pay close atten-
tion to the bushings, which can be damaged by contamination in severe condi-
tions. Replace any worn or damaged parts that are discovered.
SERVICE SCHEDULE
Suggested Service for Manitou Forks
NORMAL CONDITIONS – Short/Infrequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 4-5 months.
• Grease spring stack as needed.
• Service TPC and FFD by changing fork fluid every year.
NORMAL CONDITIONS – Long/Frequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 10-14 weeks.
• Grease spring stack as needed.
• Service TPC and FFD by changing fork fluid every 6 months.
SEVERE CONDITIONS (MUD, RAIN, SNOW, EXTREME DUST) –
Short/Infrequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 6-8 weeks.
• Grease spring stack as needed.
• Service TPC and FFD by changing fork fluid every year.
SEVERE CONDITIONS (MUD, RAIN, SNOW, EXTREME DUST) –
Long/Frequent Rides
• Lube fork as needed with Prep M via Microlube lubrication ports.
• Disassemble, clean and lubricate fork every 4-6 weeks.
• Grease spring stack as needed.
• Service TPC and FFD by changing fork fluid every 6 months.
