Manitou Circus Expert, Service Manual

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Page 2: ...ges 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 20323745...

Page 3: ...essures Warnings contained in this manual must be observed to avoid damage to fork serious injury or even death We highly recommend that service to this fork be performed by a certified bicycle mechan...

Page 4: ...E OF CONTENTS SECTION PAGENUMBER REQUIRED TOOLS 5 EXPLODED DIAGRAM 6 8 CASTING REMOVAL SERVICE 10 12 AIR SPRING SERVICE 13 17 TRAVEL CHANGE OPTIONAL 14 15 DAMPER SERVICE 18 19 CASTING INSTALLATION 20...

Page 5: ...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 8mm Hex Socket 2mm Hex Wrench 20mm Socket 24mm Socket 22m...

Page 6: ...6 CIRCUS EXPERT SERVICE MANUAL CIRCUS EXPERT Exploded view...

Page 7: ...7 CIRCUS EXPERT SERVICE MANUAL CIRCUS comp Exploded view...

Page 8: ...8 CIRCUS EXPERT SERVICE MANUAL CIRCUS sport Exploded view...

Page 9: ...s which are not defective shall be the BUYER s responsibility If permitted by local law this warranty is expressly in lieu of all other warranties except as to title express or implied and in particul...

Page 10: ...ve 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 cas...

Page 11: ...rain pan as the lower casting contains semi bath oil Allow oil in casting to drain out before continuing to next step 4 5 6 Using a downhill tire lever or similar tool gently pry the dust seals out of...

Page 12: ...RT SERVICE MANUAL CASTING REMOVAL SERVICE Remove springs from lip of dust seals Using the Manitou 32mm Seal Press Manitou part number 172 31122 or large socket press in the dust seals Reinstall spring...

Page 13: ...CUS EXPERT SERVICE MANUAL AIR SPRING SERVICE 1 2 3 Release air from the fork Depress Schrader valve a few times to ensure all air is released Remove air cap using a 20mm socket Remove the compression...

Page 14: ...stanchion Clean the assembly and re grease Travel change optional With the compression rod assembly removed you can adjust the travel on the aftermarket Circus Expert by adjusting the spacer as shown...

Page 15: ...ERVICE TRAVEL CHANGE 7 8 Liberally grease the piston seal and outer surface with Slickoleum grease Install air spring assembly into stanchion Using a 22mm crow s foot tighten assembly end cap to 80 10...

Page 16: ...SERVICE MANUAL 9 10 Insert the compression spring and install air cap onto stanchion Tighten to 60 80 in lbs 6 8 9 0 NM Liberally grease the compression spring outer surface with Slickoleum grease AI...

Page 17: ...Remove ABS knob using a 2mm hex wrench Remove knob carefully as there are two detent ball bearings on springs below the knob Unthread ABS compression damper assembly from the stanchion using a 24mm s...

Page 18: ...SERVICE MANUAL 3 4 5 DAMPER SERVICE 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 th...

Page 19: ...he 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 Replace if necessary...

Page 20: ...casting must first be installed This ensures correct oil level First apply a generous amount of grease to the oil seal dust seal area of the casting Spread grease evenly along entire seal inner diamet...

Page 21: ...get folded over on 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 Using an 8mm h...

Page 22: ...p of blue Loctite to the screw before installation to prevent the screw from backing out during riding 8 Install compression rod bolt It helps to have at least 30 50PSI in the air chamber when tighten...

Page 23: ...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 See follow...

Page 24: ...83mm 87mm 87mm machete kwik toggle 130 140mm 91mm 87mm 75mm 87mm 180 190mm oil height refers to the air space between the top of the oil and top of the fork leg fork model oil height markhor 120mm 97...

Page 25: ...set in the unlocked position when installing Install the ABS damper using a 24mm socket and torque wrench tighten the damper to 60 80 in lbs 6 8 9 0 NM Install springs and ball bearings into ABS top c...

Page 26: ...ow for reference COMPRESSION DAMPER INSTALL MAX PRESSURE NOT TO EXCEED 50PSI 3 45 BAR MAX PRESSURE NOT TO EXCEED 50PSI 3 45 BAR RIDER WEIGHT LBS KGS SOFT SPRING FIRM SPRING 220 99 8 30 50 PSI 2 0 3 4...

Page 27: ...WWW MANITOUMTB COM WWW HAYESCOMPONENTS COM 5800 W DONGES BAY ROAD MEQUON WI 53092...