Manitou Axel Comp 2004, Service Manual

Page 1: ...28209 Avenue Stanford Valencia California 91355 661 257 4411 fax 661 294 4179 www answerproducts com 2004 SERVICE MANUAL Axel Super Axel Elite Axel Comp ...

Page 2: ...d Installation Instructions 11 Troubleshooting Chart 15 Axel Schematic and Torque Specifications 16 Axel Service Kit Chart 17 Contact Information Answer Products Customer Service Department 28209 Ave Stanford Valencia CA 91355 Toll Free 800 423 0273 Direct 661 257 4411 FAX 661 775 1798 E mail warranty answerproducts com tech answerproducts com Web site www answerproducts com ...

Page 3: ...rk or the user CAUTION A CAUTION a caution indicates special precautions that must be taken to avoid damage to the product NOTE A NOTE provides key information to make procedures easier or clearer GENERAL WARNING Suspension forks by design can contain preloaded springs gases and fluids under extreme pressure and warnings contained in this manual must be observed to reduce the possibility of injury...

Page 4: ...tanchion legs inner legs the fork crown and the steer tube pressed together as one assembly This assembly is then finished by adding all of the fork internals and then outer casting slider Drop Out The end of an outer casting slider where the wheel attaches Dust Boot Usually a piece of rubber in the shape of a cylinder with baffles to allow it to compress as the fork compresses through its travel ...

Page 5: ...s fixed to the wheel It slides up and down on the stanchion leg inner leg Stanchion Legs The suspension tube inner leg fixed to the fork crown It remains stationary during the operation of the suspension Steer Tube The long cylindrical tube that extends from the top of the fork crown Its function is to be inserted into the bicycle head tube and attach the suspension to the bicycle frame Top Out Bu...

Page 6: ... rods to fall out of the inner legs Removal of Spring and Compression Rod Assembly Wind Down Travel Adjust Forks 1 Turn travel adjust knob clear plastic knob on top of the left side of the crown in a counterclockwise direction until it stops This insures that the fork is in its longest travel and reduces any spring preload on the fork 2 Remove the 2mm Allen screw from the knob Use a 28mm socket to...

Page 7: ...s from inside the top cap 3 Unscrew the compression damping assembly using a 24mm socket 4 Pour old oil out of the top of the fork then compress fork upside down over oil drain pan 3 5 times to get oil out from under rebound piston and discard appropriately Removal of Rebound Damping Assembly 1 Unscrew Damper end cap from the bottom of the right leg and then pull out the rebound damper Assembly In...

Page 8: ...of the crown steer using a 27mm socket Tighten per the Axel Schematic and Torque Specification Table Assembly of Compression Damping Assembly Adjustable Compression Lockout WARNING All top caps for Damper and Spring systems must be properly tightened prior to use Failure to do so could result in injury or possible death 1 Fill right leg with damping oil using 5wt Motorex fork oil Ref Answer Produc...

Page 9: ...or possible death WARNING When installing the outer Leg Casting to the Crown Steer Assy Compression Rod bolts and Damper Shafts must be properly tightened prior to use Failure to do so could result in injury or possible death 1 Screw the compression rod assembly into the crown steer assy Make sure that the comp rod that accepts the 4mm screw is installed in the left leg Tighten per the Axel Schema...

Page 10: ...o a main spring catch the flat end of the booster spring under the flat end of the main spring and twist it counterclockwise into the main spring Make sure that the booster spring is threaded all of the way down into and contained by the main spring Before inserting it back into the inner leg 5 Generously grease the spring and insert it into the inner leg The end of the spring needs to seat onto t...

Page 11: ...AL Page 11 REV NC Wind Down Travel Adjust Assembly Top Cap Assembly Spring Travel adjust assembly End Cap Adjuster knob O ring knob 2mm screw Remove Nylon washer that rests on top of aluminum washer 4mm recessed Allen bolt ...

Page 12: ...ate removal ring that corresponds to the leg diameter of the fork being repaired Leg Diameter Answer Kit 25 4mm 1 85 5191 28 6mm 11 8 85 5189 30mm 85 5194 32mm 85 5192 Bushing Removal Tool Components A Slide Hammer B Threaded Handle C Slide D Threaded Shaft E Removal Ring Bushing Removal Tool Assembly ...

Page 13: ...op It is important to pull one bushing out at a time Push the slide on the threaded shaft down towards the removal ring Hold the casting with one hand and the slide hammer with your other hand Now move the slide hammer in a motion away from the casting and repeat this action until the bushing comes out D For all other leg diameters use the larger diameter dark colored threaded shaft and repeat ste...

Page 14: ...ven any deeper than 5 into a casting leg If they do go deeper call Customer Service at Answer Products 800 423 0273 for a new outer casting 2 Always assemble Mandrel with the larger diameter sizer ring being placed on the mandrel first then the spacer the next largest sizer ring followed by the washer and the nut to hold it in place Be sure to lock the nut above the Mandrel and below the Mandrel a...

Page 15: ...l to be pulled through the bushing thus sizing it Keep turning the nut until the tool is all the way through the bushing and can be pulled out of the leg 8 To install top bushings repeat steps B E Note that the top bushing gets inserted until it stops against the step inside of the casting The extra sleeve that comes with the sizer kit is used to space the top cap off of the casting so that there ...

Page 16: ... volume Check oil level Replace Rebound Damping assembly if needed Fork alignment Visually inspect fork call Answer Products Customer Service Fork Top out Loss of Rebound Damping Replace Rebound Damping assembly Top out spring damaged Inspect and replace Top out spring if needed Damping oil volume not correct Check oil level Replace Rebound Damping assembly if needed Fork Bottom out Too much SAG R...

Page 17: ...ion Torque Value Bushing Depth Upper 8 9mm Min 35 Bushing Depth Lower 99 106 mm 3 9 4 2 Torque Brake Post 90 110inlbs 10 2 12 4nm Leg Caps 25 35inlbs 2 8 4 0nm Torque Comp Rod Screw 10 30inlb 1 1 3 4nm Torque Damper Screw Axel Super 10 30inlb 1 1 3 4nm Adjuster caps Torque 35 50inlbs 4 0 5 7nm Damping Oil 110 120mm 4 3 4 7 ...

Page 18: ...STD Cobalt 85 5530 STD Orange 85 5531 STD Yellow 85 5532 STD Candy Chrome 85 5533 STD Candy Red 85 5534 STD Candy Blue 85 5273 No Boss Black 26 85 5236 No Boss Silver 26 85 5233 No Boss Red 26 85 5237 No Boss White 85 5537 No Boss Cobalt 85 5538 No Boss Orange 85 5539 No Boss Yellow 85 5540 No Boss Candy Chrome 85 5541 No Boss Candy Red 85 5542 No Boss Candy Blue 85 5543 Sticker Kit F Silver 85 55...

Page 19: ...age 19 REV NC Axel Service Kits Cont Axel Model Comp Elite Super Code X 410 X 420 X 430 Travel mm 80 or 100 80 or 100 70 to 100 Bumper Kit K 85 5554 O Ring Kit K 85 5555 Bushing Kit E 85 5324 Options Damping Lock Out A 85 5318 ...

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