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Transcript of for the â€04 MANITOU SHERMAN .for the â€04 MANITOU SHERMAN FLICK ... -Ratchet...

  • 1

    PICTORIAL SERVICE INSTRUCTIONS for the

    04 MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    -Plastic bucket/drain pan-2mm and 8mm Allen wrenches -7/16 or 11mm wrench -Flat-bladed screwdriver-Pocket screwdriver -24mm (15/16) socket -Ratchet wrench-Adjustable fl at-jawed wrench-Torque wrench -Clean lint-free rags -5 wt. fork fl uid -Heavy Synthetic Grease -Super-Slick Grease or PrepM-Oil syringe (or other measuring device)

    RECOMMENDED PARTS FOR SERVICING THE

    MANITOU SHERMAN FLICK

    THESE INSTRUCTIONS ARE OPTIMIZED FOR

    ENDURO FORK SEALS

    EnduroForkSeals.com

  • 2

    TABLE OF CONTENTS

    TOOLS REQUIRED ..................................................................1

    SLIDER/LOWER ASSEMBLY, REMOVAL ............................3-6

    SEAL REMOVAL ......................................................................7

    SLIDER/LOWER ASSEMBLY, CLEANING ...........................8

    ENDURO FORK SEALS INSTALLATION .........................9-13

    RAPID TRAVEL II SERVICE..................................................14-19

    DAMPER SERVICE/OIL CHANGE ......................................20-23

    SLIDER/LOWER ASSEMBLY, RE-INSTALLATION ..........24-27

    SPACER CONFIGURATION ....................................................24

    SEMI-BATH OIL .......................................................................26

    RAPID TRAVEL II SELECTOR KNOB ..................................28

    ADJUSTING SAG...................................................................29

    ADJUSTING REBOUND.......................................................30

    ADJUSTING COMPRESSION...............................................31

    ON THE TRAIL.......................................................................32

    CARE OF YOUR ENDURO FORK SEALS..........................33

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

  • 3

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    1) Adjust the travel to its longest setting (fully extended).

    Rotate the lever on the left leg (from the riders perspective) as far as it will go toward the FRONT of the fork. If the fork was in the shorter travel mode, you will need to compress the fork so that it can unlatch and fully extend.

    2) Remove the fi xing bolt from the bottom of the spring leg.

    a) Invert the fork.

    b) Use a 7/16 or 11mm wrench and turn counter-clockwise.

  • 4

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    3) Adjust the rebound knob mid-way and use the 2mm Allen wrench to remove the retaining screw.

    Pull the rebound knob straight out toremove it.

    4) Use the 8mm Allen wrench to wind the damper rod CLOCK-WISE into the lower leg.

    Please note the inset and remember that the rod threads up INTO the lower casting. Do not try and wind it out, or damage will result.

    HAVE A BUCKET READY BEFORE THE NEXT STEP!

  • 5

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    5) OVER A BUCKET OR OIL PAN, turn the fork back over, drain the semi-bath oil out of the lower assembly, and pull the low-er assembly off of the stanchions.

    There are only 16ccs of oil in each lower leg, so you can just pull the lowers off while the oil is draining if you wish.

    6) Dont be surprised if you fi nd several pieces of hardware left inside the lowers...

  • 6

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    7) Use a metal rod, a wooden dowel, or whatever you have handy to push any spacers out of the lowers.

  • 7

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    8) Insert a fl at-bladed screw-driver under the back end of the seal/wiper.

    Note that the shaft of the screwdriver is wrapped in tape to protect the fi nish of the fork.

    9) Apply downward pressure on the screwdriver handle until the wiper/seal pops up and out.

    Be careful not to scratch the metal at the back of the lowers while prying up the old wipers.

    10) Remove the foam ring from the seal insertion area.

    The foam rings will not be re-used. They will be replaced with a special inner oil seal.

    REPEAT STEPS 8-10 FOR THE OTHER SIDE.

  • 8

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    11) If the lowers are particularly dirty, its time to move to the sink and use some biodegradable de-greaser.

    Sometimes the semi-bath lube turns to jelly and needs to be cleaned out. (Our theory is that some of the semi-bath oil splashes up into the spring area and mixes with the grease that is used to lube the spring)

    12) Chase the degreaser with a mixture of hot water and dish soap and a little brushing, if needed. RINSE well with hot water.

    Using hot water not only cuts the grease, but heats up the lowers and causes them to dry quicker due to evaporations.

    13) Thoroughly dry the lower legs.

  • 9

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    14) This is the BOTTOM of the inner oil seal. See the deep groove? IT FACES DOWN.

    15) This is the TOP of the inner oil seal. See the word ENDURO and the numbers? THEY FACE UP.

    You will notice that machined area at the top of the lowers is stepped. The area just above the bushings (where the inner oil seals will go) has a slightly smaller inside diameter than the area where the wipers will be seated.

  • 10

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    16) Use some Super-Slick Grease, Prep-M or other supsension compatible grease to lubricate the seal-insertion area of the lowers and the outside edge of the inner oil seal.

  • 11

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    17) Start the seal into the lower leg and use your thumbs to press it down evenly until flush with the top edge of the lower leg.

    18) Use a large inverted socket and extention to carefully seat the inner oil seals in each leg.

    Push very lightly, slowly increasing pres-sure until the seal begins to move. Once it starts sliding, it takes very little pressure to seat it against the bushing.

  • 12

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    19) This is the Enduro Wiper. Apply a thin coating of grease to the insertion area of the wiper.

    20) Start the wiper into the in-sertion area of the lower leg. It should be easy to start, as the leading edge is slightly tapered.

  • 13

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    21) Use a large socket (or a piece of 1-1/2 PVC pipe to press the wipers in until no gap can be seen below the wiper lip. Its fi ne to do a little gentle persua-tion with a rubber mallet, just be sure to put some padding at the other end of the lowers.

    You are now fi nished servicing the lowers, and can temporarily set them aside.

    Next up: Coil Spring/Rapid Travel II service.

    NOTE: If you wish to only change the seals at this time, you may pro-ceed to Step 40 on Page 24

  • 14

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    23) Use a 20mm socket to loosen and remove the top cap.

    22) Remove the Travel Selector Knob.

    a) Be sure the indicator is fully for-ward in the long travel position.

    b) Use a 2mm Allen wrench to loos-en the adjuster knob set screw.

    c) Lift the adjuster knob straight off of the hex shaft.

  • 15

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    24) Remove the coil spring from the stanchion.

    The coil spring pictured on the left is shown with the stock, or medium spring. Although it may appear to the human eye to be purple, be advised that this is red.

    25) Use good-quality adjustable fl at jawed pliers or a wrench to loosen the compression rod end cap.

  • 16

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    When the Travel Adjust knob at the top of the fork is turned, it causes the spring to rotate. A plastic insert in the end of the spring, called the Spring Foot (pictured later) fits over this wire loop.

    The rotation of the wire loop causes the extension of these wings, which catch the fork in the low travel position when extended. When it is time to re-install the Spring and the Compression Rod, remem-ber to ASSEMBLE THE FORK WITH THE WINGS RETRACTED (not ex-tended).

    26) Pictured at left is the Travel Adjust/ Compression Rod Assembly.

  • 17

    MANITOU SHERMAN FLICK 2005 EnduroForkSeals.com/Real World Cycling. All rights reserved.

    27) Apply a fresh coating of Red Devil Grease to the coil spring, but go lightly on the bottom half of the spring.

    The compression rod end cap does not actually seal against the rod, and some of the semi-bath oil splashes up into the coil spring area. If there is a lot of grease near the bottom of the spring, it will mix with the semi-bath oil and turn it into a gel.

    28) Apply a small amount of Blue