2004 Black Service Manual



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Air CapTop cap that threads into top of air/spring leg (this is the left leg of the fork as you are seated on the seat). Forks may be controlled with an air/spring or a coil spring. The air cap contains the Schrader Valve, which is used to control the spring rate or SAG of air forks.



Air SpringA mechanism that is used to control the SAG of an air fork.
ArchA support that connects the two outer lower legs of the casting so as to keep them moving in unison.
BossThe word used to describe an outer casting that has brake posts for V-brakes or cantilever brakes.
Bottom Out BumperA rubber or elastomer device that absorbs the shock that occurs when a suspension is compression to its limit.
Bushings – A cylindrical sleeve between a fork stanchion tube (inner leg) and a fork outer casting (slider), which facilitates the sliding movement between these two parts.
Coil Spring – A coiled piece of metal that acts as a spring to help suspend a fork.
Compression – The phase of the suspension operation in which the wheel travels up, or travels closer to the frame. The suspension forks reaction to a bump in the trail.
Compression Damping – Restriction of the rate that the suspension compresses under load.
Crown Steerer Assembly – the stanchion 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).
Damping – A function that modifies the rate of suspension compression or rebound.
Detent – An indentation that causes a rotating adjuster to stop at fixed increments.
Drop Out – The end of an outer casting (slider) where the wheel attaches.
FFD – Fluid Flow Damping. A Manitou patented low cost oil damping system. The compression damping is non-adjustable and the rebound damping may be non-adjustable or adjustable damping.

GLOSSARY OF TERMS (CONT.)
Fork Crown – The component that joins the stanchion tubes (inner legs) to the steer tube of the fork.
Hydraulic Fork Oil – Oil used in suspension designs to provide damping. It has special characteristics that determine how it reacts when exposed to compressed air, how it changes viscosity when its temperature changes, and how it moves through valves.
Hydraulic Lock Out – a condition caused when the mixture of air and damping oil is out of balance. It is caused when there is too little air space in a chamber, not allowing the fork to compress through its travel.
Lock Out – a special function that restricts the compression of the fork from moving. It is generally controlled by an external knob that is activated when a rider does not want the fork to move, thus eliminating extra energy needed to overcome the bobbing forces of the fork.
MCU – (Micro-Cellular Urethane) Special urethane that is filled with tiny air cells that act like springs when the elastomer is compressed.
No Boss - The word used to describe an outer casting that has no brake posts for V-brakes or cantilever brakes. This casting is to be used for disk brakes only.
Oil Damping – A system that uses the resistance to oil flow through holes in a valve to provide a means to alter the rate of suspension compression or rebound.
Oil Level – The level of damping oil needed for the optimal damping performance of a suspension. It is measured as the air space distance between the top of the stanchion leg (inner leg) and the height of the oil inside of the leg. The fork must be completely extended in order to get an accurate measurement.
O-Ring – A soft, flexible neoprene or Buna rubber ring with a round cross-section, which is used for sealing and retention.
Oil Weight – A description of the relative viscosity of oil, such as hydraulic oil. Oil with low weight numbers (5wt or 7wt) flow through valves with less resistance than higher weight numbers (10or 15 wt).
Outer Casting – (see Slider)
Preload – A condition of compressing a spring or elastomer before the operating loads are put on the suspension, so that it provides a stiffer spring rate.
Piston – In front suspension, the part of the damper that slides back and forth inside of the damping leg that houses the valves. It can also refer to the air piston in the air/spring assembly that slides back and forth compressing the air, thus causing a change in the spring rate of the suspension.

GLOSSARY OF TERMS (CONT.)
Porosity – The condition or property of having pores in a material that will allow gas or liquid to pass through it.
Rebound – The phase of the suspension operation in which the wheel returns to its original position on the ground after compression.
Rebound Damping – Restriction of the rate that the suspension rebounds when the compression load is relived.
Reverse Arch Technology – Also known as RA. It is a system that is designed to move the arch of a fork to the backside of a fork, rather than the conventional front position. It was designed to provide greater rotational torque strength to an outer casting (slider), without adding additional weight to the fork.
SAG – The amount a suspension fork compresses at rest with a normal load (rider’s weight).
Schrader Valve – Valve used to introduce air into a chamber.
Seal – A part, usually neoprene rubber or Buna, that keeps contaminants out and/or working fluids in.
Semi Bath – A lubrication system that uses a lubricating oil to keep the bushing surface and stanchion legs (inner legs) as friction free as possible during movement of the stanchion legs.
Spring Rate – The rate at which the resistance of a spring increases as it is compressed.
SPV – (Stable Platform Valve) new damping system that allows the rider to set the pedaling platform that he desires to pedal most efficiently in all situations. It is dependent on the pressure that the SPV valve experiences from the movement of the wheel vs. the terrain and the platform that is set by pressure introduced to other side of the SPV valve through changes of air pressure working on the damping oil.
Slider/Outer Casting – The tube (outer casting leg) of the suspension fork that remains fixed to the wheel. It slides up and down on the stanchion leg (inner leg).
Stanchion Clamps - (Double-Triple Clamps) the portions of the fork crown that clamp around the stanchion legs above and below the head tube of the bicycle frame on specific long travel applications.
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.

GLOSSARY OF TERMS (CONT.)
Top Out BumperA rubber, coil spring, or elastomer device that absorbs the shock that occurs when the load is taken off a suspension so that it is allowed to rebound to its limits
TPC – (Twin Piston Chamber) a patented damping system that has independent pistons for rebound and compression. The system utilizes a mixture of air and oil in the damping leg of the fork to enhance the damping performance.
Travel – The amount that a wheel moves between the most compressed and the most extended states of the suspension
Viscosity – A description of how a liquid flows. Liquids with higher viscosity are thicker flow less easily or quickly than liquids with low viscosity. This has an affect on the damping speeds of rebound and compression.
Volume Control – A new system designed to work with SPV as a control of the compression ramp up rate of the fork. It has a range of adjustments from linear to very progressive.
Wiper Seal – A rubber material that is used as a seal to keep dirt and water out of the outer casting legs. It is not designed to keep air pressure or extreme oil pressure in. Manitou has the new Evil Genius wiper seals.
2004 Black Forks Disassembly and Rebuild Instructions

Disassembly Instructions




Removal of Outer Casting
Disassembly of Crown Steer/Leg Assembly
Bushing Removal and Installation
Assembly Instructions
Reassembly of Crown Steer/Leg Assembly
Installation of Outer Casting
Bushing Removal & Installation
Bushing Removal
(Note: use appropriate 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

  1. Slide Hammer

  2. Threaded Handle

  3. Slide

  4. Threaded Shaft

  5. Removal Ring








Bushing Removal Tool Assembly







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