Gary Fisher 2005 manitou User Manual

1.  Remove the old fork from your bicycle.
2.  Measure and cut the steerer tube to fit your bicycle head tube. You can use

your old fork as a guide for cutting the steerer tube length. To determine
which upper triple clamp your frame will need see Table 5.

3.  Remove the headset crown race from the old fork and press onto the fork

steerer until the race is seated over the crown.

4.  Clean and grease the headset bearings and races.
5.  Install the lower bearings (if applicable) on the fork crown race.
6.  Insert the steerer tube into the head tube of the frame.
7.  Install the upper bearings, stem spacers, upper triple clamp and stem or

integrated upper handlebar stem clamp.

8.  Install the stem cap and bolt. Tighten the bolt to headset manufacturer’s

specifications. 

9.  Install the handlebars and torque the stem pinch screws or stem clamping

system to manufacturer’s specifications. Triple clamp, steerer tube, and
handlebar bolts (integrated crown/stem models only) should be tightened to
recommendations found in Table 6. 

10.  Install the brakes and adjust per manufacturer’s instructions.
11.  To install the hex axle, simply slip the axle into the dropout, small axle hex

side first into the large dropout hex. Thread in the set bolt into the small hex
side and snug slightly. Push the fork up and down a few times to center the
axle and hub and then tighten all pinch bolts to recommendations found in
Table 6.

12. Install the brake cable per manufacturer’s instructions (see WARNING below.)

Included with the fork is a small black cable guide that can be attached to the fork.
The best method we’ve found is to attach the cable so that it runs down the
outside of the left fork leg. Make sure the brake line is not crimped and does not
touch the tire as the fork moves through its travel. 

1. Measure from the highest point on the tire to the bottom of the brake arch

(see Figure A). See Table 1 for minimum brake arch clearance. All figures and
tables are located at the front of this manual. 

2.  Measure the tire at maximum width (see Figure B). See Table 1 for maximum

tire width.

To determine how much travel your fork has, simply measure the distance from
the top of the seal on the lowers (or the bottom of the fork boot) to the bottom of
the crown. See Table 2 to determine travel. For DORADO forks, measure from the
top of the dropout to the bottom of the seal.

You’ll need a tape measure, a pencil, a piece of paper and a helper. 

1.  Measure the distance from the front axle’s centerline to the bottom of the

crown when no one is sitting on the bike and write down this measurement.
(Remember the exact locations of the two points because you’ll need to use
them later.)

2.  Have the rider sit on the bike and measure the distance between the same

two points as in step one. It is important to be in the normal riding position
(weight centered) with your feet on the pedals.

3.  Subtract the second measurement from the first. The resulting measurement

is the static sag (see Table 3).

4.  On coil forks with preload adjusters, turning the knob clockwise increases

spring preload and decreases sag, while turning the knob counterclockwise
decreases spring preload and increases sag.

5.  On air forks, remove the Schrader air cap located on the top or on the bottom

of the left leg and, using a dedicated shock pump (Manitou part #85-4069),
inflate the fork with the desired pressure. Be aware that sometimes air
systems lose a small amount of pressure 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 pressure.
When setting sag on forks featuring IT technology, see “ADJUSTING MAIN
SPRING AIR PRESSURE” below. 

6.  If adjusting the preload or air pressure does not provide the proper sag, you

may require a new ride kit. 

With SPV Evolve damping, your suspension’s compression damping
characteristics and position sensitivity can be set with an SPV pump (Manitou part
#85-4161). For proper function of your SPV damping system follow this
procedure:

1.  Start by removing the red SPV air cap located on the top of the right fork

leg, as you are looking at the fork from the rider’s position. (DORADO
MRD X-Works forks have this adjustment at the bottom of the right fork leg).
Using a dedicated SPV pump (Manitou part #85-4161), inflate the fork to the
pressure recommended in Table 7. 

2.  Check sag per procedure above.
3.  Adjust SPV pressure. More pressure will create more compression damping,

hold the bike up more and pedal better. Less pressure will create less
compression damping, allow more sag, and be more responsive and supple.
Do not run SPV pressure below 30 psi. 

4.  Adjust SPV volume. With a 16 mm socket wrench or the SPV 16 mm volume

adjust socket (part #85-3007), you can adjust the air volume in your SPV
Evolve suspension. The volume adjust hex is colored red and is located on
top of the right leg. Turning the volume adjuster inwards will create a more
progressive damping effect and make the suspension firmer from mid-stroke
to bottom-out. Turning the volume adjuster outwards will make the
suspension more linear in compression damping and have a softer finish. 

Refer to the Answer Products website for specific tuning information about your
SPV suspension. 

For forks equipped with TPC and TPC+, a simple turn of the knob located on top
of the right leg is all that is needed to add compression damping. Turning the knob
clockwise (as you are looking at the fork from the rider’s position) increases
compression damping, while turning the knob counterclockwise decreases
compression damping. DORADOS featuring TPC+ damping will have this same
compression adjustment at the bottom of the right fork leg. Some forks featuring
TPC+ may not have external compression adjustments. Please consult the service
manual (located at www.answerproducts.com) for further instructions on how to
adjust these forks. 

For forks equipped with TPC with lockout, a simple turn of the knob located on top
of the right leg is all that is needed to add compression damping and activate the
lockout. Turning the knob clockwise (as you are looking at the fork from the rider’s
position) increases compression damping and activates the lockout, while turning
the knob counterclockwise decreases compression damping and deactivates the
lockout. The last 1/4 turn of the knob activates the lockout, while the initial part of
the knob’s travel increases or decreases compression damping. 

With a 16 mm socket wrench, you can adjust the main air spring volume of some
SKAREB fork models. Turning the volume adjuster inwards will create a more
progressive spring effect and make the suspension firmer from the middle to
bottom-out. Turning the volume adjuster outwards will make the spring rate more
linear and will allow the fork to have a softer finish.