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                   TABLE OF CONTENTS

Consumer Safety & Warranty information  .   .   . 1
Installation Instructions   .   .   .   .   .   .   .   .   .   .   2
Spare Parts List   .   .   .   .   .   .   .   .   .   .   .   .   .   3
Exploded View   .   .   .   .   .   .   .   .   .   .   .   .   .    4
Maintenance & Disassembly   .   .   .   .   .   .   .   .   7
Inspection.    .   .   .   .   .   .   .   .   .   .    .   .   .   .  .  8

 Re-assemble .   .   .   .   .   .   .   .   .  .    .   .   .   .   .  8
 Inner Fork Leg, Crown & Break Arch .   .   .   .   .  9

Adjusting the Ride Qualities.   .   .   .    .   .   .   .  .  10

 Trouble Shooting .   .   .   .   .   .   .  .    .   .   .   .   .  11

ANSWER PRECISION SUSPENSION

CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORK
AVAILABLE.  THE 1998 XVERT FORK MODELS HAVE STATE OF THE ART MCU/SPRING COMPRESSION
SYSTEMS.  THE XVERT SERIES ALL USE THE NEW TWIN PISTON CARTRIDGE SYSTEM (TPC) THAT
SURPASSES ALL OTHER TYPES OF OIL DAMPED SYSTEM IN PERFORMANCE AND DURABILITY.

Your  98 XVERT Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1/8Ó threadless
steer tube.  98 XVERT and XVERT R forks are available with the V-Brake cable hangerless arch.

CONSUMER SAFETY INFORMATION

IMPORTANT:

   

The 98 XVERT Fork  is an off road fork and as such, does not come with the reflectors for on road use installed.

Reflector bracket kit P/N 85-3674 is available through your dealer.  Have your dealer or mechanic install the kit to meet the
Consumer Product Safety Commission's  (C.P.S.C.) Requirements for Bicycles if the fork is going to be used on public roads at
any time.  If you have questions regarding C.P.S.C. Standards contact your dealer.

1. Never remove or have the steer tube or stanchions (inner legs) removed from the crown.  The steer tube and stanchions are press fit
assembled at the factory.  Pressing them  out will permanently damage the crown, steer tube, and stanchions beyond repair and render
them unsafe for any continued use.  Stanchions may be removed from the upper and lower triple clamps.
2.  Never attempt to thread a threadless steer tube.  Machining threads will weaken the steer tube and cause an unsafe condition.  The
only safe thing to do is to obtain the proper crown/steerer from your dealer.
3. Any other alterations or modifications to your fork should be considered unsafe.  Contact Answer Products Technical Support
prior to modifying your fork in any way for safety information.
4. Do not use any Manitou Fork if any parts appear to be broken, bent, cracked, or damaged.  Contact your dealer or Answer Products
Technical Support, (800) 670-7446,  if you have any questions concerning the integrity or condition of your fork.
5. 

 

Answer Products recommends that you periodically inspect your fork for wear and damage.  Inspect the Crown, Inner Legs, and

Outer Leg Dropout and Brake Arch areas  for cracks or damage.  Before every ride check to ensure that the proper preload exists and
that the positive rebound stop is in working order to ensure that the fork can not over extend.

WARRANTY INFORMATION

Any Answer Products fork found by the factory to be defective in materials and/or workmanship within one year from the date of
purchase will be repaired or replaced at the option of the manufacturer, free of charge, when received at the factory, freight prepaid.
This warranty does not cover breakage, bending, or damage that may result from crashes or falls.  This warranty does not cover any
fork that has been modified, subject to misuse or whose serial number has been altered, defaced or removed.  This warranty does not
cover paint damage.  Any modifications made by the user will render the warranty null and void.  This warranty is expressly in lieu of
all other warranties, and any implied are limited in duration to the same duration as the expressed warranty herein.  Answer Products
shall not be liable for any incidental or consequential damages.

If for any reason warranty work is necessary, return the fork to the place of purchase.  In the USA, dealers should call Answer
Products for a return authorization number (RA#).  At that time instructions for repair, return, or replacement shall be given.
Customers in countries other  than USA should contact their dealer or local distributor.

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Summary of Contents for 98 XVERT

Page 1: ...ny other alterations or modifications to your fork should be considered unsafe Contact Answer Products Technical Support prior to modifying your fork in any way for safety information 4 Do not use any Manitou Fork if any parts appear to be broken bent cracked or damaged Contact your dealer or Answer Products Technical Support 800 670 7446 if you have any questions concerning the integrity or condi...

Page 2: ...f frame 7 Install upper bearings spacers and stem 8 Install stem cap and screw tighten until slack just disappears 9 Install handlebars to desired height Torque stem handlebar pinch screws and stem clamping system to manufacturerÕs instructions 10 Install brakes and adjust per manufacturers instructions Note All 98 Manitou Forks Forks are equipped with a secondary catch dropout 11 Adjust front whe...

Page 3: ...BRACKET KIT 85 3674 X VERT R HAYES BUSHING KIT 85 3733 98 SOFT KIT SX SX R SX RR 85 3538 98 MEDIUM KIT SX SX R SX RR 85 3839 98 FIRM KIT SX SX R SX RR 85 3840 ADJUSTER KIT ALUMINUM SX XVERT 85 3848 98 CROWN STEER INNER LEG SET XVERT CROMOLY 85 3858 98 CROWN STEER INNER LEG SET XVERT ALUMINUM 85 3859 98 REBOUND DAMPER REBUILD KIT XVERT R 85 3864 98 REBOUND DAMPER REBUILD KIT XVERT TI 85 3865 98 COM...

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Page 7: ...ding this entire section prior to making any changes to the oil level To check the oil level remove only the compression damping assembly located in the top of the left leg Leave the right side compression stack adjuster MCU spring assembly in place to keep the fork fully extended Use a tape measure or Òdip stickÓ to determine the oil level Oil level should be between 3 5Ó 89MM and 5 75Ó 146MM bel...

Page 8: ...ut of the inner leg 3 Remove 2 nd or 3 rd Stg Elastomer and capture the 1 8Ó Dia detent ball 4 Adjuster needle must be unscrewed from the shaft 5 Remove valve nut using end wrench and holding the shaft in soft jaws or collet to prevent damage Compression Damping Disassembly figure 12 1 The compression damping assembly is almost identical to the lower shaft assembly 2 Unscrew the compression dampin...

Page 9: ...aft Figure 11 1 Install all o rings and seals removed 2 Grease all seals lightly with a seal grease 3 Apply small amount of blue loctite to piston seat threads 4 Assemble shim stack and spacers inexact order that they were removed For XVERT XVERT R thread on valve nut and torque 30 IN LB 3 5 N m max For XVERT TI hand tighten piston seat Be sure large blow off washer will slide over piston spacer a...

Page 10: ...ip snaps into the groove 5 Clean adjuster cap threads thoroughly Clean threads on inside of inner leg 6 Assemble MCUÕs springs and connectors with thick grease 7 Install adjuster assembly into inner leg just hand tight WARNING INNER FORK LEGS CROWN The inner fork legs and steer tube are press fit into the crown and may never be removed Removing them will make the fork unsafe to use If you see any ...

Page 11: ...mpression damping Try adjusting one full turn at a time To adjust XVERT TI models simply rotate the compression damping knob located on top of the left leg crown Rotating the knob clockwise will increase the damping rotating the knob counter clockwise will reduce the damping Excessive damping will give you a harsh ride over sharp bumps like rocky sections but will feel good in large hits like G ou...

Page 12: ... subjected to damping pressure A small leak in that area will not affect the performance of the fork or cause any type of damage We recommend that you store your Manitou right side up If this condition causes you some problems please contact your Answer Products dealer or call our warranty tech department for prompt service Fork is making a scraping noise that sounds as if the spring is binding Th...

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