AMERICAN MADE
MANITOU SUSPENSION
CONGRATULATIONS ON CHOOSING THE LATEST IN SUSPENSION
TECHNOLOGY AVAILABLE, A 2003 MANITOU DORADO FORK BUILT
IN THE USA.
This DORADO fork is fully assembled and is ready to
be installed onto your bicycle. It comes equipped with a 1 1/8-inch
threadless steerer tube, AND is only available with a disc brake ver-
sion.
2003 DORADO FORK LINE
DORADO DH . . . . . . . . . . 180 MM TRAVEL / COIL SPRING /
TPC+ DAMPING
DORADO SC . . . . . . . . . . . 130 MM TRAVEL / COIL SPRING /
TPC+ DAMPING
You can also download this manual at www.answerproducts.com.
BICYCLING IS A HAZARDOUS
ACTIVITY THAT REQUIRES THAT
THE RIDER STAY IN CONTROL OF HIS OR HER BICYCLE AT ALL
TIMES. READING THIS MANUAL ENTIRELY AND PROPERLY MAIN-
TAINING YOUR BICYCLE AND SUSPENSION FORK WILL REDUCE THE
POSSIBILITY OF INJURY OR POSSIBLE DEATH. PRIOR TO RIDING
YOUR BICYCLE, YOU SHOULD INSPECT YOUR SUSPENSION FORK TO
ENSURE THAT NO DAMAGE HAS OCCURRED DURING THE COURSE OF
RIDING. DO NOT RIDE YOUR BICYCLE IF THE FORK SHOWS ANY
SIGNS OF BENDING, CRACKING, LEAKING, OR IF IT IS MISSING ANY
OF THE ORIGINALLY SUPPLIED COMPONENTS. ANY FALL FROM
YOUR BICYCLE CAN RESULT IN SERIOUS INJURY OR EVEN DEATH.
FOLLOWING THESE INSTRUCTIONS CAN HELP YOU REDUCE THE RISK
OF BEING INJURED.
IF YOU ARE A MODERATE OR AGGRESSIVE OFF-ROAD RIDER,
OR RIDE AT LEAST THREE TIMES A WEEK OVER ROUGH TERRAIN,
ANSWER RECOMMENDS RETURNING YOUR SUSPENSION FORK
EVERY 2 YEARS FOR A THOROUGH INSPECTION AND UPDATE. TAKE
YOUR FORK TO A MANITOU AUTHORIZED DEALER WHO CAN
ARRANGE FOR SHIPMENT TO ANSWER PRODUCTS, OR YOU MAY
CALL ANSWER AT (661) 257-4411 TO HAVE YOUR FORK
SHIPPED DIRECTLY.
IMPORTANT: The DORADO fork is an off-road fork, and as
such, does not come with proper reflectors for on-road use.
CONSUMER SAFETY INFORMATION
1. Never remove or have the steerer tube or legs (SC version only)
removed from the crown. The steerer tube and legs are press fit
at the factory. Pressing the steerer tube or legs out will perma-
nently damage the crown beyond repair and render it unsafe for
any continued use.
2. Never attempt to thread a threadless steerer tube. Cutting
threads will weaken the steerer tube and cause an unsafe condi-
tion. The only safe thing to do is to obtain the proper
crown/steerer from your dealer.
3. Any other alteration or modification to your fork should be con-
sidered unsafe. Contact Answer Warranty prior to modifying
your fork in any way for safety information.
4. Do not use the DORADO fork if any parts are broken, bent,
cracked, or you suspect may be damaged. Contact your dealer
or Answer Warranty at (661) 257-4411 if you have any ques-
tions concerning the integrity or condition of your fork.
5. Answer Products recommends that you inspect your fork before
every ride for wear and damage. Inspect the crown, inner legs,
outer legs, and dropout areas for cracks or damage.
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 pur-
chase (or two years in EU countries) will be repaired or replaced at
the option of the manufacturer, free of charge, when received at the
factory with proof of purchase, freight prepaid. This warranty does
not cover breakage, bending, or damage that may result from crash-
es or falls. This warranty does not cover any fork that has been sub-
ject to misuse or whose serial number has been altered, defaced or
removed. This warranty does not cover paint damage. Any modifica-
tions 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 warran-
ty 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. 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.
INSTALLATION AND SETUP
INSTRUCTIONS
Ensure that the proper top crown has been delivered on your DORA-
DO first. The steerer tube may need to be cut to length to fit your
bicycle head tube. If you are not familiar with this procedure, or do
not have the proper tools to cut the steerer tube, it is recommended
that you seek a dealer with a qualified bicycle mechanic to perform
installation.
THE STEERER TUBE AND LEGS (SC VERSION)
ARE A ONE TIME PRECISION PRESS FIT AT THE
FACTORY AND CANNOT BE REMOVED FROM THE CROWN. REPLACE-
MENT OF THE ENTIRE CROWN/STEERER ASSEMBLY MUST BE DONE
TO CHANGE STEERER TUBE LENGTHS OR DIAMETERS. REMOVING
AND REPLACING THE STEERER TUBE OR LEGS WILL RESULT IN AN
UNSAFE CONDITION AND SHOULD NEVER BE DONE.
FORK INSTALLATION
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube.
You generally will want to leave about 10–20 mm excess length
for the DH version.
3. Remove the headset crown race from the old fork and press
onto the DORADO 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 fork crown race.
6. Insert the steerer tube into the head tube of the frame.
7. Install the upper bearings, small spacer ring, and then the top
crown (for DH model).
8. Install the stem cap and bolt. Tighten the bolt to headset manu-
facturer’s specifications.
9. Install the handlebars to the desired height and torque stem
bolts to manufacturer’s specifications. On the DH model, torque
the 5 mm stem clamping system bolts to 60–75 in.-lbs. (7.3–8.5
Nm).
10. Install the brakes and adjust per the manufacturer’s instructions.
11. Install the small side of the hex lock through-axle through the
large opening and wheel. Tighten down the hex lock end bolt
until it is snug. Then tighten the dropout pinch bolts to 40–60
in.-lbs. (4.5–6.8 Nm).
Summary of Contents for DORADO DH
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