Manitou MARA PIGGYBACK Service Manual Download

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MARA PIGGYBACK SERVICE MANUAL

tools and materials

• Safety Glasses

• Nitrile Gloves

• Lint-Free Rags

• Slickoleum™ Grease

• 10-Oz Tub – Manitou Part Number 20-32929

• 5Ml Tube – Manitou Part Number 141-33604-K001

• 5wt Maxima Synthetic shock Oil Manitou Part Number 85-0023

• *For cold weather use Maxima Synthetic All Temperarture 3wt fork oil.

(PN 141-34078-K016)*

• Isopropyl Alcohol

• 3/8 drive socket wrench

• 16mm socket

• Torque wrench

• 21mm crows foot

• Free Hub Tool Park Tool PN FR-1

• Metric hex wrench set

• T-10 Torx wrench

• O-Ring Pick

• Hand Dyno

• Bench mounted vise

• Side cutters

•

Small flathead screw driver

• Caliper for measuring IFP depth

• Shock Pump

• ½-13 UNC taper tap

• Blue medium strength Loctite

• Red high strength Loctite

• Mara Pro complete rebuild kit 142-37512-K032

• Air piston OD seal bullet tool PN 172-32189-K001

• Manitou Clamp Block PN 172-31464

• Manitou shaft seal bullet tool ID of the air piston PN 142-37512-K040

• Air Can / Reservoir Wrench PN 142-37512-K033

• Compression Assembly Pin Spanner HBG PN 142-37512-K031

• Air Piston Seal Pusher Tool PN 172-32189-K001

• Shaft Seal Bullet Tool PN 142-37512-K040

• Manitou Air Can Negative Seal Stop Install Tool 172-32193-K001

• Manitou Air Piston Bushing and Seal Tool 172-32192-K001

• Manitou Rear Shock Air Piston and Seal Tool 142-37512-K041

• Manitou Trunnion Tool 142-37512-K037

Summary of Contents for MARA PIGGYBACK

Page 1: ...MARA PIGGYBACK SERVICE GUIDE ...

Page 2: ... PIGGYBACK SERVICE MANUAL 5800 W Donges Bay Rd Mequon WI 53092 manitoumtb com 888 686 3472 Support manitoumtb com support MANITOU For full warranty information please visit hayesbicycle com warranty WARRANTY ...

Page 3: ...ighly recommend that service to this shock be performed by a certified bicycle mechanic Failure to follow instructions presented in this manual could lead to serious injury or death Any questions about the servicing of this shock or the manual itself should be directed to Hayes Customer Support at Phone 888 686 3472 Email techsupport hayesbicycle com Suspension shocks by design can contain preload...

Page 4: ...6 Shock Teardown 6 11 Top Cap Service 12 17 Shaft Service 18 19 Shaft and Air Piston Assembly 20 25 Air Can Service 26 28 Bleed and Fill 29 35 Set Up Guide 36 Torque Specs 37 IFP Depth Table 38 O Ring Location 39 Exploded View 40 Torque Specs 32 IFP Depths 33 O ring Guide 34 Exploded View 35 ...

Page 5: ...utters Small flathead screw driver Caliper for measuring IFP depth Shock Pump 13 UNC taper tap Blue medium strength Loctite Red high strength Loctite Mara Pro complete rebuild kit 142 37512 K032 Air piston OD seal bullet tool PN 172 32189 K001 Manitou Clamp Block PN 172 31464 Manitou shaft seal bullet tool ID of the air piston PN 142 37512 K040 Air Can Reservoir Wrench PN 142 37512 K033 Compressio...

Page 6: ...ck in vise If Trunnion shock clamp on trunion mounts Use soft jaws to not damage the shock 2 3 With the shock top cap in a vise use the air can wrench PN 142 37512 K033 to loosen the air can on the shock DO NOT completely remove the air can at this point only loosen one full turn Removing the air can completely at this point will damage the threads due to pressure in the negative chamber CAUTION D...

Page 7: ... in a bicycle frame slightly compress the shock At this point unthread the air can fully Remove air can bumper and spacers if present These may remain in the air can locate and save for later re assembly 5 6 Remove split ring from the main air piston SHOCKTEARDOWN ...

Page 8: ...ick remove quad ring seal A small side cutter can be used to first partially cut the large piston ring then break it to remove Be careful not to damage the groove 8 9 Remove the Piggyback Reservoir cap by unthreading it counter clockwise SHOCKTEARDOWN ...

Page 9: ...air is released Remove the valve core Use a freewheel removal tool example Park Tool FR 1 to remove the Reservoir End Cap 11 12 Place a catch basin under the shock to catch oil Use the air can reservoir wrench PN 142 37512 K033 to unthread the shock reservoir Alternative use a 30mm wrench SHOCKTEARDOWN CAUTION Do not proceed to the next step without completely depressurizing reservoir ...

Page 10: ... piston IFP will be inside the reservoir Remove the piston towards the hex end of the reservoir note orientation and set aside Removing the IFP in the other direction may damage the seals on the threads IFP is replaced during a full service 14 15 Using a small flathead screw driver gently pry up to remove the red LSC knob Be careful when removing this knob underneath are two detent balls and sprin...

Page 11: ...uster housing Turn counter clockwise to unthread and remove compression adjuster assembly 17 18 SHOCKTEARDOWN Place the main shock shaft into the 12mm Manitou clamp block Using an eyelet tool such as a pin wrench or an adjustable wrench accross the flat turn the top cap counter clockwise to release the top cap from the main shock shaft Hold the bottom eyelet in a vise and place a drip pan under th...

Page 12: ...ted from top cap TopCApservice Remove the lockout lever assembly by gently sliding it out Remove the two O rings Clean the spool with isopropyl alcohol Install new O rings the Larger 101 600 close to the lever and the smaller 101 500 near the end Remove the Lock Out detents by using an M1 5 hex tool and unthread the small set screw on the end near the compression adjuster Flip the shock over and t...

Page 13: ... O ring air can O ring and reservoir O ring from the top cap Thoroughly clean topcap spraying isopropyl alcohol into all ports and passageways Allow to air dry or blow out with clean compressed air 5 6 Remove valve stem with a 3mm hexwrench topcapservice ...

Page 14: ...m 20 24 INlbs Reinstall valve core 8 9 Install reservoir O ring 101 2600 150 main shaft O ring 100 013 and air can O ring 101 4100 200 topcapservice Grease O rings reinstall Work Party assembly into the top cap Install retention pin check for full movement of the Work Party lever by adjusting the depth of the retention pin Such that the lever flips just past the word WORK ...

Page 15: ...t handed thread Turn until it lightly bottoms Reinstall spring and detent ball topcapservice Replace the O Ring 101 1600 0180 on the HSC Piston Replace the O Ring 100 018 on the compression cartridge body above threads at the flange Grease both O Rings Install the compression assembly into the top cap Use the compression assembly Pin spanner tool 142 37512 K031 and torque to 5 7Nm 50 in lb ...

Page 16: ...he HSC compression adjuster Use this procedure to install detent and spring for lockout rebound and LSC knob Install detent spring using a tool and a dab of grease to help hold the spring in place Repeat procedure with detent balls Reinstall LSC knob by pushing straight down to not disrupt the detent balls ...

Page 17: ... ring type face seals 2pc 101 700 110 or figure 8 type seal 08 37751 depending on the seal gland available Lockout will be installed at the time of oil fill Note Use grease to hold face seals in place 17 Remove O ring 100 021 from the reservoir end cap Clean end cap with Isopropyl alcohol Install new O ring and apply grease Set aside on a clean lint free rag until needed after the oil fill process...

Page 18: ...reserve the sequence of components Carefully set aside 1 Remove the rebound needle inner piece with rounded head from the main shaft by gentle pulling it up Be aware of the spring and two small washers at the bottom of the rebound needle Remove O ring 101 600 from the rebound needle Clean needle with Isopropyl alchohol Replace the O ring 101 600 on the rebound shaft DO NOT grease this O ring Funct...

Page 19: ...ice warrants replacement of bushings within the air piston use a 13 UNC bottoming tap and the Manitou clamp block to remove the bushings See Manitou Air Piston Bushing and Seal Tool instructions for information SHaftservice Remove inner shaft O ring ...

Page 20: ... is not available see 50 hour air can and piston service guide for alternative method of replacing the seals If using this method the air piston will need to be installed on the main shaft It is recommended this would be done after the full service is complete Please skip to step 5 if using the alternative method 2 3 Grease new air piston quad seal 08 30017 and use the seal pusher to install onto ...

Page 21: ...t seal bullet tool 142 37512 K040 slide the air piston on at the damping end of the shaft shaftandairpistonassembly Grease new shaft Quad Ring 110 112 and install into the air piston Ensure it is not twisted Note Air Piston Service Tool can be used for this step The peg on the end acts as a stop for installing the seals in the piston ...

Page 22: ...n glide ring PN 129 30020 8 9 shaftandairpistonassembly Reinstall shim stack below the piston by gently sliding the tool into the main shaft Be careful to maintain the correct sequence of components Remove the piston and stack above the piston for further disassembly 7 Replace the top out bumper O ring 100 013 on the main shaft that will sit on the main piston ...

Page 23: ...orque to 5nm 45in lb Excess Loctite can contaminate the assembly 11 12 shaftandairpistonassembly Reinstall the piston and top shim stack by gently sliding the tool into the main shaft Be careful to maintain the correct sequence of components 10 From the bottom of the main piston install a new inner shaft O Ring PN 101 500 100 ...

Page 24: ... shaftandairpistonassembly Reinstall the rebound shaft into the main shaft Orient flat side of the spring towards the upper end of the rebound needle against the two shims Replace the bottom out bumper O Ring 101 1150 0300 above the air piston ...

Page 25: ...g shims or spacers Some shocks may have a 2 5mm plastic spacer or a 5mm aluminum spacer 17 shaftandairpistonassembly Hold the main shaft in the vise using Manitou clamp block tool 172 31464 Thread the top cap onto the main shaft and torque to 11 3Nm 100in lb ...

Page 26: ...s remove white back up ring from the middle groove Mid King Can volume setting and volume spacer rings if used Thoroughly clean the entire air can with Isopropyl alchohol 2 Aircan service 3 Optional use Air Can Negative Seal Service Tool 172 32193 K001 to ease seal installation If not available refer to 50 hour Air Can and Piston Service Guide The flat surface of the tool will help direct the seal...

Page 27: ... ring Install the wiper seal with the narrow lip facing externally Replace the King Can sleeve seals in three places if using a full King Can only the two outer seals will be used 100 030 Apply a few dabs of grease to the middle seal gland and install back up ring 08 36360 Apply Slickoleum grease to the ID of the cleaned King Can sleeve 5 4 6 Aircan service ...

Page 28: ...nch the back up ring Install wire retaining ring in the groove at the lower end of the sleeve 8 The MCU and negative spacers will be installed on the damper body at a later time Grease the air can ID and negative seals with Slickoleum Set aside on a clean shop rag for later use Aircan service ...

Page 29: ... All Temperarture 3wt fork oil PN 141 34078 K016 Install the main shaft and piston into the shock damper tube Add oil if needed to top off the damper tube once the piston is installed 2 3 Remove the bleed screw on the air piston so that air can escape while the air piston is threaded on to the damper tube Torque the air piston to 26Nm 230in lb Replace the bleed screw bleedandfill ...

Page 30: ...ll the compression assembly with oil Actuate the lockout lever 5 10x to work air out of the shock Place the lockout assembly into its location in the top cap Be sure the face seals stay in place 5 6 While pushing down firmly to engage the O ring thread the reservoir onto the top cap and torque to 9Nm 80 in lb Fill the reservoir 2 3 full of oil bleedandfill ...

Page 31: ...igh point Flip the Lockout Lever to Work Mode This will create a strong resistance to oil flow going to the reservoir Crack open the bleed screw at the damper eyelet Slowly compress the damper body noting the air coming out the bleed screw At bottom out or when oil begins to show stop the compression and close the bleed screw Slowly extend the shock 8 9 Always ensuring the reservoir is about 2 3 f...

Page 32: ...s any suspicion of air remaining in the system With Work Mode engaged the damper should be very firm Fully extend the damper body Fill the reservoir completely full with damper oil 11 12 The large cup side of the SKF IFP will be facing up towards the gas charge side Use 1 edge and scoop the shallow face of the piston into the oil allowing the small air pocket to clear before submersing Stop when t...

Page 33: ...ling up on the damper body Completely remove the bleed screw Use a finger to press the IFP down to the specified depth per shock and reservoir size published in Table 2 IFP Depth 14 15 Reinstall the bleed screw while applying a light pressure to the IFP preventing air entering into the bleed port bleedandfill ...

Page 34: ...function in a hand dyno 17 18 Clean the air can replace negative spacers apply grease and install the air can while easing the air piston back up rings into the air can Place the shock in a bike or on a hand dyno compress the shock and thread on the air can to a torque of 10 7Nm 95in lb Note If compressing by hand it may be necessary to release the gas charge to ease the process bleedandfill ...

Page 35: ...eize air can to 125 psi Recharge IFP to 300 psi if previously released Replace the dust caps on the Reservoir and mair chamber Install bottom out O ring on the damper body 20 bleedandfill Refer to Mara Set up guide for air can pressure See Below ...

Page 36: ...rspringpressures For best performance rebound speed should be equal for front and rear wheels Add rebound damping to reduce kick off jump lips and busy wheel activity on square edged rocks Reduce rebound damping to improve tire traction or ground following Reduce high speed compression to eliminate spiking or harshness Add high speed compression when the rear wheel i s busy and overshooting square...

Page 37: ...n lb 5 LOCKOUTASSEMBLY BOLTINLOCKOUTBODY 50 in lb 3 RESERVOIR RESERVOIRINTOTOPCAP 80 in lb 10 SCHRADERINSERTINTORESERVOIR 50 in lb 3 MAINSHAFT SHAFTINTOTOPCAP 100 in lb 10 NUTTOSHAFT 45 in lb 3 DAMPERBODY DAMPERBODYTOAIRPISTON 230 in lb 10 BLEEDSCREWINTODAMPERBODY 12 in lb 2 TOPCAP KNOBSCREWS 5 in lb 1 AIR CANTOTOPCAP 95 in lb 5 SChRADERVALVECORE 3 in lb 1 Table 1 Torque Spec ...

Page 38: ...6 40 x 216 X 63 44 x 222 X 68 50 44 240 X 76 50 44 190 X 40 40 x 190 X 45 40 x 210 X 50 40 x 210 X 55 40 x 230 X 60 50 44 230 X 65 50 44 250 X 70 50 44 250 X 75 50 44 160 X 40 40 x 165 X 45 40 x 185 X 50 40 x 185 X 55 40 x 205 X 60 50 44 205 X 65 50 44 225 X 70 50 44 225 X 75 50 44 230 X 60 50 44 260 X 65 50 44 Table 2 IFP Depth Chart ...

Page 39: ...stment Body 101 950 0150 Comp Adjustment Body 100 018 As568A 021 Comp Adjustment Body 101 1600 Comp Adjustment Body 101 500 Lockout Lever 101 600 Lockout Lever 101 450 Rebound Adjustment knob 101 1150 Main Shock Shaft 100 013 Main Shock Shaft 08 30017 Air Piston 08 30015 Air Piston 08 30718 Air Piston 110 112 Air Piston 110 122 Shock Damper Tube 08 30014 Shock Damper Tube 08 30019 Shock Damper Tub...

Page 40: ...40 MARA PIGGYBACK SERVICE MANUAL Marapiggybackexplodedview ...

Page 41: ...5800 W Donges Bay Rd Mequon WI 53092 manitoumtb com 888 686 3472 Support manitoumtb com support MANITOU 46 38526 REV A ...

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