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MEZZER  SERVICE MANUAL

5800 W Donges Bay Rd

Mequon, WI 53092

manitoumtb.com

888.686.3472

Support: 

manitoumtb.com/support

MANITOU

Warranty: 

For full warranty information please visit 

hayesbicycle.com/warranty

Revised 

Summary of Contents for Mezzer Expert

Page 1: ...serviceguide 2020 ...

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

Page 3: ...manual could lead to serious injury or death Any questions about the servicing of this fork or the manual itself should be directed to Hayes Customer Support at WARNING Hayes Bicycle USA 5800 W Donges Bay Road Mequon WI 53092 Phone 888 686 3472 Email techsupport hayesbicycle com Hayes Bicycle Europe Dirnismaning 20 a 85748 Garching b Munich Germany Phone 49 89 203237450 Email techsupportEU hayesbi...

Page 4: ...val Service 6 8 Air Spring Service 9 13 Pro Damper Service 14 18 Pro Casting Install 19 21 Pro Compression Knob Installation 22 Expert Damper Service 23 24 Expert Casting Install 25 27 Expert Damper Install 28 29 Travel Change Optional 30 33 Mezzer Expert IVA settings 34 Exploded Views 35 42 ...

Page 5: ...nitou Cassette Tool 8mm thin wall socket and flat ground 24mm socket Travel Spacer kit 141 36713 K032 Below is a list of additional tools necessary for a full service of the Mezzer fork 11mm Socket Pro Only Plastic or non marring pick Downhill tire lever or flat blade screwdriver 5wt Maxima Fork oil Manitou part number 85 0023 Semi bath Oil 5 40w Synthetic Manitou part number 85 0022 Slickoleum Gr...

Page 6: ... the rebound rod and loosen clockwise until rebound rod disengages from the lock nut 2 3 Unscrew air cap and attach shock pump Depress pressure bleed button until pump reads Zero Depress Schrader Valve a few times with 2mm hex wrench to ensure all air is released Manitou recommends a full service anytime the casting is removed If the fork is new and only a travel change is needed follow instructio...

Page 7: ...rod is disengaged from the lock nut Remove casting from fork It is recommended this be done over a drain pan as the lower casting contains semi bath oil Allow oil in casting to drain out before continuing to next step 4 5 6 Using a downhill tire lever or similar tool gently pry the dust seals out of the casting CASTINGREMOVAL SERVICE ...

Page 8: ...ngs Thoroughly saturate new foam rings with semi bath fluid and install into fork casting Remove springs from outer lip of new leg seals Clean casting seal press area with Isopropyl alcohol Using the Manitou 37mm Seal Press press in the dust seals Reinstall springs onto seals ...

Page 9: ...sing a standard cassette tool and 1 socket loosen IRT cap until threads are free from leg Mezzer Expert Using a 24mm socket loosen IVA cap until threads are free from leg Mezzer Pro Pull IRT assembly straight out Clean with isopropyl Inspect seal for damage If needed Replace IRT piston seals 141 36713 K026 Mezzer Expert Pull IVA assembly straight out Clean with isopropyl Inspect seal for damage If...

Page 10: ...opropyl alcohol and a lint free towel Be careful to not scratch the inner surface of the stanchion Inspect the inside and outside of the stanchion for scratches or other damage 4 Invert the fork and use Manitou cassette tool with adjustable wrench to unthread the air spring assembly from the stanchion OR depress valve on end of comp rod with 2mm hex and stroke rod to bottom Slide standard cassette...

Page 11: ...eum grease to the stanchion threads before inserting the air spring assembly Spread grease across entire thread surface AIRSPRINGSERVICE 9 Install air spring assembly into stanchion Using a 26mm crow s foot and Manitou cassette tool OR 1 Socket and Standard cassette tool torque to 20 25 in lb 2 3 2 8 Nm If rod is bottomed attach shock pump to valve and draw the rod out until fully extended ...

Page 12: ...n seal outer piston surface and IRT shaft Apply Slickoleum grease to the threads of the stanchion Mezzer Expert Liberally apply Slickoleum grease to the IVA piston seal and outer piston surface Apply Slickoleum grease to the threads of the stanchion Mezzer Pro Install IRT cap into stanchion Torque to 220 220 in lb 20 25 Nm using standard cassette lock ring tool Mezzer Expert Install IVA cap into s...

Page 13: ...p and inflate IRT to 100PSI NOTE ALWAYS SET IRT PRESSURE TOP OF FORK BEFORE DORADO AIR PRESSURE BOTTOM OF FORK Mezzer Expert Skip to step 14 Attach a shock pump and inflate main air chamber to 60PSI This will aid in installing the casting later AIRSPRINGSERVICE ...

Page 14: ... be damaged if the knob is over torqued EXPERT SKIP TO PAGE 23 Use a non marring pick or pliers with non marring barrier to remove the red LO SPEED compression knob by lifting straight up 3 With a 11mm socket unthread the exposed nut and remove the black HI SPEED adjustment knob Note Be sure to hold the knob still while removing the nut The damper adjuster may be damaged if the knob is over torque...

Page 15: ...ve the v seal that was under the black HI SPEED adjustment knob 5 6 Use a standard cassette tool and 1 socket to unthread the damper top cap from the stanchion Remove damper assembly from the stanchion Inspect damper shaft and bladder for any damage ...

Page 16: ...h pan Cycle damper shaft several times to cycle out old oil from damper 9 8 Attach M5x0 8 Luer lock fitting to both syringes 141 30695 K020 Fill one syringe with 5wt Damper oil 85 0023 Attach the empty syringe M5x 8 adapter to top cap bleed port Remove bleed screw from damper end cap and attach the filled syringe M5x 8 adapter to end cap bleed port ...

Page 17: ...s cycle the damper SLOWLY to draw air to the top of the damper Open bleed hose clamps and repeat step 10 until no air bubbles are present in oil drawn into upper syringe Fully extend damper shaft and add oil from bottom syringe until bladder is slightly expanded Closing the bleed hose clamp on both syringes remove cartridge from vise Lay cartridge flat on bench Remove lower syringe and replace ble...

Page 18: ...18 MEZZER SERVICE MANUAL prodamperservice 13 Install Damper cartridge into stanchion Using standard cassette lock ring tool Torque to 220 220 in lb 20 25 Nm ...

Page 19: ...CASTING INSTALL 1 2 3 Apply a light coating of semi bath 85 0022 to the inner diameter of the oil seal dust wiper Make sure the spring shaft is fully extended and air chamber is filled with air 60PSI Fully extend the damper shaft ...

Page 20: ... the semi bath is in the legs slide the casting the rest of the way onto the stanchion assembly until the damper and spring shaft adapters pass thru the end of the casting Some manual alignment may be needed Thread the lock nut onto the damper shaft adapter Holding the lock nut with a 14mm box wrench use an 8mm Hex wrench to tighten the rebound damper adapter to 35 40 in lb 3 95 4 5 Nm by turning ...

Page 21: ... to 35 40 in lb 3 95 4 5 Nm by turning them counter clockwise Do not overtighten doing so can damage the threads Install the rebound knob using a 2mm Hex wrench Add a small drop of blue Loctite to the screw before installation to prevent the screw from backing out during riding Note Be sure to hold the knob still while removing the screw The damper adjuster may be damaged if the knob is over torqu...

Page 22: ...pressure Lightly pull the casing away from the CSA as you add air See Mezzer Pro set up sheet for recommended air pressures Clean the adjuster knobs with isopropyl and replace v seal into top cap counter bore ProCompression Knob Installation 3 Lubricate o ring seal on red LO SPEED adjustment knob with Slickoleum Grease an install onto adjuster hex With a 2mm hex thread on the screw and torque to 4...

Page 23: ...T knob Note Be sure to hold the knob still while removing the screw The damper adjuster may be damaged if the knob is over torqued Use a non marring pick or pliers with non marring barrier to remove the black VTT knob by lifting straight up 3 Remove the v seal that was under the black VTT adjustment knob ...

Page 24: ... and 1 socket to unthread the damper top cap from the stanchion 5 6 Remove damper assembly from the stanchion Inspect damper piston seal for any damage Tip out used damper oil from top of stanchion into drain pan Cycle damper shaft serval times to cycle out old oil from damper ...

Page 25: ...rtCASTING INSTALL 1 2 3 Apply a light coating of semi bath 85 0022 to the inner diameter of the oil seal dust wiper Make sure the spring shaft is fully extended and air chamber is filled with air 60PSI Fully extend the damper shaft ...

Page 26: ...e the semi bath is in the legs slide the casting the rest of the way onto the stanchion assembly until the damper and spring shaft adapters pass thru the end of the casting Some manual alignment may be needed Thread the lock nut onto the damper shaft adapter Holding the lock nut with a 14mm box wrench use an 8mm Hex wrench to tighten the rebound damper adapter to 35 40 in lb 3 95 4 5 Nm by turning...

Page 27: ...er to 35 40 in lb 3 95 4 5 Nm by turning them counter clockwise Do not overtighten doing so can damage the threads Install the rebound knob using a 2mm Hex wrench Add a small drop of blue Loctite to the screw before installation to prevent the screw from backing out during riding Note Be sure to hold the knob still while removing the screw The damper adjuster may be damaged if the knob is over tor...

Page 28: ...aised support underneath the axle compress the fork 10 15 times With the fork fully extended add oil to the height of 65mm measured from the top of the stanchion NOTE OIL HEIGHT IS SET WITH FORK FULL EXTENDED AND CASTING INSTALLED The raised support should be wide enough and long enough to safely support the axle as well as tall enough to eliminate contact between the floor and the air cap or rebo...

Page 29: ...anchion Using a standard cassette lock ring tool Torque to 200 220 inlb 20 25 Nm ExpertDAmper Install 6 Clean the adjuster knobs with isopropyl and replace v seal into damper top cap Install the black VTT adjustment knob onto adjuster hex being sure the knob can fully rotate without contacting the crown With a 2mm hex thread on the screw and torque to 4 6 in lb 0 5 0 7 Nm Note Be sure to hold the ...

Page 30: ...30 MEZZER SERVICE MANUAL TravelChangeGuide ...

Page 31: ...his refer to page 9 13 For travel change on new forks bath oil may be preserved by removing stanchion assembly while fork is placed flat on benchtop Once the rod is removed arrange the travel spacers into the desired amount of travel using the following charts MezzerPro andexpertTravelAdustment Increasing Travel Each spacer pair Two Halfs removed Increase travel Axel To Crown by 10mm ...

Page 32: ...32 MEZZER SERVICE MANUAL mezzer travelchange MezzerPro andExpertTravelAdustment Decrease Travel Each spacer pair Two Halfs added decreases travel Axel To Crown by 10mm ...

Page 33: ...33 MEZZER SERVICE MANUAL mezzertravelchange Mezzer Pro Dorado Air and Mezzer Expert Expert Air 180MM 170MM 160MM 150MM 140MM ...

Page 34: ... desired location and reassembling the clip on spacers to secure the piston on the IVA shaft Increasing the air volume moving piston towards the top cap creates a more linear spring curve with reduced mid stroke support and end stroke ramp up Reducing the air volume moving piston away from the top cap creates a more progressive spring curve with increased mid stroke support and end stroke ramp up ...

Page 35: ...35 MEZZER SERVICE MANUAL MezzerExpert 27 5 explodedview ...

Page 36: ... 37MM 141 36713 K025 9 DAMPER ASSY REBOUND MEZZER EXPERT WITH KNOBS 141 36713 K030 10 DAMPER ASSY VTT MEZZER EXPERT WITH KNOBS 141 36713 K029 11 SEAL PISTON KIT DORADO AIR MEZZER PRO EXPERT 141 36713 K027 12 KNOB KIT MEZZER EXPERT RB VTT 141 36713 K033 13 TRAVEL ADJUST SPACER KIT 141 36713 K032 14 BLEED SCREW 2PC 141 36713 K035 15 BUMPER BOTTOM OUT REV B 2PC 141 36713 K036 FENDER AND HOSE GUIDE KI...

Page 37: ...37 MEZZER SERVICE MANUAL Meezerexpert29 explodedview ...

Page 38: ...7MM 141 36713 K025 9 DAMPER ASSY REBOUND MEZZER EXPERT WITH KNOBS 141 36713 K030 10 DAMPER ASSY VTT MEZZER EXPERT WITH KNOBS 141 36713 K029 11 SEAL PISTON KIT DORADO AIR MEZZER PRO EXPERT 141 36713 K027 12 KNOB KIT MEZZER EXPERT RB VTT 141 36713 K033 13 TRAVEL ADJUST SPACER KIT 141 36713 K032 14 BLEED SCREW 2PC 141 36713 K035 15 BUMPER BOTTOM OUT REV B 2PC 141 36713 K036 FENDER AND HOSE GUIDE KIT ...

Page 39: ...39 MEZZER SERVICE MANUAL MezzerPRO 27 5 explodedview ...

Page 40: ...E HARDWARE 141 33147 K003 8 SEAL KIT 37MM 141 36713 K025 9 DAMPER ASSY MC2 MEZZER PRE BLED WITH KNOBS 141 36713 K022 10 SEAL PISTON KIT DORADO AIR MEZZER PRO EXPERT 141 36713 K027 11 KNOB KIT MEZZER PRO IRT RB MC2 VTT 141 36713 K024 12 TRAVEL ADJUST SPACER KIT 141 36713 K032 13 REBOUND ADAPTER 141 36713 K034 14 BLEED SCREW 2PC 141 36713 K035 FENDER AND HOSE GUIDE KIT 141 36103 K001 REBUILD MEZZER ...

Page 41: ...41 MEZZER SERVICE MANUAL MezzerPRO29 explodedview ...

Page 42: ...RDWARE 141 33147 K003 8 SEAL KIT 37MM 141 36713 K025 9 DAMPER ASSY MC2 MEZZER PRE BLED WITH KNOBS 141 36713 K022 10 SEAL PISTON KIT DORADO AIR MEZZER PRO EXPERT 141 36713 K027 11 KNOB KIT MEZZER PRO IRT RB MC2 VTT 141 36713 K024 12 TRAVEL ADJUST SPACER KIT 141 36713 K032 13 REBOUND ADAPTER 141 36713 K034 14 BLEED SCREW 2PC 141 36713 K035 15 FENDER AND HOSE GUIDE KIT 141 36103 K001 REBUILD MEZZER P...

Page 43: ...WWW MANITOUMTB COM WWW HAYESCOMPONENTS COM 5800 W DONGES BAY ROAD MEQUON WI 53092 46 38529 REV A ...

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