MAINTENANCE
IMPORTANT:
Use of fork boots is required to keep your LUXE fork per-
forming well and the warranty in effect. Use of this fork without boots will
shorten the life of the fork, decrease the time between maintenance inter-
vals, reduce the performance and void the warranty.
IMPORTANT:
Before every ride you should:
1. Ensure that quick release skewers are properly adjusted and tight.
2. Wipe the inner legs and clean and check entire fork for any obvious dam-
age.
3. Check the headset for proper adjustment.
4. Ensure that the front brake cable is properly routed and check brake
adjustment.
If you have any questions regarding your 2003 Manitou LUXE suspension fork,
contact the Answer Products Customer Service Department at (661) 257-4411.
You can also log on to www.answerproducts.com and download this manual or
see detailed instructions on how to service your suspension fork.
Thank you again for choosing a 2003 Manitou LUXE suspension fork.
LUXE DEALER
SERVICE ADDENDUM
This section is designed to help you tune and maintain your Manitou
suspension fork.
MEASURING SAG
To measure sag, you’ll need a tape measure,
a pencil and a piece of paper.
1.
Measure the distance from the front axle’s centerline to the bottom of
the upper crown without anyone sitting on the bike and write this
measurement down. (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’s important to be in the normal rid-
ing position (weight centered) with the rider’s feet on the pedals.
3.
Subtract the second measurement from the first. The resulting meas-
urement is the static sag or ride height.
SAG MEASUREMENT CHART
Fork Travel
Sag
50 mm
8-12 mm
75 mm
10-14 mm
TRAVEL MEASUREMENT
To determine which travel your LUXE
fork is in, simply measure the distance from the top of the seal area on
the lowers (or the bottom of the fork boot) to the bottom of the crown.
TRAVEL MEASUREMENT CHART
Fork Travel
Seal to Crown Measurement
50 mm
Around 4 inches or 100 mm
75 mm
Around 5 inches or 125 mm
RECOMMENDED COIL SPRINGS
Once you have checked sag,
you can either preload the spring via the cap on top of the left hand leg,
or even better, make spring changes to accommodate for your riding
style and weight.
SPRING KITS
LUXE COMP
Rider Weight
Recommended Spring Kit
100-150 lbs.
Soft ride kit (Part #85-4990)
Standard Set-up
150-170 lbs.
Medium ride kit (Part #85-4991)
170 plus lbs.
Firm ride kit (Part #85-4992)
LUXE ELITE
Rider Weight
Recommended Spring Kit
100-150 lbs.
Soft ride kit (Part #85-4993)
Standard Set-up
150-170 lbs.
Medium ride kit (Part #85-4994)
170 plus lbs.
Firm ride kit (Part #85-4995)
LUXE SUPER
Rider Weight
Recommended Spring Kit
100-150 lbs.
Soft ride kit (Part #85-4996)
Standard Set-up
150-170 lbs.
Medium ride kit (Part #85-4997)
170 plus lbs.
Firm ride kit (Part #85-4998)
CHANGING COIL SPRINGS
Once you have checked sag, you can
make spring changes to accommodate for your riding style and weight.
1.
Remove the preload adjusters by unscrewing the caps from the top of
the crown/leg assembly. First, you must remove the cap by unscrew-
ing the 2 mm fastening bolt (Figure 2). An 18 mm socket will be nec-
essary with the LUXE to remove the preload adjuster assembly.
Remember: The springs are housed in both legs of the LUXE forks.
2.
With the adjuster assembly removed, the spring stack is now accessi-
ble (Figure 3).
3.
Select the appropriate coil spring for your weight and riding style
(refer to the above spring chart for recommended rates).
4.
Apply a liberal amount of grease to the outside surface of the new coil
spring and the spring couplers (what holds the springs together)
(Figure 4). We recommend any thick grease. Install the new spring
stack.
5.
Reinstall the preload adjuster assembly, taking care not to cross-
thread the cap. It should thread in by hand and lightly snug tight-
ened (Figure 5).
6.
Reinstall the preload adjuster cap.
FORK DISASSEMBLY – LUXE SUPER
Disassembly of your
LUXE Super fork is necessary to provide the proper service of your fork.
To do this:
1.
Remove the two 4 mm Allen bolts on the bottom of the fork (Figure
6).
2.
Pull apart the fork, removing the casting from crown/steerer assem-
bly (Figure 7).
3.
Wipe clean the inside of the fork casting, stanchion tubes, fork boots,
and crown. At the same time you do this, do a complete inspection on
the fork (Figure 8).
4.
Reassemble the fork and snug tighten the 4 mm bolts (Figure 9).
FORK DISASSEMBLY – LUXE COMP & ELITE
Disassembly
of your LUXE Comp and Elite fork is necessary to provide the proper
service of your fork. To do this:
1.
Remove the springs (See Changing Coil Springs above).
2.
Insert a long 4 mm wrench into the fork and loosen the bolts that hold
the casting to the crown/steerer tube assembly (Figure 10).
3.
Pull apart the fork, removing the casting from crown/steerer assem-
bly (Figure 11).
4.
Wipe clean the inside of the fork casting, stanchion tubes, fork boots,
and crown. At the same time you do this, do a complete inspection on
the fork (Figure 12).
5.
Reassemble the fork and snug tighten the 4 mm bolts (Figure 10).
CONVERTIBLE TRAVEL – LUXE SUPER
Changing the travel
from 50 to 75 millimeters or vice-versa requires the removal of the
lower legs.
1.
Start by removing the preload adjusters and spring (see Changing Coil
Springs above).
2.
Next, unthread the 4 mm bolts from the bottoms of both legs and pull
the fork apart to expose the clip mechanism which allows for travel
adjustment (Figure 6).
3.
Remove the clip and insert it into the upper position (above the rod
flange) for 75 millimeters of travel or the lower position (below the
rod flange) for 50 millimeters of travel (Figure 13).
4. Reassemble the fork.
