2005 Axel Service Manual Rev NC 05 AXEL SERVICE MANUAL Page 1 REV NC
Table of Contents Description Page Introduction 3 Front Suspension Terminology 4 Disassembly/ Assembly Instructions 8 Lock Out Troubleshooting Tips 13 Remote Lockout Service Instructions 14 Air Assist Troubleshooting Tips 16 Bushing Removal and Installation Instructions 17 Troubleshooting Chart 21 Axel Schematic and Technical Specifications 22 Axel Service Kit Chart 23 Contact Information Answer Products Customer Service Department 28209 Ave.
INTRODUCTION This manual is intended to guide the user through basic service of Manitou Axel front forks. Service is supported by the identification of common parts and assemblies that have been assembled into Service Kits. The purpose of this manual will be to describe conditions that may drive the need for service and to provide installation instructions for the kits.
FRONT SUSPENSION TERMINOLOGY Air Cap – Top cap that threads into top of air/spring leg (this is the left leg of the fork as you are seated on the seat). Forks may be controlled with an air/spring or a coil spring. The air cap contains the Schrader Valve, which is used to control the spring rate or SAG of air forks. Air Spring – A mechanism that is used to control the SAG of an air fork. Arch – A support that connects the two outer lower legs of the casting so as to keep them moving in unison.
FRONT SUSPENSION TERMINOLOGY (CONT.) Hydraulic Fork Oil – Oil used in suspension designs to provide damping. It has special characteristics that determine how it reacts when exposed to compressed air, how it changes viscosity when its temperature changes, and how it moves through valves. Hydraulic Lock Out – a condition caused when the mixture of air and damping oil is out of balance. It is caused when there is too little air space in a chamber, not allowing the fork to compress through its travel.
FRONT SUSPENSION TERMINOLOGY (CONT.) Piston – In front suspension, the part of the damper that slides back and forth inside of the damping leg that houses the valves. It can also refer to the air piston in the air/spring assembly that slides back and forth compressing the air, thus causing a change in the spring rate of the suspension. Porosity – The condition or property of having pores in a material that will allow gas or liquid to pass through it.
FRONT SUSPENSION TERMINOLOGY (CONT.) Slider/Outer Casting – The tube (outer casting leg) of the suspension fork that0. remains fixed to the wheel. It slides up and down on the stanchion leg (inner leg). Stanchion Clamps - (Double-Triple Clamps) the portions of the fork crown that clamp around the stanchion legs above and below the head tube of the bicycle frame on specific long travel applications. Stanchion Legs – The suspension tube (inner leg) fixed to the fork crown.
2005 Axel Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting 1. From the left leg dropout (Left when sitting on the bike), use a 4mm hex wrench to remove the compression rod screw. 2. From the right leg dropout, if the fork has adjustable rebound, the knob will need to be removed. Remove the 2mm hex screw inside the knob and remove the knob. 3. Use a 8mm hex wrench to turn the damper clockwise until it can be pushed into the casting. 4.
Removal of Compression Damping Assembly Forks with FFD (non-adjustable) Damping 1. Remove top leg cap (FFD Assy) on right hand side using 27mm socket. 2. Pour old oil out of the top of the fork, then compress fork upside down over oil drain pan 3-5 times to get oil out from under rebound piston and discard appropriately. Forks with Adjustable Compression/Lockout Damping 1. 2. 3. 4. Remove the 2mm fixing screw on top of the damper knob on top right side of the fork.
Assembly of Compression Damping Assembly - Adjustable Compression/Lockout WARNING All top caps for Damper and Spring systems must be properly tightened prior to use. Failure to do so could result in injury or possible death. 1. Fill right leg with damping oil using 5wt Motorex fork oil (Ref Answer Products PN 850023) to the height noted in the Axel Schematic and Torque Specification Table. Cover the opening at the top of the right leg of the crown/steer with a rag and cycle the fork six times.
3. Lightly grease the bushings on the inside of the outer leg casting and on the lower portion of the inner legs below the boots using a thick grease such as Motorex Bike Grease 2000. 4. Grease spring heavily with Motorex Bike Grease 2000. Install the spring preload and spring assy into the crown/steer assy. 5. Tighten preload adjuster using 18mm socket and tighten per the Axel Schematic and Torque Specification Table. 6.
5. Generously grease the spring and insert it into the inner leg. The end of the spring needs to seat onto the top of the compression rod. 6. Insert the wind down top cap assembly into the spring; the "D" shaped portion of the adjuster assembly must fit into the "D" shaped end of the main spring. Screw the assembly into the inner leg and tighten per the fastener torque guide at the end of this manual... 7. Install adjuster knob and 2mm hex screw.
Remove Nylon washer that rests on top of aluminum washer 4mm recessed Allen bolt Lock Out Troubleshooting Tips 1. Installation of Lock out Compression Damping System • Check the o-ring that is installed around the lower piston on the damper shaft for tears or deformation. Replace it, if it is damaged. This is the most common reason why the Lock out system will not function. • Check the level of oil in the inner leg. The oil level may be a little high, but never low.
2. Troubleshooting • If the Lock out does not lock out properly, go back through the steps listed above. • If the o-rings are damaged on the Lock out piston, replace them with P/N 062594(urethane 1998-2003 Mars, SX, & Skareb Lock outs), 065261 (04/05 Skareb Lockouts) and 02/03 Black 100/120mm Lock outs, and 040315 (Axel’s). • If the oil level is low, check to see if there is evidence of leaking at the Rebound Damper. If so, replace the Rebound Damper assembly and retry the Lock out.
Steps For Cable Disassembly 1. 2. 3. Step 3 Step 1 Step 2 Tool Placement to unscrew upper shaft assembly from lower assembly (Figure A) 4. 5. 1. 2. Cable hook up connection (Figure B) 3. 4. 5. 05 AXEL SERVICE MANUAL Page 15 Cable Replacement Instructions Step 1: Lock out assembly should be out of fork at this point. Step 2: Cable assembly should be out of Lever assembly Step 3: Look at tool placement in Figure A.
Air Assist Trouble Shooting Tips The root cause of the air leaking from the left leg of the fork (the side with the Schrader valve on top) and blowing out the seal at the top of the fork leg is that the either the end seal on the leg is bad or the seal on the compression rod is bad. Below are some steps to follow in order to trouble shoot this issue and potentially resolve it. 1. It is difficult to visually determine from the out side of the fork what problem you are having.
Bushing Removal & Installation Bushing Removal ( For Axel Super and Elite only ) (Note: use appropriate removal ring that corresponds to the leg diameter of the fork being repaired) Leg Diameter 25.4mm (1”) 28.6mm (11/8”) 30mm 32mm Answer Kit # 85-5191 85-5189 85-5194 85-5192 Bushing Removal Tool Components A. Slide Hammer B. Threaded Handle C. Slide D. Threaded Shaft E.
Bushing Removal (CONT.) Bushing Removal Instructions A. Install 25.4mm Removal ring on the shiny, smaller diameter threaded shaft. Be sure to install the ring with the tapered, chamfered end first, followed by the long slide tube. This tapered end leads the tool through the bushing. B. Start the procedure by removing the Dust/Wiper seal with a screwdriver, prying it out. C. Insert Removal tool past the upper bushing and then stop. It is important to pull one bushing out at a time.
Bushing Installation (CONT.) Bushing Installation Tool Assembly With weighted handle When selecting sizer rings to install bushings, choose the two rings that are in the middle of the size run to start with. 1. Assemble installation tool as shown in picture above. Each leg diameter kit has all of the needed pieces to remove and install bushings for forks with serviceable bushings. Some of the kits come with gauges to tell you how far to drive in the lower bushings.
Bushing Installation (CONT.) 4. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet until proper depth is achieved. If using depth gage, slide gage onto rod before installing weighted handle and let it settle on of Mandrel. Tap rod until appropriate line on gage is even with top of casting leg. 5. Remove weighted handle and gage (if applicable). 6. For sizing of the lower bushing: 7.
Troubleshooting Chart Symptom Oil leaks from Wiper Seals Oil leaks from bottom of Casting Lack of Travel Fork Top out Fork Bottom out Play in Fork Dust Seal Blows Out Lock out not functioning Cause Service Manual Page Solution Seal not seated properly Remove Casting from Inner Legs, reinstall or replace seals 9 Nicks or scratches on inner legs Replace Crown/Steerer/Inner Leg Assembly 9 Wear Remove Casting from Inner Legs, reinstall or replace seals 9 Rebound damper shaft leaks Replace R
Axel: Schematic & Technical Specifications C G E A D B H K Model: Axel Description Torque Value Bushing Depth - Upper *8.9mm Min. (.35”) Bushing Depth - Lower *99 – 106 mm (3.9 - 4.2”) Torque – Brake Post 90–110inlbs (10.2-12.4nm) Leg Caps 25–35inlbs (2.8-4.0nm) Torque - Comp Rod Screw 10-30inlb (1.1-3.4nm) Torque - Damper Screw (Axel Super) 10-30inlb (1.1-3.4nm) Adjuster caps: Torque Damping Oil 05 AXEL SERVICE MANUAL 35-50inlbs (4.0-5.7nm) 110 – 120mm (4.3 – 4.
Axel Service Kits Axel Model Comp Travel (mm) Comp Damp FFD 80 Elite 100 120 80 A 100 Super 120 70-100 RTWD 90-120 RTWD 85-5396 83-2399 85-5253 Comp Damp TPC A Lock Out - TPC A *85-5318 Remote L/O - Lever Left A *83-2180 Remote L/O - Lever Right A *83-2402 Remote L/O - Cover Left A *83-2181 Remote L/O - Cover Right A *83-2403 Remote L/O - L/O A *83-2407 Remote L/O - Cable A *83-2182 Remote L/O - Cable Guide A *83-2183 Remote L/O - O-Ring Kit A *83-2408 Rbnd Damp
Axel Service Kits (Cont.
