MRD Service Gu

8/3/2019 MRD Service Gu

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Table of Contents

Description PageIntroduction 3Disassembly/Assembly Instructions Casting systems 4- 9

Hex Thru Axle Installation9

Noble Air system Service Instructions10 - 15

MRD Damping system Service Instructions16 - 26

Technical Data 27

Service Kit Matrix 28

Fork Torque Specs 29

Trouble shooting Tips 30 - 31

Contact Information

Hayes Bicycle GroupTech Support6750 W. Florist Ave.Milwaukee, WI. 53218

Toll Free: (888) 686-3472Direct: (414) 462-0021FAX: (414) 462-0214E-mail: [email protected] site: www.manitoumtb.com

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INTRODUCTION

This manual is intended to guide the user through basic service of Manitou front forks.Service is supported by the identification of common parts and assemblies that havebeen assembled into Service Kits. The purpose of this manual will be to describeconditions that may drive the need for service and to provide installation instructions forthe kits.

Due to the time-consuming nature of suspension fork service, at this time our primaryfocus is to offer service kits that minimize the amount of downtime and labor involved.

Important information is highlighted in this manual by the following notations:

WARNINGFailure to follow WARNING instructions could result in severe injury or death to theperson inspecting or repairing the suspension fork or the user.

CAUTIONA CAUTION a caution indicates special precautions that must be taken to avoid damage tothe product.

NOTEA NOTE provides key information to make procedures easier or clearer

GENERAL WARNING: Suspension forks by design can contain preloaded springs,gases and fluids under extreme pressure and warnings contained in this manualmust be observed to reduce the possibility of injury or possible death. Followingthese instructions can help you reduce the risk of being injured. Any questions inregards to the information in this manual should be directed to HBG Tech Supportat (888) 686-3472.

WARNING: Suspension forks uses preloaded spring(s) to provide compression springresistance. This system must be relieved of preload prior to servicing. Failure to relieveair pressure could result in injury or possible death.

CAUTION: Suspension forks use precision machined aluminum and other soft alloy components.Using correct tools for assembly is essential to prevent damage.

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MRD Casting ServiceIncludes Semi Bath change, seal change, and casting change

Tool List: 12mm wrench, 1.5mm Allen, 7mm Allen, Park Green Pin Spanner (or similar), Shock Pump

1. Using a shock pump slowly release the air pressure from the Noble Air

System through the valve on the bottom of the left fork leg. Please Note: When

the air is removed too rapidly, it will cause air to be trapped in the negative air

chamber causing the fork to "suck down". If this happens, it is easily fixed bypumping up the air spring back up above the pressure that you originally had in

the system and then release the air slowly

2. Remove the 12mm nut from the compression rod on the bottom of the left

leg.

3. Remove the blue rebound knob on the bottom of the right leg with a 1.5mm

Allen wrench. Be cautious of the detent balls and springs under the knob as the

are very small and easily lost.

WARNING:This fork uses compressed air to provide spring resistance and must be

relieved of pressure prior to servicing. Failure to relieve air pressure could result in

injury or possible death.

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4. Remove the detent balls and springs from the Detent Housing.

5. Remove the Detent housing by unscrewing it counter-clockwise using a gree

Park Tool pin spanner (or similar tool) inserted into the holes that the springs

and detent balls sit in.

6. Using a 7mm Allen wrench, usnscrew the rebound assembly from the casting

by turning it clockwise.

7. Pull the casting off the Crown Steerer assembly. It is best to do this over somtype of drip pan to catch the semi-bath that is in the outer legs. Throughly clean

out the casting to get any contamiated oil and dirt out. If you are changing the

fork seals, proceed to the next step, if not go to step 13.

8. To remove the dust seals, first remove the seal tension springs (otherwise

they will get damaged), then take a large flat-bladed screwdriver and insert the

tip between the bottom of the seal and the top of the foam wiper.

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9. Push down on the screwdriver. This will pop the seal out of the casting. Next

remove the foam oil ring.

10. Oil the foam rings (new or after cleaning the old rings) with a small amount o

semi-bath oil and place them in the top of the casting above the Upper Bushing

11. Install the dust seal into the leg, use a large socket or piece of round tubing

that is large enough in diameter to press on the outside shoulder of the seal

rather than putting pressure on the sealing lip and spring so that they are not

damaged. Repeat steps 9-12 for the opposite fork leg.

12. Extend the compression rod and the rebound shaft fully, check to see if the

face seal on the rebound shaft and the o-ring on the compression rod are

damaged. If so, replace them, otherwise it is OK to reuse them.

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13. Slide the casting onto the stanchions being careful not to pinch the lip on the

dust seals. Once the seals are on the legs slide the legs down about 3/4 of the

way down.

14. Hold the fork at approximately a 45 degree angle with the drop outs up.

Using a squeeze bottle or syringe put 16cc(16ml) of Semi Bath (5w40 synthetic

oil) into each leg of the fork. Be careful that the oil is not poured into the end of

the rebound shaft or the air valve on the end of the compression rod. After the

Semi Bath is in each leg, slide the casting down the rest of the way until the

casting makes contact with the rebound shaft.

15. Using the 7mm Allen, turn the rebound shaft counter-clockwise to screw the

rebound assembly into the casting. Tighten it to 15-20inlbs (1.7-2.3N-m).

Note:You may need to put a slight amount side pressure on the Allen wrench

and pull out on the rebound shaft to get it to start in the casting. Warning: Do no

overtighten the rebound damper assembly into the casting, it will cause damage

to the sealing o-ring on the end of the shaft and cause the semi bath oil to leak

out of the casting. It is recommended to use a torque wrench when tightening

this assembly.

16. Screw the detent assembly clockwise on to the portion of thread of the

rebound shaft that protrudes out of the casting. Using a tool like the Park Tool

Pin Spanner and the 7mm Allen wrench, tighten the Detent Housing in a

clockwise direction while holding the rebound shaft stationary with the Allen

wrench. Tighten the Detent Housing to 15-20inlbs (1.7-2.3N-m).

Pinched

Correct

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17. Insert a small spring into each of the holes on the detent assembly, apply a

small amount of grease on top of the spring to hold the detent balls, and then

place a detent ball on top of each spring.

18. Place the blue rebound knob on the needle in the rebound assembly and

attach it with the machine screw using the 1.5mm wrench. Tighten it to 5-8inlbs

(.6-.9N-m) and be sure to use blue LocTite on the threads.

19. Install the 12mm nut that secures the compression rod in the left fork leg.

Tighten it in a clockwise direction to 15-20inlbs (1.7-2.3N-m). If there is not a

washer located under the 12mm nut, place a thin washer onto the exposed

threaded shaft protruding through the casting before you reinstall the nut.

20. Pressurize the main spring by turning your bike upside down, install the air

pump on to the schrader valve and then inflate to the pressure that you normally

use. Now, go have a great ride!

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32mm Leg Thru Axle and Quick Release Thru Axle Instructions

Standard Hex Thru Axle

Removal Instructions

Removal of Hex Thru Axle1. Loosen the two 3mm clamp-fixing bolts on the right fork leg. (See Fig. 1)

2. Remove the Thru Axle nut from the right side of the Thru Axle.

3. Loosen the two 3mm clamp-fixing bolts on the left fork leg.

4. Push the Hex Thru Axle out of the dropouts from left to right and

completely remove it and the front wheel from the fork.

Assembly Instructions

Fig. 1 Installation of Hex Thru Axle

1. Insert the Clamp Nuts (See Fig.3 A) into the small hexagonalhole in each of the drop outs.

2. Start two clamp fixing bolts (See Fig.3 C) in each dropout.Do not tighten these bolts down at this time

3. Hold the wheel between the dropouts of the fork.4. Insert Hex Thru Axle small hex first into the outside of the left

drop out (as you are facing the fork) and push it through the hub

of the wheel, and into the right drop out.

5. Thread the Thru Axle nut into the end of the axle that is in theright drop out. Thread the Thru Axle nut all of the way in.

Fig. 2 Tighten the 3mm clamp fixing bolts to the specified torque value6. Push down on the fork a few times to allow the hub to center.

Tighten the 3mm clamp fixing bolts to the specified torque value

as called out in Technical Specification Chart at the end of this

manual. (See Fig 1)

7. Finish the installation by tightening axle nut to specified torque(See Fig 2)

Fig. 3

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MRD Noble Air System ServiceIncludes complete disassembly and service of the air spring system

Tool List: 12mm wrench, 15mm wrench, 20mm socket, 1.5mm Allen, 7mm Allen, Park Green Pin Spanner (or




chamber causing the fork to "suck down". If this happens, it is easily fixed by

pumping up the air spring back up above the pressure that you originally had inthe system and then release the air slowly

2. Remove the 12mm nut from the compression rod on the bottom of the left leg




WARNING:This fork uses compressed air to provide spring resistance and must berelieved of pressure prior to servicing. Failure to relieve air pressure could result in


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4. Remove the Detent balls and springs from the Detent Housing.




6. Using a 7mm Allen wrench, usnscrew the rebound assembly from the casting


7. Pull the casting off the crown steerer assembly. It is best to do this over sometype of drip pan to catch the semi-bath that is in the casting. Thoroughly clean

out the casting to get any contaminated oil and dirt out. If the fork seals need to

be serviced, please reference the casting service instructions for details. If you

are planning to service the damping system please reference those instructions

8. Use a 15mm wrench to remove the compression rod from the bottom of the

left fork leg. There may be oil in the area between the endcap and the piston

(only a few cc/ml) so use caution when pulling the assembly from the fork leg.

Also it is normal to have a slight amount of negative pressure when removing th

assembly.

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9. Inspect the quad seal (might be an o-ring) and piston glide ring for wear or

damage and replace if any is found. Pay special attention to the area of the qua

seal that was moving over the negative spring charge slot, as this is where you

might see possible damage. It will appear like the image as two small areas thaare approximately 1mm wide gouged out of the sealing lips of the quad ring.

10. Using a 20mm socket, remove the top cap and air spring compensator by

turning it counter-clockwise.

11. The air spring compensator is a press fit on the end of the intermediate air

piston, a sharp pull will separate the two pieces.

12. Even though the air spring compensator is not actively compressed by the

compression rod and piston, over time this material will degrade and lose its

effective spring rate from being compressed by the air pressure in the fork and

will need to be replaced periodically. The 80mm R7 will use the 60mm long air

spring compensator, all other MRD forks, R7100mm and both Minute 100 and

130mm, will use the shorter 40mm air spring compensator.

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13. Invert the fork, lightly grease the glide ring and quad seal on the air piston

and also the o-ring on the end cap. Gently insert the piston into the left fork leg,

will ease the installation past the threads in the inner leg if you turn the assemb

like screwing in a screw. When screwing the end cap into the leg watch to be

sure that the o-ring does not catch on the edge of the leg. Torque the end cap t80inlbs (9.0N-m).

14. Turn the fork upright, and pour about 3-5cc of air piston oil (20w50 synthetic

motor oil) on the top of the air piston, this will be just enough to cover the dish in

the piston.

15. Attach the air spring compensator to the top cap assembly by pushing it on

to the post on the bottom of the top cap air piston. Lightly grease the o-rings on

the air piston and the top cap. Gently insert the piston into the left fork leg, it wil

ease the installation past the threads in the inner leg if you turn the assembly lik

screwing in a screw. Once the air piston is inside the leg you will meet some

resistance trying to insert the assembly further as it will build up some air

pressure in the system, this is normal. When screwing the endcap into the leg

watch to be sure that the o-ring does not catch on the edge of the leg. Torque

the top cap to 80inlbs.


face seal on the rebound shaft and the o-ring on the compression rod aredamaged if so replace them, otherwise it is OK to reuse them.

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17. Slide the casting onto the stanchions being careful not to pinch the lip on the

dust seals. Once the seals are on the legs slide the legs down about 3/4 of theway down.


Using a squeeze bottle or syringe put 16cc(16ml) of semibath (5w40 synthetic

oil) into each leg of the fork. Be careful that the oil is not poured into the end of

the rebound shaft or the air valve on the end of the compression rod. After thesemibath is in each leg, slide the casting down the rest of the way until the







to the sealing o-ring on the end of the shaft and cause the semi bath oil to leakout of the casting. It is recommended to use a torque wrench when tightening

this assembly.





wrench. Tighten the Detent Housing to 15-20inlbs (1.7-2.3N-m).

Pinched

Correct

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small amount of grease on top of the springs to hold the detent balls, and then




(.6-.9N-m) and be sure to use blue LocTite on the threads.

23. Install the 12mm nut that secures the compression rod in the left fork leg.If

there is not a washer located under the 12mm nut, place a thin washer onto the

exposed threaded shaft protruding through the casting before you reinstall the

nut.Tighten it in a clockwise direction to 15-20inlbs (1.7-2.3N-m).



use. Now, go have a great ride!

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MRD Damping Systems ServiceIncludes complete disassembly and service of the Various Damping Systems used in theTool List: 12mm wrench, 15mm wrench, 20mm socket, 24mm socket, 1.5mm Allen, 7mm Allen, Park Green Pin




chamber causing the fork to "suck down". If this happens, it is easily fixed by

pumping up the air spring back up above the pressure that you originally had in

the system and then release the air slowly

2. Remove the 12mm nut from the compression rod on the bottom of the left leg




WARNING:This fork uses compressed air to provide spring resistance and must berelieved of pressure prior to servicing. Failure to relieve air pressure could result in


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4. Remove the detent balls and springs from the Detent Housing.




6. Using a 7mm Allen wrench, unscrew the rebound assembly from the casting


7. Pull the casting off the crown steerer assembly. It is best to do this over sometype of drip pan to catch the semi-bath that is in the outer legs. Throughly clean

out the casting to get any contamiated oil and dirt out. If the fork seals need to

be serviced, please reference the casting service instructions for details. If you

are planning to service the damping system please reference those instructions

For TPC forks proceed to the next step, for Absolute forks: proceed to step 11

and for RCT Lock-out forks: proceed to step 14

8. TPC Forks: Turn the TPC adjustment knob on top of the right side of the forkcounter-clockwise until it reaches the travel limit.Using an 1.5mm allen wrench

remove the screw in the center of the knob, turn the screw counter-clockwise to

remove. Be cautious of the detent balls and springs under the knob as they are

very small and easily lost.

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9. Remove the detent balls and springs from the top of the assembly.

10. Using a 20mm socket remove the TPC compression assembly from the fork

leg. As you pull the piston out of the damper body be cautious not to spill the oil

Once the TPC assembly is removed, pour the oil in the damper body out and

dispose of it properly. Stroke the rebound shaft once or twice while doing this to

ensure that all of the oil is removed. Continue to step 17 Warning: If thecartridge tube becomes dislodged as you remove the compression damper

assembly, do not worry. The oil in that tube will drain into the inner leg and can

be poured out of that leg. The press fit or the "squeeze" of the o-ring between

the end cap and the tube may be too loose. This will require replacing the o-ring

in the end cap.

11. Absolute forks: Turn the adjuster counter-clockwise until the damper is the

fully open position. Using a 2mm allen remove the screw holding the knob on,turn the screw counter-clockwise to remove. Be cautious of the detent balls and

springs under the knob as they are very small and easily lost.

12. Remove the detent balls and springs from the top of the assembly.

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13. Using a 24mm socket, remove the Absolute compression assembly from the

fork leg. As you pull the piston out of the damper body be cautious not to spill th

oil. Once the Absolute assembly is removed, pour the oil in the damper body ou

and dispose of it properly. Stroke the rebound shaft once or twice while doing

this to ensure that all of the oil is removed. Continue to step 17 Warning: If

the cartridge tube becomes dislodged as you remove the CompressionDamper assembly, do not worry. The oil in that tube will drain into the

inner leg and can be poured out of that leg. The press fit or the "squeeze"

of the o-ring between the end cap and the tube may be too loose. This will

require replacing the o-ring in the end cap.

14. RCT Lock- out Forks: Using a 2mm allen remove the screw holding the

cable barrel on, turn the screw counter-clockwise to remove. Be cautious of the

return spring and cover on the bottom of the knob.

15. Next remove the cable stop clamp by loosening the clamp bolt using a 2mm

Allen wrench, then just lift the clamp off of the Lock-out assembly.

16. Using a 24mm socket, remove the Lock-out compression assembly from the

fork leg. As you pull the piston out of the damper body be cautious not to spill th

oil. Once the Absolute assembly is removed, pour the oil in the damper body ou

and dispose of it properly. Stroke the rebound shaft once or twice while doing

this to ensure that all of the oil is removed.

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17. Invert the fork, Using a 15mm wrench remove the rebound end cap by

turning it counter-clockwise. This will remove the rebound assembly and thecartridge body.

18. Separate the cartridge body from the rebound assembly by twisting the twopieces in opposite directions while pulling them apart.

19. Inspect all o-rings, seals and piston glide rings, replace any that show signs

of wear or damage. Be sure to check the o-ring on the inside of the rebound en

cap that seals on the outside surface of the cartridge body. It is adviceable to

only replace this o-ring if it is damaged as it extremely difficult to fully seat thereplacement and install the cartridge. If you are replacing the o-ring, lube it with

semi-bath oil rather than grease as it will seat into the groove in the end cap

better.

20. Lube the oring on the inside of the end cap, the outside of the cartridge tube

and the piston glide ring on the rebound assembly, using a small amout of shocfluid. These areas are pointed out in the photo to the right.

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21. Slide the rebound assembly into the cartridge tube. To insert the cartridge

tube into the endcap, place the opposite end of the cartridge tube against the

edge of the workbench, place on hand on the cartridge tube and one hand on

the end cap. While leaning your weight into the assemblies, twist the end cap in

one direction and the tube in the opposite as if screwing the pieces together.

There should be a sharp snap or click as the tube slides past the o-ring and

seats into the end cap. if you don't hear the end cap seat there is a very good

chance that the cartridge tube has cut the o-ring.

22. Screw the rebound assembly and cartridge tube assembly into the bottom o

the right leg. Torque the end cap to 80inlbs (9.0N-m) using a 15mm wrench. Be

care not to dislodge the cartridge tube from the end cap as it needs to remain

fully seated to seal properly.

23. Turn the fork upright. Fill the cartridge approximately 1/2 to 2/3 full of 5wt

shock oil. Be careful not to spill fluid in the area between the inner leg and the

cartridge. Place a shop towel over the top of the leg. Slowly stroke the rebound

shaft about 1/2 way through its travel, this will get air out from under the reboun

piston. Fully extend the rebound shaft.

24. For all MRDForks: Fill the cartridge with shock fluid until the distance from

the top of the inner leg to the top surface of the oil in the cartridge is 120mm (yo

are measuring the distance between the 2 arrows). It is easiest to set this level

using a syringe with a piece of tubing on the end to draw out the proper amount

of fluid. For TPC forks proceed to the next step; Absolute forks continue to step

28; RCT forks resume at Step 29

25. For TPC Forks: lightly lubricate, with shock fluid, the orings on the outside

and inside of the top cap. Carefully insert the TPC compression assembly to

make sure that the cartridge body is not knocked off center. Using a 20mm

socket, torque the top cap to 80inlbs (9.0N-m).

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26. Insert the 2 detent springs and balls into the holes on the top cap.

27. Using a 1.5mm Allen wrench screw the TPC knob on to the compression

assembly. Be careful when installing the knob so that you don't dislodge the

detent balls. Proceed to step 34 to finish the service.

28. For Absolute forks: Lube the o-rings on the inside and the outside of the

top cap with shock fluid. Also be sure to lube the o-ring on the piston. Carefullyinsert the Absolute compression assembly to make sure that the cartridge body

is not knocked off center. Using a 24mm socket, torque the top cap to 80inlbs

(9.0N-m).

29. Insert the 2 detent springs and balls into two holes opposite to each other othe top cap.

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28. Using a 2mm Allen wrench screw the knob and Absolute detent plate on to

the compression assembly. Be careful when installing the knob so that you dondislodge the detent balls. Proceed to step 34 to finish the service.

29. For RCT Forks: lightly lubricate, with shock fluid, the orings on the outside

and inside of the top cap. Carefully insert the TPC compression assembly tomake sure that the cartridge body is not knocked off center. Using a 24mm

socket, torque the top cap to 80inlbs (9.0N-m).

30. Install clamp w/ cable adjuster pointing to the front of the fork.

31. Turn cable spool to close the lockout, making sure that it functions properly

Clock the spool so the cable anchor is close but doesnt interfere with the cable

adjuster on the clamp.

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32. Turn spool counter clockwise about 180 degrees from the locked out

position. Remove Spool and install the return spring in the spool.

33. Install spool on lock-out in the position from the end of step 32. The return

spring goes in whichever of the holes in the top cap that it lines up best with.

Proceed to step 34 to finish the service.


face seal on the rebound shaft and the o-ring on the compression rod are

damaged. If so replace them, otherwise it is OK to reuse them.

35. Slide the casting on to the stanchions being careful not to pinch the lip on th

dust seals. Once the seals are on the legs, slide the legs about 3/4 of the way

down.


Using a squeeze bottle or syringe put 16cc (16ml) of Semi Bath (5w40 syntheticoil) into each leg of the fork. Be careful that the oil is not poured into the end of

the rebound shaft or the air valve on the end of the compression rod. After the

Semi Bath is in each leg, slide the casting down the rest of the way until the


Pinched

Correct

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to the sealing o-ring on the end of the shaft and cause the semi bath oil to leak

out of the casting. It is recommended to use a torque wrench when tightening

this assembly.





wrench. Tighten the Detent Housing to 15-20inlbs (1.7-N-m).


small amount of grease on top of the springs to hold the detent balls, and then




(.6-.9N-m)and be sure to use blue LocTite on the threads.

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41. Install the 12mm nut that secures the compression rod in the left fork leg. If

there is not a washer located under the 12mm nut, place a thin washer onto the

exposed threaded shaft protruding through the casting before you reinstall the

nut.Tighten it in a clockwise direction to 15-20inlbs (1.7-2.3N-m).



use. Now, go have a great ride!urize the main spring back to the air pressure

that you normally run and go have a great ride!

Additional note: It is possible to change the compression damping systems (Absolute/TPC) between theMRD Forks. There are different length cartridge tubes required for the Absolute subassembly versus the TPC

subassembly. So, in order to change from TPC to Absolute or vice versa, you also need the correct

corresponding cartridge tube.

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Technical Data

2008 Fork Set Up Criteria

Family Model Damping System Travel Oil LevelFactory Build

Specs

MM Inches MMSPV/IFP

PSI

AirSpring(PSI)

R7 MRD TPC 80 4.7 120 N/A 70

100 4.7 120 N/A 70

MRD Absolute 80 4.7 120 N/A 70

Minute MRD TPC 100 4.7 120 N/A 100

130 4.7 120 N/A 100

Absolute 100 4.7 120 N/A 100

130 4.7 120 N/A 100

ForkModel Seal Type

Seal Partnumber

Rebound

DamperEnd

Torque on Rebound

Damper to secure inCasting

08 R7 MRDOrange

Doughnut 065807AluminumMachined 15-25inlbs (1.69 - 2.82Nm)

08 MinuteMRD

Thin WhiteNylon 067110

AluminumMachined 15-25inlbs (1.69 - 2.82Nm)

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2008 Manitou Fork Service Kit MatrixName R7 Minute

Model R7 MRD Minute MRD

Code M-850 M-851

RG-

850

RG-

851Travel (mm) 80 100 100 130

Cartridge Damping Rebuild PartsCartridge Rebound Assy-TPC or Absolute A 83-3267 83-3283

Cartridge Rebound Assy-CID A

Cartridge TPC Assy A 83-3265 83-3281

Cartridge Absolute Assy A 83-3266 83-3282

Cartridge Body - TPC A83-

326883-

326983-

326983-

3284

Cartridge Body - Absolute A83-

327083-

327183-

327183-

3285

RCT Remote L/O Lever * A 83-3352 83-3352

RCT Remote L/O Cable * A 83-3353 83-3353

RCT Remote L/O Fork Clamp Spool/Spring * A 83-3354 83-3354

Air Cap C83-

327283-3343

83-3286

83-3287

Air Spring Compensator C 83-3273 83-3273

Crn/Str/Leg D

***Blk AL S/T(26") MRD83-3276

83-3277

83-3290

83-3291

Outer Leg Assy E

STD Merida Green 98-23568

STD Candy Red 83-3257

STD Grey (Primer) 83-3256

STD Gloss Black 98-23561

NB, STD DO Gloss Black 83-3258

NB, STD DO Carbon Clear Coated 98-23564NB, STD DO Grey Blue (Ocean Blue) 83-3292

NB,STD DO Merida Green 98-23569

NB, STD DO Candy Red 83-3260

NB, STD DO Grey (Primer) 83-3259

NB, Hex Axel Grey Blue (Ocean Blue) 83-3332

Travel Adjust/ H

Comp Rod/ H

8083-

3274

10083-

327583-3288

13083-

3289

Bushing Kit E 85-5321 85-5964

Knob Kit I 83-3279 83-3279

Dust Seal Kit K 83-2443 85-5293

O-Ring Kit K 83-3280 83-3293

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Position Fitting (Internal/

External) - Size Solution appliedFork Assembly Min Max Min Max

Brake Post Ext. - 8mm (2 sided) 92 115 80 100

Red Loctite

(impreg. threads)End Cap

(Spring & Damper) Ext. - 24mm Hex 92 115 80 100

Greased

(spring grease)

Top Caps (Spring &

Damper / Plastic

Ext. - 20mm Hex /

Ext. - 24mm Hex 52 63 45 55 NATop Caps (Spring &

Damper / MetalExt. - 20mm Hex /Ext. - 24mm Hex 69 92 60 80 NA

Drop out bolt

(Spring side)

Ext. - 11mm Hex /

Ext. - 12mm Hex 52 63 45 55 NADrop out fitting

(Damping side) Int. - 8mm Hex 15 29 13 25 NA

Rebound -adjuster knob to -needle Int. - 2mm Hex 5 7 4 6

Blue Loctite

(CartridgeDampers Only)

Triple Clamp

lower crown Int. - 4mm Hex 58 81 50 70 Blue LoctiteTriple Clampupper crown Int. - 4mm Hex 115 127 100 110 Blue Loctite

QRTA quick release

screws Int. - 4mm Hex 35 46 30 40 Blue Loctite

Std. thru Axle Clamp Screws Int. - 4mm Hex 35 46 30 40 Blue LoctiteStd. / QRTA

Thru Axle bolt Int. - 6mm Hex

Greased

(spring grease)

Sub Assembly

Air valve core Ext. (?)mm (2 sided) 3 6 3 5 NARebound Assy.

Piston Nut Ex. - 13mm Hex 14 17 12 15 Green LoctiteLO, Rem LO:

Top Cap to Shaft

Ext. - 24mm Hex to

Ext. 10mm (2 sided) 52 63 45 55 Red LoctiteLO:

Piston to Shaft

Int. 6mm Hex to

Ext. 10mm (2 sided) 46 58 40 50 Red LoctiteRem LO: Piston seat to Shaft

bottom Custom fittings 46 58 40 50 Red LoctiteRem LO: Plunger-

top to -bottom Custom fittings 6 12 5 10 Red LoctiteRem LO: Shaft -

upper to -lower Custom fittings 52 63 45 55 Red Loctite

Rem LO: End plugto Piston seat Custom fittings 6 12 5 10 Blue Loctite

Hand Tight

Fork Torque Specifications

Torque (inlbs)Torque (Kg/Cm)

CRITICAL!!!

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Trouble Shooting Tips

Symptom Cause Solution See Page #

Air LossSchrader Valveleaks

Tighten Valve core, replace bad partsas needed. 13 Sect.16

Air Cap O-ring leaksMake sure O-ring is seated properly,replace parts as needed. 13 Sect.15

Air Piston leaksCheck oil volume on top of piston,replace parts as needed. 13 - Sect.14

Air Top Cap leaksCheck O-ring, tighten cap to properTorque, and replace parts as needed. 13 Sect.15

Oil leaks from WiperSeals

Seal not seatedproperly

Remove Casting from Inner Legs,reinstall or replace seals 5 Sect.8

Nicks or scratcheson inner legs

Replace Crown/Steerer/Inner LegAssembly

Too much Semi Bathoil

Follow instructions for removal andinstallation of Outer Casting 4 Sect.9

Wear

Remove Casting from Inner Legs,

reinstall or replace seals 4 Sect.9Oil leaks from bottom

of CastingRebound dampershaft leaks Replace Rebound Damping assembly 20 Sect.17

Rebound dampershaft O-ringdamaged

Replace O-ring on threaded end ofRebound Damping assembly 24 Sect.34

Compression RodBolt leaks

Check O-ring on bolt to see if it isdamaged and then reinstall 26 Sect.41

Lack of Travel Tight BushingsResize bushings or replace with newones if damaged

Refer to2008 Fork

ServiceManual

Hydraulic lock out Replace Rebound Damping assembly See above

Semi Bath oil volumeFollow instructions for removal andinstallation of Outer Casting See Above

Damper oil volume Check oil level, Replace ReboundDamping assembly if needed See Above

Fork alignmentVisually inspect fork, call HBG TechSupport Customer Service

Fork Top outLoss of ReboundDamping Replace Rebound Damping assembly See AboveTop out springdamaged

Inspect and replace Top out spring ifneeded. 11 Sect.15

Damping oil volumenot correct

Check oil level, Replace ReboundDamping assembly if needed See Above

Fork Bottom out Too much SAGRefer to SAG Set up in Tuning sectionof Owners Manual

Table 3Pg.27

Bottom out Bumperdamaged

Inspect and replace Bottom out Bumperif needed 11 Sect.15

Damping oil volumenot correct

Check oil level, Replace ReboundDamping assembly if needed See above

Play in Fork Loose bushingsResize bushings or replace with newones if damaged See Above

Loose CompressionRod bolt Tighten bolt to specified torque

Loose Rebounddamping shaft Tighten Shaft to specified torque

Loose press fittolerances

Call HBG Tech Support CustomerService

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Trouble Shooting Tips (cont.)

Absolute DampingProblems Loss of function

Check oil level, Replace AbsoluteDamping assembly if needed 21 Sect.24

Noisy whenincreasing platform

Check oil Level, contact HBG TechSupport 21 Sect.24

RCT Lockout ProblemsVarious See Remote Lockout Section 19 - 24

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MRD Service Gu

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Transcript of MRD Service Gu