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FORK INSTALLATION
1. Remove the old fork from your bicycle.
2. Measure and cut the steerer tube to fit your bicycle head tube. You can use
your old fork as a guide for cutting the steerer tube length.
3. Remove the headset crown race from the old fork and press onto the Black
fork steerer until the race is seated over the crown.
4. Clean and grease the headset bearings and races.
5. Install the lower bearings (if applicable) on fork crown race.
6. Insert the steerer tube into the head tube of the frame.
7. Install the upper bearings, stem spacers, and stem.
8. Install the stem cap and bolt. Tighten the bolt to headset manufacturer's
specifications.
9. Install the handlebars and the torque stem pinch screws or stem clamping
system to manufacturer's specifications.
10. Install the brakes and adjust per the manufacturer's instructions.
11. For all Black forks, adjust the front wheel quick release to clear the 0.275" (7
mm) thick secondary catch dropout. The quick release must be tightened
after it is properly seated into the dropout counter bores to manufacturer's
specifications. Ensure that there is adequate thread engagement (4 or more
threads with the release adjusted to lock).
12. Install the brake cable per manufacturer's instructions.
NOTE: 2002 Black forks are equipped with a secondary catch dropout to retain
the wheel in the fork in the event the quick release comes loose.
WHEN INSTALLING THE WHEEL OR A NEW TIRE, CHECK
TO MAKE SURE THE FORK ACHIEVES MINIMUM TIRE
CLEARANCE. MEASURE FROM THE HIGHEST POINT ON THE TIRE TO THE BOTTOM
OF THE BRAKE ARCH. THIS MEASUREMENT SHOULD BE AT LEAST 9 MM FOR ALL
BLACK FORKS (SEE FIGURE 1).
IMPORTANT:
The Black fork should not be used if any parts appear to be or
are damaged. Contact your local dealer or Answer Products for
replacement parts.
MAINTENANCE
IMPORTANT:
Use of fork boots is required to keep your Black fork perform-
ing well and the warranty in effect. Use of this fork without boots will shorten
the life of the fork, decrease the time between maintenance intervals, reduce
the performance and void the warranty. The only exception is a fork that is sold
by Answer Products from the factory without boots.
Your Black fork requires periodic maintenance, cleaning and inspection. This is
because moisture and contamination may build up inside the fork depending on
the severity of riding conditions. To maintain top performance, it is recommended
that the fork be periodically disassembled, cleaned, dried and re-lubricated using
the Microlube lubricant ports located on the back of each outer leg. You can
download service and tuning instructions on the web at
www.answerproducts.com.
IMPORTANT:
When lubricating the fork through the ports, it is important to
note the lubricant is being forced between the upper and lower bushings. If the
area is overfilled, the lubricant may force the upper bushing and dust seal out.
You should only insert lubricant to the level at which stiction is no longer felt.
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 adjust-
ment.
CHECKING OIL LEVEL
IMPORTANT:
Setting the proper oil level in your TPC or FFD equipped fork
is critical. TPC or FFD is located in the right leg of your Black fork. Not enough
oil will allow foaming and reduce the performance. Too much oil will restrict
travel and may cause damage to the system and create an unsafe riding condi-
tion. Finish reading this entire section prior to altering the oil level.
To check the oil level, remove the compression assembly located in the top of the
right leg (as you are looking at the fork from the rider's position). Leave the left
side spring stack in place to keep the fork fully extended. Use a tape measure or
"dip stick" to measure from the top of the fork crown down to where the oil sits
(see figure 2). The oil level should be per the following table.
FORK MODEL
OIL LEVEL
BLACK COMP 80/100
106-116 mm (4.2-4.6") in 100 mm travel mode
BLACK ELITE 80/100
117-127 mm (4.6-5.0") in 100 mm travel mode
BLACK ELITE 100/120
117-127 mm (4.6-5.0") in 120 mm travel mode
BLACK ELITE 100/120
(LOCK OUT)
99-104 mm (3.9-4.1") in 120 mm travel mode
BLACK ELITE AIR 80
117-127 mm (4.6-5.0")
BLACK SUPER AIR 100
111-121 mm (4.4-4.8")
BLACK SUPER AIR 100
(LOCK OUT)
91-96 mm
BLACK SUPER AIR 120
117-127 mm (4.6-5.0")
BLACK SUPER AIR 120
(LOCK OUT)
99-104 mm (3.9-4.1")
(3.6-3.8")
NOTE: Use Maxima suspension SAE 5WT fork oil only.
NOTE: Check air fork oil level with air pressure at 120 psi.
When installing the knob on the adjustable compression assembly, rotate the hex
shaft completely counterclockwise prior to installing the knob. Install the knob
with the pointer pointing to the back of the fork.
If you have any questions regarding your 2002 Manitou Black suspension fork,
contact the Answer Warranty Department at (661) 257-4411. You can also log on
to www.answerproducts.com and download this manual or see detailed instruc-
tions on how to service your suspension fork.
Thank you again for choosing a 2002 Manitou Black suspension fork.
DEALER SERVICE ADDENDUM
This section is designed to help a qualified bicycle mechanic tune and main-
tain your Manitou suspension fork.
MEASURING SAG
You'll need a tape measure, a pencil, a piece of paper
and a helper.
1. Measure the distance from the front axle's centerline to the bottom of the
upper crown when no one's sitting on the bike and write this distance
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 riding position
(weight centered) with your feet on the pedals.
3. Subtract the second measurement from the first. The resulting measure-
ment is the static sag.
SAG MEASUREMENT CHART
Fork Travel
80 mm
100 mm
120 mm
TRAVEL MEASUREMENT
To determine which travel your Black 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 (see figure 3).
Fork Travel
80 mm
100 mm
120 mm
RIDE KITS
BLACK COMP/ELITE 80/100
Rider Weight
Recommended Spring Kit
100-150 lbs
Soft ride kit
150-170 lbs
Medium ride kit
170-190 lbs
Firm ride kit
190-215 lbs
Extra firm ride kit
BLACK ELITE 100/120
Rider Weight
Recommended Spring Kit
100-150 lbs
Soft ride kit
150-170 lbs
Medium ride kit
170-190 lbs
Firm ride kit
190-215 lbs
Extra firm ride kit
BLACK ELITE AIR
Rider Weight
Recommended Spring Kit
100-150 lbs
Soft ride kit
150-190 lbs
Medium ride kit
190-215 lbs
Firm ride kit
*Air pressure setting should equal 75% of body weight
BLACK SUPER AIR
Rider Weight
Recommended Spring Kit
100-150 lbs
Soft ride kit
150-190 lbs
Medium ride kit
190-215 lbs
Firm ride kit
* Air pressure setting should equal 75% of body weight in 100 mm travel set-
ting.
* Air pressure setting should equal 50% of body weight in 120 mm travel set-
ting.
* Maximum air pressure is 190 psi.
NOTE: In forks with the Rapid Travel Adjust feature, the preload should
be adjusted when the fork is in the longer travel position (for example,
120 mm for the 100/120 mm fork).
Sag
12-16 mm
18-24 mm
25-28 mm
Seal-to-Crown Measurement
Around 4 inches or 101 mm
Around 4.8 inches or 121 mm
Around 5.6 inches or 141 mm
Part #
85-4843
85-4844
85-4845
85-4846
Part #
85-4859
85-4860
85-4861
85-4862
Part #
85-4851
85-4926
85-4856
Part #
85-4865
85-4833
85-4871
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