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MAINTENANCE
IMPORTANT:
Use of fork boots is required to keep your Manitou SIX fork
performing 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:
When lubricating the fork with grease through the grease
ports, it is important to note that grease is being forced between the upper
and lower bushings. If the area is overfilled, the grease may force the upper
bushing and dust seal out. You should only insert grease to the level at
which stiction (stickiness when you compress the fork) 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
adjustment.
SIX 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, 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 dis-
tance 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
Fork Travel
80 mm
100 mm
TRAVEL MEASUREMENT
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.
Fork Travel
80 mm
100 mm
RECOMMENDED SPRINGS
SIX
Rider Weight
100-150 lbs.
Standard Set-up
150-170 lbs.
170 plus lbs.
CHANGING SPRINGS AND/OR MCU'S
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.
1. Start by removing the preload adjuster by unscrewing the 2 mm hex
bolt on the adjuster knob (Figure 2). A 20 mm socket will be neces-
sary with the SIX. Remember: The springs are housed only in the left
leg on 2003 Manitou suspension forks. (Figure 3)
2. With the adjuster assembly removed, the spring stack is now
accessible.
Sag
12-16 mm
18-24 mm
To determine which travel your SIX fork
Seal to Crown Measurement
Around 4.3 inches or 109 mm
Around 5.2 inches or 130 mm
Recommended Spring Kit
Soft ride kit (Part #85-4826)
Medium ride kit (Part #85-4827)
Firm ride kit (Part #85-4828)
Once you have checked
If you have any questions regarding your 2003 Manitou SIX 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 SIX suspension fork.
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 (Figure 4). We recommend any thick grease (not light greases
like Prep M). Install the new spring stack.
5. Reinstall the preload adjuster knob and adjuster assembly, taking
care not to cross-thread the adjuster assembly. It should be snug
tightened with a wrench. (Figure 5)
CONVERTIBLE TRAVEL
1. Changing the travel from 80 to 100 millimeters or vice-versa requires
the removal of the lower legs.
2. Unthread (clockwise to loosen) the 8 mm and 4 mm bolts on the bot-
tom of the fork and pull the lowers free from the uppers. Unscrew the
cap on the bottom of the right leg (as seen from the rider's position).
This will expose the clip that is used to adjust the travel. (Figure 6)
3. Remove the clip and insert it into the upper position (above the rod
flange) for 100 millimeters of travel or the lower position (below the
rod flange) for 80 millimeters of travel. (Figure 7)
4. Reassemble fork.
MAINTENANCE AND SERVICE – INTRODUCTION
icing the fork, take the time to inspect all parts for excessive wear or
damage. There are basically three aspects of a fork that will require
attention: the stanchions (inner legs), the bushings in the outer legs
and the spring stack. Inspecting any of these parts requires disassem-
bly of the fork. Pay close attention to the bushings, which can be dam-
aged by contamination in severe conditions. Replace any worn or dam-
aged parts that are discovered.
FORK DISASSEMBLY
to provide the proper service of your fork. To do this:
1. Remove the bolts from the bottom of the fork leg with 4 and 8 mm
wrenches and set aside. (Figure 8)
2. You can now pull apart the fork, removing the casting from
crown/steerer assembly. (Figure 9)
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 10)
MICROLUBE
All you need is a Microlube lubricant gun
(part #85-3812) and Manitou's Prep M suspension fork lubricant (part
#85-3810). Brush any dirt from the grease ports and inset the grease
gun into the small fitting located at the back of the fork and squeeze a
few times. Continue injecting grease and push the fork up and down
until stiction is eliminated.
Disassembly of your SIX fork is necessary
When serv-
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