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Summary of Contents for Manitou Mattoc
- Page 2 Section 4 - Fork Assembly 12-17 Hayes Components USA 5800 W. Donges Bay Rd. Mequon, WI 53092 Tel: 888.686.3472 Email: techsupport@hayesbicycle.com Web: www.hayescomponents.com Hayes Components Europe Dirnismaning 20 a 85748 Garching (b. Munich) Germany Email: techsupportEU@hayesbicycle.com Web: www.hayescomponents.com MATTOC TRAVEL ADJUST MANUAL...
- Page 3 This manual is intended to guide the user through the steps necessary to internally adjust the travel of the Mattoc Pro and Expert forks. NOTE: This manual does not cover the steps need to convert the fork from one wheel size to another. Please see the Mattoc Service Guide for instructions on how to perform this.
- Page 4 REQUIRED TOOLS Below is a list of tools necessary for changing the travel of the Mattoc fork. Safety Glasses Nitrile Gloves Lint-Free Rags Torque Wrench Slickoleum™ Grease Semi-bath Oil, 5/40w Synthetic Oil - Manitou part number 85-0023 Mattoc Service Tool Kit - Manitou part number 172-31133...
- Page 5 SECTION 1 - FORK DISASSEMBLY 1. Remove air valve cap. 2. Using a 2mm Allen wrench, remove the rebound damper knob. MATTOC TRAVEL ADJUST MANUAL...
- Page 6 3. Insert an 8mm Allen wrench into the end of the rebound damper rod. Turn wrench clockwise until damper rod can be pushed into fork casting. MATTOC TRAVEL ADJUST MANUAL...
- Page 7 4. Using the Mattoc 8mm Thin Wall Socket, turn the compression rod clockwise until compression rod is disengaged from the casting threads. 5. Remove casting from the fork. It is recommended that this be done over a drain pan as there is semi-bath oil in the lower legs that will be released when casting is removed.
- Page 8 3mm Allen wrench to depress the valve core while pushing compression rod into stanchion. 8. Place Mattoc Cassette Tool into the compression rod assembly end cap. 9. Using an adjustable wrench or similar tool, turn the cassette tool counter clockwise to remove compression rod assembly from fork stanchion.
- Page 9 10. Remove compression rod assembly from fork. 11. Using the Mattoc 24mm Flat Ground Socket slowly remove the air cap from the fork. NOTE: A standard socket can be used as well however the rounded edges of a standard socket can cause the socket to jump off of the air cap while turning causing cosmetic damage to the fork.
- Page 10 SECTION 2 - TRAVEL ADJUST, 26” FORKS The below photos show the different travels achievable on the Mattoc 26” forks by adding and removing the travel spacers on the compression rod assembly. Travel spacers are boxed in yellow below for reference. When setting the fork at 170mm you will remove all travel spacers from the compression rod.
- Page 11 SECTION 3 - TRAVEL ADJUST, 27.5” FORKS The below photos show the different travels achievable on the Mattoc 27.5” forks by adding and removing the travel spacers on the compression rod assembly. Travel spacers are boxed in yellow below for reference. When setting the fork at 160mm you will remove all travel spacers from the compression rod.
- Page 12 2. Slide compression rod end cap to the very bottom of the rod assembly until the bottom out bumper contacts end cap. Insert assembly into fork stanchion. Thread the end cap in a few turns by hand. MATTOC TRAVEL ADJUST MANUAL...
- Page 13 4. Using the Mattoc Cassette Tool and a torque wrench (a socket will fit over the Cassette Tool, shown in picture) tighten the compression rod end cap down to: 60-80 in lbs. [6.8-9.0 Nm] 5. Rotate fork to riding position and add a liberal amount of Slickoleum™...
- Page 14 3mm Allen wrench to depress valve core and extend compression rod. 8. Using a shock pump pressurize the air chamber. Put in 20-50 PSI. NOTE: This is to only help hold the compression rod in place for casting installation. MATTOC TRAVEL ADJUST MANUAL...
- Page 15 10. Apply Slickoleum™ grease to the dust seals.Slide casting onto fork uppers. Be careful not to fold over the lips of the dust seals and inner oil seals during installation. Only slide them on about halfway at this point. MATTOC TRAVEL ADJUST MANUAL...
- Page 16 Tighten to 30- 40 in lbs. [3.5-4.5 Nm]. 13. Using the Mattoc 8mm Thin Wall socket and torque wrench, tighten the compression rod into the casting by turning it counter-clockwise. Tighten to 30-40 in lbs.
- Page 17 14. Install rebound damper adjust knob and using a 2mm Allen wrench tighten to 4-6 in lbs. [0.5-0.7 Nm]. 15. Using a shock pump and the Mattoc set-up guide (available online at www. manitoumtb.com), pressurize fork to your optimum PSI and install air cap.
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