Manitou Mezzer Pro Service Manual

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service guide

2020

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Summary of Contents for Manitou Mezzer Pro

Page 1 service guide 2020...
Page 2 MANITOU 5800 W Donges Bay Rd Mequon, WI 53092 manitoumtb.com 888.686.3472 Support: manitoumtb.com/support Warranty: For full warranty information please visit hayesbicycle.com/warranty MEZZER SERVICE MANUAL Revised...
Page 3 INTRODUCTION This manual is intended to guide the user through the steps necessary to fully service and maintain the Mezzer Pro and Mezzer Expert suspension fork. WARNING We highly recommend that service to this fork be performed by a certified bicycle mechanic.
Page 4 TABLE OF CONTENTS SECTION PAGE NUMBER Required Tools Casting Removal & Service Air Spring Service 9-13 Pro Damper Service 14-18 Pro Casting Install 19-21 Pro Compression Knob Installation Expert Damper Service 23-24 Expert Casting Install 25-27 Expert Damper Install 28-29 Travel Change (Optional) 30-33 Mezzer Expert IVA settings...
Page 5 • 1” socket • 8mm Socket * • 24mm Socket * • (Optional, replaces items above with*) Manitou Tool Kit - Manitou part number 172-31133 (This includes the Manitou Cassette Tool, 8mm thin wall socket, and flat ground 24mm socket) •...
Page 6 CASTING REMOVAL & SERVICE Manitou recommends a full service anytime the casting is removed. If the fork is new and only a travel change is needed, follow instructions 1-4 then skip to Page 31 for Travel change instructions. Return to page 19 for casting install.
Page 7 CASTING REMOVAL & SERVICE Hold lock-nut with 14mm box end wrench. Using 8mm Socket, turn the compression rod clockwise until compression rod is disengaged from the lock-nut. Remove casting from fork. It is recommended this be done over a drain pan as the lower casting contains semi-bath oil.
Page 8 Remove springs from outer lip of new leg seals. Clean casting seal press area with Isopropyl alcohol. Using the Manitou 37mm Seal Press press in the dust seals. Reinstall springs onto seals. MEZZER SERVICE MANUAL...
Page 9 AIR SPRING SERVICE Mezzer Pro: Remove IRT air cap. Make sure the air is released from the fork. Depress IRT Schrader Valve with a 2mm hex a few times to ensure all air is released. Mezzer Expert: Skip to Step 2.
Page 10 AIR SPRING SERVICE Invert the fork and use Manitou cassette tool with adjustable wrench to unthread the air spring assembly from the stanchion.OR depress valve on end of comp-rod with 2mm hex and stroke rod to bottom. Slide standard cassette...
Page 11 Install air spring assembly into stanchion. Using a 26mm crow’s foot and Manitou cassette tool OR 1” Socket and Standard cassette tool torque to 20-25 in-lb [2.3- 2.8 Nm]. If rod is bottomed attach shock pump to valve and draw the rod out until fully extended.
Page 12 Slickoleum™ grease to the IVA piston seal and outer piston surface. Apply Slickoleum™ grease to the threads of the stanchion. Mezzer Pro: Insert IRT piston into stanchion. Apply even pressure to piston surface as you work the piston seal past the stanchion threads.
Page 13 AIR SPRING SERVICE Mezzer Pro: Attach a shock pump and inflate IRT to 100PSI. NOTE: ALWAYS SET IRT PRESSURE (TOP OF FORK) BEFORE DORADO AIR PRESSURE (BOTTOM OF FORK) Mezzer Expert: Skip to step 14. Attach a shock pump and inflate main air chamber to 60PSI.
Page 14 Pro DAMPER SERVICE Using a 2mm Hex wrench remove the screw of the red “LO-SPEED” MC2 knob. Note: Be sure to hold the knob still while removing the screw. The damper adjuster may be damaged if the knob is over torqued. EXPERT SKIP TO PAGE 23 Use a non-marring pick or pliers with non-marring barrier to remove...
Page 15 pro DAMPER SERVICE Remove the v-seal that was under the black “HI-SPEED” adjustment knob. Use a standard cassette tool and 1” socket to unthread the damper top- cap from the stanchion. Remove damper assembly from the stanchion. Inspect damper shaft and bladder for any damage.
Page 16 pro DAMPER SERVICE Pull damper shaft to full extension. Remove bleed-screw on side of top-cap. Place damper top-cap over catch pan. Cycle damper shaft several times to cycle out old oil from damper. Attach M5x0.8 Luer lock fitting to both syringes (141-30695-K020). Fill one syringe with 5wt Damper oil (85-0023).
Page 17 pro DAMPER SERVICE Holding the damper end-cap up-right in vise simultaneously compress the filled syringe and retract the empty syringe to remove air from the damper. Refill the syring as needed until oil is drawn into the upper syringe. Closing the bleed hose clamp on both syringes cycle the damper SLOWLY to draw air to the top of the damper.
Page 18 pro damper service Install Damper cartridge into stanchion. Using standard cassette lock-ring tool Torque to 220-220 in- lb [20-25 Nm] . MEZZER SERVICE MANUAL...
Page 19 pro CASTING INSTALL Apply a light coating of semi-bath (85-0022) to the inner diameter of the oil seal/dust wiper. Make sure the spring shaft is fully extended and air chamber is filled with air (60PSI). Fully extend the damper shaft. MEZZER SERVICE MANUAL...
Page 20 pro CASTING INSTALL Slide casting onto the stanchion assembly. Only slide the casting down about halfway at this point. Take care that the seal lips do not fold over upon installation. Insert 21cc of semi-bath (85-0022) into each casting leg. Once the semi-bath is in the legs slide the casting the rest of the way onto the stanchion assembly until the...
Page 21 pro CASTING INSTALL Install the rebound knob using a 2mm Hex wrench. Add a small drop of blue Loctite to the screw before installation to prevent the screw from backing out during riding. Note: Be sure to hold the knob still while removing the screw.
Page 22 Clean fork and use a shock pump to set to desired pressure. Lightly pull the casing away from the CSA as you add air. See Mezzer Pro set-up sheet for recommended air pressures. MEZZER SERVICE MANUAL...
Page 23 Expert DAMPER SERVICE Using a 2mm Hex wrench remove the screw of the black VTT knob. Note: Be sure to hold the knob still while removing the screw. The damper adjuster may be damaged if the knob is over torqued. Use a non-marring pick or pliers with non-marring barrier to remove the black VTT knob by lifting...
Page 24 Expert DAMPER SERVICE Use a standard cassette tool and 1” socket to unthread the damper top- cap from the stanchion. Remove damper assembly from the stanchion. Inspect damper piston seal for any damage. Tip out used damper oil from top of stanchion into drain pan.
Page 25 Expert CASTING INSTALL Apply a light coating of semi-bath (85-0022) to the inner diameter of the oil seal/dust wiper. Make sure the spring shaft is fully extended and air chamber is filled with air (60PSI). Fully extend the damper shaft. MEZZER SERVICE MANUAL...
Page 26 Expert CASTING INSTALL Slide casting onto the stanchion assembly. Only slide the casting down about halfway at this point. Take care that the seal lips do not fold over upon installation. Insert 21cc of semi-bath (85-0022) into each casting leg. Once the semi-bath is in the legs slide the casting the rest of the way onto the stanchion assembly until the...
Page 27 Expert CASTING INSTALL Install the rebound knob using a 2mm Hex wrench. Add a small drop of blue Loctite to the screw before installation to prevent the screw from backing out during riding. Note: Be sure to hold the knob still while removing the screw.
Page 28 Expert DAMPER Install Fill damper leg about 3/4 full with Maxima fork oil. Install the axle into the fork without a hub or wheel. Cover the damper leg opening with a lint-free towel. Using a wood block or similar raised support underneath the axle, compress the fork 10-15 times.
Page 29 Expert DAmper Install With the Vtt adjuster in the OPEN/ full counter clockwise position, install damper assembly into stanchion. Using a standard cassette lock-ring tool Torque to 200-220 inlb [20-25 Nm] Clean the adjuster knobs with isopropyl and replace v-seal into damper top cap.
Page 30 Travel Change Guide MEZZER SERVICE MANUAL...
Page 31 In order to change the travel of your Mezzer Pro or Expert (27.5 & 29), first remove the compression rod assembly. For instructions on how to do this refer to page 9-13. For travel change on new forks, bath oil may be preserved by removing stanchion assembly while fork is placed flat on benchtop.
Page 32 Mezzer Pro and Expert Travel Adustment Decrease Travel: Each spacer pair (Two Halfs) added decreases travel & Axel-To-Crown by 10mm MEZZER SERVICE MANUAL...
Page 33 Mezzer Pro, Dorado Air and Mezzer Expert, Expert Air 180MM 170MM 160MM 150MM 140MM MEZZER SERVICE MANUAL...
Page 34 mezzer Expert IVA settings Standard IVA configurations for each travel The air volume is modified by removing the clip-on spacers from the IVA shaft moving the piston into the desired location and reassembling the clip-on spacers to secure the piston on the IVA shaft. Increasing the air volume (moving piston towards the top cap) creates a more linear spring curve with reduced mid-stroke support and end-stroke ramp-up.
Page 35 Mezzer Expert 27.5" exploded view MEZZER SERVICE MANUAL...
Page 36 9 DAMPER ASSY, REBOUND MEZZER EXPERT (WITH KNOBS) 141-36713-K030 10 DAMPER ASSY, VTT MEZZER EXPERT (WITH KNOBS) 141-36713-K029 11 SEAL PISTON KIT, DORADO AIR MEZZER PRO/EXPERT 141-36713-K027 12 KNOB KIT, MEZZER EXPERT RB VTT 141-36713-K033 13 TRAVEL ADJUST SPACER KIT...
Page 37 Meezer expert 29" exploded view MEZZER SERVICE MANUAL...
Page 38 9 DAMPER ASSY, REBOUND MEZZER EXPERT (WITH KNOBS) 141-36713-K030 10 DAMPER ASSY, VTT MEZZER EXPERT (WITH KNOBS) 141-36713-K029 11 SEAL PISTON KIT, DORADO AIR MEZZER PRO/EXPERT 141-36713-K027 12 KNOB KIT, MEZZER EXPERT RB VTT 141-36713-K033 13 TRAVEL ADJUST SPACER KIT...
Page 39 Mezzer PRO 27.5" exploded view MEZZER SERVICE MANUAL...
Page 40 7 HEXLOCK SL2 AXLE HARDWARE 141-33147-K003 8 SEAL KIT 37MM 141-36713-K025 9 DAMPER ASSY, MC2 MEZZER PRE-BLED (WITH KNOBS) 141-36713-K022 10 SEAL PISTON KIT, DORADO AIR MEZZER PRO/EXPERT 141-36713-K027 11 KNOB KIT, MEZZER PRO IRT RB MC2/VTT 141-36713-K024 12 TRAVEL ADJUST SPACER KIT 141-36713-K032...
Page 41 Mezzer PRO 29" exploded view MEZZER SERVICE MANUAL...
Page 42 7 HEXLOCK SL2 AXLE HARDWARE 141-33147-K003 8 SEAL KIT 37MM 141-36713-K025 9 DAMPER ASSY, MC2 MEZZER PRE-BLED (WITH KNOBS) 141-36713-K022 10 SEAL PISTON KIT, DORADO AIR MEZZER PRO/EXPERT 141-36713-K027 11 KNOB KIT, MEZZER PRO IRT RB MC2/VTT 141-36713-K024 12 TRAVEL ADJUST SPACER KIT 141-36713-K032...
Page 43 WWW. MANITOUMTB.COM WWW.HAYESCOMPONENTS.COM 5800 W DONGES BAY ROAD MEQUON WI 53092 46-38529 REV. A...

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