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Summary of Contents for Manitou DORADO EXPERT 37MM
- Page 1 DORADO EXPERT 37MM SERVICE GUIDE...
- Page 2 INTRODUCTION This manual is intended to guide the user through basic service of Manitou Dorado Expert 37mm front forks. We highly suggest the service on these forks MANITOU be performed by an experienced suspension mechanic. Service is supported by the identification of common parts and assemblies that have been assembled into 5800 W Donges Bay Rd Service Kits.
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Page 3: Table Of Contents
Tools And Materials 200 hour complete service) Damping Leg Service Disassembly • Dorado 37mm Seal Kit - Manitou Part Number 141-38380-K019 (Needed for 50 hour basic service) Damping Leg Service Assembly • Dorado Clamp Blocks – Manitou Part Number 172-31464 Spring Leg Service Disassembly •... -
Page 4: Damping Leg Service Disassembly
Tip: The ends of the Dorado sag guide can be used to spread the clamps apart and aid in leg removal. DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE... - Page 5 Slide the inner leg out of 26mm socket. the outer leg and leave the outer leg to drain in a drainage pan. DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE...
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Page 6: Damping Leg Service Assembly
To hold the detent balls in place on the spring use a small dab of grease. TIP: You can also refer to the O-ring diagram on pages 28-29. DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE... - Page 7 TPC+ knob and apply a notch Bottom Bracket Tool and a small amount of grease to it. 12mm wrench to tighten to the proper torque of 6.8-9.0 N m (60-80 in lb). DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE...
- Page 8 After you have properly set the oil height fully extend the inner leg and tighten down the top cap using a 16 notch Bottom Bracket Tool to the proper torque of 6.8-9.0 N m (60-80 in lb). DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE...
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Page 9: Spring Leg Service Disassembly
TIP: The ends of the Dorado sag guide can be used to spread the clamps apart and aid in leg removal. DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE... -
Page 10: Spring Leg Service Assembly
Lube the threads on inside of the inner leg, lube the outer diameter of the air piston, and fill the piston cup with 3cc of Slickoleum grease and 1cc Manitou 5w/40 Bath Oil. Insert the compression rod, piston first, into the top of the inner leg using rotational motion. - Page 11 Bottom Bracket Tool and a 13mm wrench to tighten to the proper torque of 3.4-4.5 N m (30-40 in lb). Inject 35cc of Manitou Semi Bath oil (5/40wt. Synthetic oil, P/N: 85-0023) into the outer leg on top of the inner leg.
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Page 12: Dust & Oil Seal Replacement
Remove the foam ring. Clean seal bore and bushing thouroughly. Soak new foam in Manitou bath oil. Place foam ring in the bottom of the seal bore. DORADO EXPERT 37MM SERVICE GUIDE... -
Page 13: Travel Change
Rethread the top-out screw and bolt over the retaining ring, torque to 3,4 N-M [30 IN-LB]. NOTE: Consult pages 16-21 for air leg assembly and reassembly. DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE... - Page 14 Service Kit LISt (refernce exploded view) TORque table (reference exploded view) DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE...
- Page 15 O-ring Diagram O-ring chart (Use Diagram for reference) DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE...
- Page 16 GLOBAL HEADQUARTERS & HAYES BICYCLE GROUP USA 5800 W. Donges Bay Rd. Mequon, WI 53092 HAYES BICYCLE GROUP EU Dirnismaning 20 a 85748 Garching (b. Munich) Germany HAYES BICYCLE GROUP ASIA 16F, No. 37, Sec. 3 16F, No. 37, Sec. 3 Mincyuan E.
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