Manitou MATTTOC PRO Service Manual
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Manitou MATTTOC PRO Service Manual

Manitou MATTTOC PRO Service Manual

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MATTTOC PRO, EXPERT, & COMP
JUNIT 34 PRO & EXPERT
CIRCUS 34 PRO
MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

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Summary of Contents for Manitou MATTTOC PRO

  • Page 1 MATTTOC PRO, EXPERT, & COMP JUNIT 34 PRO & EXPERT CIRCUS 34 PRO MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE...
  • Page 2 INTRODUCTION This manual is intended to guide the user through the steps necessary to fully service and maintain MANITOU the Mattoc Pro, Expert, and Comp, along with Junit 34 Pro and Expert & Circus Pro suspension fork. WARNING 5800 W Donges Bay Rd Mequon, WI 53092 mechanic.

  • Page 3: Table Of Contents

    ABS+ Damper Service • 8mm Socket * Mattoc, JUnit, & Circus Casting Installation • 24mm Socket * • (Optional, replaces items above with*) Manitou Tool Kit - Manitou part number VTT6 & ABS+ Damper Installation Travel Change (Optional) ground 24mm socket) •...

  • Page 4: Casting Removal & Service

    CASTING REMOVAL & SERVICE CASTING REMOVAL & SERVICE Manitou recommends a full service anytime the Hold lock-nut with a 14mm (Pro/ casting is removed. If the fork is new and only Expert) or 19mm (Comp) box end a travel change is needed, follow instructions wrench.

  • Page 5: Air Spring Service

    Isopropyl alcohol. Using a standard cassette tool and 1” socket loosen IRT cap until threads are free from leg. Using the Manitou 34/37mm Seal Mattoc Expert / Comp, JUnit 34 Press, press in the dust seals. Expert, Circus Pro: Reinstall springs onto seals.
  • Page 6 Inspect the inside piston seals. and outside of the stanchion for scratches or other damage. Invert the fork and use Manitou Liberally apply Slickoleum™ grease cassette tool with adjustable to the piston seal, outer piston wrench to unthread the air spring surface, and spring shaft.
  • Page 7 Install air spring assembly into Mattoc / JUNIT Pro: stanchion. Using a 26mm crow’s foot and Manitou cassette tool OR Insert IRT piston into stanchion. 1” Socket and Standard cassette Apply even pressure to piston tool torque to 40-45 LB-IN [4.5- surface as you work the piston seal 5.1 Nm].
  • Page 8 AIR SPRING SERVICE AIR SPRING SERVICE Mattoc / JUNIT Pro: Mattoc / JUNIT Pro: Install IRT cap into stanchion. Torque to 200-220 LB-in [22.6-25 IRT to 100PSI. Nm] using standard cassette lock- ring tool. NOTE: ALWAYS SET IRT PRESSURE (TOP OF FORK) BEFORE DORADO AIR PRESSURE (BOTTOM OF FORK) Mattoc Expert / Comp, JUnit 34 Expert, Circus Pro:...

  • Page 9: Mc2 Sealed Damper Service

    MC2 Sealed DAMPER SERVICE MC2 Sealed DAMPER SERVICE Using a 2mm Hex wrench remove Remove the v-seal that was under the screw of the red “LO-SPEED” the black “HI-SPEED” adjustment MC2 knob. knob. Note: Be sure to hold the knob still while removing the screw.
  • Page 10 MC2 Sealed DAMPER SERVICE MC2 Sealed DAMPER SERVICE Closing the bleed hose clamp on both syringes (141-30695-K020). both syringes cycle the damper Fill one syringe with 3wt Damper oil SLOWLY to draw air to the top (141-34078-K016). of the damper. Open bleed hose clamps and repeat step 10 until no air bubbles are present in oil drawn into upper syringe.

  • Page 11: Mattoc Pro Casting Installation

    mattoc pro CASTING INSTALLation mattoc pro CASTING INSTALLation Apply a light coating of semi-bath Slide casting onto the stanchion (85-0022) to the inner diameter of assembly. Only slide the casting the oil seal/dust wiper. down about halfway at this point. Take care that the seal lips do not fold over upon installation.

  • Page 12: Mattoc Pro Compression Knob Installation

    mattoc pro CASTING INSTALLation mattoc pro Compression Knob Installation Install the rebound knob using a Clean the adjuster knobs with 2mm Hex wrench. Add a small drop isopropyl and replace v-seal into of blue Loctite to the screw before top-cap counter-bore. installation to prevent the screw from backing out during riding.

  • Page 13: Vtt6 Damper Service

    VTT6 DAMPER SERVICE VTT6 DAMPER SERVICE Using a 2mm Hex wrench remove Use a standard cassette tool and 1” the screw of the VTT6knob. socket to unthread the damper top- cap from the stanchion. Note: Be sure to hold the knob still while removing the screw.

  • Page 14: Abs+ Damper Service

    ABS+ DAMPER SERVICE ABS+ DAMPER SERVICE Using a 2mm Hex wrench remove Use 24mm socket to unthread the the screw of the ABS+ knob. damper top cap from the stanchion. Note: Be sure to hold the knob still while removing the screw. The damper adjuster may be damaged if the knob is over torqued.
  • Page 15 Mattoc exp/comp, JUnit, & Circus casting INSTALL Mattoc exp/comp, JUnit, & Circus casting INSTALL Apply a light coating of semi-bath Slide casting onto the stanchion (85-0022) to the inner diameter of assembly. Only slide the casting the oil seal/dust wiper. down about halfway at this point.

  • Page 16: Vtt6 & Abs+ Damper Installation

    Mattoc exp/comp, JUnit, & Circus casting INSTALL VTT6 and ABS+ DAMPER Installation Install the rebound knob using a Fill damper leg about 3/4 full with 2mm Hex wrench. Add a small drop Maxima fork oil (85-0023). of blue Loctite to the screw before installation to prevent the screw from backing out during riding.
  • Page 17 VTT6 and ABS+ DAMPER Installation VTT6 and ABS+ DAMPER Installation With a 2mm hex, thread on the With the VTT6 / ABS+ adjuster in the OPEN/ full counter clockwise screw and torque to 4-6 in-lb [0.5- position, install damper assembly 0.7 Nm] Note: Be sure to hold into stanchion.

  • Page 18: Travel Change (Optional)

    travel change travel change decreasing travel remove the compression rod assembly. For travel change on new forks, bath oil may be preserved by removing stanchion assembly while fork is Decrease Travel: Each spacer added decreases travel & Axel-To-Crown by 10mm. Note: Mattoc Pro / Expert and Circus Pro use a two piece spacer.
  • Page 19 Mattoc Pro / Expert TRAVEL SPACERs Mattoc Expert IVA SETTING # OF SPACERS TRAVEL DEPICTION TRAVEL IVA POSITION DEPICTION MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE...
  • Page 20 Mattoc comp TRAVEL SPACERs Mattoc comp IVA SETTING # OF SPACERS TRAVEL DEPICTION TRAVEL IVA POSITION DEPICTION MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE...
  • Page 21 junit 34 TRAVEL SPACERs junit 34 pro / expert IVA SETTING # OF SPACERS TRAVEL DEPICTION TRAVEL IVA POSITION DEPICTION MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE...
  • Page 22 circus pro TRAVEL SPACERs circus pro IVA SETTING # OF SPACERS TRAVEL DEPICTION TRAVEL IVA POSITION DEPICTION MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE...
  • Page 23 MATTOC PRO exploded view & PARTS MATTOC PRO exploded view & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 440S, M31XO 8, MY14 PRO POLISH-CLEAR 141-39022-K038 CROWN-STEER ASSY, 370S, M31XO 8, MY24 PRO POLISH-CLEAR 141-39022-K039 CASTING, 29” MY24 MATTOC GLOSS BLACK 141-39011-K007 CASTING, 27 5”...
  • Page 24 MATTOC EXPERT exploded view & PARTS MATTOC EXPERT exploded view & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 44OS, M31X0.8, MY24 MATTOC GLOSS BLK 141-39022-K003 CROWN-STEER ASSY, 37OS, M31X0.8, MY24 MATTOC GLOSS BLK 141-39022-K004 CASTING, 29’’ MY24 MATTOC GLOSS BLACK 141-39022-K007 CASTING, 27.5’’...
  • Page 25 MATTOC COMP exploded view & PARTS MATTOC COMP exploded view & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 44OS, M31X0.8, MY24 MATTOC MATTE BLK 141-39022-K005 CROWN-STEER ASSY, 37OS, M31X0.8, MY24 MATTOC MATTE BLK 141-39022-K006 CASTING, 29” MY24 MATTOC GLOSS BLACK 141-39022-K007 CASTING, 27.5”...
  • Page 26 JUNIT 34 PRO exploded view & PARTS JUNIT 34 PRO exploded view & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 34MM, 41OS, M31X0.8, MY24 PL-CLR 141-39022-K038 CASTING, 34MM, 26” MY24 JUNIT/CIRCUS PRO GLOSS BLACK 141-39022-K024 CASTING, 34MM, 24” MY24 JUNIT GLOSS BLACK 141-39022-K030 AXLE, HEXLOCK SL2, 110 ALUMINUM (WITH HARDWARE) 141-33147-K005...
  • Page 27 JUNIT 34 EXPERT exploded view & PARTS JUNIT 34 EXPERT exploded view & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 41OS, M31X0.8, MY24 MATTOC GLOSS BLK 141-39022-K003 CASTING, 26” MY24 MATTOC GLOSS BLACK 141-39022-K024 CASTING, 24” MY24 MATTOC GLOSS BLACK 141-39022-K030 AXLE, HEXLOCK SL1, 110 ALUMINUM (WITH HARDWARE) 141-33147-K002...
  • Page 28 CIRCUS 34 PRO exploded view & PARTS CIRCUS 34 PRO exploded view & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 41OS, M31X0.8, MY24 MATTOC PL-CLR 141-39022-K038 CASTING, 26” MY24 MATTOC GLOSS BLACK 141-39022-K024 AXLE, HEXLOCK SL2, 110 ALUMINUM (WITH HARDWARE) 141-33147-K005 AXLE HARDWARE, HEXLOCK SL2/SLC 141-33147-K006...
  • Page 29 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.

This manual is also suitable for:

Matttoc expertMatttoc compJunit 34 proJunit 34 expertCircus 34 pro

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