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Table of Contents
Related Manuals for Manitou MASTODON 2024
Summary of Contents for Manitou MASTODON 2024
- Page 1 MASTODON SERVICE & TRAVEL ADJUSTMENT GUIDE | MY2024+...
- Page 2 INTRODUCTION This manual is intended to guide the user through the steps necessary to fully service and MANITOU maintain the Mastodon Pro and Comp suspension fork. 5800 W Donges Bay Rd WARNING Mequon, WI 53092 We highly recommend that service to this fork be performed by a certified bicycle mechanic.
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Page 3: Table Of Contents
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) Travel Spacer kit 141-36713-K032 • Plastic or non-marring pick •... -
Page 4: Casting Removal & Service
CASTING REMOVAL & SERVICE CASTING REMOVAL & SERVICE Remove rebound knob using a 2mm Hex wrench. If the fork is new and only a travel change is needed, follow steps Be sure to hold the knob Note: 1-5, then skip to page 9 for air still while removing the screw. -
Page 5: Air Spring Service
CASTING REMOVAL & SERVICE CASTING REMOVAL & SERVICE Using a downhill tire lever or similar Using the Manitou 34/37mm Seal tool, gently pry the dust seals out of Press, press in the dust seals. the casting. Reinstall springs onto seals. - Page 6 Inspect the inside and outside of the stanchion for scratches or other damage. Liberally apply Slickoleum™ grease Invert the fork and use Manitou to the piston seal, outer piston cassette tool with adjustable wrench surface, and spring shaft. Add 3cc’s of to unthread the air spring assembly Slickoleum™...
- Page 7 Install IVA cap into stanchion. Torque stanchion. Using a 26mm crow’s to 200-220 LB-in [22.6-25 Nm] using a 24mm socket. foot and Manitou cassette tool OR 1” Socket and Standard cassette tool torque to 40-45 LB-IN [4.5-5.1 Nm]. If rod is bottomed, attach shock pump to valve and draw the rod out until fully extended.
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Page 8: Mastodon Pro Vtt6 Damper Service
MASTODON PRO VTT6 DAMPER SERVICE MASTODON PRO VTT6 DAMPER SERVICE Using a 2mm Hex wrench remove the Use a standard cassette tool and 1” screw of the VTT6 knob. socket to unthread the damper top- cap from the stanchion. Note: Be sure to hold the knob still while removing the screw. -
Page 9: Mastodon Comp Abs+ Damper Service
MASTODON COMP ABS+ DAMPER SERVICE MASTODON COMP ABS+ DAMPER SERVICE Using a 2mm Hex wrench remove the Remove damper assembly from the screw of the ABS+ knob. Knob can be stanchion. Inspect damper piston seal removed by hand. for any damage. Note: Be sure to hold the knob still while removing the screw. - Page 10 CASTING INSTALL CASTING INSTALL Apply a light coating of semi-bath (85- Insert 15cc of semi-bath (85-0022) 0022) to the inner diameter of the oil into each casting leg. Once the semi- seal/dust wiper. bath is in the legs slide the casting the rest of the way onto the stanchion assembly until the damper and spring shaft adapters pass thru the end of...
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Page 11: Vtt6 & Abs+ Damper Installation
CASTING INSTALL VTT6 AND ABS+ DAMPER INSTALLATION Fill damper leg about 3/4 full with Thread the other lock-nut onto the Maxima 3wt fork oil. spring shaft adapter. Holding the lock- nut with a 14mm Pro, 19mm Comp box wrench, use an 8mm socket tighten the compression rod adapter to 35–40 in-lb [3.95–4.5 Nm] by turning them counter-clockwise... - Page 12 VTT6 AND ABS+ DAMPER INSTALLATION VTT6 AND ABS+ DAMPER INSTALLATION With the VTT6 / ABS+ adjuster in With a 2mm hex, thread on the screw the OPEN/ full counter clockwise and torque to 4-6 in-lb [0.5-0.7 Nm] position, install damper assembly into Note: Be sure to hold the knob still while installing the screw.
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Page 13: Travel Change (Optional)
TRAVEL CHANGE TRAVEL CHANGE In order to change the travel of your Mastodon, first remove the DECREASING TRAVEL compression rod assembly. For travel change on new forks, bath oil may be preserved by removing stanchion assembly while fork is placed flat on Decrease Travel: Each spacer added decreases travel &... - Page 14 MASTODON PRO IVA SETTING MASTODON PRO TRAVEL SPACERS TRAVEL IVA POSITION DEPICTION # OF SPACERS TRAVEL DEPICTION MASTODON SERVICE GUIDE MASTODON SERVICE GUIDE...
- Page 15 MASTODON COMP TRAVEL SPACERS MASTODON COMP IVA SETTING # OF SPACERS TRAVEL DEPICTION TRAVEL IVA POSITION DEPICTION MASTODON SERVICE GUIDE MASTODON SERVICE GUIDE...
- Page 16 MASTODON PRO EXPLODED VIEW & PARTS MASTODON PRO EXPLODED VIEW & PARTS ITEM # PART DESCRIPTION KIT NUMBER UPPER LEG ASSEMBLY, MY24 MASTODON PRO M31x0.8 141-40492-K001 BLK 80-160, POLISH CLEAR LOWER LEG ASSEMBLY, MY24 MASTODON PRO M31x0.8 141-40492-K003 BLK 80-160, GLOSS BLACK IVA (AIR VOLUME COMPENSATOR), MID, M3IX0.8 141-32668-K012 AIR SPRING ASSEMBLY, DORADO AIR, M32XI...
- Page 17 MASTODON COMP EXPLODED VIEW & PARTS MASTODON COMP EXPLODED VIEW & PARTS ITEM # PART DESCRIPTION KIT NUMBER UPPER LEG ASSEMBLY, MY24 MASTODON COMP M31x0.8 141-40492-K002 BLK 80-140, MATTE BLACK LOWER LEG ASSEMBLY, MY24 MASTODON COMP M31x0.8 141-40492-K004 BLK 80-140, MATTE BLACK IVA (AIR VOLUME COMPENSATOR), MID, M3IX0.8 141-32668-K013 AIR SPRING ASSEMBLY, EXPERT AIR, M31.5X0.8...
- Page 18 GLOBAL HEADQUARTERS & HAYES BICYCLE 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 Mincyuan E. Rd. Zhongshan District facebook.com/ManitouMTB instagram.com/ManitouMTB #ScienceofSmooth HAYESBICYCLE.COM...
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