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Manitou R8 PRO Service Manual
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Manitou R8 PRO Service Manual

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R8 PRO
SERVICE GUIDE

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Summary of Contents for Manitou R8 PRO

  • Page 1 R8 PRO SERVICE GUIDE...

  • Page 2: Warranty

    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...
  • Page 3 INTRODUCTION This manual is intended to guide the user through the steps necessary to fully service and maintain the R8 Pro suspension fork. WARNING We highly recommend that service to this fork be performed by a certified bicycle mechanic. Failure to follow instructions presented in this manual could lead to serious injury or death.

  • Page 4: Table Of Contents

    VTT PRO - X Manual Knob Removal VTT PRO - X REMOTE KNOB REMOVAL R8 Sealed Damper Service R8 PRO Casting Installation R8 PRO Manual Knob Installation R8 PRO Remote Knob Installation Travel Change (Optional) Travel Spacers & IVA Settings...

  • Page 5: Required Tools

    24mm Socket * • 24mm Box End Wrench • (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 Below is a list of additional tools necessary for a full service of the R8 Pro forks: •...

  • Page 6: Casting Removal & Service

    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 27 for Travel change instructions. Remove rebound knob using a 2mm Hex wrench.
  • Page 7 Using a downhill tire lever or similar tool, gently pry the dust seals out of the casting. NOTE: Do not damage the top of the casting when removing the wiper seal. Use rag or similar to protect from contact with tool. R8 PRO SERVICE GUIDE...
  • Page 8 Remove springs from outer lip of new leg seals. Using the Manitou 34/37mm Seal Press, press in the dust seals. Reinstall springs onto seals. R8 PRO SERVICE GUIDE...

  • Page 9: Air Spring Service

    Using a 24mm socket, loosen IVA or Top Cap until threads are free from leg. Pull IVA assembly or Pull IVA assembly or top cap straight out, Clean with isopropyl, Inspect seal for damage. If needed replace IVA piston seals. R8 PRO SERVICE GUIDE...
  • Page 10 Remove Air Spring Assembly, clean with isopropyl, Inspect seal for damage. Replace air piston seal 141-32155-K012. If Travel change is need see page 27 before moving on. R8 PRO SERVICE GUIDE...
  • Page 11 Add 3cc’s of Slickoleum™ grease to the top of the air piston. Add Slickoleum™ grease to the stanchion threads before inserting the air spring assembly. Spread grease across entire thread surface. R8 PRO SERVICE GUIDE...
  • Page 12 Liberally apply Slickoleum™ grease to the IVA piston seal and outer piston surface. Apply Slickoleum™ grease to the threads of the stanchion. Insert IVA Piston into the stanchion. R8 PRO SERVICE GUIDE...
  • Page 13 AIR SPRING SERVICE Install IVA cap into stanchion. Torque to 200-220 LB-in [22.6-25 Nm] using a 24mm socket. Attach a shock pump and inflate main air chamber to 30 PSI. This will aid in installing the casting later. R8 PRO SERVICE GUIDE...

  • Page 14: Vtt Pro - X Manual Knob Removal

    Note: Be sure to hold the knob still while removing the nut. The damper adjuster may be damaged if the knob is over torqued. Lift the entire knob assembly out of the top-cap. Further disassembly of the knob assembly is not needed. R8 PRO SERVICE GUIDE...

  • Page 15: Vtt Pro - X Remote Knob Removal

    If the rubber weather plug or weather cap is installed, first remove it from remote knob assembly. Remove remote cable using a 2mm hex loosen the two set screws on the remote knob. R8 PRO SERVICE GUIDE...
  • Page 16 Holding the outer surface of the cable stop, lift the entire remote knob assembly out of the top-cap. The remote knob may spin when it disengages from the adjuster; this is normal. Further disassembly of the knob assembly is not needed. R8 PRO SERVICE GUIDE...

  • Page 17: R8 Sealed Damper Service

    Inspect damper shaft and bladder for any damage. 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. R8 PRO SERVICE GUIDE...
  • Page 18 M5x.8 adapter to top-cap bleed port. Holding the damper end-cap up-right in vise simultaneously compress the filled syringe SLOWLY to fill the damper with fresh oil. Refill the syring as needed until oil is drawn into the upper syringe. R8 PRO SERVICE GUIDE...
  • Page 19 Compress the damper shaft to ensure the lock-out is functioning correctly. If lock-out is not firm, repeat step 6-7 to remove any air in the damper. Install Damper cartridge into stanchion. Using standard cassette lock-ring tool Torque to 200-220 LB-in [22.6-25 Nm]. R8 PRO SERVICE GUIDE...

  • Page 20: R8 Pro Casting Installation

    R8 PRO CASTING INSTALLATION Apply a light coating of Slikoleum grease and 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 (30 PSI).
  • Page 21 R8 PRO CASTING INSTALLATION 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 14cc of semi-bath (85-0022) into each casting leg.
  • Page 22 R8 PRO CASTING INSTALLATION 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 23: R8 Pro Manual Knob Installation

    R8 PRO MANUAL KNOB INSTALLATION Clean the adjuster knobs with isopropyl and replace v-seal into top-cap counter-bore. Set the adjuster to “OPEN”. Install the black “VTT” adjustment knob onto adjuster hex so the tab is parallel to the crown. Check the knob rotates through all 3 positions.

  • Page 24: R8 Pro Remote Knob Installation

    R8 PRO REMOTE KNOB INSTALL If not already assembled, insert the torsion spring straight end into the small hole on the bottom of the remote knob. Insert the knob and torsion spring into the cable stop so that the set-screw threads are oriented on either side of the cable stop housing without tension on the torsion spring.
  • Page 25 R8 PRO REMOTE KNOB INSTALL Check that there is 90 degree MIN between 1st set screw and point perpendicular to the cable stop housing. 90 degrees is require for the knob to rotate MAX-to-MIN Using 5mm hex wrench install and torque the retainer nut to 0.5-0.7 N-M [4-6 lb-in].
  • Page 26 R8 PRO REMOTE KNOB INSTALL If needed, trim the cable to a length needed to be 2-4mm past the location of the second set-screw threaded hole. Holding the end of the cable in the cable track use a 2mm hex to thread a set-screw into the second threaded hole on the remote knob.

  • Page 27: Travel Change (Optional)

    TRAVEL CHANGE In order to change the travel of your R8 Pro, first remove the compression rod assembly. For travel change on new forks, bath oil may be preserved by removing stanchion assembly while fork is placed flat on benchtop. Once the assembly is removed arrange the travel spacers into the desired amount of travel using the charts on the following pages.
  • Page 28 TRAVEL CHANGE DECREASING TRAVEL Decrease Travel: Each spacer added decreases travel & Axle-To-Crown by 10mm. R8 PRO SERVICE GUIDE...

  • Page 29: Travel Spacers & Iva Settings

    R8 PRO TRAVEL SPACERS # OF SPACERS TRAVEL DEPICTION R8 PRO SERVICE GUIDE...
  • Page 30 R8 PRO IVA SETTING TRAVEL IVA POSITION DEPICTION NO IVA OR 1 R8 PRO SERVICE GUIDE...

  • Page 31: Exploded Views

    R8 PRO EXPLODED VIEW & PARTS R8 PRO SERVICE GUIDE...
  • Page 32 R8 PRO EXPLODED VIEW & PARTS ITEM # PART DESCRIPTION KIT NUMBER CROWN-STEER ASSY, 440S, M3IX0.8, MY25 R8 141-41368-K001 CASTING, 29” MY25 R8 GLOSS BLACK 141-41368-K002 AXLE, HEXLOCK SLR, 110 (WITH HARDWARE) 141-33147-K008 AXLE HARDWARE, HEXLOCK SL2 141-33147-K006 IVA ASSY M31XO.8, 31.00 R8...
  • Page 33 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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