Maintenance - Manitou Systems DORADOPRO - EXPERT Owner's Manual

8. Using a 13mm open wrench hold the flats on the comp rod
adapter (it may be necessary to slide the bottom-out spacer
down to gain access) and remove the top cap with a 36mm
wrench. Do this over an oil pan, as some oil may spill.
9. Turning the leg upside down, allow the Splash-Bath oil
to drain into an oil pan. DO NOT REUSE OIL; DISCARD
PROPERLY WITH LOCAL OIL RECYCLER. When all oil
has drained, remove the outer leg by sliding it away from the
dropout.
10. Using a 20mm open-end wrench, loosen the comp-rod
end cap and remove the comp-rod assembly form the leg. Do
this over an oil pan, as some oil may spill.
11. Locate the top-out nut (16mm) and screw (20mm) on the
comp-rod. Loosen and unthread the nut from the screw, then
slide apart to reveal the retaining ring. Lightly splay the retain-
ing ring to remove from groove and move to groove corre-
sponding to the desired travel position; 203mm is the position
closest to the air piston, 180mm is the position closest to the
end cap. Rethread the top-out screw and bolt over the retain-
ing ring, torque to 3,4 N-M [30 IN-LB]. (See Image 13)
12. It is recommended to replace the air piston seal at this
time. Coat the air piston with Splash Bath (HBG P/N 85-0023).
Insert the air piston into the leg being sure to minimize contact
between the threads and o-ring. Pour an additional 5cc of
Splash Bath on top of the inserted piston. Using a 20mm
crow's foot torque wrench tighten the comp rod end cap to 6.8-
9.0 N-M [60-80 LB-IN].
13. Slide the outer leg back onto the inner leg. Using a 13mm
open wrench hold the flats on the comp rod adapter. Tighten
the top cap with a 36mm torque wrench to 1.7-2.8 N-M [15-25
LB-IN]. Pour 30cc Splash Bath (HBG P/N 85-0023) into outer
spring leg.
14. Making sure the leg assembly is fully extended, thread the
top cap into the outer leg, hand tight, being sure the o-ring is
engaged.
15. Slide the outer leg (spring leg) completely into the upper
and lower crowns. The top of the lower crown must be within
0-15mm below of the top of the clamp diameter (see Image 1,
page 5). Tighten the two pinch bolts evenly by alternating back
and forth on the left side (spring side) on the lower crown, and
the one pinch bolt on the left side (spring side) on the upper
crown using a 5mm hex torque wrench to 10.7-12.4 N-M [95-
110 LB-IN]. DO NOT TAKE THIS STEP LIGHTLY!
16. Using a 36mm wrench tighten the top cap to 8-9.0 N-M
[60-80 LB-IN]. The upper crown pinch bolt may need to be
DORADO PRO - EXPERT OWNER'S MANUALLL
loosened to do this, to relieve compression on the top cap
threads. Do not forget to retighten upper crown pinch bolt in
this case.
17. Fill the valve on top of the left leg (spring leg) with desired
air pressure. Recommended air pressure is 50 – 90 PSI.
Replace the Schrader cap.
18. Remount the wheel and Hex Axle and brake caliper per
manufacturer's specifications. First tighten the hex Axle to 3.4-
4.5 N-M [30-40 IN-LB] using a 6mm hex torque wrench. Then
uniformly tighten all four pinch bolts to 3.4-4.5 N-M [30-40
IN-LB] by alternating between bolts using a 4mm hex torque
wrench.
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MAINTENANCE

Your fork requires periodic maintenance, cleaning and inspec-
tion. This is because moisture and contamination may build up
inside the fork depending on the severity of riding conditions.
To maintain top performance, it is recommended that the fork
be periodically disassembled, cleaned, dried and relubricated.
You can download service and tuning instructions on the web
at www.manitoumtb.com.
DORADO PRO - EXPERT OWNER'S MANUAL
WARNING!
BEFORE EVERY RIDE YOU SHOULD:
1. Ensure that the Hex Axle is properly installed per instructions.
2. Ensure that all bolts are tightened to the appropriate torque
recommendations by the parts' respective manufacturers.
3. Wipe the inner legs and clean the fork. Check the entire fork
for any obvious damage.
4. Check the headset for proper adjustment. To check for a
loose front headset apply the front brake with both wheels on
level pavement and push the bike forwards and backwards
rapidly to see if you hear the headset rattling. If it is then it is too
loose. Follow headset manufacturer's instructions to tighten.
5. Ensure that the front brake cable is properly routed and
check brake adjustment. Follow brake manufacturer's instructions.
CHECKING DAMPING OIL LEVEL
WARNING!
SETTING THE PROPER OIL LEVEL IN YOUR SUSPEN-
SION FORK IS CRITICAL. THE DAMPING IS LOCATED
IN THE RIGHT LEG OF YOUR FORK. INSUFFICIENT OIL
VOLUME WILL ALLOW FOAMING AND REDUCE PERFOR-
MANCE. EXCESS OIL WILL RESTRICT TRAVEL AND MAY
CAUSE DAMAGE TO THE SYSTEM AND CREATE AN UN-
SAFE RIDING CONDITION. FINISH READING THIS ENTIRE
SECTION PRIOR TO ALTERING THE OIL LEVEL.
To check the oil level it is recommended that the right leg
(damping leg) be completely removed from the rest of the fork
for this operation. Loosen, but do not remove, the two pinch
bolts right side (damping side) on the lower crown, and the
one pinch bolt on the right side (damping side) of the upper
crown using a 5mm hex wrench. Slide the right leg (damping
leg) completely out from the upper and lower crowns. Do not
lose the clamp spacers in the pinch slot of lower crown.
Bleed the fork by pumping 10-20 times. This will ensure an
accurate appraisal of oil level. Use a 36mm wrench to re-
move the top cap on the right outer leg (damping leg). It is
not necessary to remove the rebound knob for this operation.
Slide the outer leg all the way down the inner leg locating the
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