Manitou Systems DORADOPRO - EXPERT Owner's Manual page 8

oil height. With the top cap and rebound shaft at full extension,
the oil level should cover the entire cartridge top cap. Only
the rebound shaft and inner leg top cap should be protruding
above the oil surface. If the cartridge top cap is visible, add
SAE 5WT suspension fork oil until the top cap is completely
immersed in the damping oil. This oil height should equate
to 120mm [4.72in] from the top of outer leg. Fully extend the
outer leg away from the dropout before replacing outer top-
cap. Replace top-cap and bleed the system by stroking 10-20
times with the rebound in "full closed" position. If a significant
amount of oil was added, the oil level should be checked again
at this point. The rebound should be smooth and consistent to
the very top of extension (no air pockets). The leg may now be
replaced into the crowns per required torque specs.
NOTE: Use SAE 5WT suspension fork oil from high quality
manufacturers such as Motorex or Maxima.
120mm
[4.72in]
DORADO PRO - EXPERT OWNER'S MANUAL
CHECKING SPLASH BATH OIL (SPRING LEG ONLY)
Bleed fork by pumping 10-20 times. Keep fork vertical for
remaining procedures. Use a 36mm wrench to remove the top
cap on the left leg (spring leg). It is not necessary to remove
the Schrader cap for
this operation. Slide the outer leg down the inner leg to have
ample view into the leg. A flashlight may aide in locating the
oil height. With the top cap and comp-rod at full extension, the
oil level should cover the entire inner spring leg and top cap.
Only the comp-rod and outer leg should be protruding above
the oil surface. If the top cap is visible, add Splash Bath (HBG
P/N 85-0023) until the top cap is completely immersed in the
damping oil. Replace top-cap and bleed the oil by stroking
10-20 times. The leg may now be replaced into the crowns per
required torque specs
REPLACING SPLASH BATH OIL (SPRING LEG ONLY)
Use a 36mm wrench to remove the top cap on the left leg
(spring leg). It is not necessary to remove the Schrader cap for
this operation. Slide the outer leg down the inner leg to allow
oil to drain into an oil pan. DO NOT REUSE OIL, DISCARD
OF PROPERLY WITH LOCAL OIL RECYCLER. When fully
drained, pour 30cc of Splash Bath (HBG P/N 85-0023) into the
outer leg. With the top cap and comp-rod at full extension, the
oil level should cover the entire inner spring leg and top cap.
Only the comp-rod and outer leg should be protruding above
the oil surface. If the top cap is visible, add Splash Bath (HBG
P/N 85-0023) until the top cap is completely immersed in the
Splash Bath oil. Replace top-cap and circulate the oil by strok-
ing 10-20 times. The leg may now be replaced into the crowns
per required torque specs found in Table 6.
CHECKING AIR PISTON LUBRICATION OIL
NOTE: It is recommended to replace air piston o-ring during
this procedure. Remember to maintain absolute cleanliness
including no lint, cloth fibers, metal flakes, etc.
Apply shock pump to Schrader valve at top of left (spring
leg) and relieve all air pressure with pump pressure relief
valve. Use a 36mm wrench to remove the top cap on the left
14
leg (spring leg). Slide the outer leg down the inner leg to the
dropout. 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, some oil may spill.
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. Using a 20mm open-
end wrench, loosen the comp rod end cap and remove the
comp-rod assembly from the leg. Do this over an oil pan,
some oil may spill. Allow oil to drain off of piston and out of
inner leg. If available, replace air piston o-ring at this time. Do
not wipe oil from piston; this may contaminate the seal and
result in poor performance. If cleaning is needed, use only
isopropyl alcohol. Dip the air piston in Splash Bath (HBG P/N
85-0023). Insert the air piston back into leg. Be careful to insert
the piston straight to avoid cutting the seal on the threads.
Pour an additional 5cc of Splash Bath (HBG P/N 85-0023) on
top of the piston. Replace the spring leg top cap, and replace
the outer leg. Pour 30cc of Splash Bath (HBG P/N 85-0023)
into the outer leg. With the top cap and comp-rod at full exten-
sion, the oil level should cover the entire inner spring leg and
top cap. Only the comp-rod and outer leg should be protruding
above the oil surface. If the top cap is visible, add Splash Bath
(HBG P/N 85-0023) until the top cap is completely immersed
in the Splash Bath oil.
Replace top cap and circulate the oil by stroking 10-20 times.
The leg may now be replaced into the crowns per required
torque specs found in Table 6, next page. Make sure clamp
spacers are present within the lower crown pinch joint. (2
round washers per bolt or 1 rectangular plate spanning both
bolts)
DORADO PRO - EXPERT OWNER'S MANUAL 15
180-190 ml