2007 Manitou Shock Service Manual - Rev NC.pdf - Rower - poradniki - Eroza800

2007 Manitou Rear Shock

Service Guide

REV NC.

2007 Manitou Rear Shock Service Manual

Index

Section

Description

Page

INTRODUCTION

SETUP, TUNING, PERIODIC MAINTENANCE

GLOSSARY

AIR SPRING SYSTEM AND SPV AIR PRELOAD, SWINGER

AIR

COMPLETE SHOCK LESS HARDWARE, COIL SPRING

HARDWARE REMOVAL AND INSTALLATION

DU BUSHING REMOVAL AND INSTALLATION

RIDE KITS

BOTTOMOUT BUMPER REPLACEMENT, SWINGER COIL

REBOUND ADJUSTER KNOB REMOVAL AND

INSTALLATION, SWINGER COIL

DAMPING SYSTEM

DAMPING SYSTEM BLEEDING - SWINGER X3 AIR/ S-TYPE/

RADIUM SHOCKS

DAMPING SYSTEM BLEEDING - SWINGER X4 AIR/ EVOLVER

ISX4-ISX6/ SPLIT SHOCKS - SHIM AND SPV

DAMPING SYSTEM BLEEDING – REVOX/ SWINGER X3-X4-X6

COIL/ METAL SHOCKS - SHIM AND SPV

TROUBLESHOOTING

TABLE 1: FASTENER TORQUE REQUIREMENTS

SWINGER REAR SHOCK SERVICE KITS

Contact Information

Answer Products Customer Service Department

28209 Ave. Stanford

Valencia, CA 91355

Toll Free: (800) 423-0273

Direct : (661) 257-4411

FAX: (661) 775-1798

E-mail: warranty@answerproducts.com

tech@answerproducts.com

Web site: www.answerproducts.com

SECTION 1: INTRODUCTION

This manual is intended to guide the user through basic service of Manitou Swinger rear shocks. Service is

supported by the identification of common parts and assemblies that have been assembled into Service Kits.

The purpose of this manual will be to describe conditions that may drive the need for service and to provide

installation instructions for the kits.

Due to the time-consuming nature rear shock service, at this time our primary focus is to offer service kits that

minimize the amount of downtime and labor involved. As the program matures, and we are able to gather

feed back from our customers, we may offer kits to a more detailed level.

Important information is highlighted in this manual by the following notations:

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the

person inspecting or repairing the shock absorber or the shock absorber operator

CAUTION

A CAUTION a caution indicates special precautions that must be taken to avoid damage to

the shock absorber.

NOTE

A NOTE provides key information to make procedures easier or clearer

GENERAL WARNING: Rear shocks by design contain gases and fluids under extreme pressure and

warnings contained in this manual must be observed to reduce the possibility of injury or possible

death. Following these instructions can help you reduce the risk of being injured. Any questions in

regards to the information in this manual should be directed to Answer Products Customer Service at

(661) 257-4411.

WARNING: The Swinger Shock uses compressed air to provide fluid pressure in the

damping system and spring resistance in Air models. BOTH systems must be relieved of

pressure prior to servicing these systems. Failure to relieve air pressure could result in

injury or possible death.

CAUTION: The Swinger Shock uses precision machined aluminum and other soft alloy

components. Using correct tools for assembly is essential to prevent damage.

SECTION 2: SETUP, TUNING, PERIODIC MAINTENANCE

Instructions for shock setup, tuning, and periodic rider maintenance is not covered in detail in this manual.

Please refer to the Manitou Swinger Rear Shock Owner's Manual (PN 042105) for that information. If you did

not receive a manual, you can download one at www.answerproducts.com or contact Answer Products

Customer Service at (661) 257-4411.

SECTION 3: GLOSSARY OF TERMS

Air Canister – Can that holds the air spring air in an air shock.

Air Preload Adjuster – Located on the reservoir of SPV shocks. It contains the red Schrader valve for

setting the SPV pressure and a hex fitting for adjusting the air volume (air preload)

Bottom Out – Point at which a shock reaches full compression.

Control Eyelet (C-End) – Eyelet that is on the rebound adjuster end of a shock. The air canister is attached

to this end on air shocks and the spring retention collar is attached to this end on coil shocks.

Damper Eyelet (D-End) - Eyelet that is on the damper body end of a shock. On SPV shocks, this is the end

that contains the SPV valve and reservoir if applicable.

Damper Body – Section of shock that contains the damping system

Damper Piston – Piston in that controls the flow of oil during compression and rebound.

Damper Shaft – Shaft attached to the damper piston that connects the two moving sections (damping system

and control eyelet) of the shock together.

Damping System - Controls compression and rebound rate (speed). The system also provides the peddling

platform unique to shocks with the SPV technology.

DU Bushing – Teflon guide bushing pressed into the eyelets. Mounting hardware is inserted into the DU

bushings and rotates within the bushing as need by the suspension design.

Eyelet – Found on each end of the shock, it is where the DU bushing and mounting hardware are and

provides the connection between the shock and bicycle.

Internal Floating Piston (IFP) - A floating piston that separates damping oil from the SPV air chamber or

reservoir.

Mounting Hardware – Spacers that allow shocks to be mounted into the wide variety of suspension designs.

Schrader, Air – Black in color, it is the valve for pressurizing the air canister in an air shock

Schrader SPV - Red in color, it is the valve for pressurizing the SPV system.

Seals: O-Rings - Black synthetic rubber with a round cross section. Primarily used for fluid

sealing.

Seals: Quad Seals - : Black synthetic rubber with an “X” cross section, primarily used for sealing air.

Seals: Wipers – Teflon ring, used for keeping debris out of quad seals, guiding the damper piston, and

providing support.

Top Out – Point at which a shock returns to its full extension.

SECTION 4: AIR SPRING SYSTEM AND SPV AIR PRELOAD, SWINGER AIR, S-Type

WARNING: The Swinger Air uses compressed air to provide resistance to compression in

place of a coil spring. You must be certain that the air canister is relieved of all pressure

prior to servicing the air system. Failure to relieve air pressure could result in injury or

possible death.

Sealing of the shock is accomplished through a series of o-rings, quad seals, and wipers. When the air

canister is removed, these seals can be replaced from Seal Kit C.

1. Failure of an air shock to maintain air

pressure is usually the result of defective or

worn seals. If there is suspicion of an air

leak, pressurize the air canister to 150psi

from the adjuster eyelet Schrader Valve and

the SPV Air Preload Schrader to 100psi.

Locate the leak by spraying the air canister

and Schrader joints with a mild solution of

dish soap and water or submerge in a

bucket of water. Bubbles will form in from

the area of leakage.

2. For leaks at the adjuster eyelet or damper

end of the air canister, refer to the detailed

disassembly instructions contained in the

section on DAMPING SYSTEM BLEEDING

- Swinger Air . This will guide you on how to

replace the applicable o-rings and seals.

3. For leaks at the Schrader valves, release all

air pressure and replace the Schrader valve

core or assembly as needed. The core is

removed using a standard core removal

tool. The assembly is removed by removing

the core and unscrewing the assembly by

inserting a 3mm hex into the center of the

valve.

Adjuster Eyelet SPV Air Preload

(Air Spring)Schrader

4. For leaks in the air preload reservoir area

(4W Swinger), release all pressure replace

the preload adjuster o-ring, Schrader valve

core, or Schrader assembly as needed.

5. If when you pressurize the air canister the

shock collapses to its shortest travel

position, the shock has an air piston leak

into the negative chamber. Place the shock

in the shock tester and extend it to its full

travel. Depress the adjuster eyelet Schrader

while the shock is extended under load. If it

remains in the full travel position, refer to

the section on DAMPING SYSTEM

BLEEDING - Swinger Air for instructions on

servicing the air canister and piston seals.

6. If the shock returns to the short travel

position, it is not serviceable and the entire

shock must be replaced.

WARNING: Attempting to service a

shock with this condition could result in

injury or possible death.

2007 Manitou Shock Service Manual - Rev NC.pdf

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