2007 Fork Service Manual - Manitou

Removal Coil Spring Assembly
Section 3: spring Systems
Coil Spring Service Instructions
Fig. 1
WARNING This fork uses a preloaded coil spring provide spring resistance. The
spring must be relieved of its preload prior to servicing. Failure to do so could
result in injury or possible death.
For Forks with Pre-Load adjuster assemblies (coil spring systems):
To Change the Spring:
Fig. 2
Fig 2A
Fig 2B
1. Rotate the Pre-Load adjuster knob all of the way counter clockwise to reduce the preload
on the spring. Rotate adjuster on top left of fork crown counterclockwise until it
stops. This will relieve spring tension on the fork.
2. Remove the adjuster knob from the top of the Pre-Load adjuster assembly, by
unscrewing the 2mm Allen head screw. (See Fig 1)
3. Use a 20mm socket and unscrew the remainder of the assembly from the crown. Pull
the spring out of the fork. (See Fig 2)
4. Generously grease the new spring and insert it into the inner leg. The spring needs to
seat onto the top of the compression rod.
5. Screw the preload assembly into the inner leg and tighten per the fastener torque
guide at the end of this manual.
6. Install the adjuster knob and 2mm hex screw.
For Forks with Stage II Spring Rate Adjuster assemblies (coil spring systems):
To Change the Spring:
1. It is not necessary to adjust the knob all of the way counter clockwise prior to removal
since this assy does not significantly load the spring.
2. Remove the adjuster knob from the top of the Pre-Load adjuster assembly, by
unscrewing the 2mm Allen head screw. There are two detent balls and springs in the
cap (See Fig 2A), be careful not to lose them when removing the knob.
3. Use a 20mm socket and unscrew the remainder of the assembly from the crown. Pull
the adjuster out of the fork. (See Fig 2B)
4. Compress the fork slightly to allow the spring to rise above the crown and remove the
spring.
5. Generously grease the new spring. The spring will have a “D” shaped hole on one
end, insert the corresponding “D” fitting of the Stage II adjuster into it and insert the
spring and adjuster into the inner leg. The spring needs to seat onto the top of the
compression rod.
6. Screw the Stage II assembly into the inner leg and tighten per the fastener torque
guide at the end of this manual.
7. Install the Two detent springs and balls into the top cap. Applying a small amount of
18