Manitou 2 Rebuild help /Tips needed

[Woodyuk]

Hi All

I have a set of Manitou2 forks that I need to rebuild for a new project....
But I have a few questions I need to answer first...

The forks I have are in good condition but are completly empty inside can someone let me know what I need to get them working again?

The top caps are metal caps (Original) that fit in place but are not screws caps like on the Manitou4 forks I have . Is this normal as I am not sure if they would stay in place when the fork rebounds?

Also I have spare Manitou 4 elastomers and inside parts but with screw tops , could these be used on Manitou 2 forks?


Any Info would be appriciated ...
Does anyone on here do a rebuild service for Manitou forks?

Thanks for any help...

 

[SLIM]

they are totally incompatible with each other , mani 3/4 the elastomers are IN the stantion , mani 1/2 they are beneath the stantion , so have you removed the legs to see there are no internals , cos all you will see IN the stantions is a bolt head

 

[marc two tone]

great website this....


http://www.suspensionforkparts.net/manitou_manual.php


loads of technical info on manitou stuff.

 

[We_are_Stevo]

If you prise out the metal cap in the top of the stanchion (having first removed the crown) and shine a torch inside you will see an empty tube with a socket headed bolt at the bottom; you need either a very long allen key (they are available) or an allen bit and a long extension from a socket set.

Undo the bolt and you will be able to pull the stanchion out of the lower leg; the long bolt will (probably) have a couple of knackered elastomers, a coil spring and a couple of washers around it. remove all the bits and pieces and thoroughly clean out the stanchions and lower legs; the website in the above link sell elastomer kits to fit the Manitou II and are a worthwhile investment.

Or, you could try threading the elastomers from your IV onto the bolts (the bolts are thicker than the skewers in the III/IV but they might go if you put them in a bowl of hot water first?), you need to fill the length of the bolt with elastomers so that they are slightly preloaded when you reinstall them.

Whatever you do, do NOT forget to put the washer back on the bolt before you drop it back through the stanchion. If you leave it out the fork action will wiggle the bolt about and enlarge the hole it fits through - with obvious dire consequences!

With the bolt back in the stanchion thread your elastomers (and any spacers/washers) in more or less the order they came off. Reinsert the stanchion into the lower leg and push it down as far as it will go. Then take your allen key/socket extension and bit and screw the bolt back into place - you will have to apply a bit of pressure to compress the elastomers (I used springs...) so that the bolt will screw into its thread.

Repeat for the other stanchion/leg; refit the crown and test...

...it really is that easy

 

[Woodyuk]

Hi

Thanks for all the Info... been busy this week but will try what We_are_Stevo mentioned above next week to see if I can get them working again