2005 Axel Service Manual

Rev NC

05 AXEL SERVICE MANUAL Page 1 REV NC

 Table of Contents
Description Page

Introduction 3
Front Suspension Terminology 4
Disassembly/ Assembly Instructions 8
Lock Out Troubleshooting Tips 13
Remote Lockout Service Instructions 14
Air Assist Troubleshooting Tips 16
Bushing Removal and Installation Instructions 17
Troubleshooting Chart 21
Axel Schematic and Technical Specifications 22
Axel Service Kit Chart 23

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: [email protected]
[email protected]
Web site: www.answerproducts.com

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 INTRODUCTION

This manual is intended to guide the user through basic service of Manitou Axel front forks.
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 of suspension fork service, at this time our primary focus is to
offer service kits that minimize the amount of downtime and labor involved.

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 suspension fork or the user.

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

NOTE
A NOTE provides key information to make procedures easier or clearer

GENERAL WARNING: Suspension forks by design can contain preloaded springs, 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: Suspension forks uses preloaded spring(s) to provide compression spring

resistance. This system must be relieved of preload prior to servicing. Failure to relieve
air pressure could result in injury or possible death.

CAUTION: Suspension forks use precision machined aluminum and other soft alloy components.
Using correct tools for assembly is essential to prevent damage.

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 FRONT SUSPENSION TERMINOLOGY
Air Cap – Top cap that threads into top of air/spring leg (this is the left leg of the fork as you are
seated on the seat). Forks may be controlled with an air/spring or a coil spring. The air cap
contains the Schrader Valve, which is used to control the spring rate or SAG of air forks.

Air Spring – A mechanism that is used to control the SAG of an air fork.

Arch – A support that connects the two outer lower legs of the casting so as to keep them moving
in unison.

Black Nitrate Leg Coating – New coating for steel stanchion legs that reduces stiction.

Boss – The word used to describe an outer casting that has brake posts for V-brakes or
cantilever brakes.

Bottom Out Bumper – A rubber or elastomer device that absorbs the shock that occurs when a
suspension is compression to its limit.

Bushings – A cylindrical sleeve between a fork stanchion tube (inner leg) and a fork outer
casting (slider), which facilitates the sliding movement between these two parts.

Coil Spring Air Assist – A new feature for 2005 that utilizes a full length coil spring and allows
you to increase the spring rate of the fork by adding air as a booster to that coil spring.

Coil Spring – A coiled piece of metal that acts as a spring to help suspend a fork.

Compression – The phase of the suspension operation in which the wheel travels up, or travels
closer to the frame. The suspension forks reaction to a bump in the trail.

Compression Damping – Restriction of the rate that the suspension compresses under load.

Convertible Travel – A system used to alter the travel of a suspension fork. It requires moving a
travel clip on the compression rod to a different position. This operation is accomplished by
disassembling the fork and physically moving the travel clip on the compression rod.

Crown Steerer Assembly – the stanchion legs (inner legs), the fork crown, and the steer tube
pressed together as one assembly. This assembly is then finished by adding all of the fork
internals and then outer casting (slider).

Damping – A function that modifies the rate of suspension compression or rebound.

Detent – An indentation that causes a rotating adjuster to stop at fixed increments.

Drop Out – The end of an outer casting (slider) where the wheel attaches.

Dust Boot – Usually a piece of rubber in the shape of a cylinder with baffles to allow it to
compress as the fork compresses through its travel. Its function is to help keep dirt and water
from getting into the inner legs of the fork.

FFD – Fluid Flow Damping. A Manitou patented low cost oil damping system. The compression
damping is non-adjustable and the rebound damping may be non-adjustable or adjustable
damping.

Fork Crown – The component that joins the stanchion tubes (inner legs) to the steer tube of the
fork.
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 FRONT SUSPENSION TERMINOLOGY (CONT.)
Hydraulic Fork Oil – Oil used in suspension designs to provide damping. It has special
characteristics that determine how it reacts when exposed to compressed air, how it changes
viscosity when its temperature changes, and how it moves through valves.

Hydraulic Lock Out – a condition caused when the mixture of air and damping oil is out of
balance. It is caused when there is too little air space in a chamber, not allowing the fork to
compress through its travel.

Infinite Travel System (IT) – A handle-bar mounted air travel adjust system that allows the rider
to change the fork travel (and ride height) without a spring rate change. The travel can be
changed from full compression to full rebound and at any place in between.

Lock Out – a special function that restricts the compression of the fork from moving. It is
generally controlled by an external knob that is activated when a rider does not want the fork to
move, thus eliminating extra energy needed to overcome the bobbing forces of the fork.

MCU – (Micro-Cellular Urethane) Special urethane that is filled with tiny air cells that act like
springs when the elastomer is compressed.

Micro Lube – Lubrication system that is operated by injecting small quantities of grease directly
into ports that are inserted into outer casting legs. This enables the lubrication of the fork without
having to disassemble it.

No Boss - The word used to describe an outer casting that has no brake posts for V-brakes or
cantilever brakes. This casting is to be used for disk brakes only.

Oil Damping – A system that uses the resistance to oil flow through holes in a valve to provide a
means to alter the rate of suspension compression or rebound.

Oil Level – The level of damping oil needed for the optimal damping performance of a
suspension. It is measured as the air space distance between the top of the stanchion leg (inner
leg) and the height of the oil inside of the leg. The fork must be completely extended in order to
get an accurate measurement.

O-Ring – A soft, flexible neoprene or Buna rubber ring with a round cross-section, which is used
for sealing and retention.

Oil Weight – A description of the relative viscosity of oil, such as hydraulic oil. Oil with low weight
numbers (5wt or 7wt) flows through the valving with less resistance than higher weight numbers
(10or 15 wt).

One Point Five Standard - 1.5 inch interface standard for frame head tubes, headset, cups,
stem, and steer tubes which allows for the lightest weight and strongest design in 170mm single
crown forks. This design greatly improves the control and steering precision of the fork. It is used
predominately on forks with longer travel and the intended use is for more hardcore, extreme
riding.

Outer Casting – (see Slider)

Preload – A condition of compressing a spring or elastomer before the operating loads are put on
the suspension, so that it provides a stiffer spring rate.

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 FRONT SUSPENSION TERMINOLOGY (CONT.)
Piston – In front suspension, the part of the damper that slides back and forth inside of the
damping leg that houses the valves. It can also refer to the air piston in the air/spring assembly
that slides back and forth compressing the air, thus causing a change in the spring rate of the
suspension.

Porosity – The condition or property of having pores in a material that will allow gas or liquid to
pass through it.

Platform Plus Damping – A new damping system found on 2005 Rear shocks (featured on
Metel and Radium’s). This system will establish a pedaling efficiency platform similar to SPV, but
is done through unique valving that is not adjustable (helps in bump control).

Rapid Travel II, Wind Down – Systems that are used to control the travel of suspension forks.
Also known as RTII, and WD. RTII is used for the specific purposes of controlling the travel in two
conditions: climbing and descending. WD is an incremental travel adjustment between to set
limits and does not affect the spring rate of the fork as severely as RTII.

Quad Ring seal – New seal that replaces standard o-rings in designs that require more efficient
air and oil sealing methods.

Rebound – The phase of the suspension operation in which the wheel returns to its original
position on the ground after compression.

Rebound Damping – Restriction of the rate that the suspension rebounds when the compression
load is relived.

Remote Lock out system – A handle-bar lever actuated system that controls the lock out
function on front and rear suspension products.

Reverse Arch Technology – Also known as RA. It is a system that is designed to move the arch
of a fork to the backside of a fork, rather than the conventional front position. It was designed to
provide greater rotational torque strength to an outer casting (slider), without adding additional
weight to the fork.

Sag – The amount a suspension fork compresses at rest with a normal load (rider’s weight).

Schrader Valve – Valve used to introduce air into a chamber.

Seal – A part, usually neoprene rubber or Buna, that keeps contaminants out and/or working
fluids in.

Semi Bath – A lubrication system that uses a lubricating oil to keep the bushing surface and
stanchion legs (inner legs) as friction free as possible during movement of the stanchion legs.

Spring Rate – The rate at which the resistance of a spring increases as it is compressed.

SPV – (Stable Platform Valve) new damping system that allows the rider to set the pedaling
platform that he desires to pedal most efficiently in all situations. It is dependent on the pressure
that the SPV valve experiences from the movement of the wheel vs. the terrain and the platform
that is set by pressure introduced to other side of the SPV valve through changes of air pressure
working on the damping oil.

SPV Evolve – The latest version of SPV damping technology that has increased its performance
with modifications to the original design.
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 FRONT SUSPENSION TERMINOLOGY (CONT.)
Slider/Outer Casting – The tube (outer casting leg) of the suspension fork that0. remains fixed to
the wheel. It slides up and down on the stanchion leg (inner leg).

Stanchion Clamps - (Double-Triple Clamps) the portions of the fork crown that clamp around the
stanchion legs above and below the head tube of the bicycle frame on specific long travel
applications.

Stanchion Legs – The suspension tube (inner leg) fixed to the fork crown. It remains stationary
during the operation of the suspension.

Steer Tube – The long cylindrical tube that extends from the top of the fork crown. Its function is
to be inserted into the bicycle head tube and attach the suspension to the bicycle frame.

Thru Axle – (Hex-lock) A device used for mounting a thru axle hub to special outer legs that are
not made for standard quick release hubs. Manitou’s Hex-lock (thru axle) system is a special
patented system utilizing a hex shaped end that increases the stiffness of the fork and reduces
slippage in the joint between the axle clamps and the axle.

Top Out Bumper – A rubber, coil spring, or elastomer device that absorbs the shock that occurs
when the load is taken off a suspension so that it is allowed to rebound to its limits

TPC – (Twin Piston Chamber) a patented damping system that has independent pistons for
rebound and compression. The system utilizes a mixture of air and oil in the damping leg of the
fork to enhance the damping performance.

TPC+ - A variation of TPC that has added a floating piston to the compression damper to
enhance the performance of the compression damping under the load of bigger hits.

Travel – The amount that a wheel moves between the most compressed and the most extended
states of the suspension

Viscosity – A description of how a liquid flows. Liquids with higher viscosity are thicker flow less
easily or quickly than liquids with low viscosity. This has an affect on the damping speeds of
rebound and compression.

Volume Control – A new system designed to work with SPV as a control of the compression
ramp up rate of the fork. It has a range of adjustments from linear to very progressive.

Wiper Seal – A rubber material that is used as a seal to keep dirt and water out of the outer
casting legs. It is not designed to keep air pressure or extreme oil pressure in. Manitou has the
new Evil Genius wiper seals.

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 2005 Axel Forks Disassembly and Rebuild Instructions

Disassembly Instructions

Removal of Outer Casting

1. From the left leg dropout (Left when sitting on the bike), use a 4mm hex wrench to
remove the compression rod screw.
2. From the right leg dropout, if the fork has adjustable rebound, the knob will need to be
removed. Remove the 2mm hex screw inside the knob and remove the knob.
3. Use a 8mm hex wrench to turn the damper clockwise until it can be pushed into the
casting.
4. Remove crown/steer/inner leg assembly from the outer leg casting.

Bushing Removal & Installation

Please refer to section on Bushing Removal & Installation.

Removal of Spring and Compression Rod Assembly - Non-Wind Down Travel

Adjust Forks

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.

1. Turn spring preload adjuster knob counter clockwise until it stops. Remove 2mm hex
screw on spring preload adjuster knob and remove knob on the top left side of the fork.
2. Remove preload adjuster using 18mm socket.
3. Compress fork and remove the spring preload and spring assy.
4. Remove rubber bumper and clip on compression rod.
5. Turn crown/steer upside down to allow the comp rods to fall out of the inner legs.

Removal of Spring and Compression Rod Assembly - Wind Down Travel Adjust
Forks

1. Turn travel adjust knob (clear plastic knob on top of the left side of the crown) in a
counterclockwise direction until it stops. This insures that the fork is in its longest travel
and reduces any spring preload on the fork.
2. Remove the 2mm Allen screw from the knob. Use a 28mm socket to unscrew the top cap
assembly from the crown.
3. Pull spring out of inner leg. If spring will not come out, you must take the outer casting off
of inner legs (refer to Removal of Outer Casting instructions). Then remove the end cap
from the bottom of the left leg and remove the Wind Down compression rod assembly
and spring as a single unit through the bottom of the leg. You will find that on earlier
production fork models, that there is a nylon washer at the top of the compression rod
assembly that is holding the spring in place. Hold the spring in one hand and the
compression rod assembly in your other hand and pull the apart from each other at a
slight angle to each other. Once you have the two apart, remove the Allen bolt on top of
the compression rod with a 4mm Allen wrench and remove the nylon washer (Fig 2). Re-
install the bolt without the washer, it will not affect the operation of the Wind Down
mechanism and insure that you will not have to take the whole fork apart in the future to
change ride kit springs. (Note: the spring that you remove should have another spring
(booster spring) intertwined within it)
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Removal of Compression Damping Assembly

Forks with FFD (non-adjustable) Damping

1. Remove top leg cap (FFD Assy) on right hand side using 27mm socket.
2. Pour old oil out of the top of the fork, then compress fork upside down over oil drain pan
3-5 times to get oil out from under rebound piston and discard appropriately.

Forks with Adjustable Compression/Lockout Damping

1. Remove the 2mm fixing screw on top of the damper knob on top right side of the fork.
2. Remove 2 balls and springs from inside the top cap.
3. Unscrew the compression damping assembly using a 24mm socket.
4. Pour old oil out of the top of the fork, then compress fork upside down over oil drain pan
3-5 times to get oil out from under rebound piston and discard appropriately.

Removal of Rebound Damping Assembly

1. Unscrew Damper end cap from the bottom of the right leg and then pull out the rebound
damper.

Assembly Instructions

Assembly of Rebound Damping Assembly

WARNING All leg caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.

1. Install rebound damper into bottom of right leg and tighten per the Axel Schematic and
Torque Specification Table. Slide the black rubber bottomout up the shaft until it contacts
the damper cap. This will assist later during assembly of the outer leg casting to the
damper shaft.

Assembly of Compression Damping Assembly - Non-Adjustable FFD

WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.

1. Put a little bit of Prep M grease (Ref Answer Products PN 85-0031) on o-ring found on
the lower piston of the FFD assembly.
2. Install the FFD Assy into the top right hand of the crown/steer using a 27mm socket.
Tighten per the Axel Schematic and Torque Specification Table.

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Assembly of Compression Damping Assembly - Adjustable Compression/Lockout

WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.

1. Fill right leg with damping oil using 5wt Motorex fork oil (Ref Answer Products PN 85-
0023) to the height noted in the Axel Schematic and Torque Specification Table. Cover
the opening at the top of the right leg of the crown/steer with a rag and cycle the fork six
times. Recheck oil level and add/drain to meet the level requirement.
2. Put a little bit of Prep M grease (Ref Answer Products PN 85-0031) on the urethane or
brown rubber o-ring found on the lower piston of the Lock out assembly.
3. Twist the Hex shaped aluminum shaft that sticks up from the top cap counter clockwise
until it stops (the system is completely open to oil flow at this point).
4. Using a motion like screwing in a screw. Twist the assy. and apply a little pressure to
insert the piston part of the mechanism past the threads at the top of the inner leg. Then
push the assy. into the leg until the threads on the cap intersect the threads inside the
inner leg, screw the cap. Tighten per the Axel Schematic and Torque Specification
Table.
5. Once the cap is tightened, twist the Hex shaped shaft clockwise until it stops (this is the
locked out position). Insert the springs into opposite holes in the top cap and then place
the ball bearings on top of the springs (place a little dab of grease on spring to hold ball
bearing in place).
6. Place the adjuster knob onto the hex shaped aluminum shaft and seat it onto the top cap
and ball bearing. Position the adjuster cap so that the lever part of the cap is at the
farthest point to the back of the crown.
7. Insert 2mm fixing screw and tighten to secure the knob. Twist the knob counter clockwise
to activate the fork suspension. Compress the fork several times to circulate the oil
through the system and then activate the Lock out system by moving the lever clockwise
to its stopping point at the back of the crown. The fork should have approximately 5 mm
of progressive travel before it locks out.

Note: This system is a combination of adjustable compression damping that becomes a lock
out. It is fully active when the lever is facing all the way forward (counter clockwise) and
locked out when the lever is facing all the way towards the back of the crown (clockwise).

Installation of Spring, Compression Rod Assembly, and Outer Leg Casting - Non
Wind Down Forks

WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.

WARNING When installing the outer Leg Casting to the Crown Steer Assy, Compression
Rod bolts and Damper Shafts must be properly tightened prior to use. Failure to do so
could result in injury or possible death.

1. Screw the compression rod assembly into the crown/steer assy. Make sure that the comp
rod that accepts the 4mm screw is installed in the left leg. Tighten per the Axel Schematic
and Torque Specification Table.
2. Remove rubber fork boots from the casting and slide them onto the inner legs of the
crown/steer assy.

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 3. Lightly grease the bushings on the inside of the outer leg casting and on the lower portion
of the inner legs below the boots using a thick grease such as Motorex Bike Grease
2000.
4. Grease spring heavily with Motorex Bike Grease 2000. Install the spring preload and
spring assy into the crown/steer assy.
5. Tighten preload adjuster using 18mm socket and tighten per the Axel Schematic and
Torque Specification Table.
6. Insert 2mm hex screw into spring preload adjuster knob and install knob on the top left
side of the fork.
7. Press inner leg assembly into outer leg casting until comp rod contacts casting.
8. From the left leg dropout, use a 4mm hex wrench to install the compression rod screw
and tighten per the Axel Schematic and Torque Specification Table.
9. From the right leg dropout, use a 8mm hex wrench to turn the compression damper
counterclockwise until it screws into the casting and tighten per the Axel Schematic and
Torque Specification Table.
10. Slide fork boots down and snap over dust seal flange.
11. Lubricate the inner legs through the Microlube ports using Prep-M grease.

Installation of Spring, Compression Rod Assembly, and Outer Leg Casting - Wind
Down Forks

WARNING All top caps for Damper and Spring systems must be properly tightened prior to
use. Failure to do so could result in injury or possible death.

WARNING When installing the outer Leg Casting to the Crown Steer Assy, Compression
Rod bolts and Damper Shafts must be properly tightened prior to use. Failure to do so
could result in injury or possible death.

1. Drop the compression rod into the crown/steer assy. Make sure that the comp rod
accepts the 4mm screw is installed in the left leg.
2. Remove rubber fork boots from the casting and slide them onto the inner legs of the
crown/steer assy.
3. Lightly grease the bushings on the inside of the outer leg casting and on the lower portion
of the inner legs below the boots using a thick grease such as Motorex Bike Grease
2000.
4. Optional Ride Kits - If you need to adjust to overall ride characteristics either softer or
firmer, purchase and/or install as follows (Kit Part Numbers can be found in the Service
Part section of this manual):

• Soft - Remove the Booster Spring

• Firm - Purchase Firm Ride Kit and install the Booster Spring
• Extra Firm - Purchase Extra Firm Ride Kit and install the Booster Spring

1. To remove the booster spring from the main spring; grasp the flat end of the
booster spring with a pair of needle nose pliers and twist it in a clockwise
direction to unscrew it from the main spring.
2. To install a booster spring into a main spring catch the flat end of the booster
spring under the flat end of the main spring and twist it counterclockwise into the
main spring. Make sure that the booster spring is threaded all of the way down
into and contained by the main spring. Before inserting it back into the inner leg.

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 5. Generously grease the spring and insert it into the inner leg. The end of the spring needs
to seat onto the top of the compression rod.
6. Insert the wind down top cap assembly into the spring; the "D" shaped portion of the
adjuster assembly must fit into the "D" shaped end of the main spring. Screw the
assembly into the inner leg and tighten per the fastener torque guide at the end of this
manual...
7. Install adjuster knob and 2mm hex screw. Holding the comp rod, turn the knob
counterclockwise until the knob stops. This insures that the fork is in its longest travel
position. If the travel indicator arrow on the crown is not lined up with the maximum travel
point on the indicator dial, turn the knob counterclockwise until the indicator point to
maximum travel. Retighten the compression bolt per the fastener torque guide at the end
of this manual.
8. Press inner leg assembly into outer leg casting until comp rod contacts casting.
9. From the left leg dropout, use a 4mm hex wrench to install the compression rod screw
and tighten per the Axel Schematic and Torque Specification Table. .
10. From the right leg dropout, use a 8mm hex wrench to turn the compression damper
counterclockwise until it screws into the casting and tighten per the Axel Schematic and
Torque Specification Table.
11. Slide fork boots down and snap over dust seal flange.
12. Lubricate the inner legs through the Microlube ports using Prep-M grease.

Wind Down Travel Adjust Assembly

Top Cap Assembly & Spring

Travel adjust assembly & End Cap Adjuster knob O-ring, knob, & 2mm screw

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 Remove Nylon washer that rests on top of aluminum washer

4mm recessed Allen bolt

Lock Out Troubleshooting Tips

1. Installation of Lock out Compression Damping System
• Check the o-ring that is installed around the lower piston on the damper shaft for
tears or deformation. Replace it, if it is damaged. This is the most common reason
why the Lock out system will not function.
• Check the level of oil in the inner leg. The oil level may be a little high, but never
low. The oil level must be high enough to cover the window that opens and closes on
the damper shaft.
• Make sure that the oil flow window on the lower portion of the damper shaft,
positioned right above the piston, opens and closes when you move the lock out knob
from open to close.
• Inspect the rubber o-ring that is around the threaded portion of the cap that screws
into the inner leg of the fork. This o-ring should not have nicks or tears in it and
should fit tightly around the cap.
• Make sure that when installing the Lock out system into the fork leg that you follow
this procedure: Put a little bit of Prep M grease on the urethane o-ring, make sure that
that the oil flow window is open using a motion like screwing in a screw. Twist the
assy. and apply a little pressure to insert the piston part of the mechanism past the
threads at the top of the inner leg. Then push the assy. into the leg until the threads on
the cap intersect the threads inside the inner leg, screw the cap in and do not use any
tools to over tighten the cap. Once the cap is tightened, compression the fork several
times to circulate the oil through the system and then activate the Lock out system by
moving the lever to the other position. The fork should have between 2 & 5mm of
progressive travel before it locks out.
05 AXEL SERVICE MANUAL Page 13 REV NC
2. Troubleshooting
• If the Lock out does not lock out properly, go back through the steps listed above.
• If the o-rings are damaged on the Lock out piston, replace them with P/N
062594(urethane 1998-2003 Mars, SX, & Skareb Lock outs), 065261 (04/05
Skareb Lockouts) and 02/03 Black 100/120mm Lock outs, and 040315 (Axel’s).
• If the oil level is low, check to see if there is evidence of leaking at the Rebound
Damper. If so, replace the Rebound Damper assembly and retry the Lock out. The oil
level may be low if you are upgrading a standard Compression Damping system with
the Lock out system. In this case, make sure the oil level is at the correct level before
trying it again. If there are signs of oil leaking around the top of the Lock out system,
check the rubber o-ring (040524) and replace if needed. If the window does not open
or close when the knob is moved, replace the entire Lock out assembly.

Remote Lock Out Service Instructions

Complete Remote Lock out Assembly

There are (5) Service kits available for each fork
model that utilizes a Remote Lock out.
Lever Kit and
Cable Guide 1. Lever assembly 2. Lever Cover
Lever cover
3. Cable assembly 4. Cable guide
Kit
5. Lock out assembly
*Reference to these kits may be found in the
Service Parts Matrix

Instructions for removing assembly from fork

1. Unscrew barrel adjuster in a

counterclockwise direction until it stops.
2. Remove Lever cover by squeezing the two
plastic prongs together on the under side of
the lever and pulling the cover in an upwards
Barrel Cable direction from the lever assembly.
adjuster Assembly Lock out 3. Pull on Black cable ferrule nearest to lever
Assembly and pull cable assembly from the groove in
the Lever assembly, thus releasing cable
from lever. Unhook cable end from lever.
4. Unscrew the top cap of the Lock out
Tools needed assembly from the fork crown using socket
to service (Answer p/n: 83-2503) or an adjustable
assembly wrench.
5. Pull Lock out assembly out of crown by
twisting the assembly like unscrewing a
screw and applying an upward pressure.
Slowly pull assembly out of crown and watch
out for some excess damping oil to come out
of inner leg as the piston at the end of the
assembly comes out of crown.

Special Note: It is important to periodically remove

Adjustable Pliers Socket Wrench the Lever cover and using air pressure, blow out any
Adjustable Wrench 22mm Socket dirt or moisture that has accumulated in the
W/cut out mechanism. Then add a small amount of a “Dry”
10mm open end wrench Lubrication to the moving parts.

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 Steps For Cable Disassembly

Cable Replacement Instructions

1. Step 1: Lock out assembly should be out of fork at
this point.
2. Step 2: Cable assembly should be out of Lever
assembly
3. Step 3: Look at tool placement in Figure A. It is
recommended to use the Adjustable Pliers to grasp
Step 3
Step 1 the flange of the lower assembly right above the coil
Step 2 blow off spring. Use a 10mm open end wrench on
the flats of the upper assembly just below the top
cap. Hold the flange with the Pliers and turn the
10mm wrench in a counterclockwise direction in
Tool Placement to unscrew upper
order to unscrew the upper and lower assemblies.
shaft assembly from lower
4. Separate the two assemblies and unhook the cable
assembly (Figure A)
end from the eye hook as shown in Figure B.
5. Pull the cable out through the top cap and red cable
guide. There will also be a 75mm spring inside of
the upper shaft. This spring provides the tension for
the cable when you move the Lock out lever from
the Lock position to Unlock position. The inner
cable runs through the center of the spring.

Cable Installation Instructions

1. The inner cable is not removable from the cable
assembly. The entire cable assembly must be
replaced. Install the new cable assembly by
reversing the Disassembly the instructions.
2. Slide the inner cable through the red cable guide,
the top cap, and down through the spring. (Be sure to
Cable hook up connection put a little bit of the Prep M grease on the spring
(Figure B) before putting it back into the upper shaft assembly.)
3. Push the cable assembly together, forcing the inner
cable to stick through the spring and then out
through the end of the upper shaft assembly. (See
Figure C). Hook the cable end into the eye hook and
then pull on the cable assembly to pull the two shafts
together. Tighten them together snuggly.
4. Check oil level in fork leg (refer to oil level heights
in fork spec sheets). Install Lock out assembly into
the fork leg and tighten top cap to proper torque.
5. Re-install the other cable end into the Lever
assembly, and then put the lever cover back on to the
Lever assembly. You may have to pull the cable
assembly away from the housing of the lever
assembly to expose the inner cable, so that you can
slide the cover into its proper position.

05 AXEL SERVICE MANUAL Page 15 REV NC

 Air Assist Trouble Shooting Tips

The root cause of the air leaking from the left leg of the fork (the side with the Schrader valve on
top) and blowing out the seal at the top of the fork leg is that the either the end seal on the leg is
bad or the seal on the compression rod is bad. Below are some steps to follow in order to trouble
shoot this issue and potentially resolve it.

1. It is difficult to visually determine from the out side of the fork what problem you are
having. So you need to remove the casting and check a couple of other areas.
2. Once the casting is off, try pumping up the left leg with about 50psi. If it blows out
immediately, this means that the seal around the compression rod piston is bad. This can
be changed out with a new Quad ring (p/n: 066398). Your assembly will probably have
an o-ring on it.
3. Just as with air pistons, you want to coat the threads of the inner leg and the Quad ring
with Prep M grease, and then twist the assembly as you put force on it to get it past the
threads of the inner leg. It is also important to add the air piston oil (20/50wt) (about 3-
5cc’s) through the top of the inner leg prior to pumping it up.
4. If the air does not immediately pass from the inner leg, I recommend that you put that end
into a bucket of water and see if any air bubbles are produced. If the bubbles are seen,
check both the o-ring seal and the end cap seal on the fork leg.
5. If you get no bubbles, I would put some pressure on the compression rod in a side ways
manner to side load that shaft. If air is released, it points to the hole in the casting being
off center.
6. In this case, you need to change the casting.

Note: The maximum recommended air pressure to be used with Air-

Assist is 40 psi. and you should not exceed 50 psi. For each increase of
10 psi you raise the spring rate one level, ie 20psi is equal to a medium
spring rate. If you can not achieve the spring rate you desire with in this
range then you will need to upgrade to a firmer main spring.

05 AXEL SERVICE MANUAL Page 16 REV NC

 Bushing Removal & Installation
Bushing Removal
( For Axel Super and Elite only )

(Note: use appropriate removal ring that corresponds to the leg diameter of the fork being
repaired)

Leg Diameter Answer Kit #

25.4mm (1”) 85-5191
28.6mm (11/8”) 85-5189
30mm 85-5194
32mm 85-5192

Bushing Removal Tool Components

A. Slide Hammer
B. Threaded Handle
C. Slide
D. Threaded Shaft
E. Removal Ring

Bushing Removal Tool Assembly

05 AXEL SERVICE MANUAL Page 17 REV NC

 Bushing Removal (CONT.)

Bushing Removal Instructions

A. Install 25.4mm Removal ring on the

shiny, smaller diameter threaded shaft.
Be sure to install the ring with the
tapered, chamfered end first, followed by
the long slide tube. This tapered end
leads the tool through the bushing.

B. Start the procedure by removing the

Dust/Wiper seal with a screwdriver,
prying it out.

C. Insert Removal tool past the upper

bushing and then stop. It is important to
pull one bushing out at a time. Push the
slide on the threaded shaft down
towards the removal ring. Hold the
casting with one hand and the slide
hammer with your other hand. Now
move the slide hammer in a motion away
from the casting and repeat this action
until the bushing comes out.

D. For all other leg diameters: use the

larger diameter (dark colored) threaded
shaft and repeat steps A-C.

Bushing Installation

(Note: Sizer kits listed in above chart contain the sizers needed for each specific leg diameter.)

(1) (2)
Bushing Installation Tool Components
1. Installation Mandrel
2. Threaded Rod w/nuts
3. Sizer rings
4. Spacer
5. Washer
6. Nut

(3) (4) (3) (5) (6)

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 Bushing Installation (CONT.)

Bushing Installation Tool Assembly

With weighted handle

When selecting sizer rings to install bushings,

choose the two rings that are in the middle of
the size run to start with.

1. Assemble installation tool as shown in

picture above. Each leg diameter kit has all
of the needed pieces to remove and install
bushings for forks with serviceable
bushings. Some of the kits come with
gauges to tell you how far to drive in the
lower bushings. Upper bushings are driven
in as far as the stop in the top of the
casting will allow. The general rule of
thumb is that the lower bushings must not
be driven any deeper than 5” into a casting
leg. If they do go deeper, call Customer
Service at Answer Products – 800-423-
0273 for a new outer casting.

2. Always assemble Mandrel with the larger

diameter sizer ring being placed on the
mandrel first, then the spacer, the next
largest sizer ring, followed by the washer
and the nut to hold it in place. Be sure to
lock the nut above the Mandrel and below
the Mandrel against each other.

3. Replace the lower bushing (bushing with a

thicker wall diameter) first. Place a small
amount of Prep M grease onto the sizer
rings to help the rings come through the
bushings when pulling them out. Slide
bushing onto Mandrel until it stops. Apply
a bead of Red Loctite all the way around
the outside of the bushing. Hold casting on
top of bench with a rag under the end of
the legs and insert installation tool with
bushing into casting leg.

05 AXEL SERVICE MANUAL Page 19 REV NC

 Bushing Installation (CONT.)

4. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet
until proper depth is achieved. If using depth gage, slide gage onto rod before installing
weighted handle and let it settle on of Mandrel. Tap rod until appropriate line on gage is even
with top of casting leg.

5. Remove weighted handle and gage (if applicable).

6. For sizing of the lower bushing:

7. Use slotted top cap from sizer kit and set it into the top of the casting leg, straddling the
threaded rod. Spin the extra nut with washer down to the top cap and using a wrench,
socket, or speeder wrench, tighten the nut in a clockwise direction. This will cause the
Mandrel to be pulled through the bushing, thus sizing it. Keep turning the nut until the tool is
all the way through the bushing and can be pulled out of the leg.

8. To install top bushings, repeat steps B-E. Note that the top bushing gets inserted until it stops
against the step inside of the casting. The extra sleeve that comes with the sizer kit is used
to space the top cap off of the casting, so that there is enough room to pull the sizers out of
the casting without bottoming on the cap.

9. If you find that the bushings are too tight after installing them, use the sizer Mandrel that does
not have a stop on it to hold the bushing while installing it into the casting. This is available in
the 25.4mm leg kit (85-5191) to go back in and resize the bushings.

10. To resize bushings, Choose the next larger size rings and repeat the above process.

11. When satisfied with the results, reinstall Dust/wiper seals and then reassemble fork

05 AXEL SERVICE MANUAL Page 20 REV NC

 Troubleshooting Chart

Service
Manual
Symptom Cause Solution Page
Oil leaks from Remove Casting from Inner Legs, reinstall
Wiper Seals Seal not seated properly or replace seals 9
Nicks or scratches on Replace Crown/Steerer/Inner Leg
inner legs Assembly 9
Remove Casting from Inner Legs, reinstall
Wear or replace seals 9
Oil leaks from
bottom of Rebound damper shaft
Casting leaks Replace Rebound Damping assembly 10
Rebound damper shaft O- Replace O-ring on threaded end of
ring damaged Rebound Damping assembly 10

Lack of Travel Tight Bushings Replace outer leg 9

Hydraulic lock out Replace Rebound Damping assembly 10
Check oil level, Replace Rebound
Damper oil volume Damping assembly if needed 9
Visually inspect fork, call Answer
Fork alignment Products Customer Service 2
Loss of Rebound
Fork Top out Damping Replace Rebound Damping assembly 9
Inspect and replace Top out spring if
Top out spring damaged needed. 10
Damping oil volume not Check oil level, Replace Rebound
correct Damping assembly if needed 9
Fork Bottom Refer to SAG Set up in Tuning section of
out Too much SAG Owners Manual
Bottom out Bumper Inspect and replace Bottom out Bumper if
damaged needed 11
Damping oil volume not Check oil level, Replace Rebound
correct Damping assembly if needed 9

Play in Fork Loose bushings Replace outer leg 9

Loose Compression Rod
bolt Tighten bolt to specified torque 10
Loose Rebound damping
shaft Tighten Shaft to specified torque 9
Loose press fit tolerances Call Answer Products Customer Service 2

Dust Seal Oring on Air Assist Piston Replace o-ring on Air Assist Compression
Blows Out is damaged rod 16
No/ insufficient Oil on Air
Piston Added oil on top of Air assit piston 16
Lock out not
functioning Various symptoms See Lock out and RLO Section 13

05 AXEL SERVICE MANUAL Page 21 REV NC

 Axel: Schematic & Technical Specifications

E
A D

B H

Model: Axel
Description Torque Value
Bushing Depth - Upper *8.9mm Min. (.35”)
Bushing Depth - Lower *99 – 106 mm (3.9 - 4.2”)
Torque – Brake Post 90–110inlbs (10.2-12.4nm)
Leg Caps 25–35inlbs (2.8-4.0nm)
Torque - Comp Rod Screw 10-30inlb (1.1-3.4nm)
Torque - Damper Screw (Axel Super) 10-30inlb (1.1-3.4nm)
Adjuster caps:
Torque 35-50inlbs (4.0-5.7nm)
Damping Oil 110 – 120mm (4.3 – 4.7”)

05 AXEL SERVICE MANUAL Page 22 REV NC

 Axel Service Kits

Axel
Model Comp Elite Super
70-100 90-120
Travel (mm) 80 100 120 80 100 120
RTWD RTWD
Comp Damp FFD A 85-5253
Comp Damp TPC A
Lock Out - TPC A *85-5318
Remote L/O - Lever Left A *83-2180
Remote L/O - Lever Right A *83-2402
Remote L/O - Cover Left A *83-2181
Remote L/O - Cover Right A *83-2403
Remote L/O - L/O A *83-2407
Remote L/O - Cable A *83-2182
Remote L/O - Cable Guide A *83-2183
Remote L/O - O-Ring Kit A *83-2408
Rbnd Damp - Non Adj B 85-5254 *85-5255
Rbnd Damp - Adj B *85-5255 85-5255
Pre Load Adj C 85-4810
WD Adjuster Cap Assy C 85-5396 83-2399
Air Assist Cap C 83-2398
Crn/Str/Leg D
Steel S/T (26") 83-2400 83-2117 83-2121 83-2400 83-2117 83-2121 83-2119 83-2123
Blk AL S/T(26") *83-2401 *83-2118 *83-2122 *83-2401 *83-2118 *83-2122 *83-2120 *83-2124
Outer Leg Assy E
STD Black (26") 83-2127 83-2125
STD Silver (26") 83-2129 83-2123
STD White 83-2332 83-2339
STD Candy Chrome 83-2328
STD Candy Red 83-2337
STD Matte Black 83-2330
STD Charcoal 83-2329
STD Matte Silver 83-2331 83-2338
NB, STD DO Black (26") 83-2128 83-2126
NB, STD DO Silver (26") 83-2130 83-2132
NB, STD DO White 83-2327 83-2336
NB, STD DO Candy Chrome 83-2324
NB, STD DO Candy Red 83-2333
NB, STD DO Matte Black 83-2325 83-2334
NB, STD DO Matte Silver 83-2326 83-2335
Sticker Kit F - For Dark Colors 83-2134
F - For Light Colors 83-2133

05 AXEL SERVICE MANUAL Page 23 REV NC

 Axel Service Kits (Cont.)

Axel
Model Comp Elite Super
70-100 90-120
Travel (mm) 80 100 120 80 100 120 RTWD RTWD
Ride Kits G
WD Booster 83-2144 83-2147
Soft 83-2135 83-2138 83-2141 83-2135 83-2138 83-2141 83-2145 83-2148
Medium 83-2136 83-2139 83-2142 83-2136 83-2139 83-2142
Firm 83-2137 83-2140 83-2143 83-2137 83-2140 83-2143 83-2146 83-2149
Comp Rod/ H
80
83-2150 83-2150
80 Air Asist
100
83-2151 83-2151
100 Air Asist
120
83-2152 83-2152
120 Air Asist
70-100 RT Wind
Down 83-2153
90-120 RT Wind
Down 83-2153
Bushing Kit E 85-5324
Knob Kit I 85-5804
Boot Kit J 85-5390
Dust Seal Kit K 83-2156 83-2155
O-Ring Kit K 85-5555
Bumper Kit K 85-2154

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