Manitou 2001 MARS - User Manual

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I. ANSWER PRECISION SUSPENSION

THANK YOU FOR CHOOSING THE HIGHEST TECHNOLOGY MOUNTAIN BIKE SUSPENSION FORK AVAIL-

ABLE. 2001 MARS FORK MODELS HAVE STATE OF THE ART AIR SPRING SYSTEMS. THE MARS SERIES

ALL USE THE TWIN PISTON CHAMBER SYSTEM (TPC) THAT SURPASS ALL OTHER TYPES OF OIL DAMPED

SYSTEM IN PERFORMANCE AND DURABILITY.

Your 2001 MARS Fork is fully assembled and ready to for installation onto your bicycle and comes

equipped with a 1 1/8 threadless steerer tube. All MARS forks come in two versions: standard and

No-Boss. The standard version has mounts for both V-brakes and disc brakes. The No-Boss version

has the cantilever brake boss removed and is for disk brake use only.

II. CONSUMER SAFETY INFORMATION

GENERAL WARNING: Bicycling is a hazardous activity that requires that the rider stay in

control of his or her bicycle at all times. Reading this manual entirely and properly main-

taining your bicycle and suspension fork will reduce the possibility of injury or possible

death. Prior to riding your bicycle, you should inspect your suspension fork to ensure that

no damage has occurred during the course of riding. Do not ride your bicycle if the fork

shows any signs of bending, cracking, leaking, or if it is missing any of the originally supplied

components. Any fall from your bicycle can result in serious injury or even death.

Following these instruction can help you reduce the risk of being injured.

If you are a moderate or aggressive off-road rider, or ride at least three times a week over

rough terrain, Answer recommends returning your suspension fork every 2 years for a

through inspection and update. Take your fork to a Manitou authorized dealer who can

arrange for shipment to Answer Products, or you may call Answer to have your fork shipped

directly at (661) 257-4411.

IMPORTANT: The 2001 MARS fork is for off road use only and as such, does not come with the

reflectors for on road use.

1 Never remove or have the steerer tube or stanchions (inner legs) removed from the crown.

The steerer tube and stanchions are press fit assembled at the factory. Pressing them out will

permanently damage the crown, steerer tube, and stanchions beyond repair and render them

unsafe for any continued use.

2 Never attempt to thread a threadless steerer tube. Machining threads will weaken the steerer

tube and create an unsafe condition. The only safe thing to do is obtain the proper

crown/steerer from your dealer.

2001 MARS SERVICE MANUAL

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Summary

Consumer Safety Information

General Safety and Maintenance

General warning about bicycling hazards, manual reading, fork maintenance, and inspection for damage to prevent injury.

Component Integrity and Modification Warnings

Warnings against removing steerer tubes/stanchions and threading threadless steerer tubes due to safety risks.

Fork Damage and Inspection

Warnings against using damaged forks and emphasizes periodic inspection for wear and damage.

Steerer Tube and Stanchion Removal Warning

Warning that steerer tube/stanchions are press-fit and cannot be removed; removal leads to unsafe conditions.

Installation Instructions

Fork Installation Procedure

Detailed step-by-step guide for installing the fork, including steerer tube cutting, headset assembly, and brake installation.

Installation Safety Warnings

Critical safety warnings related to wheel/tire installation, minimum clearance, and avoiding drilling fork dropouts.

Adjusting Ride Qualities

Compression Damping Tuning

Instructions for adjusting compression damping via knob (Elite) or setscrew (Super) for ride quality.

Maintenance

TPC Oil Level Check

Instructions for checking and maintaining the correct TPC oil level to ensure proper fork performance.

Inner Fork Legs & Crown Maintenance

Inspection of Fork Components

Guidance on inspecting dust seals, bushings, outer/inner legs, and crown for damage or wear.

Internal Component Disassembly

Compression Rod & Air Spring Disassembly

Rebound Damper Assembly and Inspection

Mars Elite;Super Rebound Damper Assembly

This document is a service manual for the 2001 Manitou MARS suspension fork, a high-technology mountain bike component designed for off-road use.

Function Description

The 2001 MARS fork is a mountain bike suspension fork that utilizes state-of-the-art air spring systems and a Twin Piston Chamber (TPC) oil-damped system. This combination is designed to surpass other oil-damped systems in performance and durability. The fork's primary function is to absorb shocks and vibrations encountered during off-road cycling, providing a smoother and more controlled ride. It is available in two versions: "standard," which includes mounts for both V-brakes and disc brakes, and "No-Boss," which has the cantilever brake boss removed and is exclusively for disc brake use. The fork comes fully assembled and ready for installation with a 1 1/8" threadless steerer tube.

Important Technical Specifications

Spring System: Air spring combined with a coil spring.
Damping System: Twin Piston Chamber (TPC) oil damping.
Steerer Tube: 1 1/8" threadless (factory press-fit, not removable or threadable).
Travel: 80mm (for 80mm travel fork models).
Minimum Tire Clearance: 3.26 inches (83mm) for 80mm travel forks.
Air Spring Pressure: Adjustable via a Schrader valve on top of the left leg. Recommended pressures vary by rider weight:
- Under 115 lbs: 80 psi +/- 5 psi
- 115-145 lbs: 100 psi +/- 5 psi
- 145-175 lbs: 120 psi +/- 5 psi
- 175-205 lbs: 140 psi +/- 5 psi
- 205-230 lbs: 160 psi +/- 5 psi
- 230+ lbs: 180 psi +/- 5 psi
Coil Spring Rates:
- Blue: 80 pound coil spring
- Red: 100 pound coil spring
- Yellow: 120 pound coil spring
- Black: 150 pound coil spring
Maximum Air Spring Pressure: 190 psi.
TPC Oil Type: SAE 5WT Maxima fork oil or equivalent.
TPC Oil Quantity (Air Piston): 2.5 CC of 40-wt oil on top of the air piston.
Torque Specifications:
- End Cap (TPC Lower Shaft Assembly): 30-50 inch-lbs (3.5-5.6 N-m)
- Titanium Brake Post: 90-110 inch-lbs (10-12 N-m)
- Compression Rod Screw: 10-30 inch-lbs (1.2-3.5 N-m)
- Dropout Nut: 10-30 inch-lbs (1.1-3.5 N-m)
- Leg Cap (Compression Rod & Boots Reassembly): 10-20 in-lbs (1.1-2.5 N-m)
- Piston Seat Nut (Rebound Damper Assembly - MARS Elite/Super): 12 in-lb (1.3 N-m) max.
- Piston Seat into Shaft (Rebound Damper Assembly - MARS Elite/Super): 30 in-lb (3.5 N-m) max.
- End Cap (Rebound Damper Assembly - MARS Elite/Super): 30 in-lb (3.5 N-m) max.
- Top Cap (TPC Sport Compression Damping Assembly): 30-50 inch-lbs (3.5-5.6 N-m)
- Air Spring Cap Assembly: 30-50 inch-lbs (3.5-5.6 N-m)

Usage Features

Adjustable Ride Qualities: The fork offers a wide adjustment range to suit individual riding preferences and rider weight by changing air pressure and spring rate.
Compression Damping Tuning (MARS Elite): A knob on top of the right leg and crown allows for easy adjustment. Rotating clockwise increases damping for large hits, while counter-clockwise rotation reduces damping for plushness over sharp bumps.
Compression Damping Tuning (MARS Super - Anti-Bob): The Anti-Bob compression damping assembly can be adjusted by removing it from the top of the right leg and turning a setscrew on the valve seat. Inward increases damping, outward reduces it. This feature is factory pre-set.
Rebound Damping Fine Tuning (MARS Elite and MARS Super): A knob located on the bottom of the right leg controls rebound damping. Clockwise rotation increases damping to prevent overactive fork behavior, while counter-clockwise rotation reduces damping for quicker recovery.
Secondary Catch Dropout: All 2001 MARS forks are equipped with this feature, which requires proper tightening of the front wheel quick release with adequate thread engagement (4 or more threads).

Maintenance Features

MicroLube Lubrication System: All 2001 Manitou forks feature a MicroLube fitting at the back of the fork for easy grease injection. This system allows for lubrication without disassembly, reducing service time. Approximately 10 squirts of Prep M lube are recommended if stiction develops.
Periodic Maintenance: The fork requires periodic maintenance, cleaning, and inspection. Moisture and contamination can build up, necessitating disassembly, cleaning, drying, and re-greasing with Prep-M grease for optimal performance.
Oil Replacement: It is recommended to replace the TPC oil at least once a year, or twice if contaminated with dirt, mud, or other foreign substances.
Pre-Ride Inspection: Before every ride, users should:
- Ensure quick release skewers are properly adjusted and tight.
- Check the entire fork for any obvious damage (bending, cracking, leaking, missing components).
- Check headset adjustment.
- Ensure the front brake cable is properly seated and brake adjustment is correct.
Inspection during Disassembly: Checks should be made for tears, wear, or damage to dust seals, Teflon coating on bushings, nicks or gouges on outer leg/arch assembly, deep gouges or other damage on inner legs, cracks or flaking anodize at the bottom of the crown, and cracks on the underside of the crown.
Warranty Service: For moderate or aggressive off-road riders, or those who ride at least three times a week over rough terrain, Answer recommends returning the suspension fork every 2 years for a thorough inspection and update.
Troubleshooting: The manual provides guidance for common issues such as the fork topping out (excessive preload, insufficient rebound damping), feeling less active (stiction), or having loose outer legs/bushings.
Fork Boots: Use of fork boots is recommended for extended service cycles and maximum fork life. Using the fork without boots will require more frequent service intervals, and will void the warranty if it shows signs of not being in place and not being serviced frequently.