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Steps for disassembling the Manitou Axel fork components.
Instructions for adjusting travel on non-wind down forks.
Procedure to set the fork to its longest travel position.
Steps for installing the rebound damping assembly into the fork leg.
Procedure for assembling the FFD compression damping assembly.
Steps to assemble the adjustable compression/lockout damping system.
Guide to installing spring, compression rod, and outer leg on non-wind down forks.
Steps for installing spring, rod, and outer leg on wind down forks.
Steps and tools for removing fork bushings.
Steps and tools for installing fork bushings.
This document is a service manual for the Manitou Axel suspension fork, specifically covering the 2004 Axel Super, Axel Elite, and Axel Comp models. It provides comprehensive instructions for the maintenance, disassembly, assembly, and troubleshooting of these bicycle suspension forks.
The primary function of the Manitou Axel suspension fork is to absorb shocks and vibrations from the terrain, providing a smoother and more controlled riding experience for the cyclist. It enhances comfort and improves handling by allowing the front wheel to move independently over bumps and obstacles while maintaining contact with the ground. The suspension system helps to maintain traction, reduce rider fatigue, and improve overall control, especially on rough trails.
Key usage features of the Axel forks include their design for various riding conditions, with different models (Super, Elite, Comp) likely catering to different levels of performance and adjustability. The manual details how to set the fork's travel, indicating that some models offer "Convertible Travel," a system that allows users to alter the suspension fork's travel by physically moving a travel clip on the compression rod. This feature enables riders to customize the fork's performance based on their preferences or the specific demands of the trail. Some models also feature adjustable compression/lockout damping, allowing riders to fine-tune the fork's response to impacts or to lock out the suspension for more efficient climbing. The manual also mentions "Wind Down Travel Adjust Assembly," suggesting another mechanism for on-the-fly travel adjustment in certain models.
Maintenance features are extensively covered throughout the manual, providing detailed instructions for keeping the fork in optimal working condition. Regular maintenance is crucial for the longevity and performance of the suspension fork. The manual outlines procedures for the removal and installation of various components, including the outer casting, spring and compression rod assembly, compression damping assembly, and rebound damping assembly. These procedures involve specific steps such as removing top leg caps, draining old oil, and installing new components with appropriate greases and torques.
A significant portion of the manual is dedicated to "Bushing Removal & Installation," which is a critical maintenance task for ensuring smooth operation and preventing excessive play in the fork. The instructions detail the use of specialized tools, such as a slide hammer and various sizer rings, to properly remove old bushings and install new ones. The process emphasizes the importance of correct depth and sizing to prevent issues like tight bushings or premature wear. The manual also provides guidance on selecting the correct sizer rings and applying grease and Loctite where necessary.
Troubleshooting is another key maintenance feature, with a dedicated chart that helps users diagnose and resolve common issues. This chart lists symptoms such as oil leaks from wiper seals or the bottom of the casting, lack of travel, fork top out, fork bottom out, and play in the fork. For each symptom, potential causes are identified, along with recommended solutions. These solutions range from simple fixes like reseating seals or checking oil levels to more complex repairs such as replacing entire assemblies (e.g., rebound damping assembly, crown/steerer/inner leg assembly) or outer legs. The troubleshooting guide also advises on inspecting and replacing specific components like top out springs, bottom out bumpers, and O-rings. In cases where issues persist or are complex, the manual directs users to contact Answer Products Customer Service, highlighting the availability of expert support.
The manual also includes a "Glossary of Terms" to help users understand the specialized terminology associated with suspension forks, such as "Arch," "Boss," "Bottom Out Bumper," "Bushings," "Coil Spring," "Compression," "Convertible Travel," "Crown Steerer Assembly," "Drop Out," "Dust Boot," "Fork Crown," "MCU," "No Boss," "O-Ring," "Outer Casting," "Preload," "Rebound," "Reverse Arch Technology," "SAG," "Seal," "Spring Rate," "Slider/Outer Casting," "Stanchion Legs," "Steer Tube," "Top Out Bumper," "Travel," and "Wiper Seal." This glossary is invaluable for both novice and experienced users to fully comprehend the instructions and the mechanics of their fork.
Overall, the Manitou Axel suspension fork, as described in this service manual, is a versatile and maintainable component designed to enhance the cycling experience. Its usage features allow for customization and performance tuning, while its comprehensive maintenance guidelines and troubleshooting support ensure long-term reliability and optimal function.
General| Model | Axel Super |
|---|---|
| Year | 2004 |
| Category | Bicycle Accessories |
| Steerer Tube Diameter | 1 1/8 inch |
| Wheel Size | 26 inch |
| Brake Compatibility | Disc and V-Brake |
| Spring Type | Coil |
| Damping | Oil |
| Damper Type | TPC (Twin Piston Chamber) |
| Adjustments | Preload, Rebound |
| Travel | 80mm |
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