Manitou MARA PIGGYBACK User manual

MARA PIGGYBACK | SERVICE GUIDE

2MARA PIGGYBACK SERVICE MANUAL
5800 W Donges Bay Rd
Mequon, WI 53092
manitoumtb.com
888.686.3472
Support: manitoumtb.com/support
MANITOU
For full warranty information please visit hayesbicycle.com/warranty
WARRANTY
Revised May 26, 2020 11:43 AM

3
MARA PIGGYBACK SERVICE MANUAL
This manual is intended to provide the information necessary for the
250 hour full service of the Manitou Mara PiggyBack shock. We highly
recommend installation and service be performed by a qualied mechanic.
These instructions can be downloaded from the Hayes Performance Systems
website at www.manitoumtb.com
INTRODUCTION
We highly recommend that service to this shock be performed by a certied
bicycle mechanic. Failure to follow instructions presented in this manual
could lead to serious injury or death. Any questions about the servicing
of this shock or the manual itself should be directed to Hayes Customer
Support at:
Phone: [phone]
Email: [email protected]
Suspension shocks by design can contain preload springs, gases and uids
under extreme pressures.Warnings contained in this manual must be
observed to avoid damage to shock,serious injury or even death.
WARNING
! !

4MARA PIGGYBACK SERVICE MANUAL
table of contents
SECTION PAGE NUMBER
Tools And Materials 6
Shock Teardown 6–11
Top Cap Service 12–17
Shaft Service 18-19
Shaft and Air Piston Assembly 20-25
Air Can Service 26-28
Bleed and Fill 29–35
Set-Up Guide 36
Torque Specs 37
IFP Depth Table 38
O-Ring Location 39
Exploded View 40
Torque Specs 32
IFP Depths 33
O-ring Guide 34
Exploded View 35

5
MARA PIGGYBACK SERVICE MANUAL
tools and materials
• Safety Glasses
• Nitrile Gloves
• Lint-Free Rags
• Slickoleum™ Grease
• 10-Oz Tub – Manitou Part Number 20-32929
• 5Ml Tube – Manitou Part Number 141-33604-K001
• 5wt Maxima Synthetic shock Oil Manitou Part Number 85-0023
• *For cold weather use Maxima Synthetic All Temperarture 3wt fork oil.
(PN 141-34078-K016)*
• Isopropyl Alcohol
• 3/8 drive socket wrench
• 16mm socket
• Torque wrench
• 21mm crows foot
• Free Hub Tool Park Tool PN FR-1
• Metric hex wrench set
• T-10 Torx wrench
• O-Ring Pick
• Hand Dyno
• Bench mounted vise
• Side cutters
• Small athead screw driver
• Caliper for measuring IFP depth
• Shock Pump
• ½-13 UNC taper tap
• Blue medium strength Loctite
• Red high strength Loctite
• Mara Pro complete rebuild kit 142-37512-K032
• Air piston OD seal bullet tool PN 172-32189-K001
• Manitou Clamp Block PN 172-31464
• Manitou shaft seal bullet tool ID of the air piston PN 142-37512-K040
• Air Can / Reservoir Wrench PN 142-37512-K033
• Compression Assembly Pin Spanner HBG PN 142-37512-K031
• Air Piston Seal Pusher Tool PN 172-32189-K001
• Shaft Seal Bullet Tool PN 142-37512-K040
• Manitou Air Can Negative Seal Stop Install Tool 172-32193-K001
• Manitou Air Piston Bushing and Seal Tool 172-32192-K001
• Manitou Rear Shock Air Piston and Seal Tool 142-37512-K041
• Manitou Trunnion Tool 142-37512-K037

6MARA PIGGYBACK SERVICE MANUAL
SHOCKTEARDOWN
1Unscrew air cap, thread on
shock pump to note pressure.
Using the pump’s pressure
release button release all air.
Depress Schrader valve with
a small tool to ensure all air is
released. Remove valve core.
Clamp upper eyelet of shock in
vise. If Trunnion shock, clamp
on trunion mounts. (Use soft
jaws to not damage the shock)
2
3With the shock top cap in a
vise use the air can wrench PN
142-37512-K033 to loosen the
air can on the shock. DO NOT
completely remove the air can
at this point, only loosen one
full turn. Removing the air
can completely at this point
will damage the threads due
to pressure in the negative
chamber.
CAUTION
Do not proceed to the next
step without completely
depressurizing air spring.

7
MARA PIGGYBACK SERVICE MANUAL
4Place shock in a hand dyno
or in a bicycle frame, slightly
compress the shock. At this
point unthread the air can
fully.
Remove air can, bumper, and
spacers (if present). These
may remain in the air can,
locate and save for later re-
assembly.
5
6Remove split ring from the
main air piston.
SHOCKTEARDOWN

8MARA PIGGYBACK SERVICE MANUAL
7With a plastic pick remove
quad-ring seal.
A small side-cutter can be
used to rst partially cut the
large piston ring, then break it
to remove. Be careful not to
damage the groove.
8
9Remove the Piggyback
Reservoir cap by unthreading
it counter-clockwise.
SHOCKTEARDOWN

9
MARA PIGGYBACK SERVICE MANUAL
10 Thread on shock pump, using
the pump’s pressure release
button, release all air. Then
depress Schrader valve with
a small tool a few times to
ensure all air is released.
Remove the valve core.
Use a freewheel removal tool
(example: Park Tool FR-1) to
remove the Reservoir End Cap.
11
12 Place a catch basin under the
shock to catch oil. Use the
air can / reservoir wrench
(PN 142-37512-K033) to
unthread the shock reservoir.
(Alternative: use a 30mm
wrench)
SHOCKTEARDOWN
CAUTION
Do not proceed to the next
step without completely
depressurizing reservoir.

10 MARA PIGGYBACK SERVICE MANUAL
13
The shock’s lock-out piston
will be visible at this point,
carefully remove this assembly
and set aside on a lint-free
rag. Be sure to account for
the rubber face seal which
may still be in the top cap
when assembly is removed.
The rubber internal oating
piston (IFP) will be inside the
reservoir. Remove the piston
towards the hex end of the
reservoir, note orientation
and set aside. Removing
the IFP in the other direction
may damage the seals on
the threads. (IFP is replaced
during a full service.)
14
15 Using a small athead screw
driver, gently pry up to remove
the red LSC knob. Be careful
when removing this knob,
underneath are two detent
balls and springs. Pull these
out and set aside, remove the
O-ring used to retain the LSC
knob.
SHOCKTEARDOWN

11
MARA PIGGYBACK SERVICE MANUAL
16 Rotate the HSC so the points
of the star pattern expose the
spanner holes in the adjuster
housing underneath. Using
the Compression Assembly
Pin Spanner (PN 142-37512-
K031), engage the pins
past the HSC adjuster into
the holes in the adjuster
housing. Turn counter-
clockwise to unthread and
remove compression adjuster
assembly.
17
18
SHOCKTEARDOWN
Place the main shock shaft
into the 12mm Manitou clamp
block. Using an eyelet tool
such as a pin wrench or an
adjustable wrench accross the
at turn the top cap counter
clockwise to release the top
cap from the main shock
shaft.
Hold the bottom eyelet in a
vise, and place a drip pan
under the shock. Using a
21mm wrench, remove the air
piston from the damper body.

12 MARA PIGGYBACK SERVICE MANUAL
1
2
3Remove the M1.5 set screw
under the rebound adjustment
knob. Remove the spring
and detent ball. Remove the
rebound adjuster by turning
clock-wise (left-handed
thread). Remove O-ring
and clean the adjuster with
isopropyl alcohol. Install a
new O ring (101-450) and set
aside. *Requires main shaft
to be separated from top cap*
TopCApservice
Remove the lockout lever
assembly by gently sliding it
out. Remove the two O-rings.
Clean the spool with isopropyl
alcohol. Install new O-rings
(the Larger 101-600 close to
the lever, and the smaller 101-
500 near the end.)
Remove the Lock-Out detents
by using an M1.5 hex tool,
and unthread the small set-
screw on the end near the
compression adjuster. Flip
the shock over and tap, or use
a small pointed tool to aid in
removing the spring and ball.
Next, remove the set-screw/
retaining pin near the red
Work/Party lever.

13
MARA PIGGYBACK SERVICE MANUAL
4Remove main shaft O-ring,
air can O-ring and reservoir
O-ring from the top cap.
Thoroughly clean topcap,
spraying isopropyl alcohol into
all ports and passageways.
Allow to air dry or blow out
with clean compressed air.
5
6
Remove valve stem with a
3mm hexwrench.
topcapservice

14 MARA PIGGYBACK SERVICE MANUAL
7Replace O-Ring (101-550-
100), apply small drop of
blue Loctite to the valve stem
threads. Reinstall valve stem
into top cap torque to 2.3-
2.7Nm (20-24 INlbs) Reinstall
valve core.
8
9
Install reservoir O-ring (101-
2600-150), main shaft O-ring
(100-013) and air can O-ring
(101-4100-200).
topcapservice
Grease O-rings, reinstall
Work/Party assembly into the
top cap. Install retention pin,
check for full movement of the
Work/Party lever by adjusting
the depth of the retention pin.
Such that the lever ips just
past the word “WORK”.

15
MARA PIGGYBACK SERVICE MANUAL
10
11
12
Apply a dab of grease to
the O-ring, ramped surface
and thread on the rebound
adjuster. Insert into top cap,
rotate counter-clockwise to
engage the left handed thread.
Turn until it lightly bottoms.
Reinstall spring and detent
ball.
topcapservice
Replace the O-Ring (101-
1600-0180) on the HSC
Piston. Replace the O-Ring
(100-018) on the compression
cartridge body (above threads
at the ange). Grease both
O-Rings.
Install the compression
assembly into the top cap.
Use the compression assembly
Pin spanner tool (142-37512-
K031) and torque to 5.7Nm
(50 in-lb).

16 MARA PIGGYBACK SERVICE MANUAL
13
14
15
topcapservice
Lightly grease O-ring (PN 100-
016 ) and install on the HSC
compression adjuster.
Use this procedure to install
detent and spring for lockout,
rebound and LSC knob. Install
detent spring using a tool and
a dab of grease to help hold
the spring in place. Repeat
procedure with detent balls.
Reinstall LSC knob by pushing
straight down to not disrupt
the detent balls.

17
MARA PIGGYBACK SERVICE MANUAL
16 Remove the O-ring (101-2300-
150) from the lock-out piston
assembly. Remove face seals
if still in place. Clean assembly
with Isopropyl alcohol. Install
new piston O-ring and new
face seal(s). O-ring type face
seals (2pc) (101-700-110) or
gure 8 type seal (08-37751)
depending on the seal gland
available. Lockout will be
installed at the time of oil ll.
Note: Use grease to hold face
seals in place.
17 Remove O-ring (100-021)
from the reservoir end cap.
Clean end cap with Isopropyl
alcohol. Install new O-ring
and apply grease. Set aside
on a clean, lint free rag
until needed after the oil ll
process.
Topcapservice
Faceseals

18 MARA PIGGYBACK SERVICE MANUAL
Clamp the main shaft in the
12mm Manitou Clamp Block
(PN 172-31464) Remove
the piston nut from the shaft
with a 16mm socket wrench.
Carefully slide the shims and
piston onto a small tool like
an O-ring pick or screw driver
to preserve the sequence of
components. Carefully set
aside.
1Remove the rebound needle
(inner piece with rounded
head) from the main shaft by
gentle pulling it up. Be aware
of the spring and two small
washers at the bottom of the
rebound needle.
Remove O-ring (101-600)
from the rebound needle.
Clean needle with Isopropyl
alchohol. Replace the O-ring
(101-600) on the rebound
shaft. DO NOT grease this
O-ring! Function and assembly
is better without grease.
2
3
Shaftservice

19
MARA PIGGYBACK SERVICE MANUAL
4
5If the service warrants
replacement of bushings
within the air piston, use a
½-13 UNC bottoming tap and
the Manitou clamp block to
remove the bushings. (See
Manitou Air Piston Bushing
and Seal Tool instructions for
information)
SHaftservice
Remove inner shaft O-ring.

20 MARA PIGGYBACK SERVICE MANUAL
1Place the air piston into the
rst pocket of the service
block. Grease the outside
of the bullet tool and place
it on top of the piston. Use
the Air Piston Seal Pusher
Tool (PN 172-32189-K001) to
install the glide ring onto the
air piston. Note If bullet tool is not
available see “50 hour air can and piston
service guide” for alternative method of
replacing the seals. If using this method
the air piston will need to be installed on
the main shaft. It is recommended this
would be done after the full service is
complete. Please skip to step 5 if using
the alternative method
2
3
Grease new air piston quad
seal (08-30017) and use the
seal pusher to install onto the
air piston.
shaftandairpistonassembly
Install the Split Ring (08-
30718) onto the air piston.