Manitou Mattoc User manual

MATTOC TRAVEL ADJUST MANUAL
2
Table of Contents
Secon Page Number
Introducon & Required Tools 3-4
Secon 1 - Fork Disassembly 5-9
Secon 2 - Travel Adjust, 26” Forks 10
Secon 3 - Travel Adjust, 27.5” Fork 11
Secon 4 - Fork Assembly 12-17
Hayes Components USA
5800 W. Donges Bay Rd.
Mequon, WI 53092
Tel: [phone]
Email: [e-mail]
Web: www.hayescomponents.com
Hayes Components Europe
Dirnismaning 20 a
85748 Garching (b. Munich)
Germany
Email: [e-mail]
Web: www.hayescomponents.com

3
MATTOC TRAVEL ADJUST MANUAL
INTRODUCTION
This manual is intended to guide the user through the steps necessary to internally adjust
the travel of the Maoc Pro and Expert forks. NOTE: This manual does not cover the
steps need to convert the fork from one wheel size to another. Please see the Maoc
Service Guide for instrucons on how to perform this.
Suspension forks by design can contain preloaded springs, gases and
uids under extreme pressures. Warnings contained in this manual must be observed to
avoid damage to fork, serious injury or even death.
We highly recommend that service to this fork be performed by a
cered bicycle mechanic. Failure to follow instrucons presented in this manual could
lead to serious injury or death. Any quesons about the servicing of this fork or the
manual itself should be directed to Manitou Customer Support at:
Phone: [phone]
Email: [e-mail]

MATTOC TRAVEL ADJUST MANUAL
4
Below is a list of tools necessary for changing the travel of the Maoc fork.
Safety Glasses
Nitrile Gloves
Lint-Free Rags
Torque Wrench
Slickoleum™ Grease
Semi-bath Oil, 5/40w Synthec Oil - Manitou part number 85-0023
Maoc Service Tool Kit - Manitou part number 172-31133
This kit contains all tools below for servicing the Maoc fork:
- Maoc 8mm Thin Wall Socket
- Maoc Cassee Tool
- Maoc Flat Ground 24mm Socket
8mm Allen Wrench
8mm Allen Socket
2mm Allen Wrench
2mm Allen Socket
3mm Allen Wrench (oponal)
4mm Allen Wrench (oponal)
Fork/Shock Pump
REQUIRED TOOLS

5
MATTOC TRAVEL ADJUST MANUAL
SECTION 1 - FORK DISASSEMBLY
1. Remove air valve cap.
2. Using a 2mm Allen wrench, remove
the rebound damper knob.
1
2a
2b

MATTOC TRAVEL ADJUST MANUAL
6
3. Insert an 8mm Allen wrench into the
end of the rebound damper rod. Turn
wrench clockwise unl damper rod can
be pushed into fork casng.
3a
3b
3c

7
MATTOC TRAVEL ADJUST MANUAL
4. Using the Maoc 8mm Thin Wall Socket,
turn the compression rod clockwise unl
compression rod is disengaged from the
casng threads.
4
5. Remove casng from the fork. It is
recommended that this be done over a
drain pan as there is semi-bath oil in the
lower legs that will be released when
casng is removed.
5
6. Aach shock pump to the air valve on
the compression rod and use the pressure
release buon to release all air pressure
from the fork. If your shock pump does not
have a pressure release on it you can use
a 3mm Allen wrench to depress the valve
core and release the air.
Air pressure must be released
prior to disassembly of the fork. Failure to
properly and fully release air pressure could
result in serious injury or death.
6

MATTOC TRAVEL ADJUST MANUAL
8
7. With shock pump sll aached and
pressure release buon depressed,
compress the compression rod assembly
into the upper stanchion of the fork.
Compress rod unl boom out bumper is
contacng the end cap. If your shock pump
does not have a pressure release buon use
a 3mm Allen wrench to depress the valve
core while pushing compression rod into
stanchion.
8. Place Maoc Cassee Tool into the
compression rod assembly end cap.
9. Using an adjustable wrench or similar
tool, turn the cassee tool counter
clockwise to remove compression rod
assembly from fork stanchion.
7
8
9

9
MATTOC TRAVEL ADJUST MANUAL
10. Remove compression rod assembly
from fork.
11. Using the Maoc 24mm Flat Ground
Socket slowly remove the air cap from the
fork.
NOTE: A standard socket can be used as
well however the rounded edges of a
standard socket can cause the socket to
jump o of the air cap while turning causing
cosmec damage to the fork.
10a
10b
11a
11b

MATTOC TRAVEL ADJUST MANUAL
10
SECTION 2 - TRAVEL ADJUST, 26” FORKS
The below photos show the dierent travels achievable on the Maoc 26” forks by
adding and removing the travel spacers on the compression rod assembly. Travel
spacers are boxed in yellow below for reference. When seng the fork at 170mm you
will remove all travel spacers from the compression rod.
140mm
150mm
160mm
170mm (26” forks only!)

11
MATTOC TRAVEL ADJUST MANUAL
SECTION 3 - TRAVEL ADJUST, 27.5” FORKS
The below photos show the dierent travels achievable on the Maoc 27.5” forks
by adding and removing the travel spacers on the compression rod assembly. Travel
spacers are boxed in yellow below for reference. When seng the fork at 160mm you
will remove all travel spacers from the compression rod.
The boom spacer on the Maoc 27.5” compression rod is required to
maintain proper re clearance from the crown. Removing this spacer could cause the crown
to contact the re during riding and cause serious injury or death.
140mm
150mm
160mm
DO NOT
REMOVE!
DO NOT
REMOVE!
DO NOT
REMOVE!

MATTOC TRAVEL ADJUST MANUAL
12
SECTION 4 - FORK ASSEMBLY
1. Apply a generous amount of Slickoleum™
grease to air piston seal and glide ring.
1
2. Slide compression rod end cap to the
very boom of the rod assembly unl the
boom out bumper contacts end cap. Insert
assembly into fork stanchion. Thread the
end cap in a few turns by hand.
2a
2b

13
MATTOC TRAVEL ADJUST MANUAL
4. Using the Maoc Cassee Tool and a
torque wrench (a socket will t over the
Cassee Tool, shown in picture) ghten the
compression rod end cap down to:
60-80 in lbs. [6.8-9.0 Nm]
4
5. Rotate fork to riding posion and add a
liberal amount of Slickoleum™ grease into
the stanchion on top of the compression
rod air piston.
6. Install Air Cap using the Maoc Flat
Ground 24mm Socket and torque wrench.
Tighten cap to 60-80 in lbs. [6.8-9.0 Nm].
6a
6b

MATTOC TRAVEL ADJUST MANUAL
14
7b
7. Invert fork and aach shock pump to the
air valve. Depress the air release buon on
the pump and pull compression rod out to
fully extended posion. If your shock pump
does not have an air release buon use a
3mm Allen wrench to depress valve core
and extend compression rod.
8. Using a shock pump pressurize the air
chamber. Put in 20-50 PSI.
NOTE: This is to only help hold the
compression rod in place for casng
installaon.
8
h

15
MATTOC TRAVEL ADJUST MANUAL
9. Ensure rebound damper rod is pulled out
to full extension.
9
10. Apply Slickoleum™ grease to the dust
seals.Slide casng onto fork uppers.
Be careful not to fold over the lips of
the dust seals and inner oil seals during
installaon. Only slide them on about
halfway at this point.
10a
10b

MATTOC TRAVEL ADJUST MANUAL
16
12. Slide casng down unl it contacts the
rebound and compression rod assemblies.
Using a 8mm Allen socket and a torque
wrench, ghten the rebound damper rod by
turning it counter-clockwise. Tighten to 30-
40 in lbs. [3.5-4.5 Nm].
13. Using the Maoc 8mm Thin Wall
socket and torque wrench, ghten the
compression rod into the casng by turning
it counter-clockwise. Tighten to 30-40 in
lbs. [3.5-4.5 Nm].
12
13
11. Insert Manitou Semi-bath oil into each
side of the casng.
Maoc -7cc’s in each leg
Magnum - 15cc’s in each leg
11a
11b

17
MATTOC TRAVEL ADJUST MANUAL
15. Using a shock pump and the Maoc
set-up guide (available online at www.
manitoumtb.com), pressurize fork to
your opmum PSI and install air cap.
15
14. Install rebound damper adjust knob
and using a 2mm Allen wrench ghten
to 4-6 in lbs. [0.5-0.7 Nm].
14a
14b