Manitou R7 EXPERT User manual

R7 EXPERT / PRO | SERVICE & TRAVEL GUIDE

5800 W Donges Bay Rd
Mequon, WI 53092
manitoumtb.com
888.686.3472
Support: manitoumtb.com/support
MANITOU
Warranty:
For full warranty information please visit hayesbicycle.com/warranty
Revised June 12, 2020

3
R7 EXPERT / PRO SERVICE GUIDE
This manual is intended to provide the information necessary to service the
Manitou R7 Expert and Pro Suspension fork. We highly recommend any service
or installation be performed by a qualied mechanic. These instructions can be
downloaded from the Hayes Bicycle Group website at
www.hayesbicycle.com
INTRODUCTION
We highly recommend that service to this component 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 product or
the manual itself should be directed to Hayes Customer Support at:
WARNING
! !
Hayes
Bicycle
USA
5800 W Donges Bay Road Mequon WI 53092
Phone: [phone]
Email: [e-mail]
Hayes
Bicycle
Europe
Dirnismaning 20 a 85748 Garching (b. Munich) Germany
Phone: [phone]
Email: [e-mail]
Hayes
Bicycle
Asia
16F, No. 37, Sec. 3 Mincyuan E. Rd. Zhongshan District
Taipei City 10476 Taiwan ROC
Phone: [phone]

4R7 EXPERT / PRO SERVICE GUIDE
table of contents
SECTION PAGE NUMBER
Tools And Materials 5
Casting Removal & Service 6–8
Air Spring Service 9–11
Damper Service 12–15
Casting Install 16–18
Compression Damper Install 19–21
Recommended Starting Pressure 22
Travel Change 23
Exploded Views 24–31

5
R7 EXPERT / PRO SERVICE GUIDE
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
• Semi-Bath Oil, 5/40W Synthetic
Manitou Part Number 85-0022
• 5W Maxima Fork Oil
Manitou Part Number 85-0023
• 32mm Seal Press
Manitou Part Number 172-31122
• 32mm Rebuild Kit
Manitou Part Number 141-28528-K010
• Manitou Tool Kit – Manitou Part Number 172-31133
(Includes The 3 Tools Below)
Manitou Slotted Cassette Tool
Manitou Thin Walled 8mm Socket
Manitou 24mm Flat Ground Socket
• 2mm Hex Wrench
• 4mm Hex Wrench
• 6mm Hex Wrench
• 8mm Socket
• 11mm Socket
• 22mm Wrench, Open or Box End
• Torque Wrench
• Park Tool FR-5.2 Cassette Lockring Tool, or similar
• 1” Socket, for use with Park Tool FR-5.2 Cassette Lockring Tool
• Socket Wrench
• 22mm Crow’s Foot
• Fork/Shock Pump
• Pick
• Adjustable Wrench
• Downhill Tire Lever Or Flat Blade Screwdriver
• Support Block (2”x4”x4” Wood, Plastic, or Similar)

6R7 EXPERT / PRO SERVICE GUIDE
CASTING REMOVAL&SERVICE
1Holding the rebound knob steady,
insert 2mm hex wrench into
rebound knob screw and rotate
the wrench counter-clockwise until
threads completely disengage.
Remove rebound knob and screw.
Insert an 8mm Hex wrench into
the end of the rebound rod and
rotate clockwise. The rebound
end tting will move toward the
inside of the casting. Continue
rotating until end tting disengages
completely from casting threads.
2
3Unscrew air cap and depress
Schrader valve a few times to
ensure all air is released.
Do not proceed to next
step without completely
depressurizing air spring
CAUTION

7
R7 EXPERT / PRO SERVICE GUIDE
Insert Manitou 8mm Thin Wall
Socket onto the end of the
compression rod and rotate
clockwise. The comp rod end
tting will move toward the inside
of the casting. Continue rotating
until end tting disengages
completely from casting threads.
Remove casting from fork. It is
recommended this be done over
a drain pan as the lower casting
contains semi-bath oil. Allow oil
in casting to drain out before
continuing to next step.
4
5
6Using a downhill tire lever or similar
tool, gently pry the dust seals out
of the casting.
CASTINGREMOVAL&SERVICE
Note: the compression rod can also be loosened
by using an 8mm box end wrench on the external
hex and a 4mm hex wrench on the internal
hex of the comp rod end tting. Rotating both
wrenches clockwise simultaneously will loosen the
compression rod, reducing the risk of damaging a
seized end tting.

8R7 EXPERT / PRO SERVICE GUIDE
CASTINGREMOVAL&SERVICE
8
7Remove old foam wiper rings. Clean
seal area with isopropyl alcohol.
Apply semi-bath uid to the new
foam wiper rings and install into
fork casting.
Remove springs from lip of dust
seals. Using the Manitou 32mm Seal
Press or large socket, press in the
dust seals. Reinstall springs onto
seals.

9
R7 EXPERT / PRO SERVICE GUIDE
AIRSPRINGSERVICE
1
2
3
Using Manitou 24mm Flat Ground
Socket, rotate air spring top cap
counter-clockwise and remove
when threads completely disengage
from the stanchion.
Invert the fork. Using a 22mm
wrench, rotate the air spring
end cap counter-clockwise until
threads completely disengage from
stanchion.
Remove air spring assembly. Clean
assembly with isopropyl alcohol
and a lint-free towel. Inspect air
spring shaft, bumpers, and air
piston seal for wear/damage and
replace if necessary.
Do not begin disassembly until
completely depressurizing air
spring.
CAUTION
Make sure to apply top down
force on tool to prevent slipping
NOTICE

10 R7 EXPERT / PRO SERVICE GUIDE
AIRSPRINGSERVICE
5
6
Once the air spring assembly
is removed, clean the inside of
the stanchion with isopropyl
alcohol and a lint free towel.
Be careful to not scratch
the inner surface of the
stanchion. Inspect the inside
and outside of the stanchion
for scratches or other damage.
Liberally grease the piston quad
seal and outer surface with
Slickoleum™ grease. Also add 3cc’s
of Slickoleum™ grease to the top of
the air piston.
4
Add Slickoleum™ grease to the
stanchion threads before inserting
the air spring assembly. Spread
grease across entire thread
surface.