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BLACK ELITEŽ INSTRUCTIONS



MANITOU BLACK ELITE® SERVICE AND WIPER REPLACEMENT

These instructions apply specifically to the '03 BLACK ELITE®. The procedure for other Microlube-equiped BLACK® forks will be similar. THE NEWER "SEMI-BATH" BLACK® FORKS WILL REQUIRE A DIFFERENT KIT WITH AN INNER OIL SEAL. THE KIT FOR THE SEMI-BATH FORKS IS NOW AVAILABLE!


TIP: To make some of the subsequent steps a little easier, place your new Enduro Wipers in the freezer just before starting your fork service (this will cause the inner steel sleeve to contract, reducing the outside diameter and easing installation).

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(1) Gather the following tools and supplies:

  • Large plastic bucket
  • 2MM and 8MM Allen wrenches
  • 7/16" wrench
  • Small, flat-bladed screwdrivers
  • 20MM socket
  • Torque wrench
  • Clean terry rags
  • 5 wt. fork fluid
  • Heavy Synthetic Grease
  • "Super-Slick Grease" or "PrepM"
  • Microlube Grease Gun


(2) Begin with the fork in the extended travel position. If you are performing the work with the fork attached to the bike, remove the front wheel, disconnect the brake cable and computer lead, etc.. If the fork is removed, clamp the steerer tube in a bike stand.




(3) Use the 2MM Allen wrench to remove the Rebound Knob retaining screw. Pull straight down on the knob to remove.














(4) With the 8MM Allen wrench, turn the lower rod clockwise (bottom view) to separate it from the lowers (thread the shaft up into the lowers).














(5) Using a 7/16" wrench, remove the retaining bolt at the bottom of the left leg.*



*All "left/right" designations given in these instructions are from the rider's perspective.










(6) Slide the mini-boots up the stanchion tubes prior to removing the slider assembly.


















(7) Pull downward on the slider assembly and remove it from the stanchion tubes.



















(8) Remove the "Mini-boots" and wipe the stanchions clean with a dry cloth.















(9)
Remove the wipers by inserting a flat-bladed screwdriver between the bottom of the wiper and the top of the upper bushing. The wiper itself will act as a cushion for the screwdriver shaft, but it is recommended that the shaft also be wrapped in tape to prevent damge to the paint on the top of the sliders. Pry out the wiper by exerting downward pressure on the handle (do not twist the screwdriver blade).













(10) If you have difficulty removing the wipers, rotate the screwdriver to different positions and pry upwards until the wiper "pops" out, as pictured (be careful not to scratch the metal surface behind the wipers).















(11) Clean the the lowers using a clean cloth and, if necessary, a mild degreasing solvent. Dry throroughly.















(12) If you do not wish to service the spring stack, skip to step (27).

Use the 2MM allen wrench to remove the Rapid Travel adjuster knob. (Note that the knob is in the extended travel position.)















(13) Use a 20mm socket to remove the top cap.

















(14) Carefully loosen the plastic nut at the bottom of the left stanchion.










(15) Remove the internals of the stanchion tube by holding on to the Travel Adjustment Assembly at the bottom of the stanchion, while applying downward pressure to the top of the spring assembly. (This will remove the Travel Adj Ass'y, coil spring, etc., leaving the stanchion tube empty).







(16) In preparation for cleaning the inside of the left stanchion, spread out a clean cottom shop towel. Cut off two opposite corners and roll the cut sides inward until they meet. Fold the two sides together and twist.












(17) Insert one end of the twisted towel into the opening of the crown and push it through by twisting the towel and until it tightens, and then pushing it further into the stanchion. Continue until the end of the towel comes out of the bottom of the stanchion tube.










(18) Pull the towel out through the bottom of the stanchion tube and inspect the inside of the tube. If grease is still present, repeat the proceedure with a clean towel.
















(19) Separate the Travel Adjuster Assembly from the Coil Spring. Remove the plastic insert from the bottom of the spring.














(20) Fold over and insert a clean, cotton towel into the center of the spring coil and wind the spring by hand so that the towel works its way down the spring. If one "pass" does not remove the old grease, repeat as necessary. Also clean the plastic insert and the Travel Adjustment Assembly. Word to the wise: Clean the Travel Adjustment Assembly without removing the small spring.







(21) Lubricate the spring stack with a heavy-bodied grease such as Pedro's SynGreaseŽ. Generously lube the plastic insert and the Top Travel Adjustment Assembly (for purposes of clarity, some of the pictures do not show these parts lubed).







(22) Put the plastic insert back into the bottom of the coil spring and insert the "wire loop" of the Travel Adjusment Assembly into the slot (you will notice that turning the "loop" will cause the travel-reducing "wings" to extend from the assembly. Be sure that the wings are NOT extended during assembly, as the fork was dis-assembled in the extended travel position). The assembly is shown without grease for clarity, but be sure to apply a generous amount of heavy grease.








(23) Slide the entire assembly (Top Travel Adj, plastic insert, spring, etc.) up the left stanchion tube.


















(24) Carefully tighten the plastic nut into the bottom of the stanchion. DO NOT OVER-TIGHTEN. It is only necessary to "snug" it.
















(25) Carefully tighten the top cap using a 20mm socket. DO NOT OVER-TIGHTEN. It is only necessary to "snug" it.

















(26) Replace the Travel Adjustment Knob (orient the indicator in the "long travel" position, line up and push down into place). Tighten the 2mm retaining screw.













(27) If you do not wish to change the damping Fork Fluid in the right stanchion tube, skip to step (31).

Use the 2mm Allen wrench to remove the retaining screw and pull off the Compression Damping Adjuster knob. Take note of the indicator position.











(28) Use a 20mm socket to remove the Compression Damper Assembly.















(29) Pour the old oil out of the stanchion tube.








 




(30) Pump the rebound damping rod in and out a few times to help remove any trapped oil. If the old oil is cloudy, you may want to put the fork in an upright position, add a small amount of clean oil, pump the rebound damping rod a few times, and re-drain the oil. If the oil is particulary dirty, you may want to remove the Rebound Damping Assembly and use a mild degreasing cleaner on all associated parts.









(31) Use "Super-Slick Grease" to lubricate the top of the lowers where the wipers will be seated. (If you followed the "tip" at the beginning of these instructions, remove the new wipers from the freezer.) Lubricate the outside of the Enduro wipers.















(32) Start the wipers into the lowers by hand, taking care to start them straight and evenly. You may be able to apply body weight and seat the wipers by hand (more likely you will need the following steps).










(33) Place a piece of 1-1/2" PVC Sch 40 pipe to on top of the wiper. The pipe will span the raised lip of the wiper and rest on the flat, outer surface. Apply body weight slowly and evenly to seat the wipers.









(34) The wipers are properly seated when they are resting upon the upper bushings, as picured. A raised lip is provided in the event that you wish to re-installed the "mini boots." For best results, we recommend using the Enduro wipers without the boots.









(35) Carefully start the lowers onto the stanchion tubes. Work one wiper over its respective stanchion, and then hold it in place while starting the second wiper. Once both are started, slide the lowers up into place.










(36) Use the 8mm Allen wrench to thread the Rebound Damping Rod into the slider assembly (Turn counter-clockwise to tighten).






(37) Push the Rebound Knob back into place and tighten the retaining screw with the 2mm Allen wrench.

If you do not remember where the indicator knob was:
1) Simply push the knob into place with the indicator centered.
2) Turn the knob in the "Less Rebound" damping direction until it stops.
3) If the indicator on the knob reaches the minimum setting, pull the knob off, re-inserted it with the indicator centered, and continue to turn toward the minimum setting until until you are at the end of the available adjustment.
4) Replace the knob with the indicator at the minimum setting (you may have to "back off" the adjustment slightly to get the knob to slide in with the indicator in the proper location).
5) Tighten the retaining screw.



(38) Thread the left side retaining bolt in by hand and use the 7/16 box end wrench to tighten it.








(39) If you are not changing the damping Fork Fluid, proceed to step (41).

Add Maxima 5wt Fork Fluid (or equal) to the following levels (measured from the top of the crown to the surface of the oil, w/fork in longest travel setting):

BLK ELITE 80/100.........4.5-4.9" (115-125mm)
BLK ELITE 100/120.......4.5-4.9" (115-125mm)
BLK ELITE w/TPC+.......3.4-3.6" (86-91mm)


Re-install the Compression Damping Assembly and tighten with the 20mm socket wrench.







(40) Re-insert the Compression Damping Adjuster knob. If you do not remember the proper orientation of the indicator, use a similar proceedure to that described in step (37). Use the 2mm Allen wrench to tighten the retaining screw.










(41) Clean the Microlube ports and pump a few squirts of PrepM into each side (our preferred lube for this purpose is "SUPER-SLICK GREASE".)
















(42) HAVE FUN!

Allow a few rides for complete break-in of the new wipers. Carefully clean the stanchion tubes and the tops of the wipers after each ride. When no Super-Slick Grease  residual "ring" is visible on the stanchion tubes following a ride, it is probably time for a few more squirts to maintain plushness.

If you have any questions about these instructions, please use the link below to contact us.




INFO@REALWORLDCYCLING.COM

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