Axel GENIUS D Manuel de service

05 AXEL SERVICE MANUAL Page 1

Assembly of Compression Damping Assembly - Adjustable Compression/Lockout WARNING All top caps for Damper and Spring systems must be properly tight

3. Lightly grease the bushings on the inside of the outer leg casting and on the lower portion of the inner legs below the boots using a thick grease

5. Generously grease the spring and insert it into the inner leg. The end of the spring needs to seat onto the top of the compression rod. 6. Inser

Remove Nylon washer that rests on top of aluminum washer 4mm recessed Allen bolt Lock Out Troubleshooting Tips 1. Installation

2. Troubleshooting • If the Lock out does not lock out properly, go back through the steps listed above. • If the o-rings are damaged on the Lock o

Steps For Cable Disassembly Cable Replacement Instructions 1. Step 1: Lock out assembly should be out of fork at this point. 2. Step 2: Cab

Air Assist Trouble Shooting Tips The root cause of the air leaking from the left leg of the fork (the side with the Schrader valve on top) and blow

Bushing Removal & Installation Bushing Removal ( For Axel Super and Elite only ) (Note: use appropriate removal ring that corresponds to the leg

Bushing Removal (CONT.) Bushing Removal Instructions A. Install 25.4mm Removal ring on the shiny, smaller diameter threaded shaft. Be sure to insta

Bushing Installation (CONT.) Bushing Installation Tool Assembly With weighted handle When selecting sizer rings to install bushin

Table of Contents Description Page Introduction 3 Front Suspension Terminology 4 Disassembly/ Assembly Instructions 8 Lock Out Troubleshooting Ti

Bushing Installation (CONT.) 4. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet until proper depth is ac

Troubleshooting Chart Symptom Cause Solution Service Manual Page Oil leaks from Wiper Seals Seal not seated properly Remove Casting from Inner Legs

Axel: Schematic & Technical Specifications C GHAEDBK Model: Axel Description Torque Value Bushing Depth - Upper *8.9mm Min. (.35”

Axel Service Kits Axel Model Comp Elite Super Travel (mm) 80 100 120 80 100 120 70-100 RTWD 90-120 RTWD Comp Damp FFD A 85-5253 Comp Dam

Axel Service Kits (Cont.) Axel Model Comp Elite Super Travel (mm) 80 100 120 80 100 120 70-100 RTWD 90-120 RTWD Ride Kits G

INTRODUCTION This manual is intended to guide the user through basic service of Manitou Axel front forks. Service is supported by the identifica

FRONT SUSPENSION TERMINOLOGY Air Cap – Top cap that threads into top of air/spring leg (this is the left leg of the fork as you are seated on the sea

FRONT SUSPENSION TERMINOLOGY (CONT.) Hydraulic Fork Oil – Oil used in suspension designs to provide damping. It has special characteristics that dete

FRONT SUSPENSION TERMINOLOGY (CONT.) Piston – In front suspension, the part of the damper that slides back and forth inside of the damping leg that h

FRONT SUSPENSION TERMINOLOGY (CONT.) Slider/Outer Casting – The tube (outer casting leg) of the suspension fork that0. remains fixed to the wheel. It

2005 Axel Forks Disassembly and Rebuild Instructions Disassembly Instructions Removal of Outer Casting 1. From the left leg dropout (Left when sit

Removal of Compression Damping Assembly Forks with FFD (non-adjustable) Damping 1. Remove top leg cap (FFD Assy) on right hand side using 27mm socke