Manitou DORADO EXPERT 37MM Manuel utilisateur

DORADO EXPERT 37MM SERVICE GUIDE

This manual is intended to guide the user through basic service of Manitou

Dorado Expert 37mm front forks. We highly suggest the service on these forks

be performed by an experienced suspension mechanic. Service is supported by

the identication of common parts and assemblies that have been assembled into

Service Kits. The purpose of this manual will be to describe conditions that may

drive the need for service and to provide installation instructions for the kits.

Please read through the manual carefully before beginning the service of your

fork. Having a basic understanding of the tasks you are about to perform will

assist you greatly in the disassembly and re-assembly of your fork.

Please read through the required tools page and be sure you have all of the items

you will need for the service of your fork. The 50 hour service only requires the

dust wiper seals and lubricants to be replaced. The complete 200 hour service

requires all O-rings and seals shown in this guide to be replaced.

For any assistance with the service of your Dorado Expert please contact our

Technical Service Department at 888-686-3472 and email them at

techsupport@hayesbicycle.com.

INTRODUCTION

We highly recommend that service 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 fork 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: 888.686.3472

Email: techsupport@hayesbicycle.com

Hayes

Bicycle

Europe

Dirnismaning 20 a 85748 Garching (b. Munich) Germany

Phone: +49 89 203237450

Email: techsupportEU@hayesbicycle.com

Hayes

Bicycle

Asia

16F, No. 37, Sec. 3 Mincyuan E. Rd. Zhongshan District

Taipei City 10476 Taiwan ROC

Phone: 886-2-2518-1108

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

4 5

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

table of contents

SECTION PAGE NUMBER

Tools And Materials 5

Damping Leg Service Disassembly 6

Damping Leg Service Assembly 11

Spring Leg Service Disassembly 16

Spring Leg Service Assembly 19

Dust & Oil Seal Replacement 22

Travel Change 24

Exploded View, Parts List, & Torque Table 25

O-Ring Placement Diagram & Table 28

tools and materials

Below is a list of tools that will be used in the complete service of a Dorado fork:

• Dorado Complete Rebuild Kit – Manitou Part number 141-38361-K001 (Needed for

200 hour complete service)

• Dorado 37mm Seal Kit - Manitou Part Number 141-38380-K019 (Needed for 50 hour

basic service)

• Dorado Clamp Blocks – Manitou Part Number 172-31464

• 34mm and 37mm Seal Press – Manitou Part Number 172-37540-K002

• 5wt Maxima Fork oil - Manitou part number 85-0023

• Manitou 5w40 Semi-Bath Oil - Manitou part number 85-0022

• Slickoleum™ Grease - Manitou part number 141-33604-K001

• Torque Wrench

• 12mm Combination Wrench

• 13mm Combination Wrench

• 22mm Combination Wrench

• 22mm Crow’s Foot

• 2mm Allen Wrench

• 2.5mm Allen Wrench

• 5mm Allen Wrench

• 6mm Allen Wrench

• 24mm at ground Socket with ratchet

• 26mm Socket

• 16 notch Bottom Bracket Tool

• Cassette Tool (only needed for Pro fork IRT removal)

• Small Flat Blade Screwdriver

• Snap-ring Pliers

• Pick or similar tool for removing O-rings

• Blue Loctite

6 7

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

1 4

Loosen the damping leg top

cap using a 16 notch Bottom

Bracket Tool. It helps if the leg is

still clamped in the lower crown

assembly while breaking the top

cap loose (be sure the upper

crown is loosened, you only

want the lower tightened when

breaking loose the top cap).

Only loosen the top cap at this

point. Do not remove it.

Loosen the pinch bolts on the

lower crown and remove the

damping leg from the fork. You

will need to remove the frame

bumpers to do so. Put them

in a safe place so you do not

misplace them.

Tip: The ends of the Dorado sag

guide can be used to spread

the clamps apart and aid in leg

removal.

DAMPING LEG Disassembly DAMPING LEG Disassembly

Orient the fork with the knobs

facing up. Using a 2mm Allen

wrench, remove the TPC+

adjuster knob.

Remove O-ring and be sure you

capture the 2 detent balls and

springs under the knob.

Next you will remove the High

Speed adjuster knob. Remove

the c-clip that holds the knob

on using a snap ring pliers or

similar tool.

Once the c-clip is removed pull

the knob up. Be sure to capture

the O-ring, 2 detent balls and

springs under the knob.

8 9

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

DAMPING LEG Disassembly DAMPING LEG Disassembly

Remove the damping cartridge

from the inner leg using a

26mm socket.

Wrap the inner leg in a rag and

lightly clamp it into a bike stand

with the rebound shaft pointing

down towards the oor.

9You will now remove the top cap

from the rebound shaft. Place

a 12mm wrench on the ats of

the rebound shaft and use a

16 notch Bottom Bracket Tool

to unthread the top cap from

the shaft. Once the top cap is

unthreaded, remove the rebound

knob from the top cap.

Remove the fork leg from the

bike stand and pour the oil out of

the leg. Slide the inner leg out of

the outer leg and leave the outer

leg to drain in a drainage pan.

7Holding the inner leg over a

drainage pan, stroke the rebound

shaft several times to drain the

rest of the oil from the inner leg.

Remove the top cap from the fork leg using a 16 notch Bottom Bracket

Tool. The top cap is still attached to the rebound shaft at this point.

Clamp the upper sleeve of the fork in bike stand.

10 11

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

Replace the following O-rings on

the rebound damper assembly.

A. O-ring #100-012 - This is the

O-ring above the threads on the end of

the damper assembly.

B. O-ring #100-122 - This is the larger

O-ring on the damper end cap.

C. O-ring # 100-026 - This is the O-ring that

is around the outside of the compression

assembly top cap.

DAMPING LEG Disassembly

1Inspect the inner and outer

damper tubes and be sure

they are free from debris and

contaminants.

Apply a small amount of

Slickoleum grease to the O-ring

installed on the damper end cap.

Install the assembly in the inner

leg by sliding it into the bottom

of the leg. Use a 26mm socket to

tighten it into the leg. Tighten to

6.8-9 Nm (60-80 in lb).

Insert the detent springs into

opposite holes in the end cap

and place the detent balls on top

of the springs. To hold the detent

balls in place on the spring use a

small dab of grease.

DAMPING LEG assembly

TIP: You can also refer to the O-ring diagram on pages 28-29.

Pull the damping cartridge

completely out of the inner leg.

12 13

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

DAMPING LEG assembly

7Install the TPC+ adjuster knob

onto the end cap and secure

with the 2mm screw.

Insert the springs into opposite

holes on the TPC+ adjuster knob

and then place the detent balls

in the corresponding holes of the

high speed adjuster knob.

Place O-ring # 100-024 around

the TPC+ knob and apply a

small amount of grease to it.

DAMPING LEG assembly

10 Install the top cap onto the end

of the rebound shaft. Use a 16

notch Bottom Bracket Tool and a

12mm wrench to tighten to the

proper torque of 6.8-9.0 N m

(60-80 in lb).

9Replace O-ring # 100-027 on the top cap.

8Replace the oil and dust seals on the outer leg following the directions on

pages 22-23. Inspect the inside of the outer leg and the outside of the

inner leg and be sure they are free from debris and contaminants. Lube the

oil seal and dust wiper on the outer leg with a small amount of Slickoleum

grease. Slide the inner leg into the outer leg and clamp into the bike stand.

4Install the high speed adjuster onto

the end cap. Be sure that O-ring

# 100-025 below the adjuster is

in place and greased. Secure the

adjuster with the c-clip (retaining

ring pliers are recommended for

use during installation).

14 15

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

DAMPING LEG assembly DAMPING LEG assembly

After you have properly set the oil height fully extend the inner leg and

tighten down the top cap using a 16 notch Bottom Bracket Tool to the

proper torque of 6.8-9.0 N m (60-80 in lb).

Reinstall the damping leg into

the fork crowns on the bike.

Pour damper oil (5wt fork oil)

into the leg. Fill with 200cc of

damper uid.

Stroke the rebound shaft to

bleed the system and release

the air. You want to stroke the

rebound shaft a few times with

the rebound fully closed, then

turn the rebound knob open two

clicks counterclockwise. Stroke

the rebound shaft another 15-20

times and the system will be bled.

16 17

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

Release the air from the system.

Remove the air cap from the top

of the fork leg, and release the

air pressure using a shock pump.

Ensure all air is released by

gently depressing the air shaft

with a 3mm hex wrench.

If the fork is equippped

with an IRT Ensure all air is

released from that as well!

The air spring leg top cap needs

to be loosened. Loosen the

pinch bolt on the top crown, and

crack the top cap loose with a 16

notch Bottom Bracket Tool.

spring leg disassembly

Loosen the pinch bolts on the

lower crown, and remove the

leg from the fork. Be sure not

to misplace the frame bumper

that will need to come o the

fork leg.

TIP: The ends of the Dorado

sag guide can be used to

spread the clamps apart and

aid in leg removal.

spring leg disassembly

Lightly clamp the fork leg in a

bike stand. Remove the top cap

from the leg with a 16 notch

Bottom Bracket Tool. Remove the

top cap from the compression rod

with a 13mm wrench on the top

of the compression rod and a 16

notch Bottom Bracket Tool.

Pour the uid out of the leg, and

slide the inner leg out of the

outer leg. Remove the outer

leg from the stand and let it sit

above a drainage pan.

6Wrap the inner in a rag and clamp it lightly in the bike stand with the

compression rod pointing towards the ceiling.

18 19

DORADO EXPERT 37MM SERVICE GUIDE DORADO EXPERT 37MM SERVICE GUIDE

Loosen the Compression Rod Assembly from the inner leg with a

22mm wrench.

Remove Compression Rod

Assembly from the inner leg.

spring leg disassembly

Carefully remove the glide ring (129-27922-L013), back up ring (129-

31523-L338) and air piston quad seal (110-215). We recomend using a

plastic pick to ensure the piston is not damage.

Clean air piston then lightly grease the air piston quad seal with Slickoleum

grease and slide it on the air piston. Next install the back up ring and glide

ring on to the air piston.

For information on travel change see page 24 of this guide.

1Inspect the inner leg, inside and out, clean it and be sure it is free from

debris and contaminants. Lube the threads on inside of the inner leg, lube

the outer diameter of the air piston, and ll the piston cup with 3cc of

Slickoleum grease and 1cc Manitou 5w/40 Bath Oil.

Insert the compression rod, piston rst, into the top of the inner leg using

rotational motion.

Use a 22mm crows foot to

tighten the air spring end cap to

the proper torque of 1.8-2.8 N m

(15-25 in lb).

spring leg assembly

4Replace O-ring #100-027 on the

top cap.

Table des matières

Autres manuels Manitou Accessoires pour vélos

Manitou

Manitou JACK DROPPER POST Manuel utilisateur

Manitou

Manitou Axel Super 2004 Manuel utilisateur

Manitou

Manitou MARA PIGGYBACK Manuel utilisateur

Manitou

Manitou XVERT R Manuel utilisateur

Manitou

Manitou DORADO DH Manuel utilisateur

Manitou

Manitou 2001 MARS Manuel utilisateur

Manitou

Manitou SIX Manuel utilisateur

Manitou

Manitou Jack SL Dropper Seat Post Manuel utilisateur

Manitou

Manitou R7 EXPERT Manuel utilisateur

Manitou

Manitou Circus Expert Manuel utilisateur

Manitou

Manitou LUXE COMP Manuel utilisateur

Manitou

Manitou Mara Pro Manuel utilisateur

Manitou

Manitou Mattoc Manuel utilisateur

Manitou

Manitou MATTTOC PRO Manuel utilisateur

Manitou

Manitou Mezzer Pro Manuel utilisateur

Manitou

Manitou BLACK COMP 80/100 Manuel utilisateur

Manitou

Manitou DORADO Manuel utilisateur

Manuels Accessoires pour vélos populaires d'autres marques

Sigma

Sigma BC 16.16 Manuel utilisateur

Playcore

Playcore Dero Setbacks Manuel utilisateur

VDO Cyclecomputing

VDO Cyclecomputing x3dw Manuel utilisateur

Cateye

Cateye RAPID X2 Manuel utilisateur

buratti meccanica

buratti meccanica Clorofilla Trail Manuel utilisateur

Shimano

Shimano SG-8R20 Mode d'emploi

BOB

BOB YAK Manuel utilisateur

APLIC

APLIC 303303/20190717TW012 Manuel utilisateur

SRAM

SRAM AXS BlipBox Manuel utilisateur

Garmin

Garmin EDGE 500 Manuel utilisateur

Shimano

Shimano FD-RX810 Manuel utilisateur

Cateye

Cateye V2C - Manuel d'instructions

KMART

KMART 43115907 Manuel utilisateur

SIGMA SPORT

SIGMA SPORT Buster 2000 Manuel utilisateur

NVO Components

NVO Components STEM Manuel utilisateur

DAXYS

DAXYS BP188 Manuel utilisateur

XLC

XLC BV-W17 Manuel utilisateur

Deda Elementi

Deda Elementi SUPERBOX Manuel utilisateur