Manitou MATTTOC PRO Manuale utente

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

JUNIT 34 PRO & EXPERT

MATTTOC PRO, EXPERT, & COMP

CIRCUS 34 PRO

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

This manual is intended to guide the user through the steps necessary to fully service and maintain

the Mattoc Pro, Expert, and Comp, along with Junit 34 Pro and Expert & Circus Pro suspension fork.



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

INTRODUCTION

4 5

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

SECTION PAGE NUMBER

Required Tools 5

Casting Removal & Service 6

Air Spring Service 9

MC2 Sealed Damper Service 16

Mattoc Pro Casting Installation 20

Mattoc Pro Compression Knob Installation 23

VTT6 Damper Service 24

ABS+ Damper Service 26

Mattoc, JUnit, & Circus Casting Installation 28

VTT6 & ABS+ Damper Installation 31

Travel Change (Optional) 34

Travel Spacers & IVA Settings 36

Exploded Views 44

Below is a list of tools necessary for changing the travel on the Mattoc, JUNIT

34, and Circus Pro forks:

• Safety Glasses

• Nitrile Gloves

• Lint-Free Rags

• Torque Wrench (6-220 in-lb [0.7-25 Nm])

• 2mm Hex Wrench

• 8mm Hex Wrench

• 14mm Box End Wrench

• Shock Pump

• Cassette Lockring tool* (e.g. Park tool FR-5.2)

• 1” socket

• 8mm Socket *

• 24mm Socket *

• (Optional, replaces items above with*) Manitou Tool Kit - Manitou part number



ground 24mm socket)

• Travel Spacer kit 141-36713-K032

Below is a list of additional tools necessary for a full service of the Mattoc,

JUNIT 34, and Circus Pro forks:

• 11mm Socket (Pro and Expert Only)

• Plastic or non-marring pick

• 

• 5wt Maxima Fork oil (85-0023) or 3wt Maxima Fork oil (141-34078-K016)

• Semi-bath Oil, 5/40w Synthetic - Manitou part number 85-0022

• Slickoleum™ Grease

• Isopropyl alcohol

• 34mm seal install tool 172-37540-K002

• Cartridge Damper Bleed Kit 141-30694-K020 (Pro Only)

• 34mm seal kit 141-39022-K020 (Pro) or 141-34000 (Exp/Comp)

• Air piston Seal Kit 141-32155-K012 (Pro/Exp) or 141-32156-K011 (Comp) or

Rebuild kit 141-39022-K021

TABLE OF CONTENTS REQUIRED TOOLS

6 7

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

1Remove rebound knob using a 2mm

Hex wrench.

Note: Be sure to hold the knob

still while removing the screw. The

damper adjuster may be damaged

if the knob is over torqued.

Hold lock-nut with 14mm end

wrench for Pro & Expert, or a

19mm end wrench for Comp.

Insert a 8mm Hex wrench into

the end of the rebound rod and

loosen clockwise until rebound rod

disengages from the lock-nut.

3Unscrew air cap and attach shock

pump. Depress pressure bleed

button until pump reads “Zero”.

Depress Schrader Valve a few times

with 2mm hex wrench to ensure all

air is released.

Manitou recommends a full service anytime the

casting is removed. If the fork is new and only

a travel change is needed, follow instructions

1-4 then skip to page 34 for Travel change

instructions.

Hold lock-nut with a 14mm (Pro/

Expert) or 19mm (Comp) box end

wrench. Using 8mm Socket, turn

the compression rod clockwise

until compression rod is disengaged

from the lock-nut.

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.

6Using a downhill tire lever or similar

tool, gently pry the dust seals out

of the casting.

CASTING REMOVAL & SERVICE CASTING REMOVAL & SERVICE

8 9

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

7Remove old foam wiper rings.

Thoroughly saturate new foam



install into fork casting.

Remove springs from outer lip of

new leg seals. Clean casting seal

press area with Isopropyl alcohol.

Using the Manitou 34/37mm Seal

Press, press in the dust seals.

Reinstall springs onto seals.

Mattoc / JUNIT Pro:

Using a standard cassette tool

and 1” socket loosen IRT cap until

threads are free from leg.

CASTING REMOVAL & SERVICE AIR SPRING SERVICE

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Using a 24mm socket, loosen IVA

cap until threads are free from leg.

WARNING

! !

MAKE SURE THE AIR IS

RELEASED FROM THE FORK.

Remove IRT air cap. Depress IRT

Schrader Valve with a 2mm hex

a few times to ensure all air is

released.

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Skip to Step 2.

10 11

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

3Mattoc / JUNIT Pro:

Pull IRT assembly straight out,

Clean with isopropyl, Inspect seal

for damage. If needed Replace IRT

piston seals.

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Pull IVA assembly straight out,

Clean with isopropyl, Inspect seal

for damage. If needed replace IVA

piston seals.

4Invert the fork and use Manitou

cassette tool with adjustable

wrench to unthread the air spring

assembly from the stanchion.OR

depress valve on end of comp-rod

with 2mm hex and stroke rod to

bottom. Slide standard cassette

lock-ring tool over threaded

adapter and unthread the air spring

assembly from the stanchion.

Remove Air Spring Assembly, clean

with isopropyl, Inspect seal for

damage. Replace air piston seal

141-32155-K012 (Pro/Exp) or 141-

32156-K011 (Comp). If Travel

change is need see page 34

before moving on.

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.

7Liberally apply Slickoleum™ grease

to the piston seal, outer piston

surface, and spring shaft. Add 3cc’s

of Slickoleum™ grease to the top of

the air piston.

AIR SPRING SERVICEAIR SPRING SERVICE

12 13

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

AIR SPRING SERVICE

8Add Slickoleum™ grease to the

stanchion threads before inserting

the air spring assembly. Spread

grease across entire thread

surface.

9Install air spring assembly into

stanchion. Using a 26mm crow’s

foot and Manitou cassette tool OR

1” Socket and Standard cassette

tool torque to 40-45 LB-IN [4.5-

5.1 Nm]. If rod is bottomed, attach

shock pump to valve and draw the

rod out until fully extended.

AIR SPRING SERVICE

Mattoc / JUNIT Pro:

Liberally apply Slickoleum™ grease

to the IRT piston seal, outer piston

surface, and IRT shaft. Apply

Slickoleum™ grease to the threads

of the stanchion.

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Liberally apply Slickoleum™ grease

to the IVA piston seal and outer

piston surface. Apply Slickoleum™

grease to the threads of the

stanchion.

11 Mattoc / JUNIT Pro:

Insert IRT piston into stanchion.

Apply even pressure to piston

surface as you work the piston seal

past the stanchion threads.

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Insert IVA Piston into the stanchion.

14 15

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

12 Mattoc / JUNIT Pro:

Install IRT cap into stanchion.

Torque to 200-220 LB-in [22.6-25

Nm] using standard cassette lock-

ring tool.

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Install IVA cap into stanchion.

Torque to 200-220 LB-in [22.6-25

Nm] using a 24mm socket.

AIR SPRING SERVICE

Mattoc / JUNIT Pro:



IRT to 100PSI.

NOTE: ALWAYS SET IRT PRESSURE

(TOP OF FORK) BEFORE DORADO

AIR PRESSURE (BOTTOM OF FORK)

Mattoc Expert / Comp, JUnit 34

Expert, Circus Pro:

Skip to step 14.



main air chamber to 30 PSI. This

will aid in installing the casting

later.

AIR SPRING SERVICE

16 17

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE

Using a 2mm Hex wrench remove

the screw of the red “LO-SPEED”

MC2 knob.

Note: Be sure to hold the knob

still while removing the screw. The

damper adjuster may be damaged

if the knob is over torqued.

Use a non-marring pick or pliers

with non-marring barrier to remove

the red “LO-SPEED” compression

knob by lifting straight up.

3With a 11mm socket, unthread the

exposed nut and remove the black

“HI-SPEED” adjustment knob.

Note: Be sure to hold the knob

still while removing the nut. The

damper adjuster may be damaged

if the knob is over torqued.

MC2 Sealed DAMPER SERVICE

4Remove the v-seal that was under

the black “HI-SPEED” adjustment

knob.

Use a standard cassette tool and

1” socket to unthread the damper

top-cap from the stanchion.

Remove damper assembly from the

stanchion. Inspect damper shaft

and bladder for any damage.

MC2 Sealed DAMPER SERVICE

Pull damper shaft to full extension.

Remove bleed-screw on side of

top-cap. Place damper top-cap

over catch pan. Cycle damper shaft

several times to cycle out old oil

from damper.

18 19

MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE MATTOC / JUNIT 34 / CIRCUS 34 SERVICE GUIDE



both syringes (141-30695-K020).

Fill one syringe with 3wt Damper oil

(141-34078-K016).

Attach the empty syringe M5x.8

adapter to top-cap bleed port.

Remove bleed-screw from damper



syringe M5x.8 adapter to end-cap

bleed port.

MC2 Sealed DAMPER SERVICE

Holding the damper end-cap

up-right in vise simultaneously



retract the empty syringe to



the syring as needed until oil is

drawn into the upper syringe.

Closing the bleed hose clamp on

both syringes cycle the damper

SLOWLY to draw air to the top

of the damper. Open bleed hose

clamps and repeat step 10 until no

air bubbles are present in oil drawn

into upper syringe.

Fully extend damper shaft and

add oil from bottom syringe until

bladder is slightly expanded.

Closing the bleed hose clamp on

both syringes remove cartridge



bench. Remove lower syringe and

replace bleed screw. Some oil may

discharge from bleed port when

removing syring. Remove upper

syringe and replace bleed screw.

MC2 Sealed DAMPER SERVICE

Install Damper cartridge into

stanchion. Using standard cassette

lock-ring tool Torque to 200-220

LB-in [22.6-25 Nm].

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