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2006 Swinger Shock Service Manual - Rev NC
2006 Swinger Shock Service Manual - Rev NC
MANUAL
REV NC.
Page 1
REV NC
Description
Page
INTRODUCTION
GLOSSARY
RIDE KITS
10
10
11
11
DAMPING SYSTEM
12
12
12
13
15
14
22
15
27
16
TROUBLESHOOTING
33
17
35
18
36
Contact Information
Answer Products Customer Service Department
28209 Ave. Stanford
Valencia, CA 91355
Toll Free: (800) 423-0273
Direct : (661) 257-4411
FAX:
(661) 775-1798
E-mail: warranty@answerproducts.com
tech@answerproducts.com
Web site: www.answerproducts.com
Page 2
REV NC
SECTION 1: INTRODUCTION
This manual is intended to guide the user through basic service of Manitou Swinger rear shocks.
Service is supported by the identification 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.
Due to the time-consuming nature rear shock service, at this time our primary focus is to offer
service kits that minimize the amount of downtime and labor involved. As the program matures,
and we are able to gather feed back from our customers, we may offer kits to a more detailed
level.
GENERAL WARNING: Rear shocks by design contain gases and fluids under extreme
pressure and warnings contained in this manual must be observed to reduce the
possibility of injury or possible death. Following these instructions can help you reduce
the risk of being injured. Any questions in regards to the information in this manual
should be directed to Answer Products Customer Service at (661) 257-4411.
WARNING: The Swinger Shock uses compressed air to provide fluid pressure in the
damping system and spring resistance in Air models. BOTH systems must be relieved of
pressure prior to servicing these systems. Failure to relieve air pressure could result in
injury or possible death.
CAUTION: The Swinger Shock uses precision machined aluminum and other soft alloy
components. Using correct tools for assembly is essential to prevent damage.
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Page 4
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SECTION 4: AIR SPRING SYSTEM AND SPV AIR PRELOAD, SWINGER AIR,
S-Type
WARNING: The Swinger Air uses compressed air to provide resistance to compression in
place of a coil spring. You must be certain that the air canister is relieved of all pressure
prior to servicing the air system. Failure to relieve air pressure could result in injury or
possible death.
Sealing of the shock is accomplished through a series of o-rings, quad seals, and wipers. When
the air canister is removed, these seals can be replaced from Seal Kit C.
Adjuster Eyelet
(Air Spring)Schrader
Page 5
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AIR SPRING SYSTEM AND SPV AIR PRELOAD, SWINGER AIR/ S-TYPE SPV(CONT.)
Page 6
REV NC
DU Bushing
Eyelet
.
Figure 1
Figure 2
MOUNTING HARDWARE REPLACEMENT
Hardware should have a slight press fit into the DU bushing and can be tapped in place with a
rubber mallet or soft jaws in a vise. Apply a small amount of thick grease such as Motorex Bike
Grease 2000 (PN 85-0033) to the hardware before installation.
There are virtually an infinite number of hardware combinations in use on bikes today. When
ordering hardware from Answer Products, It will be necessary to identify the eyelet width, overall
width and mounting hole diameter.
MOUNTING HARDWARE REPLACEMENT (CONT.)
Page 7
REV NC
REMOVAL
1. Remove hardware from the shock.
2. Insert unthreaded end of punch into the
removal tool first and screw in about half a
turn.
Punch
Page 8
REV NC
INSTALLATION
1. Place a bushing onto the threaded end of
the punch and into the removal tool; screw
in about half a turn.
Bushing
Page 9
REV NC
Retaining Collar
Spring Preload Adjustment Ring
Page 10
REV NC
Rebound Knob
Removal
1. Remove control eyelet as shown under
Bottom out Bumper Replacement, Swinger
Coil.
2. Remove 1.5mm hex set screw located under
the control eyelet with the set screw pointed
up. Underneath the set screw is a spring
and detent ball bearing. Turn the eyelet
over on a cloth rag and tap the eyelet to
dislodge the spring and ball.
3. Unscrew the rebound knob from the eyelet.
Page 11
Set Screw
REV NC
Set Screw
Installation
Spring
Detent Ball
Knob Detents
Page 12
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Page 13
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Control Eyelet
Page 14
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IFP
Damper Cap
Page 15
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Page 16
REV NC
Damper Cap
Backing Plate
Page 17
REV NC
IFP
Page 18
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Page 19
REV NC
Damper Needle
Note: The following instructions will work
on all year model 4 and 6-way Swinger
shocks.
Damper Cap
Page 20
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14. Fill body and reservoir with oil. On the 6way shocks open the H/L circuits all the
way. Using the IFP Removal tool cycle the
oil thru the damping circuits between the
main body and the reservoir. Top off the oil
levels in the shock and the reservoir. Push
the damper shaft back into the main body;
tap the assembly to remove any air that
maybe trapped in the ports of the piston.
Once the end cap touches the shock body,
screw it in and tighten it to 61-78in/lbs or
70-90 Kg/cm. Fully extend the damper
shaft.
Page 21
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Page 22
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Page 23
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Air Piston
Page 24
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(1)
(1)
Page 25
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Page 26
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Page 27
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Page 28
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Air Piston
Page 29
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(2)
(2)
(1)
(3)
(2)
Page 30
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Page 31
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Page 32
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Page 33
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Cause
Solution
Service
Section
ALL SHOCKS
Cannot set pedaling
platform
Damping System
Air loss from SPV
Tighten or replace Schrader core
system: SPV
or replace Schrader assembly.
Schrader valve leaks
SPV Valve failure
Close rebound knob (clockwise).
If the shock rebounds fast after
compression, the SPV valve may
be defective. If the rebound is
very slow, the valve is probably
OK. Inspect and replace if
necessary
Air in damping system Bleed damping system
Interference with
Replace. Confirm clearance after
suspension linkage or Schrader replacement
other frame
components
Air in damping system Bleed damping system
12 - 15
12 - 15
4
12 - 15
12 - 15
6 -7
Air Spring
Air spring Schrader
Tighten or replace Schrader core
valve leaks
or replace Schrader assembly.
Seal failure on Air
Replace seal(s)
Canister
Seal failure on Air
Replace seal(s)
Piston
Failure of negative
Replace air canister and seals
spring
Page 34
REV NC
4
4
4
4
14 - 15
Cause
Solution
Service
Section
Air Spring
Air spring pressure
Increase air canister air pressure
too low
Worn bottomout
Replace bottomout bumper
bumper
Failure of negative
Replace air canister and seals
spring
Damaged adjuster
Replace o-ring
piston o-ring
Worn or damaged
seals allowing oil to
escape from damper
chamber
4
14 - 15
4
15
SWINGER COIL
Hard bottomout
Spring System
Spring rate too low
Replace with firmer spring
Worn bottomout
Replace bottomout bumper
bumper
Air in damping system Bleed damping system
Damping System
Worn or damaged
Replace adjuster needle and/or oadjuster needles
rings
and/or o-ring allowing
oil to escape
Worn or damaged
Replace seals and bleed damping
seals allowing oil to
system
escape from damper
chamber
User attempted to
Replace rebound knob
remove knob during
spring replacement
Damaged adjuster
Replace o-ring
piston o-ring
Page 35
REV NC
8
9
12 - 13
13
12 - 13
11
13
SECTION 17
TABLE 1
FASTENER TORQUE REQUIREMENTS
Feature
Torque
Swinger Coil
Air Volume Adjuster, Swinger Coil 4&6 Way
Damper Cap
Damper Piston Bolt
Damper Shaft to Control Eyelet
Schrader Valve Stem
70 - 90 KgCm ( 61 to 78 inlbs)
70 - 90 KgCm ( 61 to 78 inlbs)
70 - 90 KgCm ( 61 to 78 inlbs)
90 - 110 KgCm ( 78 to 95 inlbs)
5 10 KgCm ( 4 to 9 inlbs)
Page 36
REV NC
Kit
Swinger
3-Way
S-Type
4-Way
SRL
SPV
Air
Air Canister
Air Canister, 152mm Eye to Eye, 32mm Travel
83-2221
83-2698
83-2222
83-2699
83-2224
83-2700
83-2227
83-2702
83-2228
83-2229
83-2230
83-2271
Schrader Valves
Swinger SPV Schrader Valve Assy; inc O-Ring, Red
83-2233
83-2241
83-2240
85-6576
85-6735
85-6740
85-6577
85-6583
85-6736
85-6741
85-6579
85-6585
85-6737
85-6742
85-6580
85-6586
85-6738
85-6743
85-6582
85-6587
83-2243
83-2241
Shock, No Hardware, 320mm Eye to Eye, 63mm Travel/w hiem joint LRS
85-6588
85-13836
85-4493
85-4485
83-2239
SPV Valve
066299
85-4457
83-2706
83-2526
83-2974
Seal Kit
83-2708
83-2709
85-6277
83-2719
83-2720
83-2721
83-2722
83-2724
83-2273
Page 37
83-2723
83-2724
REV NC
Kit
Swinger
3-Way
S-Type
4-Way
SRL
SPV
TBD
TBD
Air
DU Bushing Kit
DU Bushing Kit
83-2272
Sticker Kit
83-2250
Tools
85-6105
83-2251
85-3007
85-6107
DU Bushing Tool
85-4413
85-4414
85-6075
85-4430
85-4406
85-4162
85-4163
Fixture for Clamping Reservoir and Damper Body, Swinger Air and Coil
85-6031
Page 38
83-2694
REV NC
Kit
Swinger Coil
3-Way
4-Way
Revox
6-Way
ISX
Schrader Valves
Swinger SPV Schrader Valve Assy; inc O-Ring, Red
83-2242
83-2233
85-6589
85-6595
85-6602
85-6590
85-6596
85-6603
85-6591
85-6598
85-6604
85-6592
85-6599
85-6605
85-6775
85-6593
85-6600
85-6606
85-6776
85-6594
85-6601
85-6607
85-6777
83-2243
85-6280
85-6281
Rebound Knob
85-4493
85-4485
83-2239
83-2234
066299
066299
SPV Valve
85-6098
Seal Kit
85-6778
85-4492
83-2712
83-2713
83-2714
83-2715
83-2716
83-2717
DU Bushing Kit
E
F
83-2881
83-2710
83-2718
83-2719
83-2724
85-6105
83-2252
83-2253
83-2254
85-3007
85-6107
DU Bushing Tool
85-4423
85-4163
Fixture for Clamping Reservoir and Damber Body, Swinger Air and Coil
85-6031
Page 39
TBD
85-4414
83-2879
83-2880
83-2707
Tools
85-4485
83-2878
Sticker Kit
83-2876
85-5148
TBD
REV NC
Kit
Ride Kits
Swinger
3-Way
4-Way
Revox
6-Way
85-6660
85-6661
85-6662
85-6663
85-6664
85-6665
85-6666
85-6667
85-6668
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 250
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 300
85-5431
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 350
85-6111
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 400
85-6112
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 450
85-6113
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 500
85-6114
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 550
85-6136
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 600
85-6671
Spring for Coil Shock 190 or 200 X 50 (7.5" or 7.875" X 2.0"), Rate: 650
85-6672
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 250
85-6700
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 300
85-6701
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 350
85-6702
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 400
85-6703
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 450
85-6704
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 500
85-6705
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 550
85-6706
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 600
85-6707
Spring for Coil Shock 200 x 57mm (7.875" X 2.25"), Rate: 650
85-6708
85-6186
85-6187
85-6188
85-6189
85-6190
85-6191
85-6192
85-6675
85-6676
Spring for Coil Shock 222 X 70 (8.75" or 9.0" X 2.75"), Rate: 250
85-6193
Spring for Coil Shock 222 X 70 (8.75" or 9.0" X 2.75"), Rate: 300
85-6137
Spring for Coil Shock 222 X 70 (8.75" or 9.0" X 2.75"), Rate: 350
85-6117
Spring for Coil Shock 222 X 70 (8.75" or 9.0" X 2.75"), Rate: 400
85-6118
Spring for Coil Shock 222 X 70 (8.75" or 9.0" X 2.75"), Rate: 450
85-6119
Spring for Coil Shock 222 X 70 (8.75" or 9.0" X 2.75"), Rate: 500
Page 40
ISX
85-6185
85-6120
85-5437
83-2882
REV NC
Kit
Ride Kits
Swinger
3-Way
4-Way
6-Way
ISX
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 250
85-6193
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 300
85-6137
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 350
85-6117
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 400
85-6118
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 450
85-6119
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 500
85-6120
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 550
85-5432
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 600
85-6679
Spring for Coil Shock 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 650
85-6680
Ti Spring Coil Shocks 222 or 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 300
85-6686
Ti Spring Coil Shocks 222 or 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 350
85-6687
Ti Spring Coil Shocks 222 or 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 400
85-6688
Ti Spring Coil Shocks 222 or 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 450
85-6689
Ti Spring Coil Shocks 222 or 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 500
85-6690
Ti Spring Coil Shocks 222 or 230 X 70 (8.75" or 9.0" X 2.75"), Rate: 550
85-6691
85-6711
85-6712
85-6194
85-6195
85-6196
85-6197
85-6198
85-6199
85-6201
85-4460
85-6683
85-6692
85-6693
85-6694
85-6695
85-6696
85-6697
85-6850
85-6851
85-6852
85-6853
85-6854
85-6855
85-6856
85-6857
85-6858
85-6859
Page 41
REV NC
A - Air Canister
Page 42
REV NC
C - Seal Kit
D - Hardware
E - DU Bushing Kit
F - Sticker Kit
G - Ride Kits
G Spring Collar
G - Bottomout Bumper
Page 43
REV NC
H - DU Bushing Tool
Page 44
REV NC
Page 45
REV NC