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  1. #1
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    2002 Specialized Enduro Front Fork

    Hey guys,

    i have a 2002 specialized enduro with oem front fork that will not adjust and needs repair I'm thinking about replacing it with a new front fork under $500 I primarily cross country ridebut am very unfamiliar with what fork to get. I heard the rock shock Rebais a good fork any advice would be appreciated thanks.

  2. #2
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    What is the fork?
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    Manitou elite 100/120 with reverse arch technology it also says tpc on it.

    Thanks

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  5. #5
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    Quote Originally Posted by Ljsimp View Post
    Manitou elite 100/120 with reverse arch technology it also says tpc on it.

    Thanks
    Service it. That fork is still better than 90% that you'll find today.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    It does not have black written on it so the new air shocks are not much better then this spring shock?

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    I called suspension experts in North Carolina but this is one of the few front forks they no longer work on. Anyone have a recommendation? Basically its not adjustable and I am not sure what is damaged.

  8. #8
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    Quote Originally Posted by Ljsimp View Post
    I called suspension experts in North Carolina but this is one of the few front forks they no longer work on. Anyone have a recommendation? Basically its not adjustable and I am not sure what is damaged.
    It's a very good fork and very simple to work on. Which adjustment isn't working?

    There are four adjustments on the 2002 Black I have here. On the top you have spring preload and low speed compression.
    On the bottom you have a lock-down travel adjust and rebound adjust.

    Forget about the preload and travel adjust. Do the rebound and compression knobs still turn? About 1/4 turn each.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    Thank you for your reply Dougal. The black knob at the top that has a handle moves back and fourth but feels like it is disengaged, it does not change anything. With my hands I can compress 3/4 of the fork. I work on my own motorcycle, and vehicles so if I am lead in the right direction I think I can hopefully fix the fork. Below are pictures I just took of my fork.




    This is a website I saw to rebuild a fork is this one you recommend?
    Enduro Installation for Manitou Black Elite

  10. #10
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    That is the exact fork I have here. Yes the instructions on the Enduro website are good. That is a grease fork so easy (but a bit messy) to maintain.

    Just remember, the 8mm allen key threads clockwise into the fork leg to remove.

    The top knob with the lever on it is low speed compression. If the oil level in your fork has dropped then that won't do anything. But even when working it is subtle adjustment.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    Thanks again for the info. Real quick is this a proper list of items? What seals/bearings do you recommend replacing I think they are OEM.

    Grease gun nozzle:
    Amazon.com : Dualco 4.5" Needle Nozzle : Speedplay Grease Gun : Sports & Outdoors

    5w oil:
    Amazon.com: Maxima 54916 5WT Standard Hydraulic Fork Oil - 16 oz. Bottle: Automotive

    Synthetic Grease:
    http://www.amazon.com/Valvoline-VV98...ease+cartridge

    Honey grease I forgot the name of this one I couldn't find it on amazon.

    What do you think?

  12. #12
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    Quote Originally Posted by Ljsimp View Post
    Thanks again for the info. Real quick is this a proper list of items? What seals/bearings do you recommend replacing I think they are OEM.

    Grease gun nozzle:
    Amazon.com : Dualco 4.5" Needle Nozzle : Speedplay Grease Gun : Sports & Outdoors

    5w oil:
    Amazon.com: Maxima 54916 5WT Standard Hydraulic Fork Oil - 16 oz. Bottle: Automotive

    Synthetic Grease:
    Amazon.com: Valvoline VV985 SynPower Synthetic Grease (for all US, European and Japanese Vehicles), Single Pack: Automotive

    Honey grease I forgot the name of this one I couldn't find it on amazon.

    What do you think?
    The grease you want is Prep-M or Slick-honey (also called Slickoleum). Prep M can use the grease-gun, but it's not strictly needed. You can grease them without by pulling the lower legs.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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  13. #13
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    Ok I ordered the parts I will update when the rebuild is complete

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    I have received the grease I have taken apart as much of the fork as I can but I have run into a few issues.

    1. The red gasket part seems to be damaged any ideas on how to fix, or where to get a replacement? (Pic 1)

    2. How do I remove this I believe this needs to be removed in order to properly pull up the fork. I cannot remove the fork. (Pic 2)

    3. Following the Black edition instructions are slightly different then the fork I have I cannot remove the fork from the tube I have even removed the 2 wipers. (Pic 3)

    (Pic1)


    (Pic2)


    (Pic3)

  15. #15
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    Quote Originally Posted by Ljsimp View Post
    I have received the grease I have taken apart as much of the fork as I can but I have run into a few issues.

    1. The red gasket part seems to be damaged any ideas on how to fix, or where to get a replacement? (Pic 1)

    2. How do I remove this I believe this needs to be removed in order to properly pull up the fork. I cannot remove the fork. (Pic 2)

    3. Following the Black edition instructions are slightly different then the fork I have I cannot remove the fork from the tube I have even removed the 2 wipers. (Pic 3)

    (Pic1)


    (Pic2)


    (Pic3)
    Top picture, it looks like the compression piston is okay but has been broken off the compression damper shaft. Do you have pictures of the rest of the compression assembly?

    Second picture. That is the detent for the travel adjust, it just pulls off.

    Third picture. When you get the travel adjuster off and the bolt behind it the legs will slide off.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    Ok I have disassembled everything and wiped off excess grease. Here are the broken parts:




    Any thoughts? i was thinking gorilla glue but I am not sure if it will hold.

  17. #17
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    You will need to clean all the oil out before any glue will hold. I would try gluing it, but use methylated spirits or similar several times to clean out the oil first.

    Also dismantle it before gluing.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    So I attempted to glue it but it just separates with any slight pressure. Do you know of a location that I can purchase another one?

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    Quote Originally Posted by Ljsimp View Post
    So I attempted to glue it but it just separates with any slight pressure. Do you know of a location that I can purchase another one?
    Either it's not clean or the glue isn't compatible. Have you got a photo of the complete compression assembly?
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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    I bought this stuff it is supposed to weld plastic and was highly rated, hopefully it will stick with this.
    Amazon.com: Tenax 7R: Toys & Games

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    No glue seems to hold the cracked top of the damper. Does anyone have place I get a replacement, is it worth it for the fork?

    Thanks

  22. #22
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    Have you got a photo of the complete compression assembly?
    This.

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    When you say compression assembly do you mean the broken piece? I also tried gluing with plastic epoxy.

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    Is that part from the bottom right side leg?

    Is the red part attached to the silver rod with a screw or nut?

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    The red part is supposed to be attached ot the black plastic part on the right. This is part of the leg.

    Thanks

  26. #26
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    I may have a used spare, I'll have a dig through my parts and let you know. Can you measure the total exposed silver shaft length?
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    Thanks Dougal when I get home I will measure it out.

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    Here are the sizes: 7 1/4 long, 1/2 wide


  29. #29
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    7.25" (184mm) for just the silver shaft?
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    That's correct that is without the part that snapped.

  31. #31
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    I'll need you to check the measurements. The shafts I have here are 164-165mm. I am measuring just the length of the silver crimped tube. Not the overall length of the shaft.
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    Mine is 165mm measuring just the smooth crimped section. See picture below.

  33. #33
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    Re: 2002 Specialized Enduro Front Fork

    Quote Originally Posted by Ljsimp View Post
    Mine is 165mm measuring just the smooth crimped section. See picture below.
    Perfect. I'll send you an email.
    Owner of www.shockcraft.co.nz and NZ Manitou Agent.
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  34. #34
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    Well I received my new part from Dougal thanks! It has been a month since I tore apart my front fork and the Manitou Black Guide online is not the same Manitou I have so I am struggling trying to figure out how to put it back together. Some help would be greatly appreciated see pics.


  35. #35
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    Good the see the parcel arrived.

    From the right you have the spring and spring-side top-cap. It goes with the silver adjuster knob.
    The grey adjuster knob with the claw is the rebound knob for the bottom of the damper side.
    The chrome plated knob with the claw is the compression adjuster, top of the damper side.
    The silver shim and light spring you don't need, there are good ones already on the replacement damper shaft I sent (top left).

    The rest should be easy. Post back if you're having trouble.

    You need to install onto the damper shaft the damper end-cap (not in the photo, possibly still on the broken damper shaft). Then the conical rubber bottomout bumper and then the black spacer beside the bumper. That'll then be ready to thread back into the bottom of the stanchion.

    The dust wiper seals at the bottom you'll want to replace now you've removed them. Part Number is 856-5281 for the genuine manitou ones. Enduro also do an aftermarket kit.
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    These are the last parts that I have left to install, am I missing one? Also the spring side is that supposed to be very stiff?

    Thanks

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    That's looking good.
    The black plastic piece and the red knob go on the outside of the legs on the bolt. The knobs and compression assembly are quite straight forward. Just reposition the ones with claws until you get the full range.

    5wt oil in the top of the damper side until it's about an inch above the piston when the compression assembly is in place. Measure to be sure. A syringe and short piece of clear PVC tube is good for adding/removing small amounts of oil.

    The spring side does have a lock-down function to change between 120 and 100mm. It will feel a lot firmer in 100mm.
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    Thanks Dougal for all of your help the bike is finally ready to hit the trails again and everything works like new! What I did with all the knobs is turn them to the furthest right and then tightened them down which made it easy. I have to finish greasing the forks I put some slick honey in before I installed them but I want to grease them up a bit more. I purchased a grease tip thinking I could install it on my grease gun but it will not attach, any ideas of where I could purchase a grease gun?


    Again thanks for all your help I couldn't have done it without you.

  39. #39
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    Happy to help. These forks are worth saving.

    The grease gun is an excellent question. Manitou supply the dualco guns like this : DUALCO Squeeze Tube Grease Guns

    I haven't tried to fit one on a slick honey tube and I'm not sure how standard little grease tubes are. The thread on Prep M grease tubes is about 14mm diameter and the gun fits those.

    *edit*
    The dualco page I linked above has the thread size. 9/16" and 18tpi. If your slick honey cap thread measures around 9/16" then you're good to go.
    Last edited by Dougal; 06-28-2014 at 12:44 AM.
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