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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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  3. #3
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    Manitou elite 100/120 with reverse arch technology it also says tpc on it.

    Thanks

  4. #4
    rebmem rbtm
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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  6. #6
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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?

  7. #7
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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  11. #11
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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  16. #16
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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  18. #18
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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?

  19. #19
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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 Service Agent.
    www.dougal.co.nz Suspension setup & tuning.
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  20. #20
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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

  21. #21
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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
    rebmem rbtm
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    Have you got a photo of the complete compression assembly?
    This.

  23. #23
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    When you say compression assembly do you mean the broken piece? I also tried gluing with plastic epoxy.

  24. #24
    rebmem rbtm
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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?

  25. #25
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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

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