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Discussion Starter · #1 ·
I have a Manitou Black Super Air w/ remote lockout (2005). The fork makes a clacking sound when I hold the front brake and rock the bike back and forth. It makes this sound when locked out as well. It almost feels like there is play in the stanchions. It also makes this sound while riding but not as frequently. In addition the rebound damping doesn't seem to work.

I searched and I don’t think it’s a problem with the bumbers as some have reported. Any ideas?
 

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Discussion Starter · #3 ·
The fork was ridden for maybe 150-200 miles. I bought it late last year and haven't ridden the bike it is installed on much. Wouldn't this be a bit soon for worn bushings?
 

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If there is excess movement between the lowers/uppers, it is a bushing issue period.

Keep in mind the amount of movement is relative. Fox for example actually mentions the amount of 'slop' in there forks to let customers know that they are supposed to have movement (atleast when not moving). When riding a fork, some of the lubrication oil is forced up between the bushings and stanchions, 'floating' the stancihon on a liquid bearing, preventing bushing/stanchion contact and wear (at least according to Fox)

Now to add to this, the black uses a very small amount of lubrication for the bushings (it is NOT an open bath system). Manitou also does not use a true oil seal on their forks, instead they just use a dust wiper to keep dirt out. What this means is that over time, (not a lot of time in fact) the small amount of oil can and will weep past the wipers (can be inperceptable) and leave the bushings un-lubricated.

At first, with no oil, the bushings/stanchions will seem to have more slop, and can make clunking noise when rocked (could be more noticable with a loose bushing to begin with form the factory). If allowed to continue in this way, the bushings will wear fast, making the situation worse. Eventually, the bushings will start to wear the stanchions, ruining the fork.
 

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Discussion Starter · #5 ·
davep said:
If there is excess movement between the lowers/uppers, it is a bushing issue period.

Keep in mind the amount of movement is relative. Fox for example actually mentions the amount of 'slop' in there forks to let customers know that they are supposed to have movement (atleast when not moving). When riding a fork, some of the lubrication oil is forced up between the bushings and stanchions, 'floating' the stancihon on a liquid bearing, preventing bushing/stanchion contact and wear (at least according to Fox)

Now to add to this, the black uses a very small amount of lubrication for the bushings (it is NOT an open bath system). Manitou also does not use a true oil seal on their forks, instead they just use a dust wiper to keep dirt out. What this means is that over time, (not a lot of time in fact) the small amount of oil can and will weep past the wipers (can be inperceptable) and leave the bushings un-lubricated.

At first, with no oil, the bushings/stanchions will seem to have more slop, and can make clunking noise when rocked (could be more noticable with a loose bushing to begin with form the factory). If allowed to continue in this way, the bushings will wear fast, making the situation worse. Eventually, the bushings will start to wear the stanchions, ruining the fork.
I kind of understand what you are saying. Does this mean I should service the fork? How good is the Manitou manual? I am not mechanically inclined but don't have much experience with forks. Hence I rely on a well written manual.
 

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Discussion Starter · #7 ·
davep said:
The 'manual' that came with the fork is just a glorified liability release/multi page warning about the dangers of mt biking. Nothing technical in there at all.

But....

Manitou has had had some fairly good tech articles an their web site with pics and full expliantions. Here is what i could find quickly: http://www.hbsuspension.com/guides/... Service Manual.pdf?cvar1=7/9/2007+9:22:09+PM

34 pages :thumbsup:
Thanks, that's good to know. That was actually the manual I was talking about. I found it on the Manitou website.
 
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