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2004 SWINGER SERVICE MANUAL
PN 042133, REV NC.
04 SWINGER SERVICE MANUAL Page 1 PN 042133 REV NC
04 SWINGER SERVICE MANUAL INDEX
Section
Description
Page
1
INTRODUCTION
3
2
SETUP, TUNING, PERIODIC MAINTENANCE
3
3
GLOSSARY
4
4
5
AIR SPRING SYSTEM AND SPV AIR PRELOAD, SWINGER
AIR
5
COMPLETE SHOCK LESS HARDWARE, COIL SPRING
7
6
HARDWARE REMOVAL AND INSTALLATION
7
7
DU BUSHING REMOVAL AND INSTALLATION
8
8
RIDE KITS
10
9
BOTTOMOUT BUMPER REPLACEMENT, SWINGER COIL
11
10
DAMPING SYSTEM
12
11
REBOUND ADJUSTER KNOB REMOVAL AND
INSTALLATION, SWINGER COIL
13
12
DAMPING SYSTEM BLEEDING - SWINGER 3 WAY COIL
SHOCKS
14
13
DAMPING SYSTEM BLEEDING - SWINGER 4 & 6 WAY COIL
SHOCKS
18
14
DAMPING SYSTEM BLEEDING - SWINGER 3 WAY AIR
SHOCKS
25
15
DAMPING SYSTEM BLEEDING - SWINGER 4 WAY AIR
SHOCKS
30
16
TROUBLESHOOTING
37
17
TABLE 1: FASTENER TORQUE REQUIREMENTS
39
18
SWINGER REAR SHOCK SERVICE KITS
40
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
04 SWINGER SERVICE MANUAL Page 2 PN 042133 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.
Important information is highlighted in this manual by the following notations:
WARNING
Failure to follow WARNING instructions could result in
severe injury or death
to the
person inspecting or repairing the shock absorber or the shock absorber operator
CAUTION
A CAUTION a caution indicates special precautions that must be taken to avoid damage to
the shock absorber.
NOTE
A NOTE provides key information to make procedures easier or clearer
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.
SECTION 2: SETUP, TUNING, PERIODIC MAINTENANCE
Instructions for shock setup, tuning, and periodic rider maintenance is not covered in detail in this
manual. Please refer to the Manitou Swinger Rear Shock Owner's Manual (PN 042105) for that
information. If you did not receive a manual, you can download one at
www.answerproducts.com
or contact Answer Products Customer Service at (661) 257-4411.
04 SWINGER SERVICE MANUAL Page 3 PN 042133 REV NC
SECTION 3: GLOSSARY OF TERMS
Air Canister
– Can that holds the air spring air in an air shock.
Air Preload Adjuster
–
Located on the reservoir of SPV shocks. It contains the red Schrader
valve for setting the SPV pressure and a hex fitting for adjusting the air volume (air preload)
Bottom Out
– Point at which a shock reaches full compression.
Control Eyelet (C-End)
– Eyelet that is on the rebound adjuster end of a shock. The air canister
is attached to this end on air shocks and the spring retention collar is attached to this end on coil
shocks.
Damper Eyelet (D-End)
- Eyelet that is on the damper body end of a shock. On SPV shocks,
this is the end that contains the SPV valve and reservoir if applicable.
Damper Body
– Section of shock that contains the damping system
Damper Piston
– Piston in that controls the flow of oil during compression and rebound.
Damper Shaft
– Shaft attached to the damper piston that connects the two moving sections
(damping system and control eyelet) of the shock together.
Damping System
-
Controls compression and rebound rate (speed). The system also provides
the peddling platform unique to shocks with the SPV technology.
DU Bushing
– Teflon guide bushing pressed into the eyelets. Mounting hardware is inserted into
the DU bushings and rotates within the bushing as need by the suspension design.
Eyelet
– Found on each end of the shock, it is where the DU bushing and mounting hardware are
and provides the connection between the shock and bicycle.
Internal Floating Piston (IFP)
- A floating piston that separates damping oil from the SPV air
chamber or reservoir.
Mounting Hardware
– Spacers that allow shocks to be mounted into the wide variety of
suspension designs.
Schrader, Air
–
Black in color, it is the valve for pressurizing the air canister in an air shock
Schrader SPV
- Red in color, it is the valve for pressurizing the SPV system.
Seals: O-Rings
-
Black synthetic rubber with a round cross section. Primarily used for fluid
sealing.
Seals: Quad Seals
- : Black synthetic rubber with an “X” cross section, primarily used for sealing
air.
Seals: Wipers
– Teflon ring, used for keeping debris out of quad seals, guiding the damper
piston, and providing support.
Top Out
– Point at which a shock returns to its full extension.
04 SWINGER SERVICE MANUAL Page 4 PN 042133 REV NC
SECTION 4: AIR SPRING SYSTEM AND SPV AIR PRELOAD, SWINGER AIR
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.
1. Failure of an air shock to maintain air
pressure is usually the result of defective or
worn seals. If there is suspicion of an air
leak, pressurize the air canister to 150psi
from the adjuster eyelet Schrader Valve and
the SPV Air Preload Schrader to 100psi.
Locate the leak by spraying the air canister
and Schrader joints with a mild solution of
dish soap and water or submerge in a
bucket of water. Bubbles will form in from
the area of leakage.
2. For leaks at the adjuster eyelet or damper
end of the air canister, refer to the detailed
disassembly instructions contained in the
section on
DAMPING SYSTEM BLEEDING
- Swinger Air
. This will guide you on how to
replace the applicable o-rings and seals.
3. For leaks at the Schrader valves, release all
air pressure and replace the Schrader valve
core or assembly as needed. The core is
removed using a standard core removal
tool. The assembly is removed by removing
the core and unscrewing the assembly by
inserting a 3mm hex into the center of the
valve.
Adjuster Eyelet SPV Air Preload
(Air Spring)Schrader
4. For leaks in the air preload reservoir area
(4W Swinger), release all pressure replace
the preload adjuster o-ring, Schrader valve
core, or Schrader assembly as needed.
04 SWINGER SERVICE MANUAL Page 5 PN 042133 REV NC
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