[Atomic Dog]

I pulled apart my 03 Slider the other day to service it. I pulled the lowers off the stanchions and three pieces came out from inside. One is a rubber or plastic spacer, looks like a thick washer. After looking over the service manuals on Answer's site, I figured out it's the bottom spacer washer as seen on the left:

In addition to this there were two metal spacers. They are thinner than the black one, look just like washers to me. I'm not really sure where these go.

I called Manitou tech support. The guy did confirm the black spacer goes on the compression rod. Then he said there should be two smaller washers that go on the rebound side. I assume that he meant the two spacers I mentioned above. (They are the same inner and outer diameter as the black one, just thinner)

So if someone could tell me if this sounds like the correct way to reassemble this, I'd appreciate it:

1. slide the rubber spacer on the compression rod as in the above photo, slide the two metal spacers on the rebound side the same way.

2. Push the lowers part way onto the stanchions, then add the appropriate amount of oil in through the bottom hole of each side of the lowers.

3. line up the holes and bolt the compression/rebound rods to the lowers.

4. If I manage to do the above without breaking or otherwise screwing something up, go inside and drink a beer or three.

Sounds pretty easy and it should be. However, I have a knack for messing up the most ridiculously simple of tasks. uch:

 

[davep]

You should have a total of two rubber bumpers and two washers. Look down inside of the lower casting as sometimes the parts stick down in there. When re-assembling the bumper goes on the shaft first and then the washer. The washer just provides a flat surface for the rubber bumper to squish against at full bottom (if you look into the lowers, the bottom inside surface is not flat and smooth).

While you have the lowers off, under the seals there is a foam ring to help lubricate the seal. Remove this foam ring and squeeze it in a rag to remove old dirty oil. Then carefully wipe and clean the seals and seal area being careful not to get anything (dirt) into the fork. Re wet the foam rings with clean fork oil and re install them. Now take some thin grease (like prep M) and apply (pack) it into the same area where the foam rings are, just under the seal lip. Now reassemble the lower half way, add the 16cc of oil each side through the holes in the bottom of the lowers, and completely reassemble. You might have a little of the grease left on the stantions for the first few rides, just wipe off with a soft rag.

p.s. check the o-rings that seal at the rod bolts (mine got torn every time I took mine apart) if they are torn at all pull them off and take them to a good hardware store and find some replacements.

 

[Atomic Dog]

Damn, thanks for straightening me out on those washers. I'll break out a flashlight and look for the other bumper tonight.

 

[davep]

no prob!

 

[urbaindk]

You should have a total of two rubber bumpers and two washers. .

I have 2 rubber bumpers, two Al washers, and one plastic washer in my flick. The thickness of the two Al washers is the same as the single plastic washer.