The Maverick Frame Manual

Maverick Service Centers
USA
Italy
Maverick
Products Serviced:
All Maverick frames, forks,
and components
Area B di Modolo Valter
Products Serviced:
All Maverick frames, forks,
and components
3085 Bluff St.
Boulder, CO 80301
[email protected]
(P) 303-415-0370
(F) 303-415-0379
Via Galvaligi 6/D
31058 Susegana (TV)
[email protected]
(P) 039 (0) 438 435 550
Maverick Service
Maverick
Suspension Experts, Inc. 3085 Bluff St.
United Kingdom
Products Serviced: Boulder CO 80301
All Maverick frames, forks,
and components
Extra Ltd.
Products Serviced:
[email protected]
89 Thompson St., Unit
K
All Maverick frames, forks,
Asheville, NC 28803
and components
Phone: 303-415-0370
[email protected]
Datamex
House, Morris Close
Fax: 303-415-0379
(P) 866-800-2453
Park Farm Ind. Estate, Wellingborough
The Fix
Products Serviced:
All Maverick frames, forks,
and components
3085 Bluff St.
Boulder, CO 80301
[email protected]
(P) 303-939-8349
Northants NN8 6XF
[email protected]
(P) 01933 672170
(F) 01933 672171
TF Tuned Shocks
Products Serviced:
DUC32 and SC32 forks;
SpeedBall seatposts
www.tftuned.com
(P) 01373 834455
Additional U.S. and
International Service Centers at
Germany
Toxaholics
Products Serviced:
All Maverick frames, forks,
and components
Haupstr. 200
D-66876 Rodalben
[email protected]
(P) 06331258160
South Africa
maverickbike.com
Pedal-on Marketing CC
Products Serviced:
All Maverick frames, forks,
and components
Shop 6A
8 Old Main Road
Hillcrest, KwaZulu Natal 3610
[email protected]
(P) +27 31 767 6222
(F) +27 31 767 5501
3085 Bluff Street, Boulder, Colorado 80301 H Tel: 303-415-0370 H Fax: 303-415-0379
WARRANTY
Your new Maverick frame is warranted to the original consumer against defects of workmanship and
materials from the original purchase date for a period of: three years for the shock and suspension
moving parts; and five years for the frame tubes and structural components. Should there be a defect
or malfunction of this product, Maverick will repair or replace it, at Maverick’s option, free of charge.
This warranty does not cover the labor cost of component removal or re-assembly, nor does it cover
costs of shipping to Maverick. Maverick will cover return shipping and handling costs. All warranty
coverage is based on the product being properly maintained and adjusted (as detailed in the owner's
manual), and ridden in the manner described below. There are no expressed warranties other than
those stated herein.
Maverick frames are designed and tested for riding in rough and demanding off-road terrain. While
some jumping is expected to clear natural obstacles, Maverick frames are not built to withstand
jumping from man-made ramps or other daredevil feats. This warranty is void if the product has been
subject to damage, unreasonable use, improper service, or other causes not arising from defects in
original material or workmanship.
This warranty does not include adjustments, parts or repairs required by circumstances beyond the
control of Maverick, including but not limited to leakage damage. Normal wear and tear is not
covered by this limited warranty.
It is our desire to make life with your Maverick product trouble free, so we want to eliminate any
hassles you might have with a warranty issue. To achieve a fair and liberal warranty program, you, the
customer, must be fair too. Even if you have a failure from crashing or lack of proper maintenance, we
will work with you to minimize the cost of repairs if you are honest about what happened. In cases of
crashes or accidents, you will be offered repairs or replacement under Maverick’s Crash Replacement
Program.
MAINTENANCE
Any expressed or implied warranties, including but not limited to merchantability and fitness
for a particular purpose are limited to the above one-year warranty period. Maverick shall not
be liable for any incidental or consequential cost, expenses or damages resulting from the any
failure defect or malfunction of this product. Some states do not allow the exclusion or
limitations of implied warranties or consequential damages, therefore, the above limitations
may not apply to you. This warranty grants you specific legal rights, and you may also have
other rights that vary from state to state.
Return of a product, for any reason, must be associated with a Return Authorization Number (RA#).
An RA# can be obtained by contacting Maverick directly at 303-415-0370 or
[email protected]. Maverick will not accept responsibility for any frames returned to
Maverick without an RA#. You should insure your shipment for it’s full value. If returning a frame,
please follow theses instructions:
Rev. 12/06
1
1
1. Remove all products from the frame that are not part of the warranty work.
2. Take extra care to package the product in a sturdy cardboard box. Maverick will not
be responsible for damage to products caused by improper packaging.
3. Mark the Return Authorization Number clearly on the outside of the box and address
as follows:
RA# (Fill in Number)
Maverick
3085 Bluff Street
Boulder, CO 80301
4. Include a copy of your original purchase receipt.
5. Be sure to include a copy of your contact information inside the box.
22
21
WARRANTY & SERVICE
RETURN PROCEDURE
SERVICE INTERVALS
AND VALUES
REAR SHOCK
After approximately 250 hours of riding (6 - 12 months), the rear shock damper
Item to clean the wiper
Interval
Torquethe
Value
Locktite?
should beService
removed
seal and replace
lubrication
oil. This
Check
Shock
air
pressure
2
weeks
as
required
n/a
will greatly improve the performance and life of the suspension. The process
is
Check
Boltrequires
tightness no special tools and
25 hours
8 ft/lbs
Nm)an hour. Yes
veryLink
easy,
should take
less(11
than
Check Damper Set Screw tightness
50 hours
15 in/lbs (2 Nm)
No
Re-grease
TopTHE
Shock
PivotThis
1) WASH
BIKE!
hours
70 the
in/lbsopen
(8 Nmshock.
No
will prevent100
dirt
falling into
2) Release
the air pressure from the250
shock
Re-grease
Link Bearings
hours- VERY IMPORTANT!
3) Remove
theand
top
shock
mounting250
bolt
using two 5mm hex wrenches and pull
Clean
Shock Wiper
replace
Lube
hours
the shock
away from the frame. Remove
the shock boot.
Rebuild
Shock Damper*
500 hours
4) With a 4mm hex wrench, loosen the two set screws located on either side of
* requires
special
the shock
body.tools and qualified technician.
5) Pull the damper out of the shock body. This may require loosening or removing the derailleur and brake cables to allow the rear triangle to swing back
enough for the damper to clear the frame.
Date
Service
Performed
By a clean,
6) Clean
the wiper seal, bushings
and
old oil from the shockbody using
lint-free rag.
SERVICE LOG
20
18
21
MAINTENANCE
Damper installation:
1) ML7: Add 7 ml of 15 wt. or higher shock fluid or into the shock body.
Matic & Durance: 10 ml; ML8: 15 ml.
Apply a small additional amount to the wiper lips and bushings.
2) Slide the damper back into the shock body, being careful not to invert the
wiper lips as you do so. This may require cocking the damper slightly sideways
to get one edge of the tube in first.
3) After the tube is past the seals it should slide in smoothly. Push the damper
all the way to the bottom while releasing the schrader valve to allow air to
escape from the shock.
4) With the damper held at the bottom, tighten the two set screws. If they
thread in too far, or hardly at all, then the damper may not be fully in and
seated.
5) Replace the shock boot and re-install the top shock mount.
Frame Views
Rev. 12/06
2
1
3
SUSPENSION
PIVOTS
GENERAL
MAINTENANCE
BB LINK
BEARINGS:
After
every
ride we recommend that you inspect the frame and suspension for
Afteror
approximately
riding (6
- 12 months),
the bearings
BB link
wear
damage that250
mayhours
have of
occurred
- especially
if you’ve
crashed.inAthe
quick
shouldinspection
be re-greased.
you ride often
in veryallmuddy
visual
of theIffollowing
is normally
that is conditions,
required. Ifyou
youmay
find want to
perform this
task more have
frequently.
It will by
require
off themechanic
drive-sideorcrank
anything
questionable,
it inspected
your taking
professional
bike
arm which may require a special removal tool. Otherwise this service is easy and
shop.
a good set of tools is all that is needed.
• look over the frame tubes for any dents, deformation or cracks.
Remove the right
crank arm
andtimes
take out
the two
bolts.
Holdforce
the link nut
•1)Compress
suspension
several
to check
forlink
proper
spring
with
15mm wrench
and Ifturn
the
left
side with
andarebound
damping.
youthe
do link
not bolt
knowfrom
what
the
proper
feel aofstrong
the 6mm
hex
wrench. is, learn! Have your mechanic or someone knowledgeable
suspension
2)teach
Pull the
you.BB Link out of the frame. You will need to disconnect the derailleur to
remove
the BB Link,
but
re-greasing
can be done
with it still
•completely
Rock the wheels
sideways
to feel
forthe
loose
pivots, bearings
or headset.
•attached.
Every two weeks check the pressure in the shock.
Gently
pry
out the
rubber
covering
a safety
•3)Check
the
rubber
shock
bootseals
to make
surethe
it isbearings
properly using
attached
and pin or dull
knife.
Note which
sideair
of vent
the seal
faces
positioned*
and that
holes
faceoutward.
forward.
4) Add a small amount of heavy duty, non-lithium grease to the inside of the
bearings and replace the seals with your fingers.
5) Re-install the BB Link
WASHING AND CLEANING
Armor All, spray wax, or rust preventative sprays may be used, but do not use
abrasive polishes on the anodized surfaces.
Top Shock Mounting Bolt
TOP SHOCK PIVOT:
After approximately 100 hours of riding (6 months),
the Top Shock Pivot should
Shock Boot (*Note proper position)
be re-greased. This requires two 5mm hex wrenches and should only take 10
minutes.
1) Remove the Top Shock Mounting Bolts using a 5mm Hex wrench on either
side, and pull the shock away from the frame.
Schrader Valve
2) Push the steel pivot sleeve out of the frame.
Shock Body
3) Clean the pivot Sleeve, bushings and O-rings and re-pack
with a heavy duty,
non-lithium grease.
Bolt not to lose or damage theSet
Screw
4) Re-assemble, being Link
careful
thin
O-ring that sits
between the frame and shock mount clevis.
42
3
MonoLink
Link Bolt
20
1719
MAINTENANCE
MAINTENANCE
After you ride, if the chassis is muddy or the soil in your area is corrosive, a
thorough wash should be performed. We recommend using the cleaner “Simple
Green” mixed with warm water. Do not use cleaners containing bleach, acid or
lye, as this may damage the frame finish. Rinse with water, but do not spray with
full pressure directly at the suspension pivots, headset or shock. Avoid high
pressure spray washers. When finished, wipe the chassis down with a towel.
FRAME SPECIFICATIONS
REAR SHOCK
ADVANCED
TUNING
After approximately 250 hours of riding (6 - 12 months), the rear shock damper
OIL VOLUME:
should be removed to clean the wiper seal and replace the lubrication oil. This
If you
findimprove
you are the
using
too much ofand
thelife
suspension
travel or bottoming
outistoo
will
greatly
performance
of the suspension.
The process
easily,
you
can
add
oil
to
the
rear
shock
to
make
the
spring
force
firmer
in
the
very easy, requires no special tools and should take less than an hour.
later stage of the travel. It will not help much with setting proper sag, but it will
beginning
of the
from
harshthe
if you
were
to just to increase
1)prevent
WASH THE
BIKE! This
will travel
prevent
dirtgetting
falling into
open
shock.
air
pressure
to
stop
bottoming
out.
2) Release the air pressure from the shock - VERY IMPORTANT!
3) Remove the top shock mounting bolt using two 5mm hex wrenches and pull
Factory-set
oilfrom
volume:
7ml;
ML7/5:the
10ml;
ML8:
15ml (Maximum total volume:
the
shock away
the ML7:
frame.
Remove
shock
boot.
20ml)
4) With a 4mm hex wrench, loosen the two set screws located on either side of
the shock body.
change
the oilout
level,
thebody.
air pressure
from
the shock
and remove
the
5)To
Pull
the damper
of release
the shock
This may
require
loosening
or removcore
from
the
schrader
valve.
Compress
the
shock
completely.
Fill
a
syringe
with
ing the derailleur and brake cables to allow the rear triangle to swing back
3ml
of
Maverick
“Gunna
Flow”
or
other
80w
assembly
oil
and
put
the
tip
into
the
enough for the damper to clear the frame.
schrader
valve
hole.
Now
extend
the
shock
while
gently
compressing
the
6) Clean the wiper seal, bushings and old oil from the shockbody using a clean,
syringe.This
lint-free
rag. should suck the oil into the shock. Install the schrader core and
pressurize.To remove oil, take out the valve core, turn the bike sideways and
compress the shock, oil should exit the valve.
This chart shows the effect of different oil levels on spring force
G
N
I
R
P
3
more oil volume
E
C
R
O
&
less oil volume
Damper installation:
1) ML7: Add0 7 ml of 15 wt. or higher shock
Travelfluid or into the shock body.
165 mm
Matic & Durance: 10 ml; ML8: 15 ml.
Apply a small additional amount to the wiper lips and bushings.
2)DAMPER
Slide theVALVING:
damper back into the shock body, being careful not to invert the
The damper
of any
Maverick
rear
shockcocking
can be disassembled
and tuned
by
wiper
lips as you
do so.
This may
require
the damper slightly
sideways
rebound
shim in
stack
toaltering
get onethe
edge
of the tube
first.and changing oil viscosity.This is for advanced
only,isoutfitted
properslide
special
Maverick Push
shockthe
tools.Visit
3)mechanics
After the tube
past the with
sealsthe
it should
in smoothly.
damperthe
tech”
section
of our
web
site for details.
all“owner
the way
to the
bottom
while
releasing
the schrader valve to allow air to
escape from the shock.
4) With the damper held at the bottom, tighten the two set screws. If they
thread in too far, or hardly at all, then the damper may not be fully in and
seated.
5) Replace the shock boot and re-install the top shock mount.
1816
19
4
3
5
GENERAL MAINTENANCE
GENERAL MAINTENANCE
After every ride weGENERAL
recommend that MAINTENANCE
you inspect the frame and suspension for
wear
damage
that
may have occurred
especially
you’ve
crashed.
A quick
After or
every
ride we
recommend
that you -inspect
the ifframe
and
suspension
for
visual
inspection
of recommend
the
following
is normally
all that
required.
If you find
After or
every
ride we
that
you -inspect
the is
and
suspension
for
wear
damage
that
may
have occurred
especially
ifframe
you’ve
crashed.
A quick
anything
questionable,
have
it inspected
your
professional
mechanic
bike
wear
damage
that
may
have
occurred
-by
especially
if you’ve
crashed.
A or
quick
visualor
inspection
of the
following
is normally
all that
is
required.
If you find
shop.
visual
inspection
of the have
following
is normally
all that
is required.
If you find
anything
questionable,
it inspected
by your
professional
mechanic
or bike
The
adjuster
knob is located
top of the
rear shock.
Turning
the red or bike
anything
questionable,
haveatitthe
inspected
by your
professional
mechanic
shop.
knob
determine
fastfor
the
suspension
rebounds or
(extends)
•shop.
lookwill
over
the framehow
tubes
any
dents, deformation
cracks. after it has
been
compressed.
After
the
air
pressure
has
been
set
correctly,
adjust
the
•• Compress
theframe
suspension
times to
check for proper
spring
force
look over the
tubes several
for any dents,
deformation
or cracks.
rebound
to
your
preference
by
turning
it
clockwise
(towards
"+")
and rebound
damping.
youany
dodents,
not know
whatfor
theproper
proper
feel offorce
the
• look
over the
tubesIfseveral
for
deformation
or
cracks.
Compress
theframe
suspension
times
to
check
spring
for
slower rebound,
or counter-clockwise
(towards
"-")proper
forknowledgeable
faster
rebound.
suspension
is,damping.
learn!
Have
yourdo
mechanic
someone
• Compress
the
suspension
times
to or
check
for
spring
and rebound
Ifseveral
you
not know
what
the proper
feel offorce
the
There
isrebound
about
1-1/2
turns of
adjustment.
teach
you. is,
and
damping.
If you
not know
the proper
feel of the
suspension
learn! Have
yourdo
mechanic
orwhat
someone
knowledgeable
• Rock
wheels
sideways
feelmechanic
for loose or
pivots,
bearings
or headset.
suspension
is, learn!
Have to
your
someone
knowledgeable
teachthe
you.
Every
two
weeks sideways
check thetopressure
in the pivots,
shock. bearings or headset.
teachthe
you.
•• Rock
wheels
feel for loose
•• Check
thewheels
rubbersideways
shockthe
boot
to make
it is properly
attached
and
Rock
topressure
feel
for loose
bearings
or headset.
Everythe
two
weeks
check
insure
the pivots,
shock.
positioned*
and that
airthe
vent
holes
face
forward.
Every
two
check
pressure
insure
the
shock.
• Check
the weeks
rubber
shock
boot
to
make
it is properly attached and
• Check
the rubber
shock
make
sure
it is properly attached and
positioned*
and that
air boot
vent to
holes
face
forward.
positioned* and that air vent holes face forward.
Green”
mixed
with
Do not
use
cleaners
containing
bleach,
or
After you
ride,
ifshould
thewarm
chassis
is muddy
orWe
the
soil in your
area isthe
corrosive,
a“Simple
thorough
wash
bewater.
performed.
recommend
using
cleaneracid
lye,
as
this
may
damage
the
frame
finish.
Rinse
with
water,
but
do
not
spray
with
thorough
wash
should
bewater.
performed.
using thebleach,
cleaneracid
“Simple
Green” mixed
with
warm
Do notWe
userecommend
cleaners containing
or
full
pressure
directly
at the
suspension
headset
or shock.
Avoid
high
Green”
mixed
with
warm
water.
Dofinish.
notpivots,
use
cleaners
containing
bleach,
acidwith
or
lye,
as this
may
damage
the
frame
Rinse
with water,
but do
not spray
pressure
washers.
When
finished,
wipe
the
chassis
with
a towel.
lye, pressure
as thisspray
may
damage
the
frame
finish.
Rinse
with
water,
but do
not
spray
full
directly
at the
suspension
pivots,
headset
ordown
shock.
Avoid
high with
full
pressure
directly
at the
suspension
headset
ordown
shock.with
Avoid
high
pressure
spray
washers.
When
finished,pivots,
wipe the
chassis
a towel.
NOTE:
during
initial
set-up,
you
should turn
the knob
to
slowestdoposition
Armor
All,spray
spray
wax,
or rust
preventative
sprays
bethe
used,
use
pressure
washers.
When
finished, wipe
themay
chassis
downbut
with anot
towel.
(full
clockwise)
andon
adjust
from there.
abrasive
polishes
the
anodized
surfaces.
Armor All, spray wax, or rust preventative sprays may be used, but do not use
Armor All,polishes
spray wax,
or rust
preventative
sprays may be used, but do not use
abrasive
on the
anodized
surfaces.
abrasive polishes on the anodized surfaces.
Top Shock Mounting Bolt
Top
Shock
Mounting
Bolt position)
Shock
Boot
(*Note proper
Shock Boot (*Note proper position)
Shock Boot (*Note proper position)
Schrader Valve
Schrader
Valve
Shock
Body
Schrader Valve
Shock Body
Set Screw
Shock
Body
Link Bolt
Link Bolt
MonoLink
Link Bolt
6
4
5
MonoLink
MonoLink
Link Bolt
Link Bolt
Link Bolt
18
Set Screw
Set Screw
15
17
17
17
MAINTENANCE
MAINTENANCE
MAINTENANCE
Matic
1
WASHING AND CLEANING
WASHING
After you ride, if the
chassis is muddyAND
or the soilCLEANING
in your area is corrosive, a
WASHING
AND
CLEANING
thorough
wash
should
be
performed.
We
recommend
cleanera“Simple
After you ride, if the chassis is muddy or the soil in yourusing
area isthe
corrosive,
Top Shock Mounting Bolt
4
4
SUSPENSION SET-UP
DAMPER REBOUND ADJUSTER
FRAME SPECIFICATIONS
FRAME SPECIFICATIONS
?
?
?
?
?
?
?
?
?
?
?
?
?
Preferred
Set Up
OIL
VOLUME:
OIL
VOLUME:
IfThe
yourear
findshock
you are
using
too much its
of the suspension
travel
or
bottoming
out
uses
air pressure
force. The
spring
force
is what
If you find you are
using
too muchfor
of thespring
suspension
travel
or bottoming
out too
too
easily,
you
can
add
oil
to
the
rear
shock
to
make
the
spring
force
firmer
extends
back
upshock
after to
it has
been
it must
be
easily,
youthe
cansuspension
add oil to the
rear
make
thecompressed
spring forceand
firmer
in the
inadjusted
the laterfor
stage
of the
travel.
It will
not help
much
with setting
proper
sag,
different
rider
weight,
terrain
or
riding
preference.
When
properly
later stage of the travel. It will not help much with setting proper sag, but it will
but
it willthe
prevent
beginning
of the travelabout
from 25-to-30%
getting harsh
if you were
tothe
set-up,
suspension
of its
prevent
beginning
of theshould
travel compress
from getting harsh
if you were
totravel
just towhen
increase
just
to
increase
air
pressure
to
stop
bottoming
out.
full weight
on the bike.
The initial compression is called sag, and is
airrider’s
pressure
to stopisbottoming
out.
adjusted by changing the air pressure in the shock.
Factory-set oil volume: ML7: 7ml; Matic and Durance: 10ml; ML8: 15ml
Factory-set
oil volume: ML7:ML7:
7ml; ML7/5: 10ml; ML8: 15ml (Maximum total volume:
Sag measurements:
(Maximum
total volume: 20ml) 15-17mm
20ml)
Matic & Durance: 19-23mm
ML8: 19-23mm
To change the oil level, release the air pressure from the shock and remove
ToItchange
the
level,the
release
the air sag
pressure
the shock
and remove
the
is easiest
tooil
check
suspension
usingfrom
two people.
Measure
the distance
the core from the schrader valve. Compress the shock completely. Fill a
core
from the
Compress
shock completely.
a syringe
with
between
theschrader
center ofvalve.
the upper
shockthe
mounting
bolt and theFill
bottom
of the
syringe with 5ml of 80w assembly oil and put the tip into the schrader valve
3ml
of Maverick
Flow”
or other
80w
assembly
oilwithout
and putthe
therider’s
tip intofull
the
knurled
ring on“Gunna
the shock
body.
Do this
both
with and
hole. Now extend the shock while gently compressing the syringe. This
schrader
valve
extendriding
the shock
whileBegently
compressing
theextended
weight on
thehole.
bike Now
in a normal
position.
sure the
shock is fully
should suck the oil into the shock. Install the schrader core and pressurize.
syringe.This
should
suckmeasurement.
the oil into theTake
shock.
Installofthe
schrader coreafter
and the
before taking
the first
a couple
measurements
To remove oil, take out the valve core, turn the bike sideways and compress
pressurize.To
remove oil,on
take
the
core,
turn the bike sideways and
rider has repositioned
theout
bike
tovalve
find an
average.
the shock, oil should exit the valve.
compress the shock, oil should exit the valve.
?
SUSPENSION
SAG
ADVANCED
TUNING
This chart shows the effect of different oil levels on spring force
G
N
I
R
P
3
?
?
Spring
more oil volume
E
C
R
O
&
Force
?
165 mm
150 - 190
10 - 13
190 - 250
12 - 16.5
?
75-95 kg (165 - 210 lbs)
?
DAMPER VALVING: Approximate Pressure Settings for Rider Weight
(Use sagrear
measurements
performance)
The damper of any Maverick
shock can for
be best
disassembled
and tuned by
altering the rebound
shim stack and changing
oil viscosity.This
is Pressure
for advanced
Rider Weight
Shock Pressure
- PSI
Shock
- BAR
mechanics only,< outfitted
with the proper special
Maverick shock tools.Visit
the
55 kg (120 lbs)
80 - 105
5-7
“owner tech”
section
of
our
web
site
for
details.
55-75 kg (120 - 165 lbs)
105 - 150
7 - 10
?
Travel
?
0
?
less oil volume
> 95 kg (210 lbs)
14
16
17
6
?
?
DO NOT EXCEED 250 psi (16.5 BAR) IN THE REAR SHOCK
7
5
DAMPER
REBOUND
ADJUSTER
DAMPER
REBOUND
ADJUSTER
The adjuster knob is located at the top of the rear shock. Turning the red
Theknob
adjuster
is located
thethe
top
of the rearrebounds
shock. Turning
theafter
red it has
will knob
determine
howat
fast
suspension
(extends)
knob
will
determine
how
fast
the
suspension
rebounds
(extends)
after
it has
been compressed. After the air pressure has been set correctly, adjust
the
been
compressed.
After
the
air
pressure
has
been
set
correctly,
adjust
the
rebound to your preference by turning it clockwise (direction of tightening a
rebound
your
preference
bycounter-clockwise
turning it clockwise
of tightening
a
screw)tofor
slower
rebound,
for(direction
faster. There
is about 1½
screw)
for
slower
rebound,
counter-clockwise
for
faster.
There
is
about
1½
The of
adjuster
knob is located at the top of the rear shock. Turning the red
turns
adjustment.
turns knob
of adjustment.
will determine how fast the suspension rebounds (extends) after it has
been compressed. After the air pressure has been
set correctly, adjust the
Adjuster
Adjuster
rebound to your preference by turning it clockwise
(towards "+")
for slower rebound, or counter-clockwise (towards "-") for faster rebound.
There is about 1-1/2 turns of adjustment.
SUSPENSION SET-UP
SUSPENSION SET-UP
SUSPENSION SET-UP
NOTE: during initial set-up, you should turn the knob to the slowest position
NOTE:
initialand
set-up,
you
should
turn the knob to the slowest position
(fullduring
clockwise)
adjust
from
there.
(full clockwise) and adjust from there.
69
Durance
Matic
1
DAMPER REBOUND ADJUSTER
NOTE: during initial set-up, you should turn the knob to the slowest position
(full clockwise) and adjust from there.
(Illustration for reference only - The ML7 and ML 7/5 use different dampers)
(Illustration for reference only - The ML7 and ML 7/5 use different dampers)
The ML8 rear damper assembly
The ML8 rear damper assembly
6
6
6
7
16
15
15
15
FRAME SPECIFICATIONS
FRAME SPECIFICATIONS
?
?
?
?
?
?
?
?
SUSPENSIONSAG
SAG
SUSPENSION
?
?
?
?
?
?
ML8:
19-23mm
ML8:
19-23mm
?
?
?
?
?
?
15
?
?
8
?
?
?
?
?
14
14
?
NOT
EXCEED
250
(16.5
BAR)
THE
REAR
SHOCK
DODO
NOT
EXCEED
250
psipsi
(16.5
BAR)
IN IN
THE
REAR
SHOCK
?
Shock Pressure - BAR
Shock Pressure - BAR
5-7
5-7
7 - 10
7 - 10
10 - 13
10 - 13
12 - 16.5
12 - 16.5
?
Shock Pressure - PSI
Shock Pressure - PSI
80 - 105
80 - 105
105 - 150
105 - 150
150 - 190
150 - 190
190 - 250
190 - 250
?
Rider Weight
Rider Weight
< 55 kg (120 lbs)
< 55 kg (120 lbs)
55-75 kg (120 - 165 lbs)
55-75 kg (120 - 165 lbs)
75-95 kg (165 - 210 lbs)
75-95 kg (165 - 210 lbs)
> 95 kg (210 lbs)
> 95 kg (210 lbs)
?
Approximate Pressure Settings for Rider Weight
Approximate Pressure Settings for Rider Weight
(Use sag measurements for best performance)
(Use sag measurements for best performance)
?
?
?
?
?
?
?
?
?
?
?
?
is easiest
check
suspension
using
two
people.
Measure
distance
It isIt easiest
to to
check
thethe
suspension
sagsag
using
two
people.
Measure
thethe
distance
between
the
center
of
the
upper
shock
mounting
bolt
and
the
bottom
of
between the center of the upper shock mounting bolt and the bottom of thethe
knurled
ring
shock
body.
this
both
with
and
without
rider’s
knurled
ring
onon
thethe
shock
body.
DoDo
this
both
with
and
without
thethe
rider’s
fullfull
weight
on
the
bike
in
a
normal
riding
position.
Be
sure
the
shock
is
fully
extended
weight on the bike in a normal riding position. Be sure the shock is fully extended
before
taking
the
first
measurement.
Take
a
couple
of
measurements
after
before taking the first measurement. Take a couple of measurements after thethe
rider
repositioned
bike
find
average.
rider
hashas
repositioned
onon
thethe
bike
to to
find
anan
average.
?
ML7:
15-17mm
ML7:
15-17mm
Matic
& Durance:
19-23mm
Matic & Durance:
19-23mm
?
Sag
measurements:
Sag
measurements:
?
The
rear
shock
uses
pressure
spring
force.
The
spring
force
is what
The
rear
shock
uses
airair
pressure
forfor
itsits
spring
force.
The
spring
force
is what
extends
the
suspension
back
up
after
it
has
been
compressed
and
it
must
extends the suspension back up after it has been compressed and it must
bebe
adjusted
for
different
rider
weight,
terrain
or
riding
preference.
When
properly
adjusted for different rider weight, terrain or riding preference. When properly
set-up,
suspension
should
compress
about
25-to-30%
travel
when
set-up,
thethe
suspension
should
compress
about
25-to-30%
of of
itsits
travel
when
thethe
rider’s
full
weight
is
on
the
bike.
The
initial
compression
is
called
sag,
and
is
rider’s full weight is on the bike. The initial compression is called sag, and is
adjusted
changing
pressure
shock.
adjusted
byby
changing
thethe
airair
pressure
in in
thethe
shock.
?
Preferred
Set
Preferred
Set
UpUp
7
7
Once your bike is built up you must adjust the rear shock for your individual
weight and riding preferences. This entails adding or removing air pressure and
setting the rebound damping adjuster.
Please note that this is just an approximation. You may require significantly
more or less pressure depending on how you sit on the bike, your riding style, or
just how you prefer your suspension to feel.
You should also experiment with different settings to learn how the bike reacts.
You will find that different pressures work better for different conditions. For
example, if you are going to ride tight, twisty singletrack, you might increase the
pressure to steepen the steering angle. Steep downhill riding and/or soft, sandy
conditions might require lower air pressure to prevent the front wheel from
diving in the turns.
To change the pressure in the rear shock, attach a standard high pressure shock
pump to the schrader valve located on the left side of the shock as shown.
NOTE: upon removal of the pump, the pressure in the shock is what was read on
the gauge. The small amount of air heard escaping during removal is the air that
was inside the pump. When re-installing the pump, the pressure will read
slightly lower because air from the shock fills the pump.
8
9
14
13
ASSEMBLY INFORMATION
Maverick recommends setting your rear shock pressure equal to approximately
90-to-100% of your weight when fully dressed for riding. For example, if you
weigh 200 lbs. with shoes, water pack, etc., then you would set the shock pressure
to 180-200 psi.
Travel:
Rear Spacing:
Brake system:
Headset:
Seat Post Size:
Seat Post Binder:
Bottom Bracket width:
Head angle:
Seat Angle (effective):
Wheelbase (size specific):
BB Height (2.30 tire):
Suspension Type:
Rear Shock:
AL6069-T6 Aluminum
Monocoque/drawn tube mix
Integral welded rear triangle/ shockbody
Cold forged drop outs and lugs
68.5 degrees
71.0 degrees
1096 - 1151mm
348 mm
Monolink - 15º wheel path
Maverick proprietary design. Cartridge oil damper,
internal coil spring with air assist
165 mm (6.5”)
135 mm
Disk only
Internal, Campagnolo Standard
30.9 mm
Maverick Custom polished
73.0mm
Frame material:
Construction:
SPECIFICATIONS
ML8
REAR SHOCK PRESSURE
FRAME SPECIFICATIONS
CABLE ROUTING
We recommend routing the shifter cable and brake hose around the
shock as shown.
ML7,
Matic,
Durance
Cable
Routing
ML8
Cable
Routing
Note: Use the supplied clear vinyl stickers to protect the frame from wear
caused by cables rubbing against the frame.
Use a small “ZIP TIE” to secure brake line to frame as shown
12
13
10
9
ASSEMBLY
ASSEMBLYOVERVIEW
OVERVIEW
AllAllMaverick
Maverickframesets
framesetsuse
usethe
thesupplied
suppliedD-Mount
D-Mountbracket
brackettotoattach
attachthe
thefront
front
derailleur
to
the
MonoLink.
Install
the
D-Mount
as
shown
with
no
spacers
derailleur to the MonoLink. Install the D-Mount as shown with no spacers
between
betweenit itand
andthe
theMonoLink.
MonoLink.
(Note:
(Note:Maverick
Maverickframesets
framesetscan
canonly
onlyuse
usea aShimano
Shimanobraze-on
braze-onroad
roadtriple
triplefront
frontderailleur)
derailleur)
On
Onthe
thefollowing
followingpages
pagesyou
youwill
willfind
findinformation
informationononthe
theassembly
assembly
requirements
or
techniques
pertaining
to
Maverick
framesets.
requirements or techniques pertaining to Maverick framesets.Specific
Specific
information
informationabout
aboutthe
thecomponents
componentsyou
youchoose
choosetotoinstall
installononthe
theframe
frame
should
shouldbebegathered
gatheredfrom
fromthe
themanufacturers
manufacturersofofthose
thosecomponents.
components.
REQUIRED
REQUIREDCOMPONENTS
COMPONENTS
FORK:
FORK:
The
TheML7,
ML7,Matic
Maticand
andDurance
Durancerequire
requirea afront
frontfork
forkwith
with125-150
125-150mm
mmofoftravel,
travel,with
witha a
crown
We
crownracerace-to-axle
to-axlemeasurement
measurementofofnonoless
lessthan
than505
505mm.
mm.
Wesuggest
suggestthat
that
you
youbuild
buildyour
yourML7,
ML7,Matic
MaticororDurance
Durancewith
withthe
theMaverick
MaverickSC32
SC32ororDUC32
DUC32fork
forkasasthe
the
geometry,
geometry,stiffness
stiffnessand
andtuning
tuningare
aredesigned
designedfor
forand
andcomplement
complementthese
these
frames.
We
frames.
Werecommend
recommendthe
the6”6”travel
travelDUC32
DUC32fork
forkfor
forthe
theML8
ML8frame.
frame.
HEADSET:
HEADSET:
Maverick
Maverickframes
framesare
aredesigned
designedfor
forand
andcan
canONLY
ONLYuse
useananinternal
internalheadset
headset
with
These
witha a42.0
42.0mm
mmCampagnolo
Campagnolostandard
standardbearing.
bearing.
Theseare
areavailable
availablefrom
from
FSA
FSAComponents
Componentsand
andCane
CaneCreek.
Creek.
BRAKES:
BRAKES:
Disk
Diskbrake
brakeonly,
only,with
withananinternational
internationalstandard
standardmounting.
mounting.
SEATPOST:
SEATPOST:
The
We
Therequired
requiredseatpost
seatpostsize
sizeisis30.9
30.9mm.
mm.
Werecommend
recommendusing
usingonly
onlya astrong,
strong,
high
highquality
qualitypost
postwith
withenough
enoughforward
forwardtilt
tiltofofthe
thesaddle
saddletotoallow
allowfor
forthe
the
frame’s
frame’srelaxed
relaxedseat
seattube
tubeangle.
angle.On
Onthe
theML8,
ML8,be
becareful
carefulnot
nottotolower
lowerthe
the
post
postsosofar
farasastotointerfere
interferewith
withthe
theoperation
operationofofthe
therear
rearshock.
shock.No
No
more
morethan
than6060mm
mmofofseatpost
seatpostshould
shouldextend
extendbelow
belowthe
theseat
seattube.
tube.
FRONT
FRONTDERAILLEUR:
DERAILLEUR:
Maverick
Maverickframes
framesare
aredesigned
designedtotouse
usethe
theproprietary
proprietaryMaverick
Maverick“D-Mount”
“D-Mount”
which
The
whichallows
allowsthe
theuse
useofofa aShimano
Shimanobraze-on
braze-onfront
frontroad
roadderailleur.
derailleur.
TheML7,
ML7,
Matic,
Matic,Durance
Duranceand
andML8
ML8frames
framescan
canonly
onlyuse
usea abraze-on
braze-onfront
frontderailleur.
derailleur.
1010
11
D-DDaptor
Daptor
D-Mount
D-Mount
Fig.
Fig.1 1
Fig.
Fig.2 2
FRONT
FRONTDERAILLEUR
DERAILLEURSET
SETUP:
UP:
Route
the
derailleur
cable
Route the derailleur cablethrough
througha ashort
shortpiece
pieceofofTeflon
Tefloncable
cablehousing
housingliner
liner
under
the
MonoLink
cable
guide.
under the MonoLink cable guide.
D-DAPTOR
D-DAPTORSET
SETUP
UP(Not
(Notfor
for773
773oror443
443derailleur)
derailleur)
Unscrew
the
cable
anchor
bolt
and
Unscrew the cable anchor bolt andremove
removethe
thestock
stockwasher.
washer.Slide
Slidethe
thebolt
bolt
through
the
front
of
the
D-Daptor
(with
washer
and
pocket
facing
rear),
through the front of the D-Daptor (with washer and pocket facing rear),and
and
thread
threadloosely
looselyinto
intothe
thederailleur.
derailleur.Run
Runthe
thederailleur
derailleurcable
cableinto
intothe
theopening
openingonon
the
theback
backofofthe
theD-Daptor,
D-Daptor,pulling
pullingthe
thecable
cableaway
awayfrom
fromthe
thebike
bike(see
(seefigure
figure2).2).
Looking
from
the
rear
of
the
frame,
align
the
D-Daptor
cable
angle
at
Looking from the rear of the frame, align the D-Daptor cable angle at
approximately
approximately4545degrees
degreesdownward.
downward.Set
Setthe
thebarrel
barreladjuster
adjuster1-1/2
1-1/2turns
turnsout
out
and
tighten
the
anchor
bolt
to
60-70
in.
lbs.
and tighten the anchor bolt to 60-70 in. lbs.
RECOMMENDED
RECOMMENDEDFRONT
FRONTDERAILLEURS:
DERAILLEURS:
D-Daptor
Front
D-Daptor Application
Application
Derailleur
FrontDerailleur
(1)(1) Best
Shimano
AllAllMaverick
Best
ShimanoR773
R773Flat
FlatBar
BarTriple
Triple No
No
MaverickFrames
Frames
(2)(2) Good
Good Shimano
Shimano10-speed
10-speed105
105Triple
Triple Yes
Yes AllAllMaverick
MaverickFrames
Frames
Good
Yes
Good Shimano
ShimanoDura-Ace
Dura-AceTriple
Triple
Yes AllAllMaverick
MaverickFrames
Frames
Good
Yes
Good Shimano
Shimano105
1059-speed
9-speedTriple
Triple
Yes AllAllMaverick
MaverickFrames
Frames
(3)(3) Good
ML7
Good Shimano
ShimanoR443
R443Flat
FlatBar
BarTriple
Triple No
No
ML7Only
Only
Notes:
Notes:
1)1)The
TheMaverick
MaverickD-Daptor
D-Daptorhelps
helpsmatch
matchthe
thecable
cablepull
pullofofa aMTB
MTBshifter
shiftertotoa a
road
roadtriple
triplefront
frontderailleur.
derailleur.See
Seesection
section(2)(2)ofofthe
thechart
chartabove.
above.
2)2)BeBesure
suretotoset
setcorrect
correctsag
sagononshock
shockbefore
beforeadjusting.
adjusting.(See
(Seepage
page2121ofofmanual)
manual)
3)3)Use
Usethe
thebarrel
barreladjuster
adjusterononthe
thefront
frontshifter
shifterwhile
whilesitting
sittingononthe
thebike
bikefor
forfinal
final
small-to-middle
small-to-middlechainring
chainringadjustment.
adjustment.
4)4)BeBesure
surethat
thatthe
theouter
outerderailleur
derailleurcage
cageisisparallel
paralleltotothe
thelarge
largechainring.
chainring.
5)5)Follow
Followmanufacturers
manufacturersinstructions
instructionsfor
forchainring
chainringclearance
clearanceand
andheight
height
adjustment.
adjustment.
12
1111
ASSEMBLY INFORMATION
ASSEMBLY INFORMATION
Maverick
Maverickframesets
framesetsmust
mustbebeassembled
assembledinto
intocomplete
completebikes
bikesbybya a
competent
mechanic
using
proper
tools.
Improper
assembly
competent mechanic using proper tools. Improper assemblycan
canreduce
reduce
performance,
cause
premature
failure
or
wear
of
critical
components,
performance, cause premature failure or wear of critical components,and
and
could
couldlead
leadtotoloss
lossofofcontrol
controlresulting
resultingininsevere
severeinjuries.
injuries.
FRONT
FRONTDERAILLEUR
DERAILLEURMOUNTING
MOUNTING