Manitou Mezzer Pro User manual
serviceguide
2020
3
MEZZER SERVICE MANUAL
This manual is intended to guide the user through the steps necessary to fully service and maintain
the Mezzer Pro and Mezzer Expert suspension fork.
INTRODUCTION
We highly recommend that service to this fork be performed by a certied bicycle
mechanic. Failure to follow instructions presented in this manual could lead to
serious injury or death. Any questions about the servicing of this fork or the
manual itself should be directed to Hayes Customer Support at:
WARNING
! !
Hayes
Bicycle
USA
5800 W Donges Bay Road Mequon WI 53092
Phone: 888.686.3472
Email: techsupport@hayesbicycle.com
Hayes
Bicycle
Europe
Dirnismaning 20 a 85748 Garching (b. Munich) Germany
Phone: +49 89 203237450
Email: techsupportEU@hayesbicycle.com
Hayes
Bicycle
Asia
16F, No. 37, Sec. 3 Mincyuan E. Rd. Zhongshan District
Taipei City 10476 Taiwan ROC
Phone: 886-2-2518-1108
4MEZZER SERVICE MANUAL
TABLE OF CONTENTS
SECTION PAGE NUMBER
Required Tools 5
Casting Removal & Service 6-8
Air Spring Service 9-13
Pro Damper Service 14-18
Pro Casting Install 19-21
Pro Compression Knob Installation 22
Expert Damper Service 23-24
Expert Casting Install 25-27
Expert Damper Install 28-29
Travel Change (Optional) 30-33
Mezzer Expert IVA settings 34
Exploded Views 35-42
5
MEZZER SERVICE MANUAL
Below is a list of tools necessary for changing the travel on the Mezzer fork.
• Safety Glasses
• Nitrile Gloves
• Lint-Free Rags
• Torque Wrench (6-220 in-lb [0.7-25 Nm])
• 2mm Hex Wrench
• 8mm Hex Wrench
• 14mm Box End Wrench
• Shock Pump
• Cassette Lockring tool* (e.g. Park tool FR-5.2)
• 1” socket
• 8mm Socket *
• 24mm Socket *
• (Optional, replaces items above with*) Manitou Tool Kit - Manitou part
number 172-31133 (This includes the Manitou Cassette Tool, 8mm thin wall
socket, and at ground 24mm socket)
• Travel Spacer kit 141-36713-K032
Below is a list of additional tools necessary for a full service of the Mezzer
fork.
• 11mm Socket (Pro Only)
• Plastic or non-marring pick
• Downhill tire lever or at blade screwdriver
• 5wt Maxima Fork oil - Manitou part number 85-0023
• Semi-bath Oil, 5/40w Synthetic - Manitou part number 85-0022
• Slickoleum™ Grease
• Isopropyl alcohol
• 37mm seal install tool 172-37540-K002
• Cartridge Damper Bleed Kit 141-30694-K020 (Pro Only)
• 37mm seal kit 141-36713-K025 and Air piston Seal Kit 141-36713-K027
or Rebuild kit 141-36713-K026
REQUIRED TOOLS
6MEZZER SERVICE MANUAL
CASTING REMOVAL&SERVICE
1Remove rebound knob using a 2mm
Hex wrench.
Note: Be sure to hold the knob
still while removing the screw. The
damper adjuster may be damaged
if the knob is over torqued.
Hold lock-nut with 14mm box end
wrench. Insert a 8mm Hex wrench
into the end of the rebound rod and
loosen clockwise until rebound rod
disengages from the lock-nut.
2
3Unscrew air cap and attach shock
pump. Depress pressure bleed
button until pump reads “Zero”.
Depress Schrader Valve a few times
with 2mm hex wrench to ensure all
air is released.
Manitou recommends a full service anytime the
casting is removed. If the fork is new and only a
travel change is needed, follow instructions 1-4
then skip to Page 31 for Travel change instructions.
Return to page 19 for casting install.
7
MEZZER SERVICE MANUAL
Hold lock-nut with 14mm box end
wrench. Using 8mm Socket, turn
the compression rod clockwise
until compression rod is disengaged
from the lock-nut.
Remove casting from fork. It is
recommended this be done over
a drain pan as the lower casting
contains semi-bath oil. Allow oil
in casting to drain out before
continuing to next step.
4
5
6Using a downhill tire lever or similar
tool, gently pry the dust seals out
of the casting.
CASTINGREMOVAL&SERVICE
8MEZZER SERVICE MANUAL
CASTINGREMOVAL&SERVICE
8
7Remove old foam wiper rings.
Thoroughly saturate new foam
rings with semi-bath uid and
install into fork casting.
Remove springs from outer lip
of new leg seals. Clean casting
seal press area with Isopropyl
alcohol. Using the Manitou 37mm
Seal Press press in the dust seals.
Reinstall springs onto seals.
9
MEZZER SERVICE MANUAL
AIRSPRINGSERVICE
1
2
3
Mezzer Pro: Remove IRT air cap.
Make sure the air is released from
the fork. Depress IRT Schrader
Valve with a 2mm hex a few times
to ensure all air is released.
Mezzer Expert: Skip to Step 2.
Mezzer Pro: Using a standard
cassette tool and 1” socket loosen
IRT cap until threads are free from
leg.
Mezzer Expert: Using a 24mm
socket loosen IVA cap until threads
are free from leg.
Mezzer Pro: Pull IRT assembly
straight out, Clean with isopropyl,
Inspect seal for damage. If needed
Replace IRT piston seals (141-
36713-K026).
Mezzer Expert: Pull IVA assembly
straight out, Clean with isopropyl,
Inspect seal for damage. If needed
replace IVA piston seals (141-
36713-K026).
10 MEZZER SERVICE MANUAL
AIRSPRINGSERVICE
5
6
Remove Air Spring Assembly, clean
with isopropyl, Inspect seal for
damage. Replace air piston seal
(141-36713-K027). If Travel
change is need see page 26
before moving on.
Once the air spring assembly is
removed clean the inside of the
stanchion with isopropyl alcohol
and a lint free towel (Be careful
to not scratch the inner surface of
the stanchion). Inspect the inside
and outside of the stanchion for
scratches or other damage.
4Invert the fork and use Manitou
cassette tool with adjustable
wrench to unthread the air spring
assembly from the stanchion.OR
depress valve on end of comp-rod
with 2mm hex and stroke rod to
bottom. Slide standard cassette
lock-ring tool over threaded
adapter and unthread the air spring
assembly from the stanchion.
This manual suits for next models
1
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