Hayes Performance Systems

5800 W. Donges Bay Rd.

Mequon, WI 53092

Tel: 888.686.3472
Email: techsupport@hayesbicycle.com
Web: www.hayescomponents.com

Hayes Components Europe

Dirnismaning 20 a
85748 Garching (b. Munich)
Germany
ph: +49 (0)89 203237450

Email: techsupportEU@hayesbicycle.com
Web: www.hayescomponents.com

2 M30 SERVICE MANUAL

INTRODUCTION

This manual is intended to guide the user through the steps necessary to fully service and maintain
the M30 suspension fork.

We highly recommend that service to this fork be performed by a certified

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 Manitou Customer Support at:
Phone: 888-686-3472
Email: techsupport@hayesbicycle.com

Suspension forks by design can contain preloaded springs, gases and fluids under
extreme pressures. Warnings contained in this manual must be observed to avoid damage to fork,
serious injury or even death.

M30 SERVICE MANUAL 3

 TABLE OF CONTENTS

SECTION PAGE NUMBER

REQUIRED TOOLS 5
EXPLODED DIAGRAM 6–7
CASTING REMOVAL & SERVICE 9–11
AIR SPRING SERVICE 12–15
DAMPER SERVICE 16–19
CASTING INSTALLATION 20–22
COMPRESSION DAMPER INSTALL 23–26

4 M30 SERVICE MANUAL

REQUIRED TOOLS

Below is a list of tools necessary for servicing the M30 fork.

• Safety Glasses
• Nitrile Gloves
• Lint-Free Rags
• Torque Wrench
• Slickoleum Grease
• Semi-bath Oil, 5/40w Synthetic - Manitou part number 85-0022
• 5wt Maxima Fork oil - Manitou part number 85-0023
• Mattoc Tool Kit (for MY17+ forks)
• 8mm Allen Socket
• 2mm Allen Wrench
• 20mm Socket
• 24mm Socket
• 22mm Box end Wrench
• 12mm Box End Wrench
• 12mm Socket
• Ratchet
• 22mm Crow’s Foot
• Fork/Shock Pump
• Pick
• Adjustable Wrench
• Downhill tire lever or flat blade screwdriver

M30 SERVICE MANUAL 5

 M30 26, 29 & 27.5 Exploded view (MY2016 & earlier)
PART DESCRIPTION PART NUMBER
26" 27.5" 29"
1. Crown/Steer/Leg 80/100, 1 1/8" Steer 141-31870-K004 141-31870-K005 //
1. Crown/Steer/Leg 80/100, 1.5" Steer 141-32556-K003 141-32556-K004 141-32556-K007
1. Crown/Steer/Leg 80/100, 1 1/8" Steer, Black Stanchions 141-32556-K013 141-32556-K008 141-32556-K016
1. Crown/Steer/Leg 80/100, 1.5" Steer, Black Stanchions 141-32556-K014 141-32556-K015 141-32556-K017
1. Crown/Steer/Leg 80/100, 1 1/8" Steer, Black Stanchions. 51mm Offset // // 141-32556-K006
2. ABS+ Compression Damper (includes knob) 141-32556-K001 141-32556-K001 141-32556-K001
3. Rebound Damper Assembly 141-31870-K001 141-31870-K008 141-32556-K002
4. Outer Casting, QR, Black 141-27200-K001 141-31870-K012 141-32556-K009
4. Outer Casting, QR, White 141-27200-K002 141-31870-K011 //
5. Dust Seal Kit 85-5281 85-5281 85-5281
6 .Compression Rod Assembly 80/100 141-31870-K003 141-31870-K009 141-32556-K012
7. Air Piston 83-2669 83-2669 83-2669
8. Air Cap 83-2654 83-2654 83-2654
9. Knob Kit (Includes compression damper knob and rebound adjuster knob) 141-27177-K003 141-27177-K003 141-27177-K003
Decal Kit 141-31870-K002 141-31870-K007 141-32556-K011 1

3
8

6 M30 SERVICE MANUAL

M30 26, 29 & 27.5 Exploded view (MY2017 +)
PART DESCRIPTION PART NUMBER
26" 27.5" 29"
1. Crown/Steer/Leg 80/100/120, 1 1/8" Steer 141-3382-K611 141-33382-K711 141-33382-K911
1. Crown/Steer/Leg 80/100/120, 1.5" Steer 141-3382-K621 141-33382-K721 141-33382-K921
1. Crown/Steer/Leg 80/100/120, 1 1/8" Steer, Black Stanchions 141-3382-B611 141-3382-B711 141-3382-B911
1. Crown/Steer/Leg 80/100/120, 1.5" Steer, Black Stanchions 141-3382-B621 141-3382-B721 141-3382-B921
2. Kwik Toggle Compression Damper (includes knob) 141-33385-K001 141-33385-K001 141-33385-K001
2. ABS+ Compression Damper (optional upgrade, includes knob) 141-32556-K001 141-32556-K001 141-32556-K001
3. Rebound Damper Assembly 141-33456-K001 141-33456-K002 141-33456-K003
4. Seal Kit 85-5293 85-5293 85-5293
5. Outer Casting, QR, Black 141-27200-K001
6. Compression Rod Assembly - 80/100 141-33455-K001 // //
6. Compression Rod Assembly - 80 // 141-33455-K002 141-33455-K004
6. Compression Rod Assembly - 100/120 // 141-33455-K003 141-33455-K005
7. Air Piston 141-33383-K001 141-33383-K001 141-33383-K001
8. Air Cap 141-31870-K027 141-31870-K027 141-31870-K027 1
9. Knob Kit 141-33386-K001 141-33386-K001 141-33386-K001
Decal Kit 141-31870-K002 141-31870-K007 141-32556-K011

3
8

M30 SERVICE MANUAL 7

 HAYES PERFORMANCE SYSTEMS WARRANTY
Limited Warranty:
HAYES warrants its products to be free from defects in materials or workmanship under
normal intended use for a period of one year (two years in European Union countries)
from the date of purchase, subject to normal wear and tear. Unless otherwise prohibited
by law, any such defective products will be repaired or replaced at the option of HAYES
when received with proof of purchase, freight prepaid. This warranty does not cover
breakage, bending, or damage that may result from crashes or falls. This warranty
does not cover any defects or damage caused by alterations or modifications of HAYES
products or by normal wear, accidents, improper maintenance, damages caused by the
use of HAYES products with parts of different manufacturers, improper use or abuse
of the product, application or uses other than those set forth in the HAYES instruction
manual or failure to follow the instructions contained in the applicable HAYES instruction
manual. Instruction manuals can be found on-line at www.hayescomponents.com. Any
modifications made by the BUYER or any subsequent user will render the warranty null
and void. This warranty does not apply when the serial number or production code has
been deliberately altered, defaced or removed from the product. The cost of normal
maintenance or replacement of service items, which are not defective, shall be the
BUYER’s responsibility. If permitted by local law, this warranty is expressly in lieu of all
other warranties (except as to title), express or implied, and in particular and without
limitation HAYES disclaims the implied warranties of merchantability or fitness for
purpose If for any reason warranty work is necessary, return the component to the place
of purchase or contact your dealer or local HAYES distributor. In the USA, contact HAYES
for a return authorization number (RA#) at (888) 686-3472. At that time, instructions
for repair, return, or replacement shall be given. Customers in countries other than the
USA should contact their dealer or local HAYES distributor.

Limitation of Liability.
Unless required by mandatory law, HAYES shall not be liable for any incidental, indirect,
special or consequential damages.

This warranty does not apply to normal wear and tear. Wear and tear parts are subject to
damage through normal use, failure to service according to recommendations or riding in
conditions other than recommended. The cost of normal maintenance or replacement of service
items, which are not defective, shall be paid for by the original purchaser. Wear and tear parts
that will not be replaced under warranty include but are not limited to the following:

- Bushings - Dust Seals - Stripped or worn bolts

- Rear Shock - Fork and Shock air - Remote Lockout Cable
Mount Hardware Seals and/or O-rings - Gloves
- Handlebar grips - Bearings - Lower Stanchion
- Tubeless Valves - Upper Stanchion Tubes Tubes(Dorado)

8 M30 SERVICE MANUAL

CASTING REMOVAL & SERVICE
Remove rebound knob using a
1 2mm Allen wrench.

Insert an 8mm Allen wrench into

2 the end of the rebound damper rod
and turn the rod clockwise until it
is disengaged from the casting and
can be pushed into the casting.

Use a 12mm wrench to remove the

3 compression rod bolt.

M30 SERVICE MANUAL 9

 Remove casting from fork. It is
4 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.

Using a downhill tire lever or similar

5 tool, gently pry the dust seals out
of the casting.

Remove old foam wiper rings. Apply

6 semi-bath fluid to the new foam
wiper rings and install into fork
casting.

10 M30 SERVICE MANUAL

CASTING REMOVAL & SERVICE
Remove springs from lip of dust seals.
7 Using the Manitou 30mm Seal Press
or large socket press in the dust seals.
Reinstall springs onto seals.

M30 SERVICE MANUAL 11

 AIR SPRING SERVICE
Release air from the fork. Depress
1 Schrader valve a few times to ensure all
air is released.

Remove air cap using a 20mm socket.

2

Invert the fork and use a 22mm box

3 end wrench to unthread the air spring
assembly from the stanchion.

12 M30 SERVICE MANUAL

AIR SPRING SERVICE
Remove air spring assembly from
4 the stanchion. Clean spring and rod
assembly and re-grease.
TIP: Ensure grease is worked into the ID
of the rubber top-out bumper to improve
ride quality and topping feel.

Using a long dowel rod or similar tool

5 push the air piston down the stanchion
and out of the bottom. Be careful to
not scratch the inner surface of the
stanchion. Once the piston is removed
clean the inside of the stanchion with
isopropyl alcohol and a lint free towel.
Inspect the inside and outside of the
stanchion for scratches or other damage.

M30 SERVICE MANUAL 13

 AIR SPRING SERVICE
Take new Air Piston out of bag and
6 liberally grease the piston quad seal and
outer surface with Slickoleum™ grease.

Install new, greased air piston into the

7 top of the stanchion and push it down
past the threads.

Add 8cc’s of Slickoleum™ grease to the

8 top of the air piston.

14 M30 SERVICE MANUAL

AIR SPRING SERVICE
Install air cap onto stanchion. Tighten to
9 60-80 in lbs. [6.8-9.0 NM].

Install air spring assembly into stanchion.

10 Using a 22mm crow’s foot, tighten
assembly end cap to 80-100 in lbs [9.0-
11.3 NM].

M30 SERVICE MANUAL 15

 DAMPER SERVICE
The M30 fork can have two compression
1 damper configurations, ABS+ or Kwik
Toggle. The following instructions will
work for both. Remove ABS+ or Kwik
Toggle knob using a 2mm Allen wrench.
If the fork has ABS+, remove knob
carefully as there are two detent ball
bearings on springs below the knob.

KWIK TOGGLE
(Kwik Toggle compression damper
without knob)

ABS+
(ABS+ knob detent ball and springs.)

16 M30 SERVICE MANUAL

DAMPER SERVICE
KWIK TOGGLE
2 Unthread the Kwik Toggle compression
damper from the fork. You will need to
use the Mattoc Cassette Tool and 1”
wrench or socket to remove the damper.

ABS+
Unthread the ABS+ compression
damper form the fork using a 24mm
socket.

KWIK TOGGLE
3 Remove Kwik Toggle compression
damper assembly from the stanchion.

M30 SERVICE MANUAL 17

 DAMPER SERVICE
ABS+
Remove ABS+ compression damper
assembly from the stanchion.

Pour damper oil into a catch pan.

4

Using a 22mm box end wrench, unthread

5 the rebound damper assembly from the
fork stanchion.

18 M30 SERVICE MANUAL

DAMPER SERVICE
Remove rebound damper assembly
6 from the fork. Once the damper
assembly is removed, clean the inside of
the stanchion with isopropyl alcohol and
a lint free towel. Inspect the inside and
outside of the stanchion for scratches
and other damage. Inspect rebound
damper for damage as well. Replace if
necessary.

Install rebound damper into stanchion.

7 Using a 22mm crow’s foot and torque
wrench, tighten the rebound damper
assembly end cap to 80-100 in lbs [9.0-
11.3 NM].

M30 SERVICE MANUAL 19

 CASTING INSTALL
Before filling the fork with fork oil and
1 installing the ABS+ compression damper,
we must first install the casting. This
ensures a correct oil level. First apply
a generous amount of grease to the oil
seal/dust seal area of the casting.

Fill the air chamber with a small amount

2 of air (30-50PSI). This will extend the
air spring assembly and make casting
installation easier.

Fully extend the rebound damper rod.

3

20 M30 SERVICE MANUAL

CASTING INSTALL
Slide casting onto the stanchion
4 assembly. Only slide the casting down
about halfway at this point. Take care
that the seals do not get folded over on
installation.

Insert 15cc’s (15ml) of semi-bath into

5 each casting leg. Once the semi-bath is
in the legs slide the casting the rest of
the way onto the stanchion assembly.

Using an 8mm Allen wrench tighten

6 the rebound damper rod and air spring
assembly to 35–40in lbs [3.95–4.5 Nm]
by turning them counter-clockwise. Do
not overtighten, doing so can damage
the end of the rods.

M30 SERVICE MANUAL 21

 CASTING INSTALL
Install the rebound knob using a 2mm
7 Allen wrench. Add a small drop of blue
Loctite to the screw before installation
to prevent the screw from backing out
during riding.

Install compression rod bolt. It helps to

8 have at least 50psi in the air chamber
when tightening down the bolt to the
proper torque. Use a 12mm socket and
torque wrench and tighten to 45­–55 in
lbs [5.1–6.2 NM].

22 M30 SERVICE MANUAL

COMPRESSION DAMPER INSTALL
Pour 5wt Maxima fork oil into the
1 damper leg. Fill it up about halfway.

Place a lint-free towel over the opening

2 in the damper leg and compress the fork
10-15 times.

Pour additional 5wt fork oil into the

3 damper leg until the oil height (space
from the top of the damper leg to the top
of the oil) is set at the proper level. See
following page for the correct oil height
depending on compression damper type
and fork travel. An oil height setting tool
used for motorcycle forks similar to the
one pictured makes this job easier.

M30 SERVICE MANUAL 23

 COMPRESSION DAMPER INSTALL

oil height chart

fork model oil height oil

match comp 83mm height
(refers to the air
m30 (abs+) 83mm space between the top
of the oil and top of
m30 (kwik toggle, 80/100mm) 92mm the fork leg)
m30 (kwik toggle, 120mm) 97mm
circus sport (ffd) 83mm
circus comp/expert 87mm
marvel comp/expert 87mm
marvel pro 75mm
minute comp/expert 87mm
minute pro 75mm
machete (kwik toggle) 87mm
machete (abs+) 87mm
magnum comp 87mm
magnum pro 75mm
mattoc comp 87mm
mattoc expert 80mm
mattoc pro 75mm
dorado (see dorado service guide) / /
note
1. oil height is set with compression damper
removed.
2. oil height is set with fork fully extended
and casting installed.

24 M30 SERVICE MANUAL

COMPRESSION DAMPER INSTALL
Insert the Kwik Toggle or ABS+
4 compression damper into the damper
leg. Ensure the damper is set in the
unlocked position when installing.

If installing an ABS+ damper use a

5 24mm socket and torque wrench, tighten
the damper to 60–80 in lbs [6.8–9.0 NM].
If installing a Kwik Toggle damper use
a 1” socket or crow’s foot, the Mattoc
Cassette tool and a torque wrench to
tighten down the damper to the same
torque specification.

If the damper is an ABS+, install springs

6 and ball bearings into ABS+ top cap. A
small dab of grease on top of the spring
can help hold the ball bearings in place.

M30 SERVICE MANUAL 25

 COMPRESSION DAMPER INSTALL
Using a 2mm Allen wrench, install the
7 ABS+ or Kwik Toggle knob.

Clean fork and use a shock pump to

8 set to desired pressure. Pressure chart
below for reference.

26 M30 SERVICE MANUAL

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