PRO/Comp
Hayes Performance Systems
5800 W. Donges Bay Rd.
Mequon, WI 53092
Tel: 888.686.3472
Email: techsupport@[Link]
Web: [Link]
Hayes Components Europe
Dirnismaning 20 a
85748 Garching (b. Munich)
Germany
ph: +49 (0)89 203237450
Email: techsupportEU@[Link]
Web: [Link]
2 MASTODON PRO/COMP SERVICE MANUAL
INTRODUCTION
This manual is intended to guide the user through the steps necessary to fully service and maintain
the Mastodon Pro and Mastodon Comp suspension forks. Use pages 9-15 fork both Pro and Comp
forks. Continue with pages 16-26 for the Pro. Use pages 27-36 for the Comp.
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@[Link]
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.
MASTODON PRO/COMP 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
PRO DAMPER SERVICE & CASTING INSTALL 16–26
COMP DAMPER SERVICE & CASTING INSTALL 27–36
4 MASTODON PRO/COMP SERVICE MANUAL
REQUIRED TOOLS
Below is a list of tools necessary for servicing the Mastodon Pro/Comp fork.
• Safety Glasses
• Nitrile Gloves
• Lint-Free Rags
• Torque Wrench
• Slickoleum Grease
• Semi-bath Oil, 5/40w Synthetic - Manitou PN 85-0022
• All-Temp Synthetic 3wt Fork Oil - Manitou PN 141-34078-K016
(Effective at all temperatures and required for extreme cold use)
• *Optional - Synthetic 5wt Fork Oil – Manitou PN 85-0023
(Effective in normal warm season applications)
• Mattoc Tool Kit - Manitou PN 172-31133
Manitou Cassette Tool
Manitou Thin Walled 8mm Socket
Manitou 24mm Flat Ground Socket
• Optional O-ring Kit - Manitou part number 141-28528-K008
• 8mm Hex Socket
• 2mm Hex 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
MASTODON PRO/COMP SERVICE MANUAL 5
MAstodon rebuild kit Exploded view
6 MASTODON PRO/COMP SERVICE MANUAL
MAstodon Pro std & ext Exploded view
MASTODON PRO/COMP SERVICE MANUAL 7
MAstodon comp std & ext Exploded view
8 MASTODON PRO/COMP SERVICE MANUAL
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 [Link]. 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)
MASTODON PRO/COMP SERVICE MANUAL 9
CASTING REMOVAL & SERVICE
Remove rebound knob using a
1 2mm Hex wrench.
Insert an 8mm Hex 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.
Unscrew air cap and depress
3 Schrader Valve a few times to
ensure all air is released.
10 MASTODON PRO/COMP SERVICE MANUAL
CASTING REMOVAL & SERVICE
Using the Manitou 8mm Thin Wall
4 Socket, turn the compression rod
clockwise until compression rod
is disengaged from the casting
threads.
Remove casting from fork. It is
5 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
6 tool, gently pry the dust seals out
of the casting.
MASTODON PRO/COMP SERVICE MANUAL 11
CASTING REMOVAL & SERVICE
Remove old foam wiper rings. Apply
7 semi-bath fluid to the new foam
wiper rings and install into fork
casting.
Remove springs from lip of dust seals.
8 Clean seal area with Isopropyl alcohol.
Using the Manitou 34mm Seal Press
or large socket press in the dust seals.
Reinstall springs onto seals.
12 MASTODON PRO/COMP SERVICE MANUAL
AIR SPRING SERVICE
Release air from the fork. Depress
1 Schrader valve a few times to ensure all
air is released.
Remove IVA using a 24mm socket.
2
Pull IVA straight out.
3
MASTODON PRO/COMP SERVICE MANUAL 13
AIR SPRING SERVICE
Invert the fork and use Manitou cassette
4 tool and adjustable wrench to unthread
the air spring assembly from the
stanchion.
Remove air spring assembly from
5 the stanchion. Clean spring and rod
assembly with Isopropyl alcohol.
Once the air spring assembly is removed
6 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.
14 MASTODON PRO/COMP SERVICE MANUAL
AIR SPRING SERVICE
Liberally grease the piston quad seal
7 and outer surface with Slickoleum™
grease.
Add 8cc’s of Slickoleum™ grease to the
8 top of the air piston.
Add Slickoleum™ grease to the
9 stanchion threads before inserting the
air spring assembly. Spread grease
across entire thread surface.
MASTODON PRO/COMP SERVICE MANUAL 15
AIR SPRING SERVICE
Install air spring assembly into
10 stanchion. Using a 26mm crow’s foot
and Manitou cassette tool, tighten
assembly end cap to 60-80 in lb
[6.8-9.0 N m]
Install air cap onto stanchion. Tighten to
11 60-80 in lb [6.8-9.0 N m].
Attach a shock pump and inflate air leg
12 to 60PSI. This will aid in installing the
casting later.
16 MASTODON PRO/COMP SERVICE MANUAL
PRO Damper Service
16 MASTODON PRO/COMP SERVICE MANUAL 17
pro DAMPER SERVICE
Using a 2mm Hex wrench, remove the
1 black high speed adjustment knob from
the MC2 assembly.
Note: Be sure to hold the knob still while
removing the screw/nut. These tend to
move and can damage the damper if the
knob is over turned.
With a 13mm socket, unthread the
2 exposed nut and remove the red low
speed adjustment knob.
Note: Be sure to hold the knob still while
removing the screw/nut. These tend to
move and can damage the damper if the
knob is over turned.
18 MASTODON PRO/COMP SERVICE MANUAL
pro DAMPER SERVICE
Use the Manitou cassette tool and
3 adjustable wrench to unthread the
compression damper assembly from the
stanchion.
Remove compression damper assembly
4 from the stanchion.
Pour damper oil into a catch pan.
5
MASTODON PRO/COMP SERVICE MANUAL 19
pro DAMPER SERVICE
Using a Manitou cassette tool and
6 adjustable wrench, unthread the
rebound damper assembly from the fork
stanchion.
Remove rebound damper assembly from
7 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.
8 Using a 26mm crow’s foot, Manitou
cassette tool, and torque wrench, tighten
the rebound damper assembly end cap
to 60-80 in lb [6.8-9.0 N m].
20 MASTODON PRO/COMP SERVICE MANUAL
CASTING INSTALL
Before filling the fork with fork oil and
1 installing the ABS+ compression damper,
the casting must first be installed. 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 air (60PSI). This
2 will extend the air spring assembly and
make casting installation easier.
Fully extend the rebound damper rod.
3
MASTODON PRO/COMP SERVICE MANUAL 21
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
upon 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 Hex wrench tighten the
6 rebound damper rod to 35–40 in lb
[3.95–4.5 N m] by turning them counter-
clockwise. Do not overtighten, doing so
can damage the end of the rods.
22 MASTODON PRO/COMP SERVICE MANUAL
CASTING INSTALL
Install the rebound knob using a 2mm
7 Hex wrench. Add a small drop of blue
Loctite to the screw before installation
to prevent the screw from backing out
during riding.
Using the Manitou 8mm Thin Wall
8 Socket, turn the compression rod
counter-clockwise. Tighten to
35–40 in lb [3.95–4.5 N m]
MASTODON PRO/COMP SERVICE MANUAL 23
COMPRESSION DAMPER INSTALL
Pour All-Temp synthetic 3wt Fork Oil into
1 the damper leg. (Optional, use 5wt Fork
Oil for normal warm weather use)
Fill it up about 3/4 full.
Place a lint-free towel over the opening
2 in the damper leg and compress the fork
10-15 times.
Pour additional fork oil into the damper
3 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.
24 MASTODON PRO/COMP SERVICE MANUAL
COMPRESSION DAMPER INSTALL
oil height chart 2017-2018
fork model oil height
Mastodon pro 75mm oil
mastodon comp 87mm height
markhor (80/100mm) 92mm (refers to the air
space between the top
markhor (120mm) 97mm of the oil and top of
mattoc pro 75mm the fork leg)
mattoc comp 87mm
machete (abs+) 87mm
machete (kwik toggle, 90-120mm) 87mm
machete (kwik toggle, 130-140mm) 91mm
circus comp/expert 87mm
circus sport (ffd) 83mm
R7 PRO 83mm
dorado (see dorado service guide) 180-190mm
note
1. oil height is set with compression damper
removed.
2. oil height is set with fork fully extended
and casting installed.
All forks listed us 5w synthetic oil for the damer, Manitou part number 85-0023.
All forks listed us 5w40 synthetic oil for the lowers, Manitou part number 85-0024.
[Link] MASTODON
tech support: techsupport@[Link]
PRO/COMP
eu tech support: SERVICE MANUAL
techsupporteu@[Link] 25
COMPRESSION DAMPER INSTALL
Insert compression damper into the
4 damper leg. Ensure the damper is set in
the unlocked position when installing.
If installing an ABS+ damper use a
5 1” socket or crow’s foot, the Manitou
Cassette tool and a torque 60–80 in lb
[6.8–9.0 N m].
Secure red high speed knob adjustment
6 knob with the 13mm nut using a socket,
tighten down hand tight.
26 MASTODON PRO/COMP SERVICE MANUAL
COMPRESSION DAMPER INSTALL
Using a 2mm Hex wrench reinstall the
7 black high speed adjustment knob.
Clean fork and use a shock pump to
8 set to desired pressure. Lightly pull the
casting away from the CSA as you add
air. Pressure chart below for reference.
MASTODON PRO/COMP SERVICE MANUAL 27
Comp Damper Service
28 MASTODON PRO/COMP SERVICE MANUAL 27
Comp DAMPER SERVICE
Remove ABS+ knob using a 2mm Hex
1 wrench. Remove knob carefully as there
are two detent ball bearings on springs
below the knob.
Unthread ABS+ compression damper
2 assembly from the stanchion using a
24mm socket and ratchet.
MASTODON PRO/COMP SERVICE MANUAL 29
Comp DAMPER SERVICE
Remove ABS+ compression damper
3 assembly from the stanchion.
Pour damper oil into a catch pan.
4
Using the Manitou cassette tool and
5 wrench or crow’s foot unthread the
rebound damper assembly from the fork
stanchion.
30 MASTODON PRO/COMP SERVICE MANUAL
Comp 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 the Mattoc cassette tool, a crow’s
foot and torque wrench, tighten the
rebound damper assembly end cap to
80-100 in lb [9.0-11.3 N m].
MASTODON PRO/COMP SERVICE MANUAL 31
CASTING INSTALL
Before filling the fork with fork oil and
1 installing the ABS+ compression damper,
the casting must first be installed. This
ensures a correct oil level. First apply a
generous amount of Slickoleum grease
to the oil seal/dust seal area of the
casting.
Fill the air chamber with a small amount
2 of air (20-30PSI). This will extend the
air spring assembly and make casting
installation easier.
Fully extend the rebound damper rod.
3
32 MASTODON PRO/COMP 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
upon 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 Hex wrench tighten the
6 rebound damper rod and air spring
assembly to 35–40 in lb [3.95–4.5 N m]
by turning them counter-clockwise. Do
not overtighten, doing so can damage
the end of the rods.
MASTODON PRO/COMP SERVICE MANUAL 33
CASTING INSTALL
Install the rebound knob using a 2mm
7 Hex wrench. Add a small drop of blue
Loctite to the screw before installation
to prevent the screw from backing out
during riding.
34 MASTODON PRO/COMP SERVICE MANUAL
ABS+ DAMPER INSTALL
Pour All-Temp synthetic 3wt Fork Oil into
1 the damper leg. (Optional, use 5wt Fork
Oil for normal warm weather use)
Fill it up about 3/4 full.
Place a lint-free towel over the opening
2 in the damper leg and compress the fork
10-15 times.
Pour additional fork oil into the damper
3 leg until the oil height (space from the
top of the damper leg to the top of the
oil) is 85–90mm (87mm is nominal).
An oil height setting tool used for
motorcycle forks similar to the one
pictured makes this job easier.
MASTODON PRO/COMP SERVICE MANUAL 35
ABS+ DAMPER INSTALL
Insert the ABS+ compression damper
4 into the damper leg. Ensure the damper
is set in the unlocked position when
installing.
Using a 24mm socket and torque
5 wrench, tighten the ABS+ damper to
60–80 in lb [6.8–9.0 N m].
Install springs and ball bearings into
6 ABS+ top cap. A small dab of grease on
top of the spring can help hold the ball
bearings in place.
36 MASTODON PRO/COMP SERVICE MANUAL
ABS+ DAMPER INSTALL
Using a 2mm Hex wrench, install the
7 ABS+ knob.
Clean fork and use a shock pump to
8 set to desired pressure. Pressure chart
below for reference.
ISO AIR 34
MASTODON PRO/COMP SERVICE MANUAL 37
WWW. [Link] [Link]
5800 W DONGES BAY ROAD MEQUON WI 53092
